Vnx.su Мустанг2005 2010

INTRODUCTION
NOTE: Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design
without notice and without incurring any obligation.
IMPORTANT SAFETY NOTICE
Appropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as
the personal safety of the individual doing the work. This manual provides general directions for performing service with
tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedure, techniques, tools and parts for servicing vehicles, as well as in the skill of
the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions
as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that they
compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts.
NOTES, CAUTIONS AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for
a specific purpose. NOTES give you added information that will help you to perform a particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you
to be especially careful in those areas where carelessness can cause yourself and others personal injury. The following
list contains some general WARNINGS that you should follow when you work on a vehicle.
ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
KEEP SOLVENTS AWAY FROM IGNITION SOURCES. SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE
OR EXPLODE IF NOT HANDLED CORRECTLY.
USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE.
MAKE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION, UNLESS OTHERWISE REQUIRED
BY THE PROCEDURE.
SET THE PARKING BRAKE WHEN WORKING ON THE VEHICLE. IF YOU HAVE AN AUTOMATIC TRANSMISSION,
SET IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION. IF YOU HAVE A MANUAL
TRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTED
OTHERWISE FOR A SPECIFIC OPERATION. PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKS
AGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING.
OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA TO AVOID THE DANGER OF CARBON
MONOXIDE POISONING.
KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING,
ESPECIALLY THE DRIVE BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR,
EXHAUST MANIFOLD, TAIL PIPE, THREE-WAY CATALYTIC CONVERTER AND MUFFLER.
DO NOT SMOKE WHILE WORKING ON A VEHICLE.
TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE
CLOTHING BEFORE BEGINNING TO WORK ON A VEHICLE.
WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF
THE COOLING FAN BLADES!
TOOLS
Commercially available hand tools and equipment are used along with Essential Special Service Tools (ESST) and
Rotunda equipment. Power tools have become the acceptable industry standard and are used for disassembly only
where applicable, unless specified otherwise in the Workshop Manual. The only exception to this policy is installing
wheels in conjunction with the use of torque sticks, when possible.
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100-01-1 100-01-1 Identification Codes
DESCRIPTION AND OPERATION
Identification Codes
Vehicle Identification Number (VIN) Locator
The vehicle identification number (VIN) is a
17-digit alphanumeric code. The VIN is stamped on
a metal tab riveted to the instrument panel, top
upper left of the dash. The VIN number is also
found on the vehicle certification (VC) label.
Item Description
1 World manufacturer identifier (WMI)
2 Restraint-type code
3 Line, series, body type
4 Engine code
5 Computer-generated VIN check digit
Copyright 2006, Ford Motor Company
Last updated: 6/19/2006 2007 Mustang, Mustang GT 8/2006
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DESCRIPTION AND OPERATION (Continued)
Line, Series and Body Type Code Item Description
6 Model year code
7 Assembly plant code
8 Production sequence number
Vehicle Identification Number
World Manufacturer Identifier (WMI)
Positions 5 through 7 indicate vehicle line, series
and body type.
T80 2-door coupe, base
T82 2-door coupe, GT
T84 2-door convertible, base
T85 2-door convertible, GT
T88 2-door coupe, Shelby
The first 3 vehicle identification number (VIN)
positions are the world manufacturer identifier
T89 2-door convertible, Shelby
(WMI).
Engine Code
1ZV Ford, USA, passenger car
Restraint-Type Code
The eighth VIN position is the engine displacement
and number of cylinders code.
The fourth VIN position is the vehicle restraint
H 4.6L, OHC, 3-valve, EFI, 8-cylinder
system type code.
N 4.0L, SOHC, EFI, 6-cylinder
F Active safety belts, all positions driver
S 5.4L, DOHC, 4-valve, EFI, 8-cylinder
and front passenger air bags
H Active safety belts, all positions driver
and front passenger air bags with side impact air
bags
2007 Mustang, Mustang GT 8/2006
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Computer-Generated Check Digit
The eleventh VIN position is the assembly plant
code.
5 Auto Alliance International (AAI) Flat
Rock, Michigan (USA)
Production Sequence Number
The ninth VIN position is a government-assigned,
computer-generated check digit code (0-9).
Model Year Code
The last 6 VIN positions are the production
sequence number. This number is also used as the
vehicle serial and warranty number.
100001-599999
The tenth VIN position is the model year code.
7 2007
Assembly Plant Code
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Vehicle Certification (VC) Label
Vehicle Certification (VC) Label Locator
The upper portion of the vehicle certification (VC)
label contains the manufacturer name, the month
and year of manufacture, the certification statement
and the vehicle identification number (VIN). It also
includes gross vehicle weight ratings (GVWR). The
VC label is located on the LH door jamb.
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Paint Codes
Paint codes may be listed as a 2-part code. The first
set of paint code letters/numbers listed indicate the
vehicle primary body color. The second set of paint
code letters/numbers listed (if applicable) indicate a
2-tone or accent body color. All colors are base
coat/clear coat.
D3 Colorado Red
G2 Redfire
G5 Alloy Gray
G9 Vista Blue
HP Performance White
Item Description
P3 Windveil Blue
1 Exterior paint color code
T8 Tungsten Silver
2 Region code
TL Satin Silver
3 Special order code
DSO domestic special order U3 Valencia
FSO foreign special order
UA Ebony
PTO paint, tire option special order
4 Interior trim code Interior Trim Codes
5 Tape/paint stripe code
6 Radio type code
7 Axle ratio code
8 Transmission code
9 Spring code
10 Powertrain calibration code
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Radio Codes
The interior trim codes are listed as a 2-part code.
The first character listed is the interior fabric. The
second character listed is the interior color.
5 Cloth seats with logo GT
F Preferred suede leather California Edition
G No grain mini perforation Shelby
J Verona leather seats Base
K Nudo/Aberdeen leather seats GT and
Base
P Cloth seats Base
The interior trim colors are:
The radio type codes are:
2 Light Graphite
4 Charcoal Black/Chamois 5 Premium electronic AM/FM stereo with
compact disc (CD) player and clock
C Charcoal Black/Camel
9 CDX6+, AM/FM stereo with 6-disc CD
D Charcoal/Dove
changer, MP3 and speed-sensing volume control
H Camel Tan
Axle Ratio Codes
R Midnight Black/Crimson Red
W Charcoal Black
Tape/Paint Stripe Codes
The axle ratios are:
BG 3.31 non-limited slip, base vehicle with
manual or automatic transmission
The tape and paint stripe codes are:
CD 3.55 limited slip, GT with manual
1 Black
transmission
2 Oxford White
CG 3.31 limited slip, GT with automatic
transmission
3 Light Pearl Gold
4 Performance White
6 Tungsten
7 Silver
8 Vista Blue
X Satin Black
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Transmission Codes
CC 4R33-5310-CA
DD 4R33-5310-DA
FF 4R33-5310-FA
GG 4R33-5310-GA
Rear Springs
AA 5R33-5560-AA
BB 5R33-5560-BA
CC 5R33-5560-CA
DD 5R33-5560-DA
EE 5R33-5560-EB
FF 5R33-5560-FA
The transmission codes are:
GG 5R33-5560-GA
E 6-speed manual (T56) Shelby
HH 5R33-5560-HA
F 5-speed manual (T5OD/TR3150) Base
JJ 7R3V-5560-JB
K 5-speed manual (TR3650) GT
KK 7R3V-5560-KB
L 5-speed automatic (5R55S) Base/GT
LL 7R3V-5560-LA
Spring Codes
MM 7R3V-5560-MA
Powertrain Calibration Information
The spring code portion of the vehicle certification
(VC) label identifies both the front and rear springs.
The first set of characters listed indicate the front
spring code. The second set of characters indicate
the rear spring code.
Front Springs
AA 4R33-5310-AA
BB 4R33-5310-BA
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Protocol 2
NOTE: Powertrain calibration information is limited
to a maximum of 5 characters per line on the
Vehicle Certification (VC) Label. Because of this,
calibration identification consisting of more than 5
characters will wrap to the second line on the VC
label.
Powertrain calibration information is printed in the
lower right corner of the Vehicle Certification
Label. Only the base calibration information is
printed. Revision levels will not appear, however,
this information can be found in the On Line
Automotive Service Information System (OASIS).
For the current model year, Ford Motor Company is
using 3 different protocols which describe
Item Description
powertrain base calibration. These protocols are
1 Model year (model year in which
designed to provide worldwide standardization for
calibration strategy was first
vehicle calibration. If the electronic calibration
introduced)
strategy has been used since 1998 and carried into
2 Engine code
the current model year, Protocol 1 will be used.
3 Transmission code Refer to Protocol 1 below. If the electronic
calibration strategy has been used since 1999 and is
4 Emission standard (designates the
carried into the current model year, Protocol 2 will specific country emission standard)
be used. Refer to Protocol 2 below. For new
5 Design level (design level assigned to
electronic calibration strategies introduced since the the engine)
2000 model year, use Protocol 3. Refer to Protocol
3 below.
Protocol 3
Protocol 1
Item Description
Item Description
introduced)
introduced)
2 Vehicle code
2 Engine code
3 Transmission code
3 Engine revision level
4 Unique calibration (designates different
hardware to similar vehicles). Example:
tires, drive ratios, etc.
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Item Description
5 Not assigned
5 Fleet code (describes fleet to which the
6 Evaporative emissions
vehicle belongs). Example: 6 -
7 MACAA
evaporative emissions
8 On-board diagnostics (OBD) 6 Certification region (lead region where
multiple regions are included in one
9 Not assigned
calibration). Example: A - U.S. federal
Certification Region
7 Revision level (will advance as
revisions occur). Not printed on label
5 U.S. 50 states
A U.S. federal, including altitude, may include
Canada and/or Mexico
Protocol 3
B U.S. California standard, includes U.S. green
The following offers a more detailed explanation of
states
the coding strategy used for Protocol 3.
C Canada
Model Year
D China
Y 2000
E European Community (Austria, Belgium,
1 2001
Denmark, Finland, France, Germany, Greece,
2 2002
Ireland, Italy, Luxembourg, Netherlands, Portugal,
Spain, Sweden and United Kingdom)
3 2003
F Extended European Community (E plus
4 2004
Croatia, Czech Republic, Estonia, Hungary,
5 2005
Norway, Poland, Romania, Russian Federation,
6 2006
Slovakia, Slovenia, Switzerland and Yugoslavia)
7 2007
G Gulf Cooperative Council (Bahrain, Kuwait,
Oman, Qatar, Saudi Arabia and UAE)
Vehicle Line
H Hong Kong
ZF Mustang
J Japan
Transmission
K Korea
1 Automatic transmission
L Malaysia
2 Manual transmission
M Mexico
Unique Calibration
N New Zealand
The Emissions/CAFE/CO2 Compliance Department
is responsible for assigning these calibration P Australia
numbers. Unique calibration identifications are
Q South America (Brazil)
assigned to cover similar vehicles to differentiate
S Singapore
tires, drive configurations, final drive ratios and
T Taiwan
other calibration-significant factors.
U South America (unleaded fuel regions)
These 2 characters are chosen by the analyst to
provide easily identifiable information unique to
V Vietnam
each calibration. For example, using the number 2
X Rest of world (ROW)
to denote a 2-valve engine versus using the number
Y Military
4 to denote a 4-valve engine.
Z Israel
Fleet Code
Revision Level (not printed on label)
1 HDGE/Dyno
91-99 Hardware certification levels
2 Fast AMA, U.S.
01-04 Preliminary levels
3 ADP, U.S.
00 Job 1 production (initial certification)
4 Not assigned
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05-09 Pre-job 1 revisions to calibrations 0B Durability test level
10-89 Post-job 1 revisions to calibrations BD On-board diagnostics (OBD) intermediate
level (pre-05)
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100-02-1 100-02-1 Jacking and Lifting
To jack the front end, lift at the pinch welds located
Jacking
at the front opening of the rocker panels.
WARNING: Never run the engine with one
wheel off the ground, such as when changing a Jacking Points Rear
tire. The wheel still on the ground could cause
NOTE: RH side shown, LH side similar.
the vehicle to move.
CAUTION: The jack provided with the
vehicle is intended to be used in an emergency
for changing a deflated tire. To avoid damage to
the vehicle, never use the jack to lift the vehicle
for any other purpose. Refer to the owner guide
when using the jack supplied with the vehicle.
CAUTION: Under no circumstances should
the vehicle ever be lifted by the suspension arm
brackets, rear stabilizer, differential housing or
convertible cross brace. Severe damage to the
vehicle could result.
To jack the rear end, lift at the pinch welds located
CAUTION: Do not attempt to use jack
at the rear opening of the rocker panels.
pressure on either the front bumper or the rear
bumper of any vehicle. Damage to the bumper
covers will occur.
Jack the vehicle using the jacking points shown in
this section.
Jacking Points Front
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100-02-1 100-02-1 Jacking and Lifting
NOTE: Convertible shown, coupe similar.
Lifting
CAUTION: Do not allow the lift adapters
to contact the steering linkage, suspension arms,
stabilizer arms, or to compress the lower
suspension arm stabilizer bar insulator. Damage
to the suspension, exhaust and steering linkage
components may occur if care is not exercised
when positioning the hoist adapters prior to
lifting the vehicle.
CAUTION: Never use the differential
housing as a lift point. Damage to the differential
housing and cover may occur.
CAUTION: To prevent possible damage to
the underbody, do not drive the vehicle onto the
drive-on lift without first checking for possible
interference. Check for interference between the
upright flanges of the hoist rails and the
underbody. If an interference exists, modify the
hoist flanges or build up the approach ramps as
necessary to provide clearance.
CAUTION: Adapters may be necessary to
clear vehicle components to lift the vehicle safely.
The adapters must be placed at the 4 designated
contact points. Position the adapters so they are
centered on the adapter contact area.
Lift the vehicle at the applicable lift points.
CAUTION: Do not position lift pads under
the crossmembers, body damage may occur.
CAUTION: Do not lift vehicle on
convertible cross brace. Body damage may occur.
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100-03-1 100-03-1 Maintenance Schedule
Special Operating Condition
Maintenance Schedule Gasoline
Requirements
Engines
When towing a trailer or using a camper or
The maintenance schedule is designed to protect
car-top carrier:
against major repairs resulting from neglect or
inadequate maintenance and to prolong the life of
Change engine oil and install a new oil filter
the vehicle.
every 4,800 km (3,000 miles) or 3 months.
Inspect and rotate tires every 4,800 km (3,000
General Maintenance Information
miles).
NOTE: This is a generic maintenance schedule for
Change automatic transmission fluid (not required
all Ford, Lincoln and Mercury vehicles. There may
on 6R60 transmission), lubricate rear wheel drive
be items listed that do not apply to all vehicles.
(RWD) front wheel bearings, install new grease
The Normal Schedule applies to operation of the
seals and adjust bearings every 48,000 km (30,000
vehicle under typical, everyday driving conditions.
miles). If equipped, change the in-line service
The maintenance frequency in this schedule typifies
installed transmission fluid filter.
what the vast majority of vehicles will require. The
Change transfer case fluid every 96,000 km
listed services should be carried out at specified
(60,000 miles).
mileage intervals. There are, however, additional
services required that only the noted vehicles Change manual transmission fluid as required.
require.
Inspect and lubricate U-joints and halfshafts as
If the vehicle is operated in one or more of the required.
following special operating conditions, those
During extensive idling and/or low speed driving
additional services will be required. The special
for long distances, as in heavy commercial use
operating conditions are:
such as delivery, taxi, patrol car or livery:
towing or carrying heavy loads.
extensive idling and/or driving at low speeds for every 4,800 km (3,000 miles) or 3 months or 200
long distances. hours of engine operation.
driving in dusty conditions. Inspect and rotate tires every 4,800 km (3,000
miles).
off-road operation.
Lube front lower control arm and steering linkage
use of E85 fuel 50% of the time or greater (flex
ball joints with zerk fittings (if equipped) every
fuel vehicles only).
4,800 km (3,000 miles) or 3 months.
There are also exceptions to the Normal Operating
Inspect brake system and check battery electrolyte
Schedule which will require more frequent
level every 8,000 km (5,000 miles).
maintenance for some components. Those
exceptions are: Install a new fuel filter every 24,000 km (15,000
miles) (not required for Fusion and Milan).
standard vehicle axle maintenance and
lubrication.
on 6R60 transmission), lubricate RWD front
police and taxi vehicles maintenance and
wheel bearings, install new grease seals and adjust
lubrication.
bearings every 48,000 km (30,000 miles). If
engine oil and Motorcraft Premium Gold coolant
equipped, change the in-line service installed
time-based and mileage-based intervals.
transmission fluid filter.
change brake fluid every 2 years (Class A
Install new spark plugs and change transfer case
Motorhome).
fluid every 96,000 km (60,000 miles).
Install a new cabin air filter as required (if
equipped).
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Checks and Services When operating in dusty conditions such as
unpaved or dusty roads:
Certain basic maintenance checks and inspections
should be carried out at specified intervals. Any
recognized adverse condition should be corrected as
soon as possible.
Install a new fuel filter every 24,000 km (15,000
miles) (not required for Fusion and Milan). Multi-Point Inspection
The following inspections are recommended at
on 6R60 transmission), check air filter restriction
every service interval:
gauge and install a new filter as required (Focus
Check and top off brake, coolant, manual and
engine only) every 48,000 km (30,000 miles). If
automatic transmission (if equipped with a
equipped, change the in-line service installed
underhood fluid level indicator), power steering
and window washer fluids.
Change rear axle lubricant every 80,000 km
Inspect tires for wear and correct air pressure,
(50,000 miles) (E-450 and F-450/550 only).
including spare tire.
Check exhaust system for leaks, damage, loose
(60,000 miles).
parts and foreign material.
Install a new engine air filter as required.
Check battery performance.
Install a new cabin air filter as required (if
Check operation of horn, exterior lamps, turn
equipped).
signals and hazard warning lights.
When operating in off-road conditions:
Check radiator, coolers, heater and air
conditioning hoses.
Inspect windshield wiper spray and wiper
Inspect and rotate tires every 4,800 km (3,000
operation.
miles).
Check windshield for cracks, chips and pitting.
Change automatic transmission fluid every 48,000
Inspect for oil and fluid leaks.
km (30,000 miles). If equipped, change the in-line
Inspect air cleaner filter.
service-installed transmission fluid filter.
Inspect halfshaft dust boots (if equipped).
Change rear axle lubricant every 80,000 km
(50,000 miles) (E-450 and F-450/550 only). Check shocks, struts and other suspension
components for leaks and damage.
(60,000 miles). Inspect steering and linkage.
Install a new cabin air filter as required (if Inspect accessory drive belt(s).
equipped).
Inspect clutch operation (if equipped).
Inspect and lubricate U-joints and halfshafts.
In-Line, Service-Installed Transmission
Inspect and lubricate steering linkage ball joints
Fluid Filter
with zerk fittings.
Some vehicles may be equipped with an in-line,
Use of E85 fuel 50% of the time or greater (flex
service-installed transmission fluid filter. This filter
fuel vehicles only):
is installed in the transmission fluid cooler return
line. If equipped, install a new in-line filter during
transmission fluid change intervals.
every 4,800 km (3,000 miles), 3 months or 200
hours of engine operation (whichever occurs first).
Maximum Oil Change Interval (Normal
Fill the fuel tank with regular gasoline (non E85)
Schedule)
once every 3,000 miles.
8,000 km (5,000 miles) or 6 months (whichever
occurs first).
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Maximum Oil Change Interval (Special Normal Schedule
Operating Conditions)
NOTE: Rotate tires and inspect for wear at 5,000
miles, 15,000 miles and every 15,000 miles is
4,800 km (3,000 miles), 3 months or 200 hours of
required thereafter. At other 5,000-mile intervals,
engine operation (whichever occurs first).
rotation is recommended for optimal life.
Monthly Checks
The following check procedures should be carried
Check each of the following items every month:
out for all cars, minivans, light trucks, sport utilities,
vans, four wheel drive (4WD) and natural gas
All interior and exterior lights for correct
vehicles.
operation.
Retighten the wheel nuts to the specified torque at
Tires for wear and correct air pressure, including
800 km (500 miles) after any wheel disturbance
spare tire.
(tire rotation, changing a flat tire or wheel
Engine oil fluid level.
removal).
Windshield washer solvent fluid level.
On vehicles equipped with dual rear wheels,
retighten the wheel nuts to the specified torque at
Six Month Checks
160 km (100 miles) and again at 800 km (500
Check each of the following items at least every 6
miles) of new vehicle operation or after any wheel
months:
disturbance (tire rotation, changing a flat tire or
Lap/shoulder belts and seat latches for wear and wheel removal).
function.
Carry-out multi-point inspection (recommended).
External mounted spare tire is stowed correctly
8,000 Km (5,000 Miles)
(tight to body).
Change engine oil and install a new oil filter.
Power steering fluid level.
Rotate tires and inspect for wear.
Washer spray, wiper operation and clean all wiper
blades (install new wiper blades as necessary).
Parking brake for correct operation.
16,000 Km (10,000 Miles)
Lubricate all hinges, latches, door check straps
and outside locks.
Inspect tires for wear. Rotation recommended for
Lubricate upper and lower sliding door tracks (if
optimal tire life.
equipped).
Clean sliding door contact switches (if equipped).
Lubricate door rubber weatherstrips.
24,000 Km (15,000 Miles)
Clean body and door drain holes.
Safety warning lamps (brake, ABS, air bag, safety
Inspect automatic transmission fluid level (if
belt) for correct operation.
equipped with an underhood fluid level indicator).
Coolant system fluid level and correct strength.
Inspect brake pads, shoes, rotors, drums, brake
Battery connections. Clean if necessary.
lines, hoses and parking brake system (adjust
parking brake if required).
Clutch fluid level, if equipped.
Inspect wheel ends for end play and noise.
Inspect engine cooling system and hoses.
Inspect steering linkage, ball joints, suspension
and if equipped, halfshafts, driveshaft and
U-joints.
Lubricate steering linkage, suspension and ball
joints (if equipped with zerk fittings).
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Lubricate halfshafts, driveshaft and U-joints. Install new climate controlled seat cushion filters
(if equipped) (Navigator, Freestar, Monterey and
Expedition).
Install a new cabin air filter (if equipped).
Inspect and lubricate 4WD front axle shaft
U-joints (F-250/350/450/550).
Lubricate the 4WD front axle shaft U-joints (if
equipped) (F-250/350/450/550).
32,000 Km (20,000 Miles) Carry-out multi-point inspection (recommended).
56,000 Km (35,000 Miles)
optimal tire life.
optimal tire life.
64,000 Km (40,000 Miles)
optimal tire life.
optimal tire life.
72,000 Km (45,000 Miles)
Inspect exhaust system and heat shields.
Inspect steering linkage, suspension and ball joints
and, if equipped, halfshafts, driveshaft and
U-joints.
Inspect steering linkage, suspension and ball
Install a new engine air filter (not required for
joints.
Focus).
Inspect halfshafts, driveshaft and U-joints (if
Install a new fuel filter (not required for Fusion
equipped).
and Milan).
Change automatic transmission/transaxle fluid on
all vehicles equipped with the TorqShift
transmission. Install a new remote filter if
equipped) (F-250/350/450/550).
equipped with a TorqShift transmission. Inspect
automatic transmission fluid level using the fluid Carry-out multi-point inspection (recommended).
level on all other vehicles (if equipped with an
underhood fluid level indicator). Change the
in-line service-installed transmission fluid filter (if
equipped).
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80,000 Km (50,000 Miles)
Lubricate rear wheel drive (RWD) front wheel
bearings, install new grease seals and adjust
optimal tire life.
bearings (if equipped with serviceable bearings).
Change rear axle fluid (Class A Motorhome).
Lubricate the four wheel drive (4WD) front axle
shaft U-joints (if equipped) (F-250/350/450/550).
88,000 Km (55,000 Miles)
104,000 Km (65,000 Miles) Change engine oil and install a new oil filter.
optimal tire life.
optimal tire life.
96,000 Km (60,000 Miles)
112,000 Km (70,000 Miles) Change engine oil and install a new oil filter.
optimal tire life.
120,000 Km (75,000 Miles)
joints.
equipped).
Focus).
and Milan).
joints.
all vehicles equipped with the TorqShift or 4F27E
transmissions. Install a new remote filter if
equipped).
equipped with a TorqShift transmission. Inspect
automatic transmission fluid level on all other
Check air filter restriction gauge, install a new
vehicles (if equipped with an underhood fluid
filter as necessary (Focus only).
level indicator). Change the in-line
Lubricate steering linkage, suspension and ball service-installed transmission fluid filter (if
joints (if equipped zerk fittings). equipped).
Lubricate the 4WD front axle shaft U-joints (if Change automatic transmission fluid on all
equipped) (F-250/350/450/550). vehicles equipped with a CVT transmission and
install a new high-pressure case filter and O-rings.
Install new climate controlled seat cushion filters
Expedition).
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128,000 Km (80,000 Miles)
equipped) (F-250/350/450/550).
optimal tire life.
152,000 Km (95,000 Miles)
136,000 Km (85,000 Miles)
optimal tire life.
optimal tire life.
160,000 Km (100,000 Miles)
144,000 Km (90,000 Miles)
Inspect accessory drive belt(s).
Install new spark plugs.
Change rear axle fluid (F-450/550, E-450 and
Class A Motorhome).
lines, hoses and parking brake system.
Change Premium Gold coolant or change at 6
years, whichever comes first.
Install a new external PCV on all cars and light
trucks under 6,000 lb Gross Vehicle Weight
(GVW) (except 3V engines).
joints.
Change manual transmission fluid (if equipped)
(except Escape).
equipped).
168,000 Km (105,000 Miles)
Focus).
and Milan).
all vehicles equipped with TorqShift
transmissions. Install a new remote filter element
on vehicles equipped with the TorqShift
transmission. Inspect automatic transmission fluid
level on all other vehicles (if equipped with an
underhood fluid level indicator). If equipped,
Inspect engine coolant system and hoses.
change the in-line service-installed transmission
fluid filter.
joints.
equipped).
Expedition).
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Lubricate the 4WD front axle shaft U-joints (if Change automatic transmission fluid on all
equipped) (F-250/350/450/550). vehicles equipped with a CVT transmission and
install a new high-pressure case filter and O-rings.
176,000 Km (110,000 Miles)
Expedition).
Lubricate RWD front wheel bearings, install new
grease seals and adjust bearings (if equipped with
optimal tire life.
serviceable bearings).
184,000 Km (115,000 Miles)
equipped) (F-250/350/450/550).
optimal tire life.
200,000 Km (125,000 Miles)
192,000 Km (120,000 Miles)
optimal tire life.
208,000 Km (130,000 Miles)
optimal tire life.
joints.
216,000 Km (135,000 Miles)
equipped).
Focus).
and Milan).
Install a new external PCV valve on all cars and
light trucks over 6,000 lb GVW (except 3V
engines).
all vehicles equipped with TorqShift or 4F27E
joints.
transmissions. Install a new remote filter element
on the vehicles equipped with the TorqShift
equipped).
transmission. Inspect automatic transmission fluid
level on all other vehicles (if equipped with an Install a new cabin air filter (if equipped).
underhood fluid level indicator). If equipped,
change the in-line service-installed transmission
fluid filter.
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Lubricate the 4WD front axle shaft U-joints (if Change rear axle fluid (Class A Motorhome).
equipped) (F-250/350/450/550).
Install a new accessory drive belt(s) (if a new belt
Carry-out multi-point inspection (recommended). has not been installed within the last 100,000
miles).
224,000 Km (140,000 Miles)
Expedition).
optimal tire life.
Install a new climate controlled seat back filter
(MKZ only).
Inspect PVC for flow (3V engines).
232,000 Km (145,000 Miles)
Install new non-sealed RWD front wheel bearings
optimal tire life.
and seals (if new bearings and seals have not
been installed in the last 100,000 miles).
240,000 Km (150,000 Miles)
equipped) (F-250/350/450/550).
Change front axle lubricant (4WD only).
Change transfer case fluid (4WD only).
all vehicles equipped with a 4F50N, 5R44E,
5R55E, 5R555, TorqShift and CD4E
transmission/transaxle. Install a new remote filter
if equipped with a TorqShift transmission. Inspect
Change Motorcraft Premium Gold coolant (see
automatic transmission fluid level using the fluid
Exceptions To Normal Schedule and Mileage
level indicator on all other vehicles (if equipped
Base).
with an underhood fluid level indicator). Change
Inspect exhaust system and heat shields. the in-line service-installed transmission fluid
filter (if equipped).
joints. Carry-out multi-point inspection (recommended).
Exceptions To Normal Schedule
equipped).
Maximum Oil Change Interval
and Milan).
Normal schedule: 8,000 km (5,000 miles) or 6
Install a new engine air filter (not required on months, whichever occurs first.
Focus).
Special operating conditions: 4,800 km (3,000
Check air filter restriction gauge, install a new air miles), 3 months or 200 hours of operation,
filter as necessary (Focus only). whichever occurs first.
Motorcraft Premium Gold Coolant
Change automatic transmission/transaxle fluid
Change Motorcraft Premium Gold coolant at 6
(except CVT transmission).
years or 160,000 km (100,000 miles) of the
Change automatic transaxle filter (except CVT,
vehicles life, whichever occurs first.
Five Hundred and Montego equipped with a
After the initial change, change coolant every 3
6-speed automatic transaxle).
years or 80,000 km (50,000 miles) thereafter.
Change rear axle lubricant on all RWD vehicles.
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Normal Vehicle Axle Maintenance
The axle lubricant should be changed anytime an
axle has been submerged in water.
Rear axles and transfer case/power transfer unit
(PTU) units containing synthetic lubricant and light
E and F-450 and 550 Series Axle
duty trucks equipped with Ford-design axles are
Maintenance
lubricated for life. These lubricants are not to be
Replace rear axle lubricant every 100,000 miles
checked or changed unless service is required, or if
under normal driving conditions on all E and F-450
a leak is suspected or the axle assembly has been
and 550 series applications. For E and F-450 and
submerged in water.
550 series vehicles operated at or near maximum
The axle and transfer case/PTU fluid should be
Gross Vehicle Weights, the rear axle lubricant
changed anytime they have been submerged in
should be replaced every 50,000 miles.
water. Non-synthetic rear axle lubricants should be
In addition, the 50,000 mile schedule should be
replaced every 4,800 km (3,000 miles) or 3 months,
observed when the vehicles are operated under the
whichever occurs first, during extended trailer tow
Special Operating Conditions.
operation above 21C (70F) ambient and wide
open throttle for extended periods above 45 mph.
Class A Motorhome
The 3,000 mile lube change interval may be waived
Every 2 years change brake fluid.
if the axle was filled with 75W-140 synthetic gear
Every 48,000 km (30,000 miles) change the
lubricant. Add 4 ounces of additive friction modifier
automatic transmission fluid and the transmission
for complete refill of Traction-Lok rear axles.
remote filter element.
The axle lubricant should be changed anytime an
Change rear axle fluid at 80,000 km (50,000
axle has been submerged in water.
miles), 160,000 km (100,000 miles) and 240,000
Police and Taxi Vehicle Axle Maintenance
km (150,000 miles).
Replace rear axle lubricant every 160,000 km
(100,000 miles). Rear axle lubricant change may be
waived if the axle was filled with 75W-140
synthetic gear lubricant. Add 4 ounces of additive
friction modifier for complete refill of
Traction-Lok rear axles.
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100-04-1 100-04-1 Noise, Vibration and Harshness
GENERAL PROCEDURES
5. Tighten the muffler connection.
Exhaust System Neutralizing
6. Tighten all the exhaust hanger clamps and
WARNING: Exhaust gases contain carbon
flanges (tighten the exhaust manifold flange
monoxide, which is harmful to health and
joint last).
potentially lethal. Repair exhaust system leaks
Verify there is adequate clearance to prevent
immediately. Never operate the engine in an
grounding at any point in the system. Make
enclosed area.
sure that the catalytic converter and heat
shield do not contact the frame rails.
WARNING: Exhaust system components
After neutralization, the rubber in the
are hot.
exhaust hangers should show some
NOTE: Neutralize the exhaust system to relieve
flexibility when movement is applied to the
strain on mounts which can be sufficiently bound up
exhaust system.
to transmit vibration as if grounded.
With the exhaust system installed securely
and cooled, the rear hanger should be angled
1. WARNING: The electrical power to
forward.
the air suspension system must be shut off
prior to hoisting, jacking or towing an air
7. Lower the vehicle.
suspension vehicle. This can be accomplished
by turning off the air suspension switch.
8. Test the exhaust system for normal operation.
Failure to do so can result in unexpected
inflation or deflation of the air springs,
which can result in shifting of the vehicle
during these operations.
CAUTION: Make sure the system is
warmed up to normal operating temperature,
as thermal expansion can be the cause of a
strain problem.
With the vehicle in NEUTRAL, position it on a
hoist. For additional information, refer to
Section 100-02.
2. Loosen all exhaust hanger attachments and
reposition the hangers until they hang free and
straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to
the vehicle frame with the muffler pipe bracket
free of stress.
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The diagnosis and correction of noise, vibration and
Noise, Vibration and Harshness (NVH)
harshness concerns requires:
Noise is any undesirable sound, usually unpleasant
in nature. Vibration is any motion, shaking or a road or system test to determine the exact
trembling, that can be felt or seen when an object nature of the concern.
moves back and forth or up and down. Harshness is
an analysis of the possible causes.
a ride quality issue where the vehicles response to
testing to verify the cause.
the road transmits sharply to the customer.
repairing any concerns found.
Harshness normally describes a firmer than usual
response from the suspension system. Noise,
a road test or system test to make sure the
vibration and harshness (NVH) is a term used to
concern has been corrected or brought back to
describe these conditions, which result in varying
within an acceptable range.
degrees of dissatisfaction. Although, a certain level
Glossary of Terms
of NVH caused by road and environmental
conditions is normal. This section is designed to aid
Acceleration Light
in the diagnosis, testing and repair of NVH
An increase in speed at less than 1/2 throttle.
concerns.
Acceleration Medium
Acceptable Noise, Vibration and
An increase in speed at 1/2 to nearly full throttle,
Harshness
such as 0-97 km/h (0-60 mph) in approximately 30
seconds. All internal combustion engines and drivelines
produce some noise and vibration; operating in a
Acceleration Heavy
real world environment adds noise that is not
An increase in speed at 1/2 to full throttle, such as
subject to control. Vibration isolators, mufflers and
0-97 km/h (0-60 mph) in approximately 20 seconds.
dampers reduce these to acceptable levels. A driver
Ambient Temperature who is unfamiliar with a vehicle can think that
The surrounding or prevailing temperature. some sounds are abnormal when actually the sounds
are normal for the vehicle type. For example,
Amplitude
Traction-Lok differentials produce a slight noise
The quantity or amount of energy produced by a
on slow turns after extended highway driving. This
vibrating component (G force). An extreme
is acceptable and has no detrimental effect on the
vibration has a high amplitude. A mild vibration has
locking axle function. As a technician, it is very
a low amplitude.
important to be familiar with vehicle features and
Backlash know how they relate to NVH concerns and their
Gear teeth clearance. diagnosis. For example, if the vehicle has
automatic overdrive, it is important to test drive the
Boom
vehicle both in and out of overdrive mode.
Low frequency or low pitched noise often
accompanied by a vibration. Also refer to
Diagnostic Theory
drumming.
The shortest route to an accurate diagnosis results
from: Bound Up
An overstressed isolation (rubber) mount that
system knowledge, including comparison with a
transmits vibration/noise instead of absorbing it.
known good system.
Brakes Applied
system history, including repair history and usage
When the service brakes are applied with enough
patterns.
force to hold the vehicle against movement with the
condition history, especially any relationship to
transmission in gear.
repairs or sudden change.
knowledge of possible sources.
using a systematic diagnostic method that divides
the system into related areas.
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Item Description Buffet/Buffeting
Strong noise fluctuations (less than 1000 Hz) caused
1 Positive caster
by gusting winds. An example would be wind gusts
2 True vertical
against the side glass.
3 Steering axis
Buzz
A low-pitched sound (200-5000 Hz) like that from a
Chatter
bee. Often a metallic or hard plastic humming
A pronounced series of rapidly repeating rattling or
sound. Also describes a high frequency (200-800
clicking sounds.
Hz) vibration. Vibration feels similar to an electric
razor. Chirp
A short-duration high-pitched noise associated with
Camber
a slipping drive belt.
The angle of the wheel in relation to the true
vertical as measured looking from the front of the Chuckle
vehicle. Camber is positive when the wheel angle is A repetitious low-pitched sound. A loud chuckle is
offset so that the top of the wheel is positioned usually described as a knock.
away from the vehicle.
Click
A sharp, brief, non-resonant sound, similar to
actuating a ball point pen.
Clonk
A hydraulic knocking sound. Sound occurs with air
pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency
sound. Occurs mostly on a vehicle that is
accelerating or decelerating abruptly. Also described
as a thunk.
Coast/Deceleration
Caster
Releasing the accelerator pedal at cruise, allowing
The angle of the steering knuckle in relation to the
the engine to reduce vehicle speed without applying
true vertical as measured looking from the side of
the brakes.
the vehicle.
Coast/Neutral Coast
Placing the transmission range selector in
NEUTRAL (N) or depressing the clutch pedal while
at cruise.
Constant Velocity (CV) Joint
A joint used to absorb vibrations caused by driving
power being transmitted at an angle.
Controlled Rear Suspension Height
The height at which a designated vehicle element
must be when driveline angle measurements are
made.
Coupling Shaft
The shaft between the transfer case and the front
drive axle or, in a 2-piece rear driveshaft, the front
section.
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CPS Drivetrain
Cycles per second. Same as hertz (Hz). All power transmitting components from the engine
to the wheels; includes the clutch or torque
Cracks
converter, the transmission, the transfer case, the
A mid-frequency sound, related to squeak. Sound
driveshaft and the front or rear drive axle.
varies with temperature conditions.
Drivetrain Damper
Creak
A weight attached to the engine, the transmission,
A metallic squeak.
the transfer case or the axle. It is tuned by weight
and placement to absorb vibration.
Cruise
Constant speed on level ground; neither accelerating
Drone
nor decelerating.
A low frequency (100-200 Hz) steady sound, like a
freezer compressor. Also described as a moan.
Cycle
The process of a vibrating component going through
Drumming
a complete range of motion and returning to the
A cycling, low-frequency (20-100 Hz), rhythmic
starting point.
noise often accompanied by a sensation of pressure
on the ear drums. Also described as a low rumble,
Decibel
boom or rolling thunder.
A unit of measurement, referring to sound pressure
level, abbreviated dB.
Dynamic Balance
The equal distribution of weight on each side of the
Drive Engine Run-Up (DERU) Test
centerline, so that when the wheel and tire assembly
The operation of the engine through the normal rpm
spins, there is no tendency for the assembly to
range with the vehicle standing still, the brakes
move from side-to-side (wobble). Dynamically
applied and the transmission engaged. This test is
unbalanced wheel and tire assemblies can cause
used for noise and vibration checks.
wheel shimmy.
Driveline Angles
Engine Imbalance
The differences of alignment between the
A condition in which an engines center mass is not
transmission output shaft, the driveshaft and the rear
concentric to the rotation center, causing excessive
axle pinion centerline.
motion.
Engine Misfire
When combustion in one or more cylinders does not
occur or occurs at the wrong time.
Engine Shake
An exaggerated engine movement or vibration that
directly increases in frequency as the engine speed
increases. It is caused by non-equal distribution of
mass in the rotating or reciprocating components.
Flexible Coupling
A flexible joint.
Float
Driveshaft
A drive mode on the dividing line between cruise
The shaft that transmits power to the rear axle input
and coast where the throttle setting matches the
shaft (pinion shaft). In a 2-piece driveshaft, it is the
engine speed with the road speed.
rearmost shaft.
Flutter
Mid to high (100-2000 Hz) intermittent sound due
to air flow. Similar to a flag flapping in the wind.
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Frequency Neutral Engine Run-Up (NERU) Test
The rate at which a cycle occurs within a given The operation of the engine through the normal rpm
time. range with the vehicle standing still and the
transmission disengaged. This test is used to identify
Gravelly Feel
engine related vibrations.
A grinding or growl in a component, similar to the
feel experienced when driving on gravel. Neutralize/Normalize
To return to an unstressed position. Used to
Grind
describe mounts. Also refer to bound up.
An abrasive sound, similar to using a grinding
wheel, or rubbing sand paper against wood. Outboard
Away from the centerline of the vehicle.
Hiss
Steady high frequency (200-800 Hz) noise. Vacuum Ping
leak sound. A short duration, high-frequency sound, which has a
slight echo.
Hoot
A steady low frequency tone (50-500 Hz), sounds Pinion Shaft
like blowing over a long neck bottle. The input shaft in a driving axle that is usually a
part of the smaller driving or input hypoid gear of a
Howl
ring and pinion gearset.
A mid-range frequency (200-800 Hz) noise between
drumming and whine. Also described as a hum. Pitch
The physical quality of sound that relates to its
Hum
frequency. Pitch increases as frequency increases
Mid-frequency (200-800 Hz) steady sound, like a
and vice versa.
small fan motor. Also described as a howl.
Pumping Feel
Hz
A slow, pulsing movement.
Hertz; a frequency measured in cycles per second.
Radial/Lateral
Imbalance
Radial is in the plane of rotation; lateral is at 90
Out of balance; heavier on one side than the other.
degrees to the plane of rotation.
In a rotating component, imbalance often causes
vibration.
Inboard
Toward the centerline of the vehicle.
Intensity
The physical quality of sound that relates to the
strength of the vibration (measured in decibels). The
higher the sounds amplitude, the higher the
intensity and vice versa.
Isolate
To separate the influence of one component to
another.
Knock Item Description
A heavy, loud, repetitious sound, like a knock on
1 Lateral runout
the door.
2 Radial runout
Moan
A constant, low-frequency (100-200 Hz) tone. Also
Rattle
described as a hum.
A random and momentary or short duration noise.
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Ring Gear Static Balance
The large, circular, driven gear in a ring and pinion The equal distribution of weight around the wheel.
gearset. Statically unbalanced wheel and tire assemblies can
cause a bouncing action called wheel tramp. This
Road Test
condition will eventually cause uneven tire wear.
The operation of the vehicle under conditions
intended to produce the concern under investigation. Tap
A light, rhythmic, or intermittent hammering sound,
Roughness
similar to tapping a pencil on a table edge.
A medium-frequency vibration. A slightly higher
frequency (20 to 50 Hz) than a shake. This type of Thump
vibration is usually related to drivetrain components. A dull beat caused by 2 items striking together.
Runout Tick
Lateral runout means measuring the movement or A rhythmic tap, similar to a clock noise.
wobble of a wheel or tire at the sidewall. Radial
Tip-In Moan
runout means measuring the out-of-round at the
A light moaning noise heard during light vehicle
tread surface.
acceleration, usually between 40-100 km/h (25-65
Rustling mph).
Intermittent sound of varying frequency (100-2000
TIR
Hz), sounds similar to shuffling through leaves.
The acronym for total indicated runout is TIR.
Shake
Tire Deflection
A low-frequency vibration (5-20 Hz), usually with
The change in tire diameter in the area where the
visible component movement. Usually relates to
tire contacts the ground.
tires, wheels, brake drums or brake discs if it is
vehicle speed sensitive, or engine if it is engine
Tire Flat Spots
speed sensitive. Also referred to as a shimmy or
A condition commonly caused by letting the vehicle
wobble.
stand while the tires cool off. This condition can be
corrected by driving the vehicle until the tires are
Shimmy
warm. Also, irregular tire wear patterns in the tire
An abnormal vibration or wobbling, felt as a
tread resulting from wheel-locked skids.
side-to-side motion of the steering wheel in the
driveshaft rotation. Also described as waddle.
Tire Force Vibration
A tire vibration caused by variations in the
Shudder
construction of the tire that is noticeable when the
A low-frequency vibration that is felt through the
tire rotates against the pavement. This condition can
steering wheel or seat during light brake application.
be present on perfectly round tires because of
Slap variations in the inner tire construction. This
A resonance from flat surfaces, such as safety belt condition can occur at wheel rotation frequency or
webbing or door trim panels. twice rotation frequency.
Slip Yoke/Slip Spline Transient
The driveshaft coupling that allows length changes A noise or vibration that is momentary, a short
to occur while the suspension articulates and while duration.
the driveshaft rotates.
Two-Plane Balance
Squeak Radial and lateral balance.
A high-pitched transient sound, similar to rubbing
Vibration
fingers against a clean window.
Any motion, shaking or trembling, that can be felt
Squeal or seen when an object moves back and forth or up
A long-duration, high-pitched noise. and down.
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Whine
A constant, high-pitched noise. Also described as a
screech.
Whistle
High-pitched noise (above 500 Hz) with a very
narrow frequency band. Examples of whistle noises
are a turbocharger or airflow around an antenna.
Wind Noise
Any noise caused by air movement in, out or
around the vehicle.
WOT
The acronym for wide open throttle is WOT.
Item Description
1 EVA screen
Tools and Techniques
2 Frequency mode displayed in rpm or
Vibration Analyzer (EVA)
Hz
The vibration analyzer (EVA) is a hand-held
3 Active sensor input (A or B)
electronic scan tool which will assist in locating the
4 Current active mode
source of unacceptable vibrations. The vibration
sensor can be remotely mounted anywhere in the 5 G force indicators or the strongest
frequencies in descending strength of
vehicle for testing purposes. The unit displays the 3
each vibration
most common vibration frequencies and their
6 Strength of each vibration corresponding amplitudes simultaneously. A bar
graph provides a visual reference of the relative
7 Frequency in rpm/Hz of each vibration
signal strength (amplitude) of each vibration being
displayed and its relative G force. The keypad is
The EVA allows for a systematic collection of
arranged to make the EVA simple to program and
information that is necessary to accurately diagnose
use. Some of the functions include the ability to
and repair NVH problems. For the best results,
average readings as well as record, play back and
carry out the test as follows:
freeze readings. The EVA has a strobe balancing
function that can be used to detect imbalance on
a. Test drive the vehicle with the vibration sensor
rotating components such as a driveshaft or engine
inside the vehicle.
accessories.
b. Place the sensor in the vehicle according to
feel.
If the condition is felt through the steering
wheel, the source is most likely in the front
of the vehicle.
A vibration that is felt in the seat or floor
only will most likely be found in the
driveline, drive axle or rear wheels and
tires.
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c. Record the readings. Also note when the Provide a photo-tachometer for operation of the
condition begins, when it reaches maximum driveshaft balancing function
intensity and if it tends to diminish
Provide a strobe output capable of driving a
above/below a certain speed.
standard timing light
Frequencies should be read in the
Contain a real time clock circuit that provides
average mode.
time and date information which is used for
Frequencies have a range of plus or minus tagging test data
2. A reading of 10 Hz can be displayed as
Have the capability to print to an external printer
an 8 Hz through 12 Hz.
and interface with a PC
Frequencies with a reading of 0.06 Gs or
Can be powered from a variety of power sources:
less, are barely perceptible NVH levels. No
cigarette lighter, AC power or the internal battery
corrective action is necessary.
pack
d. Place the vibration sensor on or near the
The MTS 4000 and the 4100 NVH analyzers have 4
suspect area outside the vehicle.
main operating modes. The first is for vibration
e. Continue the road test, driving the vehicle at diagnosis. This mode measures data from 1 or 2
the speed the symptom occurs, and take another accelerometers simultaneously while obtaining data
reading. from the vehicles computer system about the
operation of the vehicle. Then it does a frequency
f. Compare the readings.
analysis on the accelerometer information and
A match in frequency indicates the problem
compares the vibration frequencies with the
component or area.
frequencies associated with various rotating
Example: A vibration is felt in the seat.
components within the vehicle. The data can be
Place the sensor on the console. Record the
presented in 4 different display modes: principle
readings. Place the vibration sensor on the
component, bar chart, frequency spectrum or
rear axle. Compare the readings. If the
waterfall. All display mode formats contain the
frequencies are the same, the axle is the
same common elements, such as amplitude.
problem component.
The second is for noise diagnosis. This mode
If the 2 readings are not the same
measures noise from 1 or 2 microphones
frequency, then diagnose the frequency with
simultaneously. All noise measurements are in dbs.
the most significant amplitude (Gs) first.
All frequency bands used for noise measurements
are the same as for the vibration measurements, up
NVH Analyzer (Vetronix)
to 1000 Hz.
The MTS 4000 and the MTS 4100 NVH analyzers
The third is driveshaft balancing. Driveshaft
are tools to aid in the identification and isolation of
balancing is done using 1 or 2 accelerometers and a
a noise, vibration or harshness concern in a vehicle.
photo-tachometer. The accelerometers measure the
They measures noise and vibration data and
vibrations at both ends of the driveshaft, while the
compare it with data obtained from the vehicles
photo-tachometer measures the rotation speed and
powertrain control module (PCM) in order to
position reference.
provide possible sources. The MTS 4000 and the
4100 have the following characteristics:
The fourth mode is the strobe. A strobe or standard
timing light can be connected to an analyzer, to
Interfaces with the vehicles computer system
provide a means for measuring rotational speed. The
Support and store vibration data input from 1 or 2
strobe function is used for isolating the source of a
accelerometers
vibration.
Support and store noise data input from 2
microphones
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Vibrate Software EngineEAR Basic Unit
Vibrate Software (Rotunda tool number An electronic listening device used to detect even
215-00003) is a diagnostic aid which will assist in the faintest noises, the EngineEARs can detect the
pinpointing the source of unacceptable vibrations. noise of damaged/worn bearings in generators,
The engines crankshaft is the point of reference for coolant pumps, A/C compressors and power steering
vibration diagnosis. Every rotating component will pumps. They are also used to identify noisy lifters,
have an angular velocity that is faster, slower or the exhaust manifold leaks, chipped gear teeth and for
same as the engines crankshaft. Vibrate Software detecting wind noise. The EngineEAR has a sensing
calculates the angular velocity of each component tip, amplifier and headphones. The directional
and graphically represents these velocities on a sensing tip is used to listen to the various
computer screen and on a printed vibration components. Point the sensing tip at the suspect
worksheet. The following steps outline how Vibrate component and adjust the volume with the
Software helps diagnose a vibration concern: amplifier. Placing the tip in direct contact with a
component will reveal structure-borne noise and
Enter the vehicle information. Vibrate will do all
vibrations, generated by or passing through, the
the calculations and display a graph showing tire,
component. Various volume levels can reveal
driveshaft and engine vibrations.
different sounds.
Print a Vibration Worksheet graph. The printed
Ultrasonic Leak Detector
graph is to be used during the road test.
The Ultrasonic Leak Detector is used to detect wind
Road test the vehicle at the speed where the
noises caused by leaks and gaps in areas where
vibration is most noticeable. Record the vibration
there is weatherstripping or other sealing material. It
frequency (rpm) and the engine rpm on the
is also used to identify A/C leaks, vacuum leaks and
worksheet graph. The point on the graph where
evaporative emission noises. The Ultrasonic Leak
the vibration frequency (rpm) reading and the
Detector includes a multi-directional transmitter
engine rpm reading intersect indicates the
(operating in the ultrasonic range) and a hand-held
specific component group causing the concern.
detector. The transmitter is placed inside the
A EVA or equivalent tool capable of
vehicle. On the outside of the vehicle, the hand-held
measuring vibration frequency and engine rpm
detector is used to sweep the area of the suspected
will be needed.
leak. As the source of the leak is approached, a
beeping sound is produced which increases in both
Provide pictures of diagnostic procedures to aid in
speed and frequency.
testing components.
Squeak and Rattle Repair Kit
Combination EngineEAR/ChassisEAR
The Squeak and Rattle Repair Kit (Rotunda tool
An electronic listening device used to quickly
number 164-R4900) contains lubricants and
identify noise and the location under the chassis
self-adhesive materials that can be used to eliminate
while the vehicle is being road tested. The
interior and exterior squeaks and rattles. The kit
ChassisEARs can identify the noise and location of
consists of the following materials:
damaged/worn wheel bearings, CV joints, brakes,
springs, axle bearings or driveshaft carrier bearings.
PVC (soft foam) tape
Urethane (hard foam) tape
Flocked (black fuzzy) tape
UHMW (frosted) tape
Squeak and rattle oil tube
Squeak and rattle grease tube
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Tracing Powder
Tracing powder is used to check both the uniformity
of contact and the tension of a seal against its
sealing surface. These tests are usually done when a
suspected air leak/noise appears to originate from
the seal area or during the alignment and
adjustment of a component to a weatherstrip.
Tracing powder can be ordered from Crest
Industries as ATR Leak Trace. Carry out the tracing
powder test as follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface
only.
Index Card
Place an index card or a piece of paper between the
c. Close the door completely. Do not slam the
weatherstrip and the sealing surface, then close the
door.
door. Slowly withdraw the index card or paper after
d. Open the door. An imprint is made where the
the door is closed and check the amount of pressure
weatherstrip contacted the mating surface seal.
on the weatherstrip. There should be a medium
Gaps or a faint imprint will show where there
amount of resistance as it is withdrawn. Continue
is poor contact with the weatherstrip.
around the entire seal area. If there is little or no
resistance, this indicates insufficient contact to form
a good seal. At these points, the door, the glass or
the weatherstrip is out of alignment.
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DIAGNOSIS AND TESTING
To assist the service advisor and the technician, a
Noise, Vibration and Harshness (NVH)
Write-up Job Aid and an NVH Diagnostic Guide
Special Tool(s)
are included with this material. The Write-up Job
Aid serves as a place to record all important
ChassisEAR
symptom information. The NVH Diagnostic Guide
107-R2102 or equivalent
serves as a place to record information reported on
the Write-up Job Aid as well as data from the
testing to be carried out.
Electronic Vibration Analyzer
100-F027 (014-00344) or
equivalent
EngineEAR
Ultrasonic Leak Detector
Dial Indicator Gauge with
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
Holding Fixture
100-D002 (D78P-4201-B) or
equivalent
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DIAGNOSIS AND TESTING (Continued)
To begin a successful diagnosis, fill out the NVH
Diagnostic Guide, record the reported findings, then
proceed to each of the numbered process steps to
complete the diagnosis.
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Customer Interview
Remember that the vibrating source component
(originator) may only generate a small vibration.
The diagnostic process starts with the customer
This small vibration can in turn cause a larger
interview. The service advisor must obtain as much
vibration/noise to emanate from another receiving
information as possible about the problem and take
component (reactor), due to contact with other
a test drive with the customer. There are many ways
components (transfer path).
a customer will describe NVH concerns and this
will help minimize confusion arising from
Conduct the road test on a quiet street where it is
descriptive language differences. It is important that
safe to duplicate the vibration/noise. The ideal
the concern is correctly interpreted and the customer
testing route is an open, low-traffic area where it
descriptions are recorded. During the interview, ask
is possible to operate the vehicle at the speed in
the following questions:
which the condition occurs.
If possible, lower the radio antenna in order to
When was it first noticed?
minimize turbulence. Identify anything that could
Did it appear suddenly or gradually?
potentially make noise or be a source of wind
Did any abnormal occurrence coincide with or
noise. Inspect the vehicle for add-on items that
proceed its appearance?
create vibration/noise. Turn off the radio and the
heating and cooling system blower.
Use the information gained from the customer to
accurately begin the diagnostic process.
The engine speed is an important factor in
arriving at a final conclusion. Therefore, connect
Pre-Drive Check
an accurate tachometer to the engine, even if the
It is important to do a pre-drive check before road
vehicle has a tachometer. Use a tachometer that
testing the vehicle. A pre-drive check verifies that
has clearly defined increments of less than 50
the vehicle is relatively safe to drive and eliminates
rpm. This ensures an exact engine speed reading.
any obvious faults on the vehicle.
Verify the Customer Concern
The pre-drive check consists of a brief visual
Verify the customer concern by carrying out a road
inspection. During this brief inspection, take note of
test, an engine run-up test, or both.
anything that will compromise safety during the
road test and make those repairs/adjustments before
The decision to carry out a road test, an engine
taking the vehicle on the road.
run-up test, or both depends on the type of NVH
concern. A road test may be necessary if the
Preparing for the Road Test
symptom relates to the suspension system or is
Observe the following when preparing for the road
sensitive to torque. A drive engine run-up (DERU)
test:
or a neutral engine run-up (NERU) test identifies
noises and vibrations relating to engine and
Review the information recorded on the NVH
drivetrain rpm. Remember, a condition will not
Diagnostic Guide. It is important to know the
always be identifiable by carrying out these tests,
specific concern the customer has with the
however, they will eliminate many possibilities if
vehicle.
carried out correctly.
Do not be misled by the reported location of the
noise/vibration. The cause can actually be some
distance away.
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Road Test
The Engine Accessory Test helps to locate faulty
belts and accessories that cause engine
NOTE: It may be necessary to have the customer
speed-related concerns.
ride along or drive the vehicle to point out the
concern. During the road test, take into
The Vehicle Cold Soak Procedure helps to
consideration the customers driving habits and the
identify concerns occurring during initial start-up
driving conditions. The customers concern just may
and when an extended time lapse occurs between
be an acceptable operating condition for that
vehicle usage.
vehicle.
Slow Acceleration Test
The following is a brief overview of each test in the
To carry out this test, proceed as follows:
order in which it appears. A review of this
information helps to quickly identify the most
Slowly accelerate to the speed where the reported
appropriate process necessary to make a successful
concern occurs. Note the vehicle speed, the engine
diagnosis. After reviewing this information, select
rpm and, if possible, determine the vibration
and carry out the appropriate test(s), proceeding to
frequency.
the next step of this process.
Attempt to identify from what part of the vehicle
The Slow Acceleration Test is normally the first
the concern is coming.
test to carry out when identifying an NVH
Attempt to identify the source of the concern.
concern, especially when a road test with the
Proceed as necessary.
customer is not possible.
The Heavy Acceleration Test helps to determine if
Heavy Acceleration Test
the concern is torque-related.
The Neutral Coast Down Speed Test helps to
Accelerate hard from 0-64 km/h (0-40 mph).
determine if the concern is vehicle speed-related.
Decelerate in a lower gear.
The Downshift Speed Test helps to determine if
The concern is torque related if duplicated while
the concern is engine speed-related.
carrying out this test.
The Steering Input Test helps to determine how
the wheel bearings and other suspension
components contribute to a vehicle speed-related
Neutral Coast Down Speed Test
concern.
The Brake Test helps to identify vibrations or
noise that are brake related.
Drive at a higher rate of speed than where the
concern occurred when carrying out the Slow
The Road Test Over Bumps helps isolate a noise
Acceleration Test.
that occurs when driving over a rough or bumpy
surface.
Place the transmission in NEUTRAL and coast
down past the speed where the concern occurs.
The Engine Run-Up Tests consist of the Neutral
Run-Up Test and the Engine Load Test. These
The concern is vehicle speed-related if duplicated
tests help to determine if the concern is engine
while carrying out this test. This eliminates the
speed-related.
engine and the torque converter as sources.
The Neutral Run-Up Test is used as a follow-up
If the concern was not duplicated while carrying
test to the Downshift Speed Test when the
out this test, carry out the Downshift Speed Test
concern occurs at idle.
to verify if the concern is engine speed related.
The Engine Load Test helps to identify
vibration/noise sensitive to engine load or torque.
Downshift Speed Test
It also helps to reproduce engine speed-related
concerns that cannot be duplicated when carrying
out the Neutral Run-Up Test or the Neutral Coast
Shift into a lower gear than the gear used when
Down Test.
carrying out the Slow Acceleration Test.
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Neutral Engine Run-Up (NERU) Test
Drive at the engine rpm where the concern
occurs.
The concern is engine speed related if duplicated
Install a tachometer.
while carrying out this test. This eliminates the
Increase the engine rpm up from an idle to
tires, wheels, brakes and the suspension
approximately 4000 rpm while in PARK on front
components as sources.
wheel drive vehicles with automatic transmissions,
If necessary, repeat this test using other gears and
or NEUTRAL for all other vehicles. Note the
NEUTRAL to verify the results.
engine rpm and, if possible, determine the
vibration frequency.
Attempt to identify what part of the vehicle the
Steering Input Test
concern is coming from.
Attempt to identify the source of the concern.
Drive at the speed where the concern occurs,
while making sweeping turns in both directions.
Drive Engine Run-Up (DERU) Load Test
If the concern goes away or gets worse, the wheel
bearings, hubs, U-joints (contained in the axles of
four wheel drive [4WD] applications), and tire
tread wear are all possible sources. WARNING: Block the front and rear
wheels, and apply the parking brake and the
service brake, or injury to personnel can result.
Brake Test
CAUTION: Do not carry out the Engine
Load Test for more than five seconds or damage
Warm the brakes by slowing the vehicle a few to the transmission or transaxle can result.
times from 80-32 km/h (50-20 mph) using light Block the front and rear wheels.
braking applications. At highway speeds of 89-97
Apply the parking brake and the service brake.
km/h (50-60 mph), apply the brake using a light
Install a tachometer.
pedal force.
Shift the transmission into DRIVE, and increase
Accelerate to 89-97 km/h (55-60 mph).
and decrease the engine rpm between an idle to
Lightly apply the brakes and slow the vehicle to
approximately 2000 rpm. Note the engine rpm
30 km/h (20 mph).
and, if possible, determine the vibration
A brake vibration noise can be felt in the steering frequency.
wheel, seat or brake pedal. A brake noise can be
Repeat the test in REVERSE.
heard upon brake application and diminish when
If the vibration/noise is duplicated when carrying
the brake is released.
out this test, inspect the engine and transmission
or transaxle mounts.
Road Test Over Bumps
If the concern is definitely engine speed-related,
carry out the Engine Accessory Test to narrow
Drive the vehicle over a bump or rough surface
down the source.
one wheel at a time to determine if the noise is
coming from the front or the back and the left or
the right side of the vehicle.
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Engine Accessory Test
CAUTION: Never probe moving parts.
Isolate the vibration/noise by carefully listening.
Move around the vehicle while listening to find
WARNING: Block the front and rear
the general location of the vibration/noise. Then,
wheels, and apply the parking brake and the
search for a more precise location by using a
service brake, or injury to personnel can result.
stethoscope or EngineEAR.
CAUTION: Limit engine running time to GO to Symptom Chart Idle Noise/Vibration to
one minute or less with belts removed or serious assist with the diagnosis.
engine damage will result.
6: Check OASIS/TSBs/Repair History
NOTE: A serpentine drive belt decreases the
After verifying the customer concern, check for
usefulness of this test. In these cases, use a
OASIS reports, TSBs and the vehicle repair history
vibration analyzer, such as the VA, to pinpoint
for related concerns. If information relating to a
accessory vibrations. An electronic listening device,
diagnosis/repair is found, carry out the procedure(s)
such as an EngineEAR, will also help to identify
specified in that information.
noises from specific accessories.
Remove the accessory drive belts. If no information is available from these sources,
carry out the vehicle preliminary inspection to
Increase the engine rpm to where the concern
eliminate any obvious faults.
occurs.
If the vibration/noise is duplicated when carrying
7: Diagnostic Procedure
out this test, the belts and accessories are not
Qualifying the concern by the particular sensation
sources.
present can help narrow down the concern. Always
If the vibration/noise was not duplicated when
use the symptom to system to component
carrying out this test, install each accessory belt,
to cause diagnosis technique. This diagnostic
one at a time, to locate the source.
method divides the problem into related areas to
correct the customer concern.
Vehicle Cold Soak Procedure
Verify the symptom.
To carry out this procedure, proceed as follows:
Determine which system(s) can cause the
Test preparations include matching customer
symptom.
conditions (if known). If not known, document the
If a vibration concern is vehicle speed related,
test conditions: gear selection and engine rpm.
the tire and wheel rpm/frequency or driveshaft
Monitor the vibration/noise duration with a watch
frequency should be calculated.
for up to three minutes.
If a vibration concern is engine speed related,
Park the vehicle where testing will occur. The
the engine, engine accessory or engine firing
vehicle must remain at or below the concern
frequencies should be calculated.
temperature (if known) for 6-8 hours.
After determining the system, use the
Before starting the engine, conduct a visual
diagnostic tools to identify the worn or damaged
inspection under the hood.
components.
Turn the key on, but do not start the engine.
After identifying the components, try to find
Listen for the fuel pump, anti-lock brake system
the cause of the failure.
(ABS) and air suspension system noises.
Once the concern is narrowed down to a
Start the engine.
symptom/condition, proceed to NVH Condition and
Symptom Categories.
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NVH Condition and Symptom Categories Operating Condition Vehicle is Moving
A good diagnostic process is a logical sequence of 1. Depends more on how the vehicle is operated
steps that lead to the identification of a causal
1 Speed related
system. Use the condition and symptom categories
X Related to vehicle speed
as follows:
Pitch increases with vehicle speed.
Identify the operating condition that the vehicle is
GO to Symptom Chart Tire
exhibiting.
Noise/Vibration.
Match the operating condition to the symptom.
Noise occurs at specific vehicle
Verify the symptom.
speed. A high-pitched noise (whine).
GO to Symptom Chart Driveline
Identify which category or system could cause the
Noise/Vibration.
symptom.
Loudness proportional to vehicle
Refer to the diagnostic symptom chart that is
speed. Low-frequency noise at high
referred to.
speeds, noise and loudness increase
Operating Condition Vehicle is Not
with speed. GO to Symptom Chart
Moving
Driveline Noise/Vibration.
1. Static operation
A low-pitched noise (drumming). GO
to Symptom Chart Engine
Noise occurs during component/system
Noise/Vibration.
functioning. GO to Symptom Chart
Squeak and Rattle.
Vibration occurs at a particular speed
(mph) regardless of acceleration or
2. While cranking
deceleration. GO to Symptom Chart
1 Grinding or whine, differential ring gear or
Tire Noise/Vibration.
starter motor pinion noise. GO to Symptom
Noise varies with wind/vehicle speed
Chart Engine Noise/Vibration.
and direction. GO to Symptom Chart
2 Rattle. Exhaust hanger, exhaust heat shield
Air Leak and Wind Noise.
or A/C line noise. GO to Symptom Chart
X Related to engine speed.
Squeak and Rattle.
Noise varies with engine rpm. GO to
3 Vibration. Acceptable condition.
Symptom Chart Engine
3. At idle
Noise/Vibration.
Idle noise. GO to Symptom Chart Idle
Vibration occurs at a particular speed
Noise/Vibration.
(mph) regardless of engine speed
Idle vibration or shake. GO to Symptom
(rpm).
Chart Idle Noise/Vibration.
2 Acceleration
4. During Gear Selection
X Wide open throttle (WOT)
1 Vehicle parked on a steep incline.
Engine induced contact between
Acceptable noise.
components. Inspect and repair as
2 Vehicle parked on a flat surface. GO to
necessary.
Symptom Chart Driveline
Noise is continuous throughout
Noise/Vibration.
WOT. Exhaust system or engine
3 Vehicle with a manual transmission. GO to
ground out. GO to Symptom Chart
Symptom Chart Transmission (Manual)
Engine Noise/Vibration.
and Transfer Case Noise/Vibration.
X Light/moderate acceleration
Tip-in moan. Engine/exhaust noise.
GO to Symptom Chart Engine
Noise/Vibration.
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Knock-type noise. GO to Symptom X Noise or vibration related to the
Chart Engine Noise/Vibration. transmission (manual). GO to Symptom
Chart Transmission (Manual) and
Driveline shudder. GO to Symptom
Transfer Case Noise/Vibration.
Chart Driveline Noise/Vibration.
7 Engaged in four-wheel drive. GO to
Engine vibration. GO to Symptom
Symptom Chart Transmission (Manual)
Chart Engine Noise/Vibration.
and Transfer Case Noise/Vibration.
3 Turning noise. GO to Symptom Chart
8 Cruising speeds
Steering Noise/Vibration.
X Accelerator pedal vibration. GO to
4 Braking
Symptom Chart Engine
X Clicking sound is signaling ABS is
Noise/Vibration.
active. Acceptable ABS sound.
X Driveline vibration. GO to Symptom
X A continuous grinding/squeal. GO to
Chart Driveline Noise/Vibration.
Symptom Chart Brake
X A shimmy or shake. GO to Symptom
Noise/Vibration.
Chart Tire Noise/Vibration.
X Brake vibration/shudder. GO to Symptom
9 Driving at low/medium speeds
Chart Brake Noise/Vibration.
X A wobble or shudder. GO to Symptom
5 Clutching
Chart Tire Noise/Vibration.
X A noise occurring during clutch
2. Depends more on where the vehicle is operated
operation. GO to Symptom Chart
Transmission (Manual) and Transfer Case 1 Bump/pothole, rough road or smooth road.
Noise/Vibration. GO to Symptom Chart Suspension
Noise/Vibration.
X Vibration. GO to Symptom Chart
Transmission (Manual) and Transfer Case X Noise is random or intermittent occurring
Noise/Vibration. from road irregularities. GO to Symptom
Chart Squeak and Rattle.
6 Shifting
X Noise or vibration changes from one road
X Noise or vibration condition related to the
surface to another. Normal sound
transmission (automatic). GO to Symptom
changes.
Chart Transmission (Automatic)
Noise/Vibration. X Noise or vibration associated with a
hard/firm ride. GO to Symptom Chart
Suspension Noise/Vibration.
Symptom Charts
Symptom Chart Air Leak and Wind Noise
Condition Possible Sources Action
Air leak around door Loose fit seal PINCH the seal carrier to
perimeter improve retention on the seal
flange.
Seal installed incorrectly REINSTALL the seal.
Door misaligned REALIGN the door. CHECK
door gaps and fit in the door
opening and ADJUST as
necessary.
Scuff plate installed REINSTALL the scuff plate.
incorrectly
Seal or seal push pins INSTALL a new seal.
damaged
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Symptom Chart Air Leak and Wind Noise (Continued)
Air leak around glass run Door glass misaligned ADJUST the door glass.
Glass run installed incorrectly ADJUST the glass run.
INSERT foam in the glass
run carrier.
Leak path behind glass run INSTALL foam rope behind
the glass run.
Glass run channel spread PINCH the glass run channel
wide to reduce the size of the
opening.
Blow-out clip bent or ADJUST the blow-out clip or
contacting door glass INSTALL a new glass
run/blow-out clip molding
assembly.
Glass run damaged INSTALL a new glass run.
Air leak at inner belt line Belt line seal installed ADJUST the seal. (Do not
incorrectly on flange bend the flange.)
Belt line seal integrated with REINSTALL the door trim.
door trim installed incorrectly
(no glass contact)
No contact with side glass ADJUST the door glass.
No contact with glass runs at ADJUST the belt line seal or
both ends of belt line seal ADD foam at the seal ends.
Belt line seal damaged INSTALL a new seal.
Air leak at outer belt line Belt line seal installed ADJUST the seal.
incorrectly on flange (no
glass contact)
Belt line seal does not contact ADJUST the door glass.
the glass
No contact with glass runs at ADJUST the belt line
both ends of belt line seal seal/ADD foam at the seal
ends.
Belt line seal damaged INSTALL a new seal.
Draft at inner door Hole in watershield SEAL the hole with a suitable
handle/speaker opening tape.
Watershield misaligned REALIGN the watershield.
INSTALL a new watershield
if the pressure sensitive
adhesive fails.
Exterior door handle seal REALIGN or INSTALL a
misaligned/damaged new seal as necessary.
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Wind noise from side view Outside mirror housing REALIGN with the edges
mirror misaligned shingled correctly and no
gaps.
Mirror sail gasket REINSTALL with the gasket
folded/misaligned unfolded and aligned
correctly.
Mirror housing trim cap REINSTALL with the edges
installed incorrectly shingled to the air flow.
Air leak through mirror Fully ENGAGE the mirror
housing hinge into its operating
position/USE foam to block
the air path through the
hinge.
Inner sail trim installed REINSTALL the sail
incorrectly trim/ADJUST the door trim.
Inner sail gasket/barrier REINSTALL the trim cover
installed incorrectly with the gasket/barrier aligned
correctly.
Air path through wiring BLOCK the air path(s) with
bundle/fastener access holes foam/tape.
Exposed fastener access hole INSTALL a new cap if it is
on mirror housing/sail missing.
Air leak around perimeter of Gaps in the sealant bead APPLY approved sealant.
fixed glass
Air traveling up windshield INSTALL foam rope the full
molding along A-pillar length of the A-pillar.
Windshield/backlite REINSTALL the
misaligned or not installed windshield/backlite.
correctly
Rear hood seal at base of REALIGN or INSTALL a
windshield new seal as necessary.
misaligned/damaged
Air leak at cowl Cowl gasket REALIGN or INSTALL a
misaligned/damaged new seal as necessary.
Wind noise from antenna Shape of antenna INSTALL an antenna boot or
a spiral antenna.
Air leak around antenna cable INSPECT the antenna access
access hole hole grommet. REPAIR as
necessary.
Air leak from closed roof Seal installed incorrectly REINSTALL the seal.
opening panel
Roof opening panel REALIGN the roof opening
glass/door misaligned panel glass/door.
Roof opening panel damaged INSTALL a new roof
opening panel.
Buffeting from an open roof Wind deflector REPAIR or INSTALL a new
opening panel inoperative/damaged wind deflector as necessary.
Wind deflector height ADJUST the wind deflector
incorrect higher.
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Wind noise created by airflow Fender splash shield REALIGN the fender splash
over or behind body panels misaligned shield.
Body panel misaligned REALIGN the appropriate
(exposed edge) body panel.
Hood misaligned (front CHECK hood gaps and fit.
margin) ADJUST the hood as
necessary.
Front grille edge noise APPLY foam in the hollow
areas behind the louvers.
Wind noise created by grille Grille relationship to leading ADJUST the grille opening
opening panel edge on hood panel forward to eliminate
wind noise.
Sharp edges due to material REMOVE the sharp edges
imperfections (no damage to visible
surface).
Wind noise from air extractor Air extractor housing seated REINSTALL the air extractor
incorrectly housing.
Air extractor housing or flaps INSTALL a new air
damaged extractor.
Air leak at top of A-pillar Seal at windshield header REINSTALL the seal.
vehicles with a convertible installed incorrectly
top
Seal pinched FILL the seal with foam to
reshape it.
Gap between side rail and ADJUST the J-hook/vinyl
header seal at A-pillar top.
Air leak at rear quarter glass No contact between front side ADJUST the front side glass
(division bar) vehicles glass and quarter glass regulator and the rear quarter
with a convertible top division bar glass regulator.
Air leak or wind noise from Gap between side rail and ADD additional foam tape to
top of side glass vehicles vinyl top seal between the side rail and
with a convertible top the vinyl top.
Seal at windshield header REINSTALL the seal.
installed incorrectly
Seal damaged between side INSTALL a new seal.
rail and vinyl top
Vinyl top damaged INSPECT the vinyl top.
INSTALL a new vinyl top as
necessary.
Air leak or wind noise at Vinyl top not flush with ADJUST the J-hook to lower
windshield header vehicles header the top to achieve a flush
with a convertible top condition.
Seal at windshield header REINSTALL the seal.
installed incorrectly
Header seal not flush with REINSTALL the seal.
header
Convertible top flapping with Vinyl top contacting interior Working from front to back,
the top up headliner INSTALL a 6.35 mm (0.25
in) foam sheet between the
headliner and the vinyl top at
the suspected area. Allow a
clearance of 50 mm (2 in) -
75 mm (3 in) away from the
roof bows and the side rails.
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Noise from roof rack Roof rack rails or crossbars TIGHTEN the fasteners.
loose
Roof rack fasteners missing INSTALL the approved
fasteners.
Roof rack crossbars installed REINSTALL the crossbars.
backward
Roof rack rub strips partially REAPPLY adhesive or
lifting from roof fasteners or INSTALL new
rub strips as necessary.
Roof rack gaskets loose or REINSTALL the gasket.
misaligned
Wind noise from bug Turbulence created by REMOVE per customer
shield/exterior windshield sun location and shape direction if it is a dealer
visor installed option.
Symptom Chart Brake Noise/Vibration
Rattling noise Caliper mounting bolts loose CHECK the caliper bolts.
TIGHTEN to specifications.
REFER to Section 206-03 for
front disc brakes or Section
206-04 for rear disc brakes.
Damaged or worn caliper pins CHECK the caliper pins and
or retainers retainers for lubrication and
correct fit. LUBRICATE or
INSTALL new components
as necessary.
Missing or damaged CHECK the brake pads for
anti-rattle clips or springs missing clips or broken
springs. INSTALL new
components as necessary.
Loose brake disc shield TIGHTEN the brake disc
shield bolts to specification.
REFER to Section 206-03.
Clicking noise with brakes ABS hydraulic control unit Acceptable condition.
applied with ABS brakes
Squealing noise occurs on Disc brake pads Acceptable condition. Caused
first (morning) brake by humidity and low disc
application brake pad temperature.
Squealing noise a Disc brake pads or linings INSTALL new disc brake
continuous squeal worn below minimum pads. REFER to Section
thickness 206-03 for front disc brake
pads or Section 206-04 for
rear disc brake pads.
Squealing noise an Disc brake pad Acceptable condition.
intermittent squeal brought on
by cold, heat, water, mud or
snow
Groaning noise occurs at Disc brake pads Acceptable condition.
low speeds with brake lightly
applied (creeping)
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Symptom Chart Brake Noise/Vibration (Continued)
Grinding noise continuous Disc brake pads or linings INSPECT the disc brake
worn below minimum pads, brake discs and
thickness attaching hardware for
damage. REPAIR or
as necessary. REFER to
Section 206-03 for front disc
brakes and Section 206-04
for rear disc brakes.
Moaning noise Brake linings contaminated INSPECT the brake pads and
with grease or oil shoes for contamination.
REPAIR or INSTALL new
Brake vibration/shudder Uneven disc or drum wear GO to Pinpoint Test A.
occurs when brakes are Uneven disc brake pad or
applied lining transfer
Suspension components
Brake vibration/shudder Brake drag INSPECT the disc brake pads
occurs when the brake pedal or linings for premature wear.
is released REPAIR or INSTALL a new
caliper or wheel cylinder as
necessary. REFER to Section
206-03 for front disc brakes
and Section 206-04 for rear
disc brakes.
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Symptom Chart Driveline Noise/Vibration
Axle howling or whine Axle lubricant low CHECK the lubricant level.
front or rear axle FILL the axle to
specification.
Axle housing damage INSPECT the axle housing
for damage. REPAIR or
INSTALL a new axle as
205-02A for Ford 7.5 rear
axles or Section 205-02B for
Ford 8.8 integral axles.
Damaged or worn wheel CHECK for abnormal wheel
bearings or axle bearings bearing play or roughness.
REFER to Wheel Bearing
Check in this section.
ADJUST or INSTALL new
wheel bearings as necessary.
Damaged or worn differential INSPECT the ring and pinion
ring and pinion ring for abnormal wear
patterns or broken teeth.
INSTALL a new ring and
pinion as necessary. REFER
to Section 205-02A for Ford
7.5 rear axles or Section
205-02B for Ford 8.8 integral
axles.
Damaged or worn differential CHECK for abnormal bearing
side or pinion bearings play or roughness. INSTALL
new bearings as necessary.
Damaged or worn differential DISASSEMBLE the
side gears and pinion gears differential carrier. INSPECT
the side and pinion gears for
abnormal wear patterns or
broken teeth. INSTALL new
gears as necessary. REFER to
Section 205-02A for Ford
axles.
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Symptom Chart Driveline Noise/Vibration (Continued)
Driveline clunk loud clunk Incorrect axle lubricant level CHECK the lubricant level.
when shifting from reverse to FILL the axle to
drive specification.
Excessive backlash in the CARRY OUT a total
axle or transmission backlash check. REFER to
Section 205-00.
Damaged or worn pinion CHECK for abnormal bearing
bearings play or roughness. INSTALL
REFER to Section 205-02A
for Ford 7.5 rear axles or
Section 205-02B for Ford 8.8
integral axles.
Damaged or worn universal INSPECT the U-joints for
joints (U-joints) wear or damage. INSTALL
new U-joints as necessary.
Loose suspension components INSPECT the suspension for
damage or wear. REPAIR or
as necessary.
Broken powertrain mounts INSPECT the powertrain
mounts. INSTALL new
mounts as necessary. REFER
to Section 303-01A orSection
303-01B.
Idle speed too high CHECK for the correct idle
speed.
Driveline clunk occurs as Worn or galled driveshaft CLEAN and INSPECT the
the vehicle starts to move slip-yoke splines splines of the yoke for a
forward following a stop worn or galled condition.
INSTALL a new yoke as
205-01.
Worn or galled driveshaft and CLEAN and INSPECT the
coupling shaft splines splines of the driveshaft and
coupling shaft for a worn or
galled condition. INSTALL a
new driveshaft assembly as
205-01.
Driveline clunk (front wheel Damaged or worn inboard INSPECT the inboard CV
drive [FWD] vehicles) constant velocity (CV) joint joint and boot. REPAIR or
occurs during acceleration or INSTALL a new CV joint as
from cruise to necessary.
coast/deceleration
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Clicking, popping or grinding Inadequate or contaminated CHECK the CV boots and
occurs while vehicle is lubrication in the (CV) joints joints for wear or damage.
turning REPAIR or INSTALL new
Another component CHECK the halfshafts and
contacting the halfshaft the area around the halfshafts.
REPAIR as necessary.
Brake components INSPECT the front brakes for
wear or damage. REPAIR as
206-03.
Steering components INSPECT the drag link, inner
and outer tie-rods or idler arm
for wear or damage. REPAIR
Section 211-02.
Suspension components INSPECT the upper and
lower ball joints for wear or
damage. REPAIR as
204-01.
Damaged or worn wheel CHECK for abnormal wheel
bearings bearing play or roughness.
Refer to Wheel Bearing
ADJUST or INSTALL new
wheel bearings as necessary.
Clicking or snapping Damaged or worn outboard INSPECT the outboard CV
occurs when accelerating CV joint joint and boot. REPAIR or
around a corner INSTALL a new CV joint as
necessary.
High pitched chattering Incorrect or contaminated CHECK the vehicle by
noise from the rear axle when lubricant driving in tight circles (5
the vehicle is turning clockwise, 5
counterclockwise). FLUSH
and REFILL with the
specified rear axle lubricant
and friction modifier as
necessary.
Damaged or worn differential DISASSEMBLE the
(differential side gears and differential assembly.
pinion gears) INSPECT the differential
case, pin and gears for wear
or damage. REPAIR or
INSTALL a new differential
Section 205-02A for Ford 7.5
rear axles or Section 205-02B
for Ford 8.8 integral axles.
Buzz buzzing noise is the Damaged or worn tires CHECK for abnormal tire
same at cruise or wear or damage. INSTALL a
coast/deceleration new tire as necessary. REFER
to Section 204-04.
Incorrect driveline angles CHECK for correct driveline
angles. REPAIR as necessary.
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Rumble or boom noise Driveshaft is out-of-balance CHECK the driveshaft for
occurs at coast/deceleration, damage, missing balance
usually driveshaft speed weights or undercoating.
related and noticeable over a REPAIR or INSTALL a new
wide range of speeds driveshaft.
U-joints binding or seized ROTATE the driveshaft and
CHECK for rough operation
or seized U-joints. INSTALL
Excessive pinion flange CARRY OUT a runout
runout check. REPAIR as necessary.
REFER to Pinion Flange
Runout Check in this section.
Grunting normally Driveshaft slip yoke binding CLEAN and LUBRICATE
associated with a shudder the male and female splines.
experienced during
acceleration from a dead stop
Howl can occur at various Incorrect ring and pinion CHECK the ring and pinion
speeds and driving conditions. contact, incorrect bearing and bearings for damage.
Affected by acceleration and preload or gear damage INSPECT the ring and pinion
deceleration wear pattern. REFER to
Section 205-00. ADJUST or
Chuckle heard at Incorrect ring and pinion CHECK the ring and pinion
coast/deceleration. Also contact or by damaged teeth for damage. INSPECT the
described as a knock on the coast side of the ring ring and pinion wear pattern.
and pinion REFER to Checking Tooth
Contact Pattern and Condition
of the Ring and Pinion
component test in this
section. ADJUST or
Knock noise occurs at Gear tooth damage to the CHECK the differential case
various speeds. Not affected drive side of the ring and and ring and pinion for
by acceleration or pinion damage. INSTALL new
deceleration components as necessary.
integral axles.
Excessive axle shaft end play. CHECK the axle end play
(Vehicles with integral axles) using a dial indicator.
INSTALL a new axle shaft or
side gears as necessary.
integral axles.
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Scraping noise a Worn or damaged pinion CHECK the pinion bearings.
continuous low pitched noise bearings INSTALL new pinion
starting at low speeds bearings as necessary. REFER
to Section 205-02A for Ford
axles.
Driveline shudder occurs Rear drive axle assembly CHECK the axle mounts and
during acceleration from a mispositioned the rear suspension for
slow speed or stop damage or wear. REPAIR as
necessary.
Incorrect or high CV joint CHECK vehicle ride height is
operating angle within limits. REPAIR as
206-00.
Damaged or worn front CHECK for a loose stabilizer
suspension components bar, damaged or loose
strut/strut bushings or loose
or worn ball joints. INSPECT
the steering linkage for wear
as necessary.
Driveline angles out of CHECK for correct driveline
specification angles. REPAIR as necessary.
REFER to Driveline Angles
in this section.
U-joints binding or seized ROTATE the driveshaft and
CHECK for rough operation
or seized U-joints. INSTALL
Binding, damaged or galled CLEAN and INSPECT the
splines on the driveshaft splines of the slip-yoke,
slip-yoke driveshaft and coupling shaft
for a worn, damaged or
galled condition. INSTALL a
new slip-yoke or driveshaft
assembly as necessary.
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Driveline vibration occurs U-joints are worn CHECK for wear or incorrect
at cruising speeds seating. INSTALL new
U-joints as necessary. REFER
to Section 205-01.
Worn or damaged driveshaft CHECK the insulator for
center bearing support damage or wear. ROTATE
the driveshaft and CHECK
for rough operation.
INSTALL a new center
bearing support as necessary.
Loose axle pinion flange bolts INSPECT the axle pinion
flange. TIGHTEN the pinion
flange bolts to specification.
Excessive axle pinion flange CARRY OUT a Runout
runout Check. REPAIR as necessary.
Driveshaft is out-of-balance CHECK the driveshaft for
damage, missing balance
weights or undercoating.
REPAIR or INSTALL a new
driveshaft as necessary.
Binding or damaged splines CLEAN and INSPECT the
on the driveshaft slip-yoke splines of the slip-yoke,
driveshaft and coupling shaft
for wear or damage.
INSTALL a new slip-yoke or
driveshaft assembly as
205-01. REPAIR as
necessary.
Driveshaft runout CARRY OUT a Runout
Check. REPAIR as necessary.
Incorrect lateral and radial INSPECT the tire and wheels.
tire/wheel runout MEASURE tire runouts.
Driveline angles out of CHECK for correct driveline
specification angles. REPAIR as necessary.
in this section.
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Symptom Chart Engine Noise/Vibration
Grinding noise occurs Incorrect starter motor INSPECT the starter motor
during engine cranking mounting for correct mounting.
Starter motor CHECK the starter motor.
REPAIR or INSTALL a new
starter motor as necessary.
Incorrect starter motor drive INSPECT the starter motor
engagement drive and flexplate/flywheel
for wear or damage.
INSTALL a new starter
motor drive or flywheel as
303-06.
Engine ticking noise Fuel injector GO to Pinpoint Test B.
Fuel line
Oil pump
Valve lifter
Belt tensioner
Water pump
Obstruction of cooling fan
Engine drumming noise Powertrain mount CARRY OUT
normally accompanied by Powertrain/Drivetrain Mount
vibration Neutralizing in this section.
Damaged or misaligned INSPECT the exhaust system
exhaust system for loose or broken clamps
and brackets. CARRY OUT
Exhaust System Neutralizing
in this section.
Whistling noise normally Air intake system CHECK the air intake ducts,
accompanied with poor idle air cleaner, throttle body and
condition vacuum hoses for leaks and
correct fit. REPAIR or
ADJUST as necessary.
Clunking noise Water pump has excessive CHECK the water pump for
end play or imbalance excessive end play. INSPECT
the water pump with the drive
belt off for imbalance.
INSTALL a new water pump
Section 303-03A.
Generator has excessive end CHECK the generator for
play excessive end play. REPAIR
or INSTALL a new
generator. REFER to Section
414-02.
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Symptom Chart Engine Noise/Vibration (Continued)
Pinging noise Exhaust system leak INSPECT the exhaust system
for leaks. REPAIR as
necessary.
Gasoline octane too low VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
Knock sensor operation CHECK the knock sensor.
INSTALL a new knock
sensor as necessary. REFER
to Section 303-14.
Incorrect spark timing CHECK the spark timing.
High operating temperature INSPECT cooling system for
leaks. CHECK the coolant
level. REFILL as necessary.
CHECK the coolant for the
correct mix ratio. DRAIN and
REFILL as needed. CHECK
engine operating temperature
is within specifications.
Foul-out spark plug CHECK the spark plugs.
spark plugs as necessary.
Catalytic converter Acceptable noise.
Knocking noise light Excessive clearance between Engine cold and at high idle.
knocking noise, also the piston and the cylinder Using an EngineEAR, pull a
described as piston slap. wall spark plug or fuel injector
Noise is most noticeable connector until the noise goes
when engine is cold with away. CARRY OUT a
light to medium acceleration. cylinder bore clearance to
Noise disappears as engine piston check. INSTALL a
warms new piston. REFER to
Section 303-01A orSection
303-01B.
Knocking noise light Excessive clearance between INSTALL a new piston or
double knock or sharp rap the piston and the piston pin piston pin. REFER to Section
sound. Occurs mostly with 303-01A orSection 303-01B.
warm engine at idle or low
speeds in DRIVE. Increases
in relation to engine load.
Associated with poor
lubrication history
Knocking noise light Excessive clearance between Engine warm and at idle.
knocking noise is most the connecting rod bearings Using an EngineEAR, PULL
noticeable when engine is and the crankshaft a spark plug or fuel injector
warm. Noise tends to connector until the noise goes
decrease when vehicle is away. INSTALL new
coasting or in NEUTRAL bearings. REFER to Section
303-01A or Section
303-01B.
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Knocking deep knocking Worn or damaged crankshaft CARRY OUT DERU test.
noise. Noise is most main bearings CHECK for noise with
noticeable when engine is vehicle at operating
warm, at lower rpm and temperature, during medium
under a light load and then at to heavy acceleration.
float CHECK at idle with injector
disconnected, noise does not
change. INSTALL new main
bearings. REFER to Section
303-01A orSection 303-01B.
Knocking noise occurs Spark plugs CHECK the spark plug for
mostly with warm engine at damage or wear. INSTALL
light/medium acceleration new spark plugs as necessary.
Carbon accumulation in REMOVE carbon from
combustion chamber combustion chamber.
Whine or moaning noise Air intake system CHECK the air cleaner and
ducts for correct fit.
INSPECT the air intake
system for leaks or damage.
Generator electrical field or CARRY OUT generator load
bearings test. REPAIR or INSTALL a
new generator as necessary.
Drone type noise Exhaust system CARRY OUT the Exhaust
System Neutralizing in this
section. REPAIR as
necessary.
A/C compressor CHECK for noise with
vehicle at constant speeds.
CYCLE the compressor on
and off and listen for a
change in pitch. REPAIR as
412-01.
Powertrain mounts CARRY OUT the
Powertrain/Drivetrain Mount
Neutralizing in this section.
Sputter type noise noise Damaged or worn exhaust INSPECT the exhaust system
worse when cold, lessens or system components for leaks or damage. REPAIR
disappears when vehicle is at as necessary. REFER to
operating temperature Section 309-00.
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Rattling noise noise from Low oil level CHECK oil level. FILL as
the upper engine (valve train). necessary.
Worse when engine is cold
Thin or diluted oil INSPECT the oil for
contamination. If oil is
contaminated, CHECK for the
source. REPAIR as necessary.
CHANGE the oil and filter.
Low oil pressure CARRY OUT an oil pressure
test. If not within
specifications, REPAIR as
303-00.
Worn rocker arms/fulcrums or CARRY OUT a valve train
followers analysis. INSTALL new valve
train components as
303-01A or Section
303-01B.
Worn valve guides CARRY OUT a valve train
analysis. INSTALL new valve
guides as necessary. REFER
to Section 303-01A or
Section 303-01B.
Excessive runout of valve CARRY OUT a valve seat
seats on the valve face runout test. INSPECT the
valve face and seat.
INSTALL new valves as
303-01A or Section
303-01B.
Rattling noise from the Loose muffler shields or CHECK the exhaust system
bottom of the vehicle catalytic converter shields for loose exhaust shields.
Thumping noise from the Exhaust pipe/muffler CHECK the exhaust system
bottom of the vehicle, worse grounded to chassis to chassis clearance. CHECK
at acceleration the exhaust system hangers
for damage. REPAIR as
309-00.
Whoosh occurs during Throttling late, creating CHECK for leaks or missing
light vehicle acceleration. turbulence transmitted seal in the dash panel.
Heard inside the vehicle through the plastic manifold
Engine vibration increases Engine out-of-balance CARRY OUT Neutral Engine
intensity as engine rpm is Run-Up (NERU) Test.
increased ROTATE the torque
converter, 120 for 3 bolt and
180 for 4 bolt. INSPECT the
torque converter pilot outer
diameter to crankshaft pilot
inner diameter. REPAIR as
307-01.
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Engine vibration is felt Strain on exhaust mounts CARRY OUT the Exhaust
with increases and decreases System Neutralizing
in engine rpm procedure in this section.
Damaged or worn CHECK the
powertrain/drivetrain mounts powertrain/drivetrain mounts
for damage. REPAIR as
necessary.
Engine or transmission INSPECT the
grounded to chassis powertrain/drivetrain for
correct clearances. REPAIR
as necessary.
Engine vibration vibration Excessive engine pulley CARRY OUT Engine
felt at all times runout Accessory Test. INSTALL a
new engine pulley as
303-01A or Section
303-01B.
Damaged or worn accessory CARRY OUT Engine
component Accessory Test. REPAIR or
INSTALL a new component
as necessary.
Accelerator pedal vibration Throttle cable loose or INSPECT the throttle cable.
felt through the pedal as a misrouted REPAIR as necessary.
buzz REFER to Section 310-02.
Engine vibration mostly at Combustion instability CHECK the ignition system.
coast/neutral coast. Condition INSTALL new components
improves with vehicle as necessary.
accelerating
Engine vibration or shudder Worn or damaged spark plugs INSPECT the spark plugs for
occurs with light to cracks, high resistance or
medium acceleration above broken insulator. INSTALL a
56 km/h (35 mph) new spark plug(s) as
necessary.
Plugged fuel injector REPAIR or INSTALL a new
injector as necessary. REFER
to Section 303-04A or
Section 303-04B.
Damaged spark plug wire INSPECT the spark plug
wires for damage. INSTALL
a new spark plug wire(s) as
necessary.
Contaminated fuel INSPECT the fuel for
contamination. DRAIN the
fuel system and refill.
Worn or damaged torque CHECK the torque converter.
converter INSTALL a new torque
converter as necessary.
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Symptom Chart Idle Noise/Vibration
Idle air control (IAC) valve IAC valve is contaminated GO to Component Tests in
moan occurs on throttle with oil this section.
tip-out
Accessory drive belt chirp Accessory drive belt worn, or INSPECT for loose or
occurs at idle or high idle, pulley is misaligned or loose misaligned pulleys. CHECK
cold or hot. Most common the drive belt for wear or
occurrence is during humid damage. INSTALL new
weather pulley(s)/drive belt, or
accessory drive components
Section 303-05.
Accessory drive bearing hoot Accessory drive idler or GO to Pinpoint Test C.
occurs at idle or high idle tensioner pulley bearing is
in cold temperatures of experiencing stick/slip
approximately +4C (+40F) between ball bearings and
or colder at first start of the bearing race
day
Power steering moan High fluid viscosity, or GO to Pinpoint Test D.
occurs at high idle and plugged reservoir screen in
possibly at idle during the power steering reservoir
first cold start of the day in starves pump causing
temperatures of approximately cavitation
-18C (0F) or colder. Noise
can even be a severe screech
for less than one minute in
very cold temperatures of
approximately -29C (-20F)
or colder
Generator whine during Generator electrical field Using an EngineEAR,
high electrical loads at idle or noise PROBE near the generator
high idle, a high pitch whine housing. LISTEN for changes
or moan is emitted from the in the noise level while
generator changing electrical loads
(such as rear defrost,
headlamps, etc.). CARRY
OUT a generator load test. If
the system passes the load
test, the noise is from the
generator bearings, INSTALL
new bearings. If the system
fails the load test, INSTALL
a new generator. REFER to
Section 414-02.
Engine-driven cooling fan The viscous cooling fan GO to Pinpoint Test E.
moan occurs during the clutch engages until the fluid
first start of the day. It is in the clutch reaches normal
most objectionable near idle operating temperature,
speeds up to 2000 rpm. The causing the fan to fully
noise increases with rpm engage
Drumming noise occurs Exhaust system vibration GO to Pinpoint Test F.
inside the vehicle during idle excites the body resonances
or high idle, hot or cold. inducing interior noise
Very low-frequency Engine vibration excites the
drumming is very rpm body resonances inducing
dependent interior noise
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Symptom Chart Idle Noise/Vibration (Continued)
Hissing noise occurs Vacuum leak or idle air Use the Ultrasonic Leak
during idle or high idle that is control (IAC) valve flow Detector/EngineEAR to locate
apparent with the hood open noise the source. Scan the air intake
system from the inlet to each
cylinder intake port.
DISCARD the leaking parts,
and INSTALL a new
component.
Vehicles with a plastic intake Acceptable condition. Some
manifold plastic manifolds exhibit this
noise, which is the effect of
the plastic manifold.
Automatic transmission buzz Incorrect driveline angles CHECK for correct driveline
or hiss angles. REPAIR as necessary.
in this section.
Worn or damaged main Using a transmission tester,
control solenoids or valves activate the solenoids to
duplicate sound. INSTALL
new components as necessary.
Manual Transmission Clutch Worn throw-out bearing INSTALL a new throw-out
throw-out bearing whine. A bearing. REFER to Section
change in noise pitch or 308-01.
loudness while depressing the
clutch pedal
Heating, vacuum and air Damaged or worn HVAC INSTALL a new blower
conditioning (HVAC) system blower bearing motor. REFER to Section
chirp most audible inside 412-01.
the vehicle. Listen for a
change in noise pitch or
loudness while changing the
HVAC system blower speed
Air conditioning (A/C) clutch Acceptable noise LISTEN to the clutch to
ticking occurs when the Incorrect air gap determine if the noise occurs
compressor clutch engages with clutch engagement. A
small amount of noise is
acceptable. If the noise is
excessive, CHECK the A/C
clutch air gap. INSPECT the
A/C clutch for wear or
damage. INSTALL a new
clutch as necessary. REFER
to Section 412-01.
Intermittent rattle, or Loose exhaust heat shield(s) INSPECT the exhaust system
scraping/rubbing noise for loose parts using a glove
or clamps to verify cause.
Wiring, hose or other part INSPECT accessory drive
interfering with accessory system closely verifying there
drive belt or pulley is adequate clearance to all
rotating components. REPAIR
as necessary.
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Symptom Chart Idle Noise/Vibration (Continued)
Engine ticking or knocking Piston noise or valvetrain GO to Pinpoint Test G.
noise occurs during idle or noise (bled down lifter/lash
high idle during the first cold adjuster)
start of the day
A continuous, Piston noise or valvetrain GO to Pinpoint Test G.
speed-dependent rattle from noise (bled down lifter/lash
the engine occurs during adjuster)
idle or high idle during the
first cold start of the day and
disappears as the engine
warms up
Idle vibration a Cylinder misfire Using a scan tool, CHECK
low-frequency vibration (5-20 the ignition system. CARRY
Hz) or mild shake that is felt OUT a cylinder power test.
through the seat/floorpan REFER to Section 303-00.
Engine or torque converter VERIFY the torque converter
out of balance to crankshaft pilot clearance
is correct, REPAIR as
necessary. RE-INDEX the
torque converter on the flex
plate by 120 on a 3 bolt
converter or 180 for a 4 bolt
converter. REFER to Section
307-01. RETEST the vehicle.
Idle vibration a Exhaust system mounts bound VERIFY concern occurs at
high-frequency vibration up engine firing frequency.
(20-80 Hz) or buzz, that is CHECK that the exhaust
felt through the steering system vibrates at the same
wheel or seat frequency as the engine.
ADD 9-14 km (20-30 lb.) to
the tail pipe to test, CARRY
OUT Exhaust System
Body mounts loose INSPECT the body mounts.
Power steering lines grounded INSPECT that the power
out steering lines are not
contacting the chassis or each
other. REPAIR as necessary.
Symptom Chart Squeak and Rattle
Squeak heard inside the Insufficient lubrication on the LUBRICATE the hinge or
vehicle when closing/opening door hinge or check strap check strap.
the door
Internal door components CHECK the inside of the
loose, rubbing or misaligned door. TIGHTEN or ALIGN
as necessary. USE the
Rotunda Squeak and Rattle
Kit to isolate any rubbing
components.
Squeak heard inside the Worn or damaged glass REPAIR or INSTALL a new
vehicle when closing/opening run/channel glass run/channel. REFER to
the window Section 501-11.
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Symptom Chart Squeak and Rattle (Continued)
Squeak heard outside of Exhaust shield rubbing CHECK the exhaust system.
vehicle when closing/opening against the chassis or exhaust REPAIR as necessary.
the door pipe REFER to Section 309-00.
Squeak occurs with initial Disc brake pads Under certain conditions,
brake pedal application asbestos free pads can
generate a squeak noise. This
noise is normal and does not
indicate a concern.
Squeak a constant noise Damaged or worn disc brake INSPECT the pads for oil,
that occurs with brake pedal pads grease or brake fluid
applications contamination. CHECK for
glazed linings. A brake disc
with hard spots will also
cause a squeak type noise.
pads as necessary. REFER to
brakes and Section 206-04 for
rear disc brakes.
Squeak noise occurs over Worn control arm bushings INSPECT the control arm
bumps or when turning bushings. Spray with lubricant
and CARRY OUT a bounce
test to determine which
bushing. REPAIR as
204-01.
Worn or damaged shock INSPECT the shock absorber
absorber/strut for damage. CARRY OUT a
bounce test to isolate the
noise. INSTALL a new shock
absorber/strut as necessary.
the front shock absorber/strut
or Section 204-02 for the rear
shock absorber/strut.
Rattle heard when Loose internal door REPEAT the motion or
closing/opening the door or mechanism, bracket or CARRY OUT a tap test to
window attachment duplicate the noise. INSPECT
the door for loose
components. TIGHTEN loose
components or USE the
Rotunda Squeak and Rattle
Kit to isolate any rattling
components.
Rattle GT models only, A loose or under torqued VERIFY the torque on the
noise occurs from the rear of shock damper attaching nut shock damper-to-axle nuts is
the vehicle 63 Nm (46 lb-ft). VERIFY
the torque for the shock
damper-to-rail bracket nuts is
90 Nm (66 lb-ft). Do not over
torque. TIGHTEN as
necessary.
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Symptom Chart Squeak and Rattle (Continued)
Squeak or rattle heard Misaligned glove ALIGN the glove
inside the vehicle over rough compartment door/hinge compartment door.
roads/bumps
Instrument panel trim loose or INSPECT the instrument
misaligned panel trim for missing or
loose clips or screws.
Loose interior component or CARRY OUT a touch
trim test. ELIMINATE the noise
by pressing or pulling on
interior trim and components.
USE the Rotunda Squeak and
Rattle Kit to isolate any
rattling/squeaking
components.
Squeak or rattle noise with Damaged or worn body INSPECT the upper and
a vibration concern mounts lower absorbers and washers
for damage or wear. CHECK
the body mount brackets for
damage. CHECK the nuts and
bolts are tightened to
specifications. TIGHTEN as
necessary.
Damaged or worn sub-frame INSPECT the upper and
mounts lower absorbers for damage
or wear. CHECK the
sub-frame for damage.
CHECK the nuts and bolts
are tightened to specifications.
TIGHTEN as necessary.
Symptom Chart Steering Noise/Vibration
Steering grunt or shudder Steering gear or power GO to Steering Gear
occurs when turning into or steering hoses Grunt/Shudder Test
out of a turn at low speeds component test in this
(temperature sensitive) section.
Steering System clonk Air in the steering hydraulic CHECK for leaks in the
hydraulic knocking sound system system. PURGE the air from
the system. REFER to
Section 211-00.
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Symptom Chart Steering Noise/Vibration (Continued)
Power steering pump moan Power steering hose grounded INSPECT the power steering
loud humming noise out to chassis hoses. REPAIR as necessary.
occurs when the steering
wheel is rotated to the stop
position. Produces a 120-600
Hz frequency that changes
with rpm
Aerated fluid CHECK for leaks in the
system. PURGE the air from
the system. REFER to
Section 211-00.
Steering gear isolators INSPECT the isolators for
wear or damage. REPAIR as
necessary.
Low fluid CHECK the fluid level.
REFILL as necessary.
Power steering pump brackets CHECK bolts, brackets and
loose or misaligned bracket alignment. TIGHTEN
bolts to specification.
brackets as necessary. REFER
to Section 211-02.
Steering gear clunk occurs Steering gear INSPECT the steering gear
only while cornering over a for loose mounting bolts.
bump (can be temperature TIGHTEN as necessary.
sensitive) REFER to Section 211-02.
Feedback (rattle, chuckle or Column intermediate/flexible INSTALL a new
knocking noise in the steering shaft joints damaged or worn intermediate/flexible shaft.
gear) a condition where REFER to Section 211-04.
roughness is felt in the
steering wheel when the
vehicle is driven over rough
surfaces
Loose, damaged or worn TIGHTEN the nuts to
tie-rod ends specification or INSTALL
new tie-rod ends as
211-02.
Steering gear insulators or TIGHTEN the bolts or
mounting bolts loose or INSTALL new bolts as
damaged necessary. REFER to Section
211-02.
Steering column intermediate TIGHTEN the bolts to
shaft bolts are loose specification. REFER to
Section 211-04.
Steering column damaged or REPAIR or INSTALL a new
worn steering column as necessary.
Loose suspension bushings, INSPECT the suspension
bolts or ball joints system. TIGHTEN or
Section 204-01.
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Feedback (nibble at the Lateral runout in the tire or GO to Pinpoint Test H.
steering wheel) a condition wheel
where slight rotational
movement is felt in the
steering wheel when the
vehicle is driven over rough
or grooved surfaces
Yoke spring in the steering CHECK TSBs for revised
gear yoke spring for applicable
vehicles.
Accessory drive belt Loose or worn accessory ADJUST or INSTALL a new
squeal/chirp when rotating drive belt accessory belt as necessary.
the steering wheel from stop REFER to Section 303-05.
to stop
Power steering gear hiss Steering column REPAIR or INSTALL a new
intermediate/flexible intermediate/flexible shaft as
shaft-to-steering gear is necessary. REFER to Section
binding or misaligned 211-04.
Grounded or loose steering REPAIR as necessary.
column boot at the dash panel
Damaged or worn steering REPAIR or INSTALL a new
gear input shaft and valve steering gear as necessary.
Steering column rattle Loose bolts or attaching TIGHTEN the bolts to
brackets specifications.
Loose, worn or insufficiently LUBRICATE or INSTALL
lubricated column bearings new steering column bearings
Section 211-04.
Steering shaft insulators INSTALL new insulators.
damaged or worn REFER to Section 211-04.
Intermediate/flexible shaft INSPECT the rubber spider
compressed or extended coupling for damage.
INSTALL a new
intermediate/flexible shaft.
Steering column squeak or Insufficient lubricated steering LUBRICATE the steering
cracks shaft bushings shaft and shaft tube seals.
Loose or misaligned steering TIGHTEN or ALIGN the
column shrouds steering column shrouds.
Steering wheel rubbing REPOSITION the steering
against steering column column shrouds.
shrouds
Insufficient lubricated speed LUBRICATE the speed
control slip ring control slip ring.
Upper or lower bearing sleeve REPOSITION the bearing
out of position sleeves.
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Power steering pump noisy Incorrect assembly of REPAIR or INSTALL a new
components power steering pump as
Imperfections on the outside necessary. REFER to Section
diameter or end surface of the 211-02.
power steering pump rotor
Damaged or worn power
steering pump rotor splines
A crack on the inner surface
of the power steering pump
cam
Interference between the
power steering pump rotor
and cam
Damaged or worn power
steering pump rotor and
pressure plates
Power steering pump swish Power steering fluid flow into Acceptable condition.
noise the bypass valve of the pump
valve housing with fluid
temperature below 54C
(130F)
Power steering pump whine Aerated fluid PURGE the air from the
noise system. REFER to Section
211-00. CHECK for a leak in
the system.
Damaged power steering REPAIR or INSTALL a new
pump cam power steering pump as
211-02.
Damaged valve cover O-ring REPAIR or INSTALL a new
seal power steering pump as
211-02.
Power steering pump clicking Power steering pump rotor REPAIR or INSTALL a new
(mechanical) noise slippers too long, excessive power steering pump as
rotor slipper-to-slot clearance necessary. REFER to Section
or damaged or worn rotor 211-02.
assembly
Power steering pump clatter Damaged corners on the REPAIR or INSTALL a new
noise outside diameter or the power power steering pump as
steering rotor or distorted necessary. REFER to Section
rotor slipper ring 211-02.
Symptom Chart Suspension Noise/Vibration
Squeak or grunt noise Front stabilizer bar insulators Under these conditions, the
from the front suspension, noise is acceptable. CHECK
occurs more in cold ambient TSBs.
temperatures. More noticeable
over rough roads or when
turning
Clunk noise from the front Loose front struts or shocks INSPECT for loose nuts or
suspension, occurs in and out bolts. TIGHTEN to
of turns specifications. REFER to
Section 204-01.
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Symptom Chart Suspension Noise/Vibration (Continued)
Clunk noise from the rear Loose rear suspension INSPECT for loose or
suspension, occurs when components damaged rear suspension
shifting from REVERSE to components. REPAIR or
DRIVE INSTALL new components
Section 204-02.
Click or pop noise from Worn or damaged ball joints CARRY OUT a ball joint
the front suspension. More inspection. INSTALL new
noticeable over rough roads ball joints or control arms as
or over bumps necessary. REFER to Section
204-01.
Click or pop (front wheel Worn or damaged ball joints CARRY OUT a ball joint
drive [FWD] vehicles) inspection. INSTALL new
noise occurs when vehicle is ball joints or control arms as
turning necessary.
Click or snap occurs when Damaged or worn outboard INSPECT the outboard CV
accelerating around a corner CV joint joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
Front suspension noise a Steering components GO to Pinpoint Test H.
squeak, creak or rattle noise. Loose or bent front struts or
Occurs mostly over bumps or shock absorbers
rough roads Damaged spring or spring
mounts
Damaged or worn
control/radius arm bushings
Worn or damaged stabilizer
bar bushings or links
Rear suspension noise a Loose or bent rear shock GO to Pinpoint Test I.
squeak, creak or rattle noise. absorbers
Occurs mostly over bumps or Damaged spring or spring
rough roads mounts
Damaged or worn control arm
bushings
Worn or damaged stabilizer
bar bushings or links
Shudder occurs during Rear drive axle assembly CHECK the axle mounts and
acceleration from a slow mispositioned the rear suspension for
speed or stop damage or wear. REPAIR as
necessary.
Incorrect or high CV joint CHECK vehicle ride height is
operating angle within limits. REPAIR as
necessary.
Damaged or worn front CHECK for a loose stabilizer
suspension components bar, damaged or loose
strut/strut bushings or loose
or worn ball joints. INSPECT
the steering linkage for wear
as necessary.
Shimmy most noticeable Excessive positive caster CHECK the caster alignment
on coast/deceleration. Also angle. CORRECT as
hard steering condition necessary. REFER to Section
204-00.
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Symptom Chart Tire Noise/Vibration
Tire noise hum/moan at Abnormal wear patterns SPIN the tire and CHECK for
constant speeds tire wear. INSTALL a new
tire as necessary. INSPECT
for damaged/worn suspension
components. CARRY OUT
wheel alignment.
Tire noise noise tone Out-of-balance tire BALANCE the tire and road
lowers as the vehicle speed is test. INSTALL a new tire as
lowered necessary. REFER to Section
204-04.
Tire noise ticking noise, Nail puncture or stone in tire INSPECT the tire. REPAIR
changes with speed tread as necessary.
Wheel and tire vibration Damaged or worn tire GO to Pinpoint Test J.
and noise concern is directly
related to vehicle speed and is
not affected by acceleration,
coasting or decelerating
Tire wobble or shudder Damaged wheel bearings SPIN the tire and CHECK for
occurs at lower speeds abnormal wheel bearing play
or roughness. ADJUST or
INSTALL new wheel
bearings as necessary. REFER
to Section 204-01.
Damaged wheel INSPECT the wheel for
damage. INSTALL a new
wheel as necessary. REFER
to Section 204-01.
Damaged or worn suspension INSPECT the suspension
components components for wear or
damage. REPAIR as
necessary.
Loose wheel nuts CHECK the wheel nuts.
TIGHTEN to specification.
Damaged or uneven tire wear SPIN the tire and CHECK for
abnormal tire wear or
damage. INSTALL a new tire
Section 204-04.
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Symptom Chart Tire Noise/Vibration (Continued)
Tire shimmy or shake Wheel/tire out of balance BALANCE the wheel/tire
occurs at lower speeds assembly.
Uneven tire wear CHECK for abnormal tire
wear. INSTALL a new tire as
204-04.
Excessive radial runout of CARRY OUT a radial runout
wheel or tire test of the wheel and tire.
INSTALL a new tire as
204-04.
Worn or damaged wheel INSPECT the wheel studs
studs or elongated stud holes and wheels. INSTALL new
the front wheels or Section
204-02 for the rear wheels.
Excessive lateral runout of CARRY OUT a lateral runout
the wheel or tire test of the wheel and tire.
CHECK the wheel, tire and
hub. REPAIR or INSTALL
Foreign material between the CLEAN the mounting
brake disc and hub or in the surfaces of the brake disc and
brake disc fins hub. CHECK the brake disc
fins for material.
High speed shake or shimmy Excessive wheel hub runout GO to Pinpoint Test K.
occurs at high speeds Damaged or worn tires
Damaged or worn wheel
bearings
Worn or damaged suspension
or steering linkage
components
Brake disc or drum imbalance
Symptom Chart Manual Transmission and Transfer Case Noise/Vibration
Clutch rattling noise Flywheel bolts, clutch TIGHTEN the bolts to
occurs with clutch engaged, housing bolts or clutch specifications. CHECK the
noise changes/disappears with pressure plate bolts loose bolts for damage.
clutch pedal depressed
Clutch squeaking noise Pilot bearing seized or INSTALL a new pilot
noise is heard when the damaged bearing. REFER to Section
clutch is operated. Vehicle 308-01.
moves slowly or creeps when
the clutch is disengaged. Can
also be difficult to shift into
1st and reverse gear
Clutch squeaking noise Worn clutch pedal shaft or INSPECT the clutch pedal for
occurs with clutch pedal bushings wear or damage. REPAIR as
depressed/released necessary. REFER to Section
308-02.
Clutch whirring/rattle noise Worn, damaged or misaligned INSTALL a new clutch
occurs when clutch pedal clutch release bearing release bearing. REFER to
is depressed Section 308-01.
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Symptom Chart Manual Transmission and Transfer Case Noise/Vibration (Continued)
Clutch grating/grinding noise Clutch pressure plate fingers INSPECT the clutch pressure
occurs when clutch pedal bent or worn plate release fingers.
is depressed INSTALL a new pressure
plate as necessary. REFER to
Section 308-01.
Contact surface of clutch INSTALL a new clutch
release bearing worn or release bearing. REFER to
damaged Section 308-01.
Clutch chatter a small Clutch engagement Acceptable operating
amount of noise when clutch condition.
pedal is released at initial
take-off
Clutch chatter/grabs in Damaged or worn INSPECT the
some cases a shudder is felt. powertrain/driveline mounts powertrain/drivetrain mounts.
Occurs with clutch pedal INSTALL new mounts as
depressed/released necessary. REFER to Section
303-01A or Section
303-01B.
Binding or dragging plunger CHECK the master and slave
of the clutch master cylinder cylinder operation. INSPECT
or slave cylinder the components for damage
or wear. INSTALL a new
master or slave cylinder as
308-02.
Grease or oil on the clutch CHECK the input shaft seal
disc facing and rear main oil seal.
INSTALL a new clutch disc.
for T50D transmissions or
Section 308-03B for TR3650
transmissions.
Clutch disc surface glazed or INSPECT the clutch disc
damaged surface for a glazed, hardened
or damage condition. CARRY
OUT a disc check. INSTALL
a new clutch disc as
308-01.
Damaged or worn clutch INSPECT the clutch pressure
pressure plate plate for wear or damage.
INSTALL a new clutch
pressure plate as necessary.
Flywheel surface damaged or INSPECT the flywheel for
glazed damage or wear. CARRY
OUT a flywheel runout
check. INSTALL a new
flywheel as necessary.
or Section 303-01B.
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Clutch chatter noise noise Pilot bearing worn, damaged INSPECT the clutch pressure
when clutch pedal is released or not correctly aligned in plate release fingers for
at initial take-off. Clutch is bore uneven wear, clutch
hard to engage and disengage components burnt or a seized
pilot bearing. INSTALL a
new pilot bearing as
308-01.
Clutch vibration Loose flywheel bolts GO to Pinpoint Test L.
Damaged or loose clutch
pressure plate
Excessive flywheel runout
Transmission Gearshift lever joint worn or INSTALL a new gearshift
rattling/clattering noise damaged lever. REFER to Section
noise at idle or on light 308-03A for T50D
acceleration from a stop. Gear transmissions or Section
selection difficult 308-03B for TR3650
transmissions.
Gearshift lever loose TIGHTEN the bolts to
specification. REFER to
Section 308-03A for T50D
transmissions or Section
308-03B for TR3650
transmissions.
Gearshift linkage rods worn CHECK the linkage bushings
or damaged for wear. INSTALL new
linkage rods as necessary.
REFER to the appropriate
workshop manual for the
service procedures.
Transmission Incorrect fluid level or fluid CHECK that the transmission
rattling/clattering noise quality is filled to the correct level
occurs in NEUTRAL or in and with the specified fluid.
gear, at idle REFER to Section 308-03A
transmissions.
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Transmission Worn or rough reverse idler CHECK the reverse idler
rattling/clattering noise gear gear. REPAIR as necessary.
noise at idle in NEUTRAL REFER to Section 308-03A
transmissions.
Rough running engine, CHECK the ignition system.
cylinder misfire CARRY OUT a cylinder
power test. REFER to Section
303-00.
Excessive backlash in gears CHECK the gear backlash.
integral axles.
Worn countershaft gears REPAIR as necessary.
transmissions.
Transmission whine a mild Rotating gears/geartrain Acceptable noise.
whine at extreme speeds or
high rpm
Transmission whine a high Transmission gears are worn Result of normal gear wear.
pitched whine, also described (high mileage vehicle) REPAIR as necessary.
as a squeal REFER to Section 308-03A
transmissions.
Mismatched gear sets INSPECT the gear sets for an
uneven wear pattern on the
face of the gear teeth.
transmissions.
Damaged or worn INSPECT the transmission
transmission bearing bearings. INSTALL new
bearings as necessary. REFER
to Section 308-03A for T50D
308-03B for TR3650
transmissions.
Transmission Gear is cracked, chipped or INSPECT the transmission
growling/humming noise rough gears for damage or wear.
occurs in the FORWARD INSTALL new gears as
gears. The noise is more necessary. REFER to Section
prominent when the gear is 308-03A for T50D
loaded. The problem gear can transmissions or Section
be located as the noise occurs 308-03B for TR3650
in a specific gear position transmissions.
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Transmission hissing noise Damaged or worn bearings INSPECT the transmission
in NEUTRAL or in bearings. INSTALL new
FORWARD gears. As bearings as necessary. REFER
bearings wear or break up, to Section 308-03A for T50D
the noise changes to a transmissions or Section
thumping noise 308-03B for TR3650
transmissions.
Transmission Bearings with damaged balls INSPECT the transmission
knocking/thudding noise at or rollers or with pitted and bearings. INSTALL new
low speeds in FORWARD spalled races bearings as necessary. REFER
gears to Section 308-03A for T50D
308-03B for TR3650
transmissions.
Transmission rumble/growl Incorrect driveline angle CHECK the driveline angle.
noise at higher speeds in REPAIR as necessary.
FORWARD gears, more REFER to Section 205-00.
pronounced in a
coast/deceleration condition
Driveshaft out of balance or CHECK the driveshaft for
damaged damage, missing balance
weights or undercoating.
Using the vibration analyzer
(VA), CHECK the driveshaft
balance. CARRY OUT a
driveline vibration test.
Transmission rumble/growl Damaged or worn CHECK transmission fluid
noise at all speeds in transmission bearing or gears for excessive metal particles.
FORWARD gears, more (high mileage vehicles) REPAIR as necessary.
pronounced in a heavy REFER to Section 308-03A
acceleration condition for T50D transmissions or
transmissions.
Transfer case whine noise Incorrect fluid level or fluid CHECK that the transfer case
at all ranges quality is filled to the correct level
and with the specified fluid.
transmissions.
Worn oil pump DISASSEMBLE the transfer
case. CHECK the oil pump
as necessary.
Under-inflated or oversized CONFIRM that the tires and
tires wheels are correct for the
vehicle. CHECK that the tire
inflation pressures are correct.
Transfer case growl/rumble Damaged or worn bearings or DISASSEMBLE the transfer
noise at all ranges (A planetary gear case. CHECK the bearings or
small amount of planetary planetary gear for wear or
noise can be heard when the damage. REPAIR as
transfer case is operated in necessary.
LOW range.)
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Transfer case scraping/grating Excessively stretched drive DISASSEMBLE the transfer
noise at all ranges chain hitting the case case. CHECK the drive chain
as necessary.
Transfer case howl/hum Worn or damaged sun (input) DISASSEMBLE the transfer
noise at all ranges or HIGH gear, clutch pack case. CHECK the gears for
range only (intermediate) gear or output wear or damage. REPAIR as
shaft gear necessary.
Transfer case howl/hum Worn or damaged DISASSEMBLE the transfer
noise at LOW range only intermediate gear and sliding case. CHECK the gears for
gears (clutch pack) wear or damage. REPAIR as
necessary.
Transfer case vibration Transfer case mounting GO to Pinpoint Test M.
vibration felt with vehicle in Driveshaft out of balance
four wheel drive (4WD) Excessive pinion flange
runout
Symptom Chart Automatic Transmission Noise/Vibration
Rattle occurs at idle or at Damaged engine or CHECK the
light acceleration from a stop transmission mounts powertrain/drivetrain mounts
for damage. REPAIR or
INSTALL new mounts as
necessary.
A loose front exhaust pipe REPAIR or INSTALL a new
heat shield heat shield as necessary.
Loose inspection plate or dust CHECK for loose bolts.
cover plate TIGHTEN to specifications.
Loose flex plate to converter CHECK for loose nuts.
nuts TIGHTEN to specifications.
Whine pitch increases with Damaged or worn low INSPECT the transmission
vehicle speed. Starts in 1st one-way clutch for wear or damage. REPAIR
and 2nd gear, decreases or Damaged or worn or INSTALL new
goes away at higher gears intermediate one-way clutch components as necessary.
Friction elements REFER to Section 307-01.
Damaged or worn planetary
or sun gear
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Symptom Chart Automatic Transmission Noise/Vibration (Continued)
Whine the pitch changes A worn or damaged accessory CARRY OUT the Engine
with engine speed drive component Accessory Test. REPAIR or
as necessary.
Incorrect fluid level CHECK that the transmission
is filled to the correct level.
ADD fluid as necessary.
Partially blocked filter INSPECT the filter. CLEAN
or INSTALL a new filter as
307-01.
Worn or damaged torque CARRY OUT the torque
converter converter service and
replacement check. REFER to
Section 307-01.
Worn or damaged front pump INSPECT the front pump.
INSTALL a new front pump
Section 307-01.
Whine pitch changes with Speedometer cable or gears REPAIR or INSTALL new
vehicle speed cables or gears as necessary.
Whine/moan type noise Damaged engine or CHECK the
pitch increases or changes transmission mount powertrain/drivetrain mounts
with vehicle speed for damage. CARRY OUT
U-joints worn or damaged INSPECT the U-joints for
wear or damage. INSTALL
Damaged or worn differential INSPECT the differential ring
ring and pinion and pinion for damage.
CARRY OUT the Checking
Tooth Contact Pattern and
Condition of the Ring and
Pinion component test in this
section. REPAIR or
INSTALL a new differential
ring and pinion as necessary.
integral axles.
Planetary gears nicked or CHECK the planetary gears
chipped for damage. INSTALL new
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Whistle noise is high Hydraulic pressure in the INSPECT the main control.
pitched, constant. Changes in main control REPAIR or INSTALL new
pitch with throttle position components as necessary.
Incorrect band/clutch apply CARRY OUT the line
pressure pressure tests. REPAIR or
INSTALL components as
307-01.
Worn or damaged torque CARRY OUT the torque
converter converter service and
replacement check. REFER to
Section 307-01.
Clunk occurs when Damaged powertrain mounts INSPECT the powertrain
shifting from PARK to a mounts for damage.
DRIVE or REVERSE INSTALL new mounts as
position necessary.
Damaged or worn pinion CHECK for abnormal bearing
bearings play or roughness. INSTALL
integral axles.
Worn or galled driveshaft slip CLEAN and INSPECT the
yoke splines splines of the yoke.
INSTALL a new slip yoke as
205-01.
Worn friction elements or INSPECT the transmission
excessive clutch pack end for wear. CHECK that all end
plate play play and clearances are within
specification. REPAIR or
Section 307-01.
Bump occurs when Initial gear engagement Acceptable condition.
shifting from PARK to a
DRIVE or REVERSE
position. Similar to Clunk but
with no sound
Buzz or hiss Incorrect driveline angles CHECK for correct driveline
angles. REPAIR as necessary.
in this section.
Worn or damaged main Using a transmission tester,
control solenoids or valves ACTIVATE the solenoids to
duplicate sound. INSTALL
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Vibration a high frequency Transmission cooler lines CHECK the transmission
(20-80 Hz) that is felt through grounded out cooler lines. REPAIR as
the seat or gear shifter. necessary.
Changes with engine speed
Flexplate to torque converter CHECK the flexplate nuts.
nuts loose TIGHTEN to specification.
Fluid filler tube grounded out CHECK the fluid filler tube.
Shift cable incorrectly routed, CHECK the shift cable.
grounded out or loose REPAIR as necessary.
Section 307-05.
Shutter or chatter occurs Electrical inputs/outputs CARRY OUT a Torque
with light to medium Vehicle wiring harness Converter Clutch Operation
acceleration from low speeds Incorrect inputs/outputs from Test. RUN on-board
or a stop the powertrain control module diagnostics or self-test.
(PCM), digital transmission REFER to Section 307-01.
range (TR) sensor, brake CLEAR the DTCs, ROAD
pedal position (BPP) sensor, TEST and RERUN on-board
throttle position (TP) sensor, diagnostics or self-test.
transmission speed sensor
(TSS), output speed shaft
(OSS) sensor or the torque
converter clutch (TCC)
Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic
process designed to determine the cause of a
condition. It may not always be necessary to follow
a pinpoint test to its conclusion. Carry out only the
steps necessary to correct the condition. Then, test
the system for normal operation. Sometimes, it is
necessary to remove various vehicle components to
gain access to the component requiring testing.
Reinstall all components after verifying system
operation is normal.
PINPOINT TEST A: BRAKE VIBRATION/SHUDDER
Test Step Result / Action to Take
A1 ROAD TEST THE VEHICLE LIGHT BRAKING
Check that the wheel and tires are correct for the vehicle.
Inspect the tires for abnormal wear patterns.
Road test the vehicle. Warm the brakes by slowing the vehicle a
few times from 80-32 km/h (50 to 20 mph) using light braking
Yes
applications. At highway speeds of 89-97 km/h (55-60 mph),
GO to A4.
apply the brake using a light pedal force.
Is there a vibration/shudder felt in the steering wheel, seat No
or brake pedal? GO to A2.
(Continued)
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PINPOINT TEST A: BRAKE VIBRATION/SHUDDER (Continued)
A2 ROAD TEST THE VEHICLE MODERATE TO HEAVY
BRAKING
Road test the vehicle. At highway speeds of 89-97 km/h (55-60 Yes
mph), apply the brake using a moderate to heavy pedal force. For vehicles with ABS, GO to A3.
Is there a vibration/shudder?
For vehicles with standard brakes, GO to
A4.
No
Vehicle is OK. VERIFY condition with
customer. TEST the vehicle for normal
operation.
A3 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS
During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS system.
Yes
Pedal pulsation or steering wheel nibble, (frequency is
GO to A5.
proportioned to the vehicle speed) indicates a concern with a
brake or suspension component. No
Is the vibration/shudder vehicle speed sensitive? The brake system is operating correctly.
A4 APPLICATION OF THE PARKING BRAKE
NOTE: Begin at the front of the vehicle unless the vibration or
shudder has been isolated to the rear.
This test is not applicable to vehicles with drum-in-hat type
parking brakes. For vehicles with drum-in-hat parking brakes,
proceed to the next test. For all other vehicles, apply the parking
brake to identify if the problem is in the front or rear brake. At
Yes
highway speeds of 89-97 km/h (55-60 mph), lightly apply the
GO to A7.
parking brake until the vehicle slows down. Release the parking
brake immediately after the test. No
Is there a vibration/shudder? GO to A5.
A5 CHECK THE FRONT WHEEL BEARINGS
Check the front wheel bearings. Refer to Wheel Bearing Check Yes
in this section. GO to A6.
Are the wheel bearings OK?
No
INSPECT the wheel bearings. ADJUST or
REPAIR as necessary. TEST the system
for normal operation.
A6 CHECK THE FRONT SUSPENSION
Check the front suspension for:
broken or loose bolts.
Yes
damaged springs.
GO to A7.
worn or damaged upper and lower control arm bushings.
loose or rough front bearings. No
uneven tire wear. REPAIR or INSTALL new components as
Are all the suspension components in satisfactory necessary. TEST the system for normal
condition? operation.
A7 RESURFACE THE FRONT BRAKE DISCS
CAUTION: Do not use a bench lathe to machine brake
discs.
NOTE: Follow the manufacturers instructions to machine the
Yes
brake discs. After machining, make sure the brake disc meets
GO to A8.
the thickness specification.
Resurface the front brake discs. Road test the vehicle. No
Is the vibration/shudder present? Vehicle is OK.
(Continued)
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PINPOINT TEST A: BRAKE VIBRATION/SHUDDER (Continued)
A8 CHECK THE REAR SUSPENSION
Check the rear suspension for:
broken or loose bolts.
damaged or worn springs or spring bushings.
Yes
worn or damaged upper and lower control arm bushings.
GO to A9.
worn or damaged trailing arms.
loose or rough rear bearings. No
uneven tire wear. REPAIR or INSTALL new components as
Are all the suspension components in satisfactory necessary. TEST the system for normal
condition? operation.
A9 RESURFACE THE REAR BRAKE DISC OR DRUM
CAUTION: Do not use a bench lathe to machine brake Yes
discs. CHECK the front suspension for wear or
damage. RESURFACE the front brake
discs. TEST the system for normal
operation.
Resurface the rear brake discs or drums. Road test the vehicle. No
Is the vibration/shudder present? Vehicle is OK.
PINPOINT TEST B: ENGINE TICKING NOISE
B1 CHECK FOR TICKING NOISE AT THE FUEL RAIL
Disconnect the first fuel line clip. Yes
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
No
GO to B2.
B2 CHECK FOR TICKING NOISE AT THE FUEL INJECTOR
Using an EngineEAR, listen at the fuel injectors by placing a Yes
probe on each injector. To isolate the faulty injector, disconnect INSTALL a new fuel injector. REFER to
the injector electrical connector and listen for the noise. Section 303-04A or Section 303-04B.
Is the fuel injector the source of the ticking noise? TEST the system for normal operation.
No
GO to B3.
B3 CHECK THE BELT TENSIONER FOR TICKING NOISE
Inspect the accessory drive. Check for the belt tensioner Yes
bottoming at end of travel or not at end of stroke. INSTALL a new belt tensioner. TEST the
Using an EngineEAR, listen at the belt tensioner. system for normal operation.
Is the belt tensioner the source of the noise?
No
GO to B4.
B4 CHECK THE WATER PUMP FOR TICKING NOISE
Using an EngineEAR, listen at the water pump for ticking noise. Yes
Is the water pump the source of the noise? INSTALL a new water pump. REFER to
Section 303-03A. TEST the system for
normal operation.
No
GO to B5.
B5 CHECK FOR AN OBSTRUCTION OF THE COOLING FAN
Inspect the cooling fan for obstructions. Yes
Check the cooling fan and shroud for wear or damage. REPAIR or INSTALL a new cooling fan.
Was there an obstruction or does the cooling fan show REFER to Section 303-03A. TEST the
signs of damage? system for normal operation.
No
GO to B6.
(Continued)
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PINPOINT TEST B: ENGINE TICKING NOISE (Continued)
B6 CHECK THE OIL PUMP FOR TICKING NOISE
Check the oil pump using EngineEARs and probe at the oil filter Yes
adapter to verify the oil pump as a source. INSTALL a new oil pump. REFER to
Is the oil pump the source of the noise? Section 303-01A or Section 303-01B.
TEST the system for normal operation.
No
GO to B7.
B7 CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR
CORRECT OPERATION
Check valve lifter/lash adjuster for correct operation, using Yes
EngineEARs. VERIFY customer concern. CONDUCT a
Are the valve lifters/lash adjusters operating correctly? diagnosis of other suspect components.
No
INSTALL a new valve lifter/lash
adjuster(s). TEST the system for normal
operation.
PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT
C1 CHECK THE IDLER AND TENSIONER PULLEY BEARINGS
Carry out the Vehicle Cold Soak Procedure in this section. Yes
Key in START position. INSTALL a new pulley/idler. CARRY OUT
Place an EngineEAR probe directly on the pulley center post or the Vehicle Cold Soak Procedure and
bolt to verify which bearing is making the noise. TEST the system for normal operation.
Key in OFF position.
No
Is either bearing making the noise?
CONDUCT a diagnosis on other suspect
accessory drive components.
PINPOINT TEST D: POWER STEERING MOAN
D1 CHECK THE POWER STEERING SYSTEM
Carry out the Vehicle Cold Soak Procedure in this section.
Key in START position.
Yes
Turn the steering wheel while the noise is occurring and listen
GO to D2.
for changes in sound pitch or loudness.
Key in OFF position. No
Does the sound pitch or loudness change while turning the CONDUCT a diagnosis on other suspect
steering wheel? accessory drive components.
D2 VERIFY THE SOURCE
Key in START position. Yes
Place an EngineEAR probe near the power steering VERIFY that the supply tube to the pump
pump/reservoir while the noise is occurring. While an assistant is unobstructed. CHECK the fluid condition
turns the steering wheel, listen for changes in sound pitch or and level. DRAIN the fluid and REFILL.
loudness. CARRY OUT the Vehicle Cold Soak
Key in OFF position. Procedure and TEST the system for
Does the sound pitch or loudness change while turning the normal operation. REFER to Section
steering wheel? 211-02.
No
Normal system operation.
PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN
E1 CHECK THE ENGINE DRIVEN COOLING FAN AFTER A COLD
SOAK
Yes
TEST the fan for normal operation. If the
Assess the airflow.
fan tests normal, GO to E2. Otherwise,
Raise the engine speed to 1500 rpm while listening for the moan
to increase in proportion to the airflow.
Does the moan increase in proportion to the airflow? Normal system operation.
(Continued)
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PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN (Continued)
E2 CHECK THE ENGINE DRIVEN COOLING FAN AT NORMAL
OPERATING TEMPERATURE
Run the engine to normal operating temperature while listening Normal clutch operation.
for the moan to stop.
No
INSTALL a new fan clutch. TEST the
Does the moan stop?
system for normal operation.
PINPOINT TEST F: DRUMMING NOISE
F1 CHECK THE EXHAUST SYSTEM
Increase the engine rpm until the noise is the loudest. Note the
engine rpm.
Add approximately 9 kg (20 lb) of weight to the exhaust system.
First place the weight at the tail pipe and test, then at the front
pipe.
Increase the engine rpm and listen for the drumming noise. Note
Yes
the engine rpm if the noise occurs.
CARRY OUT Exhaust System Neutralizing
in this section. TEST the system for
Using a vibration analyzer (VA), determine the amount of
normal operation.
vibration that occurs with the drumming noise.
Is the noise/vibration reduced or eliminated, or does the No
noise/vibration occur at a different rpm? GO to F2.
F2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING
Carry out Powertrain/Drivetrain Mount Neutralizing in this Yes
section. Test the system for normal operation. Vehicle OK. TEST the system for normal
Is the noise reduced or eliminated? operation.
No
CONDUCT diagnosis of other suspect
components.
PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE
G1 CHECK FOR NOISE AT THE VALVE COVERS AND THE FRONT
COVERS (OHC ENGINES)
Yes
NOTE: For a short-duration ticking noise, multiple engine starts
REMOVE the appropriate cover and
may be necessary.
INSPECT for loose, worn/broken
Using an EngineEAR, listen closely at the valve covers and the
components. REPAIR as necessary. TEST
front covers (OHC engines) by placing the probe near the
the system for normal operation.
surface of the valve cover and then on the surface front cover.
Is the noise source apparent? GO to G2.
(Continued)
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PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE (Continued)
G2 CHECK FOR NOISE AT THE CYLINDER BLOCK
Using an EngineEAR, listen closely at the cylinder block by REPAIR or INSTALL new components as
placing a probe on or near each freeze plug. necessary.
No
Is the noise source apparent?
GO to G3.
G3 CHECK FOR NOISE WHILE DISCONNECTING EACH FUEL
INJECTOR ELECTRICAL CONNECTOR, ONE AT A TIME
Disconnect each fuel injector electrical connector, one at a time, INSTALL a new fuel injector. TEST the
to decrease piston force and listen for the noise. system for normal operation.
No
Is the noise reduced or eliminated?
INSPECT accessory drive system or the
transmission as a possible source.
PINPOINT TEST H: FRONT SUSPENSION NOISE
H1 ROAD TEST THE VEHICLE
Test drive the vehicle.
Yes
NOTE: An assistant will be needed for this road test.
GO to H2.
During the road test, drive the vehicle over a rough road. Using
ChassisEARs, determine from which area/component the noise No
is originating. The suspension system is OK. CONDUCT
Is there a squeak, creak or rattle noise? a diagnosis on other suspect systems.
H2 INSPECT THE STEERING SYSTEM
WARNING: The electrical power to the air suspension
system must be shut off prior to hoisting, jacking or towing
an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these
operations.
Yes
Raise and support the vehicle.
REPAIR the steering system. INSTALL
Check the steering system for wear or damage. Carry out a
new components as necessary. TEST the
steering linkage test. Refer Section 211-00.
Inspect the tire wear pattern. Refer to Tire Wear Patterns chart
in this section. No
Are the steering components worn or damaged? GO to H3.
H3 FRONT SHOCK ABSORBER/STRUT CHECK
Check the front shock absorbers/strut mounts for loose bolts or Yes
nuts. TIGHTEN to specifications if loose.
Check the front shock absorbers/struts for wear or damage. INSTALL new front shock absorbers/struts
Carry out a bounce test. if damaged. TEST the system for normal
Are the front shock absorbers/struts loose or damaged? operation.
No
GO to H4.
H4 CHECK THE FRONT SPRINGS
Check the front spring and front spring mounts/brackets for wear Yes
or damage. REPAIR or INSTALL new components as
Are the front springs or spring mounts/brackets worn or necessary. TEST the system for normal
damaged? operation.
No
GO to H5.
H5 CHECK THE CONTROL ARMS/RADIUS ARMS
Inspect the control arm bushings for wear or damage. Yes
Inspect for twisted or bent control/radius arm. REPAIR or INSTALL new components as
Are the control/radius arms damaged or worn? necessary. TEST the system for normal
operation.
No
GO to H6.
(Continued)
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PINPOINT TEST H: FRONT SUSPENSION NOISE (Continued)
H6 CHECK THE STABILIZER BAR/TRACK BAR
Check the stabilizer bar/track bar bushings and links for damage Yes
or wear. REPAIR or INSTALL new components as
Check the stabilizer bar/track bar for damage. necessary. TEST the system for normal
Check for loose or damaged stabilizer bar isolators or brackets. operation.
Are the stabilizer bar/track bar components loose, worn or
No
damaged?
Suspension system OK. CONDUCT
diagnosis on other suspect systems.
PINPOINT TEST I: REAR SUSPENSION NOISE
I1 ROAD TEST THE VEHICLE
Yes
NOTE: An assistant will be needed for this road test.
GO to I2.
During the road test, drive the vehicle over a rough road. Using
ChassisEARs, determine from which area/component the noise No
is originating. The suspension system is OK. Conduct a
Is there a squeak, creak or rattle noise? diagnosis on other suspect systems.
I2 REAR SHOCK ABSORBER/STRUT CHECK
Yes
operations.
TIGHTEN to specifications if loose.
Raise and support the vehicle.
INSTALL new rear shock absorbers/struts
Check the rear shock absorber/strut mounts for loose bolts or
if damaged. TEST the system for normal
nuts.
operation.
Check the rear shock absorbers/struts for damage. Carry out a
shock absorber check. No
Are the rear shock absorbers/struts loose or damaged? GO to I3.
I3 CHECK THE REAR SPRINGS
Check the rear springs and rear spring mounts/brackets for wear Yes
or damage. REPAIR or INSTALL new components as
Are the rear springs or spring mounts/brackets worn or necessary. TEST the system for normal
damaged? operation.
No
GO to I4.
I4 CHECK THE CONTROL ARMS/TRAILING ARMS
Inspect the control arm/trailing arm bushings for wear or Yes
damage. Check for loose control arm/trailing arm bolts. REPAIR or INSTALL new components as
Inspect for twisted or bent control arm/trailing arms. necessary. TEST the system for normal
Are the control arm/trailing arms loose, damaged or worn? operation.
No
GO to I5.
I5 CHECK THE STABILIZER BAR/TRACK BAR
Check the stabilizer bar/track bar bushings and links for damage Yes
or wear. REPAIR or INSTALL new components as
Check the stabilizer bar/track bar for damage. necessary. TEST the system for normal
Check for loose or damaged stabilizer bar isolators or brackets. operation.
Are the stabilizer bar/track bar components loose, worn or
No
damaged?
Suspension system OK. CONDUCT
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PINPOINT TEST J: WHEEL AND TIRE
J1 ROAD TEST THE VEHICLE
NOTE: Wheel or tire vibrations felt in the steering wheel are
most likely related to the front wheel or tire. Vibration felt
through the seat are most likely related to the rear wheel or tire.
This may not always be true, but it can help to isolate the
problem to the front or rear of the vehicle.
Yes
Test drive the vehicle at different speed ranges.
GO to J2.
During the road test, if the vibration can be eliminated by placing
the vehicle in NEUTRAL or is affected by the speed of the No
engine, the cause is not the wheels or tires. The wheel and tires are OK. CONDUCT a
Is there a vibration and noise? diagnosis on other suspect systems.
J2 CHECK THE FRONT WHEEL BEARINGS
Check the front wheel bearings. Refer to Wheel Bearing Check Yes
in this section. GO to J3.
Are the wheel bearings OK?
No
INSPECT the wheel bearings. ADJUST or
J3 INSPECT THE TIRES
Check the tires for missing weights. Yes
Check the wheels for damage. CORRECT the condition that caused the
Inspect the tire wear pattern. Refer to the Tire Wear Patterns abnormal wear. INSTALL new tire(s).
chart in this section. TEST the system for normal operation.
Do the tires have an abnormal wear pattern?
No
GO to J4.
J4 TIRE ROTATION
Spin the tires slowly and watch for signs of lateral runout.
Spin the tires slowly and watch for signs of radial runout.
Yes
GO to J5.
No
CHECK the wheel and tire balance.
CORRECT as necessary. TEST the
Are there signs of visual runout? system for normal operation.
(Continued)
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PINPOINT TEST J: WHEEL AND TIRE (Continued)
J5 RADIAL RUNOUT CHECK ON THE TIRE
Measure the radial runout of the wheel and tire assembly. A
typical specification for total radial runout is 1.14 mm (0.045 in).
Yes
GO to J8.
No
Is the radial runout within specifications? GO to J6.
J6 RADIAL RUNOUT CHECK ON THE WHEEL
Measure the radial runout of the wheel. A typical specification Yes
for total radial runout is 1.14 mm (0.045 in). INSTALL a new tire. TEST the system for
Is the radial runout within specifications? normal operation.
No
GO to J7.
J7 CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR
BOLT CIRCLE RUNOUT
Measure the pilot or bolt circle runout. A typical specification for Yes
radial runout is: INSTALL a new wheel. TEST the system
Pilot runout less than 0.15 mm (0.006 in). for normal operation.
Bolt circle runout less than 0.38 mm (0.015 in).
No
Is the radial runout within specifications?
REPAIR or INSTALL new components as
necessary. REFER to Section 204-01 for
the front wheels or Section 204-02 for the
rear wheels.
J8 LATERAL RUNOUT CHECK ON THE TIRE
Measure the lateral runout of the wheel and tire assembly. A
typical specification for total lateral runout is 1.14 mm (0.045 in).
Yes
Wheel and tires OK. CONDUCT diagnosis
on other suspect systems.
No
Is the lateral runout within specifications? GO to J9.
J9 LATERAL RUNOUT CHECK ON THE WHEEL
Measure the lateral runout of the wheel. A typical specification Yes
for total radial runout is 1.14mm (0.045 in). INSTALL a new tire. TEST the system for
Is the lateral runout within specifications? normal operation.
No
GO to J10.
(Continued)
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PINPOINT TEST J: WHEEL AND TIRE (Continued)
J10 CHECK THE FLANGE FACE LATERAL RUNOUT
Measure the flange face lateral runout. A typical specification for Yes
lateral runout is: INSTALL a new wheel. TEST the system
Hub/brake disc less than 0.13 mm (0.005 in). for normal operation.
Axle shaft less than 0.25 mm (0.010 in).
No
Is the lateral runout within specifications?
necessary. REFER to Section 204-04.
PINPOINT TEST K: HIGH SPEED SHAKE OR SHIMMY
K1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS
Chock the rear wheels. Yes
Raise and support the front end of the vehicle so that the front INSPECT the wheel bearings. REPAIR as
wheel and tire assemblies can spin. necessary. TEST the system for normal
Spin the front tires by hand. Refer to Wheel Bearing Check in operation.
this section.
No
Do the wheel bearings feel rough?
GO to K2.
K2 CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS
Check the end play of the front wheel bearings. Refer to Section Yes
204-01. GO to K3.
Is the end play OK?
No
ADJUST or REPAIR as necessary. TEST
K3 MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT
OF THE FRONT WHEELS ON THE VEHICLE
Measure the lateral runout and the radial runout of the front Yes
wheels on the vehicle. Refer to GO to Pinpoint Test J. GO to K4.
Are the measurements within specifications?
No
INSTALL new wheels as necessary and
BALANCE the assembly. TEST the
K4 MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES ON
THE VEHICLE
Measure the lateral runout of the front tires on the vehicle. GO Yes
to Pinpoint Test J. GO to K5.
Is the runout within specifications?
No
INSTALL new tires as necessary and
BALANCE the assembly. TEST the
K5 MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES ON
THE VEHICLE
Measure the radial runout of the front tires on the vehicle. GO to Yes
Pinpoint Test J. BALANCE the front wheel and tire
Is the runout within specifications? assemblies. If any tire cannot be balanced,
INSTALL a new tire. TEST the system for
normal operation.
No
GO to K6.
K6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY
Mark the high runout location on the tire and also on the wheel. Yes
Break the assembly down and rotate the tire 180 degrees BALANCE the assembly. TEST the
(halfway around) on the wheel. Inflate the tire and measure the system for normal operation.
radial runout.
No
Is the runout within specifications?
If the high spot is not within 101.6 mm (4
inches) of the first high spot on the tire,
GO to K7.
(Continued)
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PINPOINT TEST K: HIGH SPEED SHAKE OR SHIMMY (Continued)
K7 MEASURE THE WHEEL FLANGE RUNOUT
Dismount the tire and mount the wheel on a wheel balancer.
Measure the runout on both wheel flanges. GO to Pinpoint Test
J.
Yes
LOCATE and MARK the low spot on the
wheel. INSTALL the tire, matching the
high spot on the tire with the low spot on
the wheel. BALANCE the assembly. TEST
the system for normal operation. If the
condition persists, GO to K8.
No
INSTALL a new wheel. CHECK the runout
on the new wheel. If the new wheel is
within limits, LOCATE and MARK the low
spot. INSTALL the tire, matching the high
spot on the tire with the low spot on the
wheel. BALANCE the assembly. TEST the
system for normal operation. If the
Is the runout within specifications? condition persists, GO to K8.
K8 CHECK FOR VIBRATION FROM THE FRONT OF THE VEHICLE
WARNING: If only one drive wheel is allowed to rotate,
speed must be limited to 55 km/h (34 mph) using the
speedometer reading, since actual wheel speed will be twice
that indicated on the speedometer. Exceeding a speed of 55
km/h (34 mph) or allowing the drive wheel to hang
unsupported can result in tire disintegration or differential
Yes
failure, which can cause serious personal injury and extensive
SUBSTITUTE known good wheel and tire
vehicle damage.
assemblies as necessary. TEST the
Spin the front wheel and tire assemblies with a wheel balancer
while the vehicle is raised on a hoist. Feel for vibration in the
front fender or while seated in the vehicle. No
Is the vibration present? GO to K9.
K9 CHECK FOR VIBRATION FROM THE REAR OF THE VEHICLE
vehicle damage.
Chock the front wheels.
Raise and support the rear end of the vehicle so that the rear
Yes
wheel and tire assemblies can spin.
GO to K10.
Engage the drivetrain and carefully accelerate the drive wheels
while checking for vibration. No
Is the vibration present? TEST the system for normal operation.
K10 CHECK THE DRIVETRAIN
Yes
CHECK/TEST the drivetrain and driveline
vehicle damage.
components. TEST the system for normal
Remove the rear wheel and tire assemblies. Refer to the
operation.
appropriate workshop manual for the service procedures.
Secure the brake drums (if so equipped), by installing wheel hub No
bolt nuts, reversed. SUBSTITUTE known good wheel and tire
Carefully accelerate the drivetrain while checking for vibration. assemblies as necessary. TEST the
Is the vibration present? system for normal operation.
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PINPOINT TEST L: CLUTCH VIBRATION
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
NOTE: Make sure the clutch is the cause of the vibration
concern. The vibration should occur during clutch operation. The
clutch can also be difficult to engage or disengage. Eliminate all
related systems before checking the clutch components.
NOTE: Check the driveline angles and driveshaft runout before
Yes
disassembling the clutch system. Refer to Section 205-00 for the
correct driveline angle specifications.
Check the powertrain/drivetrain mounts, exhaust manifolds or
other engine components for grounding on the chassis. No
Are any mounts or engine components grounded? GO to L2.
L2 CHECK THE ACCESSORY DRIVE
Remove the accessory drive belt. Yes
Does the vibration stop with the accessory drive belt DIAGNOSE the accessory drive
removed? components.
No
GO to L3.
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE BOLTS
Check for loose clutch pressure plate bolts. Inspect the clutch Yes
pressure plate for damage or for material between the pressure TIGHTEN the bolts to specifications or if
plate and flywheel. damaged, INSTALL a new clutch pressure
Are there any loose bolts or damage? plate. REFER to Section 308-01. TEST
No
GO to L4.
L4 CHECK THE CLUTCH DISC SPRINGS
Check for worn, broken or loose clutch disc springs. Yes
Are the clutch springs worn, broken or loose? INSTALL a new clutch disc. REFER to
Section 308-01. TEST the system for
normal operation.
No
GO to L5.
L5 CHECK THE CLUTCH DISC SPLINES
Inspect the clutch disc splines for damage or wear. Yes
Is there damage or wear? INSTALL a new clutch disc. REFER to
normal operation.
No
GO to L6.
L6 CHECK THE FLYWHEEL BOLTS
Check for loose flywheel bolts. Yes
Are the bolts loose? TIGHTEN the bolts to specifications.
REFER to Section 308-01. TEST the
No
GO to L7.
L7 CHECK THE FLYWHEEL SURFACE
Inspect the flywheel surface for wear or damage. Check the Yes
flywheel runout. INSTALL a new flywheel. TEST the
Is there any damage or excessive wear? system for normal operation.
No
Clutch system normal. CONDUCT a
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PINPOINT TEST M: TRANSFER CASE VIBRATION
M1 INSPECT THE TRANSFER CASE
Yes
TIGHTEN to specifications or INSTALL
operations.
new bolts as necessary. TEST the system
Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission. No
Are the mounting bolts missing or loose? GO to M2.
M2 INSPECT THE REAR DRIVESHAFT
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
Inspect the driveshaft for missing weights, damage or
Yes
undercoating.
REPAIR or INSTALL a new driveshaft as
Inspect the U-joints for freedom of movement.
necessary. TEST the system for normal
Check driveshaft runout and, if necessary, check the pinion
operation.
flange runout.
Is the driveshaft or U-joints worn or damaged or No
misaligned? GO to M3.
M3 CHECK THE DRIVELINE ANGLES
Measure the rear driveshaft and pinion angles. Refer to Section Yes
205-00. REPAIR as necessary. TEST the system
Measure the front driveshaft and pinion angles. Refer to Section for normal operation.
205-00.
No
Are the driveline angles incorrect?
GO to M4.
M4 INSPECT THE FRONT DRIVESHAFT
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
Yes
Inspect the front driveshaft for missing weights, damage or
REPAIR or INSTALL a new driveshaft as
undercoating.
Inspect the U-joints and slip yoke for freedom of movement.
operation.
Check driveshaft runout and, if necessary, check the pinion
flange runout. No
Is the driveshaft or U-joints worn or damaged? GO to M5.
M5 ROAD TEST WITH THE FRONT DRIVESHAFT ONLY
NOTE: Index mark the driveshaft to the pinion flange and to the
output shaft before removal.
Yes
Remove the rear driveshaft.
INSTALL and BALANCE the rear
Plug the transfer case with an output shaft seal plug.
driveshaft. TEST the system for normal
NOTE: Shift the transfer case into four wheel drive (4WD) high
operation.
so the vehicle is driven by the front driveshaft only.
Test drive the vehicle. No
Is the vibration gone? GO to M6.
M6 ROAD TEST WITH THE REAR DRIVESHAFT ONLY
NOTE: Index mark the front driveshaft to the pinion flange. Yes
INSTALL and BALANCE the front
Remove the front driveshaft.
driveshaft. TEST the system for normal
operation.
Is the vibration gone?
No
GO to M7.
M7 TRANSFER CASE TAIL SHAFT INSPECTION
Inspect the splines of the output shaft for wear or damage. Yes
Inspect the splines of the driveshaft slip yoke for wear or REPAIR or INSTALL new components as
damage. necessary. TEST the system for normal
Are the splines worn or damaged? operation.
No
The transfer case is OK. CONDUCT a
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Component Tests Wheel Hub Bolt Circle Runout
NOTE: The brake discs must be removed to carry
Idle Air Control (IAC) Valve
out all runout measurements.
1. Open the hood.
1. Position the special tool on the wheel hub bolt,
2. NOTE: Key symptom is elevated idle speed
as close to the hub face as possible. Zero the
while noise is occurring.
indicator to allow the pointer to deflect either
NOTE: Snapping the throttle can induce the way.
noise.
Verify the condition by operating the vehicle
for a short time.
3. Inspect the IAC valve. If physical evidence of
contamination exists, install a new IAC valve.
4. While the noise is occurring, either place an
EngineEAR probe near the IAC valve and the
inlet tube, or create a 6.35-mm (0.25-in) to
12.7-mm (0.50-in) air gap between the inlet
tube and the clean air tube. If the IAC valve is
making the noise, install a new IAC valve.
5. Test the vehicle for normal operation.
2. Rotate the hub until the next bolt is contacted.
Steering Gear Grunt/Shudder Test
Record the measurement and continue until
1. Start and run the vehicle to operating each bolt is checked. The difference between
temperature. the maximum and minimum contact readings
will be the total wheel hub bolt circle runout.
2. Set engine idle speed to 1200 rpm.
The runout must not exceed 0.38 mm (0.015
3. CAUTION: Do not hold the steering
in).
wheel against the stops for more than three
Pilot Runout
to five seconds at a time. Damage to the
power steering pump will occur.
1. Position the special tools on the pilot, as close
to the hub as possible. Zero the indicator to
Rotate the steering wheel to the RH stop, then
allow the pointer to deflect either way.
turn the steering wheel 90 degrees back from
that position. Turn the steering wheel slowly in
a 15 to 30 degree arc.
4. Turn the steering wheel another 90 degrees.
Turn the steering wheel slowly in a 15 to 30
degree arc.
5. Repeat the test with power steering fluid at
different temperatures.
6. If a light grunt is heard or a low (50-200 Hz)
shudder is present, this is a normal steering
system condition.
7. If a loud grunt is heard, or a strong shudder is
felt, fill and purge the power steering system.
2. Rotate the hub 1 full turn and note the
maximum and minimum readings. The
difference between the maximum and minimum
readings will be the total pilot runout. Pilot
runout must not exceed 0.15 mm (0.006 in).
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Wheel Hub Runout
2. Rotate the hub 1 full turn and note the
maximum and minimum readings. The
1. Position the special tool on the wheel hub, as
close to the outer edge as possible. Zero the
readings will be the total wheel hub runout. The
way.
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Tire Wear Patterns and frequency calculations
Tire Wear Chart
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Wheel and tire NVH concerns are directly related to For a vibration concern, use the vehicle speed to
vehicle speed and are not generally affected by determine tire/wheel frequency and rpm. Calculate
acceleration, coasting or decelerating. Also, tire and wheel rpm and frequency by carrying out
out-of-balance wheel and tires can vibrate at more and following:
than one speed. A vibration that is affected by the
Measure the diameter of the tire.
engine rpm, or is eliminated by placing the
Record the speed at which the vibration occurs.
transmission in NEUTRAL is not related to the tire
and wheel. As a general rule, tire and wheel
Obtain the corresponding tire and wheel rpm and
vibrations felt in the steering wheel are related to
frequency from the Tire Speed and Frequency
the front tire and wheel assemblies. Vibrations felt
Chart.
in the seat or floor are related to the rear tire and
If the vehicle speed is not listed, divide the
wheel assemblies. This can initially isolate a
vehicle speed at which the vibration occurs by
concern to the front or rear.
16 km/h (10 mph). Multiply that number by
Careful attention must be paid to the tire and
16 km/h (10 mph) tire rpm listed for that tire
wheels. There are several symptoms that can be
diameter in the chart. Then divide that number
caused by damaged or worn tire and wheels. Carry
by 60. For example: a 40 mph vibration with
out a careful visual inspection of the tires and wheel
835 mm (33 in) tires. 40 10 = 4. Multiply 4
assemblies. Spin the tires slowly and watch for
by 105 = 420 rpm. Divide 420 rpm by 60
signs of lateral or radial runout. Refer to the tire
seconds = 7 Hz at 40 mph.
wear chart to determine the tire wear conditions and
actions.
Tire Speed and Frequency Chart
Tire Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (inch) @ 16 km/h (10 mph) @ 80 km/h (50 mph) @ 97 km/h (60 mph) @ 113 km/h (70
mph)
483 (19) 182 910/15 1092/18 1274/21
508 (20) 173 865/14 1038/17 1211/20
533 (21) 165 825/14 990/16 1155/19
560 (22) 158 790/13 948/16 1106/18
585 (23) 151 755/13 906/15 1057/18
610 (24) 145 725/12 870/14 1015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12
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GENERAL PROCEDURES
7. Tighten the RH and LH engine mount nuts.
Neutralizing Tighten the nuts to 63 Nm (46 lb-ft).
The front 2 engine mounts are neutralized.
NOTE: This procedure applies to both the 4.0L
SOHC engine and the 4.6L (3V) engine.
1. With the vehicle in NEUTRAL, position it on a
Section 100-02.
2. Working under the hood, loosen the RH and
LH engine mount nuts.
8. Raise the vehicle.
9. Place a transmission jack under the
transmission.
Slightly raise the transmission to remove the
weight from the transmission mount.
10. Loosen the 4 rear transmission mount outer
bolts.
3. Raise the vehicle.
The transmission should be fully supported
by the transmission jack.
4. Remove the rear transmission mount center
bolt.
11. Raise the transmission until it is not contacting
the transmission mount.
12. Install the rear transmission center bolt. Do not
6. Move the vehicle in forward and reverse 0.6-1.2
tighten at this time.
meters (2-4 feet).
13. Lower the transmission until it sits at the
installed height.
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GENERAL PROCEDURES (Continued)
14. Center the transmission mount until the gap
between the transmission mount snubber and
the front face of the transmission mount is the
same as the gap between the transmission
mount snubber and the rear face or the
transmission mount.
1 The entire gap of the front transmission
mount snubber equals the entire gap of the
rear mount snubber.
16. Tighten the rear transmission center bolt to
specification.
Tighten to 70 Nm (52 lb-ft).
15. Tighten the 4 rear transmission mount outer
bolts. Remove the transmission jack, check that
the gaps are still equally spaced.
18. Test the system for normal operation.
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GENERAL PROCEDURES
Wheel Bearing Check
1. WARNING: The electrical power to
the air suspension system must be shut off
prior to hoisting, jacking or towing an air
suspension vehicle. This can be accomplished
by turning off the air suspension switch.
Failure to do so can result in unexpected
inflation or deflation of the air springs,
which can result in shifting of the vehicle
during these operations.
Raise the vehicle until the front tires are off the
floor.
Make sure the wheels are in a straight
forward position.
2. NOTE: Make sure the wheel rotates freely and
that the brake pads are retraced sufficiently to
allow free movement of the tire and wheel
assembly.
Spin the tire by hand to check the wheel
bearings for roughness.
3. Grip each front tire at the top and bottom and
move the wheel inward and outward while
lifting the weight of the tire off the front wheel
bearing.
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4. If the tire and wheel (hub) is loose on the
spindle, does not rotate freely or has a rough
feeling when spun, carry out one of the
following:
1 On vehicles with inner and outer bearings,
inspect the bearings and cups for wear or
damage. Adjust or install new bearings and
cups as necessary.
2 On vehicles with one sealed bearing, install
a new wheel hub.
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204-00-1 204-00-1 Suspension System General Information
General Specifications (Continued)
SPECIFICATIONS
Item Specification
Alignment Specifications
Rear Coupe 115 mm 8 mm (4.5 in
Total/ 0.3 in)
Item LH RH Split
Dogtracking
Front
Maximum 13 mm (0.5 in)
Caster 7.1 7.1 0
Clear vision (negative 0 3
0.75 0.75 0.75
value is counterclockwise)
Camber -0.75 -0.75 0
Ball Joint Deflection
0.75 0.75 0.75
Lower ball joint 0-0.3 mm (0-0.012 in)
Toe (positive value is 0.10
toe-in, negative value 0.20
is toe-out)
Torque Specifications
Description Nm lb-ft
General Specifications
Tie-rod jam nut 55 41
Item Specification
Lower control arm rear 175 129
Front Ride Height inboard cam nut
Front 37 mm 8 mm (1.5 in Strut-to-wheel spindle cam 200 148
0.3 in) nut
Rear Ride Height Brake line bracket bolt 20 15
Rear Convertible 118 mm 8 mm (4.6 in Wheel speed sensor bolt 15 11
0.3 in)
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GENERAL PROCEDURES
Camber Adjustment Front 4. CAUTION: Support the wheel spindle
using mechanics wire.
1. NOTE: If camber adjustment is necessary to Note the orientation of the strut-to-spindle bolts
resolve a vehicle alignment issue, then slotting and flag nuts, then remove and discard the bolts
the strut at the lower mounting plate and and flag nuts.
installing a cam bolt is an acceptable method.
This procedure should not be routinely
5. CAUTION: Do not enlarge the holes
performed with all alignments and only after
any more than indicated by the etchings on
all other possible sources have been inspected
the strut mount.
and corrected as necessary.
Using a suitable grinding tool, enlarge the
strut-to-wheel spindle lower mounting holes as
indicated by the etchings in the strut lower
Section 100-02.
mount.
Remove any burrs.
2. Remove the wheel speed sensor bolt and
Clean and paint any exposed metal.
position the sensor aside.
6. NOTE: Do not fully tighten the cam bolts until
3. Remove the brake line bracket bolt and
the alignment has been corrected.
disconnect the wheel speed sensor wire from
the bracket.
Position the wheel spindle and install a cam
adjusting nut and bolt in the bottom location,
using the opposite orientation noted in Step 4.
Then install a new bolt and flag nut in the top
location.
Tighten the upper bolt and cam nut until
snug.
7. Position the brake line bracket and install the
bolt, connect the wheel speed sensor wire to the
bracket.
8. Position the wheel speed sensor and install the
bolt.
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9. Using alignment equipment and the 10. Using the cam bolt, adjust the front camber
manufacturers instructions, measure the front until it is within specifications.
camber.
Tighten the upper bolt and the cam nut to
200 Nm (148 lb-ft).
11. Recheck the front camber settings, adjust as
necessary.
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GENERAL PROCEDURES
3. Install the front lower control arm using a cam
Caster Adjustment Front
bolt and a new nut in the rear inboard mounting
hole. For additional information, refer to
1. NOTE: If caster adjustment is necessary to
Section 204-01.
resolve a vehicle alignment issue, then slotting
Do not tighten the cam bolt until the
the subframe and installing cam bolts is an
alignment has been corrected.
acceptable method. This procedure should not
be routinely performed with all alignments and
only after all other possible sources have been
inspected and corrected as necessary.
Remove the front lower control arm. For
additional information, refer to Section 204-01.
2. CAUTION: Do not elongate the hole
any more than indicated by the etchings on
the subframe.
Using a suitable grinding tool, elongate the
lower control arm rear outboard mounting hole
as indicated by the etchings in the subframe.
Remove any burrs.
4. Using alignment equipment and the
Clean and paint any exposed metal.
manufacturers instructions, measure the caster.
5. Using the cam bolt, adjust the front caster until
it is within specifications.
Tighten the nut to 175 Nm (129 lb-ft).
6. Recheck the caster settings and adjust as
necessary
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X Install a new shock absorber, if
Suspension System
necessary.
Inspection and Verification
Vehicle Sag: Many times new shock
1. Road test.
absorbers are installed in an effort to solve a
vehicle sag concern. Shock absorbers by
Verify the customers concern by
design are hydraulic damping units only
performing a road test on a smooth road.
and, unlike suspension springs, do not
2. Inspect tires.
support any suspension loads. Therefore,
Check the tire pressure with all normal
installing a new shock absorber will not
loads in the vehicle and the tires cold. For
correct a vehicle sag concern.
additional information, refer to the vehicle
Installment in Pairs: In the past it was
certification (VC) label.
recommended that new shock absorbers be
Verify that all tires are sized to
installed in pairs if one unit became
specification.
unrepairable. New shock absorbers no longer
need to be installed in pairs when only one
Inspect the tires for incorrect wear and
unit is not repairable.
damage.
3. Inspect chassis and underbody.
Visual Inspection Chart
Remove any excessive accumulation of
Mechanical
mud, dirt or road deposits from the chassis
Front wheel bearing(s)
and underbody.
Loose or damaged front or rear suspension
components 4. Inspect for aftermarket equipment.
Loose, damaged or missing suspension fastener(s)
Check for aftermarket changes to the
Damaged spring(s)
steering, suspension, wheel and tire
Damaged or leaking strut and spring assemblies
components (such as competition, heavy Damaged or leaking shock absorber(s)
Worn or damaged suspension bushing(s)
duty, etc.). The specifications shown in this
Loose, worn or damaged steering system components
manual do not apply to vehicles equipped
Damaged axle components
with aftermarket equipment.
5. Inspect shock absorbers.
6. If an obvious cause for an observed or reported
All vehicles are equipped with gas-pressurized
condition is found, correct the cause (if
hydraulic shock absorbers. These shock
possible) before proceeding to the next step.
absorbers are not adjustable or refillable and
7. If the fault is not visually evident, determine
cannot be repaired.
the symptom and GO to Symptom Chart.
Oil Leak: A light film of oil (weepage) on
the upper portion of the shock absorber is
permissible and is a result or correct shock
lubrication. Weepage is a condition in which
a film of oil accumulates on the thin tube
(body) and is normally noticed due to the
collection of dust in this area. If shock
absorbers exhibit this weepage condition,
they are functional units and new shock
absorbers should not be installed. Leakage is
a condition in which the entire shock
absorber body is covered with oil and the
oil will drip from the shock absorber onto
the pavement. If condition exists:
X Make sure fluid observed is not from
sources other than the shock absorber.
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Symptom Chart
Symptom Chart
Incorrect thrust angle Incorrect rear thrust angle CHECK the rear wheel
(dogtracking) alignment.
Rear suspension components INSPECT the rear suspension
system. REPAIR or
INSTALL new suspension
Drive axle damaged REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure.
Drift/pull Unequal tire pressure ADJUST tire pressure.
Excessive side-to-side CHECK the wheel alignment.
difference in caster or camber ADJUST as necessary
Tire forces ROTATE tires front to rear.
Unevenly loaded or NOTIFY the customer of
overloaded vehicle incorrect vehicle loading.
Steering components REFER to Section 211-00.
Brake drag REFER to Section 206-00.
Front bottoming or riding low Strut(s) INSTALL new strut(s) as
204-01.
Front coil springs CHECK ride height.
INSTALL new springs as
204-01.
Incorrect tire wear Incorrect tire pressure (rapid ADJUST tire pressure.
center rib or inner and outer
edge wear)
Excessive front or rear toe CHECK the wheel alignment.
(rapid inner or outer edge ADJUST as necessary.
wear)
Excessive negative or positive
camber (rapid inner or outer
edge wear)
Tires out of balance (tires BALANCE tires.
cupped or dished)
Rough ride Strut(s) INSTALL new strut(s) as
204-01.
Shock absorber(s) INSTALL new shock
absorber(s) as necessary.
Front coil springs or rear INSTALL new front coil
springs springs or rear springs as
204-01 or Section 204-02.
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Symptom Chart (Continued)
Shimmy or wheel tramp Loose wheel nut(s) TIGHTEN to specification.
Loose front suspension TIGHTEN to specification.
fasteners REFER to Section 204-01.
Front wheel bearing(s) REFER to Section 100-04
Wheel or tire runout REFER to Section 204-04.
Tire flatspotting
Loose, worn or damaged ball GO to the Ball Joint
joint(s) Inspection component test in
this section.
Loose, worn or damaged REFER to Section 211-00.
steering components
Front wheel alignment CHECK the wheel alignment.
Sticky steering, poor Ball joint(s) GO to the Ball Joint
returnability Inspection component test in
this section
Steering wheel off-center Unequal front or rear toe CHECK the wheel alignment.
settings (side-to-side) ADJUST as necessary.
Sway or roll Overloaded, unevenly or NOTIFY the customer of
incorrectly loaded vehicle incorrect vehicle loading.
Loose wheel nut(s) TIGHTEN to specification.
Strut(s) INSTALL new strut(s) as
204-01.
Loose front stabilizer bar or TIGHTEN to specification.
rear stabilizer bar REFER to Section 204-01 or
Section 204-02.
Worn stabilizer assembly INSTALL new bushing(s) as
bushing(s) necessary. REFER to Section
204-01 or Section 204-02.
Front coil spring(s) or rear INSTALL new front coil
spring(s) springs or rear springs as
204-01 or Section 204-02.
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Vehicle leans to one side Unevenly loaded or NOTIFY the customer of
Front or rear suspension INSPECT the front and rear
components suspension system. REPAIR
or INSTALL new suspension
REFER to Section 204-01 or
Section 204-02.
Front coil springs or rear INSTALL new front coil
springs springs or rear springs as
204-01 or Section 204-02.
Incorrect ride height. Lateral CHECK ride height.
tilt out of specification INSTALL new front coil
springs or rear springs as
204-01 or Section 204-02.
Vibration/noise Tire or wheel runout REFER to Section 100-04.
Tire flatspotting
Wheel bearings
Wheel hubs
Brake components
Steering components
Wander Unevenly loaded or NOTIFY the customer of
Ball joint(s) GO to the Ball Joint
Inspection component test in
this section.
Front wheel bearing(s) REFER to Section 100-04
Loose, worn or damaged INSTALL new suspension
suspension component(s) components as necessary.
Section 204-02.
Loose suspension fasteners TIGHTEN to specification.
Section 204-02.
Wheel alignment CHECK wheel alignment.
ADJUST as necessary
(excessive total front toe out).
Component Tests 3. Inspect the ball joint and ball joint boot for
damage.
Ball Joint Inspection
If the ball joint or ball joint boot is
1. Prior to inspecting the ball joints for wear,
damaged, install a new ball joint as
inspect the wheel bearings. For additional
necessary. For additional information, refer
information, refer to Section 100-04.
to Section 204-01.
2. NOTE: In order to obtain accurate
measurements, the suspension must be in full
rebound with the weight of the vehicle
supported by the frame.
Raise and support the vehicle by the frame to
allow the wheels to hang in the rebound
position.
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If relative movement is found, continue with
4. CAUTION: Do not use any tools or
Step 5.
equipment to move the wheel and tire
assembly or suspension components while
5. NOTE: In order to obtain an accurate
checking for relative movement or suspension
measurement, the dial indicator should be
damage can occur. The use of tools or
aligned as close as possible with the vertical
equipment will also create relative movement
axis (center line) of the ball joint.
that may not exist when using hand force.
To measure ball joint deflection, attach a
Relative movement must be measured using
suitable dial indicator with a flexible arm
hand force only.
between the lower control arm and the wheel
Inspect the ball joint for relative movement by
knuckle or ball joint stud.
alternately pulling downward and pushing
upward on the lower control arm by hand. Note
any relative vertical movement between the
wheel knuckle and lower arm at the lower ball
joint.
If relative movement is not felt or seen, the
ball joint is OK. Do not install a new ball
joint
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6. Measure the ball joint deflection while pushing If the deflection meets the specification, no
up and pulling down on the lower control arm, further action is required.
by hand.
If the deflection exceeds the specification, a
new ball joint must be installed. For
additional information, refer to Section
204-01.
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GENERAL PROCEDURES
Toe Adjustment Front
1. Start the engine and center the steering wheel.
2. Turn the engine off and, using a suitable
steering wheel holding device, lock the steering
wheel in the straight ahead position.
3. Using alignment equipment and the
manufacturers instructions, measure the front
toe.
4. Remove the clamps.
7. NOTE: Do not allow the inner tie rods to
rotate while tightening the jam nuts.
Tighten the jam nuts to 55 Nm (41 lb-ft).
5. Loosen the jam nuts.
8. Install the clamps.
6. NOTE: Do not allow the steering gear bellows
to twist when the inner tie rod is rotated.
Rotate the inner tie rods until the toe reading is
9. Recheck the toe settings and adjust as
within specifications.
necessary.
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Caster is the deviation from vertical of an imaginary
Wheel Alignment Angles
line drawn through the pivot points (top of strut and
Camber and toe are adjustable on the front
lower ball joint), when viewed from the side. The
suspension systems. Front camber is adjusted
caster specifications in this section will give the
through the use of a service repair kit (2B236).
vehicle the best directional stability characteristics
Caster is preset at the factory and should only be
when loaded and driven. The caster setting is not
adjusted, through the use of a service repair kit
related to tire wear.
(2B236), after all other possible sources have been
inspected and corrected as necessary. Front toe is
Toe
adjusted by the use of the front wheel spindle tie
Positive Toe (Toe In)
rod.
Camber
Negative and Positive Camber
Negative Toe (Toe Out)
Camber is the vertical tilt of the wheel when viewed
from the front. Camber can be positive or negative
and has a direct effect on tire wear.
Caster
The vehicle toe setting affects tire wear and
directional stability.
Item Part Number Description
1 True vertical
2 Positive caster angle
3 Strut-to-ball joint centerline
4 Pivot centerline
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Rear Ride Height Measurement
Ride Height
Front Ride Height Measurement
Item Description
1 Body reinforcement
2 Ride height (shortest distance)
3 Rear axle
Incorrect Thrust Angle (Dogtracking)
Item Description
1 Ride height = B - A
2 Measurement A
3 Measurement B
1 Vehicle centerline
2 Axle centerline
3 Thrust angle
Incorrect thrust angle (also known as dogtracking) is
the condition in which the rear axle is not square to
the chassis. Heavily crowned roads can give the
illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require
frequent, random left and right steering wheel
corrections to maintain a straight path down a level
road.
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Shimmy
Drift describes what a vehicle with this condition
does with hands off the steering wheel.
Shimmy, as observed by the driver, is large,
consistent, rotational oscillations of the steering
Drift/pull may be induced by conditions external
wheel resulting from large, side-to-side (lateral)
to the vehicle (that is, wind, road camber).
tire/wheel movements.
Poor Groove Feel
Shimmy is usually experienced near 64 km/h (40
Poor groove feel is characterized by little or no
mph), and can begin or be amplified when the tire
buildup of turning effort felt in the steering wheel
contacts pot holes or irregularities in the road
as the wheel is rocked slowly left and right within
surface.
very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Efforts
Nibble
may be said to be flat on center.
Sometimes confused with shimmy, nibble is a
condition resulting from tire interaction with various
Under 20 degrees of turn, most of the turning
road surfaces and observed by the driver as small
effort that builds up comes from the mesh of gear
rotational oscillations of the steering wheel.
teeth in the steering gear. In this range, the
steering wheel is not yet turned enough to feel the
Poor Returnability/Sticky Steering
effort from the self-aligning forces at the road
Poor returnability and sticky steering is used to
wheel or tire patch.
describe the poor return of the steering wheel to
In the diagnosis of a handling problem, it is
center after a turn or steering correction is
important to understand the difference between
completed.
wander and poor groove feel.
Drift/Pull
Pull is a tugging sensation, felt in the steering
wheel, that must be overcome to keep the vehicle
going straight.
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204-01-1 204-01-1 Front Suspension
Front Suspension
WARNING: All vehicles are equipped with
gas-pressurized shock absorbers which will
extend unassisted. Do not apply heat or flame to
the shock absorbers during removal or
component servicing. Failure to follow these
instructions can result in personal injury.
CAUTION: Suspension fasteners are
critical parts because they affect performance of
vital components and systems and their failure
can result in major service expense. A new part
with the same part number or an equivalent part
must be installed, if installation is necessary. Do
not use a part of lesser quality or substitute
design. Torque values must be used as specified
during reassembly to ensure correct retention of
these parts. Never attempt to heat, quench or
straighten any front suspension part. Install a
new part.
The front suspension is a MacPherson strut design.
The design consists of:
Front shock absorber
Front wheel spindle
Front suspension lower arm
Front stabilizer bar
Front stabilizer bar link
Front coil spring
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Front Suspension
Refer to Section 204-00.
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REMOVAL AND INSTALLATION
Lower Arm
4.0L and 4.6L shown, 5.4L similar
Item Part Number Description Item Part Number Description
4 3A053 LH/ Lower control arm 1 W710141 Lower control arm rearward
3A052 RH flag bolt (2 required)
5 W711123 Lower ball joint bolt 2 W709865 Lower control arm forward
bolt
6 W520215 Lower control arm rearward
nut (2 required) 3 W710909 Steering gear bolt (2 required)
(Continued) 7 W520214 Lower ball joint nut
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REMOVAL AND INSTALLATION (Continued)
Removal and Installation
5. CAUTION: Do not damage the
steering gear boot while removing or
CAUTION: Suspension fasteners are installing the lower control arm forward bolt.
Remove the lower control arm forward nut and
bolt.
To install, tighten to 175 Nm (129 lb-ft).
6. NOTE: To ease installation, the position of the
lower control arm nut and flag bolt can be
reversed to allow installation of the nut from
during reassembly to make sure of correct
underneath the vehicle.
retention of these parts.
Remove the lower control arm rearward nuts
and flag bolts.
Section 100-02.
7. Remove the lower control arm and bracket
2. CAUTION: Note the orientation of the assembly.
lower ball joint nut and bolt. They must be
8. Remove the 3 heat shield bolts.
installed using the same orientation.
To install, tighten to 7 Nm (62 lb-in).
Remove the lower ball joint nut and bolt.
To install, tighten the nut to 103 Nm (76
9. Remove the heat shield.
lb-ft).
10. CAUTION: Tighten the lower control
3. Separate the lower control arm and the wheel
arm and lower ball joint nuts with the
spindle.
suspension at curb height.
4. Remove the steering gear bolts. Position the
CAUTION: The lower ball joint seal
steering gear to gain access to the lower control
must be fully seated against the knuckle or
arm forward bolt.
premature damage to the ball joint can
occur.
To install, reverse the removal procedure.
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Torque Specifications (Continued)
SPECIFICATIONS
Description Nm lb-ft lb-in
Lower control arm 175 129
Item Specification rearward nuts
Lubricant Brake line bracket bolt 20 15
Silicone Spray Lubricant ESR-M13P4-A Strut rod nut 62 46
XL-6
Strut-to-spindle bolts 200 148
Strut upper mount nuts 35 26
Wheel hub nut 300 221
Stabilizer bar bracket 70 52
nuts
Caliper anchor plate 133 98
bolts
Stabilizer bar link nuts 115 85
Brake disc shield bolts 20 15
Wheel speed sensor 15 11
bolt
Lower ball joint nut 103 76
Tie-rod end nuts 80 59
Lower control arm 175 129
forward bolt
Steering gear bolts 115 85
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Stabilizer Bar Bushing
Material
Item Specification
Silicone Spray Lubricant ESR-M13P4-A
XL-6
1 5482 Stabilizer bar
2 5484 Stabilizer bar bushing
1. Remove the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
2. NOTE: To aid removal, apply a light coat of
lubricant to the necessary parts of the front
stabilizer bar.
Remove the stabilizer bar bushing by sliding if
off the stabilizer bar.
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3. NOTE: To aid installation, apply a light coat of
lubricant to the necessary parts of the front
stabilizer bar and the inside diameter of the
stabilizer bar bushing.
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Stabilizer Bar Link
Item Part Number Description 2. CAUTION: Use the holding feature to
prevent the studs from turning while
1 5K483 Stabilizer bar link
removing or installing the stabilizer bar link
2 W520214 Stabilizer bar link upper nut
nuts. The boot seal must not be allowed to
3 W520214 Stabilizer bar link lower nut
twist at all while tightening the nuts.
Remove and discard the stabilizer bar link
lower nut.
3. Disconnect the link from the stabilizer bar.
4. CAUTION: Use the holding feature to
nuts. The boot seal must not be allowed to
twist at all while tightening the nuts.
upper nut.
Section 100-02.
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5. Disconnect the link from the strut. 6. To install, reverse the removal procedure.
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Stabilizer Bar
3 W520213 Bracket nut (4 required) 1 5482 Stabilizer bar
4 W520214 Stabilizer bar link lower nut 2 5486 Stabilizer bar bracket (2
(2 required) required)
(Continued)
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CAUTION: Suspension fasteners are removing or installing the stabilizer bar link
critical parts because they affect performance of nuts. The boot seal must not be allowed to
vital components and systems and their failure twist at all while tightening the nut.
Remove and discard both stabilizer bar link
lower nuts.
3. Disconnect both links from the stabilizer bar.
4. Remove and discard the 4 stabilizer bracket
nuts, then remove the stabilizer bar brackets
and the stabilizer bar.
Section 100-02.
5. If necessary, remove the stabilizer bar bushings.
For additional information, refer to Stabilizer
Bar Bushing in this section.
6. To install, reverse the removal procedure.
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DISASSEMBLY AND ASSEMBLY
Disassembly and Assembly
Strut and Spring Assembly
gas-pressurized struts which will extend
unassisted. Do not apply heat or flame to the
struts during removal or component servicing.
Failure to follow these instructions can result in
personal injury.
WARNING: The strut and spring assembly
is under extreme load. Do not attempt to
disassemble the strut and spring assembly
without using a spring compressor. Failure to
follow these instructions can result in personal
injury.
with the same part number must be installed if
installation is necessary. Do not use a new part
of lesser quality or substitute design. Torque
values must be used as specified during
reassembly to make sure of correct retention of
these parts.
1. Remove the strut and spring assembly. For
additional information, refer to Strut and Spring
Assembly in this section.
1 W520215 Strut rod nut and washer
2 18045 Strut
3 Dust boot (part of 18045)
4 Jounce bumper (part of
18045)
5 18183 Upper mount assembly
6 5310 Spring
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DISASSEMBLY AND ASSEMBLY (Continued)
2. NOTE: If installing a new spring, make sure 4. If necessary, remove the dust boot and jounce
the part number is correct. Refer to the vehicle bumper.
certification (VC) label for the correct spring
5. Remove the upper mount assembly.
code. Refer to Section 100-01 to convert the
spring code to a part number.
6. Carefully release the tension on the spring
Using a suitable spring compressor, compress
compressor and remove the spring.
the spring until the tension is released from the
strut.
7. When installing the spring onto the strut, make
sure the spring end is positioned against the
seat stop and is resting in the spring seat
pocket.
3. While holding the strut rod, remove and discard
the strut rod nut and washer and remove the
strut.
8. To assemble, reverse the disassembly procedure.
Align the notch on the upper bearing
assembly with the clevis at the bottom of
the strut.
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Strut and Spring Assembly
1 W709870 Strut-to-wheel spindle bolt (2
required) WARNING: All vehicles are equipped with
gas-pressurized struts which will extend
2 Strut and spring assembly
3 N807144 Stabilizer bar link upper nut
struts during removal or component servicing.
4 W711091 Strut-to-wheel spindle flag
nut (2 required)
personal injury.
5 W520112 Strut upper mount nut (4
required)
1. Remove the 4 strut upper mount nuts.
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Section 100-02.
4. Remove the brake line bracket bolt and
disconnect the wheel speed sensor wire from
the bracket.
8. WARNING: All vehicles are equipped
with gas-pressurized struts which will extend
struts during removal or component
servicing. Failure to follow these instructions
can result in personal injury.
NOTE: If equipped, do not discard the
strut-to-spindle cam nuts and bolts.
Remove and discard the strut-to-spindle bolts
and flag nuts.
9. CAUTION: Damage to the lower
control arm bushings may occur if the lower
control arm is not supported.
nuts. Carefully lower the lower control arm and
remove the strut and spring assembly.
upper nut and disconnect the link from the To install, the notch and the arrow etched
strut. into the upper bearing assembly must face
the outboard side of the vehicle.
10. If necessary, disassemble the strut and spring
6. Using a suitable jack stand, support the lower
assembly. For additional information, refer to
control arm.
Strut and Spring Assembly in this section.
7. If equipped, index mark the 2 strut-to-spindle
cam bolts.
12. Check and, if necessary, adjust the front end
alignment. For additional information, refer to
Section 204-00.
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Wheel Bearing and Wheel Hub
1 W710233 Caliper anchor plate bolt (2
required) CAUTION: Suspension fasteners are
2 Brake caliper, pads and
anchor plate assembly vital components and systems and their failure
3 1125 Brake disc
4 1N135 Wheel hub grease cap
5 3B477 Wheel hub nut
6 Dust shield bolt (3 required)
7 2K004 Dust shield
8 2B663/2C300 Wheel hub assembly retention of these parts.
(ABS/non-ABS)
Section 100-02.
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2. CAUTION: Do not allow the caliper 5. WARNING: The wheel hub nut is a
and anchor plate assembly to hang from the one-time-use item and must be replaced with
brake hose or damage to the hose can occur. a new nut when removed. Failure to do so
can cause the retainer to come loose during
Remove the anchor plate bolts and position the
vehicle operation resulting in loss of vehicle
brake caliper and anchor plate assembly aside.
control. Failure to follow these instructions
Support the caliper and anchor plate
may result in personal injury.
assembly using mechanics wire.
Remove and discard the wheel hub nut.
3. Remove the brake disc.
6. Remove the front wheel bearing and hub
assembly.
4. Remove and discard the wheel hub grease cap.
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Wheel Spindle
Special Tool(s)
Tie-Rod End Remover
211-001 (TOOL-3290-D) or
Equivalent
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4.0L and 4.6L shown, 5.4L similar
6 W520214 Lower ball joint nut 1 Brake dust shield bolt (3
required)
7 2C204 Wheel speed sensor
2 2K004 Brake disc shield
8 W711091 Strut-to-wheel spindle flag
nut (2 required) 3 W705606 Tie-rod end nut
9 Wheel speed sensor bolt 4 W711123 Lower ball joint bolt
10 W709870 Strut-to-wheel spindle bolt (2 5 3107/3108 Wheel spindle (LH/RH)
required)
(Continued)
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7. Remove the lower ball joint nut and bolt.
8. CAUTION: Do not damage the lower
ball joint boot while separating the lower
control arm and the wheel spindle.
Separate the lower control arm and the wheel
spindle.
9. If equipped, index-mark the 2 strut-to-spindle
cam bolts.
1. Remove the wheel bearing and hub assembly.
For additional information, refer to Wheel
Bearing and Wheel Hub in this section.
2. Remove the 3 brake disc shield bolts, then
remove the dust shield.
4. Remove and discard the tie-rod end nut.
10. WARNING: All vehicles are equipped
with gas-pressurized struts which will extend
struts during removal or component
5. CAUTION: Use care not to damage
servicing. Failure to follow these instructions
the tie-rod end dust boot.
Using the special tool, disconnect the tie-rod
NOTE: If equipped, do not discard the
end from the front wheel spindle.
strut-to-spindle cam nuts and bolts.
Remove and discard the strut-to-spindle bolts
and flag nuts.
11. Remove the wheel spindle.
13. Check and, if necessary, adjust the front end
alignment. For additional information, refer to
Section 204-00.
6. Support the front suspension lower arm with a
jack stand.
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Wheel Studs
Installation
1. Using a press, install a new wheel stud.
1 2B663/2C300 Wheel hub assembly
(ABS/non-ABS)
2 Wheel stud
Removal
1. Remove the wheel bearing and hub assembly.
For additional information, refer to Wheel
Bearing and Wheel Hub in this section.
2. Using a press, remove the wheel stud from the
wheel bearing and hub assembly.
2. Install the wheel bearing and hub assembly. For
additional information, refer to Wheel Bearing
and Wheel Hub in this section.
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204-02-1 204-02-1 Rear Suspension
Lateral Stiffener Bar
1 W711331 Lateral stiffener bar-to-body
bolt (2 required)
2 3424 Lateral stiffener bar
3 W710693 Lateral stiffener bar flag bolt
4 W520214 Lateral stiffener bar nut
vital parts and systems and their failure can
result in major service expense. A new part with
the same part number must be installed if
Section 100-02.
installation becomes necessary. Torque values
must be used as specified during reassembly to
make sure of correct retention of these parts.
3. CAUTION: Do not support the rear
axle at the differential housing.
1. Mark the rear shock absorber relative to the
Using 2 suitable jackstands, support the rear
protective sleeve with the vehicle in a static,
axle.
level ground position (curb height).
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4. Raise the rear axle so the mark made on the
rear shock absorber in Step 1 lines up with the
protective sleeve.
6. Remove and discard the lateral stiffener
bar-to-body bolts.
5. Remove and discard the RH panhard rod bolt,
7. Remove the lateral stiffener bar.
then remove and discard the lateral stiffener
bar-to-body mount nut and flag bolt.
8. CAUTION: Tighten the RH panhard
To install:
rod bolt while the suspension is at curb
height.
X Tighten the RH panhard rod bolt to 175
Nm (129 lb-ft).
X Tighten the lateral stiffener bar-to-body
mount nut to 115 Nm (85 lb-ft).
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Lower Arm
4 W704886 Lower control arm front bolt 1 5538 Lower control arm (2
(2 required) required)
5 W704888 Lower control arm rear bolt 2 W710089 Lower control arm front nut
(2 required) (2 required)
3 W704991 Lower control arm rear nut (2
required)
(Continued)
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1. To aid in installation, mark the rear shock
absorber relative to the protective sleeve with
5. Disconnect the parking brake cable from the
the vehicle in a static, level ground position
rear caliper.
(curb height).
1 Remove the clip.
2 Disconnect the parking brake cable.
Section 100-02.
6. Remove the parking brake cable bracket bolt.
To install, tighten the bolt to 27 Nm (20
lb-ft).
Using 2 suitable jack stands, support the rear
axle.
protective sleeve.
7. Remove and discard the lower arm front bolt.
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8. Remove and discard the lower arm front nut. 9. Remove and discard the lower arm rear bolt
and flag nut and then remove the lower arm.
1 Rotate the nut clockwise.
2 Remove and discard the nut.
10. CAUTION: Tighten the lower arm
bolts while the suspension is at curb height.
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Panhard Rod
4 W710689 Panhard rod flag nut (LH) 1 W704886 Panhard rod bolt (RH)
5 4264 Panhard rod 2 W710022 Panhard rod flag nut (RH)
3 W704886 Panhard rod bolt (LH)
(Continued)
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5. Using 2 screwdrivers inserted through the
access hole, depress the tabs of the panhard rod
(curb height).
bolt cover retaining clip and remove the cover.
6. Remove and discard the LH panhard rod bolt
and flag nut.
Section 100-02.
7. Remove and discard the RH panhard rod bolt
and flag nut and remove the panhard rod.
axle.
8. CAUTION: Tighten the LH and RH
panhard rod bolts with the suspension at
protective sleeve.
curb height.
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The rear suspension consists of the following
Rear Suspension
components:
Rear spring
Rear shock absorber
Rear upper suspension arm and bushings
Rear lower suspension arm and bushings
common LH and RH
Panhard rod and bushings
common LH and RH
Stabilizer bar assembly with drop links
tagged on LH side (GT and Pony packages
only)
make sure of correct retention of these parts. Lateral stiffener bar
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Rear Suspension
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Shock Absorber
3 Shock flag nut (part of 1 Upper nut, washer and
service kit 18008) insulator (part of service kit
18008)
4 Shock (part of service kit
18008) 2 Shock lower bolt (part of
service kit 18008)
(Continued)
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Removal
CAUTION: Do not allow the axle
assembly to hang supported only by the
upper control arm or lower control arms.
This could damage the control arm bushings.
axle.
5. Remove and discard the shock absorber upper
nut, washer and insulator assembly.
installation becomes necessary. Torque values 6. Raise the rear axle so the mark made on the
must be used as specified during reassembly to rear shock absorber in Step 2 lines up with the
make sure of correct retention of these parts. protective sleeve.
CAUTION: When using a hoist that lifts
the vehicle by the frame, install new shock
absorbers one at a time. If the rear axle is
allowed to hang unsupported by the control
arms, damage to the control arm bushings may
result. A drive-on type hoist is the preferred
hoist to use for this procedure.
All vehicles
1. Open the luggage compartment and position the
carpet out of the way.
Vehicles with a rear stabilizer bar
2. Mark the rear shock absorber that is not being
removed relative to the protective sleeve with
the vehicle in a static, level ground position 7. Remove and discard both stabilizer bar link
(curb height). bolts and clip nuts.
8. Position the stabilizer bar to gain access to the
shock absorber lower bolt.
All vehicles
9. Remove and discard the shock absorber lower
bolt and nut and remove the shock absorber.
Section 100-02.
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10. CAUTION: Tighten the shock absorber
lower bolt while the suspension is at curb
height.
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SPECIFICATIONS
Panhard rod-to-axle bolt 175 129
Item Specification
Lateral stiffener bar-to-body 115 85
Lubricant mount nut
Silicone Spray Lubricant ESR-M13P4-A Lateral stiffener bar-to-body 62 46
XL-6 bolts
Stabilizer bar bracket nuts 70 52
Torque Specifications Stabilizer bar link bolts 115 85
Parking brake cable 27 20
bracket-to-lower arm
Rear shock absorber upper 40 30
Upper control arm front bolt 175 129
nut
Upper control arm rear bolts 115 85
Rear shock absorber lower 115 85
bolt
Upper control arm bushing 175 129
nut
Lower arm-to-body bolt 175 129
Fuel tank strap bolt 51 38
Brake caliper anchor plate 103 76
bolts
Brake hose bracket bolt 20 15
Lower arm-to-axle bolt 175 129
Panhard rod-to-body mount 175 129
bolt
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Spring Coil
NOTE: Rear stabilizer bar equipped shown, non-equipped similar.
5 W708737 Stabilizer bar link bolt 1 5599 Upper spring insulators
6 Shock absorber lower bolt 2 5560 Spring
(part of service kit 18008)
3 5536 Lower spring insulator
7 W712385 Clip nut
4 Shock absorber lower nut
(part of service kit 18008)
(Continued)
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Removal
5. Remove and discard both stabilizer bar link CAUTION: Suspension fasteners are
bolts and clip nuts. critical parts because they affect performance of
6. Position the stabilizer bar to gain access to the
shock absorber lower bolt.
All vehicles make sure of correct retention of these parts.
All vehicles
7. Remove and discard the shock absorber lower
bolt and nut.
8. Remove the brake hose bracket bolt.
(curb height).
9. Lower the rear axle and remove the spring.
10. Inspect the upper and lower spring insulators
for wear or damage. Install new insulators if
necessary.
Installation
All vehicles
1. NOTE: The springs are vehicle specific and are
marked with a tag indicating the spring code.
Make sure the new spring has the same spring
code as the one being replaced. If the tag is not
on the spring being replaced, look on the
Section 100-02.
vehicle information label located on the
Convertible vehicles
drivers door for the spring code and compare
that to the new spring code.
3. Remove the rear support braces. Position the spring onto the axle with the tag
toward the axle assembly.
For additional information, refer to Section
502-00.
All vehicles
axle.
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2. Raise the rear axle so the mark made on the 4. Install the brake hose bracket bolt.
rear shock absorber in Removal Step 1 lines up
with the protective sleeve.
5. Install the rear support braces. For additional
6. Position the stabilizer bar and links and install
new stabilizer bar link bolts and clip nuts.
3. CAUTION: Tighten the shock absorber
lower bolt while the suspension is at curb
height.
Install a new shock absorber lower bolt and nut.
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Stabilizer Bar Link
Material
Item Specification
XL-6
1 5C488 Stabilizer bar link (2
required) (also part of 5A771)
2 5A771 Stabilizer bar
1. Remove the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
2. NOTE: To aid removal, apply a light coat of
silicone lubricant to the necessary parts of the
rear stabilizer bar and the inside diameter of the
stabilizer bar bushing and link.
Remove the stabilizer bar bushing and link.
1 Slide the bushing off of the stabilizer bar.
2 Slide the link off of the stabilizer bar.
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3. NOTE: The stabilizer bar links and bushings
are vehicle specific (convertible and coupe).
Make sure the correct link and bushing go on
the correct vehicle.
The link for the convertible GT and V6 Pony
package will have a B suffix in the part
number and it will be colored white. The
bushing for the convertible will have a B
suffix in the part number.
The link for the GT coupe and Shelby GT 500
convertible will have an A suffix in the part
number and it will be colored black. The
bushing will have an A suffix in the part
number.
NOTE: To aid installation, apply a light coat of
silicone lubricant to the necessary parts of the
rear stabilizer bar and the inside diameter of the
stabilizer bar bushing and link.
NOTE: The stabilizer bar link for the Shelby
GT 500 convertible will have a C suffix in
the part number and it will be blue/gray in
color. The bushing will have a C suffix in
the part number.
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Stabilizer Bar
1 W708737 Stabilizer bar link bolts (2
required) CAUTION: Suspension fasteners are
2 W712385 Stabilizer bar link flag nuts (2
required) vital parts and systems and their failure can
3 W520213 Stabilizer bar bracket nut (4
required) the same part number must be installed if
4 5486 Stabilizer bar bracket (2
required) must be used as specified during reassembly to
5 5A771 Stabilizer bar
6 W711368 Stabilizer bar bracket clip
stud (4 required)
7 5C488 Stabilizer bar link (2
Section 100-02.
8 4A037 Stabilizer bar bushing (2
2. Remove and discard the stabilizer bar link bolts
and clip nuts.
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3. Remove the stabilizer bar bracket nuts, studs,
5. CAUTION: The stabilizer bar is
brackets and stabilizer bar.
equipped with a tag. This tag indicates the
LH side of the stabilizer bar. When installing
Discard the stabilizer bar bracket nuts and
a new stabilizer bar, make sure the tag is on
studs.
the LH side of the vehicle.
NOTE: The stabilizer bar is vehicle specific
4. If necessary, remove the stabilizer bar bushings (convertible and coupe). Make sure the correct
and links. For additional information, refer to stabilizer bar goes on the correct vehicle.
Stabilizer Bar Link in this section.
Make sure that a new stabilizer bar has the
same tag color as the one being replaced. If the
stabilizer bar being replaced does not have a
tag, it will be necessary to inspect the stabilizer
bar link coating color to determine the proper
replacement stabilizer bar.
Black-coated stabilizer bar link will require a
yellow tag stabilizer bar with the suffix A
in the part number.
White-coated stabilizer bar link will require a
green tag stabilizer bar with the suffix B
in the part number.
Blue/gray-coated stabilizer bar link will
require an orange tag stabilizer bar with the
suffix C in the part number.
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Removal
Upper Arm Bushing
CAUTION: Suspension fasteners are Special Tool(s)
Adapter
204-034 (T78P-5638-A4)
Receiver Cup
1. Mark the rear shock absorber relative to the
205-813
protective sleeve with the vehicle in a static,
level ground position (curb height).
Remover/Installer, Bushing
204-590
Forcing Screw
205-813
Section 100-02.
axle.
4. Remove and discard the upper control arm
bushing nut and flag bolt.
1 5A638 Upper control arm bushing
2 4001 Rear drive axle
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5. Partially lower the rear axle and, using the 3. Install the bushing so there is a 12 mm (0.47
special tools, remove the upper control arm in) gap between the bushing flange and the rear
bushing. axle bracket.
Installation
rear shock absorber in Removal Step 1 lines up
1. Position the new bushing into the rear axle with the protective sleeve.
bracket with the voids in the rubber positioned
at the top and bottom of the bushing.
5. CAUTION: Tighten the upper control
arm rear nut with the suspension at curb
2. Using the special tools, install the upper control
height.
arm bushing.
Install a new upper control arm rear nut and
flag bolt.
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Upper Arm
4 5K671 Upper control arm assembly 1 W708795 Upper control arm front bolt
5 W709884 Upper control arm rear bolt 2 W520215 Upper control arm bushing
(2 required) nut
6 W710947 Fuel tank strap bolt (2 3 W710051 Upper control arm bushing
required) bolt
(Continued)
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CAUTION: The upper arm is a 2-piece
design and is replaced as an assembly. Do not
remove or loosen the nut and bolt that joins the
2 pieces together. The assembly is set at ride
Section 100-02.
height during production, loosening the nut and
bolt will disturb this setting.
5. Place a safety support under the fuel tank.
1. Remove the rear seat cushion. For additional
2. Remove and discard the upper control arm front
bolt.
6. Remove the rear bolts from the 2 fuel tank
support straps and position both straps aside.
To install, tighten to 51 Nm (38 lb-ft)
(curb height).
7. Partially lower the fuel tank to gain access to
the upper control arm.
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8. Remove and discard the 2 upper control arm
rear bolts.
9. Remove and discard the upper control arm
bushing flag bolt and nut.
To install, tighten the nut to 175 Nm (129
lb-ft).
10. Remove the upper control arm assembly.
11. Raise the rear axle so the mark made in Step 3
lines up with the protective sleeve.
12. CAUTION: Tighten the upper control
arm fasteners while the suspension is at curb
height.
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Wheel Studs
Special Tool(s)
C-Frame and Clamp Assembly
211-023 (T74P-3044-A1)
3 Wheel stud 1 2553 LH/ 2552 Brake caliper and anchor
RH plate assembly
4 W704797 Anchor plate bolt (2 required)
2 2C026 Brake disc
(Continued)
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Removal Installation
CAUTION: Suspension fasteners are CAUTION: Do not use air tools to install
critical parts because they affect performance of the wheel stud. The serrations in the hub flange
vital parts and systems and their failure can can be stripped.
1. Position the wheel stud in the axle flange,
making sure that the serrations are aligned with
those made by the original wheel stud.
2. Position washers and a reversed wheel nut on
the wheel stud and tighten the wheel nut until
the stud seats on the back of the axle flange.
Section 100-02.
2. CAUTION: Care must be used when
servicing rear brake components without
disconnecting the parking brake cable from
the brake caliper lever. Carefully position the
caliper aside using a suitable support or
damage to the parking brake cable end
fittings can occur.
CAUTION: Do not allow the caliper
and anchor plate assembly to hang from the
brake hose or damage to the hose can occur.
Remove the bolts and position the caliper and
3. Remove the wheel nut and washers.
anchor plate assembly aside.
Discard the nut.
Support the caliper and anchor plate
assembly using mechanics wire.
4. Install the rear brake disc.
3. Remove the rear brake disc.
5. Position the brake caliper and anchor plate
assembly and install the bolts.
4. Using the special tool, remove and discard the
wheel stud.
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204-04-1 204-04-1 Wheels and Tires
SPECIFICATIONS
Wheel nuts 133 98
Item Specification
Sensor strap (worm 3 27
Cleaners gear)
Wheel and Tire Cleaner
ZC-27-A or B
Tire Balance Weight
Max tire balance weight 140g (5 oz) per wheel,
70g (2.5 oz) per flange
Tire inflation
Tires See safety certification
sticker located inside
glove compartment door
CAUTION: Use only Digital Tire Pressure
Gauge 204-354 any time tire pressures are measured
to be sure that accurate values are obtained.
For accuracy, Ford recommends the use of a digital
or dial-type tire pressure gauge rather than a
stick-type pressure gauge.
Inflate the tire to the pressure specified on the safety
certification sticker located on the driver door or door
pillar.
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GENERAL PROCEDURES
NOTE: The tire pressure monitoring system is not
Tire Pressure Monitoring System
affected by wheel and tire rotation.
(TPMS) Sensor Training
1. Turn the ignition switch to the OFF position,
Special Tool(s)
then press and release the brake pedal.
Vehicle Communication Module
(VCM) and Integrated 2. Cycle the ignition switch from the OFF position
Diagnostic System (IDS)
to the RUN position 3 times, ending in the
software with appropriate
RUN position. Do not wait more than one
hardware, or equivalent scan
minute between each key cycle.
tool
3. Press and release the brake pedal.
Activation Tool, Tire Pressure
4. Turn the ignition switch to the OFF position.
Monitor
204-363
5. Turn the ignition switch from the OFF position
to the RUN position 3 times, ending in the
RUN position. Do not wait more than one
minute between each key cycle.
The horn will sound once and the TPMS
NOTE: A new tire pressure sensor is shipped in an
indicator will flash if the training mode has
OFF mode (or battery saver mode) and must be
been entered successfully. If equipped, the
turned ON before it can be trained. To turn the
message center will display TRAIN LF
sensor ON, deflate the tire slightly if necessary, then
TIRE.
inflate the tire to the recommended inflation
pressure and wait at least 2 minutes, then continue
6. NOTE: It may take up to 6 seconds to activate
with the sensor training procedure.
a tire pressure sensor. During this time, the
activation tool must remain in place 180
NOTE: The tire pressure sensor training procedure
degrees from the valve stem.
must be done on a single vehicle, in an area without
Place the activation tool on the LF tire sidewall
radio frequency (RF) noise and at least 1 meter (3
opposite (180 degrees) from the valve stem.
feet) away from other vehicles equipped with
The horn will sound briefly to indicate that the
TPMS.
tire pressure sensor has been recognized by the
RF noise is generated by electrical motors and
smart junction box (SJB).
appliance operation, cellular telephones, remote
transmitters, power inverters and portable
entertainment equipment.
NOTE: If a sensor does not respond to the
activation tool, attempt to activate the same sensor
with the activation tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at
least 1/4 of a turn and attempt to activate the same
sensor again.
NOTE: If the SJB does not recognize any 1 of the
4 tire pressure sensors during the sensor training
procedure, the horn will sound twice and the
message center (if equipped) will display TIRE
NOT TRAINED REPEAT and the procedure must
be repeated.
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7. Within 2 minutes of the horn sounding, place 8. NOTE: Do not wait more than 2 minutes
the activation tool on the RF tire sidewall between training each sensor.
opposite (180 degrees) from the valve stem to
Repeat Step 7 for the RR and LR tires.
train the RF tire pressure sensor.
The procedure is completed after the last tire
has been trained. When the training procedure
is complete, the message center (if equipped)
will display TIRE TRAINING COMPLETE.
For vehicles not equipped with a message
center, successful completion of the training
procedure will be verified by turning the
ignition switch to the OFF position without the
horn sounding. If the horn sounds twice when
the switch is turned to the OFF position, the
training procedure was not successful.
9. Using the scan tool, locate the updated TPMS
sensor IDs trained to the SJB and document
them on the applicable warranty claim.
10. NOTE: This step is required to clear DTC
C2780, cause the SJB to exit the manufacturing
mode and to make sure there are no other
concerns with a newly programmed SJB.
If the sensors are being trained due to the
installation of a new SJB, clear any DTCs and
perform the SJB on-demand self-test.
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OF SUBASSEMBLIES
(TPMS) Sensor
NOTE: Tire pressure sensors are equipped with
Lithium-ion batteries and must be disposed of
1 1A150/1A189 Tire pressure sensor/sensor kit
accordingly.
2 1A175 Sensor cradle
3 14C202 Locking clip (also part of
1. CAUTION: The sensor, cradle and
1A189)
strap can be damaged by incorrect tire
mounting or dismounting. Dismount the tire
Disassembly
only as instructed.
Remove the tire from the wheel. For additional
CAUTION: Tire pressure sensors are
information, refer to Wheel and Tire in this
manufactured in multiple colors based on their
section.
application. When installing a new sensor, make
sure the color of the sensor being installed
matches the color of the sensor that was
removed. The different colored sensors are not
interchangeable.
NOTE: The sensor can be removed and installed
without removing the strap or the cradle.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Assembly
2. CAUTION: Do not use a large
screwdriver. Apply minimum force during
removal or damage to the sensor locking clip
1. CAUTION: Damage to the sensor can
can occur.
occur if excessive force is applied during
sensor installation.
Using a pocket screwdriver, or similar tool,
remove the sensor locking clip.
NOTE: Make sure the sensor is fully seated
into the cradle. The sensor will make a click
noise when correctly seated.
Position the sensor into the cradle by inserting
the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of
the sensor down onto the cradle.
3. CAUTION: Do not use a large
screwdriver. Apply minimum force during
removal or damage to the sensor can occur.
Using a pocket screwdriver or similar tool,
detach the sensor from the cradle.
2. NOTE: The locking clip can only be fully
seated when installed in the correct orientation.
If the sensor locking clip cannot be fully
inserted, then the sensor may not be fully
seated on the cradle or the locking clip may be
inserted backward.
Insert a new locking clip into the sensor.
4. Remove the sensor.
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4. NOTE: A new tire pressure sensor is shipped
in an off mode (or battery saver mode) and
must be turned on before it can be trained. To
mounting or dismounting. Mount the tire
turn the sensor on, inflate the tire to the
only as instructed.
recommended inflation pressure and wait at
Install the tire onto the wheel. For additional
least 2 minutes, then continue with the sensor
training procedure.
section.
Train the tire pressure sensor(s). For additional
information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training Procedure
component test in this section.
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OF SUBASSEMBLIES
(TPMS) Strap and Cradle
Material
Item Specification
Wheel and Tire Cleaner
ZC-37-A or -B
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1 1A177/1A193 Strap/strap kit
2 1A150/1A189 Tire pressure sensor/sensor kit
3 1A175 Sensor cradle (also part of
1A193)
4 14C202 Locking clip (also part of
1A189)
Disassembly
CAUTION: Tire pressure sensors are
manufactured in multiple colors based on their
application. When installing a new sensor, make
3. To remove a dealer installed strap, turn the
sure the color of the sensor being installed
worm gear screw until the strap is fully released
matches the color of the sensor that was
from the worm gear.
removed. The different colored sensors are not
Discard the strap.
interchangeable.
4. NOTE: To aid assembly, mark the location of
NOTE: The sensor is available separately, the
the cradle prior to disassembly.
cradle and strap are available as a strap kit. There
Using a screwdriver, or similar tool, remove the
are several different strap kits available based on
cradle by inserting the screwdriver under the
wheel diameter but all strap kits share the same
cradle and prying up.
base part number.
Assembly
NOTE: Tire pressure sensors are equipped with
Lithium-ion batteries and must be disposed of
accordingly. 1. NOTE: Make sure the sensor is fully seated
into the new cradle. The sensor will make a
1. Remove the tire pressure monitoring system
click noise when fully seated.
(TPMS) sensor. For additional information,
Position the sensor into the new cradle by
refer to Tire Pressure Monitoring System
inserting the hinge end of the sensor into the
(TPMS) Sensor in this section.
hook end of the cradle and pushing the opposite
end of the sensor down onto the cradle.
2. WARNING: The TPMS band is under
tension. Always use safety goggles or a face
shield and gloves when removing the TPMS
band/strap. Failure to follow these
instructions may result in personal injury.
Remove a factory installed strap in the
following sequence:
1 Locate the strap buckle and secure the strap
to the wheel using duct tape or a similar
item, on both sides of the buckle
approximately 25 mm (0.98 in) from the
buckle.
2 Using a large screwdriver and a twisting
motion, unbuckle the strap.
3 Discard the strap.
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2. CAUTION: Metal scrapers can damage
the wheel. Use only plastic or non-metallic
scrapers to remove the cradle adhesive strip
residue.
NOTE: The sensor and cradle must be installed
in the drop well of the wheel, 180 degrees from
the valve stem.
Clean the area where the sensor and cradle are
to be installed.
5. CAUTION: Steel wheels have a high
spot along their circumference. Make sure
the strap is positioned in the lowest spot
possible for correct sensor and cradle
retention.
NOTE: Keep the strap parallel with the wheel
flange while tightening the worm gear.
Position the worm gear 13-26 mm (0.5-1.0 in)
away from the sensor and tighten the worm
gear.
3. NOTE: The sensor and cradle must be
Tighten to 3 Nm (27 lb-in).
positioned with the hinge side of the sensor on
the RH side when viewed from the curb side
(beauty side) of the wheel.
NOTE: The sensor has raised markings
indicating how to position the sensor.
Remove the adhesive tape liner from the cradle
and position the sensor and cradle into the
wheel drop well 180 degrees from the valve
stem.
mounting or dismounting. Mount the tire
only as instructed.
Install the tire onto the wheel. For additional
section.
4. Install the tapered end of the strap through the
opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
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7. NOTE: A new tire pressure sensor is shipped
in an off mode (or battery saver mode) and
must be turned on before it can be trained. To
turn the sensor on, inflate the tire to the
recommended inflation pressure and wait at
least 2 minutes, then continue with the sensor
training procedure.
Train the tire pressure sensor(s). For additional
information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training Procedure
component test in this section.
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Ambient Temperature Change and Tire
Pressure
Special Tool(s)
CAUTION: Do not inflate tire higher than
Vehicle Communication Module maximum pressure stamped on tire sidewall.
(VCM) and Integrated
Tire pressures fluctuate with temperature changes.
For this reason, tire pressure must be set to
hardware, or equivalent scan specification when tires are at outdoor ambient
tool
temperatures. If the vehicle is allowed to warm up
to shop temperatures, and the outside temperature
is less than shop temperature, the tire inflation
Activation Tool, Tire Pressure
pressure must be adjusted accordingly.
Monitor
If the tires are inflated to specification at shop 204-363
temperatures and the vehicle is moved outdoors
when the outdoor ambient temperature is
significantly lower, the tire pressure may drop
enough to be detected by the TPMS and activate the
TPMS warning lamp.
Digital Tire Gauge
204-354
Principles of Operation
The tire pressure monitoring system (TPMS)
monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via
radio frequency (RF) signals, to the smart junction
box (SJB). TPMS functionality is integral to the
SJB. These transmissions are sent approximately
every 60 seconds when the vehicle speed exceeds
32 km/h (20 mph). The TPMS function compares
each tire pressure sensor transmission against a
low-pressure limit. If it has been determined that the
tire pressure has fallen below this limit, the SJB
communicates this on the vehicle communication
bus to the instrument cluster. The instrument cluster
then illuminates the TPMS indicator and displays
the appropriate message(s) in the message center (if
equipped).
The system is not affected by wheel and tire
rotation.
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As the ambient temperature decreases by 6C
(10F), tire pressure decreases 7 kPa (1 psi). Adjust
the tire pressure by 7 kPa (1 psi) for each 6C
(10F) ambient temperature drop as necessary to
keep the tire at the specified vehicle certification
label pressure. Refer to the following tables to
adjust the tire pressure indoors for colder outside
temperatures.
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TPMS Indicator and Message Center
1. Tire Pressure Sensor Fault If equipped, the
Messages
message center will display TIRE SENSOR
FAULT when a tire pressure sensor is
The TPMS indicator and vehicle message center (if
malfunctioning. GO to Symptom Chart.
equipped) sometimes displays faults that cannot be
resolved by the customer. Treat these messages as
2. No communication with the SJB (TPMS is
TPMS faults that must be serviced.
integral to the SJB) The TPMS indicator is
illuminated when the instrument cluster has
TPMS Indicator Illuminates Continuously
received no signals from the SJB for more than
NOTE: If the spare tire is in use, the damaged road
5 seconds. If equipped, the message center
tire must be repaired and installed on the vehicle to
displays TIRE MONITOR FAULT. GO to
restore complete TPMS functionality before carrying
Symptom Chart.
out any diagnosis.
3. Tire Pressure Monitor Fault If equipped, the
message center will display TIRE MONITOR
1. The TPMS indicator remains on continuously
FAULT when the tire pressure monitoring
for the following condition:
system is malfunctioning or communication
Low Tire Pressure The TPMS indicator
with the instrument cluster has been lost. GO
is illuminated solid and the message center
to Symptom Chart.
displays LOW TIRE PRESSURE (if
equipped). This is displayed when any of
the tire pressures are low. When this
1. NOTE: The tire pressure sensors are not
condition exists, the tire pressure must be
designed to be used with aftermarket wheels.
adjusted to the recommended cold pressure
NOTE: The use of run-flat tires (tires with
as indicated on the vehicle certification
steel body cord plies in the tire sidewall) where
label.
not originally equipped, may cause the TPMS
2. NOTE: The TPMS sensors do not transmit
system to malfunction and is therefore not
when the vehicle is stationary. If the vehicle
recommended.
has been stationary for more than 30 minutes, it
Verify the customer concern by inspecting the
will be necessary to wake up the sensors so
vehicle and observing the message center (if
they will transmit the latest tire pressure
equipped) and the TPMS indicator.
information to the SJB.
2. NOTE: The valve-mounted TPMS sensors and
If the vehicle has been stationary for more than
the strap-mounted TPMS sensors are not
30 minutes, carry out the following procedure
compatible. Swapping wheels from one vehicle
to wake up the TPMS sensors.
to another with the different systems will
1 Turn the ignition switch to the ON position.
adversely affect TPMS operation.
2 Adjust the air pressure in the LF tire.
NOTE: Non-original equipment manufacturer
3 Activate the LF TPMS sensor, at least 2
(OEM) modifications made to the vehicle may
times, using the tire pressure monitor
result in false TPMS warnings.
activation tool.
Inspect to determine if one of the following
4 Repeat Steps 2 and 3 for the remaining
mechanical or electrical concerns apply:
tires.
5 If the TPMS indicator remains illuminated
after adjusting and activating each sensor,
GO to Symptom Chart.
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then
remains ON solid when the ignition key is turned to
the ON position for the following conditions:
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check the scan tool connection to the VCM.
Mechanical Electrical refer to Section 418-00, No Power To The
Scan Tool, to diagnose no communication
Low tire pressure Circuitry
TPMS sensor damaged Electrical connectors with the scan tool.
or missing SJB missing or
6. If the scan tool does not communicate with the
Spare tire installed as a damaged
vehicle:
road wheel
Incorrect TPMS sensor
verify the ignition key is in the ON position.
installed
verify the scan tool operation with a known
TPMS sensor installed
incorrectly good vehicle.
Non-OEM wheels
refer to Section 418-00 to diagnose no
installed (aftermarket
response from the powertrain control module
rims)
(PCM). Non-OEM equipped
run-flat tires installed
7. Carry out the network test.
Other non-OEM
modifications (roll If the scan tool responds with no
cages, service barriers,
communication for one or more modules,
part racks, ladder racks)
refer to Section 418-00.
If the network test passes, retrieve and
record continuous memory diagnostic
concern is found, correct the cause (if possible)
trouble codes (DTCs).
before proceeding to the next step.
8. Clear the continuous DTCs and carry out the
4. NOTE: Make sure to use the latest scan tool
self-test diagnostics for the TPMS module.
software release.
9. If the DTCs retrieved are related to the concern,
If the cause is not visually evident, connect the
go to the Tire Pressure Monitor System (TPMS)
scan tool to the data link connector (DLC).
Module Diagnostic Trouble Code (DTC) Chart.
For all other DTCs, refer to Section 419-10.
5. NOTE: The vehicle communication module
(VCM) LED prove out confirms power and
10. If no DTCs related to the concern are retrieved,
ground from the DLC are provided to the
VCM.
Tire Pressure Monitor System (TPMS)
If the scan tool does not communicate with the
Diagnostic Trouble Code (DTC) Chart
VCM:
check the VCM connection to the vehicle.
Tire Pressure Monitor System (TPMS) Diagnostic Trouble Code (DTC) Chart
DTC Description Source Action
B1342 ECU is Defective SJB INSTALL a smart junction box (SJB).
B2872 Tire Pressure Sensor Fault SJB GO to Pinpoint Test C.
Tire Pressure Monitor System (TPMS)
Module Replacement Diagnostic Trouble
Code (DTC) Chart
Tire Pressure Monitor System (TPMS) Module Replacement Diagnostic Trouble Code (DTC) Chart
B106A Pressure Sensor Range Bit Incorrect State SJB GO to Pinpoint Test D.
B106B Tire Pressure Sensor Low Battery (Could SJB GO to Pinpoint Test E.
be set configuring new SJB)
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Tire Pressure Monitor System (TPMS) Module Replacement Diagnostic Trouble Code (DTC)
Chart (Continued)
B2477 Module Configuration Failure/Mismatch SJB DTC B2477 is only present when a new
SJB is installed, the SJB is incorrectly
flashed or the SJB is incorrectly
configured. Successfully configuring the
SJB is the only way to clear this DTC.
Make sure the SJB is configured
correctly. If the DTC B2477 is still
present, REFER to Section 418-00.
B2868 Left Front Tire Pressure Sensor Fault SJB DTC B2868 is only present when a new
SJB is installed, the SJB is flashed or the
SJB is reconfigured. REFER to Section
419-10, follow all SJB removal and
installation steps.
B2869 Right Front Tire Pressure Sensor Fault SJB DTC B2869 is only present when a new
installation steps.
B2870 Right Rear Tire Pressure Sensor Fault SJB DTC B2870 is only present when a new
installation steps.
B2871 Left Rear Tire Pressure Sensor Fault SJB DTC B2871 is only present when a new
installation steps.
C2780 ECU in Manufacturing Mode SJB DTC C2780 is only present when a new
installation steps.
Symptom Chart
NOTE: TPMS is not affected by wheel and tire
rotation.
Failure of a TPMS component may not cause the
message center to display a fault message or a DTC
to be stored. The Symptom Chart is a starting point
to begin diagnosis of these concerns.
Symptom Chart
TPMS indicator ON Air pressure not set to GO to Pinpoint Test A.
continuously and message specifications listed on the
center (if equipped) displays vehicle certification label
LOW TIRE PRESSURE
Message center (if equipped) Spare tire currently in use INSTALL the repaired road
displays LOW TIRE wheel/tire in place of the
PRESSURE spare tire.
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SJB will not enter sensor Brake on/off (BOO) switch GO to Pinpoint Test B.
training mode Ignition switch
Vehicle communication bus
ABS/TC/IVD module
Smart junction box (SJB)
TPMS indicator FLASHES TPMS sensor(s) GO to Pinpoint Test C.
for 70 seconds and then TPMS sensor(s) not trained to
remains ON solid when the the SJB
ignition key is turned to the SJB
ON position and DTC B2872
is present
TPMS indicator FLASHES SJB REFER to Section 419-10.
for 70 seconds and then
remains ON solid when the
ignition key is turned to the
ON position, the message
center (if equipped) displays
TIRE MONITOR FAULT
and DTC B1342 is present
TPMS indicator FLASHES Vehicle communication bus REFER to Section 419-10.
for 70 seconds and then SJB
remains ON solid when the
ignition key is turned to the
ON position, the message
center (if equipped) displays
TIRE MONITOR FAULT
and there are no DTCs
present in the SJB
Vehicle communication issue REFER to Section 413-00.
between SJB and instrument
cluster
Possible Causes
Pinpoint Tests
Low air pressure in tire(s)
Pinpoint Test A: TPMS Indicator ON
Continuously and Message Center (if Tire pressure sensor(s)
Equipped) Displays LOW TIRE PRESSURE
Normal Operation
The tire pressure monitoring system (TPMS)
monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via
radio frequency (RF) signals, to the smart junction
box (SJB). TPMS functionality is integral to the
SJB. These transmissions are sent approximately
every 60 seconds when the vehicle speed exceeds
32 km/h (20 mph). The TPMS function (integral to
the SJB) compares each tire pressure sensor
transmission against a low-pressure limit. If it has
been determined that the tire pressure has fallen
below this limit, the SJB communicates this on the
vehicle communication bus to the instrument cluster.
The instrument cluster then illuminates the TPMS
indicator and displays the appropriate message(s) in
the message center (if equipped).
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PINPOINT TEST A: TPMS INDICATOR ON CONTINUOUSLY AND MESSAGE CENTER (IF EQUIPPED)
DISPLAYS LOW TIRE PRESSURE
CAUTION: Use only special tool 204-354 any time tire pressures are measured to
be sure that accurate values are obtained.
NOTE: If a warranty case is opened for an actual TPMS fault, document and include the
actual tire pressure data in all warranty communications.
A1 CHECK THE TIRE PRESSURE
Measure and record the air pressure in all 4 road tires.
Yes
Adjust the air pressure for those found to be below the
The system is functioning normally,
specification listed on the vehicle certification label.
diagnosis is complete. INFORM the
NOTE: If the vehicle has been stationary for more than 30
customer of correct tire pressure
minutes, activate each TPMS sensor at least 2 times with the
maintenance as instructed in the
tire pressure monitor activation tool. The TPMS sensor does not
scheduled maintenance guide and the
transmit when the vehicle is stationary.
owner guide.
Verify system operation.
Have the TPMS indicator and the message center (if No
equipped) warnings gone out? GO to A2.
A2 CHECK THE SYSTEM COMPONENTS
Train all 4 tire pressure sensors. Refer to Tire Pressure Yes
Monitoring System (TPMS) Sensor Training in this section. The system is functioning normally,
Using the scan tool, read and record the tire pressures: diagnosis complete.
LF PRES, RF PRES, RR PRES and LR PRES.
No
Compare the air pressure readings recorded from the function
Before installing a new sensor(s): If a
test to those recorded in A1.
sensor(s) does not respond to the special
Do the compared tire pressure values match within 5 psi,
tool, ATTEMPT to activate the same
and have the TPMS indicator and the message center (if
sensor(s) with the special tool. If the
equipped) warnings gone out?
sensor(s) still does not respond, MOVE
the vehicle to rotate the wheels at least
1/4 of a turn and ATTEMPT to activate the
same sensor(s) again. INSTALL new tire
pressure sensors for those with
discrepancies. REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this
section.
CLEAR the DTCs. REPEAT the self-test.
VERIFY system operation.
Possible Causes
Pinpoint Test B: SJB Will Not Enter Sensor
Training Mode
Circuit open
Normal Operation
Circuit shorted
For the smart junction box (SJB) to enter tire
Brake on/off (BOO) switch
pressure monitoring system (TPMS) sensor training
Ignition switch
mode, the SJB must receive valid input from the
brake pedal position switch and ignition switch, and
ABS/TC/IVD module
it must receive valid vehicle speed sensor input
from the ABS/TC/IVD module.
PINPOINT TEST B: SJB WILL NOT ENTER SENSOR TRAINING MODE
B1 CHECK THE BRAKE PEDAL POSITION (BPP)/BRAKE ON/OFF
(BOO) SWITCH
Using the scan tool, monitor the SJB BPP/BOO switch PID (SJB
Yes
reads the brake switch directly).
GO to B2.
Press and release the brake pedal while monitoring the PID.
Do the brake pedal PID values match the brake pedal No
positions? REFER to Section 206-09.
(Continued)
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PINPOINT TEST B: SJB WILL NOT ENTER SENSOR TRAINING MODE (Continued)
B2 CHECK THE IGNITION SWITCH
Using the scan tool, monitor the SJB ignition switch status PID.
Yes
Cycle the ignition switch to the ON and OFF position while
GO to B3.
monitoring the PID (SJB reads the ignition switch directly).
Do the ignition switch status PID values match the ignition No
switch positions? REFER to Section 413-01.
B3 CHECK THE VEHICLE SPEED INPUT TO THE SJB
Using the scan tool, monitor the SJB vehicle speed PID (SJB Yes
receives vehicle speed from the ABS/TC/IVD module). REFER to Section 419-10.
Does the vehicle speed PID value match the speed of the
No
vehicle?
Possible Causes
Pinpoint Test C: TPMS Indicator FLASHES
For 70 Seconds and Then Remains ON Solid
TPMS sensor(s) missing
When the Ignition Key is Turned to the ON
TPMS sensor(s) not trained to the vehicle
Position and DTC B2872 is Present
TPMS sensor(s) swapped due to wheel swap
Normal Operation
TPMS sensor(s) damaged If there is a fault in the tire pressure monitor system
(TPMS), such as a damaged or missing sensor(s),
Vehicle communication issue
damaged module or a communication issue within
SJB
the vehicle, diagnostic trouble codes (DTCs) are set
in the smart junction box (SJB), the TPMS warning
indicator will flash for 70 seconds and then remain
ON solid when the ignition switch is turned to the
ON position and the message center (if equipped)
will display TIRE PRESSURE SENSOR FAULT.
PINPOINT TEST C: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON SOLID
WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION AND DTC B2872 IS PRESENT
NOTE: If a warranty case is opened for an actual TPMS fault, document and include the
actual tire pressure data in all warranty communications.
C1 CHECK FOR DTCs
Connect the scan tool.
Using the scan tool, read the TPMS sensor IDs currently trained
Yes
to the SJB.
GO to C2.
Record the sensor IDs.
Using the scan tool, read the TPMS System Status: TP STAT. No
Is the TPMS system status (TP STAT) equal to $02 If the TPMS system status is equal to $01
SENSOR FAULT? SYSTEM FAULT, GO to C4.
C2 CHECK THE TIRE PRESSURE SENSOR RESPONSE TO THE
TRAINING TOOL
Activate a sensor by positioning the tire pressure monitor
activation tool against the tire sidewall 180 degrees from the tire
valve stem.
Press the test button on the special tool.
NOTE: The special tool will provide feedback in the form of a
Yes
flashing green light and a beep sound for each successful
GO to C3.
response from a tire pressure sensor.
Activate the 3 remaining sensors. No
Did all tire pressure sensors respond back to the training The sensor(s) that did not respond to the
tool? tool could be the cause. GO to C3.
(Continued)
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PINPOINT TEST C: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON SOLID
WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION AND DTC B2872 IS PRESENT (Continued)
C3 CARRY OUT THE SENSOR TRAINING PROCEDURE
Monitoring System (TPMS) Sensor Training in this section. Using the scan tool, locate the updated
Did all of the tire pressure sensors transmit correctly and TPMS sensor IDs trained to the SJB
did the horn sound when each tire pressure sensor module.
transmitted to the SJB?
COMPARE these values to those recorded
prior to the TPMS sensor training
procedure. Disregarding sensor position
(the system is not affected by tire
rotation), any sensor IDs that do not
match those retrieved from the module
were changed but not retrained. The
sensors are now trained to the vehicle,
diagnosis is complete.
DOCUMENT all TPMS sensor IDs on the
applicable warranty claim.
No
same sensor(s) again.
If the sensor(s) fail to train a second time,
INSTALL a new tire pressure sensor(s).
REFER to Tire Pressure Monitoring
System (TPMS) Sensor.
C4 TPMS SYSTEM STATUS EQUALS $01 SYSTEM FAULT
Monitoring System (TPMS) Sensor Training in this section. Using the scan tool, locate the updated
Did all of the tire pressure sensors transmit correctly and TPMS sensor IDs trained to the SJB
did the horn sound when each tire pressure sensor module.
COMPARE these values to those recorded
prior to the TPMS sensor training
procedure. Disregarding sensor position
(the system is not affected by tire
rotation), any sensor IDs that do not
match those retrieved from the module
were changed but not retrained. The
sensors are now trained to the vehicle,
diagnosis is complete.
DOCUMENT all TPMS sensor IDs on the
applicable warranty claim.
No
Before diagnosing the SJB: If a
REFER to Section 419-10 for SJB and
SJB antenna diagnosis.
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204-04-10 204-04-10 Wheels and Tires
Pinpoint Test D: DTC B106A Pressure
This DTC may be encountered if a high-pressure
Sensor Range Bit Incorrect State
sensor (designed for trucks with much higher tire
pressures and molded in green plastic) was installed.
Normal Operation
The SJB will only allow a low-pressure sensor
If there is a fault in the tire pressure monitoring
(molded in blue plastic) to be trained using the
system (TPMS), such as a damaged or missing
TPMS sensor training procedure. Make sure the
sensor(s), damaged module or a communication
correct sensors are used to avoid compatibility
issue within the vehicle, DTCs are set in the smart
issues.
junction box (SJB), the TPMS warning indicator
will flash for 70 seconds and then remain ON solid Possible Causes
when the ignition switch is turned to the ON
Tire pressure sensor(s)
position and the message center (if equipped) will
Incorrect tire pressure sensor(s) installed
display TIRE PRESSURE SENSOR FAULT.
SJB
PINPOINT TEST D: DTC B106A PRESSURE SENSOR RANGE BIT INCORRECT STATE
D1 DETERMINE IF THE VEHICLE IS EQUIPPED WITH AN
INCORRECT SENSOR
Monitoring System (TPMS) Sensor Training in this section. CLEAR the DTCs. REPEAT the self-test.
Did all of the tire pressure sensors transmit correctly and VERIFY system operation.
did the horn sound when each tire pressure sensor
No
Pinpoint Test E: DTC B106B Tire Pressure
The tire pressure sensor is battery powered.
Sensor Low Battery
This DTC may be set when attempting to train a
tire pressure sensor(s) with a low battery.
Normal Operation
If there is a fault in the tire pressure monitoring
Possible Causes
system (TPMS), such as a damaged or missing
Tire pressure sensor battery
sensor(s), damaged module or a communication
issue within the vehicle, DTCs are set in the smart Tire pressure sensor(s)
junction box (SJB), the TPMS warning indicator
SJB
will flash for 70 seconds and then remain ON solid
when the ignition switch is turned to the ON
position and the message center (if equipped) will
display TIRE PRESSURE SENSOR FAULT.
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204-04-11 204-04-11 Wheels and Tires
PINPOINT TEST E: DTC B106B TIRE PRESSURE SENSOR LOW BATTERY
E1 DETERMINE WHICH SENSOR HAS A LOW BATTERY
Monitoring System (TPMS) Sensor Training in this section. CLEAR the DTCs. REPEAT the self-test.
Did all of the tire pressure sensors transmit correctly and VERIFY system operation.
did the horn sound when each tire pressure sensor
No
CLEAR the DTCs.
REPEAT the self-test.
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Wheel and Tire
Special Tool(s)
Digital Tire Gauge
204-354
1 1508 Tire
2 1007 Wheel
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Disassembly
2. CAUTION: Tire and valve stem
position is critical to prevent damage to the
CAUTION: Use only special tool 204-354 TPMS sensor when using a paddle-type bead
any time tire pressures are measured to be sure separator.
that accurate values are obtained.
NOTE: Some machines may have a nylon
roller bead separator at the 12 oclock position
CAUTION: Failure to follow the
instead of the paddle-type bead separator at the
instructions below may result in damage to the
3 oclock position.
tire pressure monitoring system (TPMS) sensor.
Position the wheel and tire assembly on a
suitable tire machine and separate both beads of
NOTE: A wheel and tire assembly equipped with a
the tire from the wheel.
TPMS sensor will have the following verbiage
stamped or cast on the wheel: SENSOR MAY BE
For a paddle-type tire machine, position the
INSIDE.
valve stem at the 12 oclock or 6 oclock
position and the paddle at the 3 oclock
NOTE: The TPMS sensor is mounted to the wheel
position.
180 degrees opposite of the valve stem and is held
For a roller-type tire machine, align the
in place by a stainless steel strap. The sensor is not
valve stem with the roller at any position.
mounted to the valve stem.
1. Remove the wheel and tire assembly. For
additional information, refer to Wheel and Tire
in this section.
CAUTION: Do not allow the tire beads to
move beyond the wheel mid-plane (middle of the
wheel) when separating the beads from the
wheels, damage to the TPMS sensor may occur.
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3. NOTE: Index-mark the valve stem and wheel 5. Inspect the TPMS sensor, cradle and strap for
weight positions on the tire. damage, install new parts as necessary.
Place the wheel and tire assembly on the For information on removal and installation
turntable of the tire machine with the valve of the TPMS sensor, refer to Tire Pressure
stem between the 5 and 6 oclock positions and Monitoring System (TPMS) Sensor in this
the machine arm at the 12 oclock position and section.
dismount the outer bead from the wheel.
When installing a new wheel, reuse the
TPMS sensor from the previous wheel if
possible. The TPMS will not have to be
trained if the sensor is reused. The new
wheel will not come with a sensor strap. A
sensor strap kit will need to be ordered
with the new wheel.
Assembly
CAUTION: Damage to the TPMS sensor
may result if the tire mounting is not carried out
as instructed.
1. CAUTION: Use only a soap and water
4. Reset the wheel and tire assembly on the
solution to lubricate the tire. Use of anything
turntable of the tire machine with the valve
other than soap and water may result in
stem between the 5 and 6 oclock positions and
damage to the TPMS sensor.
the machine arm at the 12 oclock position and
dismount the inner bead from the wheel.
CAUTION: Do not mount the tire at
this time.
Position the wheel on the turntable of the tire
machine, then lubricate and position the inner
bead of the tire on the wheel.
2. Position the wheel to align the valve stem with
the machine arm, at the 12 oclock position,
and mount the bottom bead of the tire.
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3. Reposition the wheel to align the valve stem
4. CAUTION: Use only special tool
with the machine arm, at the 12 oclock
204-354 any time tire pressures are measured
position, and mount the top bead of the tire.
to be sure that accurate values are obtained.
Inflate the tire to the pressure specified on the
vehicle certification label located on the driver
door or door pillar.
5. Install the wheel and tire assembly. For
additional information, refer to Wheel and Tire
in this section.
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Installation
Wheel and Tire
1. WARNING: When a wheel is installed,
always remove any corrosion, dirt or foreign
material present on the mounting surfaces of
the wheel and the surface of the wheel hub,
brake drum or brake disc that contacts the
wheel. Installing wheels without correct
metal-to-metal contact at the wheel mounting
surfaces can cause the wheel nuts to loosen
and the wheel to come off while the vehicle is
in motion, causing loss of control.
Position the wheel and tire assembly on the
vehicle.
2. CAUTION: Failure to tighten the
1 1130 Center cap
wheel nuts in the pattern indicated can result
2 1012 Wheel nut (5 required)
in high brake disc runout, which will speed
3 Wheel and tire assembly
up the development of brake roughness,
(1007 wheel) (1508 tire)
shudder and vibration.
Install the wheel nuts and tighten to 133 Nm
Removal
(98 lb-ft) in the sequence shown.
Section 100-02.
2. CAUTION: Do not use heat to loosen a
seized wheel nut. Heat can damage the wheel
and wheel bearings.
NOTE: Place the center cap face up after
removal to avoid damage.
If equipped, remove the center cap.
3. CAUTION: Do not use heat to loosen a
seized wheel because heat can shorten the life
3. If removed, install the center cap.
of the wheel and damage the wheel bearings.
If the wheel cannot be removed by hand, use
a wheel puller to remove the seized wheel.
Remove the wheel nuts and the wheel and tire
assembly.
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GENERAL PROCEDURES
Wheel Leaks
WARNING: Wheel repairs that use
welding or peening are not approved. An inner
tube is not an acceptable repair for leaking
wheels or tires.
If the air pressure in a tire mounted on an
aluminum wheel is found to be low, carry out the
following procedure. Failure to follow these
1. Remove the tire and wheel assembly and
inspect the wheel for structural damage. If the
wheel is damaged, install a new wheel.
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Wheels And Tires WARNING: Use only wheels and wheel
nuts that have been designed for current model
WARNING: Do not mix different types of
Ford trucks. Aftermarket wheels or wheel nuts
tires on the same vehicle such as radial, bias or
may not fit or function correctly. Failure to
bias-belted tires except in emergencies
follow these instructions may result in personal
(temporary spare usage), because vehicle
injury.
handling may be seriously affected and may
result in loss of control. Failure to follow these
WARNING: Always wear safety goggles or
a face shield when performing any work with the
tire and wheel assemblies. Failure to follow these
Factory-installed tires and wheels are designed to
operate satisfactorily with loads up to and including
full-rated load capacity when inflated to
CAUTION: Reduce the air pressure as
recommended inflation pressures.
much as possible by pushing the valve core
Correct tire pressure and driving techniques have an plunger in prior to removing the valve core.
important influence on tire life. Heavy cornering, Avoid working in a position in which the face or
excessively rapid acceleration and unnecessary sharp body is directly over a tire in which there is
braking increase tire wear. pressure.
To equalize tire wear, the tires should be rotated at
CAUTION: Do not clean aluminum wheels
recommended intervals.
with steel wool, abrasive-type cleaners or strong
detergents. Use Wheel and Tire Cleaner ZC-37-A
Safety Precautions
or -B or equivalent.
When carrying out any inspection or repair
wheel off the ground, for example, when
procedures on wheels and tires, follow the preceding
changing a tire. The wheel(s) resting on the
safety precautions.
ground could cause the vehicle to move. Failure
to follow these instructions may result in Tire Pressure Monitoring System (TPMS)
personal injury.
The TPMS includes:
WARNING: The tire and wheel must
the smart junction box (SJB), TPMS functionality
always be correctly matched. It is very important
is integrated within the SJB.
to determine the size of each component before
four tire pressure sensors.
any assembly operations commence. Failure to
four tire pressure sensor cradles.
adhere to these instructions can result in an
explosive separation and cause serious bodily
four tire pressure sensor straps.
injury or death.
an instrument cluster indicator.
WARNING: Aftermarket aerosol tire
a message center (if equipped).
sealants are extremely flammable. Always
question the customer to make sure these TPMS System Module
products have not been used. Failure to follow
The SJB contains the TPMS functionality. Refer to
these instructions may result in personal injury.
Tire Pressure Monitoring System in Diagnosis and
Testing for TPMS fault diagnosis and repair.
WARNING: Aftermarket wheel assemblies
may not be compatible with the vehicle. Use of
The SJB compares the information of each tire
incompatible wheel assemblies can result in
pressure sensor transmission against a pressure limit.
equipment failure and possible injury. Use only
If the SJB determines that the tire pressure has
approved wheel assemblies. Failure to follow
fallen below the low limit, the SJB communicates
this to the instrument cluster on the vehicle
communication bus.
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TPMS Pressure Sensor TPMS Pressure Sensor Strap
The SJB monitors the air pressure in the 4 road The sensor strap is what keeps the sensor and the
tires with tire pressure sensors. The sensors transmit cradle retained to the wheel. A factory-installed
radio frequency (RF) signals to the SJB strap is joined together with a one-time use buckle
approximately every 60 seconds when the vehicle and a dealer-installed strap is joined together with a
speed exceeds 32 km/h (20 mph). worm gear (similar to a radiator hose clamp). Both
straps should be discarded after removal and should
The tire pressure sensors are battery operated and
not be re-used.
are mounted to metal brackets (called cradles) on
the wheels inside the tires. The sensors are mounted The strap can be serviced separately from the sensor
180 degrees from the valve stem. and the cradle. The sensor is available separately
from the cradle and the strap. The cradle and strap
The tire pressure sensor can be serviced separately
are available as a strap kit. There are several
from the cradle and the strap.
different strap kits available based on wheel
TPMS Pressure Sensor Cradle diameter, all strap kits share the same base part
number.
The tire pressure sensor cradles are mounted to the
wheels with metal straps and have an adhesive strip
Instrument Cluster and Message Center
to aid in their retention to the wheel.
The instrument cluster illuminates the TPMS
To service the sensor cradle, the strap must also be
indicator when it receives a message from the SJB
removed.
to do so and displays the appropriate message(s) in
the message center (if equipped).
The instrument cluster and message center are
diagnosed and serviced in their own respective
workshop manual sections.
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Use of any other tire size or type can seriously
Wheels And Tires
affect:
ride.
WARNING: If, while the vehicle is being
handling.
serviced, only one wheel is raised off the ground
speedometer/odometer calibration.
and the rear axle is driven by the engine, the
wheel on the ground could drive the vehicle off
vehicle ground clearance.
the stand or jack. Be sure both rear wheels are
tire clearance between the body and chassis.
off the ground. Failure to follow these
wheel bearing life.
brake cooling.
New wheels need to be installed when vehicles
wheel off the ground, for example, when
wheels:
changing a tire. The wheel(s) resting on the
ground could cause the vehicle to move. Failure
are bent.
to follow these instructions may result in
are cracked.
personal injury.
are dented.
WARNING: Do not balance the wheels and
are heavily corroded.
tires while they are mounted on the vehicle.
Possible tire disintegration or differential failure are leaking.
could result, causing personal injury and
have elongated wheel hub bolt holes.
extensive component damage. Use off-vehicle
have excessive lateral or radial runout.
wheel and tire balancer only. Failure to follow
Wheel and tire assemblies are attached by 5 wheel
nuts.
Be sure to follow the warnings when carrying out
It is mandatory to use only the tire sizes
the inspection and verification.
recommended on the tire chart attached to the
Road Test
vehicle. Larger or smaller tires can damage the
vehicle, affect durability and require changing the
Verify the customer concern by carrying out a road
speedometer calibration. Make sure wheel size and
test on a smooth road. If any vibrations are
offsets match those recommended for the tire in use.
apparent, refer to Section 100-04.
1. Inspect for signs of uneven wear that may
To maximize tire performance, inspect for signs of
indicate a need for balancing, rotation, front
incorrect inflation and uneven wear, which may
suspension alignment, damaged tie rod or
indicate a need for balancing, rotation or front
steering components.
suspension alignment.
2. Check tires for:
Correct tire pressure and driving techniques have an
important influence on tire life. Heavy cornering,
cuts.
excessively rapid acceleration and unnecessary sharp
stone bruises.
braking increase tire wear.
abrasions.
Replacement tires must follow the recommended:
blisters.
tire sizes.
embedded objects.
speed rating.
3. Tread wear indicators are molded into the
load range.
bottom of the tread grooves. Install a new tire
tire construction type. when the indicator bands become visible.
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Symptom Chart
Symptom Chart
Tires show excess wear on Underinflated tires ADJUST air pressure in tires.
edge of tread
Vehicle overloaded RETURN vehicle. NOTIFY
customer of overload
condition.
High-speed cornering RETURN vehicle. NOTIFY
customer of cause of
condition.
Incorrect ride height SET ride height.
Incorrect wheel alignment SET alignment to
Section 204-00.
Incorrect tire rotation ADVISE customer of
intervals condition. ROTATE tires.
Tires show excess wear in Tires overinflated ADJUST air pressure.
center of tread
Other excessive tire wear Incorrect tire rotation ADVISE customer of
problems intervals condition. ROTATE tires.
Incorrect tire pressure ADJUST pressure.
Loose or leaking shock TIGHTEN or INSTALL new
absorbers shock absorbers as necessary.
front shock absorbers and
Section 204-02 for rear shock
absorbers.
Incorrect wheel alignment SET alignment to
Section 204-00.
Loose, worn or damaged REFER to Section 204-00.
suspension components
Wheel and tire assembly out BALANCE wheel and tire
of balance assembly.
Excessive lateral or radial REFER to Section 100-04.
runout of wheel
Wobble or shimmy Damaged wheel bearings REFER to Section 204-00.
Loose or damaged suspension
components
Bent wheel INSTALL a new wheel as
necessary.
Damaged tire INSTALL a new tire as
necessary.
Loose wheel nuts TIGHTEN to specification.
REFER to Specifications in
this section.
High-speed shake Wheel hub face/pilot/bolt REFER to Section 100-04.
circle runout
Tires/wheels
Wheel bearings
Suspension/steering linkage
Engine
Transmission
Brake discs/imbalance
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Vehicle vibration Driveline engine REFER to Section 100-04.
Tires
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205-00-1 205-00-1 Driveline System General Information
SPECIFICATIONS
Item Specification
Driveline Angles @ Curb Specifications
Motorcarft SAE 80W90 WSP-M2C197-A
Engine Driveshaft Pinion Premium Rear Axle
Angle Angle Angle Lubricant XY-80W90-QL
Engine (Deg) (Deg) (Deg) (US); CXY-80W90-1L
(Canada) (7.5 inch axle)
4.0L 3.5 1.8 0.55
Additive Friction Modifier EST-M2C118-A
4.6L (3V) 2.2 3.9 1.1
XL-3 (US); CXL-3
(Canada)
All driveshaft and pinion angles point downward.
Premium Long-Life ESA-M1C75-B
Grease XG-1-C or
XG-1-K (Canada
CXG-1-C)
Item Specification
Axle Capacities a Service refill capacities are determined by filling the
axle 11.1 mm (0.4375 in) to 12.7 mm (0.5 in)
7.5 inch rear axle
a
1.5 liters (3.0 pints)
below the bottom of the filler hole. The vehicle
8.8 inch rear axle
b
1.9 liters (4.0/3.75 pints) must be on a level surface.
b Service refill capacities are determined by filling the
Additive Friction Modifier 118 ml (4 oz)
axle 25.4 mm (1 in) to 28.6 mm (1.125 in) below
Lubricants
the bottom of the filler hole. The vehicle must be
on a level surface.
Motorcraft SAE 75W-140 WSP-M2C192-A
Premium Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada) (8.8 inch axle)
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GENERAL PROCEDURES
3. To check the pinion angle, rotate the driveshaft
Driveline Angle Measurement
so the axle flange yoke is parallel to the floor.
If equipped, remove the U-joint snap ring and
Special Tool(s)
install the special tool.
Anglemaster II Driveline
Inclinometer
NOTE: An incorrect driveline angle can cause a
vibration or shudder. For additional information,
1. Preliminary setup procedures.
1 Inspect the U-joints for correct operation.
4. To check the engine angle, rotate the driveshaft
2 Park the vehicle on a level surface such as
so the slip yoke ear is parallel to the floor. If
a drive-on hoist or back onto a front end
equipped, remove the U-joint snap ring and
alignment rack.
3 Verify the curb position ride height is
within specifications with the vehicle
unloaded, and all of the tires are inflated to
their normal operating pressures.
4 Rotate the transmission output yoke until
vertical. This will simplify taking
measurements.
5 Calibrate the special tool by placing the tool
on clean, flat level section of the frame rail
and press the ALT-ZERO button.
2. Using the special tool, measure the slope of the
components. Record the measurements and the
direction of the components slope.
5. Calculate the difference in the slope of the
components to determine the U-joint operating
angle.
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5 Driveshaft slope minus (-) the 1 Output yoke slope
pinion flange slope equals the
2 Driveshaft slope
driveshaft/axle operating
3 Driveshaft slope minus (-) the
angle
output yoke slope equals the
When 2 connected components slope in the same
transmission/driveshaft
direction, subtract the smaller number from the
operating angle
largest to find the U-joint operating angle. When 2
4 Pinion flange slope
connected components slope in the opposite
(Continued)
direction, add the measurements to find the U-joint
operating angle.
The U-joint operating angle is the angle formed by
2 yokes connected by a cross and bearing kit.
Ideally, the operating angles on each end of the
driveshaft must:
be equal or within 1 degree of each other.
have a 3 degree maximum operating angle.
have a least 1/2 of 1 degree continuous
operating angle.
If the driveline angle is not the cause, carry out the NVH
test to determine whether the concern is caused by a
condition in the axle. Refer to Section 100-04.
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Vehicle Certification (VC) Label Example
Driveline System
The source of the drivetrains power is generated by
the engine and delivered to the transmission. The
driveline transfers the engine torque through the
driveshaft to the axle.
The driveshaft is connected to the output shaft of
the transmission and to the axle.
Vehicles with 4.0L engines use universal joints at
both ends of the driveshaft to allow for angular
motion. A slip yoke is used to allow for any
changes to the length of the driveshaft.
Vehicles with 4.6L engines use a constant velocity
joint in the rear of the driveshaft and a universal
joint in the front. A center bearing and the constant
velocity joint allow for length changes to the
driveshaft.
The engine torque enters the axle through the drive
pinion, which rotates the ring gear. The ring gear is
mounted to the differential case, which contains the
gears that transmit power to the axle shafts. These
shafts rotate the drive wheels. Available axles are
as follows:
Conventional axle-Ford 7.5-inch ring gear
Conventional axle-Ford 8.8-inch rear axle
Limited slip axle-Ford 8.8-inch rear axle
For additional information on the driveshaft, refer to
Section 205-01.
For additional information on the axle, refer to
Section 205-02A or Section 205-02B.
The engine angle is built into the engine mounts. If
the engine angle is out of specification, the engine
mounts must be inspected for damage.
For additional information, refer to Section 303-01A
or Section 303-01B.
The vehicle certification (VC) label is located in the
driver door jamb. The axle code is on the VC label.
For additional information on the VC label, refer to
Section 100-01.
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Rear Axle Identification Label
Item Description Item Description
1 Plant code 5 Build year
2 Axle ratio 6 Build month
3 Denotes Traction-Lok 7 Build day
4 Ring gear diameter (inch)
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Special Tool(s)
Driveline System
Vibration Analyzer
Special Tool(s)
100-F027 (014-00344)
Clamp Plate
205-320 (T92L-4851-C)
Gauge, Differential Clutch
205-022 (T66L-4204-A)
Clutch Housing Alignment
Adapter
308-021 (T75L-4201-A)
Certain axle noise or vibration symptoms are also
Companion Flange Holding
common to the engine, transmission, wheel
Tool
205-126 (T78P-4851-A) bearings, tires and other components of the vehicle.
For this reason, make sure that the cause of the
trouble is in the axle before disassembling,
adjusting or repairing the axle. Refer to Section
100-04.
Certain driveshaft vibration symptoms are common Companion Flange Runout
Gauge to the front engine accessory drive (FEAD), the
205-319 (T92L-4851-B)
engine, transmission or tires. Make sure the cause of
the concern is the driveshaft before repairing or
installing a new driveshaft. Refer to Section
100-04.
Certain symptoms may be caused by Traction-Lok
Dial Indicator with Holding
differentials. Check the vehicle certification label
Fixture
and axle identification tag to determine the type of
100-002 (TOOL-4201-C) or
differential. Refer to Section 100-01.
equivalent
Noise Acceptability
NOTE: A gear-driven unit will produce a certain
amount of noise. Some noise is acceptable and
Dial Indicator/Magnetic Base audible at certain speeds or under various driving
100-D002 (D78P-4201-B) or
conditions such as a newly paved blacktop road.
equivalent
Slight noise is not detrimental to the operation of
the axle and is considered normal.
With the Traction-Lok differential axle, slight
chatter noise on slow turns after extended highway
driving is considered acceptable and has no
(Continued)
detrimental effect on the locking axle function.
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Universal Joint (U-Joint) Inspection
The rubber lips can occasionally become hard (like
plastic) with cracks at the oil lip contact point. The
Place the vehicle on a frame hoist and rotate the
contact point on the pinion flange may blacken,
driveshaft by hand. Check for rough operation or
indicating excessive heat. Marks, nicks, gouges or
seized U-joints. Install a new driveshaft if it shows
rough surface texture on the drive pinion seal
signs of seizure, excessive wear, or incorrect
journal of the pinion flange will also cause leaks.
seating. Refer to Section 205-01.
When a drive pinion seal leak occurs, install a new
Analysis of Leakage
drive pinion seal and check the vent and the vent
Clean up the leaking area enough to identify the
hose to make sure they are clean and free of foreign
exact source. An axle leak can be caused by the
material.
following:
Axle Shaft Seals
Axle lubricant level is too high
Axle shaft oil seals are susceptible to the same
Worn or damaged axle shaft seals or differential
kinds of damage as drive pinion seals if incorrectly
seals
installed. The axle shaft oil seal bore must be clean
and the lip handled carefully to avoid cutting or
Differential housing is cracked
tearing it. The axle shaft journal surface must be
Flange yoke seat is worn or damaged
free of nicks, gouges, and rough surface texture.
Pinion flange is scored or damaged
Differential Seals
Axle cover is not sealed
Refer to Section 205-02A or Section 205-02B.
Vent is plugged
Repair the axle as necessary. Make sure the axle
Analysis of Vibration
lubricant is at the correct level. Refer to
WARNING: A vehicle equipped with a
Specifications in this section.
Traction-Lok differential will always have both
wheels driving. If only one wheel is raised off the
Axle Vent
floor and the axle is driven by the engine, the
NOTE: If a plugged vent cannot be cleared, install
wheel on the floor could drive the vehicle off the
a new one.
stand or jack. Be sure both rear wheels are off
A plugged vent will cause excessive seal lip wear
the floor.
due to internal pressure buildup. If a leak occurs,
Few vibration conditions are caused by the axle. On
check the vent.
a vibration concern, follow the diagnosis procedure
in Section 100-04 unless there is a good reason to
Flange Yoke Seal
suspect the axle.
Leaks at the drive pinion seal originate for the
following reasons:
Tires
Drive pinion seal was not correctly installed.
WARNING: Do not balance the wheels and
Poor quality drive pinion seal journal surface. tires while they are mounted on the vehicle.
Possible tire disintegration/differential failure
Any damage to the drive pinion seal bore (dings,
could result, causing personal injury/extensive
dents, gouges or other imperfections) will distort the
component damage. Use an off-vehicle wheel and
seal casing and allow leakage past the outer edge of
tire balancer only.
the drive pinion seal.
Most vibration in the rear end is caused by tires or
The drive pinion seal can be torn, cut or gouged if
driveline angle.
it is not installed carefully. The spring that holds the
drive pinion seal against the pinion flange may be
knocked out and allow leakage past the lip.
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Driveline Angle
Vibration is a concern with modern, high-mileage
tires if they are not true both radially and
Driveline angularity is the angular relationship
laterally. They are more susceptible to vibration
between the engine crankshaft, the driveshaft and
around the limits of radial and lateral runout of the
the axle pinion. Factors determining driveline
tire and wheel assembly. They also require more
angularity include ride height, rear spring and
accurate balancing. Wheel and tire runout checks,
engine mounts.
truing and balancing are normally done before axle
inspection. Refer to Section 204-04.
Driveline Angle
Item Description
A vibration during acceleration, from 56 to 72
km/h (35 to 45 mph) may indicate an excessive 1 Bottom of the frame
U-joint angle at the axle (pinion nose upward).
2 Engine crankshaft centerline
When these conditions exist, check the driveline
3 Engine angle
angles as described in the General Procedures
4 Driveshaft and coupling shaft centerline
portion of this section.
5 Driveshaft and coupling shaft angle
If the tires and driveline angle are not the cause,
6 Axle pinion centerline
carry out the NVH tests to determine the cause.
7 Axle pinion angle
Universal Joint (U-Joint) Wear
An incorrect driveline (pinion) angle can often be
Place the vehicle on a frame hoist and rotate the
detected by the driving condition in which the
driveshaft by hand. Check for rough operation or
vibration occurs.
seized U-joints. Install a new driveshaft if it shows
A vibration during coastdown from 72 to 56 km/h
signs of seizure, excessive wear or incorrect seating.
(45 to 35 mph) is often caused by an excessive
U-joint angle at the axle (pinion nose downward).
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Wheel Hub or Axle Flange Bolt Circle
2. Rotate the hub or flange one full turn and note
Runout
the maximum and minimum readings. The
NOTE: The brake discs must be removed to carry
readings will be the total pilot runout. Pilot
out all runout measurements.
1. Position the special tool perpendicular to the
wheel hub or axle flange bolt, as close to the
Wheel Hub or Axle Flange Face Runout
hub or flange face as possible. Zero the
NOTE: If the axle shaft assembly is removed,
check runout of the shaft itself. The forged
way.
(unmachined) part of the shaft is allowed to have as
much as 3.0 mm (0.120 in) runout. This alone will
not cause a vibration condition.
1. Position the special tool on the wheel hub or
axle flange face, as close to the outer edge as
possible. Zero the indicator to allow the pointer
to deflect either way.
2. Rotate the hub or flange until the next bolt is
contacted. Record the measurement and
continue until each bolt is checked. The
contact readings will be the total wheel hub or
axle flange bolt pattern runout. The runout
must not exceed 0.38 mm (0.015 in).
2. Rotate the hub or flange one full turn and note
Pilot Runout
the maximum and minimum readings. The
1. Position the special tools as close to the hub or
readings will be the total face runout. The
axle flange face as possible. Zero the indicator
to allow the pointer to deflect either way.
Drive Pinion Stem and Pinion Flange
Check the pinion flange runout when all other
checks have failed to show the cause of vibration.
One cause of excessive pinion flange runout is
incorrect installation of the axle drive pinion seal.
Check to see if the spring on the seal lip has been
dislodged before installing the pinion flange.
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Axle Noise
NOTE: Before disassembling the axle to diagnose
and correct gear noise, eliminate the tires, exhaust,
trim items, roof racks, axle shafts and wheel
bearings as possible causes. Follow the diagnostic
procedures in Section 100-04.
The noises described as follows usually have
specific causes that can be diagnosed by observation
as the unit is disassembled. The initial clues are the
type of noise heard during the road test.
Gear Howl and Whine
Howling or whining of the ring gear and pinion is
If the wheel bearing is damaged, the roller surface
due to an incorrect gear pattern, gear damage or
on the axle shaft may also be damaged. Install a
incorrect bearing preload.
new axle shaft if any damage is detected.
Bearing Whine
Bearing whine is a high-pitched sound similar to a
whistle. It is usually caused by worn/damaged
pinion bearings, which are operating at driveshaft
speed. Bearing noise occurs at all driving speeds.
This distinguishes it from gear whine which usually
comes and goes as speed changes.
As noted, pinion bearings make a high-pitched,
whistling noise, usually at all speeds. If however
there is only one pinion bearing that is
worn/damaged, the noise may vary in different
driving phases. If pinion bearings are scored or
damaged or there is a specific pinion bearing noise,
Chuckle
new pinion bearings must be installed. A
Chuckle that occurs on the coast driving phase is
worn/damaged bearing will normally be obvious at
usually caused by excessive clearance between the
disassembly. Examine the large end of the rollers
differential gear hub and the differential case bore.
for wear. If the pinion bearings original blend radius
has worn to a sharp edge, a new pinion bearing
Damage to a gear tooth on the coast side can cause
must be installed.
a noise identical to a chuckle. A very small tooth
nick or ridge on the edge of a tooth can cause the
NOTE: A low-pitched rumble normally associated
noise.
with a worn/damaged wheel bearing can also be
caused by tires.
Clean the gear tooth nick or ridge with a small
grinding wheel. If the damaged area is larger than
A wheel bearing noise can be mistaken for a pinion
3.2 mm (1/8 in), install a new gearset.
bearing noise. Check the wheel bearing for a spalled
cup and spalled/damaged rollers. Check the wheel
To check the ring gear and pinion, remove as much
bearing for rotating smoothness and end play. Install
lubricant as possible from the gears with clean
a new wheel bearing if any of these concerns are
solvent. Wipe the gears dry or blow them dry with
detected.
compressed air. Look for scored or damaged teeth.
Also look for cracks or other damage.
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If either gear is scored or damaged badly, install a 1. A gear tooth damaged on the drive side is a
new ring gear and pinion. common cause of the knock. This can usually
be corrected by grinding the damaged area.
2. NOTE: Measure the end play with a dial
indicator with holding fixture and not by feel.
Knock is also caused by excessive end play in
the axle shafts. Up to 0.762 mm (0.030 in) is
allowed in semi-float axles. The frequency of
the knock will be less because the axle shaft
speed is slower than the driveshaft.
Clunk
Clunk is a metallic noise heard when the automatic
transmission is engaged in REVERSE or DRIVE.
The noise may also occur when throttle is applied
or released. It is caused by backlash somewhere in
If metal has broken loose, the axle housing must be
the driveline or loose suspension components; it is
cleaned to remove particles that will cause damage.
felt or heard in the axle.
At this time, any other new components in the axle
housing must also be installed, if necessary.
Additionally, clunk may be heard upon initial
drive-away. This occurs as engine torque shifts
Knock
vehicle weight, forcing changes in driveline angles,
Knock, which can occur on all driving phases, has
preventing the driveshaft slip-yoke from sliding on
several causes including damaged teeth or gearset.
the output shaft. To correct for this condition,
lubricate the slip-yoke splines.
Axle Shaft Bearing Noise
Axle bearing shaft noise is similar to gear noise and
differential pinion bearing whine. Axle shaft bearing
noise will usually distinguish itself from gear noise
by occurring in all driving modes (drive, coast and
float), and will persist with the transmission in
NEUTRAL while the vehicle is moving at the speed
in which the concern is occurring. If the vehicle
makes this noise, remove the suspect axle shaft,
install a new bearing and a new axle shaft oil seal.
Re-evaluate the vehicle for noise before removing
In most cases, one of the following conditions will any internal components.
occur:
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Bearing Rumble
Bearing rumble sounds like marbles being tumbled.
This condition is usually caused by a worn/damaged
wheel bearing. The lower pitch is because the wheel
bearing turns at only about 1/3 of the driveshaft
speed. Wheel bearing noise also may be
high-pitched, similar to gear noise, but will be
evident in all 4 driving modes.
Symptom Chart
Symptom Chart
Traction-Lok does not work Differential. CARRY OUT the
in snow, mud or on ice Traction-Lok Differential
Operation Check in this
section. REPAIR as
205-02B.
Lubricant leaking from the Vent. CLEAN the axle housing
pinion seal, axle shaft oil Damage in the seal contact vent.
seals area or damaged or worn INSTALL a new seal if
seal. damage is found.
Differential side gears/pinion Insufficient lubrication. INSTALL new gears. REFER
gears are scored to Section 205-02A or
Section 205-02B. FILL the
axle to specification.
Incorrect or contaminated INSTALL new gears. REFER
lubricant type. to Section 205-02A or
Section 205-02B. CLEAN
and REFILL the axle to
specification.
Axle overheating Lubricant level too low. CHECK the lubricant level.
FILL the axle to
specification.
Incorrect or contaminated INSPECT the axle for
lubricant type. damage. REPAIR as
necessary. CLEAN and
REFILL the axle to
specification.
Bearing preload adjusted too CHECK the ring and pinion
tight. for damage. INSPECT the
ring and pinion wear pattern.
ADJUST the preload as
necessary.
Excessive gear wear. INSPECT all the axle gears
for wear or damage.
as necessary.
Incorrect ring gear backlash. INSPECT the ring gear for
scoring. INSPECT the ring
and pinion wear pattern.
ADJUST the ring gear
backlash as necessary.
Broken gear teeth on the ring Overloading the vehicle. INSTALL a new ring and
gear or pinion pinion. REFER to Section
205-02A or Section 205-02B.
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Axle shaft broken Overloading the vehicle. INSTALL a new axle shaft.
or Section 205-02B.
Misaligned axle shaft tube. INSPECT the axle for
damage. CHECK axle shaft
tube alignment. INSTALL a
new axle shaft. REFER to
Section 205-02A or Section
205-02B.
Component Tests
2. Mark the relative position of the drive wheels
to the wheel nuts. Remove the wheels. Install
Driveline Vibration
all the nuts in the reversed position and repeat
An analysis of driveline vibration can also be
the road speed acceleration. If the vibration is
conducted using the Vibration Analyzer; follow the
gone, refer to the tire and wheel runout
manufacturers directions.
procedure in Section 204-04. If the vibration
persists, proceed to Step 3.
Driveline vibration exhibits a higher frequency and
lower amplitude than does high-speed shake.
3. Inspect the driveshaft for signs of physical
Driveline vibration is directly related to the speed of
damage, missing balance weight, undercoating,
the vehicle and is usually noticed at various speed
incorrect seating, wear and binding universal
ranges. Driveline vibration can be perceived as a
joints. Install a new driveshaft if damaged.
tremor in the floorpan or is heard as a rumble, hum
Check the index marks (paint spots) on the rear
or boom. Driveline vibration can exist in all drive
of the driveshaft and pinion flange. If these
modes, but may exhibit different symptoms
marks are more than 1/4 turn apart, disconnect
depending upon whether the vehicle is accelerating,
the driveshaft and re-index to align the marks
decelerating, floating or coasting. Check the
as closely as possible. After any corrections are
driveline angles if the vibration is particularly
made, recheck for vibration at the road test
noticeable during acceleration or deceleration,
speed. If the vibration is gone, reinstall the
especially at lower speeds. Driveline vibration can
wheels and road test. If the vibration persists,
be duplicated by supporting the axle upon a hoist or
proceed to Step 4.
upon jack stands, though the brakes may need to
be applied lightly in order to simulate road
resistance.
1. Raise the vehicle promptly after road testing.
Use a twin-post hoist or jack stands to prevent
tire flat-spotting. Engage the drivetrain and
accelerate to the observed road test speed to
verify the presence of the vibration. If the
vibration is not evident, check the non-driving
wheels with a wheel balancer to rule out
imbalance as a possible cause. If required,
balance the non-driving wheels and repeat the
road test. If the vibration is still evident,
proceed to Step 2.
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4. Raise the vehicle on a hoist and remove the
wheels. Rotate the driveshaft by turning the
axle and measure the runout at the front, the
center, and the rear of the driveshaft with the
indicator. If the runout exceeds 0.89 mm (0.035
inch) at the front or center, a new driveshaft
must be installed. If the front and center are
within this limit, but the rear runout is not,
mark the rear runout high point and proceed to
Step 5. If the runout is within the limits at all
points, proceed to Step 7.
If the marks are on opposite sides of the driveshaft,
the yoke or pinion flange is responsible for the
vibration.
5. NOTE: Check the U-joints during re-indexing.
If a U-joint feels stiff or gritty, install a new
U-joint.
Scribe alignment marks on the driveshaft and
the pinion flange. Disconnect the driveshaft, When installing a new pinion flange, the driveshaft
rotate it one-half turn, and reconnect it. Circular runout must not exceed 0.89 mm (0.035 in). When
pinion flanges can be turned in one-quarter runout is within limits, recheck for vibration at road
increments to fine tune the runout condition. speed. If vibration persists, balance the driveshaft.
Check the runout at the rear of the driveshaft.
7. To balance the driveshaft, install 1 or 2 hose
If it is still over 0.89 mm (0.035 inch), mark
clamps on the driveshaft, near the rear. Position
the high point and proceed to Step 6. If the
of the hose clamp head(s) can be determined by
runout is no longer excessive, check for
trial-and-error.
vibration at the road test speed. If vibration is
still present, re-index the driveshaft slip yoke
on the transmission output shaft 1/2 turn and
road test the vehicle. If the vibration persists,
proceed to Step 7.
6. Excessive driveshaft runout may originate in the
driveshaft itself or in the pinion flange. To
determine which, compare the 2 high points
marked in Steps 4 and 5. If the marks are close
together, within about 25 mm (1 in), a new
shaft must be installed and the vehicle road
tested.
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8. Mark the rear of the driveshaft into 4
approximately equal sectors and number the
marks 1 through 4. Install a hose clamp on the
driveshaft with its head at position No. 1.
Repeat the process with increasing separation until
the best combination is found or the vibration is
reduced to an acceptable level.
10. Install the wheels and road test (vibration
noticeable on the hoist may not be evident
Check for vibration at road speed. Recheck with the
during the road test). If the vibration is still not
clamp at each of the other positions to find the
acceptable, install a new axle driveline vibration
position that shows minimum vibration. If 2
damper first, if so equipped. If the vibration is
adjacent positions show equal improvement, position
still not acceptable, refer to Section 205-02A or
the clamp head between them.
Section 205-02B for differential case and ring
9. If the vibration persists, add a second clamp at
gear runout checks.
the same position and recheck for vibration.
Driveshaft Vibrates
1. Road test the vehicle to determine the critical
vibration points. Note the road speed, the
engine RPM, and the shift lever positions at
which the vibration occurs.
2. Stop the vehicle, place the transmission lever in
neutral and run the engine through the critical
speed ranges determined in Step 1.
3. If no vibration is felt, balance the driveshaft.
Refer to Driveline Vibration in this section.
Traction-Lok Differential Operation Check
A Traction-Lok differential can be checked for
If no improvement is noted, rotate the clamps in
correct operation without removing it from the rear
opposite directions, equal distances from the best
axle housing.
position determined in Step 8. Separate the clamp
heads about 13 mm (1/2 in) and recheck for
vibration at the road speed.
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2. Gradually open the throttle to obtain maximum
WARNING: A vehicle equipped with a
traction prior to break away. The ability to
Traction-Lok differential will always have both
move the vehicle demonstrates correct operation
wheels driving. If only one wheel is raised off the
of a Traction-Lok axle assembly.
floor and the axle is driven by the engine, the
wheel on the floor could drive the vehicle off the
3. When starting with one wheel on an excessively
stand or jack. Be sure both rear wheels are off
slippery surface, a slight application of the
the floor.
parking brake may be necessary to help
energize the Traction-Lok feature of the
With the engine off, raise only one rear wheel.
differential. Release the brake when traction is
Install the special tool on the wheel nuts.
established. Use light throttle on starting to
provide maximum traction.
4. If, with unequal traction, both wheels slip, the
limited slip axle has done all it can possibly do.
5. In extreme cases of differences in traction, the
wheel with the least traction may spin after the
Traction-Lok has transferred as much torque
as possible to the non-slipping wheel.
Companion Flange Runout Check
CAUTION: Pinion bearing preload must
be reset if the pinion nut has been loosened or
removed for pinion flange reindexing or
Use a torque wrench with a capacity of at least 271
installation.
Nm (200 lb-ft) to rotate the axle shaft. Be sure that
the transmission is in NEUTRAL, and that one rear
hoist. Refer to Section 100-02.
wheel is on the floor while the other rear wheel is
raised off the floor. The breakaway torque required 2. Remove the driveshaft. Refer to Section 205-01.
to start rotation must be at least 27 Nm (20 lb-ft).
3. Check the pinion flange for damage.
The initial breakaway torque may be higher than the
4. Position the Companion Flange Runout Gauge
continuous turning torque.
on the pinion flange.
The axle shaft must turn with even pressure
Item Part Number Description throughout the check without slipping or binding. If
the torque reading is less than specified, check the
1 Pilot (part of 205-319
differential case. Refer to Section 205-02B. [T92L-4851-B])
2 354845 Pinion nut
Traction-Lok Differential Check Road Test
3 205-319 Companion flange runout
1. Place one wheel on a dry surface and the other
(T92L-4851-B) gauge
wheel on ice, mud or snow.
(Continued)
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4 Bolts (2 required) (Part of
205-320 [T92L-4851-C])
5 205-320 Clamp plate (T92L-4851-C)
6 4851 Pinion flange
5. Position the special tools on the pinion flange.
If the pinion flange runout exceeds 0.25 mm (0.010
in), remove the pinion flange, reindex the pinion
flange 1/2 turn on the pinion, and reinstall it. Refer
to Section 205-02A or Section 205-02B.
8. Check the runout again. If necessary, rotate the
pinion flange until an acceptable runout is
obtained. If the pinion flange runout is still
more than 0.25 mm (0.010 in), install a new
6. Align the holes on the clamp plate with the
pinion flange.
holes in the pinion flange and install the bolts.
Snug the bolts evenly.
9. If excessive runout is still evident after
installing a new pinion flange, install a new
7. Position the special tool as shown. Turn the
ring and pinion. Repeat the above checks until
Companion Flange Runout Gauge, and locate
the runout is within specifications.
and mark the high spot on the pinion flange
10. Install the driveshaft. Refer to Section 205-01.
with yellow paint.
Tooth Contact Pattern Check Gearset
1. To check the gear tooth contact, paint the gear
teeth with the special marking compound. A
mixture that is too wet will run and smear; a
mixture that is too dry cannot be pressed out
from between the teeth.
2. Use a box wrench on the ring gear bolts as a
lever to rotate the ring gear several complete
revolutions in both directions or until a clear
tooth contact pattern is obtained.
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3. Certain types of gear tooth contact patterns on Correct backlash with a thicker pinion position shim
the ring gear indicate incorrect adjustment. required.
Incorrect adjustment can be corrected by
readjusting the ring gear or the pinion.
Contact Pattern Location
In general, desirable ring gear tooth patterns must
have the following characteristics:
drive pattern on the drive side ring gear well
centered on the tooth
coast pattern on the coast side ring gear well
centered on the tooth
clearance between the pattern and the top of the
tooth
Correct pinion position shim that requires a decrease
no hard lines where the pressure is high
in backlash.
Acceptable ring gear tooth patterns for all axles.
Correct pinion position shim that requires an
Correct backlash with a thinner pinion position shim
increase in backlash.
required.
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205-01-1 205-01-1 Driveshaft
Driveshaft 4.0L
Material
Item Specification
Threadlock and Sealer WSK-M2G351-A5
TA-25
7 Pinion flange 1 Transmission output flange
2 Driveshaft flange (part of
Removal and Installation 4602)
3 Driveshaft flange bolt
4 Driveshaft slip yoke boot
(part of 4602) hoist. For additional information, refer to
Section 100-02.
5 Driveshaft flange bolt
4602)
(Continued)
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205-01-2 205-01-2 Driveshaft
2. Index-mark the driveshaft to maintain alignment
during installation.
4. CAUTION: The driveshaft flanges fit
tightly on the flange pilots. Never hammer
on the driveshaft or any of its components to
disconnect the driveshaft flanges from the
flange pilots. Pry only in the area shown
with a suitable tool, to disconnect the
driveshaft flanges from the flange pilots.
Using a suitable tool as shown, disconnect the
driveshaft flanges from the flange pilots and
remove the driveshaft.
3. Remove and discard the 8 driveshaft flange
bolts.
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205-01-3 205-01-3 Driveshaft
tightly on the pinion flange pilots. To make
sure that the driveshaft flanges seat squarely
on the pinion flange pilots, tighten the
driveshaft flange bolts evenly in a cross
pattern.
CAUTION: If new driveshaft flange
bolts are not available, coat the threads of
the original driveshaft flange bolts with
threadlock and sealer.
Install new fasteners.
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205-01-1 205-01-1 Driveshaft
Driveshaft 4.6L and 5.4L
Material
Item Specification
TA-25
2. Index-mark the driveshaft to maintain alignment
during installation.
1 4K177 Transmission output flange
4K145)
3 N800594-S100 Driveshaft flange bolt
4 N506434-S439 Center bearing bolt
5 W710432-S300 Spacer
6 Center bearing (part of
4K145)
7 4K145 Driveshaft assembly
8 W708259 Constant velocity (CV) joint
bolt (6 required)
9 4682 CV joint washer (3 required)
10 CV joint (part of 4K145)
Section 100-02.
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205-01-2 205-01-2 Driveshaft
tightly on the transmission flange pilot.
Never hammer on the driveshaft or any of its
components to disconnect the driveshaft
flange from the transmission flange pilot. Pry
only in the area shown, with a suitable tool,
to disconnect the driveshaft flange from the
transmission flange pilot.
driveshaft flange from the transmission flange
pilot.
3. Remove the 6 constant velocity (CV) joint bolts
and CV joint washers, then disconnect the CV
joint from the pinion flange.
Discard the CV joint bolts.
6. Remove the 2 center bearing bolts and spacers,
then remove the driveshaft.
Discard the center bearing bolts.
X Install the center bearing bolts finger tight
until after the front and rear flanges are
tightened to specifications.
4. Remove and discard the 4 driveshaft flange
bolts.
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205-01-3 205-01-3 Driveshaft
tightly on the transmission output flange
pilot. To make sure that the driveshaft flange
seat squarely on the transmission output
flange, tighten the driveshaft flange bolts
evenly in a cross pattern.
CAUTION: If new driveshaft flange
bolts are not available, coat the threads of
the original driveshaft flange bolts with
NOTE: Tighten the CV joint bolts evenly in a
star pattern.
Install new fasteners.
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205-01-1 205-01-1 Driveshaft
4. Remove and discard all 4 of the snap rings.
Driveshaft Universal Joint Snap
Ring Type
Special Tool(s)
Installer/Remover, C-Frame and
Screw
205-086 (T74P-4635-C)
Material
Item Specification
5. Place the special tool in a vise.
Grease
XG-1-C or XG-1-K (US);
CXG-1-C (Canada)
Disassembly
1. Remove the driveshaft. For additional
information, refer to Driveshaft 4.0L.
2. CAUTION: Do not, under any
circumstance, clamp the driveshaft assembly
in the jaws of a vise or similar holding
fixture. Denting or localized fracturing may
result, causing driveshaft failure during
vehicle operation.
Place the driveshaft on a suitable workbench.
Do not damage the tube.
3. NOTE: If the components are not marked and
therefore installed incorrectly, driveshaft
imbalance can occur.
Index-mark the driveshaft components.
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205-01-2 205-01-2 Driveshaft
6. NOTE: If necessary, use a pair of pliers to
remove a bearing cup that fails to press out all
the way.
Remove the bearing cups and the driveshaft slip
yoke.
1 Position the driveshaft slip yoke in the
special tool.
2 Press out a bearing cup.
3 Rotate the driveshaft slip yoke 180 degrees.
4 Press on the U-joint spider to remove the
remaining bearing cup.
Assembly
5 Remove the driveshaft slip yoke.
1. NOTE: Install the Universal Joint Kits as
complete assemblies only. Do not mix
components from other Universal Joint Kits.
NOTE: Lubricate the driveshaft slip yoke and
driveshaft yoke bearing cup bores with grease
before installing the bearing cups.
Install a new U-joint spider and bearing cup.
1 Start a new bearing cup in the driveshaft
yoke.
X Check the needle bearings for correct
positioning.
2 Position the new U-joint spider in the
7. Repeat steps to remove the remaining bearing
driveshaft yoke.
cups and the U-joint spider from the driveshaft
yoke.
3 Press the bearing cup to just below the snap
ring groove.
8. NOTE: Inspect the bearing cup bores and
retaining ring grooves. Remove any rust or
other surface irregularities.
Inspect the bearing cup bores of the driveshaft
slip yoke and driveshaft yoke. Make sure that
the bearing cup bores are clean and smooth.
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205-01-3 205-01-3 Driveshaft
5. Remove the driveshaft from the special tool and
2. CAUTION: Never mix yellow and
install a new yellow snap ring.
black snap rings on opposing sides.
Remove the shaft from the special tool and
install a new yellow snap ring.
6. CAUTION: Never mix yellow and
black snap rings on opposing sides.
3. Repeat steps to install the new bearing cup and Repeat steps to install the new bearing cup and
snap ring on the opposite side of the driveshaft snap ring on the opposite side of the driveshaft
yoke. slip yoke.
If the yellow snap ring will not seat in the If the yellow snap ring will not seat in the
snap ring groove, install the black snap snap ring groove, install the black snap
rings. rings.
4. Install the driveshaft slip yoke and new bearing
7. CAUTION: Do not strike the bearings.
cup.
A sharp rap on the driveshaft yoke with a brass
1 Align the index marks made during
or plastic hammer will seat the bearing cups.
disassembly and install the driveshaft slip
yoke on the U-joint spider.
2 Start a new bearing cup in the driveshaft
slip yoke.
X Check the needle bearings for correct
positioning.
3 Position the assembly in the special tool.
4 Press the bearing cup to just below the snap
ring groove.
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205-01-4 205-01-4 Driveshaft
8. Rotate the driveshaft yoke to make sure the 9. Install the driveshaft. For additional
universal joints are free to rotate easily, without information, refer to Driveshaft 4.0L.
binding, before installing the driveshaft.
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205-01-1 205-01-1 Driveshaft
The 4.6L drive shaft consists of a driveshaft
Driveshaft
centering socket yoke, a single-cardon universal
NOTE: All driveshaft assemblies are balanced. If
joint, a center bearing and 2 constant velocity
undercoating the vehicle, protect the driveshaft to
(CV) joints.
prevent overspray of any undercoating material.
The splined driveshaft slip yoke permits the
The driveshafts have the following features:
driveshaft to move forward and rearward during
A tubular shaft used to transfer engine torque drivetrain movement and during driveshaft
from the transmission output shaft to the removal and installation.
differential in the axle housing, which transmits
The staked universal joint driveshafts are not
torque through the axle shafts to the drive wheels.
serviced.
The 4.0L driveshaft consists of 2 driveshaft
centering socket yokes, 2 single-cardan universal
joints, a driveshaft slip yoke, a driveshaft slip
yoke boot, 2 driveshaft slip yoke boot clamps and
a welded tube assembly.
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205-01-1 205-01-1 Driveshaft
Driveshaft
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205-01-1 205-01-1 Driveshaft
SPECIFICATIONS
Driveshaft flange bolts 103 76
Item Specification
Center bearing bolts 48 35
Driveshaft constant velocity 55 41
Grease XG-1-C or
(CV) joint bolts
XG-1-K (US); CXG-1-C
(Canada) Exhaust pipe nuts 48 35
TA-25
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205-01-1 205-01-1 Driveshaft
Universal Joints Item Part Number Description
3 32 needle bearings (part of
The universal joints are:
4635)
lubed-for-life design and require no lubrication.
4 Thrust washer (part of 4635)
equipped with nylon thrust washers, located at
5 Bearing cup (part of 4635)
each base of the bearing cup, which control end
play, position the needle bearing and improve
grease movement.
1 4635 Universal joint (U-joint)
2 Grease seal (part of 4635)
(Continued)
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205-02A-1 205-02A-1 Rear Drive Axle/Differential Ford 7.5-Inch Ring Gear
IN-VEHICLE REPAIR
Axle Housing Bushing
1. Refer to upper suspension arm bushing in
Section 204-02.
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Axle Housing
All vehicles
1. CAUTION: The vehicle must be on
level ground and at curb height.
Mark the rear shock absorbers relative to their
protective sleeve.
During installation, raise the suspension to
this reference mark before tightening the
5. Remove and discard the 2 upper support brace
suspension fasteners.
bolts.
6. Remove and discard the 4 front support brace
Section 100-02.
bolts.
3. Remove the rear wheel and tire assemblies. For To install, tighten to 63 Nm (46 lb-ft).
Convertibles
4. Remove and discard the 4 rear support brace
bolts.
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All vehicles
7. NOTE: Using 2 screwdrivers through the
access hole, depress the tabs of the trackbar
cover retaining clip.
Remove the trackbar cover.
9. CAUTION: Secure the differential
housing to the transmission jack with a
suitable strap.
Support the differential housing with a suitable
transmission jack.
10. Remove and discard the shock absorber nuts
and shock absorber bolts.
8. NOTE: The suspension must be at ride height
when tightening suspension components.
Remove the trackbar bolts and trackbar flag
nuts, then the trackbar.
Discard the trackbar bolts and trackbar flag
nuts.
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11. Remove and discard the upper suspension arm 14. Disconnect the lower suspension arms from the
nut and upper suspension arm bolt. axle housing.
15. Lower the axle housing from the vehicle.
12. Lower the axle slightly, and remove the springs.
16. CAUTION: Raise the suspension to the
reference marks on the rear shock absorbers
before tightening the suspension fasteners.
Install new fasteners as listed:
X Rear support brace bolts.
X Upper support brace bolts.
X Front support brace bolts.
X Trackbar bolts.
X Trackbar flag nuts.
X Shock absorber bolts.
X Shock absorber nuts.
13. Remove and discard the trailing arm nuts and
trailing arm bolts. X Upper suspension arm bolts.
To install, tighten to 175 Nm (129 lb-ft). X Upper suspension arm nuts.
X Trailing arm bolts.
X Trailing arm nuts.
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IN-VEHICLE REPAIR
Axle Shaft
Material
Item Specification
Grease
CXG-1-C (Canada)
TA-25
High Temperature Nickel ESE-M12A4-A
Anti-Seize Lubricant
XL-2 (US); CXG-2-B
(Canada)
6 4211 Differential pinion shaft 1 4346 Differential housing cover
bolt
7 4N237 Axle shaft U-washer
2 4033 Differential housing cover
8 4234 Axle shaft
3 Disc brake caliper
9 1177 Axle shaft seal
4 Brake disc
10 1225 Axle shaft bearing
5 4241 Differential pinion shaft lock
bolt
(Continued)
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IN-VEHICLE REPAIR (Continued)
Removal
Section 100-02.
3. Remove the differential housing cover. For
additional information, refer to Differential
Housing Cover in this section.
4. Remove the 2 disc brake caliper bolts, then 7. Remove the brake disc.
position aside the disc brake caliper.
Using mechanics wire, support the disc
brake caliper.
8. CAUTION: Damage to the rear brake
anti-lock sensor may occur if it is not
removed before the axle shaft U-washer.
5. Remove the disc brake pads.
Remove the anti-lock sensor bolt, then the
anti-lock sensor from the hub.
6. Remove the 2 disc brake caliper anchor bolts
and the disc brake caliper anchor.
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9. Remove the differential pinion shaft.
1 Remove and discard the differential pinion
shaft lock bolt.
2 Remove the differential pinion shaft.
Installation
1. Lubricate the lip of the axle shaft oil seal with
grease.
2. CAUTION: Do not damage the axle
10. CAUTION: Do not damage the rubber
shaft oil seal when installing the axle shaft.
O-ring in the axle shaft grooves.
Install the axle shaft.
Remove the axle shaft U-washer.
1 Push in on the axle shaft.
2 Remove the U-washer.
shaft oil seal.
Remove the axle shaft.
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5. NOTE: Be sure to apply High Temperature
Nickel Anti-Seize Lubricant.
O-ring in the U-washer groove.
Install the anti-lock sensor and the anti-lock
Install the axle shaft U-washer.
sensor bolt.
1 Position the U-washer on the button end of
the axle shaft.
2 Pull the axle shaft outward.
6. Install the brake disc.
4. NOTE: If a new differential pinion shaft lock
bolt is unavailable, coat the threads of the old
differential pinion shaft lock bolt with
Threadlock and Sealer.
Install the differential pinion shaft.
Align the hole in the differential pinion
shaft with the differential case lock bolt
hole.
Install a new differential pinion shaft lock
bolt.
X Tighten to 30 Nm (22 lb-ft).
7. Install the disc brake caliper anchor, then install
the 2 disc brake caliper anchor bolts.
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8. Install the disc brake pads.
10. Install the differential housing cover. For
9. Install the disc brake caliper and the 2 disc
brake caliper bolts.
11. Install the tire and wheel assembly. For
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IN-VEHICLE REPAIR
Special Tool(s)
Differential Bearings
Installer, Differential Shim
205-220 (T85L-4067-AH)
Special Tool(s)
Protector, Drive Pinion Thread
205-460
Dial Indicator Gauge With
Bracketry
100-002 (TOOL-4201-C)
2-Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent
Installer, Drive Pinion Oil Seal
205-208 (T83T-4676-A)
Step Plate
205-D061 (D80L-630-5) or
equivalent
Puller, Bearing
205-D064 (D84L-1123-A) or
equivalent
Installer, Drive Pinion Flange
205-002 (TOOL-4858-E)
Installer, Drive Pinion Bearing
Cup
205-054 (T71P-4616-A)
Holding Fixture, Drive Pinion
Flange
205-126 (T78P-4851-A)
Adapter for 205-S127
205-105 (T76P-4020-A3)
Installer, Differential Side
Bearing
205-009 (T57L-4221-A1)
205-109 (T76P-4020-A9)
(Continued)
(Continued)
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Special Tool(s) Material
Adapter for 205-S127 Item Specification
205-110 (T76P-4020-A10)
Stud and Bearing Mount WSK-M2G349-A1
TA-27
Removal
1. Remove the differential carrier. For additional
information, refer to Differential Carrier in this Adapter for 205-S127
205-111 (T76P-4020-A11) section.
2. Index-mark the driveshaft flange and pinion
flange for correct alignment during installation.
205-125 (T78P-4020-A15)
Gauge Tube
205-D034 (D80T-4020-F49) or
equivalent
3. Remove the 4 driveshaft flange bolts.
Cone
205-005 (T53T-4621-C)
Plate, Bearing/Oil Seal
205-090 (T75L-1165-B)
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4. CAUTION: The driveshaft centering
socket yoke fits tightly on the pinion flange
pilot. Never hammer on the driveshaft or
any of its components to disconnect the
driveshaft centering socket yoke from the
pinion flange. Pry only in the area shown
with a suitable tool to disconnect the
pinion flange.
pinion flange.
Using mechanics wire, position the
7. Using the special tool, remove the pinion
driveshaft aside.
flange.
8. Using a screwdriver, force up the rear axle
5. CAUTION: Discard the nut after
drive pinion seal metal flange.
removal. Use a new nut during installation.
Use the special tool to hold the pinion flange
while removing the drive pinion nut.
6. Index-mark the pinion flange and the drive
pinion stem for correct alignment during
installation.
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9. Using gripping pliers and a hammer, remove 14. Using the special tool and a suitable press,
the axle drive pinion seal. remove the inner pinion bearing.
10. Remove the axle drive pinion shaft oil slinger. 15. Using a brass drift, remove the pinion bearing
cups by tapping alternately on opposite sides of
11. Using the special tool and a soft-faced hammer,
the bearing cups.
drive the pinion assembly out of the outer
pinion bearing and remove it through the rear
of the differential housing.
12. Remove the outer pinion bearing.
13. Remove the drive pinion collapsible spacer and
discard it.
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16. Using the special tools, remove the differential
bearings.
2. Tighten the special tool to seat the drive pinion
bearing cups into their bores.
3. NOTE: If a feeler gauge can be inserted
Installation
between a drive pinion bearing cup and the
bottom of its bore at any point around the drive
1. Position the special tool and the inner and outer
pinion bearing cup, the drive pinion bearing cup
drive pinion bearing cups in their respective
is not correctly seated.
bores.
Make sure the drive pinion bearing cups are
1 After placing the inner and outer drive
correctly seated in their bores.
pinion bearing cups in their bores, place the
special tool (inner) on the inner drive pinion
bearing cup.
2 Place the special tool (outer) on the outer
drive pinion bearing cup.
3 Install the special tool.
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4. NOTE: Install new drive pinion bearings 6. NOTE: The special tool must be offset to
without any additional lubricant since the obtain an accurate reading.
anti-rust oil provides adequate lubricant without
Rotate the special tool several half-turns to
upsetting the drive pinion bearing preload
make sure of correct seating of the drive pinion
settings.
bearings and position the special tool.
Assemble and position the special tools in the
sequence shown.
7. Install the special tool.
1 Position the special tool.
5. NOTE: This step duplicates final drive pinion
2 Install the differential bearing caps.
bearing preload.
3 Install the 4 differential bearing cap bolts.
Tighten the special tool.
Tighten to 2.2 Nm (20 lb-in).
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8. NOTE: Drive pinion bearing adjustment shims 10. Install a new drive pinion collapsible spacer on
must be flat and clean. the pinion shaft against the pinion shaft
shoulder.
NOTE: A slight drag should be felt for correct
drive pinion bearing adjustment shim selection.
Do not attempt to force the drive pinion bearing
adjustment shim between the gauge block and
the gauge tube. This will minimize selection of
a drive pinion bearing adjustment shim thicker
than required, which results in a deep tooth
contact in final assembly of integral axle
assemblies.
Use a drive pinion bearing adjustment shim as a
gauge for drive pinion bearing adjustment shim
selection.
After the correct drive pinion bearing
adjustment shim thickness has been
11. Install the outer drive pinion bearing and the
determined, remove all of the special tools.
drive pinion shaft oil slinger.
9. Using the special tool, press the inner drive
12. Using the special tools, install the drive pinion
pinion bearing and drive pinion bearing
seal.
adjustment shim until it is firmly seated on the
pinion shaft.
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13. Install the drive pinion assembly into the axle
housing.
circumstance, loosen the drive pinion nut to
reduce pinion bearing preload. If it is
necessary to reduce the preload, install a new
drive pinion collapsible spacer and drive
pinion nut.
CAUTION: Remove the special tool
while taking rotational pinion bearing
preload checks with the Nm (lb-in) torque
wrench.
while tightening the pinion nut.
Rotate the pinion occasionally to make sure
the differential pinion bearings are seating
correctly. Take frequent differential pinion
bearing preload checks by rotating the
flange.
differential pinion with a Nm (lb-in) torque
wrench. Tighten the pinion nut in small
increments to avoid excessive pinion bearing
preload. Tighten the pinion nut until the
drive pinion bearing preload is in
specification.
X Tighten to a rotational torque of 1.8-3.3
Nm (16-29 lb-in).
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16. Using the special tool, install the new
19. CAUTION: Always install the bearing
differential bearings.
caps in their original locations and positions.
NOTE: Apply pressure toward the LH side to
make sure the left differential bearing cup seats
correctly.
Install the LH bearing cap and loosely install
the bolts.
17. Position the differential carrier assembly and
the new differential bearing cups in the
differential housing.
20. Install progressively larger differential bearing
shims on the RH side until the largest shim is
installed by hand.
18. Install a differential bearing shim of the shown
dimension on the left side.
21. Install the RH side bearing cap and bolts.
Tighten the left and right bearing cap bolts.
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22. Rotate the differential carrier several times to 25. To correct for high or low backlash, increase
verify the differential bearings have seated the thickness of one differential bearing shim
correctly. and decrease the thickness of the other
differential bearing shim by the same amount.
Refer to the following tables when adjusting the
backlash. When the backlash is within
specification, proceed to Step 26.
Backlash Change Thickness Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
23. Install the special tools and measure the ring
0.152 0.006 0.203 0.008
gear backlash.
0.177 0.007 0.254 0.010
If the backlash is within specification,
0.203 0.008 0.254 0.010
proceed to Step 26.
0.228 0.009 0.304 0.012
If a zero backlash condition occurs, proceed
0.254 0.010 0.355 0.014
to Step 24.
0.279 0.011 0.355 0.014
If the backlash is not within specification,
0.304 0.012 0.406 0.016
proceed to Step 25.
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart 4067
Dimension A
Stripes and
mm Inch Color Code
2 C-COAL 7.7978-7.8105 0.3070-0.3075
1 C-COAL 7.7470-7.7597 0.3050-0.3055
5 BLU 7.6962-7.7089 0.3030-0.3035
4 BLU 7.6454-7.6581 0.3010-0.3015
24. If a zero backlash condition occurs, add 0.50 3 BLU 7.5946-7.6073 0.2990-0.2995
mm (0.020 in) to the RH side shim and subtract
2 BLU 7.5458-7.5565 0.2970-0.2975
0.50 mm (0.020 in) from the LH side shim to
5 PINK 7.4422-7.4549 0.2930-0.2935
allow a backlash indication. Go back to Step
4 PINK 7.3914-7.4041 0.2910-0.2915
23.
3 PINK 7.3406-7.3533 0.2890-0.2895
2 PINK 7.2898-7.3025 0.2870-0.2875
1 PINK 7.2390-7.2517 0.2850-0.2855
5 GRN 7.1882-7.2009 0.2830-0.2835
4 GRN 7.1374-7.1501 0.2810-0.2815
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Differential Shim Size Chart 4067 (Continued)
28. Using the special tool, fully seat the differential
bearing shims. Make sure the assembly rotates
Dimension A
Stripes and
freely.
mm Inch Color Code
3 GRN 7.0866-7.0993 0.2790-0.2795
2 GRN 7.0358-7.0485 0.2770-0.2775
1 GRN 6.9850-7.0485 0.2750-0.2755
5 WH 6.9342-6.9469 0.2730-0.2735
4 WH 6.8834-6.8961 0.2710-0.2715
3 WH 6.8326-6.8453 0.2690-0.2695
2 WH 6.7818-6.7945 0.2670-0.2675
1 WH 6.7310-6.7437 0.2650-0.2655
5 YEL 6.6802-6.6929 0.2630-0.2635
4 YEL 6.6294-6.6421 0.2610-0.2615
3 YEL 6.5786-6.5913 0.2590-0.2595
29. Install the bearing caps and bolts.
2 YEL 6.5278-6.5405 0.2570-0.2575
1 YEL 6.4770-6.4897 0.2550-0.2555
5 ORNG 6.4262-6.4389 0.2530-0.2535
4 ORNG 6.3754-6.3881 0.2510-0.2515
3 ORNG 6.3246-6.3373 0.2490-0.2495
2 ORNG 6.2738-6.2865 0.2470-0.2475
1 ORNG 6.2223-6.2357 0.2450-0.2455
2 RED 6.1722-6.1849 0.2430-0.2435
1 RED 6.1214-6.1341 0.2410-0.2415
26. Remove the bearing cap bolts and bearing caps.
27. To establish differential bearing preload,
increase both LH and RH differential bearing
30. Using the special tools, recheck the ring gear
shim size by the thickness shown.
backlash.
31. Apply marking compound and rotate the
differential assembly 5 complete revolutions.
32. Verify an acceptable pattern check.
33. Install the axle shafts. For additional
information, refer to Axle Shaft in this section.
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34. Position the driveshaft and align the index
marks on the pinion flange.
pilot. To make sure that the driveshaft
centering socket yoke seats squarely on the
pinion flange, tighten the driveshaft flange
bolts evenly in a cross pattern.
Install the driveshaft flange bolts.
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Differential Carrier
Special Tool(s)
205-220 (T85L-4067-AH)
Removal
Installation
1. Remove the axle shafts. For additional
1. Position the differential assembly in the axle
housing.
2. CAUTION: Index-mark the position of
the differential bearing caps, as arrows may
not be visible. The differential bearing caps
must be installed in their original locations
and positions.
Remove the 4 differential bearing cap bolts and
the 2 differential bearing caps.
2. Install the originally removed differential
bearing shim on the LH side.
3. WARNING: Be careful not to allow
the differential assembly to fall.
CAUTION: Place a wood block
between the pry bar and the axle housing to
protect the machined surface from damage.
CAUTION: Index-mark the position of
the differential bearing shims. The
differential bearing shims must be installed
in their original locations and positions.
Using pry bars and wood blocks, remove the
differential carrier assembly from the axle
housing.
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3. NOTE: Apply pressure toward the LH side to 6. Install the RH side differential bearing cap and
make sure the LH differential bearing cap is tighten the LH side and RH side differential
seated. bearing cap bolts.
Install the LH differential bearing cap and Tighten to 105 Nm (77 lb-ft).
loosely install the differential bearing cap bolts.
7. Rotate the differential assembly to make sure it
4. Install the original differential bearing shim on rotates freely.
the RH side.
8. Measure the ring and pinion backlash.
bearing shims.
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Differential Case and Ring Gear
Special Tool(s)
2-Jaw Puller
205-D072 (D97L-4221-A) or
equivalent
Step Plate
205-D016 (D80L-630-5) or
equivalent
Bearing
205-009 (T57L-4221-A1)
Material
Item Specification
Motorcraft 75W-140 WSL-M2C192-A
Synthetic Rear Axle
Lubricant
XY-75W-140-QL (US);
CXY-75W140-1L
(Canada)
TA-25
TA-27
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2. Remove the 10 differential ring gear bolts.
1 4236 Differential side gear
2 4228 Differential side gear thrust
washers
3 4215 Differential pinion gear
4 4230 Differential pinion thrust
washer
6 4209 Differential ring gear
bolt
8 4211 Differential pinion shaft
9 4204 Differential case
10 4216 Differential ring gear bolts
11 4221 Differential bearing
12 4222 Differential bearing cup
Disassembly
1. Remove the differential case. For additional
information, refer to Differential Carrier in this
section.
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differential ring gear bolt hole threads.
Insert a punch in the differential ring gear bolt
holes and drive the differential ring gear off.
7. Rotate and remove the differential pinion gears
and differential pinion gear thrust washers.
bearings.
8. Remove the differential side gears and the
differential side gear thrust washers.
5. Remove the differential pinion shaft lock bolt.
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Assembly
4. Install the differential pinion gears and
differential pinion gear thrust washers opposite
the differential side gears.
1. Lubricate the differential side gear thrust
washer and the differential side gear journals
with axle lube, then position the differential
side gear thrust washers on the differential side
gears.
5. Rotate the differential pinion gears to align with
the differential pinion shaft bore.
2. Install the differential side gears.
6. Install the differential pinion shaft.
shaft with the hole in the differential case.
3. Using axle lubricant, lubricate the differential
pinion gear thrust washers and the differential
pinion gears.
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bolt is unavailable, coat the threads with
Threadlock and Sealer.
Install a new differential pinion shaft lock bolt
and finger-tighten.
10. Apply Stud and Bearing Mount to the
differential ring gear bolt threads and install the
differential ring gear bolts.
8. Using the special tool, install new differential
bearings.
11. Install the differential case. For additional
section.
9. Press the differential ring gear on the
differential assembly.
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IN-VEHICLE REPAIR
Installation
Differential Housing Cover
Material 1. CAUTION: Make sure the machined
surfaces on both the differential housing and
Item Specification
the differential housing cover are clean and
Motorcraft SAE 75W-140 WSL-M2C192-A
free of oil before applying the new silicone
Synthetic Rear Axle
sealant. To prevent contamination, cover the
Lubricant
inside of the axle prior to cleaning the XY-75W140-QL (US);
CXY-75W140-1L machined surface.
(Canada)
Clean the differential housing and the
Silicone Gasket and WSE-M4G323-A4
differential housing cover gasket mating
Sealant
surfaces.
TA-30
Removal
2. CAUTION: Install the differential
housing cover within 15 minutes of applying
the silicone sealant, or it will be necessary to
remove and reapply new silicone sealant.
Section 100-02.
Apply a continuous bead of silicone sealant of
the specified thickness to the differential
2. Remove the differential housing cover.
housing cover.
1 Remove the 10 differential housing cover
bolts and drain the lubricant from the axle
housing.
2 Remove the differential housing cover.
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3. NOTE: The differential housing cover must be
4. CAUTION: When filling the axle it
installed within 15 minutes of application of the
must be done on a level surface with the
silicone sealant, or new silicone sealant must be
vehicle at ride height.
applied. If possible, allow one hour before
NOTE: In-vehicle repair refill capacities are
filling the axle housing with axle lubricant to
determined by filling the axle with the specified
make sure the silicone sealant has correctly
lubricant to 11.1-12.7 mm (7/16-1/2 in) below
cured.
the bottom of the fill hole.
Install the differential housing cover and the 10
Fill the axle to the level shown, approximately
differential housing cover bolts.
1.42 liters (3.0 pints) of axle lubricant, and
install the filler plug.
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IN-VEHICLE REPAIR
Special Tool(s)
Differential Ring And Pinion
Bracketry
Special Tool(s)
100-002 (TOOL-4201-C)
205-460
205-220 (T85L-4067-AH)
2-Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent
Bearing
205-009 (T57L-4221-A1)
Step Plate
205-D016 (D80L-630-5) or
equivalent
Cup
205-054 (T71P-4616-A)
205-002 (TOOL-4858-E)
205-105 (T76P-4020-A3)
Flange
205-126 (T78P-4851-A)
205-109 (T76P-4020-A9)
205-208 (T83T-4676-A)
205-110 (T76P-4020-A10)
(Continued)
(Continued)
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Special Tool(s)
205-111 (T76P-4020-A11)
205-125 (T78P-4020-A15)
differential ring gear bolt hole threads.
Gauge Tube
205-D034 (D80T-4020-F49) or
equivalent
Cone
205-005 (T53T-4621-C)
Plate, Bearing/Oil Seal
205-090 (T75L-1165-B)
bearings.
Material
Item Specification
TA-27
Removal
section.
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8. Using the special tool to hold the pinion flange,
remove and discard the pinion nut.
flange.
pinion flange.
pinion flange.
driveshaft aside.
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10. Force up on the metal flange of the drive 14. Using a brass drift, remove the drive pinion
pinion seal. Install gripping pliers and strike bearing cups by tapping alternately on opposite
with a hammer until the drive pinion seal is sides of the drive pinion bearing cups.
removed.
Installation
11. Remove the drive pinion shaft oil slinger and
the outer drive pinion bearing. 1. Position the special tool and the inner and outer
12. Install the special tool. Using a soft-faced
bores.
hammer, drive the pinion assembly out of the
axle housing.
bearing cup.
13. Remove and discard the drive pinion collapsible
spacer.
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bearing preload.
6. NOTE: The special tool must be offset to
obtain an accurate reading.
4. NOTE: Install new drive pinion bearings
without any additional lubricant since the
settings.
Assemble and position the special tools in the
sequence shown.
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7. Install the special tool. 9. Using the special tool, press the inner drive
pinion bearing and drive pinion bearing
adjustment shim until it is firmly seated on the
pinion shaft.
10. Install a new drive pinion collapsible spacer on
the pinion shaft against the pinion shaft
shoulder.
8. NOTE: Drive pinion bearing adjustment shims
must be flat and clean.
assemblies.
selection.
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seal.
pinion nut.
wrench.
housing.
specification.
X Tighten to a rotational torque of 1.8-3.3
Nm (16-29 lb-in).
flange.
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16. Using the special tool, install the new 19. Position the differential carrier assembly and
differential bearings. the new differential bearing cups in the
17. Press the differential ring gear on the
differential assembly. 20. Install a differential bearing shim of the shown
dimension on the LH side.
18. NOTE: Apply stud and bearing mount to the
Install the differential ring gear bolts.
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NOTE: Apply pressure toward the left side to
make sure the LH differential bearing cup seats
correctly.
the bolts.
gear backlash.
proceed to Step 28.
to Step 26.
proceed to Step 27.
installed by hand.
26. If a zero backlash condition occurs, add 0.50
23. Install the right side bearing cap and bolts.
Tighten the LH and RH bearing cap bolts.
25.
24. Rotate the differential carrier several times to
verify the differential bearings have seated
correctly.
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27. To correct for high or low backlash, increase
the thickness of one differential bearing shim
Dimension A
Stripes and
and decrease the thickness of the other
mm Inch Color Code
4 GRN 7.1374-7.1501 0.2810-0.2815
3 GRN 7.0866-7.0993 0.2790-0.2795 backlash. When the backlash is within
2 GRN 7.0358-7.0485 0.2770-0.2775
1 GRN 6.9850-7.0485 0.2750-0.2755
Required Required 5 WH 6.9342-6.9469 0.2730-0.2735
mm Inch mm Inch 4 WH 6.8834-6.8961 0.2710-0.2715
0.025 0.001 0.050 0.002 3 WH 6.8326-6.8453 0.2690-0.2695
0.050 0.002 0.050 0.002 2 WH 6.7818-6.7945 0.2670-0.2675
0.076 0.003 0.101 0.004 1 WH 6.7310-6.7437 0.2650-0.2655
0.101 0.004 0.152 0.006 5 YEL 6.6802-6.6929 0.2630-0.2635
0.127 0.005 0.152 0.006 4 YEL 6.6294-6.6421 0.2610-0.2615
0.152 0.006 0.203 0.008 3 YEL 6.5786-6.5913 0.2590-0.2595
0.177 0.007 0.254 0.010 2 YEL 6.5278-6.5405 0.2570-0.2575
0.203 0.008 0.254 0.010 1 YEL 6.4770-6.4897 0.2550-0.2555
0.228 0.009 0.304 0.012 5 ORNG 6.4262-6.4389 0.2530-0.2535
0.254 0.010 0.355 0.014 4 ORNG 6.3754-6.3881 0.2510-0.2515
0.279 0.011 0.355 0.014 3 ORNG 6.3246-6.3373 0.2490-0.2495
0.304 0.012 0.406 0.016 2 ORNG 6.2738-6.2865 0.2470-0.2475
0.330 0.013 0.457 0.018 1 ORNG 6.2223-6.2357 0.2450-0.2455
0.335 0.014 0.457 0.018 2 RED 6.1722-6.1849 0.2430-0.2435
0.381 0.015 0.508 0.020 1 RED 6.1214-6.1341 0.2410-0.2415
Dimension A
Stripes and
mm Inch Color Code
2 C-COAL 7.7978-7.8105 0.3070-0.3075
1 C-COAL 7.7470-7.7597 0.3050-0.3055
5 BLU 7.6962-7.7089 0.3030-0.3035
4 BLU 7.6454-7.6581 0.3010-0.3015
3 BLU 7.5946-7.6073 0.2990-0.2995
2 BLU 7.5458-7.5565 0.2970-0.2975
5 PINK 7.4422-7.4549 0.2930-0.2935
4 PINK 7.3914-7.4041 0.2910-0.2915
3 PINK 7.3406-7.3533 0.2890-0.2895
2 PINK 7.2898-7.3025 0.2870-0.2875
1 PINK 7.2390-7.2517 0.2850-0.2855
5 GRN 7.1882-7.2009 0.2830-0.2835
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30. Using the special tool, fully seat the differential 35. Install the axle shafts. For additional
bearing shims. Make sure the assembly rotates information, refer to Axle Shaft in this section.
freely.
backlash.
34. Verify an acceptable pattern check.
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IN-VEHICLE REPAIR
Special Tool(s)
Drive Pinion Flange and Drive Pinion
Seal
205-133 (T79P-4676-A)
Special Tool(s)
Flange
205-126 (T78P-4851-A)
205-002 (TOOL-4858-E)
2-Jaw Puller
205-D072 (D97L-4221-A) or
equivalent
Material
Item Specification
(Continued)
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Grease
CXG-1-C (Canada)
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and the 2 disc brake caliper anchors.
1 389546-S100 Pinion nut
3 4859 Deflector
4 4676 Drive pinion seal
Removal
Section 100-02.
2. NOTE: The wheels and disc brake calipers
must be removed to prevent brake drag during
drive pinion bearing preload adjustment.
6. Remove the 2 brake discs.
Remove the wheel and tire assembly. For
3. Remove the 4 disc brake caliper bolts and the 2
disc brake calipers.
Using mechanics wire, support the 2 disc
brake calipers.
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pinion flange.
pinion flange.
driveshaft aside.
12. Index-mark the pinion flange in relation to the
drive pinion stem to make sure of correct
alignment during installation.
10. Using a Nm (lb-in) torque wrench on the pinion
nut, record the torque required to maintain
rotation of the pinion gear through several
revolutions.
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flange.
3. Lubricate the pinion flange splines with axle
lubricant.
14. Force up on the metal flange of the drive 4. NOTE: Disregard the scribe marks if a new
pinion seal. Install gripping pliers and strike pinion flange is being installed.
with a hammer until the drive pinion seal is
Align the index marks on the pinion flange with
removed.
the drive pinion shaft.
Installation
5. Using the special tool, install the pinion flange.
1. Lubricate the new drive pinion seal with grease.
2. CAUTION: If the new drive pinion
seal becomes misaligned during installation,
remove the drive pinion seal and install a
new drive pinion seal.
Using the special tool, install a new drive
pinion seal.
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6. Position the new pinion nut.
8. Position the driveshaft to the pinion flange and
align the index marks made during removal.
7. CAUTION: Under no circumstances is
the pinion nut to be backed off to reduce
drive pinion bearing preload. If reduced
drive pinion bearing preload is required, a
new drive pinion collapsible spacer and
pinion nut must be installed.
while taking drive pinion bearing preload
readings with the Nm (lb-in) torque wrench.
Using the special tool to hold the pinion flange,
tighten the pinion nut.
Rotate the drive pinion occasionally to make
sure the drive pinion bearings are seating
correctly.
Install a Nm (lb-in) torque wrench on the
pinion nut.
Rotating the drive pinion through several
revolutions, take frequent drive pinion
bearing preload readings until the original
Install the 4 driveshaft flange bolts.
recorded drive pinion bearing preload
reading is obtained.
If the original recorded drive pinion bearing
preload is lower than specifications, tighten
to the appropriate specifications. If the drive
pinion bearing preload is higher than
specification, tighten the pinion nut to the
original reading as recorded. For additional
information, refer to the Specifications
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10. Install the 2 brake discs.
13. Install the 2 disc brake calipers and the 4 disc
11. Install the 2 disc brake caliper anchors, then
install the 4 disc brake caliper anchor bolts.
14. Install the wheel and tire assembly. For
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Rear Drive Axle and Differential
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32 4628 Drive pinion bearing cup 1 4236 Differential side gears
(inner)
2 4228 Differential side gear thrust
33 4630 Drive pinion bearing (inner) washers
34 Drive pinion gear (part of 3 4221 Differential bearings
4209)
4 4222 Differential bearing cups
35 4663 Drive pinion bearing
5 4067 Differential bearing shims
adjustment shim
6 4216 Differential ring gear bolt (10
36 Differential bearing cap bolt
required)
(4 required) (part of 4010)
8 Differential ring gear (part of
bolt
4209)
9 Differential bearing cap (2
39 4N237 Axle shaft U-washers
required) (part of 4010)
10 4010 Axle housing
bolt (10 required)
11 373098-S Filler plug
41 Axle identification tag
12 4662 Drive pinion collapsible
spacer
43 4230 Differential pinion gear thrust
13 4670 Drive pinion shaft oil slinger
washers
44 4215 Differential pinion gears
The axle housing consists of a cast center section
with 2 steel tube assemblies and a stamped
17 4621 Drive pinion bearing (outer)
differential housing cover. The differential
18 2C026 Brake disc
housing cover uses silicone sealant as a gasket.
19 Axle shaft flange (2 required)
The hypoid-design gearset consists of 7.5-in ring
(part of 4234)
gear and a drive pinion gear. Two opposed
20 2C189 Anti-lock sensor indicator (2
tapered roller bearings (drive pinion bearings)
required)
support the drive pinion in the axle housing.
21 2552 Disc brake caliper (2
required) A drive pinion collapsible spacer, located on the
differential pinion shaft, maintains drive pinion
22 N601951-S2 Brake line clip bolt
bearing preload. The pinion nut adjusts the drive
23 N804361-S100 Brake line clip
pinion bearing preload.
24 Anti-lock sensor bolt (2
required) Differential bearing shims, located between the
differential bearing cups and the axle housing,
25 2C190 Anti-lock sensor (2 required)
adjust the differential bearing preload and the
26 2C101 LH disc brake adapter
differential ring gear backlash.
27 2C100 RH disc brake adapter
The differential case is a one-piece design with 2
28 N8015163-S190 Disc brake caliper anchor bolt
openings to allow for assembly of the internal
(4 required)
components and lubricant flow. Two opposed
29 2C028 Brake disc shield (2 required)
tapered roller bearings (differential bearings)
30 N602726-S2 Brake disc shield bolt (6
support the differential assembly in the axle
required)
housing. Removable bearing caps retain the
31 4616 Drive pinion bearing cup
differential assembly in the axle housing.
(outer)
(Continued)
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Inside the differential assembly, the differential
pinion shaft supports 2 differential pinion gears.
The pinion gears engage the differential side
gears, to which the axle shafts are splined. The
differential pinion shaft lock bolt retains the
differential pinion shaft in the differential case.
An embossed metal tag, bolted to the differential
housing cover, contains the axle identification.
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5 Are there any special conditions affecting
the concern or will alter the concern? For
Special Tool(s)
example:
Dial Indicator Gauge with X road speed.
Holding Fixture
X type of road.
100-002 (TOOL-4201-C) or
equivalent X drive mode.
X temperature.
X vehicle loaded or unloaded.
6 Is the condition constant or intermittent?
Can the concern be duplicated at any time? Inspection and Verification
7 Check for TSBs, SSM and OASIS
messages.
Section 100-02.
3. NOTE: If the inspection reveals an obvious
concern, repair the vehicle.
The technician should have a thorough knowledge
of driveline system operation and accepted general
Do a preliminary investigation. Visually inspect
driveline guidelines to detect any problems.
for obvious signs of damage.
A gear driven unit will produce a certain amount of
1 Inspect the driveshaft:
noise. Some noise is acceptable and audible at
X for build up of any foreign material.
certain speeds or under various driving conditions.
X for damage, such as a bent tube or
Certain conditions, such as road conditions and
missing weights.
weather, will amplify normal vehicle noise.
X U-joints or flex couplers for wear or
Certain rear axle and driveline concern symptoms
damage.
are also common to the engine, transmission, rear
wheel bearings and tire. For this reason, be sure the
2 Inspect the axle:
cause of the concern is in the axle before repairing
X for signs of leakage at the drain or fill
or installing any axle components.
plug, differential seal, vent or halfshaft
The following is a guide to diagnose a driveline
seals.
concern:
a plugged vent or vent tube will
cause a leak.
Verify and document the customer concern.
X for damage, such as cracks, bent
Carry out a preliminary investigation.
halfshafts or dented rear cover.
Road test the vehicle.
X for missing fasteners.
Find the cause of the problem.
3 Inspect other suspect components/systems:
Inspect the components.
X inspect the halfshaft assemblies for
2. Verify and document the customer concern.
damaged CV joints or torn CV boots
1 When was it first noticed?
X inspect the suspension for broken springs,
2 Did it appear suddenly or gradually?
damaged shock absorbers and worn
3 Did anything unusual occur that would suspension bushings.
coincide with it or precede it?
X inspect the rear brake components
4 Has the driveline system been repaired lines, cables and calipers.
before or new components installed?
X inspect the tires; are they in good
X Check the vehicle service record. Note condition and do they match?
any repairs other than driveline, such as
brakes or suspension.
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Diagnostic Routine Chart (Continued)
4. NOTE: A road test is necessary for any
customer concern of noise or vibration.
Condition Action
Axle noise GO to Diagnostic
(chatter/shudder)
a
in Routine Noise
1 During the road test, use the following
tight turn, limited slip (Chatter/Shudder) In
driving methods to diagnose the problem. Is
differential Tight Turns, Limited
the concern most noticeable:
Slip Differential
X from a stop?
Axle noise (whine)
a
in GO to Diagnostic
all or more than one Routine Noise
X on shifts from REVERSE to DRIVE?
drive mode (Whine) In All Or More
X on turns? Than One Drive Modes
sweeping type turn. Axle noise (tick/click)
a
GO to Diagnostic
in all or more than one Routine Noise
tight turn (to the stop).
drive mode (drive, (Tick/Click) In All Or
cruise, coast) More Than One Drive X in DRIVE?
Modes
accelerating the vehicle, definite
throttle depression, applying engine
(howl/moan)
a
in all or Routine Noise
torque?
more than one drive (Howl/Moan) In All Or
mode (drive, cruise, More Than One Drive X in CRUISE?
coast) Modes
maintain a constant speed with the
Axle noise (clunk)
a
on GO to Diagnostic
throttle applied?
changes in speed or Routine Noise
X in COAST? direction of power (Clunk) On Changes In
Speed Or Direction Of
decelerating with the throttle closed?
Power
2 Record when the concern occurs. Write
Vibration For information on
down the kp/h (mph) range at which the
driveline vibration
noise/vibration occurs. diagnostics, REFER to
Section 100-04.
5. Find the cause of the problem.
1 Compare the inspection and road test results
a. Refer to Section 100-04 for a glossary of
with the following chart.
noise-related terms.
2 Use the following diagnostic routine chart
6. NOTE: If the conclusion of the road test points
to identify the probable cause and know
to an axle center section (ring and pinion or
what corrective actions should be taken to
differential case) concern, carry out a visual
repair the component/vehicle, and to prevent
inspection of the axle.
a reoccurrence.
Inspect the axle components.
Diagnostic Routine Chart
Condition Action
Drain the axle lubricant through a white
cloth. Check the fluid for: Fluid loss GO to Diagnostic
Routine Fluid Loss
X any foreign material.
Noise louder on turns GO to Diagnostic
X metal particles.
(sweeping turn) Routine Noise
Louder On Turns X burnt odor.
(Sweeping)
2 NOTE: When inspecting the axle, do not
Axle noise (growl)
a
in GO to Diagnostic
clean the components immediately. Cleaning
tight turn Routine Noise
may remove diagnostic evidence.
(Growl) In Tight Turn
X Look for:
loose fasteners.
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notches or visible steps or grooves notches or visible steps or grooves
created by wear. created by wear.
pitting or cracking along gear contact pitting or cracking along gear contact
lines. lines.
scuffing or deformations. scuffing or deformations.
discolorations. discolorations.
nicks or ridges on gear teeth. nicks or ridges on gear teeth.
X Clean the axle components for inspection. X Check backlash and carry out a ring and
pinion pattern test. Refer to Checking
Remove as much lubricant as
Differential Ring Gear Backlash and
possible with clean solvent. Wipe the
Checking Tooth Contact Pattern and
components or blow them dry with
Condition of the Ring and Pinion in this
compressed air.
section.
X Re-inspect for:
loose fasteners.
Diagnostic Routines
Diagnostic Routine Fluid Loss
Possible Component Reference/Action
Vent CLEAN the axle vent and vent hose.
Overfilled axle CHECK the lubricant level for specific amount.
Fill plug CLEAN the area around the plug. REMOVE the plug.
APPLY pipe sealant and INSTALL the plug.
Halfshaft oil seal INSTALL a new halfshaft oil seal.
Pinion seal INSTALL a new pinion seal.
Differential housing cover RESEAL the differential housing cover.
Diagnostic Routine Noise Louder on Turns (Sweeping)
Wheel end bearing CHECK the wheel end bearing for wear or damage.
INSTALL a new bearing.
Diagnostic Routine Noise (Growl) In Tight Turn, Conventional Differential
Differential side gears and differential pinion gears DISASSEMBLE the differential carrier. INSPECT the
differential case assembly. INSTALL new side gears
and differential pinion gears or case assembly.
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Diagnostic Routine Noise (Chatter/Shudder) In Tight Turns, Limited Slip Differential
Clutch pack VERIFY the condition. With the vehicle in cold startup,
MAKE SURE that the vehicle is in 2WD, to isolate the
rear axle. TURN the wheel fully right (or fully left) and
then ACCELERATE the vehicle. If the condition is
verified to be in the rear axle, REMOVE and
INSTALL new clutch packs.
Diagnostic Routine Noise (Whine) In All Or More Than One Drive Modes
Axle ring and pinion REMOVE and INSTALL a new ring gear, pinion and
bearings.
Diagnostic Routine Noise (Tick/Click) In All Or More Than One Drive Modes
bearings.
Diagnostic Routine Noise (Howl/Moan) In All Or More Than One Drive Modes
Axle bearings INSPECT differential and pinion bearings. INSTALL
new bearings.
Diagnostic Routine Noise (Clunk) On Changes In Speed Or Direction Of Power
Axle and pinion system MEASURE total backlash. If end play and total
backlash are within specification, INSTALL a new
differential case assembly.
Differential pinion shaft INSTALL a new differential pinion shaft and pin.
Pinion bearings INSTALL new pinion and differential bearings and
bearing cups.
Diagnostic Routine Vibration
For additional information on driveline vibration, REFER to Section 100-04.
Checking Differential Ring Gear
Backlash
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2. Using a suitable dial indicator and the special Apply a marking compound to a third of the gear
tool, measure and record the differential ring teeth on the differential ring gear. Rotate the
gear backlash in 4 opposing points on the ring differential ring gear several complete turns in both
gear. directions until a good, clear tooth pattern is
obtained. Compare the contact patterns on the ring
gear teeth with the following illustrations.
Good Contact Pattern
Pattern inspection allows the technician to detect
gross errors in set up prior to complete assembly of
the differential assembly. Pattern contact should be
within the primary area of the ring gear tooth
section. Avoid narrow or hard contact with the
outer perimeter of the ring gear tooth. Pattern
inspection should be on the drive side of the tooth.
Correct assembly of the drive pattern will result in
satisfactory coast performance.
NOTE: If a gross pattern error is detected with the
correct backlash, check the pinion shim selection.
Condition of the Ring and Pinion
There are 2 basic types of conditions that will
produce ring and pinion noise. The first type is a
howl or chuckle produced by broken, cracked,
chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range.
The second type of ring and pinion noise pertains to
the mesh pattern of the gear pattern. This gear noise
can be recognized as it produces a constant pitch or
whine. Ring and pinion noise tends to peak in a
narrow speed range or ranges, and will tend to
remain constant in pitch.
NOTE: In the following steps, the movement of the
contact pattern along the length is indicated as
toward the heel or toe of the differential ring
gear.
Low Contact Pattern That Is Contacting
More Toward the Heel
Gross Pattern Error
1 Heel
2 Toe
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High, Thin Contact Pattern In the Center Of Thick Contact Pattern That Is Contacting
the Tooth Tooth Toward the Toe
Gross Pattern Error Gross Pattern Error
Thick Contact Pattern That Is Contacting
Tooth Toward the Heel
Gross Pattern Error
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IN-VEHICLE REPAIR
Material
Rear Wheel Bearing and Axle Shaft
Item Specification
Seal
Grease
Special Tool(s)
Slide Hammer CXG-1-C (Canada)
100-001 (T50T-100-A)
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Remover, Axle Bearing Removal
205-219 (T85L-1225-AH)
1. Remove the axle shaft. For additional
2. NOTE: If the axle shaft oil seal is leaking, the
axle housing vent may be plugged.
Adapter for 303-224
Using the special tools, remove the rear wheel
205-153 (T80T-4000-W)
bearing and axle shaft oil seal.
Installer, Axle Shaft Bearing
205-124 (T78P-1225-A)
Installer, Rear Axle Oil Seal
205-390 (T97T-1177-B)
Installation
1. Lubricate the new rear wheel bearing with the
axle lubricant.
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2. Using the special tools, install the new rear 4. Using the special tools, install the new axle
wheel bearing. shaft oil seal.
3. Lubricate the lip of the new axle shaft oil seal 5. Install the axle shaft. For additional
with grease. information, refer to Axle Shaft in this section.
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SPECIFICATIONS
Item Specification
Available drive pinion 0.254 mm (0.010 in)
Item Specification bearing adjustment shim 0.965 mm (0.038 in)
in steps of 0.25 mm
Lubricants and Sealers
(0.010 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Synthetic Rear Axle
Lubricant
a In-vehicle repair refill capacities are determined by
XY-75W140-QL (US);
filling the rear axle with the specified lubricant to
CXY-75W140-1L
11.1-12.7 mm (0.44-0.50 in) below the bottom of
(Canada)
the fill hole with the axle at ride height.
Grease XG-1-C or
Rear Axle Backlash Shim Adjustment Table
(Canada)
Required Required
Anti-Seize Lubricant XL-2
mm Inch mm Inch
(US); CXG-2-B (Canada)
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
Sealant TA-30
0.076 0.003 0.101 0.004
TA-25
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
TA-27
0.152 0.006 0.203 0.008
Lubricant Capacities
0.177 0.007 0.254 0.010
Approximate axle fill 1.42 liters (3.0 pints)
0.203 0.008 0.254 0.010
capacity
a
11.1-12.7-mm (7/16-1/2
in) below the bottom of 0.228 0.009 0.304 0.012
the fill hole with the axle
0.254 0.010 0.355 0.014
at ride height
0.279 0.011 0.355 0.014
Clearance, Tolerance and Adjustments
0.304 0.012 0.406 0.016
Maximum differential case 0.076 mm (0.003 in)
runout 0.330 0.013 0.457 0.018
Differential side gear 0.762-0.813 mm 0.335 0.014 0.457 0.018
thrust washer thickness (0.030-0.032 in)
0.381 0.015 0.508 0.020
Differential pinion gear 0.762-0.813 mm
Maximum axle shaft end 0.762 mm (0.030 in)
play
Pinion bearing preload 1.8-3.3 Nm (16-29 lb-in)
Differential pinion 30 22
shaft lock bolt
Ring gear backlash 0.203-0.304 mm
(0.008-0.012 in)
Disc brake caliper bolts 33 24
Variation between teeth 0.102 mm (0.004 in)
Disc brake caliper 103 76
maximum backlash
anchor bolts
Driveshaft flange bolts 112 83
Differential housing 46 33
cover bolts
Filler plug 30 22
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SPECIFICATIONS (Continued)
Torque Specifications (Continued) Torque Specifications (Continued)
Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Handle adapter for 2.2 20 Upper suspension arm 175 129
205-S127 nut
Differential bearing cap 105 77 Trailing arm nut 175 129
bolts
Rear support brace 63 46
Differential ring gear 105 77 bolts (convertible)
bolts
Upper support brace 63 46
Anti-lock sensor bolt 7 62 bolts (convertible)
Lower shock absorber 115 85 Front support brace 63 46
nuts bolts (convertible)
Trackbar nuts 175 129
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205-02B-1 205-02B-1 Rear Drive Axle/Differential Ford 8.8-Inch Ring Gear
IN-VEHICLE REPAIR
Axle Housing Bushing
1. To remove the axle housing bushing, refer to
Upper Arm Bushing in Section 204-02.
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5. For convertible models, remove and discard the
Axle Housing
2 upper support brace bolts.
Removal and Installation To install, tighten to 63 Nm (46 lb-ft).
1. CAUTION: The vehicle must be on
level ground and at curb height.
Mark the rear shock absorbers relative to their
protective sleeve.
During installation, raise the suspension to
this reference mark before tightening the
suspension fasteners.
4 front support brace bolts.
Section 100-02.
3. Remove the rear wheel and tire assemblies. For
4 rear support brace bolts.
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7. Remove the stabilizer bar bracket-to-frame bolts 9. NOTE: The suspension must be at ride height
and disconnect the stabilizer bar from the axle. when tightening suspension components.
Discard the stabilizer bar bracket-to-frame Remove the trackbar bolts and the trackbar
bolts. flagnuts, then the trackbar.
To install, tighten to 70 Nm (52 lb-ft). Discard the trackbar bolts and the trackbar
flagnuts.
8. NOTE: Using 2 screwdrivers through the
access hole, depress the tabs of the trackbar
cover retaining clip.
10. CAUTION: Secure the differential
Remove the trackbar cover.
housing to the transmission jack with a
suitable strap.
Support the differential housing with a suitable
transmission jack.
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11. Remove and discard the shock absorber nuts 14. Remove and discard the trailing arm nuts and
and shock absorber bolts. trailing arm bolts.
To install, tighten to 115 Nm (85 lb-ft). To install, tighten to 175 Nm (129 lb-ft).
12. Remove and discard the upper suspension arm 15. Disconnect the lower suspension arms from the
nut and upper suspension arm bolt. axle housing.
16. Lower the axle housing from the vehicle.
13. Lower the axle slightly and remove the springs.
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17. CAUTION: Raise the suspension to the
reference marks on the rear shock absorbers
before tightening the suspension fasteners.
Install new fasteners as listed:
X Rear support brace bolts
X Upper support brace bolts
X Front support brace bolts
X Stabilizer bar bracket-to-frame bolts
X Track bar bolts
X Trackbar flag nuts
X Shock absorber bolts
X Shock absorber nuts
X Upper suspension arm bolts
X Upper suspension arm nuts
X Trailing arm bolts
X Trailing arm nuts
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IN-VEHICLE REPAIR
Axle Shaft
Material
Item Specification
Grease
CXG-1-C (Canada)
TA-25
XL-2 (US); CXG-2-B
(Canada)
6 4211 Differential pinion shaft 1 4346 Differential housing cover
bolt
8 4234 Axle shaft
3 Disc brake caliper
9 1177 Axle shaft seal
4 Brake disc
10 1225 Axle shaft bearing
bolt
(Continued)
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Removal
Section 100-02.
3. Remove the differential housing cover. For
4. Remove the 2 disc brake caliper bolts and 7. Remove the brake disc.
position aside the disc brake caliper.
Using mechanics wire, support the disc
brake caliper.
8. CAUTION: Damage to the rear brake
anti-lock sensor may occur if it is not
removed before the axle shaft U-washer.
Remove the anti-lock sensor bolt, then remove
the anti-lock sensor from the hub.
and the disc brake caliper anchor.
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1 Remove and discard the differential pinion
shaft lock bolt.
2 Remove the differential pinion shaft.
Installation
1. Lubricate the lip of the axle shaft oil seal with
grease.
shaft oil seal.
O-ring in the axle shaft grooves.
Install the axle shaft.
Remove the axle shaft U-washer.
1 Push in on the axle shaft.
2 Remove the U-washer.
shaft oil seal.
Remove the axle shaft.
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5. NOTE: Be sure to apply anti-seize lubricant to
the sensor body where it will make contact
O-ring in the U-washer groove.
when installed.
Install the axle shaft U-washer.
Install the anti-lock sensor.
1 Position the U-washer on the button end of
the axle shaft.
2 Pull the axle shaft outward.
Install the differential pinion shaft.
shaft with the differential case lock bolt
hole.
Install a new differential pinion shaft lock
bolt.
7. Install the disc brake caliper anchor, then install
the 2 disc brake caliper anchor bolts.
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10. Install the differential housing cover. For
9. Install the disc brake caliper and the 2 disc
11. Install the tire and wheel assembly. For
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IN-VEHICLE REPAIR
Special Tool(s)
Differential Bearings
Adapter For 205-S127
205-109 (T76P-4020-A9)
Special Tool(s)
2-Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent
205-129 (T79P-4020-A18)
Step Plate
205-D061 (D83T-4205-C2) or
equivalent
205-110 (T76P-4020-A10)
Bearing
205-010 (T57L-4221-A2)
205-130 (T79P-4020-A19)
205-105 (T76P-4020-A3)
Dial Indicator With Holding
Fixture
100-002 (TOOL-4201-C) or
equivalent Adapter For 205-S127
205-111 (T76P-4020-A11)
Gauge, Clutch Housing
308-021 (T57L-4201-A)
Remover, Differential Bearing
205-116 (T77F-4220-B1)
Shim Driver
205-220 (T85L-4067-AH)
(Continued)
(Continued)
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Special Tool(s) Special Tool(s)
Holding Fixture, Drive Pinion Protector, Drive Pinion Thread
Flange 205-460 or equivalent
205-126 (T78P-4851-A)
Installer, Drive Pinion Bearing Puller, Bearing
Cone 205-D064 (D84L-1123-A) or
205-005 (T53T-4621-C) equivalent
Cup
205-024 (T67P-4616-A)
205-002 (TOOL-4858-E) or
equivalent
205-208 (T83T-4676-A)
Plate, Bearing Oil Seal
205-090 (T75L-1165-B)
(Continued)
1 4670 Oil slinger
2 4621 Outer pinion bearing
3 4616 Outer pinion bearing cup
4 4662 Collapsible spacer
5 Inner pinion bearing cup shim
(5.4L only)
(Continued)
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Item Part Number Description 4. CAUTION: The driveshaft centering
socket yoke fits tightly on the pinion flange 6 4628 Inner pinion bearing cup
7 4630 Inner pinion bearing
8 4663 Pinion bearing adjustment
shim
9 4209 Drive pinion
10 4209 Ring gear
pinion flange.
13 4067 Differential bearing shim
pinion flange.
Removal
driveshaft aside.
1. Remove the differential carrier assembly. For
Carrier in this section.
5. CAUTION: Discard the nut after
removal. Use a new nut during installation.
while removing the drive pinion nut.
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6. Index-mark the pinion flange and the drive
pinion stem for correct alignment during
installation.
10. Remove the axle drive pinion shaft oil slinger.
11. Using the special tool and a soft-faced hammer,
drive the pinion assembly out of the outer
7. Using the special tool, remove the pinion pinion bearing and remove it through the rear
flange. of the differential housing.
8. Using a screwdriver, force up the rear axle 12. Remove the outer pinion bearing.
drive pinion seal metal flange.
13. Remove the drive pinion collapsible spacer and
discard it.
9. Using gripping pliers and a hammer, remove
the axle drive pinion seal.
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14. Using the special tool and a suitable press,
remove the inner pinion bearing.
15. NOTE: On 5.4L applications, remove the inner
pinion cup shim from the housing.
Using a brass drift, remove the pinion bearing
cups by tapping alternately on opposite sides of
the bearing cups.
Installation
1. Press the left and right differential bearing on
the differential assembly.
1 Position the differential bearings.
2 Using the special tool, press the differential
bearings on the differential assembly.
bearings.
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2. NOTE: On 5.4L applications, install the inner 4. NOTE: If a feeler gauge of the specification
pinion bearing cup shim in the housing before shown can be inserted between a cup and the
installing the bearing cups. bottom of its bore at any point around the cup,
the cup is not correctly seated.
Position the special tool and the inner and outer
bearing cups in their respective bores. Make sure the differential pinion bearing cups
are correctly seated.
1 After placing the inner and outer bearing
cups in their respective bores, place the
special tool of the inner bearing cup.
2 Place the special tool on the outer bearing
cup.
3. Tighten the special tool to seat the pinion
bearing cups in their bores.
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5. NOTE: Install new drive pinion bearings 6. NOTE: The gauge block must be offset to
without any additional lubricant since the obtain an accurate reading.
Rotate the gauge block several half turns to
settings.
bearings and position the gauge block.
Assemble and position the drive pinion depth
gauge set.
1 Position the screw.
2 Position the aligning adapter.
3 Position the gauge disc.
4 Position the gauge block.
5 Position the inner drive pinion bearing.
6 Position the outer drive pinion bearing.
7 Thread on the handle and tighten.
X Tighten to 2.2 Nm (20 lb-in).
1 Position the gauge tube and the paper
shipping tabs.
3 Install the differential bearing cap bolts.
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adjustment shim between gauge block and
gauge tube. This will minimize selection of a
drive pinion bearing adjustment shim thicker
assemblies.
selection.
housing.
13. Using the special tool, install the drive pinion
9. Using the special tool and a shop press, drive
seal.
the inner drive pinion bearing and drive pinion
bearing adjustment shim until they are firmly
seated on the pinion shaft.
shoulder.
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14. Using the special tools, install the drive pinion 16. Place the differential carrier assembly with the
flange. new differential carrier bearing cups in the axle
housing.
17. Install a differential bearing shim on the LH
side.
pinion nut.
wrench.
18. NOTE: Apply pressure toward the LH side to
make sure the left differential bearing cup is
seated.
Install the LH differential bearing cap and
specification.
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19. Install progressively larger differential bearing 22. Install the special tools and measure the ring
shims on the RH side until the largest gear backlash.
differential bearing shim selected can be
inserted by hand.
proceed to Step 25.
to Step 23.
proceed to Step 24.
20. Install the RH side differential bearing cap and
tighten the differential bearing cap bolts.
22.
specifications, proceed to Step 25.
rotates freely.
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
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Differential Shim Size Chart 4067 (Continued) Backlash Change Thickness Change
Required Required
Dimension A
Stripes and
mm Inch mm Inch
mm Inch Color Code
0.254 0.010 0.355 0.014
5 ORNG 6.4262-6.4389 0.2530-0.2535
0.279 0.011 0.355 0.014
4 ORNG 6.3754-6.3881 0.2510-0.2515
0.304 0.012 0.406 0.016
3 ORNG 6.3246-6.3373 0.2490-0.2495
0.330 0.013 0.457 0.018
2 ORNG 6.2738-6.2865 0.2470-0.2475
0.335 0.014 0.457 0.018
1 ORNG 6.2223-6.2357 0.2450-0.2455
0.381 0.015 0.508 0.020
2 RED 6.1722-6.1849 0.2430-0.2435
1 RED 6.1214-6.1341 0.2410-0.2415
Dimension A
Stripes and
25. Rotate the differential assembly several times to
mm Inch Color Code
make sure the differential bearings are seated.
2 C-COAL 7.7978-7.8105 0.3070-0.3075
1 C-COAL 7.7470-7.7597 0.3050-0.3055
5 BLU 7.6962-7.7089 0.3030-0.3035
4 BLU 7.6454-7.6581 0.3010-0.3015
3 BLU 7.5946-7.6073 0.2990-0.2995
2 BLU 7.5458-7.5565 0.2970-0.2975
5 PINK 7.4422-7.4549 0.2930-0.2935
4 PINK 7.3914-7.4041 0.2910-0.2915
3 PINK 7.3406-7.3533 0.2890-0.2895
2 PINK 7.2898-7.3025 0.2870-0.2875
1 PINK 7.2390-7.2517 0.2850-0.2855
5 GRN 7.1882-7.2009 0.2830-0.2835
4 GRN 7.1374-7.1501 0.2810-0.2815
backlash.
3 GRN 7.0866-7.0993 0.2790-0.2795
2 GRN 7.0358-7.0485 0.2770-0.2775
1 GRN 6.9850-7.0485 0.2750-0.2755
5 WH 6.9342-6.9469 0.2730-0.2735
4 WH 6.8834-6.8961 0.2710-0.2715
3 WH 6.8326-6.8453 0.2690-0.2695
2 WH 6.7818-6.7945 0.2670-0.2675
1 WH 6.7310-6.7437 0.2650-0.2655
5 YEL 6.6802-6.6929 0.2630-0.2635
4 YEL 6.6294-6.6421 0.2610-0.2615
3 YEL 6.5786-6.5913 0.2590-0.2595
2 YEL 6.5278-6.5405 0.2570-0.2575
27. Remove the differential bearing cap bolts and
1 YEL 6.4770-6.4897 0.2550-0.2555 differential bearing caps.
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28. To establish differential bearing preload, 31. Using the special tools, recheck the backlash.
shim sizes as shown.
33. Check and verify an acceptable pattern.
information, refer to Axle Shaft in this section
freely.
30. Install the differential bearing caps and
differential bearing cap bolts.
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Differential Carrier
Special Tool(s)
Shim Driver
205-220 (T85L-4067-AH)
Removal
Installation
1. Remove the axle shafts. For additional
1. Position the differential assembly in the axle
housing.
2. CAUTION: Index-mark the position of
the differential bearing caps, as arrows may
not be visible. The differential bearing caps
must be installed in their original locations
and positions.
Remove the 4 differential bearing cap bolts and
the 2 differential bearing caps.
2. Install the originally removed differential
bearing shim on the LH side.
3. NOTE: Apply pressure toward the LH side to
make sure the LH differential bearing cap is
seated.
Install the LH differential bearing cap and
3. WARNING: Be careful not to allow
the differential assembly to fall.
CAUTION: Place a wood block
between the pry bar and the axle housing to
protect the machined surface from damage.
CAUTION: Index-mark the position of
the differential bearing shims. The
differential bearing shims must be installed
in their original locations and positions.
Using pry bars and wood blocks, remove the
differential carrier assembly from the axle
housing.
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4. Install the original differential bearing shim on
the RH side.
rotates freely.
bearing shims.
8. Measure the ring and pinion backlash.
6. Install the RH side differential bearing cap and information, refer to Axle Shaft in this section.
tighten the LH side and RH side differential
bearing cap bolts.
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Special Tool(s)
Differential Case and Ring Gear
Bearing
Special Tool(s)
205-010 (T57L-4221-A2)
2-Jaw Puller
205-D072 (D97L-4221-A) or
equivalent
Gauge, Differential Clutch
205-022 (T66L-4204-A)
Step Plate
205-D016 (D80L-630-5) or
equivalent
Material
Item Specification
(Continued)
TA-25
TA-27
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1 4236 Differential side gear
2 4215 Differential pinion gear
3 4230 Differential pinion gear thrust
washer
4 4947 Differential clutch pack
5 4A324 Rear axle differential clutch
shim
6 4214 Differential clutch spring
7 4209 Differential ring gear
bolt
bearings.
11 4216 Differential ring gear bolts
Disassembly
section.
5. Remove the differential pinion shaft lock bolt
and remove the differential pinion shaft.
Discard the differential pinion shaft lock
bolt.
3. CAUTION: Care should be taken not
to damage the differential ring gear bolt hole
threads.
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6. WARNING: Due to the spring tension, 8. CAUTION: Keep the differential clutch
care must be used when removing the packs in order. Do not mix the differential
differential clutch spring. clutch packs. The differential clutch packs
must be reassembled in the same sequence.
Remove the differential clutch spring.
Remove the differential clutch packs and
differential side gears and tag them RH and
LH with the selective shim.
Clean and inspect the remaining components
of the differential case for wear or damage
and install new components as necessary.
7. Remove the differential gears.
1 Remove the differential pinion gear and
thrust washers.
2 Remove the 2 differential side gears.
9. CAUTION: Do not use acids or
solvents when cleaning the differential clutch
pack. Wipe components with a clean,
lint-free cloth only.
Clean and inspect the differential clutch packs
for wear or damage and install new components
as necessary.
Assembly
1. Install selective shims on the clutch pack and
differential side gear assembly.
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2. Install the differential side gear in the
differential case.
Install the differential pinion shaft and install a
new differential pinion shaft lock bolt
finger-tight.
3. Install the differential pinion gears with
differential pinion gear thrust washers in the
differential case.
6. Using the special tool, install the differential
bearings on the differential case.
1 Position the differential bearing.
2 Using the special tool, press on the
differential bearing.
4. Using a soft-faced hammer, install the
differential clutch spring.
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7. Press the differential ring gear on the 9. Check the torque required to rotate one
differential assembly. differential side gear.
Mount the differential assembly and special
8. NOTE: On the 5.4L applications, the
tool in a vise.
differential flange and ring gear flange must be
The initial minimum break-away torque, if
free of any old stud and bearing mount
original clutch plates are used, must be
material. Failure to clean the surfaces can result
within specification. The minimum rotating
in ring gear runout concerns.
torque required to keep the differential side
Apply stud and bearing mount to the
gear turning with new clutch plates may
differential ring gear bolts and the rear face of
vary.
the 5.4L application ring gear. Install the
Tighten 4.0L and 4.6L to 105 Nm (77 lb-ft).
Tighten the 5.4L application ring gear bolts
to 135 Nm (100 lb-ft).
10. Install the differential carrier. For additional
section.
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IN-VEHICLE REPAIR
2. Apply a new continuous bead of sealant to the
Differential Housing Cover
differential housing cover.
Material
Item Specification
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Sealant
TA-30
Removal
3. NOTE: The differential housing cover must be
installed within 15 minutes of application of the
silicone sealant, or new sealant must be applied.
Section 100-02.
If possible, allow one hour before filling the
2. Remove the differential housing cover. axle housing with axle lubricant to make sure
the silicone sealant has cured.
1 Remove the 10 differential housing cover
bolts and drain the lubricant from the axle Install the differential housing cover and the
housing. differential housing cover bolts.
2 Remove the differential housing cover. Tighten to 45 Nm (33 lb-ft).
Installation
1. CAUTION: Make sure the machined
surfaces on both the axle housing and the
differential housing cover are clean and free
of oil before installing the new silicone
sealant. The inside of the axle housing must
be covered when cleaning the machined
surface to prevent contamination.
Clean the gasket mating surface of the axle
housing and the differential housing cover.
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4. NOTE: Service refill capacities are determined
by filling the axle to the level shown.
Fill the axle with 1.50 liters (3.17 pints) of axle
lubricant and install the filler plug.
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IN-VEHICLE REPAIR
Special Tool(s)
Differential Ring And Pinion
Flange
Special Tool(s)
205-126 (T78P-4851-A)
205-460 or equivalent
Cup
205-024 (T67P-4616-A)
205-208 (T83T-4676-A)
205-105 (T76P-4020-A3)
205-002 (TOOL-4858-E) or
equivalent
205-111 (T76P-4020-A11)
Bracketry
100-002 (TOOL-4201-C) or
equivalent
205-109 (T76P-4020-A9)
Remover, Differential Bearing
205-116 (T77F-4220-B1)
205-129 (T79P-4020-A18)
205-220 (T85L-4067-AH)
205-110 (T76P-4020-A10)
(Continued)
(Continued)
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Adapter For 205-S127 Item Specification
205-130 (T79P-4020-A19)
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
XL-3 (US); CXL-3
Cone
(Canada)
205-005 (T53T-4621-C)
TA-27
Sealant
TA-30
2-Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent
Step Plate
205-D016 (D80L-630-5) or
equivalent
Bearing
205-010 (T57L-4221-A2)
205-090 (T75L-1165-B)
1 4670 Oil slinger
2 4621 Outer pinion bearing
3 4616 Outer pinion bearing cup
4 4662 Collapsible spacer
5 Inner pinion bearing cup shim
(5.4L only)
(Continued)
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4. NOTE: The anti-lock ring cannot be reused
once removed. Remove the anti-lock ring only
6 4628 Inner pinion bearing cup
if damaged.
7 4630 Inner pinion bearing
If necessary, remove the anti-lock ring.
8 4663 Pinion bearing adjustment
shim
9 4209 Drive pinion
10 4209 Ring gear
11 4221 Differential bearings
Removal
1. Remove the differential carrier assembly. For
Carrier in this section.
bearings.
3. CAUTION: Care should be taken not
to damage the differential ring gear bolt hole
threads.
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flange.
pinion flange.
pinion flange.
driveshaft aside.
11. Force up on the metal flange of the drive
pinion seal. Install gripping pliers and strike
removed.
12. Remove the drive pinion shaft oil slinger and
the outer drive pinion bearing.
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13. Install the special tool. Using a soft-faced
hammer, drive the pinion assembly out of the
axle housing.
14. NOTE: On 5.4L applications, remove the inner
pinion cup shim from the housing.
Using a brass drift, remove the drive pinion
bearing cups by tapping alternately on opposite
sides of the drive pinion bearing cups.
Installation
1. NOTE: On 5.4L applications, install the inner
pinion bearing cup shim in the housing before
installing the bearing cups.
Position the special tool and the inner and outer
bores.
bearing cup.
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4. NOTE: Install new drive pinion bearings
without any additional lubricant since the
settings.
Assemble and position the special tools.
6. NOTE: The special tool must be offset to
obtain an accurate reading.
1 205-105 Adapter for 205-S127 (1.612
inch O.D.) (T76P-4020-A3)
2 205-111 Adapter for 205-S127
(T76P-4020-A11) X Tighten to 105 Nm (77 lb-ft).
4 205-109 Adapter for 205-S127
(T76P-4020-A9)
5 4630 Drive pinion bearing (inner)
6 205-129 Adapter for 105-S127 (1.1884
inch thick) (T79P-4020-A18)
7 205-110 Adapter for 205-S127 (1.7
inch thick) (T76P-4020-A10)
bearing preload.
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assemblies.
selection.
housing.
9. Using the special tool and a shop press, drive
seal.
the inner drive pinion bearing and the selected
drive pinion bearing adjustment shim until they
are firmly seated on the pinion shaft.
shoulder.
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14. Using the special tools, install the drive pinion 16. Using the special tool, install the new
flange. differential bearings.
17. NOTE: On the 5.4L application, the differential
flange and ring gear flange must be free of any
old stud and bearing mount material. Failure to
clean the surfaces can result in ring gear runout
concerns.
pinion nut.
NOTE: Apply stud and bearing mount to the
differential ring gear bolts and the back face of
the 5.4L application ring gear.
Install the differential ring gear bolts.
wrench.
Tighten the 5.4L application ring gear bolts
to 135 Nm (100 lb-ft).
specification.
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18. Position the differential carrier assembly and
the new differential bearing cups in the
installed by hand.
19. Install a differential bearing shim of the shown
dimension on the left side.
22. Install the right side bearing cap and bolts.
Tighten the LH and RH bearing cap bolts.
23. Rotate the differential carrier several times to
verify the differential bearings have seated
NOTE: Apply pressure toward the LH side to
correctly.
make sure the left differential bearing cup seats
correctly.
the bolts.
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Required Required
gear backlash.
mm Inch mm Inch
0.254 0.010 0.355 0.014
proceed to Step 27.
0.279 0.011 0.355 0.014
to Step 25. 0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018 If the backlash is not within specification,
proceed to Step 26.
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Dimension A
Stripes and
mm Inch Color Code
2 C-COAL 7.7978-7.8105 0.3070-0.3075
1 C-COAL 7.7470-7.7597 0.3050-0.3055
5 BLU 7.6962-7.7089 0.3030-0.3035
4 BLU 7.6454-7.6581 0.3010-0.3015
3 BLU 7.5946-7.6073 0.2990-0.2995
2 BLU 7.5458-7.5565 0.2970-0.2975
5 PINK 7.4422-7.4549 0.2930-0.2935
4 PINK 7.3914-7.4041 0.2910-0.2915
3 PINK 7.3406-7.3533 0.2890-0.2895
24. 2 PINK 7.2898-7.3025 0.2870-0.2875
1 PINK 7.2390-7.2517 0.2850-0.2855
5 GRN 7.1882-7.2009 0.2830-0.2835
4 GRN 7.1374-7.1501 0.2810-0.2815
differential bearing shim by the same amount. 3 GRN 7.0866-7.0993 0.2790-0.2795
2 GRN 7.0358-7.0485 0.2770-0.2775
1 GRN 6.9850-7.0485 0.2750-0.2755
5 WH 6.9342-6.9469 0.2730-0.2735
4 WH 6.8834-6.8961 0.2710-0.2715
Required Required
3 WH 6.8326-6.8453 0.2690-0.2695
mm Inch mm Inch
2 WH 6.7818-6.7945 0.2670-0.2675
0.025 0.001 0.050 0.002
1 WH 6.7310-6.7437 0.2650-0.2655
0.050 0.002 0.050 0.002
5 YEL 6.6802-6.6929 0.2630-0.2635
0.076 0.003 0.101 0.004
4 YEL 6.6294-6.6421 0.2610-0.2615
0.101 0.004 0.152 0.006
3 YEL 6.5786-6.5913 0.2590-0.2595
0.127 0.005 0.152 0.006
2 YEL 6.5278-6.5405 0.2570-0.2575
0.152 0.006 0.203 0.008
1 YEL 6.4770-6.4897 0.2550-0.2555
0.177 0.007 0.254 0.010
5 ORNG 6.4262-6.4389 0.2530-0.2535
0.203 0.008 0.254 0.010
4 ORNG 6.3754-6.3881 0.2510-0.2515
0.228 0.009 0.304 0.012
3 ORNG 6.3246-6.3373 0.2490-0.2495
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Dimension A
Stripes and
mm Inch Color Code
2 ORNG 6.2738-6.2865 0.2470-0.2475
1 ORNG 6.2223-6.2357 0.2450-0.2455
2 RED 6.1722-6.1849 0.2430-0.2435
1 RED 6.1214-6.1341 0.2410-0.2415
backlash.
33. Check for an acceptable pattern.
35. CAUTION: Make sure the machined
surfaces on both the axle housing and the
differential housing cover are clean and free
of oil before applying the new silicone
sealant. The inside of the axle must be
covered when cleaning the machined surface
to prevent contamination.
freely.
Clean the gasket mating surface of the axle and
the differential housing cover.
36. Apply a new, continuous bead of sealant to the
differential housing cover.
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37. CAUTION: For Traction-Lok axles,
first fill the axle with 118 ml (4 ounces) of
friction modifier.
NOTE: Service refill capacities are determined
by filling the axle with the specified lubricant
to the specified level below the bottom of the
filler hole.
Fill the axle to the level shown with axle
lubricant and install the filler plug.
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IN-VEHICLE REPAIR
Special Tool(s)
Drive Pinion Flange and Drive Pinion
Seal
205-208 (T83T-4676-A)
Special Tool(s)
Flange
205-126 (T78P-4851-A)
205-002 (TOOL-4858-E)
2-Jaw Puller
205-D072 (D97L-4221-A) or
equivalent
Material
Item Specification
(Continued)
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Grease
CXG-1-C (Canada)
TA-25
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and the 2 disc brake caliper anchors.
3 4859 Deflector
Removal
Section 100-02.
2. NOTE: The wheels and disc brake calipers
must be removed to prevent brake drag during
drive pinion bearing preload adjustment.
6. Remove the 2 brake discs.
Remove the wheel and tire assembly. For
3. Remove the 4 disc brake caliper bolts and the 2
disc brake calipers.
Using mechanics wire, support the 2 disc
brake calipers.
7. Index-mark the constant velocity (CV) joint and
pinion flange for correct alignment during
installation.
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8. Remove the 6 CV joint bolts and 3 CV joint
washers, then disconnect the CV joint from the
pinion flange.
driveshaft aside.
Discard the CV joint bolts.
11. Index-mark the pinion flange in relation to the
drive pinion stem to make sure of correct
alignment during installation.
9. Using a Nm (lb-in) torque wrench on the pinion
nut, record the torque required to maintain
rotation of the pinion gear through several
revolutions.
flange.
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13. Force up on the metal flange of the drive
pinion seal. Install gripping pliers and strike
removed.
5. Using the special tool, install the pinion flange.
Installation
1. Lubricate the new drive pinion seal with grease.
2. CAUTION: If the new drive pinion
seal becomes misaligned during installation,
remove the drive pinion seal and install a
new drive pinion seal.
Using the special tool, install a new drive
pinion seal.
6. Position the new pinion nut.
3. Lubricate the pinion flange splines with axle
lubricant.
4. NOTE: Disregard the scribe marks if a new
pinion flange is being installed.
Align the pinion flange with the drive pinion
shaft.
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7. CAUTION: Under no circumstances is
the pinion nut to be backed off to reduce
drive pinion bearing preload. If reduced
drive pinion bearing preload is required, a
new drive pinion collapsible spacer and
pinion nut must be installed.
while taking drive pinion bearing preload
readings with the Nm (lb-in) torque wrench.
Using the special tool to hold the pinion flange,
tighten the pinion nut.
Rotate the drive pinion occasionally to make
9. CAUTION: If new CV joint bolts are
sure the drive pinion bearings are seating
not available, coat the threads of the original
correctly.
CV joint bolts with threadlock and sealer.
Install a Nm (lb-in) torque wrench on the
NOTE: Tighten the CV joint bolts evenly in a
pinion nut.
star pattern.
Rotating the drive pinion through several
Connect the CV joint to the pinion flange, then
revolutions, take frequent drive pinion
install the 6 new CV joint bolts and CV joint
bearing preload readings until the original
washers.
recorded drive pinion bearing preload
reading is obtained.
If the original recorded drive pinion bearing
preload is lower than specifications, tighten
to the appropriate specifications for used
drive pinion bearings. If the drive pinion
bearing preload is higher than specification,
tighten the pinion nut to the original
reading as recorded. For additional
information, refer to the Specifications
10. Install the 2 brake discs.
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11. Install the 2 disc brake caliper anchors, then 13. Install the 2 disc brake calipers and the 4 disc
install the 4 disc brake caliper anchor bolts. brake caliper bolts.
Tighten to 103 Nm (76 lb-ft). Tighten to 33 Nm (24 lb-ft).
12. Install the disc brake pads. 14. Install the wheel and tire assembly. For
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34 4630 Drive pinion bearing (inner) 1 4236 Differential side gears
35 4663 Drive pinion bearing 2 4228 Differential side gear thrust
adjustment shim washers
36 Differential bearing cap bolt 3 4221 Differential bearings
bolt
6 4216 Differential ring gear bolt (10
required)
39 4N237 Axle shaft U-washers
8 4209 Differential ring gear and
bolt (10 required)
pinion set
41 Axle identification tag
9 Differential bearing cap (2
42 4033 Differential housing cover required) (part of 4010)
43 4230 Differential pinion gear thrust 10 4010 Axle housing
washers
11 373098-S Filler plug
44 4215 Differential pinion gears
12 4662 Drive pinion collapsible
45 Steel plate (part of 4947) spacer
46 Clutch disc (part of 4947) 13 4670 Drive pinion shaft oil slinger
47 4214 Differential clutch spring 14 4676 Drive pinion seal
48 4947 Differential clutch pack 15 4851 Pinion flange
49 4A324 Rear axle differential clutch 16 389546-S100 Pinion nut
shim
18 2C026 Brake disc The axle housing consists of a cast center section
with 2 steel tube assemblies and a stamped
19 Axle shaft flange (2 required)
(part of 4234) differential housing cover. The differential
housing cover uses silicone sealant as a gasket.
20 2C189 Anti-lock sensor indicator (2
required)
The hypoid-design gearset consists of 8.8-inch
21 2552 Disc brake caliper (2
ring gear and a drive pinion gear. Two opposed
required)
tapered roller bearings (drive pinion bearings)
22 N601951-S2 Brake line clip bolt
support the drive pinion in the axle housing.
23 N804361-S100 Brake line clip
A drive pinion collapsible spacer, located on the
24 Anti-lock sensor bolt (2
differential pinion shaft, maintains drive pinion
required)
bearing preload. The pinion nut adjusts the drive
25 2C190 Anti-lock sensor (2 required)
pinion bearing preload.
26 2C101 LH disc brake adapter
Differential bearing shims, located between the
27 2C100 RH disc brake adapter
differential bearing cups and the axle housing,
28 N8015163-S190 Disc brake caliper anchor bolt adjust the differential bearing preload and the
(4 required)
differential ring gear backlash.
29 2C028 Brake disc shield (2 required)
The differential case is a one-piece design with 2
30 N602726-S2 Brake disc shield bolt (6
openings to allow for assembly of the internal
required)
components and lubricant flow. Two opposed
tapered roller bearings (differential bearings)
(outer)
support the differential assembly in the axle
32 Drive pinion bearing cup
housing. Removable bearing caps retain the
shim (5.4L only)
differential assembly in the axle housing.
(Continued)
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Inside the differential assembly, the differential
pinion shaft supports 2 differential pinion gears.
The pinion gears engage the differential side
gears, to which the axle shafts are splined. The
differential pinion shaft lock bolt retains the
differential pinion shaft in the differential case.
An embossed metal tag, bolted to the differential
housing cover, contains the axle identification.
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4 Has the driveline system been repaired
before or new components installed?
Special Tool(s)
X Check the vehicle service record. Note
Dial Indicator Gauge with any repairs other than driveline, such as
Holding Fixture
brakes or suspension.
100-002 (TOOL-4201-C) or
5 Are there any special conditions affecting
equivalent
the concern or will alter the concern? For
example:
X road speed.
X type of road.
Gauge, Clutch Housing
308-021 (T75L-4201-A)
X drive mode.
X temperature.
X vehicle loaded or unloaded.
6 Is the condition constant or intermittent?
Can the concern be duplicated at any time?
7 Check for TSBs, SSM and OASIS
messages.
2. NOTE: If the inspection reveals an obvious
of driveline system operation and accepted general
concern, repair the vehicle.
driveline guidelines to detect any problems.
Do a preliminary investigation. Visually inspect
for obvious signs of damage.
1 Inspect the driveshaft:
Certain conditions, such as road conditions and
X for buildup of any foreign material.
weather, will amplify normal vehicle noise.
X for damage, such as a bent tube or
Certain rear axle and driveline concern symptoms
missing weights.
are also common to the engine, transmission, rear
X U-joints or flex couplers for wear or
wheel bearings and tire. For this reason, be sure the
damage.
cause of the concern is in the axle before repairing
or installing any axle components. 2 Inspect the axle:
The following is a guide to diagnose a driveline X for signs of leakage at the drain or fill
concern: plug, differential seal, vent or halfshaft
seals.
a plugged vent will cause a leak.
Carry out a preliminary investigation.
X for damage, such as cracks, bent
halfshafts or dented rear cover.
Find the cause of the problem.
X for missing fasteners.
Inspect the components.
3 Inspect other suspect components/systems:
1. Verify and document the customer concern.
X inspect the halfshaft assemblies for
1 When was it first noticed?
damaged CV joints or torn CV boots.
X inspect the suspension for broken springs,
damaged shock absorbers and worn
3 Did anything unusual occur that would
suspension bushings.
X inspect the rear brake components
lines, cables and calipers.
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Diagnostic Routine Chart (Continued)
X inspect the tires; are they in good
condition and do they match?
Condition Action
3. NOTE: A road test is necessary for any
customer concern of noise or vibration. (chatter/shudder)
a
in Routine Noise
tight turn, limited slip (Chatter/Shudder) In
differential Tight Turns, Limited
Slip Differential 1 During the road test, use the following
driving methods to diagnose the problem. Is
Axle noise (whine)
a
in GO to Diagnostic
the concern most noticeable: all or more than one Routine Noise
drive mode (Whine) In All Or More
X from a stop?
Than One Drive Modes
X on shifts from REVERSE to DRIVE?
Axle noise (tick/click)
a
GO to Diagnostic
in all or more than one Routine Noise
X on turns?
drive mode (DRIVE, (Tick/Click) In All Or
sweeping type turn.
CRUISE, COAST) More Than One Drive
Modes
tight turn (to the stop).
X in DRIVE?
(howl/moan)
a
in all or Routine Noise
accelerating the vehicle, definite more than one drive (Howl/Moan) In All Or
mode (DRIVE, More Than One Drive throttle depression, applying engine
CRUISE, COAST) Modes
torque?
Axle noise (clunk)
a
on GO to Diagnostic
X in CRUISE?
changes in speed or Routine Noise
maintain a constant speed with the direction of power (Clunk) On Changes In
Speed Or Direction Of throttle applied?
Power
X in COAST?
Vibration For driveline vibration
decelerating with the throttle closed?
diagnostics, REFER to
Section 100-04
2 Record when the concern occurs. Write
down the kph (mph) range at which the
noise/vibration occurs. a. Refer to Section 100-04 for a glossary of
noise-related terms.
4. Find the cause of the problem.
5. NOTE: If the conclusion of the road test points
1 Compare the inspection and road test results
to an axle center section (ring and pinion or
with the following chart.
differential case) concern, carry out a visual
2 Use the following diagnostic routine chart
inspection of the axle.
to identify the probable cause and know
what corrective actions should be taken to
repair the component/vehicle, and to prevent
a reoccurrence.
Drain the axle lubricant through a white
cloth. Check the fluid for:
Diagnostic Routine Chart
X any foreign material.
Condition Action
X metal particles.
Fluid loss GO to Diagnostic
X burnt odor.
Routine Fluid Loss
2 NOTE: When inspecting the axle, do not Noise louder on turns GO to Diagnostic
(sweeping turn) Routine Noise clean the components immediately. Cleaning
Louder On Turns
may remove diagnostic evidence.
(Sweeping)
Axle noise (growl)
a
in GO to Diagnostic
X Look for: tight turn Routine Noise
(Growl) In Tight Turn
loose fasteners.
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notches or visible steps or grooves notches or visible steps or grooves
created by wear. created by wear.
pitting or cracking along gear contact pitting or cracking along gear contact
lines. lines.
scuffing or deformations. scuffing or deformations.
discolorations. discolorations.
nicks or ridges on gear teeth. nicks or ridges on gear teeth.
X Clean the axle components for inspection. X Check backlash and carry out a ring and
pinion pattern test. Refer to Checking
Remove as much lubricant as
Differential Ring Gear Backlash and
possible with clean solvent. Wipe the
components or blow them dry with
Condition of the Ring and Pinion in this
compressed air.
section.
X Re-inspect for:
loose fasteners.
Diagnostic Routines
Diagnostic Routine Fluid Loss
Vent CLEAN the axle vent.
Overfilled axle CHECK the lubricant level for specific amount.
Fill plug CLEAN the area around the plug. REMOVE the plug.
APPLY pipe sealant and INSTALL the plug.
Halfshaft oil seal INSTALL a new halfshaft oil seal.
Pinion seal INSTALL a new pinion seal.
Differential housing cover RESEAL the differential housing cover.
Pinion nut INSTALL a new pinion nut.
Diagnostic Routine Noise Louder On Turns (Sweeping)
Wheel end bearing CHECK the wheel end bearing for wear or damage.
INSTALL a new bearing.
Diagnostic Routine Noise (Growl) In Tight Turn, Conventional Differential
Differential side gears and differential pinion gears DISASSEMBLE the differential carrier. INSPECT the
differential case assembly. INSTALL new side gears
and differential pinion gears or case assembly.
Diagnostic Routine Noise (Chatter/Shudder) In Tight Turns, Limited Slip Differential
Clutch pack ADD 4 oz. of friction modifier and RE-VERIFY.
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Diagnostic Routine Noise (Chatter/Shudder) In Tight Turns, Limited Slip Differential (Continued)
VERIFY the condition. With the vehicle in cold startup,
MAKE SURE that the vehicle is in rear wheel drive
(RWD), to isolate the rear axle. TURN the wheel fully
right (or fully left) and then ACCELERATE the
vehicle. CHECK axle end play. If end play is over
specification, REMOVE and INSTALL new clutch
packs. If the condition is verified to be in the rear axle,
REMOVE and INSTALL new clutch packs.
Diagnostic Routine Noise (Whine) In All Or More Than One Drive Modes
bearings.
Diagnostic Routine Noise (Tick/Click) In All Or More Than One Drive Modes
bearings.
Diagnostic Routine Noise (Howl/Moan) In All Or More Than One Drive Modes
Axle bearings INSPECT differential and pinion bearings. INSTALL
new bearings.
Diagnostic Routine Noise (Clunk) On Changes In Speed Or Direction Of Power
Axle and pinion system MEASURE total backlash. If end play and total
backlash are within specification, INSTALL a new
differential case assembly.
Differential pinion shaft INSTALL a new differential pinion shaft and pin.
Pinion bearings INSTALL new pinion and differential bearings and
bearing cups.
Diagnostic Routine Vibration
For additional information on driveline vibration, REFER to Section 100-04.
Checking Differential Ring Gear
Backlash
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Item Description
2. Using a suitable dial indicator and the special
tool, measure and record the differential ring 2 Toe
gear backlash in 4 opposing points on the ring
gear.
Apply a marking compound to 1/3 of the gear teeth
on the differential ring gear. Rotate the differential
ring gear several complete turns in both directions
until a good, clear tooth pattern is obtained.
Compare the contact patterns on the ring gear teeth
with the following illustrations.
Pattern inspection allows the technician to detect
gross errors in set up prior to complete assembly of
the differential assembly. Pattern contact should be
within the primary area of the ring gear tooth
section. Avoid narrow or hard contact with the
outer perimeter of the ring gear tooth. Pattern
inspection should be on the drive side of the tooth.
Condition of the Ring and Pinion Correct assembly of the drive pattern will result in
satisfactory coast performance.
There are 2 basic types of conditions that will
produce ring and pinion noise. The first type is a NOTE: If a gross pattern error is detected with the
howl or chuckle produced by broken, cracked, correct backlash, check the pinion shim selection.
chipped, scored or forcibly damaged gear teeth and
is usually quite audible over the entire speed range.
The second type of ring and pinion noise pertains to
the mesh pattern of the gear pattern. This gear noise
can be recognized as it produces a constant pitch or
whine. Ring and pinion noise tends to peak in a
narrow speed range or ranges and will tend to
remain constant in pitch.
NOTE: In the following steps, the movement of the
contact pattern along the length is indicated as
toward the heel or toe of the differential ring
gear.
Item Description
1 Heel
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Low Contact Pattern That Is Contacting Thick Contact Pattern That Is Contacting
More Toward the Heel Tooth Toward the Heel
High, Thin Contact Pattern In the Center Of Thick Contact Pattern That Is Contacting
the Tooth Tooth Toward the Toe
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IN-VEHICLE REPAIR
Material
Rear Wheel Bearing and Axle Shaft
Item Specification
Seal
Grease
Special Tool(s)
Slide Hammer CXG-1-C (Canada)
100-001 (T50T-100-A)
Synthetic Rear Axle
Lubricant
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Remover, Axle Bearing Removal
205-219 (T85L-1225-AH)
1. Remove the axle shaft. For additional
2. NOTE: If the axle shaft oil seal is leaking, the
axle housing vent may be plugged.
Adapter For 303-224
Using the special tools, remove the rear wheel
205-153 (T80T-4000-W)
bearing and axle shaft oil seal.
Installer, Axle Shaft Bearing
205-124 (T78P-1225-A)
205-390 (T97T-1177-B)
Installation
1. Lubricate the new rear wheel bearing with the
axle lubricant.
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2. Using the special tools, install the new rear 4. Using the special tools, install the new axle
wheel bearing. shaft oil seal.
3. Lubricate the lip of the new axle shaft oil seal 5. Install the axle shaft. For additional
with grease. information, refer to Axle Shaft in this section.
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SPECIFICATIONS
Item Specification
Variation between teeth 0.102 mm (0.004 in)
Item Specification maximum backlash
Lubricants and Sealers Available drive pinion 0.254 mm (0.010 in) -
bearing adjustment shim 0.965 mm (0.038 in)
in steps of 0.25 mm
Synthetic Rear Axle
(0.010 in)
Lubricant
XY-75W140-QL (US); Pinion flange runout 0.25 mm (0.010 in) T.I.R.
CXY-75W140-1L
a In-vehicle repair refill capacities are determined by (Canada)
filling the rear axle with the specified lubricant to
Motorcraft High Contrast
25.4-28.6 mm (1.0-1.125 in) below the bottom of
Hypoid Gear Marking
the fill hole with the axle at ride height.
Compound XG-14
Rear Axle Backlash Shim Adjustment Table
Grease XG-1-C or
(Canada)
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
Sealant TA-30
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
TA-25
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
TA-27
0.177 0.007 0.254 0.010
XL-3 (US); CXL-3 0.203 0.008 0.254 0.010
(Canada)
0.228 0.009 0.304 0.012
Lubricant Capacities
0.254 0.010 0.355 0.014
Approximate axle fill 1.7 liters (3.15 pints)
0.279 0.011 0.355 0.014
capacity
a
25.4-28.6 mm (1.0-1.125
in) below the bottom of 0.304 0.012 0.406 0.016
the fill hole with the axle
0.330 0.013 0.457 0.018
at ride height
0.335 0.014 0.457 0.018
Additive friction modifier 118 mi (4 oz)
0.381 0.015 0.508 0.020
Clearance, Tolerance and Adjustments
Maximum differential case 0.076 mm (0.003 in)
runout Torque Specifications
Differential side gear 0.762-0.813 mm
Anti-lock sensor bolt 7 62
Differential pinion gear 0.762-0.813 mm
Differential bearing cap 105 77
bolts
Maximum axle shaft end 0.762 mm (0.030 in)
Differential housing 45 33
play
cover bolts
Pinion bearing preload 1.8-3.3 Nm (16-29 lb-in)
Differential pinion 30 22
Ring gear backlash 0.203-0.304 mm
shaft lock bolt
(0.008-0.012 in)
Differential ring gear 105 77
bolts (4.6L)
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Differential ring gear 135 100 Rear support brace 63 46
bolts (5.4L) bolts (convertible)
Disc brake caliper 103 76 Stabilizer bar 70 52
anchor bolts bracket-to-frame bolts
Disc brake caliper bolts 33 24 Tool 205-135 nut 6.7 60
Driveshaft flange bolts 103 76 Trackbar flagnuts 175 129
Filler plug 30 22 Trailing arm nut 175 129
Front support brace 63 46 Upper support brace 63 46
bolts (convertible) bolts (convertible)
Handle adapter for 2.2 20 Upper suspension arm 175 129
205-S127 nut
Lower shock absorber 115 85
nuts
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206-00-1 206-00-1 Brake System General Information
SPECIFICATIONS
Item Specification
High Performance DOT 3 ESA-M6C25-A or
Item Specification Motor Vehicle Brake WSS-M6C62-A
Fluid PM-1 or PM-1-C
Brake Pads 4.0L SOHC and 4.6L (3V)
(US); CPM-1 or CPM-1-C
Minimum brake pad 3.0 mm (0.118 inch)
(Canada)
thickness
Maximum brake pad 2.0 mm (0.079 inch)
thickness variation
(pad-to-pad)
Silicone Brake Caliper ESE-M1C171-A
Maximum brake pad taper 3.0 mm (0.118 inch)
Grease and Dielectric
wear (in any direction)
Compound XG-3-A
Brake Disc 4.0L SOHC and 4.6L (3V)
Metal Brake Parts Cleaner
PM-4-A or PM-4-B (US);
Minimum front brake disc 28.4 mm (1.11 in)
CPM-4 (Canada)
thickness
Minimum rear brake disc 17.4 mm (0.68 in)
thickness
Minimum thickness to 29 mm (1.14 in)
machine front brake disc
Brake caliper bolts
a
33 24
machine rear brake disc Front brake caliper 10 89
bleeder screw 4.0L
Brake Pads 5.4L
SOHC and 4.6L (3V)
Minimum front brake pad 1.8 mm (0.071 in)
Front brake caliper 18 13
thickness
bleeder screws 5.4L
Minimum rear brake pad 3.0 mm (0.118 in)
Master cylinder brake 17 13
thickness
tube fittings
Brake Disc 5.4L
Rear brake caliper 10 89
Minimum front brake disc 3.0 mm (1.18 in) bleeder screw all
thickness vehicles
Minimum thickness to 30.6 mm (1.20 in)
a The bolts retaining the front caliper halves together
on 5.4L equipped vehicles are not serviceable.
Lubricant
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GENERAL PROCEDURES
2. For vehicles with a 2-piece brake disc and hub
Brake Disc Machining
assembly:
Material 1 Mark the brake disc and the wheel stud for
correct indexing during re-assembly.
Item Specification
2 Remove the brake disc from the hub.
3 CAUTION: Do not use an abrasive
XL-2 (US); CXG-2-B
sanding disc since it will remove paint or
(Canada)
other protective finishes from the wheel
or metal from the mounting surfaces,
adversely affecting corrosion protection
CPM-4 (Canada)
and brake disc lateral runout.
CAUTION: Do not use a bench lathe to
Remove corrosion from the wheel mounting
machine the brake discs.
surface, both disc mounting surfaces and
hub mounting surface.
NOTE: Read the entire operating manual and view
4 Align the match marks and install the brake
the video shipped with the lathe before installing,
disc on the hub.
operating or repairing the lathe.
3. Machine the brake disc using an on-vehicle
NOTE: If the thickness of the brake disc is less
brake lathe.
than the minimum thickness to machine
specification, install a new brake disc. This will
1 Install the hub adapter and silencer belt if
make sure that the brake disc will be above
necessary.
minimum thickness after machining.
2 Install the cutting lathe.
NOTE: Do not machine new brake discs. 3 If the lathe is not self adjusting, adjust the
lathe oscillation using a dial indicator. Total
NOTE: Lateral runout and disc thickness variation
indicated reading (TIR) target is 0.000 mm
measurements are not required because correct
(0.000 in), maximum is 0.08 mm (0.003 in).
adjustment of the on-vehicle brake lathe will make
4 Center the cutting head, adjust the cutting
sure that these dimensions are within specifications.
bits and install the chip deflector.
5 NOTE: The depth of cut should be between
1. NOTE: It is not necessary to disconnect the
0.10 and 0.20 mm (0.004 and 0.008 in).
brake line from the brake caliper.
Lighter cuts will cause the bit to heat up
Position the brake caliper and brake caliper
and wear faster. Heavier cuts will cause
anchor bracket aside. For additional
poor brake disc surface finish.
information, refer to Section 206-03 for front
Machine the brake disc.
brake discs or Section 206-04 for rear brake
discs.
6 Remove the lathe and, if installed, the
silencer belt.
7 Remove the hub adapter.
4. Remove the metal shavings.
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5. For vehicles with a 2-piece brake disc and hub 6. NOTE: It is not required to install new brake
assembly: pads if friction material properties are within
guidelines. For additional information, refer to
1 Remove the brake disc from the hub.
Brake Pads in this section.
2 Remove metal shavings from the hub, the
Install the brake caliper and brake caliper
brake disc mounting surfaces and from the
anchor bracket. For additional information, refer
ABS sensors.
to Section 206-03 for front brake discs or
3 Apply anti-seize lubricant to the hub
Section 206-04 for rear brake discs.
mounting surface to prevent corrosion.
4 Align the match marks and install the brake
disc on the hub.
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GENERAL PROCEDURES
Brake System Bleeding CAUTION: After the installation of a
hydraulic control unit replacement, conduct the
Brake System Pressure Bleeding procedure Special Tool(s)
before the scan tool based bleed procedure. A
scan tool based bleed procedure is then required
to completely bleed the system. Follow the
instructions from the scan tool. software with appropriate
tool NOTE: If the hydraulic control unit (HCU), or any
component upstream of the HCU are installed new,
carry out the Brake System Pressure Bleeding
procedure first without the scan tool, followed by
Material
the Brake System Bleed procedure using the scan
Item Specification
tool. The Component Bleeding Rear Brake
High Performance DOT 3 ESA-M6C25-A or Caliper procedure is not required as new rear
Motor Vehicle Brake Fluid WSS-M6C62-A
calipers were not installed.
PM-1 or PM-1-C (US);
CPM-1 or CPM-1-C
NOTE: When any part of the hydraulic system is
(Canada)
disconnected for repair or installation of new
components, air can get into the system and cause
Manual
spongy brake pedal action. This requires bleeding of
the hydraulic system after it is correctly connected.
WARNING: Use of any other than
The hydraulic system can be bled manually or with
approved DOT 3 motor vehicle brake fluid will
pressure bleeding equipment.
cause permanent damage to brake components
and will render the brakes inoperative. Failure to
All vehicles
injury.
1. Connect the scan tool cable adapter into the
vehicle data link connector (DLC) under the
WARNING: Carefully read cautionary
dash and follow the scan tool instructions.
information on product label. For additional
information, see product Material Safety Data
2. Clean all the dirt from the area, remove the
Sheet (MSDS). For 24-hour MEDICAL
brake master cylinder reservoir cap and fill the
EMERGENCY INFORMATION on
brake master cylinder reservoir with clean,
Ford/Motorcraft products call: 1-800-959-3673
specified brake fluid.
(FORD). Failure to follow these instructions may
result in personal injury.
CAUTION: Brake fluid is harmful to
painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface,
immediately wash it with water.
CAUTION: Do not allow the brake master
cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder
reservoir filled with clean, specified brake fluid.
Never reuse the brake fluid that has been
drained from the hydraulic system.
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3. Remove the RH rear bleeder cap and place a
box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear
bleeder screw and submerge the free end of the
hose in a container partially filled with clean,
9. Have an assistant hold firm pressure on the
brake pedal.
10. Loosen the RH front brake caliper bleeder
screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the
brake pedal, tighten the RH front brake caliper
4. Have an assistant hold firm pressure on the bleeder screw.
brake pedal.
Repeat until clear, bubble-free fluid comes
out.
5. Loosen the RH rear bleeder screw until a
Refill the brake master cylinder reservoir as
stream of brake fluid comes out. While the
necessary.
assistant maintains pressure on the brake pedal,
tighten the RH rear bleeder screw.
11. Tighten the RH front brake caliper bleeder
screw and install the bleeder cap.
out.
necessary.
12. Repeat Steps 8 through 11 for the LH front
brake caliper bleeder screw.
6. Tighten the RH rear brake caliper bleeder screw
and install the bleeder cap.
7. Repeat Steps 3 through 6 for the LH rear brake
caliper bleeder screw.
Vehicles equipped with a 4.0L SOHC or 4.6L
(3V) engine
8. Remove the RH front bleeder cap and place a
box-end wrench on the RH front brake caliper
bleeder screw. Attach a rubber drain hose to the
RH front brake caliper bleeder screw and
submerge the free end of the hose in a
container partially filled with clean, specified
brake fluid.
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Vehicles equipped with a 5.4L engine
21. Repeat Steps 13-16 for the LH front inner brake
13. Remove the RH front inner bleeder cap and
Pressure
place a box-end wrench on the RH front inner
brake caliper bleeder screw. Attach a rubber
drain hose to the RH front inner bleeder screw
and submerge the free end of the hose in a
container partially filled with clean, specified
brake fluid.
injury.
information on product label. For EMERGENCY
MEDICAL INFORMATION seek medical advice.
In the USA or Canada on Ford/Motorcraft
products call: 1-800-959-3673. For additional
information, consult the product Material Safety
Data Sheet (MSDS) if available. Failure to follow
spilled onto a painted or plastic surface, 14. Have an assistant hold firm pressure on the
immediately wash it with water. brake pedal.
15. Loosen the RH front inner brake caliper bleeder CAUTION: Do not allow the brake master
screw until a stream of brake fluid comes out. cylinder reservoir to run dry during the bleeding
While the assistant maintains pressure on the operation. Keep the brake master cylinder
brake pedal, tighten the RH front brake caliper reservoir filled with clean, specified brake fluid.
bleeder screw. Never reuse the brake fluid that has been
out.
CAUTION: After the installation of a
hydraulic control unit replacement, conduct the
necessary.
Brake System Pressure Bleeding procedure
before the scan tool based bleed procedure. A
16. Tighten the RH front inner brake caliper
scan tool based bleed procedure is then required
bleeder screw and install the bleeder cap.
to completely bleed the system. Follow the
instructions from the scan tool.
17. Repeat Steps 13-16 for the RH front outer NOTE: If the hydraulic control unit (HCU), or any
brake caliper bleeder screw. component upstream of the HCU are installed new,
carry out the Brake System Pressure Bleeding
18. Repeat Steps 13-16 for the RH front inner
procedure first without the scan tool, followed by
brake caliper bleeder screw.
the Brake System Bleed procedure using the scan
tool. The Component Bleeding Rear Brake
19. Repeat Steps 13-16 for the LH front inner brake
Caliper procedure is not required as new rear
calipers were not installed.
20. Repeat Steps 13-16 for the LH front outer brake
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All vehicles
1. Clean all the dirt from the area and remove the
brake master cylinder filler cap. Fill the brake
master cylinder reservoir with clean, specified
4. Open the valve on the bleeder tank.
brake fluid.
Vehicles equipped with a 4.0L SOHC or 4.6L
(3V) engine
5. Loosen the RH rear brake caliper bleeder
screw. Leave open until clear, bubble-free brake
fluid flows, then tighten the RH rear brake
caliper bleeder screw and remove the rubber
hose and install the RH rear bleeder cap.
6. Continue bleeding the system, going in order
from the LH rear brake caliper bleeder screw to
the RH front brake caliper bleeder screw ending
2. NOTE: Master cylinder pressure bleeder
with the LH front brake caliper bleeder screw.
adapter tools are available from various
manufacturers of pressure bleeding equipment.
7. Close the bleeder tank valve. Remove the tank
Follow the instructions of the manufacturer
hose from the adapter, and remove the adapter.
when installing the adapter.
Vehicles equipped with a 5.4L engine
Install the bleeder adapter to the brake master
cylinder reservoir and attach the bleeder tank
8. Loosen the RH rear brake caliper bleeder
hose to the fitting on the adapter.
screw. Leave open until clear, bubble-free brake
fluid flows, then tighten the RH rear brake 3. NOTE: Bleed the longest line first. Make sure
caliper bleeder screw and remove the rubber the bleeder tank contains enough clean,
hose and install the RH rear bleeder cap. specified brake fluid to complete the bleeding
operation.
Remove the RH rear bleeder cap and place a
box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear
bleeder screw and submerge the free end of the
hose in a container partially filled with clean,
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9. Continue bleeding the system in the following 10. Close the bleeder tank valve. Remove the tank
order: hose from the adapter, and remove the adapter.
1 LH rear brake caliper bleeder screw
2 RH front inner brake caliper bleeder screw
3 RH front outer brake caliper bleeder screw
4 RH front inner brake caliper bleeder screw
5 LH front inner brake caliper bleeder screw
6 LH front outer brake caliper bleeder screw
7 LH front inner brake caliper bleeder screw
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rear disc brakes with an integral parking brake,
Brake System
using a single piston brake caliper and disc
The brake system consists of the following
system
components:
a 4-wheel anti-lock brake system (ABS). Refer to
a vacuum-assisted power brake booster
Section 206-09.
a front-to-rear split hydraulic system
front disc brakes using a dual piston brake caliper
and disc system
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Brake System
WARNING: Use of any brake fluid other
Special Tool(s)
than the approved DOT 3 will cause permanent
damage to brake components and will render the
brakes inoperative. Failure to follow these
tool
73III Automotive Meter
Flex Probe Kit spilled onto a painted or plastic surface,
105-R025B or equivalent
NOTE: Always check the fluid level in the brake
master cylinder reservoir before carrying out the test
procedures. If the fluid level is below the MIN level
mark, clean the reservoir cap before removing, then
add clean, specified brake fluid.
Material NOTE: Prior to carrying out any diagnosis, make
sure the red brake warning indicator is functional.
Item Specification
The first indication that something may be wrong in Motor Vehicle Brake Fluid WSS-M6C62-A
PM-1 or PM-1-C (US); the brake system is a change in the feeling through
CPM-1 or CPM-1-C
the brake pedal. The brake warning indicator in the
(Canada)
instrument cluster and the brake fluid level in the
brake master cylinder reservoir are also indicators
of system concerns.
Compound
XG-3-A If a wheel is locked and the vehicle must be moved,
open a bleeder screw at the locked wheel to let out
PM-4-A or PM-4-B (US); enough fluid to relieve the pressure. Close the
CPM-4 (Canada)
bleeder screw. This bleeding operation may release
the brakes but does not correct the concern. If this
does not relieve the locked wheel condition, repair
the locked components before proceeding.
Inspect all hoses and connections. All unused
vacuum connectors should be capped. Make sure
hoses and their connections are correctly secured
and in good condition with no holes, soft or
collapsed areas.
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Road Test
Inspect and measure the thickness of the brake
pad friction material.
of the brake system operation and accepted general
Install new brake pads if the thickness of the
braking guidelines in order to detect any problems.
friction material is less than 3.0 mm (0.118
inch). Refer to Section 206-03 for front disc
Select a road that is reasonably smooth and level.
brakes or Section 206-04 for rear disc brakes.
Gravel or bumpy roads are not suitable because the
surface does not allow the tires to grip the road
Compare all 4 front or rear pads for uneven
equally. Avoid crowned roads.
wear. Install new brake pads if the thickness
of the friction material varies from pad to pad
A key factor in evaluating brake concerns is the
by more than 2.0 mm (0.079 inch). Refer to
deceleration rate. This varies from vehicle to vehicle
Section 206-03 for front disc brakes or Section
and with changes in operating conditions. It is
evident how well the brakes are working after just a
few applications.
Install new brake pads if there are missing
chunks or cracks in the lining through to the
For low or spongy brake pedal concerns:
backing plate. Refer to Section 206-03 for
bleed the brake system and retest the brake pedal
front disc brakes or Section 206-04 for rear
feel.
disc brakes.
if the brake pedal is still low or feels spongy,
If the friction material shows taper wear and
check the brake pedal mounting for looseness and
the thickness varies by more than (3.0 mm
correct installation. Check the brake booster and
[0.118 inch] in any direction), or if the pads
the brake master cylinder for loose mounting.
show uneven wear (2.0 mm [0.079 inch]
Correct as necessary and retest the system for
difference between the inboard and the
normal operation.
outboard pad), verify the caliper guide pins
are functioning correctly. Refer to Section
check the fluid level. The fluid level must be at or
206-03 for front disc brakes or Section 206-04
above the minimum mark. If the fluid level is
for rear disc brakes.
below the minimum mark, check the system for
leaks.
Brake Discs
For a slow or incomplete brake pedal return
CAUTION: Using an impact tool without a
concern:
torque socket leads to unevenly tightened wheel
inspect for binding, damage, correct installation or
nuts. This causes brake disc on-vehicle lateral
interference at the brake pedal.
runout and brake roughness.
check the brake booster for binding, damage and
NOTE: It is generally not required to install new
correct installation.
brake discs to address noise issues.
Brake Pads
Remove the brake disc. Refer to Section 206-03
for front disc brakes or Section 206-04 for rear
NOTE: New brake pads are not required if friction
disc brakes.
material properties are within guidelines. New brake
pads are not required when the brake discs are
machined.
Remove the brake pads. Refer to Section 206-03
for front disc brakes or Section 206-04 for rear
disc brakes.
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Brake Hoses and Tubes
Inspect the brake discs and measure the brake disc
thickness in a minimum of 4 places around the
CAUTION: Never use copper tubing. It is
circumference of the brake disc. Record the
subject to fatigue, cracking and corrosion, which
measurements.
could result in brake tube failure.
Install new brake discs if any thickness
Double-wall steel tubing is used throughout the
measurement is less than the minimum
brake hydraulic system. All brake tube fittings
specification. Refer to Section 206-03 for front
must be correctly flared to provide strong,
disc brakes or Section 206-04 for rear disc
leakproof connections. When bending tubing to fit
brakes.
the underbody or rear axle contours, be careful
Install new brake discs if cracked. Refer to
not to kink or crack the tube.
Section 206-03 for front disc brakes or Section
If a section of the brake tube is damaged, the
entire section must be installed new with a tube
Machine the brake discs if the diagnosis has
of the same type, size, shape and length.
revealed vibration in the steering wheel, seat
When installing the hydraulic brake tubing, hoses,
or pedal while braking. Heavily scored brake
or connectors, tighten all connections to
discs, similar to that caused by pads worn
specifications. After installation, bleed the brake
down to the backing plate, should also be
system. Refer to Brake System Bleeding in this
machined. In order to machine, discs must be
section.
above the minimum thickness to machine
specification. Refer to Specifications and The wet appearance on the outer cover of rubber
Brake Disc Machining in this section. brake hoses is called sweating. This is a normal
condition for neoprene rayon-braided hose and is
Brake Caliper
not a sign of leakage or cause to install a new
Inspect the brake calipers for the following: hose.
Install a new flexible brake hose if the hose shows
Brake fluid leaks.
signs of softening, cracking or other damage.
Boots and seals for tears or cracks.
When installing a new brake hose, position the hose
Caliper piston for binding and corrosion.
to avoid contact with other vehicle components.
Guide pins for correct operation. Refer to Section
Non-Pressure Leaks
206-03 for front disc brakes or Section 206-04 for
rear disc brakes.
The only part of the brake system that could have a
brake fluid loss that does not appear when the
Brake Caliper Guide Pins
system is under pressure is the brake master
cylinder reservoir under the following conditions:
CAUTION: Do not use power tools for
caliper guide pin bore cleaning.
Missing or poorly-fitted brake master cylinder
NOTE: Guide pin kits are not available.
filler cap.
The guide pins should slide with a reasonable
Punctured or otherwise damaged brake master
amount of hand force. If the brake pads show taper
cylinder reservoir.
wear or the guide pins are difficult to move, install
Missing or damaged brake master cylinder filler
a new caliper assembly. For additional information,
cap gasket.
refer to Section 206-03 or Section 206-04.
Missing, damaged or poorly-fitted sealing
grommets between the brake master cylinder and
the brake master cylinder reservoir.
The brake master cylinder reservoir grommets are
not repairable and must be installed new as part of
a new brake master cylinder reservoir.
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Brake Master Cylinder Normal Conditions Brake Booster
The following conditions are considered normal and Inspect the brake booster for the following:
are not indications that the brake master cylinder is
Excessive corrosion or damage.
in need of service.
Vacuum connections for leakage.
Condition 1: During normal operation of the brake
Vacuum hoses for kinks or leakage.
master cylinder, the fluid level in the brake master
cylinder reservoir rises during brake application and
Brake booster check valve for correct operation.
falls during release. The net fluid level (such as
Changes in the brake pedal feel or travel are
after brake application and release) remains
indicators that something could be wrong in the
unchanged.
brake system. GO to Symptom Chart for abnormal
Condition 2: A trace of brake fluid exists on the
condition diagnosis.
booster shell below the master cylinder mounting
Parking Brake
flange. This results from the normal lubricating
action of the master cylinder bore and seal.
Check the operation of the parking brake system
with the vehicle on a hoist and the parking brake
Condition 3: Fluid level decreases with pad wear.
control fully released. Check for any damaged
Brake Master Cylinder Abnormal
cables and install new components as necessary.
Conditions
Check the rear brake adjustment or carry out the
brake system diagnosis. Refer to Section 206-05.
Changes in brake pedal feel or travel are indicators
that something could be wrong in the brake system.
GO to Symptom Chart for abnormal condition
diagnosis.
Symptom Chart
Symptom Chart
The red brake warning Brake fluid level If the fluid level is below the
indicator is always on Brake fluid leak minimum level, CHECK the
system for leaks. REPAIR as
necessary.
Parking brake switch GO to Pinpoint Test A.
Brake fluid level switch
Circuitry
Instrument cluster
The red brake warning Circuitry REFER to Section 413-01.
indicator is inoperative Instrument cluster
The brakes pull or drift Tire air pressure CHECK the tires for uneven
or excessive wear and
CORRECT the inflation.
Brake pads CHECK the brake pads for
Brake components uneven taper or excessive
wear. REPAIR as necessary.
Suspension components CHECK the suspension
Wheel alignment components and the wheel
alignment. REFER to Section
204-00.
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The brake pedal goes down Brake fluid level INSPECT the system for
fast leaks, REPAIR as necessary.
FILL the brake master
cylinder reservoir. BLEED
the system. REFER to Brake
System Bleeding in this
section.
Air in the system INSPECT the system for
leaks, REPAIR as necessary.
BLEED the system. REFER
to Brake System Bleeding in
this section.
Brake master cylinder CARRY OUT the brake
master cylinder component
test in this section.
The brake pedal eases down Air in the system INSPECT the system for
slowly leaks, REPAIR as necessary.
BLEED the system. REFER
this section.
Brake lockup under light Brake pads CHECK the brake pads for
brake pedal force uneven taper or excessive
wear. REPAIR as necessary.
Brake component CHECK the brake
components for correct
operation. REPAIR as
necessary.
Parking brake component REPAIR or INSTALL new
Anti-lock brake control CHECK the anti-lock brake
system control system. REFER to
Section 206-09.
Excessive/erratic brake pedal Leak in the hydraulic system INSPECT the system for
travel Air in the system leaks, REPAIR as necessary.
Brake caliper BLEED the system. REFER
this section.
Brake pads CHECK the brake pads for
excessive wear. REPAIR as
necessary.
Brake pedal CHECK the brake pedal for
binding or obstructions.
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Brakes drag Parking brake component REPAIR or INSTALL new
Brake caliper guide pins REPAIR or INSTALL new
brake calipers as necessary.
Brake caliper REPAIR or INSTALL new
Brake switches REMOVE and REINSTALL
the stoplamp switch and the
speed deactivation switch.
Brake booster CARRY OUT the brake
booster component test in this
section.
Excessive brake pedal effort Brake booster CARRY OUT the brake
booster component test in this
section.
Brake booster check valve CARRY OUT the check
valve component test in this
section.
Brake booster manifold REROUTE, REPAIR or
vacuum hose INSTALL new components
as necessary.
Rattling noise Caliper mounting bolts loose CHECK the caliper bolts.
TIGHTEN to specifications.
Damaged or worn caliper CHECK the caliper guide
guide pins or retainers pins and retainers for
lubrication and correct
operation. LUBRICATE or
brakes or Section 206-04 for
rear disc brakes.
Missing or damaged CHECK the brake pads for
anti-rattle clips or springs missing clips or broken
springs. INSTALL new
Loose brake disc shield TIGHTEN the brake disc
shield bolts to specification.
206-04 for rear disc brakes
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Clicking noise with brakes ABS hydraulic control unit Acceptable condition.
applied with anti-lock brake (HCU)
system (ABS)
Squealing noise occurs on Brake pads Acceptable condition. Caused
first brake application by humidity and low brake
pad temperature.
Squealing noise a Brake pads or linings worn INSPECT the brake pads for
continuous squeal below minimum thickness excessive wear, taper wear or
uneven wear. VERIFY the
brake pads are within
minimum specifications.
REFER to Brake Pads in this
section.
Squealing noise an Brake pads Acceptable condition.
intermittent squeal brought on
by cold, heat, water, mud or
snow
Groaning noise occurs at Brake pads Acceptable condition.
low speeds with brake lightly
applied (creeping)
Grinding noise continuous Brake pads or linings worn INSPECT the brake pads,
below minimum thickness brake discs and attaching
hardware for damage.
VERIFY brake pads are
within minimum
specifications. REFER to
Brake Pads in this section.
Moaning noise Brake linings contaminated INSPECT the brake pads for
with grease or oil contamination. REPAIR or
brakes or Section 206-04 for
rear disc brakes.
Vibration when the brakes are Uneven brake pad wear COMPLETE the brake
applied Brake disc pad transfer system inspection described
Brake disc in Inspection and Verification
Suspension components in this section.
GO to Pinpoint Test B.
Brake vibration/shudder Brake caliper guide pins INSPECT the brake caliper
occurs when the brake pedal guide pins for correct
is released operation. REFER to Section
or Section 206-04 for rear
disc brakes.
Brake drag INSPECT the brake pads for
premature wear. REPAIR or
INSTALL a new caliper as
or Section 206-04 for rear
disc brakes.
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Possible Causes Pinpoint Tests
Circuit shorted
Pinpoint Test A: The Red Brake Warning
Indicator is Always On Low brake fluid level
Refer to Wiring Diagrams Cell 60, Instrument Brake fluid level switch
Cluster for schematic and connector information.
Parking brake engaged
Normal Operation
Parking brake switch
The red brake warning indicator is located in the
Instrument cluster
instrument cluster and illuminates when the brake
SJB
fluid in the brake master cylinder reservoir is below
a specific level or when the parking brake is
engaged. When the parking brake is applied, the
instrument cluster receives a ground input on circuit
1309 (RD/YE) through the parking brake switch and
circuit 1205 (BK), turning on the brake warning
indicator. The smart junction box (SJB) provides a
voltage to the brake fluid level switch through
circuit 547 (LG/YE) and back through the SJB
return circuit 512 (TN/LG). When the brake fluid
level is low, the brake fluid level switch closes and
connects circuit 547 (LG/YE) to circuit 512
(TN/LG). The voltage reference signal the SJB is
sending to the brake fluid level switch drops to
zero, then the SJB sends a message over the
medium speed communication area network
(MS-CAN) to the instrument cluster to turn on the
brake warning indicator.
PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON
CAUTION: Use the Flex Probe Kit for all test connections to prevent damage to the
wiring terminals. Do not use standard multi-meter probes.
A1 CHECK THE PARKING BRAKE SWITCH
Verify the parking brake is fully released. Yes
Key in OFF position. GO to A2.
Disconnect: Parking Brake Switch C306.
No
Key in ON position.
INSTALL a new parking brake switch.
Is the red brake warning indicator illuminated?
A2 CHECK THE BRAKE FLUID LEVEL SWITCH
Disconnect: Brake Fluid Level Switch C124. Yes
Is the red brake warning indicator illuminated? GO to A3.
No
INSTALL a new brake fluid reservoir.
REFER to Section 206-06. CLEAR the
DTCs. REPEAT the self-test.
A3 CHECK CIRCUIT 1309 (RD/YE) FOR A SHORT TO GROUND
Disconnect: SJB C2280c.
(Continued)
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PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON (Continued)
A3 CHECK CIRCUIT 1309 (RD/YE) FOR A SHORT TO GROUND
(Continued)
Measure the resistance between parking brake switch C306-1,
circuit 1309 (RD/YE), harness side and ground.
Yes
REPAIR circuit 1309 (RD/YE). CLEAR the
No
Is the resistance less than 5 ohms? GO to A4.
A4 CHECK CIRCUIT 547 (LG/YE) FOR A SHORT TO GROUND
Measure the resistance between brake fluid level switch C124-1,
circuit 547 (LG/YE), harness side and ground.
Yes
REPAIR circuit 547 (LG/YE). CLEAR the
No
A5 CHECK FOR A SHORT BETWEEN CIRCUIT 512 (TN/LG) AND
CIRCUIT 547 (LG/YE)
Measure the resistance between brake fluid level switch C124-1,
circuit 547 (LG/YE), harness side and between brake fluid level
switch C124-2, circuit 512 (TN/LG), harness side.
Yes
GO to A6.
No
Is the resistance less than 5 ohms? DTCs. REPEAT the self-test.
(Continued)
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PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON (Continued)
A6 CHECK THE SMART JUNCTION BOX (SJB) OUTPUT
Connect: SJB C2280c. Yes
Disconnect: SJB C2280b. GO to A7.
Observe the red brake warning indicator.
No
Is the red brake warning indicator illuminated?
GO to A8.
A7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Connect: SJB C2280b.
Yes
Disconnect all the instrument cluster connectors.
INSTALL a new instrument cluster.
Check for:
corrosion.
pushed-out pins.
spread terminals. No
Connect all the instrument cluster connectors and make sure The system is operating correctly at this
they seat correctly. time. The concern may have been caused
Operate the system and verify if the concern is still present. by a loose or corroded connector. CLEAR
Is the concern still present? the DTCs. REPEAT the self-test.
A8 CHECK FOR CORRECT SJB OPERATION
Disconnect all the SJB connectors. Yes
Check for: INSTALL a new SJB. REFER to Section
corrosion. 419-10. CLEAR the DTCs. REPEAT the
pushed-out pins. self-test.
spread terminals.
No
Connect all the SJB connectors and make sure they seat
The system is operating correctly at this
correctly.
time. The concern may have been caused
Operate the system and verify if the concern is still present.
by a loose or corroded connector. CLEAR
Is the concern still present?
the DTCs. REPEAT the self-test.
Pinpoint Test B: Vibration When the Brakes
are Applied
Possible Causes
Uneven brake pad wear
Brake disc pad transfer
Brake disc
PINPOINT TEST B: VIBRATION WHEN THE BRAKES ARE APPLIED
B1 CHECK OASIS AND FOR TSBs
Check the On-Line Automotive Service Information System Yes
(OASIS) and Technical Service Bulletins (TSBs) for applicable REFER to OASIS or the TSB. CARRY
brake concerns. OUT any necessary repairs that are
Is there applicable information available on OASIS or in a indicated by OASIS or the TSB. If the
TSB? concern is still present, GO to B2.
No
GO to B2.
B2 ROAD TEST THE VEHICLE LIGHT BRAKING
Inspect the wheels and tires. Refer to Section 204-00.
Road test the vehicle. Warm the brakes by slowing the vehicle
from 80-32 km/h (50-20 mph) using light brake force. At highway
Yes
speeds of 89-97 km/h (55-60 mph), apply the brake using light
GO to B5.
pedal force.
Is there a vibration/shudder felt in the steering wheel, seat No
or brake pedal? GO to B3.
(Continued)
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PINPOINT TEST B: VIBRATION WHEN THE BRAKES ARE APPLIED (Continued)
B3 ROAD TEST THE VEHICLE MODERATE TO HEAVY
BRAKING
Road test the vehicle. At highway speeds of 89-97 km/h (55-60 Yes
mph), apply the brake using a moderate to heavy pedal force. GO to B4.
Is there a vibration/shudder?
No
The concern is not present at this time.
B4 NORMAL ACTUATION OF THE ANTI-LOCK BRAKE SYSTEM
(ABS) SYSTEM DIAGNOSIS
During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS system.
Yes
Pedal pulsation or steering wheel nibble (frequency is
GO to B5.
proportioned to the vehicle speed) indicates a concern with a
brake or suspension component. No
Is the vibration/shudder vehicle speed sensitive? The concern is not present at this time.
B5 CHECK THE FRONT SUSPENSION
Check the front suspension. Refer to Section 204-00. Yes
Are all the suspension components in satisfactory GO to B6.
condition?
No
B6 RESURFACE THE FRONT BRAKE DISCS
CAUTION: Do not use a bench lathe to machine the
brake discs.
Yes
Resurface the front brake discs. Refer to Brake Disc Machining
GO to B7.
in this section.
Road test the vehicle. No
Is the vibration/shudder present? The concern is not present at this time.
B7 CHECK THE REAR SUSPENSION
Check the rear suspension. Refer to Section 204-00. Yes
Are all the suspension components in satisfactory GO to B8.
condition?
No
B8 RESURFACE THE REAR BRAKE DISC
CAUTION: Do not use a bench lathe to machine the
brake discs.
Yes
REFER to Section 100-04 to continue
Resurface the rear brake discs. Refer to Brake Disc Machining
diagnosis of the vibration.
in this section.
Road test the vehicle. No
Is the vibration/shudder present? The concern is not present at this time.
Component Tests 2. With the transmission in NEUTRAL, stop the
engine and apply the parking brake control.
Brake Booster
Apply the brake pedal several times to exhaust
1. Check the hydraulic brake system for leaks or
all vacuum in the system.
insufficient fluid.
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3. Apply the brake pedal and hold it in the applied To test the function of the brake booster check
valve: position. Start the engine. If the vacuum system
is operating, the brake pedal tends to move
start and run the engine for at least 10 seconds.
downward under constant foot pressure. If no
operate the brake pedal to check for power assist.
motion is felt, the brake booster system is not
functioning. Continue with the following steps.
disconnect the vacuum booster hose from the
brake booster check valve. Do not remove the
4. Remove the vacuum booster hose from the
brake booster check valve from the brake booster.
check valve connection. Manifold vacuum must
be available at the check valve end of the there should be enough vacuum retained in the
vacuum booster hose with the engine at idle brake booster for at least one more power-assisted
speed and the transmission in NEUTRAL. If brake operation.
the manifold vacuum is available to the brake
Brake Master Cylinder Bypass Condition
booster, connect the vacuum booster hose to the
1. Disconnect the brake tubes at the brake master brake booster check valve and repeat Steps 2
cylinder. and 3.
2. Plug the outlet ports of the brake master 5. If no downward movement of the brake pedal is
cylinder. felt, install a new brake booster. For additional
3. Apply the brakes. If brake pedal height cannot
be maintained, the brake master cylinder has an
6. Operate the engine a minimum of 10 seconds at
internal leak and a new brake master cylinder
fast idle. Stop the engine, and let the vehicle
must be installed.
stand for 10 minutes. Then apply the brake
pedal with approximately 89 N (20 lb) of force.
Brake Master Cylinder Compensator Port
The brake pedal feel should be the same as that
Check
noted with the engine operating. If the brake
The purpose of the compensator ports in the brake
pedal feels hard (no power assist), install a new
master cylinder is to supply any additional brake
brake booster check valve and retest. If the
fluid required by the system due to brake pad wear
brake pedal feels spongy, bleed the hydraulic
and to allow brake fluid returning from the brake
system to remove air. Refer to Brake System
hoses and tubes to the brake master cylinder to
Bleeding in this section.
enter the brake master cylinder reservoir.
Check Valve
The returning brake fluid causes a slight turbulence
The function of the brake booster check valve is to in the brake master cylinder reservoir. Turbulence
allow manifold vacuum to enter the brake booster seen in the brake master cylinder reservoir upon
and prevent the escape of vacuum in case manifold application or release of the brake pedal is normal
vacuum is lost during sustained full throttle and shows that the compensating ports are not
operation. plugged.
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GENERAL PROCEDURES
Component Bleeding CAUTION: Brake fluid is harmful to
spilled onto a painted or plastic surface, Special Tool(s)
components, air can enter the system and cause
tool spongy brake pedal action. This requires bleeding of
Adapter for Adjuster, Rear
Brake Caliper Piston
206-026 (T87P-2588-A)
NOTE: When a new brake master cylinder is
installed, or the system is emptied or partially
emptied, it should be primed to prevent air from
entering the system.
1. For in-vehicle priming, disconnect the brake
Material
tubes.
Item Specification
CPM-1 or CPM-1-C
(Canada)
Master Cylinder
WARNING: Use of any brake fluid other
than approved DOT 3 will cause permanent
damage to brake components and will render the
brakes inoperative. Failure to follow these
2. For bench priming, mount the brake master
cylinder in a vise.
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Rear Brake Caliper
3. Install short brake tubes onto the primary and
secondary ports with the ends submerged in the
brake master cylinder reservoir.
injury.
4. Fill the brake master cylinder reservoir with
clean, specified brake fluid.
5. Have an assistant pump the brake pedal, or
slowly press the primary piston until clear fluid
flows from the brake tubes, without air bubbles.
6. If the brake master cylinder has been primed at
the bench, install it in the vehicle. For
7. Remove the short brake tubes and install the
master cylinder brake tubes.
8. Bleed each brake tube at the brake master
cylinder as follows:
1 Have an assistant pump the brake pedal,
and then hold firm pressure on the brake
pedal.
2 Loosen the rear-most brake tube fittings
NOTE: Due to the complexity of the fluid path
until a stream of brake fluid comes out.
within the rear integral parking brake calipers, it
While the assistant maintains pressure on
may be necessary to follow this procedure when
the brake pedal, tighten the brake tube
new calipers are installed.
fitting.
1. NOTE: This procedure is necessary only when
3 Repeat this operation until clear, bubble-free
installing a new rear brake caliper. To bleed the
fluid comes out.
brake system, refer to Brake System Bleeding
4 Refill the brake master cylinder reservoir as
in this section.
necessary. Repeat the bleeding operation at
the front brake tube.
Section 100-02.
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2. Remove the 2 brake caliper bolts and position 5. Slowly apply the brake pedal to extend the
the brake caliper aside. brake caliper piston outward.
6. Remove the 2 brake caliper bolts and position
the brake caliper aside.
3. Remove the outer brake pad.
7. Bleed the brake caliper.
Remove the bleeder screw cap and place a
box end wrench on the brake caliper bleeder
screw. Attach a rubber drain hose to the
brake caliper bleeder screw and submerge
the free end of the hose in a container
partially filled with clean, specified brake
fluid.
4. NOTE: Place a shop towel between the caliper
and the brake disc.
Install the brake caliper using the 2 brake
caliper bolts.
8. Loosen the brake caliper bleeder screw.
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9. Using the special tool, fully retract the brake 13. Position the brake caliper and install the 2
caliper piston and tighten the bleeder screw. brake caliper bolts.
Tighten to 10 Nm (89 lb-in). Tighten to 33 Nm (24 lb-ft).
necessary.
Hydraulic Control Unit (HCU)
NOTE: This procedure is only required when a new
10. Repeat Steps 5 through 9 until clear, bubble
HCU is installed.
free fluid comes out.
Install the bleeder screw cap. NOTE: When any part of the hydraulic system has
been disconnected for repair or new installation, air
11. Remove the 2 brake caliper bolts and the shop
may get into the system and cause spongy brake
towel.
pedal action. This requires bleeding of the hydraulic
system after it has been correctly connected. The
12. Install the outer brake pad.
hydraulic system can be gravity bled, manually bled
or bled with pressure bleeding equipment.
1. Connect the scan tool and follow the anti-lock
brake system (ABS) bleed instructions.
2. Use the pressure or manual bleed procedure(s)
to bleed the system. Begin at the RH rear brake
caliper.
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206-03-1 206-03-1 Front Disc Brake
Disc Brake System Exploded View
4.0L SOHC and 4.6L (3V)
NOTE: LH shown, RH similar.
3 2001 Brake pads kit 1 Brake caliper guide pin bolts
(2 required) (part of 2B134,
4 Spring clips (4 required) (part
also part of 2001)
of 2001)
2 2C357 RH/ Brake caliper
5 W710233 Brake caliper anchor plate
2C358 LH
bolts (2 required)
(Continued)
(Continued)
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6 2B134 Brake caliper anchor plate 13 Brake tube fittings
7 Guide pins (part of 2B134) 14 N802191 Brake flexible hose bracket
bolts
8 1125 Brake disc
15 2078 RH/ Brake flexible hose
9 W500020 Brake disc shield bolts (3
2B557 LH
required)
16 Bleeder screw cap (part of
2208)
11 W712275 Brake caliper flow bolt
17 2208 Bleeder screw
12 W712362 Copper washers (2 required)
(Continued)
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5.4L
NOTE: RH shown, LH similar
7 Brake pad mounting pin (2 1 383609 Retaining nut
required) (part of 2B164)
2 1125 Brake disc
8 Spring retainer clip (part of
3 2B220 RH/ Brake caliper
2K583)
2B221 LH
9 N802191 Brake hose-to-strut bolt
4 W500020 Brake disc shield bolt (3
10 W710233 Brake caliper bolt (2 required)
required)
11 Brake tube fitting
6 2001 Brake pad (2 required)
(Continued)
(Continued)
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1. NOTE: A revised part, with the same base part
number, has been released for the RH brake
12 N802191 Brake hose bracket-to-body
hose. When installing a new RH brake hose,
bolt
position the anti-rotation tab on the mounting
13 2078 RH/ Brake flexible hose
bracket toward the front of the vehicle and
2B557 LH
install the bolt with the head toward the rear of
14 W712362 Copper washer (2 required)
the vehicle.
For additional information, refer to the
procedures in this section.
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Brake Caliper 4.0L SOHC and 4.6L
(3V)
Section 100-02.
Material
2. Remove the brake caliper flow bolt and discard
Item Specification the 2 copper washers.
3. CAUTION: Do not use the caliper
sight hole to retract pistons as this can
CPM-1 or CPM-1-C
damage the pistons and boots.
(Canada)
Remove and discard the 2 brake caliper guide
Removal
pin bolts and remove the brake caliper.
4. Inspect the brake caliper.
If leaks or damaged boots are found, install
a new brake caliper.
Installation
injury.
1. Position the brake caliper and install 2 new
guide pin bolts.
2. Using 2 new copper washers, position the brake
flexible hose on the brake caliper and install the
brake caliper flow bolt.
3. Bleed the brakes. For additional information,
4. Test the brakes for normal operation.
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Brake Caliper 5.4L
Section 100-02.
Material
Item Specification
2. Remove the brake pads. For additional
High Performance DOT 3 ESA-M6C25-A or information, refer to Brake Pads 5.4L in this
section.
CPM-1 or CPM-1-C
(Canada)
the 2 copper washers.
WARNING: Use of any other than 4. CAUTION: Do not remove the bolts
approved DOT 3 motor vehicle brake fluid will securing the 2 caliper halves together. Do not
cause permanent damage to brake components attempt to separate the 2 caliper halves.
Remove the 2 brake caliper anchor plate bolts
and the brake caliper.
injury.
Bleed the brakes. For additional information,
Test the brakes for normal operation.
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2. NOTE: Clean any residual thread lock
Brake Caliper Anchor Plate 4.0L
compound from the anchor plate threads before
SOHC and 4.6L (3V)
installing the bolts.
Remove and discard the 2 anchor plate bolts
Material
and remove the brake caliper anchor plate.
Item Specification
3. Inspect the brake caliper anchor plate assembly.
Compound
XG-3-A
Check the guide pins and boots for binding
and damage.
Replace worn or damaged pins. Lubricate
the pins with the specified grease.
Install a new brake caliper anchor plate if it
information, refer to Brake Pads 4.0L SOHC
is worn or damaged.
and 4.6L (3V) in this section.
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Brake Disc Shield
1. Remove the brake disc. For additional
information, refer to Brake Disc in this section.
2. Remove the 3 bolts and the brake disc shield.
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Brake Disc
Material
Item Specification
XL-2 (US); CXG-2-B
(Canada)
CPM-4 (Canada)
Removal
4.0L SOHC and 4.6L (3V) equipped vehicles
Installation
1. CAUTION: Do not allow the brake All vehicles
caliper, brake pads and anchor plate
assembly to hang from the brake hose or
1. CAUTION: Do not use an abrasive
damage to the hose can occur.
sanding disc since it will remove paint or
Remove and discard the 2 brake caliper anchor
other protective finishes from the wheel or
plate bolts and position the brake caliper, brake
metal from the mounting surfaces, adversely
pads and anchor plate aside as an assembly.
affecting corrosion protection and brake disc
Support the brake caliper, brake pads and lateral runout.
anchor plate assembly using mechanics
Remove corrosion from the wheel mounting
wire.
surfaces, both disc mounting surfaces and hub
mounting surfaces.
5.4L equipped vehicles
Use brake parts cleaner to clean the brake
disc and hub surfaces.
2. CAUTION: Do not allow the brake
Apply anti-seize lubricant to the hub
caliper assembly to hang from the brake
mounting surfaces to prevent future
hose or damage to the hose can occur.
corrosion.
Remove and discard the 2 brake caliper bolts
and position the caliper assembly aside.
Support the caliper assembly using
4.0L SOHC and 4.6L (3V) equipped vehicles
mechanics wire.
All vehicles
3. NOTE: Clean any residual thread lock
compound from the anchor plate threads before
installing the bolts.
3. If equipped, remove and discard the retainer
nuts.
Position the brake caliper, brake pads and
anchor plate assembly.
Install 2 new brake caliper anchor plate
bolts and tighten to 115 Nm (85 lb-ft).
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4. Position the brake caliper assembly and install 2
new caliper bolts.
Tighten the bolts to 115 Nm (85 lb-ft).
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Brake Flexible Hose
Material To install, tighten to 40 Nm (30 lb-ft).
Item Specification
2. Disconnect the brake tube fitting from the brake
flexible hose.
To install, tighten to 17 Nm (13 lb-ft). PM-1 or PM-1-C (US);
CPM-1 or CPM-1-C
(Canada)
3. Remove the 2 bracket bolts and the brake
flexible hose.
Bleed the brake system. For additional
injury.
these instructions may result in personal injury
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Brake Pads 4.0L SOHC and 4.6L 3. CAUTION: Do not use the caliper
sight hole to retract pistons as this can (3V)
damage the pistons and boots.
Material
CAUTION: Do not allow the brake
caliper, brake pads and anchor plate Item Specification
assembly to hang from the brake hose or
damage to the hose can occur.
Remove and discard the 2 brake caliper guide
CPM-1 or CPM-1-C
pin bolts and position the brake caliper aside.
(Canada)
Support the brake caliper using mechanics
wire. PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Silicone Brake Caliper ESE-M1C171-A 4. CAUTION: Install new brake pads if
worn past the specified thickness above the
Compound
metal backing plate or rivets. Install brake
XG-3-A
pads in complete axle sets.
Removal
Remove the brake pads and discard the 4 spring
clips.
a new brake caliper. For additional
information, refer to Brake Caliper 4.0L
injury.
SOHC and 4.6L (3V) in this section.
WARNING: Carefully read cautionary 6. Inspect the brake caliper anchor plate assembly.
Check the guide pins and boots for binding
or damage.
Lubricate the guide pins with the specified
grease.
is worn or damaged. For additional
information, refer to Brake Caliper 4.0L
SOHC and 4.6L (3V) in this section. CAUTION: Brake fluid is harmful to
1. Check the brake fluid level in the brake fluid
reservoir.
If required, remove fluid until the brake
master cylinder reservoir is half full.
Section 100-02.
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Installation
2. CAUTION: Do not allow grease, oil,
brake fluid or other contaminants to contact
1. NOTE: Protect the pistons and the boots when
the pad lining material. Do not install
compressing the brake caliper piston into the
contaminated pads.
caliper bore.
NOTE: Install all the hardware supplied with
Using a suitable tool, compress the caliper
the brake pad kits.
pistons into the brake caliper bore.
Install 4 new spring clips and the 2 brake pads.
3. Position the brake caliper on the anchor plate
and install 2 new guide pin bolts.
4. If necessary, fill the brake fluid reservoir with
clean, specified brake fluid.
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Brake Pads 5.4L 3. CAUTION: Do not allow the brake
caliper to hang from the brake hose or
damage to the hose can occur. Removal and Installation
Remove and discard the 2 brake caliper bolts
and position the brake caliper aside. CAUTION: Install new brake pads in
complete axle sets.
Support the brake caliper using mechanics
wire.
Section 100-02.
4. NOTE: Use a wood block or old brake pad to
protect the caliper piston and dust boots. Use a
2. NOTE: Inspect and install new brake pad
soft cloth to protect the painted surface of the
mounting hardware as necessary.
brake caliper.
Remove the brake pad mounting pins and
Using a C-clamp or similar tool, compress the
spring retainer clip.
caliper pistons.
Remove the brake pads from the caliper
assembly.
6. Apply the brake pedal several times before
driving the vehicle.
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Front Disc Brake
The front disc brake system includes the brake
caliper, the disc brake pads, the anchor plate and the
brake disc. The brake caliper on 4.0L SOHC and
4.6L (3V) equipped vehicles is a dual piston
floating design. The brake caliper is mounted to the
anchor plate by the caliper guide bolts. The brake
caliper slides, or floats, on the caliper guide bolts.
The brake caliper on 5.4L equipped vehicles is a
quad piston, non-floating design. The brake caliper
is mounted directly to the wheel knuckle and does
not have an anchor plate. The brake disc is a cast,
ventilated type rotor. When mechanical force is
applied by the driver to the brake pedal, the force is
converted into hydraulic pressure by the master
cylinder. The hydraulic force is directed to the
brake calipers. The brake pads are then forced
against the brake disc friction surfaces by the brake
caliper pistons. The friction of the brake pads on the
brake disc causes the slowing of wheel rotation and
the vehicle. The brake disc shield, mounted to the
wheel knuckle, protects the inner surface of the
brake disc from foreign material.
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Front Disc Brake
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SPECIFICATIONS
Item Specification
Brake Pads 4.0L SOHC and 4.6L (3V)
Minimum brake pad 3.0 mm (0.118 in)
(Canada)
thickness
Maximum brake pad 2.0 mm (0.079 in)
thickness variation
(pad-to-pad)
Maximum brake pad taper 3.0 mm (0.118 in)
Compound XG-3-A
Brake Disc 4.0L SOHC and 4.6L (3V)
CPM-4 (Canada)
thickness
Minimum rear brake disc 17.4 mm (0.68 in)
thickness
Bleeder screw 10 89
machine rear brake disc Brake caliper anchor 115 85
plate bolts
Brake Pads 5.4L
Brake caliper guide pin 34 25
Minimum front brake pad 1.8 mm (0.071 in)
bolts
thickness
Brake caliper flow bolt 40 30
Minimum rear brake pad 3.0 mm (0.118 in)
thickness Brake disc shield bolts 20 15
Brake Disc 5.4L Brake flexible 20 15
hose-to-body bolt
thickness Brake flexible 20 15
hose-to-strut bolt
machine front brake disc Brake tube fittings 17 13
Lubricant Brake caliper bolt 115 85
5.4L
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206-04-1 206-04-1 Rear Disc Brake
Installation
Brake Caliper Anchor Plate
Material 1. CAUTION: In order for the brake
caliper anchor plate bolts to attain the
Item Specification
proper clamp load when installed, the
residual thread lock compound must be
cleaned out of the bolt threads of the anchor
CPM-4 (Canada)
plate.
Removal
Clean any residual thread lock compound, and
any other foreign material, from the threads of
the brake caliper anchor plate.
information, refer to Brake Pads in this section.
2. Position the brake caliper anchor plate and
2. Remove the 2 brake caliper anchor plate bolts
install 2 new anchor plate bolts.
and the brake caliper.
Discard the bolts.
3. Install the brake pads. For additional
information, refer to Brake Pads in this section.
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206-04-1 206-04-1 Rear Disc Brake
3. NOTE: Make sure the anti-moan bracket holes,
Brake Caliper Support Bracket
the brake caliper support bracket and the brake
caliper anchor plate holes line up during
installation.
Remove the anti-moan bracket.
1. Remove the rear axle shaft. For additional
information, refer to Section 205-02A or
Section 205-02B.
4. Remove the 4 brake caliper support bracket
nuts, bolts and the bracket.
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206-04-1 206-04-1 Rear Disc Brake
Brake Caliper
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
Removal
4. Remove the 2 brake caliper guide pin bolts and
the brake caliper.
injury.
If leaks or a damaged piston boot are found,
install a new brake caliper.
Installation
1. Position the brake caliper and install the 2
brake caliper guide pin bolts until snug.
Tighten the RH caliper guide pin bolts in
CAUTION: Brake fluid is harmful to the following sequence:
X Tighten the top bolt to 33 Nm (24 lb-ft).
X Tighten the bottom bolt to 33 Nm (24
lb-ft).
1. With the vehicle in NEUTRAL, position it on a Tighten the LH caliper guide pin bolts in
hoist. For additional information, refer to the following sequence:
Section 100-02.
lb-ft).
2. Remove the retaining clip and the parking brake
cable and conduit from the brake caliper.
2. Using 2 new copper washers, position the front
brake hose on the brake caliper and install the
flow bolt.
3. Connect the parking brake cable and conduit to
the brake caliper.
Install the retaining clip.
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206-04-2 206-04-2 Rear Disc Brake
4. Bleed the caliper. For additional information,
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206-04-1 206-04-1 Rear Disc Brake
Brake Disc Shield
1. Remove the brake disc. For additional
information, refer to Brake Disc in this section.
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206-04-1 206-04-1 Rear Disc Brake
Brake Disc
Installation
Material
Item Specification
1. Clean any rust or foreign material from the
High Temperature Nickel ESE-M12A4-A brake disc and the wheel hub.
Use brake parts cleaner to clean the brake
XL-2 (US); CXG-2-B
disc and hub surfaces.
(Canada)
2. CAUTION: In order for the brake PM-4-A or PM-4-B (US);
CPM-4 (Canada) caliper anchor plate bolts to attain the
proper clamp load when installed, the
Removal
residual thread lock compound must be
cleaned out of the bolt threads of the anchor
plate.
Clean any residual thread lock compound, and
Section 100-02.
any other foreign material, from the threads of
the brake caliper anchor plate.
2. CAUTION: Care must be used when
3. CAUTION: Do not allow the lubricant
disconnecting the parking brake cable from
to make contact with the wheel studs, brake
pads or brake disc.
Apply a thin coat of anti-seize lubricant to the
hub flange.
fittings can occur.
CAUTION: Do not allow the brake
4. Position the brake disc onto the wheel hub.
caliper and anchor plate assembly to hang
from the brake hose or damage to the hose
5. Position the brake caliper anchor plate and
can occur.
install 2 new anchor plate bolts.
Remove and discard the 2 anchor plate bolts
and position the brake caliper anchor plate and
brake caliper assembly aside. 6. Test the brakes for normal operation.
Support the caliper using mechanics wire.
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206-04-1 206-04-1 Rear Disc Brake
Brake Flexible Hose
Material To install, tighten to 40 Nm (30 lb-ft).
Item Specification
2. Disconnect the brake tube fitting from the brake
flexible hose.
Motor Vehicle Brake Fluid WSS-M6C62-A)
To install, tighten to 17 Nm (13 lb-ft). PM-1 or PM-1-C (US);
CPM-1 or CPM-1-C
(Canada)
3. Remove the bracket bolt and the brake hose.
Bleed the brake caliper. For additional
injury.
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206-04-1 206-04-1 Rear Disc Brake
Brake Pads 2. CAUTION: Care must be used when
disconnecting the parking brake cable from Special Tool(s)
Adapter, Rear Brake Caliper
Piston Adjuster
206-026 (T87P-2588-A) or
fittings can occur. equivalent
CAUTION: Do not use caliper sight
hole to retract pistons as this can damage the
pistons and boots.
CAUTION: Do not allow the caliper to Material
hang from the brake hose or damage to the
Item Specification
hose can occur.
Remove the 2 brake caliper guide pin bolts and
position the brake caliper aside. Compound
XG-3-A
Support the caliper using mechanics wire.
3. CAUTION: Install new pads if worn to
or past the specified thickness above the
CPM-1 or CPM-1-C
(Canada) metal backing plate or rivets. Install pads in
complete axle sets.
Removal
Remove the brake pads and discard the spring
clips.
4. Measure the brake disc thickness.
Install a new brake disc if not within
specification. For additional information,
refer to Brake Disc in this section.
injury.
a new brake caliper. For additional
information, refer to Brake Caliper in this
section.
6. Inspect the brake caliper anchor plate assembly.
these instructions may result in personal injury. Check the guide pins and boots for binding
and damage.
Replace worn or damaged pins. Lubricate
the pins with the specified grease.
is worn or damaged.
Section 100-02.
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206-04-2 206-04-2 Rear Disc Brake
Installation 4. Position the brake caliper on the anchor plate
and install the 2 brake caliper guide pin bolts
until snug.
1. Using the special tool, compress the brake
caliper piston into the brake caliper bore.
Tighten the RH caliper guide pin bolts in
the following sequence:
lb-ft).
Tighten the LH caliper guide pin bolts in
the following sequence:
lb-ft).
2. Position the notch in the caliper piston up and
down to align with the alignment pin on the
brake pad.
3. CAUTION: Do not allow grease, oil,
brake fluid or other contaminants to contact
the pad lining material. Do not install
contaminated pads.
NOTE: Install all hardware supplied with the
pad kit.
Install the 2 new spring clips and the brake
pads.
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206-04-1 206-04-1 Rear Disc Brake
Disc Brake System Exploded View
NOTE: 4.0L SOHC and 4.6L (3L) shown, 5.4L similar.
5 Guide pin and boot (part of 1 2N386 Brake caliper guide pin bolts
kit 2B296)
2 2552 RH/ 2553 Brake caliper
6 W705821 Brake caliper anchor plate LH
bolt kits (2 bolts each side)
3 2218 Brake pads (kit)
7 2B511 Brake caliper anchor plate
4 Spring clips (part of kit 2200)
8 2C026 Brake disc
(Continued)
(Continued)
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206-04-2 206-04-2 Rear Disc Brake
9 W500020 Brake disc shield bolts (3 19 Anti-moan bracket U-bolt and
required) (part of 2C029) clamp (part of 2C371)
10 2C029 Brake disc shield 20 2C371 Anti-moan bracket (4.0L
SOHC and 4.6L [3V] only)
11 Brake tube fitting
21 Brake caliper support bracket
bolts (4 required) (part of
13 W712362 Copper washers (2 required)
4001)
14 2A442 RH/ Brake hose
22 Brake caliper support bracket
2A478 LH
flag nuts (4 required) (part of
4001) 15 N802191 Brake hose bracket bolt
23 Brake caliper support bracket 16 Bleeder screw cap (part of
(part of 4001) 2N033)
17 2N033 Bleeder screw
1. For additional information, refer to the
18 W520112 Anti-moan bracket U-bolt
nuts (2 required) procedures in this section.
(Continued)
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206-04-1 206-04-1 Rear Disc Brake
Rear Disc Brake
The braking system includes the brake caliper, the
brake pads and the brake disc. The brake caliper is
a single piston, floating design. The brake caliper is
mounted to the brake caliper anchor plate by the
caliper guide bolts. The brake caliper slides, or
floats, on the caliper guide pins. The brake disc is a
cast, non-ventilated type rotor. When mechanical
force is applied by the driver to the brake pedal, the
force is converted into hydraulic pressure by the
master cylinder. The hydraulic force is directed to
the disc brake calipers and transferred to the brake
pads. The brake pads are then forced against the
brake disc friction surfaces by the brake caliper
pistons slowing the vehicle.
The brake caliper is also used for the parking brakes
and is activated by the rear parking brake cable.
When the cable is actuated, a lever on the caliper
engages a self-adjusting ratchet assembly inside the
brake caliper piston. This applies pressure to the
brake pads, preventing the brake disc from moving.
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206-04-1 206-04-1 Rear Disc Brake
Rear Disc Brake
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206-04-1 206-04-1 Rear Disc Brake
SPECIFICATIONS
Item Specification
Item Specification Grease and Dielectric
Compound XG-3-A
Brake Pads
Minimum brake pad 3.0 mm (0.118 in)
PM-4 or PM-4-B (US);
thickness
CPM-4 (Canada)
Maximum brake pad 2.0 mm (0.079 in)
thickness variation
(pad-to-pad)
Maximum brake pad taper 3.0 mm (0.118 in)
Anti-moan bracket 35 26
Brake Disc
U-bolt nuts
Minimum brake disc 17.4 mm (0.68 in)
Bleeder screw 10 89
thickness
Brake caliper flow bolt 40 30
Brake disc shield bolts 20 15 machine brake disc
Brake caliper anchor 103 76 Lubricant
plate bolts
Brake hose bracket 15 11 Motor Vehicle Brake WSS-M6C62-A
bolts Fluid PM-1 or PM-1-C
Brake caliper guide pin
(Canada)
bolts
a
Brake tube fitting 17 13
Brake caliper support 68 50
bracket bolts
a Refer to the procedure for the proper tightening
sequence and torque specifications.
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206-05-1 206-05-1 Parking Brake and Actuation
Parking Brake Exploded View
7 2A635 Rear parking brake cable 1 N804796 Parking brake control nuts (2
(RH) required)
8 2A823 Rear parking brake cable 2 W704911 Parking brake control bolt (2
(LH) required)
9 Front parking brake cable 3 2780 Parking brake control
(part of 2780)
4 2860 Parking brake cable retaining
clips (2 required)
5 W505263 Parking brake cable bracket
bolts procedures in this section.
6 W704911 Parking brake cable
crossmember bracket bolt
(Continued)
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5. Remove and discard the appropriate support
Parking Brake Cable Rear
brace front bolts.
All vehicles
Section 100-02.
2. Release the tension on the parking brake cable.
For additional information, refer to Parking
Brake Cable Tension Release in this section.
All vehicles
brace rear bolts.
6. Disconnect the appropriate rear parking brake
cable from the front parking brake cable at the
equalizer, and release the cable from the body
bracket.
brace upper bolts.
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8. Remove the parking brake cable bracket bolt.
7. CAUTION: Verify that the boot is
attached to the conduit end fitting and the
strand end fitting. A clamp must be secured
on the strand end fitting (t-end). There 9. If removing the RH cable, remove the parking
should be no exposed strand at the wheel end brake cable crossmember bracket bolt.
of the parking brake cable.
Remove the parking brake cable retaining clip
from the parking brake cable and disconnect the
rear parking brake cable from the brake caliper.
Adjust the parking brake cable tension. For
additional information, refer to the Parking
Brake Cable Adjustment in this section.
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GENERAL PROCEDURES
Parking Brake Cable Adjustment
CAUTION: Do not overtighten the parking
brake cable adjustment nut. Overtightening will
cause the brakes to drag or lock up.
1. Remove the access cover inside the floor
console bin.
4. Apply the tension by tightening the parking
brake cable adjustment nut until there is no lash
in the system with the handle in the lowered
position.
5. Cycle the parking brake control 4 times and
adjust as necessary.
6. Lower the parking brake handle and install the
access cover.
2. Position the parking brake handle up at the
fourth notch to access the adjuster nut.
7. Test the parking brake system for proper
operation.
3. NOTE: The rod is staked to prevent the
removal of the nut.
Loosen, but do not remove, the parking brake
cable adjuster nut.
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GENERAL PROCEDURES
2. Position the parking brake control handle at the
Parking Brake Cable Tension Release
fourth notch to access the parking brake cable
adjuster nut.
CAUTION: Do not overtighten the parking
brake cable adjustment nut. Overtightening will
3. NOTE: The rod is staked to prevent the
cause the brakes to drag or lock up.
removal of the nut.
Loosen, but do not remove, the parking brake
1. Remove the access cover inside the floor
cable adjuster nut.
console bin.
4. Lower the parking brake control handle.
5. To adjust the parking brake cable tension, refer
to Parking Brake Cable Adjustment in this
section.
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5. Disconnect the parking brake switch electrical
Parking Brake Control
connector.
6. Remove the 2 nuts from the parking brake
control.
Section 100-02.
7. Remove the 2 bolts from the parking brake
control.
2. Remove the floor console. For additional
information, refer to Section 501-12. To install, tighten to 30 Nm (22 lb-ft).
3. Release the tension on the parking brake cable. 8. Remove the parking brake control.
For additional information, refer to Parking
Position the cable and equalizer through the
Brake Cable Tension Release in this section.
floorpan.
4. Disconnect the front parking brake cable from
the 2 rear parking brake cables at the equalizer
Adjust the parking brake cable tension. For
and release the front cable from the body
additional information, refer to Parking
bracket.
Brake Cable Adjustment in this section.
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The parking brake cable tension is not
Parking Brake
self-adjusting. Refer to Parking Brake Cable
Parking Brake
Adjustment in this section.
The parking brake system is a mechanical system
that activates a self-adjusting brake system within
the rear brake caliper.
The parking brake system is cable-actuated and
controlled by an independent hand-operated parking
brake control. The parking brake system is actuated
when the parking brake control is pulled up and
released by pressing the release button on the end
of the parking brake control handle. The parking
brake control applies tension to rear brake pads
through the front parking brake cable and conduit
and the LH and RH rear parking brake cables. The
respective rear parking brake assemblies are then
applied.
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2. Visually inspect for obvious signs of
Parking Brake
mechanical damage.
Parking Brake System
Mechanical
controlled by an independent hand-operated parking Parking brake control
Parking brake cables
brake control that is not self adjusting, The parking
Parking brake release handle
brake system is actuated when the parking brake
control is pulled up. The parking brake control
applies tension to the brake pads through the front
parking brake cable and conduit and the LH and RH
rear parking brake cables.
4. If the cause is not visually evident, verify the
symptom and GO to Symptom Chart.
NOTE: Prior to carrying out any diagnosis, make
sure the red brake warning indicator is functional.
The first indication that something may be wrong in
the brake system is a change in the feeling through
the parking brake control. The parking brake not
holding on an incline or dragging after being
released are also indicators of system concerns.
Check the operation of the parking brake system
with the vehicle on a hoist and the parking brake
control fully released. Check for any damaged
cables and install new components as necessary.
Carry out the brake system diagnosis.
1. Verify the customer concern.
Symptom Chart
Symptom Chart
Rear brakes drag Parking brake component REPAIR or INSTALL new
parking brake components as
necessary. REFER to Parking
Brake Control or Parking
Brake Cable Rear in this
section.
Brake caliper guide pins REPAIR or INSTALL new
brake caliper guide pins.
Brake caliper REPAIR or INSTALL new
Brake booster CARRY OUT the Brake
Booster Component Test.
Brake master cylinder CARRY OUT the Brake
Master Cylinder Component
Test. REFER to Section
206-00.
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The parking brake will not Parking brake control GO to Pinpoint Test A.
apply Parking brake cables
Parking brake rear wheel
components
The parking brake will not Parking brake cables GO to Pinpoint Test B.
release Parking brake control
Parking brake rear wheel
components
Parking brake control
Pinpoint Test A: The Parking Brake Will Not
Apply Parking brake cables
Parking brake rear wheel components
Normal Operation
brake control that is not self adjusting, The parking
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
A1 CHECK THE PARKING BRAKE CABLES
With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02. INSTALL a new parking brake cable as
Inspect for broken or binding parking brake cables. necessary. REFER to Parking Brake
Is there a parking brake cable concern? Cable Rear in this section. TEST the
No
GO to A2.
A2 CHECK THE PARKING BRAKE CONTROL
Operate the parking brake control. Yes
Does the parking brake control operate smoothly? GO to A3.
No
INSTALL a new parking brake control.
REFER to Parking Brake Control in this
section. TEST the system for normal
operation.
A3 CHECK THE PARKING BRAKE COMPONENTS
Operate the parking brake control and observe the parking brake Yes
components. CHECK the brake pad installation. REFER
Do the parking brake components operate correctly? to Section 206-04.
No
INSTALL new components. TEST the
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Possible Causes
Pinpoint Test B: The Parking Brake Will Not
Release
Parking brake cables
Normal Operation
Parking brake control
Parking brake rear wheel components
brake control that is not self adjusting. The parking
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1 CHECK THE FRONT PARKING BRAKE CABLE
Release the parking brake control. Yes
If the vehicle cannot be moved, raise and support it. INSPECT the front parking brake cable for
Release the parking brake cable tension. Refer to Parking Brake binding. INSPECT the parking brake
Cable Tension Release in this section. control for wear or damage. INSTALL new
Disconnect the parking brake cable at the parking brake lever. components as necessary. Refer to
Does the parking brake release? Parking Brake Control in this section.
No
GO to B2.
B2 CHECK THE PARKING BRAKE REAR CABLES
Disconnect the RH parking brake rear cable and conduit and the Yes
LH parking brake rear cable and conduit from the parking brake INSPECT the parking brake rear cable
lever at each wheel. and conduits for wear or damage.
Does the parking brake release? INSTALL new components as necessary.
Refer to Parking Brake Cable Rear in
this section. TEST the system for normal
operation.
No
REPAIR the worn or damaged rear wheel
parking brake components as necessary.
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SPECIFICATIONS
Parking brake control bolts 30 22
Parking brake control nuts 17 13
Parking brake cable 20 15
Support brace bolts 63 46
crossmember bracket bolt
Parking brake cable bracket 27 20
bolts
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206-06-1 206-06-1 Hydraulic Brake Actuation
Brake Fluid Reservoir
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
NOTE: Automatic transmission shown, all others similar.
1 2462 Brake fluid reservoir pin
2 Brake fluid reservoir seals (2
3 2422 Brake fluid reservoir
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WARNING: Use of any other than spilled onto a painted or plastic surface,
approved DOT 3 brake fluid will cause immediately wash it with water.
permanent damage to brake components and will
1. Using a suitable tool, remove the brake fluid
render the brakes inoperative. Failure to follow
from the brake fluid reservoir.
2. Remove the brake fluid reservoir pin.
Sheet (MSDS). For 24-hour MEDICAL
3. NOTE: Use new seals provided with a new
EMERGENCY INFORMATION on
brake fluid reservoir.
Remove the brake fluid reservoir and discard
the seals.
When installing the brake fluid reservoir,
lubricate the new seals with brake fluid.
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Brake Master Cylinder
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
NOTE: Automatic transmission and ABS shown, all others similar.
3 N808159 Brake master cylinder nut (2 1 Brake tube fittings
required)
2 Brake fluid level sensor
4 2A032 Brake master cylinder electrical connector
(Continued)
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2. If equipped, remove the suction accumulator. WARNING: Use of any other than
For additional information, refer to Section approved DOT 3 motor vehicle brake fluid will
412-01. cause permanent damage to brake components
All vehicles
injury.
3. Disconnect the brake fluid sensor electrical
connector.
information, see product Material Safety Data 4. If equipped with a manual transmission, remove
Sheet (MSDS). For 24-hour MEDICAL the clutch hose clamp and disconnect the clutch
EMERGENCY INFORMATION on hose from the brake fluid reservoir.
5. NOTE: Cap the brake lines and plug the master
cylinder ports.
Disconnect the 2 brake tubes from the master
cylinder.
6. Remove and discard the 2 nuts and remove the
brake master cylinder.
All vehicles
To install, tighten 25 Nm (18 lb-ft).
1. Disconnect the battery ground cable. For
Bleed the master cylinder. For additional
information, refer to Section 206-00 in this
section.
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Brake Pedal and Bracket
NOTE: Manual transmission pedal assembly shown, automatic transmission pedal assembly similar.
4 2475 Redundant self-locking clip 1 Speed control deactivator
cover switch (brake)
5 380699-S100 Self-locking clip 2 Stoplamp switch
6 2A309 Brake booster rod bushing 3 Speed control deactivator
switch (clutch)
7 2N513 Brake booster rod pin
(Continued)
(Continued)
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8 W520112-S440 Brake booster nuts (4
required)
9 W701834-S439 Brake pedal bracket bolts (2
required)
10 2450 Brake pedal bracket
All vehicles
1. CAUTION: The brake pedal must be
7. NOTE: The clutch master cylinder is connected to the booster rod and in the at
self-bleeding. Pump the clutch pedal until all rest position before removing or installing
the air is forced back into the brake master the speed control deactivator switch. Failure
cylinder reservoir. to follow this instruction will damage the
switch.
Remove the hairpin clip and disconnect the
clutch pedal high pressure hydraulic hose from Remove the stoplamp switch and, if equipped,
the clutch master cylinder. the speed control deactivator switch (brake).
Install the hairpin clip into the clutch master
2. Remove the redundant self-locking pin cover
cylinder.
and the self-locking pin.
3. Remove the booster rod pin and bushing from
the brake pedal.
Manual transmission vehicles
4. CAUTION: The clutch pedal must be
connected to the clutch master cylinder
actuation rod and in the at rest position
before removing or installing the speed
control deactivator switch. Failure to follow
this instruction will damage the switch.
Remove the speed control deactivator switch
All vehicles
(clutch) and position it aside.
8. Remove the 4 brake booster nuts
5. Disconnect the clutch pedal interlock switch
electrical connector.
6. Disconnect the clutch pedal low pressure
9. Remove the top 2 bolts from the brake pedal
hydraulic hose from the master cylinder
bracket assembly.
reservoir.
10. Remove the brake pedal bracket assembly from
the vehicle.
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Brake Pedal and Bracket
Hydraulic Brake Actuation
The brake pedal is connected to the power brake
Brake Master Cylinder
booster, which is connected to the brake master
The dual brake system is split front and rear with
cylinder. When the brake pedal is pressed, brake
the front wheel brakes comprising one circuit and
fluid is forced from the brake master cylinder
the rear wheel brakes the other circuit.
through the steel tubing and flexible hoses to the
front and rear brake calipers.
The brake master cylinder is a dual piston type.
When the brake pedal is pressed, pressure is applied
The brake pedal bracket provides a mounting
by mechanical linkage to the primary and secondary
location for the clutch pedal and clutch pedal master
piston. The pistons then apply hydraulic pressure to
cylinder for vehicles with manual transmissions. The
the two hydraulic circuits. The brake master
bracket also provides a mounting location for the
cylinder can not be repaired. Install a new master
speed control deactivator switches, stoplamp
cylinder if replacement is necessary.
switch, and on vehicles with manual transmissions,
the starter interlock switch, mounted just below the
The brake master cylinder consists of:
clutch.
brake master cylinder reservoir
Brake Tubes and Hoses
brake master cylinder body
CAUTION: Never use copper tubing. It is
Brake Master Cylinder Reservoir
subject to fatigue, cracking and corrosion which
The brake master cylinder reservoir:
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic
is mounted to the brake master cylinder.
system. All brake tube fittings must be correctly
holds fluid supply for each brake master cylinder
flared to provide strong leakproof connections.
hydraulic piston.
When bending the tubing to fit the underbody or
provides visual fluid level markings.
rear axle contours, be careful not to kink or crack
contains the brake master cylinder fluid level the tube.
sensor.
If a section of brake tube is damaged, the entire
section must be removed and a new tube of the
same type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or
connectors, tighten all connections securely. After
installation, bleed the brake system. For additional
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Hydraulic Brake Actuation
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SPECIFICATIONS
Brake booster nuts 25 18
Item Specification
Brake fluid 25 18
Lubricant proportioning valve
High Performance DOT 3 ESA-M6C25-A or Brake fluid reservoir 8 71
Motor Vehicle Brake WSS-M6C62-A pin
Fluid
Brake tube fittings 17 13
CPM-1 or CPM-1-C Brake master cylinder 25 18
(Canada) nuts
Brake pedal bracket 25 18
bolt
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206-07-1 206-07-1 Power Brake Actuation
is divided into separate chambers by the
Brake Booster
diaphragms.
The vacuum type power brake booster:
will not operate if vacuum fails.
is a dual diaphragm, vacuum assisted power brake
is installed as an assembly.
booster.
If the power assist fails, the brake system continues
reduces brake pedal force and travel distance.
to operate with increased brake pedal effort.
is located on the LH side of the cowl in the
engine compartment, between the brake pedal and
the brake master cylinder.
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Brake Booster
5 2N513 Brake booster rod pin 1 9C482 Brake booster vacuum hose
6 13480 Stop lamp switch 2 Brake booster vacuum check
valve (part of 2B195)
7 9C872 Speed deactivation switch
3 2475 Redundant self-locking clip
8 W520112-S440 Brake booster nuts (4
cover
required)
4 380699-S100 Self-locking clip
9 2B195 Brake booster
(Continued)
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4. NOTE: Do not apply the brake pedal during
the removal or installation of the speed
deactivation switch.
1. Remove the brake master cylinder. For
Disconnect the electrical connector and remove
the speed deactivation switch.
2. Disconnect the brake booster vacuum hose from
the brake booster vacuum check valve.
5. Remove the redundant self-locking pin cover,
self-locking pin and the booster rod pin.
3. NOTE: Do not apply the brake pedal during
the removal or installation of the stop lamp
6. Remove the 4 brake booster nuts.
switch.
Disconnect the electrical connector and remove
the stop lamp switch.
7. Remove the brake booster assembly from the
vehicle.
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Power Brake System
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SPECIFICATIONS
Brake booster nuts 25 18
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206-09-1 206-09-1 Vehicle Dynamic Systems
Anti-Lock Brake System (ABS)
Module
1 Anti-lock brake system (ABS)
module electrical connector
(part of 14A005)
2 ZD061 ABS module screws (4
required)
3 2C219 ABS module
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4. Remove the 4 screws and the ABS module.
To install, tighten to 3 Nm (27 lb-in) in the
CAUTION: Electronic modules are
sequence shown.
sensitive to electrical charges. The anti-lock
brake system (ABS) module can be damaged if
exposed to these charges.
2. Remove the air cleaner assembly. For additional
3. Disconnect the ABS module electrical
connector.
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Rear wheel speed sensors
Anti-Lock Control
Rear wheel speed sensor rings
Anti-Lock Brake System (ABS) with
Traction control switch
Traction Control
Traction control switch indicator
The anti-lock brake system (ABS) consists of the
following components:
Trac off indicator
Yellow ABS warning indicator
Hydraulic control unit (HCU)
ABS module
Front wheel speed sensors
Front wheel speed sensors rings
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The ABS module is self-monitoring. When the
Anti-Lock Control
ignition switch is turned to the run position, the
Special Tool(s)
ABS module does a preliminary electrical check
and, at approximately 12 km/h (8 mph), the pump
motor is turned on for approximately one
Diagnostic System (IDS) half-second. Any malfunction of the ABS causes
the ABS to shut OFF and the yellow ABS warning
indicator to illuminate, however normal power
tool
assisted braking remains.
The traction control system controls wheelspin by
73III Digital Multi-meter modulating engine torque and by applying and
releasing the appropriate rear brake to restore
traction when driving on slippery or loose surfaces.
The traction control system can be disabled by
pressing the traction control switch and is indicated
by an indicator lamp in the traction control switch.
The traction control will reset and return to normal
Flex Probe Kit
traction assist when the ignition switch is cycled or
418-F090 (105-R025B) or
when the traction control switch is pressed and
equivalent
released a second time.
2. Verify the stoplamps operate correctly by
applying and releasing the brake pedal with the
ignition switch in the OFF position. If the
The anti-lock brake system (ABS) module receives
stoplamps do not operate correctly, refer to
wheel speed readings from each wheel speed sensor
Section 417-01. If the stoplamps operate
and processes this information to determine if an
correctly, proceed to the next step.
ABS event is necessary. The wheel speed sensor
electrically senses each tooth of the wheel speed
sensor indicators as it passes through the wheel
mechanical or electrical damage:
speed sensors magnetic field.
The ABS module continuously monitors and
Mechanical Electrical compares the rotational speed of each wheel and,
when it detects an impending wheel lock, modulates
Brake fluid level Bussed electrical center
hydraulic brake pressure to the appropriate brake Tire inflation (BEC) fuse(s):
Wheel and tire sizes 8 (40A)
caliper. This is accomplished by the ABS module
Steering components 65 (30A)
triggering the hydraulic control unit (HCU) to open
and suspension Smart junction box
and close the appropriate solenoid valves. Once the
components (SJB) fuse 18 (10A)
affected wheel returns to normal speed, the ABS
Base brake system Circuitry
module returns the solenoid valves to their normal
Wheel speed sensor ring Brake fluid level switch
HCU Stoplamp switch position and normal (base) braking resumes.
Wheel speed sensor
Anti-lock brake system
(ABS) module
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5. NOTE: Make sure to use the latest scan tool refer to Section 418-00 to diagnose no
software release. response from the powertrain control module
(PCM).
scan tool to the data link connector (DLC). 8. Carry out the network test.
6. NOTE: The vehicle communication module If the scan tool responds with no
(VCM) LED prove out confirms power and communication for one or more modules,
ground from the DLC are provided to the refer to Section 418-00.
VCM.
If the scan tool does not communicate with the record continuous memory diagnostic
VCM: trouble codes (DTCs).
check the VCM connection to the vehicle. 9. Clear the continuous DTCs and carry out the
self-test diagnostics for the anti-lock brake
system (ABS) module.
refer to Section 418-00, No Power To The
go to the Anti-Lock Brake System (ABS)
with the scan tool.
Module Diagnostic Trouble Code (DTC) Chart.
vehicle:
good vehicle.
Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart
B1317 Battery Voltage High ABS Module GO to Pinpoint Test A.
B1318 Battery Voltage Low ABS Module GO to Pinpoint Test A.
NOTE: If other DTCs are present, repair B1342 ECU is Faulted ABS Module
them before installing a new module.
CLEAR the DTCs. RETRIEVE the
DTCs. If DTC B1342 is retrieved again,
INSTALL a new ABS module. REFER
to Anti-Lock Brake System (ABS)
Module in this section. REPEAT the
self-test.
C1093 Traction Control Disable Switch Circuit Instrument GO to Pinpoint Test H.
Failure Cluster
C1095 ABS Hydraulic Pump Motor Circuit ABS Module GO to Pinpoint Test B.
Failure
C1096 ABS Hydraulic Pump Motor Circuit ABS Module GO to Pinpoint Test B.
Open
C1115 ABS Power Relay Output Short Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
to Battery DTC C1115 is retrieved again, INSTALL
a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module
in this section. CARRY OUT the
self-test with the brake pedal not
applied.
C1145 Wheel Speed Sensor RF Input Circuit ABS Module GO to Pinpoint Test C.
Failure
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Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart (Continued)
C1155 Wheel Speed Sensor LF Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1165 Wheel Speed Sensor RR Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1175 Wheel Speed Sensor LR Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1185 ABS Power Relay Output Circuit Failure ABS Module CLEAR all DTCs. If DTC C1185 is
retrieved again, INSTALL a new ABS
module. REFER to Anti-Lock Brake
System (ABS) Module in this section.
CARRY OUT the self-test with the brake
pedal not applied.
C1194 ABS Outlet Valve Coil LF Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
Failure DTC C1194 is retrieved again, INSTALL
applied.
C1198 ABS Inlet Valve Coil LF Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
DTC C1198 is retrieved again, INSTALL
a new ABS module. INSTALL a new
ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this
section. CARRY OUT the self-test with
the brake pedal not applied.
C1210 ABS Outlet Valve Coil RF Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1214 ABS Inlet Valve Coil RF Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1222 Wheel Speed Mismatch ABS Module GO to Pinpoint Test D.
C1233 Wheel Speed LF Input Signal Missing ABS Module GO to Pinpoint Test D.
C1234 Wheel Speed RF Input Signal Missing ABS Module GO to Pinpoint Test D.
C1235 Wheel Speed RR Input Signal Missing ABS Module GO to Pinpoint Test D.
C1236 Wheel Speed LR Input Signal Missing ABS Module GO to Pinpoint Test D.
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C1242 ABS Outlet Valve Coil LR Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1246 ABS Outlet Valve Coil RR Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1250 ABS Inlet Valve Coil LR Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1254 ABS Inlet Valve Coil RR Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1329 ABS Valve Outlet Coil Over RF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
Temperature DTC C1329 is retrieved again, INSTALL
applied.
C1330 ABS Valve Outlet Coil Over LR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1331 ABS Valve Outlet Coil Over RR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
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C1332 ABS Valve Outlet Coil Over LF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1333 ABS Valve Inlet Coil Over RF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1334 ABS Valve Inlet Coil Over LR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1335 ABS Valve Inlet Coil Over RR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1336 ABS Valve Inlet Coil Over LF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1404 Traction Control Valve Rear Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1446 Brake Switch Circuit Failure ABS Module GO to Pinpoint Test F.
C1527 ABS TC Valve Inlet Coil Over ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
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C1531 ABS TC Valve Outlet Coil Over ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1730 Reference Voltage Out of Range (+5 V) ABS Module If any other DTC(s) are present,
DIAGNOSE those DTC(s) first. CLEAR
all DTCs. DRIVE the vehicle. If the
DTC is still present, INSTALL a new
C1958 ABS TC Valve Outlet Coil Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
U0073 CAN Bus Off Transmit Error ABS Module REFER to Section 418-00.
U1900 CAN Communication Bus Fault ABS Module REFER to Section 418-00.
Receive Error
U2011 Module Transmitted Invalid Data ABS Module VERIFY powertrain control module
(PCM) configuration. If PCM is not
correctly configured, CONFIGURE the
PCM. If the PCM is correctly configured,
Symptom Chart
Symptom Chart
No communication with the Circuitry Refer to Section 418-00 to
anti-lock brake system (ABS) ABS module diagnose the no
module communications problem.
No communication with the Circuitry Refer to Section 418-00 to
instrument cluster Instrument cluster diagnose the no
communication problem.
The red brake warning Circuitry Refer to Section 413-01 to
indicator does not self-check Instrument cluster continue diagnosis of the red
brake warning indicator.
The red brake warning Base brake system Refer to Section 413-01 to
indicator stays on when the Circuitry continue diagnosis of the red
ignition is in RUN Low brake fluid warning brake warning indicator.
switch
Anti-lock brake system (ABS)
module
Instrument cluster
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The yellow anti-lock brake Circuitry Refer to Section 413-01 to
system (ABS) warning Instrument cluster continue diagnosis of the
indicator does not self-check yellow brake warning
indicator.
Spongy/soft/low brake pedal Air in brake hydraulic system GO to Pinpoint Test F.
with no warning indicator Base brake system
Poor vehicle tracking during Tire pressure Refer to Section 206-00 to
anti-lock function Air in the brake system continue diagnosis of the
Base brake system brake system.
Hydraulic control unit (HCU) GO to Pinpoint Test G.
The traction control is Circuitry Install a new ABS module.
inoperative Traction control switch Refer to Anti-Lock Brake
Anti-lock brake system (ABS) System (ABS) Module in this
module section.
The traction control system Circuitry GO to Pinpoint Test H.
cannot be disabled Traction control switch
Instrument cluster
module
The traction control switch Circuitry GO to Pinpoint Test I.
indicator is never/always on Traction control switch
module
Instrument cluster
Fuse(s)
Pinpoint Test A: DTCs B1317 and B1318
Battery Voltage High/Low Circuit open
Refer to Wiring Diagrams Cell 42, Vehicle Charging system
Dynamic Systems for schematic and connector
Anti-lock brake system (ABS) module
information.
Normal Operation
The vehicle electrical system voltage supplied is
within the range of 10-16 volts. Above or below
that voltage range, the DTC B1317 (Battery Voltage
High) or the DTC B1318 (Battery Voltage Low)
will be set.
Fused ignition voltage is supplied to the anti-lock
brake system (ABS) module from smart junction
box (SJB) fuse 18 (10A) along circuit 1844
(LG/RD), bussed electrical center (BEC) fuse 65
(30A) along circuit 601 (LB/BK) and BEC fuse 8
(40A) along circuit 534 (YE/LG). Ground is
provided along circuit 1205 (BK). There are 2
ground circuits, both share the same circuit number
and wire color.
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PINPOINT TEST A: DTCs B1317 AND B1318 BATTERY VOLTAGE HIGH/LOW
A1 CHECK THE BATTERY VOLTAGE
Measure the battery voltage between the positive and negative
Yes
battery terminals with:
GO to A2.
the key ON and the engine OFF (KOEO).
the engine running. No
Is the battery voltage between 10 and 13 volts with KOEO, REFER to Section 414-00 to continue
and between 13 and 17 volts with the engine running? diagnosis of the charging system.
A2 CHECK VOLTAGE TO THE ABS MODULE
Disconnect: ABS Module C135.
Key in ON position.
Measure the voltage between ground and:
ABS module C135-2, circuit 601 (LB/PK), harness side.
ABS module C135-32, circuit 1844 (LG/RD), harness side.
Yes
GO to A3.
No
VERIFY SJB fuse 18 (10A) is OK. If OK,
REPAIR circuit 1844 (LG/RD).
VERIFY BEC fuse 65 (30A) is OK. If OK,
REPAIR circuit 601 (LB/PK).
CLEAR the DTCs. CARRY OUT the
Are the voltages greater than 10 volts? self-test with the brake pedal not applied.
A3 CHECK THE ABS MODULE GROUND
Measure the resistance between ground and:
ABS module C135-45, circuit 1205 (BK), harness side.
Yes
GO to A4.
No
REPAIR the affected circuit(s). REPEAT
Are the resistances less than 5 ohms? the self-test.
(Continued)
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PINPOINT TEST A: DTCs B1317 AND B1318 BATTERY VOLTAGE HIGH/LOW (Continued)
A4 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect: ABS Module C135. Yes
Check for: INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module in
corrosion.
this section. CLEAR the DTCs. REPEAT
spread terminals.
the self-test.
pushed-out pins.
Connect the ABS module connector and make sure it seats No
correctly. The system is operating correctly at this
Operate the system and verify the concern is still present. time. The concern may have been caused
Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. CARRY OUT the self-test with
Pinpoint Test B: DTCs C1095 and C1096
Fused battery voltage is supplied from the bussed
ABS Hydraulic Pump Motor Circuit
electrical center (BEC) fuse 8 (40A) along circuit
Failure/Open
534 (YE/LG). Ground is provided along circuit
1205 (BK).
Refer to Wiring Diagrams Cell 42, Vehicle
Possible Causes
information.
Fuse
Normal Operation
Circuit open
Anti-lock brake system (ABS) diagnostic trouble
Hydraulic pump motor
code (DTC) C1095 sets only when the motor is
initially commanded on for 100 ms (+/-6 ms) and
the ABS hydraulic pump motor is then commanded
off and the voltage back is read after 6 ms. If the
voltage indicates the motor is spinning at less than
500 rpm, there may be a locked motor. If this
condition is detected 4 times, then a locked motor
DTC C1095 is set. The pump motor is checked for
an open circuit 2 seconds after the most recent
successful pump motor off command. If the pump
motor feedback remains greater than 0.75 volt for
more than 50 ms (+/-6 ms) after these conditions
have been met, then DTC C1096 is set.
PINPOINT TEST B: DTCs C1095 AND C1096 ABS HYDRAULIC PUMP MOTOR CIRCUIT
FAILURE/OPEN
B1 CHECK THE ABS PUMP MOTOR
Key in ON position. Yes
Is the ABS pump motor running all the time? INSTALL a new ABS module and
hydraulic control unit (HCU). REFER to
and Hydraulic Control Unit (HCU) in this
section. CLEAR the DTCs. REPEAT the
ABS self-test.
No
GO to B2.
(Continued)
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FAILURE/OPEN (Continued)
B2 CHECK THE PUMP MOTOR OPERATION
Trigger the ABS module pump motor ON active command. Yes
Does the ABS pump motor run for approximately 2 CLEAR the DTCs. CHECK the yellow ABS
seconds? warning indicator while driving the vehicle
(brakes must not be applied) above 32
km/h (20 mph). If the yellow ABS warning
indicator illuminates, RETRIEVE the
DTCs. If DTC C1096 is retrieved, GO to
B5.
If DTC C1095 is retrieved, INSTALL a new
HCU. REFER to Hydraulic Control Unit
(HCU) in this section. CLEAR the DTCs.
No
TRIGGER the ABS module pump motor
OFF active command. GO to B3.
B3 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
Measure the voltage between ABS module C135-31, circuit 534
(YE/LG), harness side and ground.
Yes
GO to B4.
No
VERIFY BEC fuse 8 (40A) is OK. If OK,
REPAIR circuit 534 (YE/LG). CLEAR the
Is the voltage greater than 10 volts? DTCs. REPEAT the self-test.
B4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Yes
REPAIR the affected circuit(s). CLEAR the
No
INSTALL a new HCU. REFER to Hydraulic
Control Unit (HCU) in this section. CLEAR
Are the resistances greater than 10,000 ohms? the DTCs. REPEAT the self-test.
(Continued)
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FAILURE/OPEN (Continued)
B5 CHECK FOR CORRECT ABS MODULE OPERATION
corrosion.
spread terminals.
the self-test.
pushed-out pins.
Pinpoint Test C: DTCs C1145, C1155, C1165
Voltage and ground signals are supplied to the
and C1175 Wheel Speed Sensor Input
wheel speed sensors from the ABS module.
Circuit Failure
Possible Causes
Circuit open
information. Circuit shorted
Wheel speed sensor
Normal Operation
The active wheel speed sensors generate a square
wave signal that is sent to the anti-lock brake
system (ABS) module. The wheel speed sensor
circuitry connects to the ABS module through 2
wires and a connector at each wheel speed sensor.
When the ignition is turned to the run position, the
ABS module carries out a self-test by sending a
reference voltage to all of the wheel speed sensors
and their circuitry to determine if they are
functional.
PINPOINT TEST C: DTCs C1145, C1155, C1165 AND C1175 WHEEL SPEED SENSOR INPUT CIRCUIT
FAILURE
C1 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
NOTE: Both circuits must be checked for each DTC.
Disconnect: Suspect Wheel Speed Sensor.
Key in ON position.
For DTC C1145, measure the voltage between:
ABS module C135-26, circuit 514 (YE/RD), harness side
and ground.
ABS module C135-27, circuit 516 (YE/BK), harness side
and ground.
ABS module C135-13, circuit 522 (TN/BK), harness side
and ground.
ABS module C135-12, circuit 521 (TN/OG), harness side
and ground.
ABS module C135-44, circuit 524 (PK/BK), harness side
and ground.
ABS module C135-43, circuit 523 (RD/PK), harness side
and ground.
(Continued)
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FAILURE (Continued)
TO VOLTAGE (Continued)
Yes
ABS module C135-42, circuit 518 (LG/RD), harness side
and ground.
ABS module C135-41, circuit 519 (LG/BK), harness side
and ground. No
Is voltage present? GO to C2.
TO GROUND
For DTC C1145, measure the resistance between:
and ground.
and ground.
and ground.
and ground.
and ground.
and ground.
Yes
GO to C3.
and ground.
ABS module C135-41, circuit 519 (LG/BK), harness side No
and ground. REPAIR the affected circuit(s). CLEAR the
Are the resistances greater than 10,000 ohms? DTCs. REPEAT the self-test.
C3 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR AN OPEN
and RH front wheel speed sensor C160-1, circuit 514
(YE/RD), harness side.
and RH front wheel speed sensor C160-2, circuit 516
(YE/BK), harness side.
and LH front wheel speed sensor C150-2, circuit 522
(TN/BK), harness side.
and LH front wheel speed sensor C150-1, circuit 521
(TN/OG), harness side.
and RH rear wheel speed sensor C3117-2, circuit 524
(PK/BK), harness side.
and RH rear wheel speed sensor C3117-1, circuit 523
(RD/PK), harness side.
and LH rear wheel speed sensor C3116-1, circuit 518
Yes
(LG/RD), harness side.
GO to C4.
ABS module C135-41, circuit 519 (LG/BK), harness side
and LH rear wheel speed sensor C3116-2, circuit 519 No
(LG/BK), harness side. REPAIR the affected circuit(s). CLEAR the
Are the resistances less than 5 ohms? DTCs. REPEAT the self-test.
(Continued)
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FAILURE (Continued)
C4 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS
Measure the resistance between the suspect wheel speed
sensor pins, harness side with the meter in the 10 mega ohm
range.
Yes
No
Is there any continuity? GO to C5.
C5 CHECK THE ABS MODULE OUTPUT
Connect: ABS Module C135.
Key in ON position.
Measure the voltage between the suspect wheel speed sensor
pins, harness side.
Yes
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor Front
or Wheel Speed Sensor Rear in this
self-test.
No
Is the voltage greater than 10 volts? GO to C6.
C6 CHECK FOR CORRECT ABS MODULE OPERATION
corrosion.
spread terminals.
the self-test.
pushed-out pins.
Pinpoint Test D: DTCs C1222, C1233, C1234, Normal Operation
C1235 and C1236 Wheel Speed Sensor
The wheel speed sensor and sensor ring generate a
Input Signal Missing/Mismatch
square wave signal to the anti-lock brake system
(ABS) module that is proportional to wheel speed.
The ABS module compares wheel speed inputs
from all wheel speed sensors to determine an
information.
impending wheel lockup. Incorrect tire size can set
these DTCs as well.
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Possible Causes
Wheel speed sensor
ABS module
PINPOINT TEST D: DTCs C1222, C1233, C1234, C1235 AND C1236 WHEEL SPEED SENSOR INPUT
SIGNAL MISSING/MISMATCH
D1 CHECK THE DTCs FROM THE SELF-TEST
Retrieve the recorded results from the anti-lock brake system Yes
(ABS) module continuous and on-demand self tests. GO to Pinpoint Test C.
Are DTCs C1145, C1155, C1165 or C1175 present?
No
If DTC C1222 is present, GO to D3. All
others, GO to D2.
D2 CHECK THE WHEEL SPEED SENSOR OUTPUT
NOTE: The ignition switch must be in the OFF position until the
connections are made or a DTC will set and the ABS warning
indicator will illuminate, cutting voltage to the wheel speed sensors.
If this happens, turn the ignition switch to the OFF position and
make sure that no jumper connections are shorted to ground or
shorted together. Turn the ignition switch to the ON position and
wait for the ABS warning indicator to prove out.
Disconnect: Suspect Wheel Speed Sensor.
Connect a fused (5A) jumper wire between the suspect wheel
speed sensor, component side, and the wheel speed sensor,
harness side, as follows:
For DTC C1233: LH front wheel speed sensor C150-1,
circuit 521 (TN/OG), harness side and LH front wheel speed
sensor C150 pin 1, circuit 521 (TN/OG), component side.
For DTC C1234: RH front wheel speed sensor C160-1,
circuit 514 (YE/RD), harness side and RH front wheel speed
sensor C160 pin 1, circuit 514 (YE/RD), component side.
For DTC C1235: RH rear wheel speed sensor C3117-1,
circuit 523 (RD/PK), harness side and RH rear wheel speed
sensor C3117 pin 1, circuit 523 (RD/PK), component side.
For DTC C1236: LH rear wheel speed sensor C3116-1,
circuit 518 (LG/RD), harness side and LH rear wheel speed
sensor C3116 pin 1, circuit 518 (LG/RD), component side.
(Continued)
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PINPOINT TEST D: DTCs C1222, C1233, C1234, C1235 AND C1236 WHEEL SPEED SENSOR INPUT
SIGNAL MISSING/MISMATCH (Continued)
D2 CHECK THE WHEEL SPEED SENSOR OUTPUT (Continued)
Connect a digital multi-meter between the suspect wheel speed
sensor, component side, and the wheel speed sensor, harness
side, as follows:
For DTC C1233: LH front wheel speed sensor C150-2,
circuit 522 (TN/BK), harness side and LH front wheel speed
sensor C150 pin 2, circuit 522 (TN/BK), component side.
For DTC C1234: RH front wheel speed sensor C160-2,
circuit 516 (YE/BK), harness side and RH front wheel speed
sensor C160 pin 2, circuit 516 (YE/BK), component side.
For DTC C1235: RH rear wheel speed sensor C3117-2,
circuit 524 (PK/BK), harness side and RH rear wheel speed
sensor C3117 pin 2, circuit 524 (PK/BK), component side.
For DTC C1236: LH rear wheel speed sensor C3116-2,
circuit 519 (LG/BK), harness side and LH rear wheel speed
Yes
sensor C3116 pin 2, circuit 519 (LG/BK), component side.
GO to D4.
Key in ACCESSORY position.
NOTE: The wheel must be moved very slowly to allow the meter
No
to read the high and low current as the sensor tone ring
INSTALL a new wheel speed sensor.
openings pass the sensor.
REFER to Wheel Speed Sensor Front
Measure the current while rotating the wheel slightly. or Wheel Speed Sensor Rear in this
Does the digital multi-meter switch between the low state section. CLEAR the DTC(s). REPEAT the
(5-8 mA) and the high state (11-18 mA)? self-test.
D3 CHECK FOR CORRECT ABS MODULE CONFIGURATION
OPERATION
NOTE: DTC C1222 indicates there is a problem with the Yes
configuration in the ABS module. GO to D4.
Carry out the ABS module configuration. Verify the vehicle data
No
matches the vehicle options. Refer to Section 418-01.
Clear the DTCs and carry out the self-test.
time. CLEAR the DTCs. REPEAT the
Is DTC C1222 still present?
self-test.
D4 CHECK FOR CORRECT ABS MODULE OPERATION
corrosion.
spread terminals.
the self-test.
pushed-out pins.
Possible Causes
Pinpoint Test E: DTC C1446 Brake Switch
Circuit Failure
Circuit shorted
Brake pedal switch
Brake fluid level sensor (master cylinder)
information.
Normal Operation
The anti-lock brake system (ABS) module receives
a voltage signal from the smart junction box (SJB)
along circuit 535 (LB/RD) through the brake pedal
switch. When the brake pedal is applied the voltage
signal is no longer referenced by the ABS module.
The SJB provides 5 volts to the brake fluid level
switch along circuit 547 (LG/YE). When the brake
fluid reaches a certain level, the switch closes and
the 5 volts are sent back to the SJB along circuit
512 (TN/LG).
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PINPOINT TEST E: DTC C1446 BRAKE SWITCH CIRCUIT FAILURE
E1 MONITOR THE SMART JUNCTION BOX (SJB) STOPLAMP
SWITCH PID
Connect the scan tool. Yes
Key in ON position. GO to E2.
Press and release the brake pedal while monitoring the SJB
No
stoplamp switch PID.
For further diagnosis of the stoplamps,
Do the stoplamps illuminate and does the PID agree?
E2 MONITOR THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE
STOPLAMP SWITCH PID
Press and release the brake pedal while monitoring the ABS Yes
module stoplamp switch PID and observing the stoplamps. GO to E3.
Does the PID agree with the brake pedal position?
No
REPAIR circuit 535 (LB/RD). CLEAR the
E3 CHECK THE BRAKE FLUID LEVEL SWITCH FOR A SHORT
Yes
Disconnect: Brake Fluid Level Switch C124.
GO to E4.
Key in ON position.
No
Clear the DTCs.
Perform the smart junction box (SJB) self test. Retrieve and
REFER to section Section 206-06.
record any DTCs.
Did DTC C1446 return? CLEAR the DTCs. REPEAT the self-test.
E4 CHECK CIRCUIT 512 (TN/LG) FOR A SHORT TO VOLTAGE
Yes
Disconnect: Smart Junction Box (SJB) C2280c.
REPAIR circuit 512 (TN/LG). CLEAR the
Key in ON position.
Measure the voltage between brake fluid level switch C124-2,
circuit 512 (TN/LG), harness side and ground. No
Is any voltage present? GO to E5.
E5 CHECK THE ABS MODULE CONNECTOR
Key in OFF position. Yes
Disconnect: ABS Module C135. INSTALL a new ABS module. REFER to
Check the ABS module connector for: Anti-Lock Brake System (ABS) Module in
corrosion. this section. CLEAR the DTCs. REPEAT
pushed-out pins. the self-test.
spread terminals.
No
Connect: ABS Module C135.
Make sure the ABS module connector seats correctly, then
operate the system and verify if the concern is still present.
the DTCs. REPEAT the self-test with the
brake pedal not applied.
Possible Causes
Pinpoint Test F: Spongy/Soft/Low Brake
Pedal with No Warning Indicator
Base brake system
Normal Operation
The brake pedal should be firm when applied.
PINPOINT TEST F: SPONGY/SOFT/LOW BRAKE PEDAL WITH NO WARNING INDICATOR
F1 CHECK THE BASE BRAKE COMPONENTS
Visually inspect the brake hoses and tubes from the hydraulic Yes
control unit (HCU) to the brake calipers. REPAIR or INSTALL new components as
Visually inspect the calipers and brake components. necessary. TEST the system for normal
Are any of these components damaged? operation.
No
GO to F2.
(Continued)
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PINPOINT TEST F: SPONGY/SOFT/LOW BRAKE PEDAL WITH NO WARNING INDICATOR (Continued)
F2 CHECK FOR A LEAKING DUMP VALVE
Remove the rubber boots from the 2 HCU low pressure
accumulators (LPA) and insert a clean steel implement (e.g.
paper clip or a small screwdriver) into each LPA.
Key in ON position.
Yes
NOTE: A leaking dump valve is similar to the master cylinder
bypass condition. It is important that the pedal be quickly and
Control Unit (HCU) in this section.
forcefully applied to rule out master cylinder bypass as a
condition.
No
Have an assistant press hard on the brake pedal while REMOVE the steel implements. INSTALL
observing the steel implements. the rubber boots on each LPA. REFER to
Do either of the implements move out 6.35 mm (0.25 in) or Section 206-00 to continue diagnosis of
more? the base brake system.
Pinpoint Test G: Poor Vehicle Tracking
Fused ignition voltage is supplied by the smart
During Anti-lock Function
junction box (SJB) through circuit 1844 (LG/RD)
and fused battery voltage is supplied by the bussed
Normal Operation
electrical center (BEC) through circuit 601 (LB/PK)
The operating voltage required to supply the
and circuit 534 (YE/LG). Ground is provided
anti-lock brake system (ABS) module, hydraulic
through circuit 1205 (BK).
pump and isolation valves is in a range between 10
and 16 volts. Possible Causes
Base brake system
PINPOINT TEST G: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION
G1 BLEED THE BRAKE SYSTEM
Bleed the brake system using the scan tool. Refer to Section Yes
206-00. The brake system is operating correctly.
Test drive the vehicle. The concern may have been caused by
Does the vehicle track correctly? air in the hydraulic system or a sticky
valve.
No
GO to G2.
G2 CHECK THE ABS INLET VALVE (CLOSED POSITION)
Rotate all the wheels to make sure they rotate freely (the TRIGGER the LF INLET OFF active
transmission must be in NEUTRAL). command. GO to G3.
Trigger the ABS module LF INLET ON active command.
No
Apply moderate brake pedal effort.
Have an assistant attempt to rotate the LF wheel.
Control Unit (HCU) in this section. TEST
Does the LF wheel rotate?
(Continued)
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PINPOINT TEST G: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION (Continued)
G3 CHECK THE ABS INLET VALVE (OPEN POSITION)
Apply moderate brake pedal effort. Yes
Have an assistant attempt to rotate the LF wheel. INSTALL a new HCU. REFER to Hydraulic
Does the LF wheel rotate? Control Unit (HCU) in this section. TEST
No
GO to G4.
G4 CHECK THE ABS OUTPUT VALVE (OPEN POSITION)
Apply moderate brake pedal effort.
Trigger ABS module LF INLET ON active command.
Trigger ABS module ABS POWER ON active command (turns
Yes
on the pump motor) for 6 seconds. (The trigger must be pressed
TRIGGER all active commands OFF. GO
3 times. Each press runs the pump for 2 seconds.)
to G5.
Trigger the ABS module LF OUTLET ON active command, then
trigger the ABS module LF OUTLET OFF active command. No
Repeat 3 times. INSTALL a new HCU. REFER to Hydraulic
Have an assistant attempt to rotate the LF wheel. Control Unit (HCU) in this section. TEST
Does the LF wheel rotate? the system for normal operation.
G5 CHECK THE ABS INLET AND OUTLET VALVES (CLOSED
POSITION)
Apply moderate brake pedal effort. Yes
Have an assistant attempt to rotate the LF wheel. INSTALL a new HCU. REFER to Hydraulic
Does the LF wheel rotate? Control Unit (HCU) in this section. TEST
No
REPEAT this procedure (beginning with
Step H2) for the RF, LR and RR wheels
using the appropriate active commands. If
no failure occurs, the system is operating
normally.
Possible Causes
Pinpoint Test H: DTC C1093 Traction
Control Disable Switch Circuit Failure and/or
Circuit open
the Traction Control System Cannot be
Circuit shorted
Disabled
Refer to Wiring Diagrams Cell 60, Instrument
Instrument cluster Normal Operation
Engine torque modulation is achieved by regulating
fuel and spark to the cylinders. The traction control
system operates using the anti-lock brake system
(ABS) module to interact with the powertrain
control module (PCM) to reduce engine torque and
apply the brakes if the wheels lose traction and
begin to spin during acceleration.
The instrument cluster circuit 1412 (WH/PK)
monitors for a ground (change of state). When the
traction control switch is pressed, a momentary
ground occurs through circuit 1205 (BK). The
instrument cluster then sends a voltage to the
traction control switch through circuit 939 (VT)
illuminating the traction control switch and
disabling the system.
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PINPOINT TEST H: DTC C1093 TRACTION CONTROL DISABLE SWITCH CIRCUIT FAILURE AND/OR
THE TRACTION CONTROL SYSTEM CANNOT BE DISABLED
H1 MONITOR THE INSTRUMENT CLUSTER PID
Monitor the instrument cluster traction control switch status PID GO to H6.
while pressing the traction control disable switch repeatedly.
No
Does the PID agree with the switch position?
GO to H2.
H2 CHECK THE TRACTION CONTROL SWITCH INPUT
Disconnect: Instrument Cluster C220.
Measure the resistance between instrument cluster C220-20,
circuit 1412 (WH/PK), harness side and ground while pressing
and releasing the traction control switch.
Yes
GO to H3.
No
INSTALL a new traction control switch.
REFER to Traction Control Switch in this
Is the resistance less than 5 ohms with the switch pressed section. CLEAR the DTCs. REPEAT the
and greater than 10,000 ohms with the switch released? self-test.
H3 CHECK CIRCUIT 1412 (WH/PK) FOR A SHORT TO GROUND
Disconnect: Traction Control Switch C2039.
Measure the resistance between traction control switch C2039-7,
circuit 1412 (WH/PK), harness side and ground.
Yes
REPAIR circuit 1412 (WH/PK). CLEAR the
No
Is the resistance less than 5 ohms? GO to H4.
(Continued)
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PINPOINT TEST H: DTC C1093 TRACTION CONTROL DISABLE SWITCH CIRCUIT FAILURE AND/OR
THE TRACTION CONTROL SYSTEM CANNOT BE DISABLED (Continued)
H4 CHECK CIRCUIT 1412 (WH/PK) FOR AN OPEN
circuit 1412 (WH/PK), harness side and traction control switch
C2039-7, circuit 1412 (WH/PK), harness side.
Yes
REPAIR circuit 1412 (WH/PK). CLEAR the
No
Is the resistance greater than 10,000 ohms? GO to H5.
H5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between traction control switch C2039-1,
circuit 1205 (BK), harness side and ground.
Yes
REPAIR circuit 1205 (BK). CLEAR the
No
INSTALL a new traction control switch.
REFER toTraction Control Switch in this
Is the resistance greater than 10,000 ohms? self-test.
H6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Disconnect: Instrument Cluster C220. Yes
Check for: INSTALL a new instrument cluster.
corrosion.
spread terminals.
pushed-out pins. No
Connect the instrument cluster connector and make sure it seats The system is operating correctly at this
correctly. time. The concern may have been caused
Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR
Pinpoint Test I: The Traction Control Switch Normal Operation
Indicator is Never/Always On
The instrument cluster circuit 1412 (WH/PK)
monitors for a ground (change of state). When the
traction control switch is pressed momentary ground
occurs through circuit 1205 (BK). The instrument
information.
cluster then sends a voltage to the traction control
switch through circuit 939 (VT) illuminating the
traction control switch and disabling the system.
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Possible Causes
Circuit open
Circuit shorted
Instrument cluster
PINPOINT TEST I: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON
I1 VERIFY THE TRACTION CONTROL SYSTEM OPERATION
Operate the system and verify the traction control system can be Yes
enabled and disabled. GO to I2.
Does the traction control system operate correctly?
No
REFER to symptom chart to continue
diagnosis.
I2 CHECK CIRCUIT 939 (VT) FOR VOLTAGE
Disconnect: Traction Control Switch C2039.
Key in ON position.
Measure the voltage between traction control switch C2039-4,
circuit 939 (VT), harness side and ground.
Yes
GO to I3.
No
Is voltage present? GO to I4.
I3 CHECK CIRCUIT 939 (VT) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between traction control switch C2039-4,
circuit 939 (VT), harness side and ground.
Yes
REPAIR circuit 939 (VT). TEST the
No
Is voltage present? GO to I6.
(Continued)
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PINPOINT TEST I: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON (Continued)
I4 CHECK CIRCUIT 939 (VT) FOR AN OPEN OR SHORT TO
GROUND
circuit 939 (VT), harness side and:
traction control switch C2039-4, circuit 939 (VT), harness
side.
ground.
Yes
REPAIR circuit 939 (VT). TEST the
Is the resistance greater than 10,000 ohms between the
instrument cluster and the traction control switch, and less No
than 5 ohms between the instrument cluster and ground? GO to I5.
I5 CHECK THE INSTRUMENT CLUSTER OPERATION
Connect: Traction Control Switch C2039.
Connect a fused (10A) jumper wire between instrument cluster
C220-21, circuit 939 (VT), harness side and instrument cluster
C220-3, circuit 1001 (WH/YE), harness side.
Yes
Remove the jumper wire. GO to I6.
No
Remove the jumper wire. INSTALL a new
traction control switch. REFER to Traction
Control Switch in this section. CLEAR the
Does the traction control switch indicator illuminate? DTCs. REPEAT the self-test.
I6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Disconnect: Instrument Cluster C220. Yes
corrosion.
spread terminals.
pushed-out pins. No
Connect the instrument cluster connector and make sure it seats The system is operating correctly at this
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Hydraulic Control Unit (HCU)
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
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1 Anti-lock brake system (ABS)
module electrical connector
(part of 14A005)
2 Brake tube-to-hydraulic
control unit (HCU) fittings
3. Disconnect the anti-lock brake system (ABS) (part of 2C296) (6 required)
module electrical connector.
3 13083701 HCU bracket-to-frame bolts
(3 required)
4. NOTE: Brake tubes must be installed in the
4 2C215 HCU
same location as removed.
5 3B676 Bracket-to-HCU bolt
Loosen the 6 brake tube-to-hydraulic control
6 2C304 HCU bracket
unit (HCU) fittings, disconnect and position the
brake tubes aside.
5. Remove the 3 HCU bracket-to-frame bolts.
approved DOT 3 brake fluid will cause
permanent damage to brake components and will
render the brakes inoperative. Failure to follow
6. Remove the HCU assembly.
7. If necessary, remove the HCU bracket bolt and
bracket.
products call: 1-800-959-3673. For additional 8. To install, reverse the removal procedure.
Bleed the brake system. For additional
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SPECIFICATIONS
Anti-lock brake system 3 27
Item Specification (ABS) module screws
Lubricant Bracket-to-HCU bolt 11 8
High Performance DOT 3 ESA-M6C25-A or Brake tube-to-HCU 17 13
Motor Vehicle Brake WSS-M6C62-A fittings
Hydraulic control unit 25 18
(HCU) bracket-to-frame
(Canada)
bolts
Wheel speed sensor 15 11
bolt
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Traction Control Switch
1. Remove the instrument panel center finish
panel. For additional information, refer to
Section 501-12.
2. Press the retaining tabs and remove the
switchblock.
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Wheel Speed Sensor Front
3 Wheel speed sensor grommet 1 Wheel speed sensor electrical
retainers (part of 2C204) (2 connector (part of 14406)
required)
2 Wheel speed sensor harness
4 S997960825 Wheel speed sensor bolt pin-type retainers (part of
2C204) (3 required)
(Continued)
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5. Disconnect the 2 wheel speed sensor grommet
retainers from the brake hose clips.
6. Remove the wheel speed sensor bolt.
7. Remove the wheel speed sensor and harness
Section 100-02.
assembly.
3. Disconnect the wheel speed sensor electrical
connector.
4. Disconnect the 3 wheel speed sensor harness
pin-type retainers.
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Wheel Speed Sensor Rear
4 S997960825 Wheel speed sensor bolt 1 14406 Wheel speed sensor electrical
connector
2 Wheel speed sensor harness
pin-type retainers (part of
2C190) (2 required)
3 Wheel speed sensor grommet
retainer (part of 2C190)
(Continued)
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2. With the vehicle in NEUTRAL, position it on a 5. Disconnect the wheel speed sensor grommet
hoist. For additional information, refer to retainer from the brake hose clip.
Section 100-02.
6. Remove the wheel speed sensor bolt.
3. Disconnect the wheel speed sensor electrical
connector.
7. Remove the wheel speed sensor.
4. Disconnect the 2 wheel speed sensor harness
pin-type retainers.
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Wheel Speed Sensor Ring Front
Special Tool(s)
Pinion Bearing Cone Remover
205-D002 (D79P-4621A)
Axle Bearing/Seal Plate
205-090 (T75L-1165-B)
Installer, Wheel Speed Sensor
Ring
Installation 206-041 (T89P-20202-A)
1. Using the special tool, install the front wheel
speed sensor ring to the front hub.
Remover/Installer, Wheel Speed
Sensor
206-033 (T88P-20202-A)
Removal
1. Remove the front hub and bearing assembly.
204-01.
2. Install the front hub and bearing assembly. For
2. Using the special tools, remove the front wheel
speed sensor ring from the front hub.
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Wheel Speed Sensor Ring Rear
Special Tool(s)
205-D002 (D79P-4621A) or
equivalent
Axle Bearing/Seal Plate
205-090 (T75L-1165-B)
Installer, Wheel Speed Sensor
Ring
206-041 (T89P-20202-A)
Removal
1. Remove the rear axle shaft. For additional
Section 205-02B.
2. Using the special tool, remove the anti-lock
brake sensor indicator from the axle shaft.
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Installation
2. Using the special tools, press the rear anti-lock
brake sensor on the rear axle shaft to
specification.
1. Using the special tools, align the rear anti-lock
brake sensor indicator to the rear axle shaft.
3. Install the rear axle shaft. For additional
information, refer to Section 205-02A.
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211-00-1 211-00-1 Steering System General Information
SPECIFICATIONS
Item Specification
Flow 4.0L and 4.6L 8.35
Item Specification liters/minute
(2.2 gpm)
Lubricants
5.4L 7.57 liters/minute
MERCON MERCON
(2.0 gpm)
Multi-Purpose Automatic
Fluid @ 41-46 C
Transmission Fluid
(105-115F)
XT-2-QDX (US);
4.0L at 2150 RPM
XT-2-LM12 (Canada)
4.6L at 2000 RPM
Power Steering Gear
Pressure 345 kPa
(50 psi)
Fluid capacity 1.13 L (2.4 pt)
Fluid @ 41-46C
Turning effort 2.27 kg (5 lb)
(105-115F)
4.0L at 2150 RPM
Turns lock-to-lock (4.0L) 3.13
4.6L and 5.4L at 2000
Turns lock-to-lock (4.6L) 2.83
RPM
Turns lock-to-lock (4.6L 2.60
Minimum capacity 4.9 liters/minute
with optional 18-inch
(1.3 gpm)
wheels)
Fluid @ 41-46C
(105-115F) Turns lock-to-lock (5.4L) 2.60
Engine at idle
Power Steering Purge Vacuum
Pressure at 5,171 kPa
Vacuum 68-85 kPa (20-25 in-Hg) (750 psi)
Power Steering Pump Relief pressure 9,653-10,549 kPa
(1,400-1,530 psi)
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GENERAL PROCEDURES
4. Install the vacuum pump to the fill adapter
Power Steering System Filling
manifold control valve.
Special Tool(s)
5. Install the hose to the opposite fill adapter
Vacuum Pump Kit
manifold control valve and submerge the open
416-D002 (D95L-7559-A) or
end of the hose into a container of new power
equivalent
steering fluid.
6. NOTE: The fill adapter manifold control valves
are in the open position when the point of the
handles face the center of the fill adapter
Evacuation Cap, Power Steering manifold.
Close the fill adapter manifold control valve
connected to the power steering fluid container.
7. Open the fill adapter manifold control valve
connected to the vacuum pump.
Fill Adapter Manifold, Power 8. Using the vacuum pump, apply 68-85 kPa
Steering
(20-25 in-Hg) of vacuum to the power steering
system.
9. Observe the vacuum gauge for 30 seconds.
10. If the vacuum gauge reading drops more than 3
kPa (0.88 in-Hg), correct any leaks in the
Material
power steering system or the filling tools before
proceeding. Item Specification
MERCON Multi-Purpose MERCON
11. NOTE: The vacuum pump gauge reading will
Automatic Transmission
drop slightly during this step. Fluid
XT-2-QDX (US);
Slowly open the fill adapter manifold control
XT-2-LM12 (Canada)
valve connected to the power steering fluid
container until power steering fluid completely
1. CAUTION: If the air is not purged
fills the hose.
from the power steering system correctly,
premature power steering pump failure can
12. Close the fill adapter manifold control valve
result. The condition can occur on
connected to the power steering fluid container.
pre-delivery vehicles with evidence of aerated
fluid or on vehicles that have had steering
13. Using the vacuum pump, apply 68-85 kPa
component repairs.
(20-25 in-Hg) of vacuum to the power steering
system.
Remove the power steering pump reservoir cap.
14. Close the fill adapter manifold control valve
2. Tightly install the evacuation cap to the power
connected to the vacuum pump.
steering pump reservoir.
15. Slowly open the fill adapter manifold control
3. Install the hose from the fill adapter manifold
tee to the evacuation cap on the power steering
container.
pump reservoir.
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16. When the power steering fluid has drained from 20. If equipped with Hydro-Boost, apply the
the hose connected to the power steering fluid brake pedal twice.
container, close the fill adapter manifold control
container.
22. CAUTION: Do not overfill the
17. Remove the tools from the vehicle.
reservoir.
Remove the power steering reservoir cap and
18. Install the power steering reservoir cap.
fill the reservoir.
23. Install the power steering reservoir cap.
wheel against the stops for more than 3 to 5
seconds at a time. Damage to the power
steering pump can occur.
NOTE: There will be a slight drop in the
power steering fluid level in the power steering
fluid reservoir when the engine is started.
Start the engine and turn the steering wheel
from stop-to-stop.
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GENERAL PROCEDURES
Power Steering System Flushing 9. CAUTION: Avoid turning the steering
wheel without the engine running as this may
cause air to be pulled into the steering gear. Material
Item Specification CAUTION: Do not overfill the
reservoir.
Fill the power steering fluid reservoir with the
Fluid
approved power steering fluid.
XT-2-QDX (US);
XT-2-LM12 (Canada)
10. Repeat Steps 8 and 9, turning the steering
wheel in the opposite direction each time, until
WARNING: Do not mix oil types. Any
the fluid exiting the power steering fluid return
mixture or any unapproved oil can lead to seal
hose is clean and clear of foreign material.
deterioration and leaks. A leak can ultimately
cause loss of fluid, which can result in a loss of
11. Remove the extension hose from the power
power steering assist. Failure to follow these
steering return hose.
12. Remove the plug from the power steering fluid
1. Remove the power steering fluid reservoir cap.
reservoir inlet port.
2. Using a suitable suction device, remove the
13. Install the power steering return hose to the
power steering fluid from the reservoir.
reservoir.
3. Disconnect the power steering fluid return hose Install the clamp.
from the reservoir.
Remove the clamp.
4. Plug the power steering fluid reservoir inlet
port.
5. Attach an extension hose to the power steering
return hose.
6. NOTE: Do not reuse the power steering fluid
that has been flushed from the power steering
system.
Place the open end of the extension hose into a
suitable container.
reservoir.
Fill the power steering fluid reservoir with new
fluid.
8. CAUTION: Do not allow the power
steering pump to run completely dry of
power steering fluid.
Start the engine while simultaneously turning
the steering wheel to lock and then immediately
turn the ignition switch to the OFF position.
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14. NOTE: It is necessary to correctly fill the
power steering system to remove any trapped
air and completely fill the power steering
system components.
If, after correctly filling the power steering
system, there is power steering noise
accompanied by evidence of aerated fluid and
there are no fluid leaks, it may be necessary to
purge the power steering system. For additional
information, refer to Power Steering System
Purging in this section.
Fill the power steering system. For additional
information, refer to Power Steering System
Filling in this section.
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GENERAL PROCEDURES
5. Install the vacuum pump, apply vacuum and
Power Steering System Purging
maintain the maximum vacuum of 68-85 kPa
(20-25 in-Hg).
Special Tool(s)
Vacuum Pump Kit
6. If equipped with Hydro-Boost, apply the
416-D002 (D95L-7559-A) or
brake pedal twice.
equivalent
Evacuation Cap, Power Steering
Cycle the steering wheel fully from stop-to-stop
10 times.
8. Stop the engine.
9. Release the vacuum and remove the vacuum
pump.
Material
Item Specification
reservoir.
Fill the reservoir.
Fluid
Use approved transmission fluid.
XT-2-QDX (US);
XT-2-LM12 (Canada)
11. Start the engine.
CAUTION: If the air is not purged from
12. Install the vacuum pump. Apply and maintain
the power steering system correctly, premature
the maximum vacuum of 68-85 kPa (20-25
power steering pump failure can result. The
in-Hg).
condition can occur on pre-delivery vehicles with
evidence of aerated fluid or on vehicles that have
had steering component repairs.
1. NOTE: A whine heard from the power steering
pump can be caused by air in the system. The
Cycle the steering wheel fully from stop-to-stop
power steering purge procedure must be carried
10 times.
out prior to any component repair for which
power steering noise complaints are
14. Stop the engine, release the vacuum and
accompanied by evidence of aerated fluid.
remove the vacuum pump.
Remove the power steering pump reservoir cap.
Check the fluid.
reservoir.
2. Raise the front wheels off the floor. Refer to
the appropriate section in Group 100 for the
Fill the reservoir as needed and install the
procedure.
reservoir cap.
3. Tightly insert the stopper of the vacuum pump
16. Visually inspect the power steering system for
into the reservoir.
leaks.
4. Start the engine.
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18. Install the reservoir cap.
reservoir.
Fill the reservoir as needed and visually inspect
the power steering system for leaks.
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Rack-and-pinion steering gear
Steering System
Power steering fluid cooler
The steering system consists of the following
components:
Power steering pressure and return lines/hoses
Steering column
Power steering pump
Steering column switches
Power steering fluid reservoir
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Material
Steering System
Item Specification
Special Tool(s)
Automatic Transmission Dial Thermometer 0-220F
Fluid 023-R0007 or equivalent
XT-2-QDX (US);
XT-2-LM12 (Canada)
Power Steering
The power steering system uses a CIII power
steering vane-type pump to pump the fluid from the
reservoir to the rack-and-pinion steering gear. The
power steering pump is mounted to the engine and
driven by the engine accessory drive belt. Power
steering fluid is pulled into the pump from the
reservoir by vacuum. The minimum vacuum
required is 68-84 kPa (20-25 in-Hg). The power
Power Steering Analyzer
steering fluid is then trapped and squeezed into a
211-F001 (014-00207) or
smaller area inside the pump. This action
equivalent
pressurizes the fluid at the output, as it flows to the
rest of the system. A pressure relief/flow valve is
built into the pump to control the maximum
pressure. The relief pressure is between
9,653-10,549 kPa (1,400-1,530 psi). This action
Gauge, Spring Tension
prevents damage to the system during different
211-034 (T74P-3504-Y)
engine speeds. While under pressure, the power
steering fluid flows through the high pressure power
steering line to the rack-and-pinion steering gear.
DIS/EDIS Tach Adapter
418-F102 (007-00061) or
equivalent mechanical damage.
Tie-Rod End Remover
211-105 (T85M-3395-A)
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CAUTION: Do not hold the
Mechanical steering wheel at the stops for an
extended amount of time. Damage to the
Fluid level
power steering pump can occur. Tire pressure
Tires
Start the engine and turn the steering wheel
Drive belt
from stop-to-stop several times and check
Drive belt tensioner
for leaks.
Steering column alignment
Tie-rod ends
5. Inspect the power steering pressure and return
hoses, the fittings and the O-rings for leaks.
Steering column shaft U-joints
Intermediate shaft bolts
If a leak is detected at a power steering
Power steering reservoir baffle
pressure or return hose, install a new hose.
Power steering reservoir filter
Power steering pressure lines, fittings or O-rings
Power steering return hoses and clamps
If a leak is detected at a fitting or clamp
Steering gear
plate, tighten to specification. If the leak is
Power steering pump
still evident, visually inspect the fittings, the
clamp plate, the O-rings, and the Teflon
3. NOTE: The 3 areas that should be inspected
seals. Install new as necessary. Refer to
for possible contamination are the power
Section 211-02.
steering reservoir filter, the flow control and
If a leak is detected at the power steering
pressure relief valve in the pump, and the check
reservoir, install a new reservoir. Refer to
valve in the inlet port on the power steering
Section 211-02.
gear (if equipped).
If a leak is detected at a constant tension
Inspect the power steering fluid for the
spring clamp, verify that the hose is fully
following conditions:
installed on the fitting and that the constant
Aerated or foamy: Purge the power steering
tension spring clamp is correctly positioned.
system. Refer to Power Steering System
If the leak remains, install a new constant
Purging in this section.
tension spring clamp.
Overheating or contamination: Flush the
If a leak is detected at a screw clamp joint,
power steering system. Refer to Power
tighten the screw clamp. If the leak remains,
Steering System Flushing in this section.
inspect the tube end and install a new hose.
4. Check the power steering system for fluid
leaks.
If a leak is detected at the power steering
pump, install a new power steering pump.
Check the power steering fluid level.
NOTE: It may be necessary to add power steering
NOTE: It may be necessary to remove the
fluid to achieve the correct level.
squeeze-type clamp from the steering gear boots to
With the ignition OFF:
inspect for leaks.
Wipe off the power steering pump, the
6. Inspect the power steering gear for leaks. If a
power steering pressure hose, the power
leak is detected at the power steering gear,
steering return hose, the power steering fluid
install a new power steering gear. Refer to
cooler, the hose assembly and the steering
Section 211-02.
gear.
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External Leak Check Potential Power Rack-and-Pinion Steering Gear Leak Points
7. If an obvious cause for an observed or reported 8. If the cause is not visually evident, verify the
concern is found, correct the cause (if possible) symptom and GO to Symptom Chart.
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Steering System Symptom Definitions
Hard steering or lack of assist can result from either
hydraulic or mechanical conditions. It is extremely
Drift/Pull
important to know if this concern occurs during
Pull is described as a tugging sensation felt by the
driving or during high-effort parking maneuvers.
hands on the steering wheel that must be overcome
to keep the vehicle going straight.
Nibble
Sometimes confused with shimmy, nibble is a
Drift describes what a vehicle with this condition
condition resulting from tire interaction with various
does with the hands off the steering wheel.
road surfaces and observed by the driver as small
A vehicle-related drift/pull on a flat road can
rotational oscillations of the steering wheel.
cause a consistent deviation from the
Poor Returnability/Sticky Steering
straight-ahead path and require constant steering
Poor returnability and sticky steering is used to
input in the opposite direction to counteract the
describe the poor return of the steering wheel to
effect.
center after a turn (or steering correction) is
Drift/pull can be induced by conditions external to
completed.
the vehicle, such as wind or road camber.
Shimmy
Excessive Steering Wheel Play
Shimmy, as observed by the driver, is large,
Excessive steering wheel play is a condition in
consistent, rotational oscillations of the steering
which there is too much steering wheel movement
wheel resulting from large, side to side (lateral)
before the wheels move. A small amount of steering
tire/wheel movements.
wheel free play is considered normal.
Shimmy is usually experienced near 64 km/h (40
Feedback
mph), and can begin or be amplified when the tire
Feedback is a roughness felt in the steering wheel
contacts pot holes or irregularities in the road
when the vehicle is driven over rough pavement.
surface.
Hard Steering or Lack of Assist
Wander
Hard steering or lack of assist is experienced when
Wander is the tendency of the vehicle to require
the steering wheel effort exceeds specifications.
frequent, random left and right steering wheel
Hard steering can remain constant through the full
corrections to maintain a straight path down a level
turn or occur near the end of a turn. It is important
road.
to know the difference between hard steering/lack
of assist and binding.
Symptom Chart
Symptom Chart
Steering system noise Low fluid level GO to Pinpoint Test A.
Fluid aeration
Steering gear
Power steering pump
Loose or damaged steering
linkage
Loose or damaged suspension
component(s)
Steering column
Steering column boot bearing
Intermediate shaft
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Steering is very difficult/very Seized intermediate shaft GO to Pinpoint Test B.
easy U-joints
Damaged, fractured steering
column bearing(s)
Steering gear
Power steering pump
Power steering hoses
Ball joints
Strut bearing plate (if
applicable)
Binding dash boot seal
Excessive steering wheel play Steering gear GO to Pinpoint Test C.
Steering column
Steering column intermediate
shaft
Steering linkage
Ball joints
Strut bearing plate
Steering system Unevenly loaded vehicle CORRECT the vehicle
drift/pull/wander loading as necessary.
Tire pressure GO to Pinpoint Test D.
Wheel alignment
Steering gear
Steering column intermediate
shaft
Frame alignment
Feedback Loose, worn or damaged tie GO to Component Test,
rods Steering Linkage in this
section.
Loose, worn or damaged GO to Component Test,
tie-rod ends Steering Linkage in this
section.
Loose or damaged steering TIGHTEN or INSTALL new
gear insulators or bolts steering gear insulators or
bolts as necessary.
Loose steering column TIGHTEN the bolts or
intermediate shaft U-joint or INSTALL a new steering
pinch bolts column intermediate shaft as
needed. REFER to Section
211-04.
Loose suspension bushings, INSTALL new components
fasteners, ball joints or strut as necessary. REFER to
bearing plate Section 204-01.
Worn or damaged steering INSTALL a new steering
column bearing(s) column. REFER to Section
211-04.
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Poor returnability/sticky Binding steering column INSTALL a new steering
steering intermediate shaft U-joints column intermediate shaft.
Loose, worn or damaged tie GO to Component Test,
rods Steering Linkage in this
section.
Loose, worn or damaged GO to Component Test,
section.
Suspension components REFER to Section 204-00 to
continue the suspension
diagnosis.
Binding steering column INSTALL a new steering
bearing(s) column. REFER to Section
211-04.
Binding dash boot seal INSTALL a new dash boot
seal. REFER to Section
211-04.
Shimmy Loose, worn or damaged GO to Component Test,
section.
Suspension components REFER to Section 204-00 for
the suspension diagnosis and
testing.
Possible Causes
Pinpoint Tests
Front suspension components
Pinpoint Test A: Steering System Noise
Power steering fluid level
Normal Operation
Power steering pump
The power steering pump, which is driven by the
crankshaft through a drive belt and pulleys, Steering column
develops the hydraulic pressure necessary to operate
Steering column dash boot
the system. When the engine is running, fluid is
Steering gear
drawn into the power steering pump from the power
Steering linkage steering pump reservoir. Hydraulic fluid is
pressurized in the power steering pump and sent to
Drive belt
the steering gear. The rotary valve determines fluid
Belt tensioner
direction to assist the driver in the turning of the
vehicle. When the steering wheel is turned, the
steering gear converts this hydraulic pressure and
flow into mechanical motion that moves the front
wheels in the direction of the turn. The steering
gear uses tie rods to connect the front knuckles,
which then pivot on the ball joints, steering the
vehicle.
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PINPOINT TEST A: STEERING SYSTEM NOISE
A1 CHECK FOR MECHANICAL NOISE
Test drive the vehicle to verify the steering system noise. Yes
Does the steering system make a clunk noise? If the noise is from the steering linkage,
CHECK for loose, worn, or damaged inner
tie-rod or tie-rod ends. REFER to
Component Test, Steering Linkage in this
section.
If the noise is from the steering column,
CHECK the steering column intermediate
shaft for grounding through the body and
repair as necessary. TEST the system for
normal operation.
If the noise is from the steering column
boot bearing, INSTALL a new steering
column boot bearing. REFER to Section
211-04. TEST the system for normal
operation.
If the noise is from suspension
components, INSTALL new suspension
components as necessary. REFER to
Section 204-01 for the front suspension or
Section 204-02 for the rear suspension.
If the noise is from loose, worn or
damaged intermediate shaft U-joint(s),
INSTALL a new steering column shaft.
No
If a squeak is present in the steering
column, REPAIR the steering column
mountings or align the steering column as
For all other concerns, GO to A2.
(Continued)
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PINPOINT TEST A: STEERING SYSTEM NOISE (Continued)
A2 VERIFY THE CONCERN
NOTE: Make sure the vehicle is on a flat dry surface, the Yes
transmission is in PARK and the windows are rolled up. If a grunt noise is present, VERIFY the
steering column dash boot is OK and the
NOTE: Some power steering noise is expected. If in doubt of the
exhaust system is not grounding out.
acceptability of the noise level, evaluate another vehicle of the
same model and powertrain. If a moan is present, VERIFY that the
inner tie rod, tie-rod ends and ball joints Key in START position.
are OK. Turn the steering wheel one-half turn off-center to the right then
one-half turn off-center to the left.
GO to A3.
Is the power steering noisy?
No
If a squeal is present, INSPECT and
INSTALL a new engine drive belt or belt
tensioner as necessary. REFER to Section
operation.
If the steering system noise is a hiss or
whistle, INSPECT the dash boot at the
instrument panel cowl. REPAIR or
INSTALL a new dash boot as necessary.
INSPECT the steering gear input shaft and
valve for wear or damage. REFER to
normal operation.
INSPECT the power steering gear, the
intermediate shaft, and the power steering
lines and hoses for grounding to the body
and repair as necessary.
INSPECT for openings or missing plugs in
the instrument panel cowl and repair as
operation.
If there are no missing plugs or openings
in the instrument panel cowl, and no
grounded power steering gear,
intermediate shaft, or power steering lines
or hoses, GO to A6.
A3 CHECK FOR COLD START NOISE
NOTE: Some noise during an extremely cold start (-25.5C [-14F]) Yes
is normal and should improve as the steering system warms up CHECK for contamination in the power
(usually within 60 seconds). steering reservoir screen. FLUSH the
power steering system as necessary.
REFER to Power Steering System
Verify the noise condition.
Flushing in this section. TEST the system
Is the noise present only during cold start up?
No
GO to A4.
A4 INSPECT THE POWER STEERING FLUID
With the engine OFF, inspect the power steering fluid for GO to A5.
aeration.
No
Is the power steering fluid foamy or aerated?
PURGE the power steering system.
REFER to Power Steering System Purging
normal operation.
If a whine or moan is still present,
INSTALL a new power steering pump.
If a grunt is still present, INSTALL a new
power steering gear. REFER to Section
operation.
(Continued)
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PINPOINT TEST A: STEERING SYSTEM NOISE (Continued)
A5 CHECK THE POWER STEERING FLUID LEVEL WITH THE
ENGINE ON AND OFF
NOTE: Record the vacuum level when the pump noise occurs with
no steering input. Vacuum level should be greater than 51 kPa (15
Yes
in/Hg) with the CIII pump.
PURGE the power steering system.
REFER to Power Steering System Purging
With the engine running, inspect the power steering fluid level.
normal operation.
With the engine off, inspect the power steering fluid level.
Does the power steering fluid level change with the engine No
off? GO to A6.
A6 CHECK THE POWER STEERING PUMP
NOTE: Do not turn the steering wheel to either the right or left stop. Yes
Power steering relief noise will occur and is normal at the stop INSTALL a new power steering gear.
positions. REFER to Section 211-02. TEST the
With the engine running, rotate the steering wheel 90 degrees to
No
the left then to the right.
INSTALL a new power steering pump.
Does the frequency of the hiss change between the left and
right positions?
Possible Causes
Pinpoint Test B: Steering is Very
Difficult/Very Easy
Intermediate shaft
Normal Operation
Intermediate shaft U-joints
The power steering pump, which is driven by the
Steering column
crankshaft through a drive belt and pulleys,
Steering column bearings
develops the hydraulic pressure necessary to operate
the system. When the engine is running, fluid is
Steering gear
drawn into the power steering pump from the power
Power steering pump
steering pump reservoir. Hydraulic fluid is
Power steering hoses
pressurized in the power steering pump and sent to
the steering gear. The rotary valve determines fluid Ball joints
direction to assist the driver in the turning of the
vehicle. When the steering wheel is turned, the
steering gear converts this hydraulic pressure and
flow into mechanical motion that moves the front
wheels in the direction of the turn. The steering
gear uses tie rods to connect the front knuckles,
which then pivot on the ball joints, steering the
vehicle.
PINPOINT TEST B: STEERING IS VERY DIFFICULT/VERY EASY
B1 CHECK THE STEERING COLUMN BEARINGS AND THE
INTERMEDIATE SHAFT
NOTE: Be sure to keep the clockspring centered when Yes
disconnecting the intermediate shaft. Refer to Section 501-20B. GO to B2.
Check the steering column and intermediate shaft for grounding.
No
Disconnect the steering column intermediate shaft at the
If the steering column or the intermediate
steering column.
shaft is grounding, REPAIR as necessary.
Verify that the intermediate shaft universal joints do not bind and
move freely and that the steering column bearing rotates freely.
If the steering column bearings or the
Are the steering column bearings and intermediate shaft
intermediate shaft are binding, INSTALL a
universal joints OK?
new intermediate shaft or steering column.
(Continued)
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PINPOINT TEST B: STEERING IS VERY DIFFICULT/VERY EASY (Continued)
B2 CHECK THE FRONT BALL JOINTS AND UPPER STRUT
BEARINGS
Verify that the front ball joints and upper strut bearings move Yes
freely and are not binding or sticking. Refer to Section 204-00 GO to B3.
for the suspension diagnosis.
No
Are the front ball joints and upper strut bearings OK?
INSTALL new ball joints or upper strut
bearings as necessary. REFER to Section
operation.
B3 MONITOR ENGINE RPM CHANGES
NOTE: Make sure that the vehicle is on a flat dry surface. Yes
If no power steering assist is present and
the engine rpm changes, INSTALL a new
CAUTION: Do not hold the steering wheel at the steering gear. REFER to Section 211-02.
stops for an extended amount of time. Damage to the power TEST the system for normal operation.
If left-to-right variation is present, INSTALL
Turn the steering wheel once to the left stop position and then to
a new steering gear. REFER to Section
the right stop position.
Note the engine rpm during the turns.
operation.
Does the engine rpm change when turning the steering
If excessive effort is required in one or
wheel?
both directions, INSTALL a new power
steering pump. REFER to Section 211-02.
No
CARRY OUT the Power Steering Pump
Flow and Pressure Test. REFER to the
Component Tests in this section.
Possible Causes
Pinpoint Test C: Excessive Steering Wheel
Play
Steering column bearings
Normal Operation
Steering linkage
When the steering wheel is turned, the steering shaft
rotates in the steering column on bearings. When
the engine is running, fluid is drawn into the power
steering pump from the power steering pump
reservoir. Hydraulic fluid is pressurized in the
power steering pump and sent to the steering gear.
The rotary valve determines fluid direction to assist
the driver in the turning of the vehicle. When the
steering wheel is turned, the steering gear converts
this hydraulic pressure and flow into mechanical
motion that moves the front wheels in the direction
of the turn. The steering gear uses inner tie rods and
tie-rod ends to connect the front knuckles, which
then pivot on the ball joints, steering the vehicle.
PINPOINT TEST C: EXCESSIVE STEERING WHEEL PLAY
C1 CHECK THE STEERING COLUMN BEARINGS
Inspect the steering column mounting fasteners and bearings for Yes
looseness. GO to C2.
Are the fasteners and bearings OK?
No
TIGHTEN the steering column mounting
fasteners or INSTALL a new steering
column. REFER to Section 211-04. TEST
(Continued)
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PINPOINT TEST C: EXCESSIVE STEERING WHEEL PLAY (Continued)
C2 CHECK THE STEERING LINKAGE FOR LOOSENESS
Carry out the steering linkage component test. Refer to Yes
Component Tests in this section. REFER to Section 204-00 to diagnose the
Is the steering linkage OK? suspension components.
No
INSTALL new steering linkage
components as necessary. REFER to
normal operation.
Possible Causes
Pinpoint Test D: Steering System
Drift/Pull/Wander
Steering gear
Normal Operation
Intermediate shaft
When the steering wheel is turned, the steering shaft
Intermediate shaft U-joints
rotates in the steering column on bearings. When
Steering gear mounts
the engine is running, fluid is drawn into the power
steering pump from the power steering pump
reservoir. Hydraulic fluid is pressurized in the
power steering pump and sent to the steering gear.
The rotary valve determines fluid direction to assist
the driver in the turning of the vehicle. When the
steering wheel is turned, the steering gear converts
this hydraulic pressure and flow into mechanical
motion that moves the front wheels in the direction
of the turn. The steering gear uses inner tie rods and
tie-rod ends to connect the front knuckles, which
then pivot on the ball joints, steering the vehicle.
PINPOINT TEST D: STEERING SYSTEM DRIFT/PULL/WANDER
D1 CHECK FOR TIRE PULL
Rotate the front wheel and tire assemblies side to side. Refer to Yes
Section 204-04. If vehicle pulls in the opposite direction,
Carry out a road test on a smooth, flat road. GO to D2.
Does the vehicle drift/pull?
If vehicle pulls in the original direction, GO
to D3.
No
The concern has been corrected.
D2 ROTATE THE WHEEL AND TIRE ASSEMBLIES FRONT TO
REAR
Rotate the wheel and tire assemblies front to rear. Refer to Yes
Section 204-04. GO to D3.
Carry out a road test on a smooth, flat road.
No
Does the vehicle drift/pull?
The concern has been corrected.
D3 CHECK THE STEERING COLUMN INTERMEDIATE SHAFT
NOTE: Be sure to keep the clockspring centered when
Yes
disconnecting the intermediate shaft. Refer to Section 501-20B.
GO to D4.
Check the steering column and intermediate shaft for grounding.
Disconnect the steering column intermediate shaft at the No
steering column. INSTALL a new steering column
Inspect the steering column intermediate shaft U-joints for intermediate shaft. REFER to Section
looseness or wear. 211-04. TEST the system for normal
Are the steering column intermediate shaft U-joints OK? operation.
(Continued)
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PINPOINT TEST D: STEERING SYSTEM DRIFT/PULL/WANDER (Continued)
D4 CHECK THE STEERING GEAR MOUNTING
Check the steering gear mounts for looseness or wear. Yes
Are the steering gear mounts OK? GO to D5.
No
INSTALL a new steering gear. REFER to
Section 211-02.
D5 CHECK THE STEERING GEAR
Carry out the Steering Gear Valve component test. Refer to Yes
Component Tests in this section. GO to D6.
Is the steering gear valve OK?
No
REPAIR or INSTALL a new steering gear.
D6 CHECK THE SUSPENSION COMPONENTS
Check for loose or worn suspension components. Refer to Yes
Section 204-00. GO to D7.
Are the suspension components OK?
No
INSTALL new suspension components.
REFER to Section 204-01 for the front
suspension or Section 204-02 for the rear
suspension. TEST the system for normal
operation.
D7 CHECK THE WHEEL ALIGNMENT
NOTE: The vehicle will tend to pull toward the side with the least Yes
positive caster and the most positive camber. CHECK for correct frame alignments.
Using a suitable alignment system, measure the wheel
alignment settings. Refer to Section 204-00.
No
Are the alignment settings within specifications?
ADJUST the alignment angles to
specifications. DO NOT exceed the
specifications. TEST the system for normal
operation.
Component Tests Turning Effort Test
NOTE: Make sure that the front wheels are
Steering Linkage
correctly aligned and the tire pressure is correct
1. NOTE: Excessive vertical motion of the studs
before checking the steering effort.
relative to the sockets may indicate excessive
1. Park the vehicle on dry concrete and set the
wear.
parking brake.
With the vehicle on the ground and the parking
2. Insert a thermometer into the power steering
brake applied, start the vehicle and carry out
fluid reservoir.
the following:
Have an assistant rotate the steering wheel
back and forth 360 degrees and watch for
relative motion of the studs in the steering
linkage ball sockets.
Idle the engine for 2 to 3 minutes. Turn the
Watch for loose steering gear mounting.
steering wheel from stop to stop several times
2. An additional check is with the key ON engine
to warm the fluid to 50-60C (122-140F).
OFF and the front wheels raised off the ground,
4. With the engine running, attach the spring scale
grasp the wheel at the front and rear and watch
to the rim of the steering wheel.
for excessive play or binding in the joints while
trying to steer the wheels.
5. Measure the pull required to turn the steering
wheel one complete revolution in each
3. Install new components if necessary. Tighten
direction. Refer to General Specifications,
any worn, damaged or loose components.
Steering Wheel Turning Effort in this section.
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Power Steering Pump Flow and Pressure
8. CAUTION: Do not allow the gate valve
Test
to remain closed for more than 5 seconds.
WARNING: Do not touch the flowmeter
Completely close and partially open the gate
during the test procedure or severe burns and
valve 3 times. Record the pressure relief valve
serious injury can occur. Failure to follow these
actuation pressure reading.
If the pressure does not meet the relief
pressure specification, install a new power 1. CAUTION: Make sure that the
connection point does not interfere with any steering pump. Refer to General
of the engine accessory drive components or Specifications, Power Steering Pump in this
drive belts. section.
Install the power steering analyzer at the high 9. Set engine speed to 2,100 rpm. Record the flow
pressure port of the power steering pump. Make rate.
sure the power steering analyzer gate valve is
If the flow rate varies more than 3.785
fully open.
liters/minute (1 gallon/minute) from the
2. Place a dial thermometer in the power steering
initial flow rate reading, install a new power
fluid reservoir.
steering pump. Refer to General
Specifications, Power Steering Pump in this
3. Check the power steering fluid level. If
section.
necessary, add the specified power steering
fluid.
4. Install a digital tachometer. wheel against the stops for more than 3 to 5
Set the engine speed at idle. Turn (or have an
assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure
Start the engine. Place the transmission in
readings at the stops.
NEUTRAL. Set the parking brake. Raise the
The pressure reading at both stops should be
power steering fluid temperature to 41-46C
nearly the same as the maximum pump
(105-115F) by rotating the steering wheel fully
relief pressure. to the left and right several times.
The flow rate should drop to less than 1.9 6. With the steering wheel in the straight-ahead
liters/minute (0.5 gallons/minute). position, set the engine speed to 2,100 rpm.
Record the flow rate and pressure readings.
If the pressure does not reach the maximum
pump relief pressure or the flow rate does If the flow rate is less than the flow rate
not drop to less than the specified value, specification, continue with the test
procedure. Refer to General Specifications, excessive internal leakage is occurring.
Power Steering Pump in this section. Install a new steering gear as necessary.
If the pressure reading is greater than the
maximum pressure specification, check the 11. Turn (or have an assistant turn) the steering
power steering hoses for kinks and wheel slightly in both directions and release
restrictions. quickly while watching the pressure gauge.
7. Partially close the gate valve to obtain 5,171 The pressure reading should move from the
kPa (750 psi). Set the engine speed at idle. normal backpressure reading and snap back
Record the flow rate. as the steering wheel is released.
If the flow is less than the specified flow If the pressure returns slowly or sticks, the
rate, install a new power steering pump. rotary valve in the steering gear is sticking
Refer to General Specifications, Power or the steering column is binding. Check the
Steering Pump in this section. steering column and linkages before
repairing the steering gear.
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Steering Gear Valve
3. If the vehicle pulls to the opposite side, switch
the front wheels with the rear wheels keeping
1. With the vehicle in motion, place the
them on the same side of the vehicle.
transmission in NEUTRAL and turn the engine
OFF.
4. If the vehicle pull direction does not change,
check the front suspension components, wheel
If the vehicle does not pull with the engine
alignment and frame alignment. Refer to
OFF, repair or install a new steering gear.
Section 204-00 or an appropriate frame
dimensions manual.
2. If the vehicle pulls with the engine OFF, switch
the right side front wheel to the left side of the
vehicle and the left side front wheel to the right
side of the vehicle.
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211-02-1 211-02-1 Power Steering
Inner Tie Rod
Special Tool(s)
Tie Rod End Remover
211-105 Tool-3290-D
Boot Clamp Pliers
205-D067 (D87P-1098-A) or
equivalent
Inner Tie-Rod Socket Tool
211-D029 or equivalent
Material
Item Specification
Premium Long Life ESA-M1C75-B
Grease
CXG-1-C (Canada)
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Item Part Number Description CAUTION: The inner tie-rod ball joint
grease is not compatible with water.
1 14094 Tie-rod jam nut (part of
3280) Contamination trapped in the grease will
degrade the life of the joint.
2 W705606 Tie-rod end nut
3 3289 Tie-rod end
CAUTION: If present, the orientation of
4 3C650A Outer bellows boot clamp
the vent tube must be noted so the boots and
5 3K745 Inner bellows boot clamp
vent tubes can be installed in the correct
6 3K661 Steering gear bellows boot
location.
7 3280 Inner tie-rod
Removal hoist. For additional information, refer to
Section 100-02.
CAUTION: The steering gear bellows boots
2. Loosen the tie-rod end jam nut.
and clamps are designed to provide an airtight
seal and protect the internal components of the
3. Remove and discard the tie-rod end nut.
steering gear. If the seal is not airtight the
vacuum generated during turning will draw
water and contamination into the gear causing
premature damage.
CAUTION: Zip ties do not produce an
airtight seal and must not be used.
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4. Using the special tool, disconnect the tie-rod
end from the wheel knuckle.
10. CAUTION: Thoroughly remove any
abrasive material. This material is extremely
harmful to the steering gear.
5. NOTE: Count the number of turns required to
Thoroughly clean and inspect all the parts to be
remove the tie-rod end for reference during
reused. Install new parts as necessary.
installation.
Installation
Remove the tie-rod end.
Installation
6. Remove the tie-rod end jam nut.
1. Using the special tool, install the inner tie rod.
7. NOTE: New bellows boot clamps must be
installed.
Remove and discard the inner and outer bellows
boot clamp.
8. Remove the steering gear bellows boot.
9. CAUTION: Place the steering gear at
the center position. Use a 1-7/16 inch
crowfoot on the flat of the rack gear to resist
rotation and to prevent damage during
removal and installation of the inner tie rod.
NOTE: If repairing the RH side, it will be
necessary to pull back the LH inner tie-rod boot
to hold the steering gear.
2. NOTE: Apply steering gear grease to the
NOTE: An assistant may be needed for
steering gear bellows boot groove in the inner
removal of the RH inner tie rod.
tie rod.
Using the special tool, remove the inner tie rod.
NOTE: Make sure the steering gear bellows
boot is positioned correctly over the steering
gear housing bead and the groove in the inner
tie rod.
NOTE: Make sure the steering gear bellows
boot is not twisted and the vent tube is securely
inserted into the vent nipple of the steering gear
bellows boot.
Install the steering gear bellows boot.
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3. Using the special tool, install a new inner 5. Thread the tie-rod end jam nut onto the inner
bellows boot clamp. tie rod.
6. NOTE: Install the tie-rod end the same number
of turns as recorded during the removal.
Install the tie-rod end to the inner tie rod.
7. Position the tie-rod end to the wheel knuckle
and install a new tie-rod end nut.
8. Tighten the tie-rod end jam nut.
9. Check and, if necessary, align the front end.
4. NOTE: Make sure the end of the steering gear
204-00.
bellows is positioned between the 2 grooves on
the inner tie rod or an internal leak can result.
Install a new outer bellows boot clamp.
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Power Steering Fluid Cooler
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
NOTE: 4.0L shown, 4.6L and 5.4L similar.
1 Fluid cooler-to-reservoir hose
clamp (part of 3E525) CAUTION: When repairing the power
steering system, care should be taken to prevent
2 3D746 Power steering fluid cooler
tube the entry of contaminants or premature failure
of the power steering components can result.
3 W520101 Fluid cooler nuts (2 required)
4 Pin-type retainer (part of
3F780)
5 Return line-to-fluid cooler
Section 100-02.
hose clamp (part of 3F780)
6 3A697 Power steering fluid reservoir
2. Release the clamp and disconnect the fluid
cooler-to-reservoir hose.
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3. Release the clamp and disconnect the return 6. To install, reverse the removal procedure.
line-to-fluid cooler hose.
Fill the power steering system. For
4. Disconnect the fluid cooler pressure line
211-00.
pin-type retainer from the stabilizer bar bracket.
5. Remove the 2 fluid cooler nuts and the fluid
cooler tube.
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Power Steering Fluid Reservoir
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
4.0L and 4.6L Engine
4 3D746 Power steering fluid return 1 W503924 Power steering fluid reservoir
hose bolt
3 3691 Power steering fluid
reservoir-to-pump supply hose
(Continued)
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5.4L Engine
2. Remove the power steering fluid reservoir bolt.
To install, tighten to 9 Nm (80 lb-in). 1 W503924 Power steering fluid reservoir
bolt
3. Release the clamp and disconnect the power
steering pump supply hose from the power
3 Power steering fluid return
steering reservoir.
hose (part of 3D746)
4 3E525 Power steering fluid
4. Release the clamp, disconnect the fluid return
reservoir-to-power steering
hose and remove the power steering fluid pump supply hose
reservoir.
CAUTION: When repairing the power
211-00.
the entry of contaminants or premature failure
1. Using a suitable suction device, drain the power
steering fluid reservoir.
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Power Steering Pump 4.0L
Special Tool(s)
Installer Set, Teflon Seal
211-D027 (D90P-3517-A) or
equivalent
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
3 N605784 Power steering pump pulley 1 3A674 Power steering pump
bolts (3 required)
2 W700839 Power steering pump bolts (3
4 3A733 Power steering pump pulley required)
(Continued) (Continued)
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7. Remove the power steering fluid
reservoir-to-pump hose bracket bolt.
5 Pressure line-to-pump fitting
(part of 3A719)
6 388898 Teflon O-ring seal
8. NOTE: A new Teflon O-ring seal must be
7 3A719 Power steering pressure line
installed.
8 W503924 Pressure line
bracket-to-engine bolt Disconnect the pressure line from the power
steering pump. 9 W503934 Power steering fluid
reservoir-to-pump hose
Discard the Teflon O-ring seal.
bracket bolt
10 Power steering pump supply
hose clamp
9. Remove the 3 bolts and the power steering
11 Power steering fluid
pump.
pump supply hose (part of
3A697)
10. NOTE: For additional information on the
accessory drive belt routing, refer to Section
303-05.
installed.
Using the special tool, install a new Teflon
1. Remove the air cleaner outlet pipe. For
O-ring seal to the pressure line fitting.
additional information, refer toSection 303-12.
2. Loosen the 3 power steering pump pulley bolts.
3. Rotate the tensioner and remove the accessory
drive belt from the power steering pump pulley.
4. Remove the 3 power steering pump pulley
bolts.
steering pump.
12. Fill the power steering system. For additional
6. Remove the pressure line
bracket-to-engine-to-alternator stud nut.
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Special Tool(s)
211-D027 (D90P-3517-A) or
equivalent
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
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1 3A733 Power steering pump pulley
2 N805320 Pressure line bracket-to-pump
stud nut
3 3691 Power steering fluid
pump supply hose
4 Pressure line-to-pump fitting
hoist. For additional information, refer to (part of 3A719)
Section 100-02.
5 W707225 Power steering pump bolts
(3 required)
6 3A674 Power steering pump
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2. Remove the power steering pump pulley. For 7. NOTE: A new Teflon O-ring seal must be
additional information, refer to Power Steering installed.
Pump Pulley 4.6L, 5.4L in this section.
Using the special tool, install a new
3. Remove the pressure line bracket-to-pump stud
Teflon O-ring seal to the pressure line
nut.
fitting.
steering pump supply hose from the pump.
installed.
Disconnect the pressure line from the power
steering pump.
pump.
To Install, tighten to 25 Nm (18 lb-ft).
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Special Tool(s)
211-D027 (D90P-3517-A) or
equivalent
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
3 Pressure line-to-pump fitting 1 W700839 Power steering pump bolts (3
(part of 3A719) required)
(Continued)
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installed.
Disconnect the pressure line from the power
steering pump.
1. Remove the power steering pump pulley. For
additional information, refer to Power Steering
pump.
2. CAUTION: Make sure to remove the
power steering reservoir bolt and separate
the reservoir from the bracket or damage to
the power steering reservoir will occur.
installed.
Remove the power steering fluid reservoir bolt
and separate the reservoir from the power
steering reservoir bracket.
steering pump.
Position the power steering fluid reservoir
aside.
4. Remove the pressure line bracket-to-engine bolt.
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Power Steering Pump Pulley 4.0L
1 N605784 Power steering pump pulley
bolts (3 required)
pump pulley.
For additional information on accessory
drive belt routing, refer to Section 303-05.
2. Loosen the 3 power steering pump pulley bolts.
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5.4L Engine
Power Steering Pump Pulley 4.6L,
5.4L
Special Tool(s)
Remover, Power Steering Pump
Pulley
211-016 (T69L-10300-B)
Installer, Power Steering Pump
Pulley
211-185 (T91P-3A733-A)
4.6L Engine
Removal
Item Part Number Description 4.6L engine
1. Remove the air cleaner outlet pipe. For 2 3A674 Power steering pump
4.6L and 5.4L engines
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3. Using the special tool, remove the pulley.
2. Rotate the tensioner and install the accessory
drive belt to the power steering pump pulley.
Installation
For additional information on the accessory
4.6L and 5.4L engines
4.6L engine
1. CAUTION: If the pulley has been
3. Install the air cleaner outlet pipe. For additional
removed and installed twice, install a new
power steering pump pulley.
Using the special tool, install the pulley.
Inspect the pulley for paint marks in the
web area near the hub. If there are 2 paint
marks, install a new pulley. If there is no
paint or one paint mark, use a paint pencil
to mark the web area of the pulley near the
hub.
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Power Steering Pump to Steering
Gear Pressure Line 4.0L, 4.6L
Special Tool(s)
211-D027 (D90P-3517-A) or
equivalent
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
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NOTE: 4.0L engine shown, 4.6L engine similar.
6 3493 Power steering cooler return 1 N605784 Power steering pump pulley
line bolts
7 3F886 Power steering return 2 3A733 Power steering pump pulley
line-to-steering gear O-ring
3 388898 Power steering pressure
seal
line-to-pump TeflonO-ring
8 3F886 Power steering pressure seal
4 Power steering pressure line
seal
fitting (part of 3A719)
9 W707622 Power steering line clamp
5 3A719 Power steering pressure line
plate bolt
(Continued)
(Continued)
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9. Remove the pressure line bracket bolt.
10 W520101 Power steering pressure line To install, tighten to 9 Nm (80 lb-in).
bracket-to-alternator stud nut
11 W505255 Power steering pressure line
10. CAUTION: When installing the
bracket-to-crossmember bolt
pressure and return lines to the steering
(2 required)
gear, make sure the lines are fully seated
into the steering gear prior to installing the
clamp plate. Additionally, make sure that the
clamp plate surfaces are free of foreign
material and debris. DO NOT exceed the
specified torque when tightening the clamp
plate. Failure to follow these instructions
may result in leakage and/or premature
failure of the power steering components.
4.0L and 4.6L engine
NOTE: New O-ring seals must be installed any
time the lines are disconnected from the
steering gear.
Remove the power steering line clamp plate
Section 100-02.
bolt, rotate the clamp plate and remove the
power steering pressure line.
additional information, refer toSection 303-12. Discard the O-ring seal.
4.0L engine
3. Loosen the power steering pump pulley bolts.
NOTE: New Teflon O-ring seals must be
installed.
5. Remove the 3 power steering pump pulley bolts
and the power steering pump pulley.
4.6L engine
4.0L and 4.6L engine
7. Remove the pressure line bracket-to-alternator
stud nut.
8. Disconnect the pressure line from the power
steering pump.
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12. For additional information on the accessory
211-00.
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Power Steering Pump to Steering
Gear Pressure Line 5.4L
Special Tool(s)
211-D027 (D90P-3517-A) or
equivalent
Lifting Bracket, Engine
303-D087 (D93P-6001-A1)
Support Bar, Engine
303-F070
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
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5 W505255 Power steering pressure line 1 3A674 Power steering pump
(2 required)
bracket bolt
plate bolt
4 Power steering pressure line
7 3F886 O-ring seals
fitting (part of 3A719)
(Continued)
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1. With the vehicle in NEUTRAL position it on a
Section 100-02.
6. Remove the LH engine mount nut.
installed.
Remove the pressure line from the power
steering pump.
Using the special tools, raise the LH side of
the engine to gain clearance for removal of
the power steering pressure line clamp plate
bolt.
4. Remove the pressure line bracket-to-engine bolt.
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8. Remove the pressure line bracket-to-alternator 11. To install, reverse the removal procedure.
stud nut.
installed.
9. Remove the 2 pressure line bracket-to-subframe
bolts.
NOTE: New O-ring seals must be installed any
time the lines are disconnected from the
steering gear.
bolt, rotate the clamp plate and remove the
power steering pressure line.
Discard the O-ring seal.
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Power Steering
The power steering system consists of the following
components:
Power steering pump
Power steering fluid reservoir
Rack-and-pinion steering gear
Power steering fluid cooler
Power steering pressure and return lines/hoses
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Power Steering
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SPECIFICATIONS
Power steering pressure 7 62
Item Specification line
bracket-to-alternator
Lubricants
stud nut
MERCON MERCON
line bracket-to-A/C
Transmission Fluid
compressor stud nut
XT-2-QDX (US);
(4.0L)
XT-2-LM12 (Canada)
line-to-engine bracket
Grease XG-1-C or
bolt (5.4L)
(Canada) Power steering pressure 65 48
line-to-pump fitting nut
line union fitting
Power steering fluid 8 71
reservoir-to-pump hose
Inner tie rod 120 89
bracket bolt (4.0L)
LH engine mount nut 63 46
Power steering fluid 8 71
line
cooler nuts
bracket-to-crossmember
bolt Power steering fluid 9 80
reservoir bolt
Steering column 25 18
coupling-to-steering
Power steering line 23 17
gear bolt clamp plate bolt
Steering gear bolts 115 85 Power steering pump 25 18
bolts (4.0L, 5.4L)
Tie-rod end nuts 80 59
Power steering pump 25 18
Tie-rod jam nuts 55 41
bolts (4.6L)
pulley bolts (4.0L)
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Steering Gear
Special Tool(s)
Tie Rod End Remover
211-105 (TOOL-3290-D)
303-D087 (D93P-6001-A1)
Support Bar, Engine
303-F070
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
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6 3F886-BA Power steering return 1 W705606 Tie-rod end nut (2 required)
2 W704980 Steering column
seal
coupling-to-steering gear bolt
7 3504 Steering gear
3 3B676 Steering column lower shaft
8 W10909 Steering gear bolts (2
required)
plate bolt
5 3F886-AA Power steering pressure
bracket bolts (2 required)
seal
(Continued)
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Using the special tools, raise the LH side of
the engine to gain clearance for removal of
the power steering pressure line clamp plate
bolt and the steering gear mounting bolt.
CAUTION: Do not allow the intermediate
shaft to rotate while it is disconnected from the
steering gear or damage to the clockspring can
result. If there is evidence that the intermediate
shaft has rotated, the clockspring must be
removed and recentered. For additional
information, refer to Section 501-20B.
5.4L engine
All vehicles
hoist. For additional information, refer toSection
100-02.
5. Remove the 2 nuts from the tie-rod ends. Using
the special tool, disconnect the tie-rod ends
from the wheel knuckles.
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6. CAUTION: Do not allow the
intermediate shaft to rotate while it is
disconnected from the steering gear or
damage to the clockspring can result. If
there is evidence that the intermediate shaft
has rotated, the clockspring must be removed
and recentered. For additional information,
refer to Section 501-20B.
Remove the steering column
coupling-to-steering gear bolt and disconnect
the coupling from the steering gear.
Discard the bolt.
8. Remove the 2 pressure line bracket bolts and
position the pressure line aside.
NOTE: New O-ring seals must be installed
anytime the power steering lines are
disconnected from the steering gear.
9. Remove the 2 bolts and the steering gear.
bolt, rotate the clamp plate and disconnect the
power steering pressure and return lines.
Discard the O-ring seals.
information, refer toSection 211-00.
12. Check and, if necessary, align the front end.
For additional information, refer Section
204-00.
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211-04-1 211-04-1 Steering Column
SPECIFICATIONS
Description Nm lb-ft lb-in coupling-to-steering
gear bolt
Dash boot bearing nuts 9 80
Steering column nuts 18 13
Lower steering column 47 35
shaft-to-steering Steering column 25 18
column coupling bolt shaft-to-steering
column bolt
shaft-to-upper steering Steering wheel bolt 55 41
column shaft bolt
Instrument panel 9 80
reinforcement bolts
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Steering Column Coupling
1 W702600 Lower steering column
shaft-to-steering column CAUTION: Do not allow the steering
coupling bolt
column to rotate while the steering column shaft
2 W704980 Steering column is disconnected or damage to the clockspring can
result. If there is evidence that the steering
3 W707137 Dash boot bearing nuts (2 column shaft has rotated the clockspring must be
required)
4 3N725 Steering column coupling information, refer to Section 501-20B.
Section 100-02.
2. Place the steering wheel in the straight-ahead
position and turn the ignition switch to the OFF
position.
3. Remove and discard the lower steering column
shaft-to-steering column coupling bolt.
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4. Remove and discard the steering column 6. Collapse the upper steering column shaft
coupling-to-steering gear bolt. slightly and disconnect the lower steering
column shaft from the coupling.
7. Remove the steering column coupling.
5. Remove the 2 dash boot bearing nuts.
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Steering Column Shaft Lower
shaft-to-upper steering CAUTION: Do not allow the steering
column shaft bolt
2 W704980 Steering column is disconnected or damage to the clockspring can
3 W707137 Dash boot bearing nuts (2 column shaft has rotated the clockspring must be
required)
4 3C662 Lower steering column shaft information, refer to Section 501-20B.
Section 100-02.
shaft-to-upper steering column shaft bolt.
3. Remove and discard the steering column
coupling-to-steering gear bolt.
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4. Remove the 2 dash boot bearing nuts. 6. Remove the lower steering column shaft.
5. Collapse the upper steering column shaft
slightly and disconnect the coupling from the
lower steering column shaft.
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Steering Column Shaft Upper
3 W704980 Lower steering column 1 W704980 Steering column
shaft-to-upper steering shaft-to-steering column bolt
column shaft bolt
2 W707137 Dash boot bearing nuts (2
4 3E751 Steering column shaft required)
(Continued)
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shaft-to-upper steering column shaft bolt.
CAUTION: Do not allow the steering
is disconnected or damage to the clockspring can 4. Remove the 2 dash boot bearing nuts.
column shaft has rotated the clockspring must be
5. Remove and discard the steering column
shaft-to-steering column bolt.
6. Remove the steering column shaft.
Section 100-02.
Collapse the steering column shaft slightly
to facilitate removal.
position.
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Steering Column
The steering column is the mechanical linkage
between the steering wheel and the steering gear. It
houses the steering column switches and is able to
tilt to various positions for driver preference. The
steering wheel is bolted to the main shaft that runs
down the center of the column, connecting to the
upper steering column intermediate shaft. The upper
steering column intermediate shaft goes through the
dash panel, connects to the lower steering column
intermediate shaft, which connects to the steering
gear. The steering column shaft connections are
made by U-joint type couplings. The steering
column shaft is centered by roller ball bearings,
which are contained within the steering column. The
tilt steering column is controlled by a mechanical
lever on the underside of the steering column which
uses a cam to lock and unlock the steering column.
When the tilt column is unlocked it allows the
steering column to adjust up or down using a
pin-type pivot in the steering column. The steering
column switches (multifunction and ignition) are
mounted to the steering column. These switches are
covered by the upper and lower steering column
shrouds and can be accessed by removing the
shrouds.
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Steering Column
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Steering Column
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6. Remove the left center stack wing.
1 3530 Upper steering column shroud
shroud screw
3 W707281-S Lower steering column
shroud screws (2 required)
4 3533 Lower steering column
shroud
shaft-to-steering column bolt
6 3E751 Steering column shaft
7 W705047 Steering column nuts (4
required)
8 3C529 Steering column
7. Remove the 2 lower instrument panel cover
screws and position the lower instrument panel
cover aside.
1. Depower the supplemental restraint system
(SRS). For additional information, refer to
Section 501-20B.
position and remove the ignition key.
3. NOTE: The instrument cluster finish panel is
held in place with retaining clips that are
attached to the bezel.
Remove the instrument cluster finish panel.
8. Disconnect the electrical connectors and remove
Section 501-12.
the lower instrument panel cover.
5. Remove the LH A-pillar lower trim panel.
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9. Remove the 4 bolts and the instrument panel
reinforcement.
14. Disconnect the wiring harness pin-type
retainers.
10. Remove the upper steering column shroud by
carefully pressing the sides inward.
11. Remove the 3 screws and the lower steering
column shroud.
12. Disconnect the 4 electrical connectors.
15. CAUTION: Do not allow the steering
column to rotate while the steering column
shaft is disconnected or damage to the
clockspring can result. If there is evidence
that the steering column shaft has rotated
the clockspring must be removed and
recentered. For additional information, refer
to Section 501-20B.
Remove and discard the steering column
13. Disconnect the ignition switch electrical
shaft-to-steering column bolt and disconnect the
connector.
shaft from the steering column.
16. Remove the 4 nuts and the steering column.
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Steering Wheel
1 3F830 Steering wheel spoke finish
1. Place the steering wheel in the straight-ahead panel (3 required)
2 043B13 Steering wheel bolt
position.
3 3600 Steering wheel
2. Remove the driver air bag module. For
501-20B.
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3. CAUTION: Do not use a screwdriver
or prying device to remove the steering
wheel spoke finish panel(s) or damage to the
steering wheel can occur. Place your fingers
near the base of the wheel spoke and gently
pull upwards to remove the finish panel(s).
NOTE: The steering wheel spoke finish
panel(s) can be serviced separately. A new
steering wheel does not need to be installed.
NOTE: It is not necessary to remove the
steering wheel when installing new steering
wheel spoke finish panel(s).
4. Remove and discard the steering wheel bolt.
If necessary, remove the steering wheel spoke
finish panel(s).
5. Remove the steering wheel.
Route the connectors for the clockspring
through the steering wheel.
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211-05-1 211-05-1 Steering Column Switches
Ignition Switch
4 3533 Lower steering column 1 3530 Upper steering column shroud
shroud
5 Ignition switch electrical shroud screw
connector (part of 14401)
6 11572 Ignition switch shroud screws (2 required)
(Continued)
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CAUTION: Do not remove the ignition
lock cylinder and the ignition switch at the same
time or damage to the column can result.
Section 501-20B.
column shroud.
Repower the SRS. For additional
4. Disconnect the ignition switch electrical
connector.
5. Release the 2 locking tabs and remove the
ignition switch.
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Steering Column Multifunction Switch
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1. Remove the steering wheel. For additional
shroud screw
shroud
3. Remove the 3 lower steering column shroud
5 Upper multi-function switch
screws and the shroud.
electrical connectors (part of
14401)
4. Disconnect the 4 lower multi-function switch
6 Lower multi-function switch
electrical connectors.
electrical connector (part of
14401)
5. Disconnect the upper multi-function switch
7 W504694 Upper multi-function switch
screw (2 required)
8 W504694 Lower multi-function switch
6. Remove the 4 screws and the multi-function
screw (2 required)
switch.
9 14B522 Multi-function switch
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The integrated multi-function switch is mounted to
Steering Column Switches
the LH side of the steering column and controls the
The steering column switches system consists of the
turn signals, hazard flasher, windshield wiper/washer
control and headlamp dimmer/flash-to-pass.
Multi-function switch
The key release button is equipped with manual
Key release button (manual transmission only) transmissions only.
Ignition switch The ignition switch is mounted below the steering
column and is activated by rotating the key lock
cylinder on the steering column.
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Special Tool(s)
mechanical or electrical damage.
hardware, or equivalent scan Mechanical Electrical
tool
Multi-function switch Bussed electrical center
Ignition key (BEC) fuse 68 (20A)
Ignition switch Circuitry
73III Automotive Meter Ignition key turning Ignition switch
105-R0057 or equivalent effort BEC
SJB
NOTE: For multi-function switch concerns, refer to
one of the following sections:
Exterior Lighting, Section 417-01.
Flex Probe Kit
105-R025B
Wipers and Washers, Section 501-16.
software release.
The steering column switches include the ignition
switch and the multi-function switches (high
beam/low beam, flash-to-pass, turn signal and
windshield wiper). The ignition switch is controlled
VCM.
by the ignition lock cylinder with a key. When the
ignition lock cylinder is turned using the key, the
VCM:
ignition switch is rotated to the selected position
and allows the ignition switch to send voltage to
specific components. check the scan tool connection to the VCM.
The multi-function switch controls the various refer to Section 418-00, No Power To The
components electrically. The headlamp switch sends Scan Tool, to diagnose no communication
constant voltage to the headlamps when placed in with the scan tool.
the ON position, while the flash-to-pass is a
momentary switch used to send voltage to the
vehicle:
headlamp high beams only. The headlamp high
beam/low beam switch sends voltage to the low or
high beam headlamps while the headlamps are on.
good vehicle.
The turn signal switch portion of the multi-function
switch operates the left and right turn signals. The
windshield wiper switch function uses a ground
signal to activate the various wiper modes and the
(PCM).
wiper/washer.
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7. Carry out the network test. 9. If the DTCs retrieved are related to the concern,
go to Smart Junction Box (SJB) Diagnostic
If the scan tool responds with no
Trouble Code (DTC) Chart or the Instrument
Cluster Diagnostic Trouble Code (DTC) Chart.
self-test diagnostics for the smart junction box
(SJB) and the instrument cluster.
Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Chart
B1356 Ignition Run Circuit Open SJB GO to Pinpoint
Test C.
B1360 Ignition Run/ACC Circuit Open SJB GO to Pinpoint
Test B.
B1365 Ignition Start Circuit Short to Battery SJB GO to Pinpoint
Test E.
Instrument Cluster Diagnostic Trouble Code (DTC) Chart
B1556 Ignition RUN/START Circuit Open Instrument Cluster GO to Pinpoint
Test B.
B1557 Ignition RUN/START Circuit Shorted to Battery Instrument Cluster GO to Pinpoint
Test E.
For a complete master list of DTCs, refer to Section
419-10.
Symptom Chart
Symptom Chart
The ignition switch is Fuse GO to Pinpoint Test A.
inoperative Circuitry
Ignition switch
BEC
No power in ACC Circuitry GO to Pinpoint Test B.
Ignition switch
SJB
No power in RUN Circuitry GO to Pinpoint Test C.
Ignition switch
SJB
No power in START Circuitry GO to Pinpoint Test D.
Starting system CHECK the starting system.
Ignition switch REFER to Section 303-06.
SJB
The ignition key is Key GO to Pinpoint Test F.
inoperative/hard to turn Ignition lock cylinder
Ignition switch
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The multi-function Multi-function switch CARRY OUT the
switch/hazard switch does not Multi-function Switch
operate correctly Continuity Test for electrical
diagnosis. Refer to Wiring
Diagrams Cell 149 for
component testing.
Fuse
Pinpoint Test A: The Ignition Switch is
Inoperative Circuit open
Refer to Wiring Diagrams Cell 13, Power Circuit shorted
Distribution/SJB for schematic and connector
Ignition switch
information.
BEC
Normal Operation
The ignition switch receives fused B+ voltage from
bussed electrical center (BEC) fuse 68 (20A)
through circuit 1050 (LG/VT). The ignition switch
has 4 possible states:
OFF
ACC
RUN
START
PINPOINT TEST A: THE IGNITION SWITCH IS INOPERATIVE
A1 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE
Disconnect: Ignition Switch C250.
Measure the voltage between ignition switch C250-4, circuit
1050 (LG/VT), harness side and ground.
Yes
INSTALL a new ignition switch. REFER to
Ignition Switch in this section. TEST the
No
VERIFY bussed electrical center (BEC)
Is the voltage greater than 10 volts? fuse 68 (20A) is OK. If OK, GO to A2.
A2 CHECK CIRCUIT 1050 (LG/VT) FOR AN OPEN OR A SHORT TO
GROUND
Disconnect: Bussed Electrical Center (BEC) Fuse 68 (20A).
(Continued)
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PINPOINT TEST A: THE IGNITION SWITCH IS INOPERATIVE (Continued)
A2 CHECK CIRCUIT 1050 (LG/VT) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
Measure the resistance between:
ignition switch C250-4, circuit 1050 (LG/VT), harness side
and BEC fuse 68 (20A), circuit 1050 (LG/VT), output side.
ignition switch C250-4, circuit 1050 (LG/VT), harness side
and ground.
Yes
REPAIR circuit 1050 (LG/VT). TEST the
No
Are the resistances greater than 10,000 ohms between the REPAIR or INSTALL a new BEC as
ignition switch and the BEC, and less than 5 ohms between necessary. TEST the system for normal
the ignition switch and ground? operation.
Possible Causes
Pinpoint Test B: No Power in ACC
Refer to Wiring Diagrams Cell 13, Power Circuit open
Circuit shorted
information.
Ignition switch
Normal Operation
SJB
The ignition switch ACC circuit provides fused
battery voltage along circuit 1002 (BK/PK) to the
smart junction box (SJB) when the key is in the
ACC position.
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PINPOINT TEST B: NO POWER IN ACC
B1 CHECK CIRCUIT 1002 (BK/PK) FOR VOLTAGE
Disconnect: Smart Junction Box (SJB) 2280a.
Measure the voltage between SJB C2280a-11, circuit 1002
(BK/PK), harness side and ground.
Yes
GO to B3.
No
Is the voltage greater than 10 volts? GO to B2.
B2 CHECK CIRCUIT 1002 (BK/PK) FOR AN OPEN OR A SHORT TO
GROUND
SJB C2280a-11, circuit 1002 (BK/PK), harness side and
ignition switch C250-6, circuit 1002 (BK/PK), harness side.
SJB C2280a-11, circuit 1002 (BK/PK), harness side and
ground.
Yes
Ignition Switch in this section. TEST the
Are the resistances less than 5 ohms between the SJB and No
the ignition switch, and greater than 10,000 ohms between REPAIR circuit 1002 (BK/PK). TEST the
the SJB and ground? system for normal operation.
B3 CHECK FOR CORRECT SJB OPERATION
Disconnect all the SJB connectors.
Yes
Check for:
INSTALL a new SJB. REFER to Section
corrosion.
419-10. REPEAT the self-test.
pushed-out pins.
Connect all the SJB connectors and make sure they seat The system is operating correctly at this
Operate the system and verify the concern is still present. by a loose or corroded connector. TEST
Is the concern still present? the system for normal operation.
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Possible Causes
Pinpoint Test C: No Power in RUN
Refer to Wiring Diagrams Cell 13, Power Circuit shorted
Distribuiton/SJB for schematic and connector
Circuit open
information.
Ignition switch
Normal Operation
SJB
The ignition switch RUN circuit provides fused
battery voltage along circuit 1044 (WH/YE) to the
RUN position.
PINPOINT TEST C: NO POWER IN RUN
C1 CHECK CIRCUIT 1044 (WH/YE) FOR VOLTAGE
Disconnect: Smart Junction Box (SJB) 2280a.
Key in ON position.
(WH/YE), harness side and ground.
Yes
GO to C3.
No
C2 CHECK CIRCUIT 1044 (WH/YE) FOR AN OPEN OR A SHORT TO
GROUND
(Continued)
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PINPOINT TEST C: NO POWER IN RUN (Continued)
C2 CHECK CIRCUIT 1044 (WH/YE) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
SJB C2280a-36, circuit 1044 (WH/YE), harness side and
ignition switch C250-1, circuit 1044 (WH/YE), harness side.
SJB C2280a-36, circuit 1044 (WH/YE), harness side, and
ground.
Yes
REPAIR circuit 1044 (WH/YE). TEST the
Are the resistances greater than 10,000 ohms between the
SJB and the ignition switch, and less than 5 ohms between No
the SJB and ground? GO to C3.
C3 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion.
pushed-out pins.
Possible Causes
Pinpoint Test D: No Power in START
Refer to Wiring Diagrams Cell 13, Power Circuit open
Circuit shorted
information.
Ignition switch
Normal Operation
SJB
The ignition switch START circuit provides fused
battery voltage along circuit 1522 (DG) to the smart
junction box (SJB) when the key is in the START
position.
PINPOINT TEST D: NO POWER IN START
D1 CHECK CIRCUIT 1522 (DG) FOR VOLTAGE
Disconnect: Smart Junction Box (SJB) C2280a.
(Continued)
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PINPOINT TEST D: NO POWER IN START (Continued)
D1 CHECK CIRCUIT 1522 (DG) FOR VOLTAGE (Continued)
(DG), harness side and ground.
Yes
GO to D3.
No
Is the voltage greater than 10 volts? GO to D2.
D2 CHECK CIRCUIT 1522 (DG) FOR AN OPEN OR A SHORT TO
GROUND
SJB C2280a-12, circuit 1522 (DG), harness side and ignition
switch C250-7, circuit 1522 (DG), harness side.
SJB C2280a-12, circuit 1522 (DG), harness side and ground.
Yes
GO to D3.
Are the resistances greater than 10,000 ohms between the No
SJB and the ignition switch, and less than 5 ohms between REPAIR circuit 1522 (DG). TEST the
the SJB and ground? system for normal operation.
D3 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion.
pushed-out pins.
Pinpoint Test E: DTC B1365 Ignition Start Normal Operation
Circuit Short to Battery
The ignition switch START circuit provides fused
battery voltage along circuits 1522 (DG) to the
Refer to Wiring Diagrams Cell 13, Power
START position.
information.
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Possible Causes
Circuit shorted
Ignition switch
SJB
PINPOINT TEST E: DTC B1365 IGNITION START CIRCUIT SHORT TO BATTERY
E1 CHECK THE IGNITION SWITCH
Carry out the Ignition Switch Component Test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to E2.
Is the ignition switch OK?
No
Ignition Switch in this section. CLEAR the
DTC. REPEAT the self-test.
E2 CHECK CIRCUIT 1522 (DG) FOR VOLTAGE WITH THE IGNITION
SWITCH IN THE ACC POSITION
Disconnect: Smart Junction Box (SJB) C2280a.
Yes
REPAIR circuit 1522 (DG). CLEAR the
No
Is voltage present? GO to E3.
E3 CHECK CIRCUIT 1522 (DG) FOR VOLTAGE WITH THE IGNITION
SWITCH IN THE RUN POSITION
Key in ON position.
Yes
REPAIR circuit 1522 (DG). CLEAR the
No
(Continued)
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PINPOINT TEST E: DTC B1365 IGNITION START CIRCUIT SHORT TO BATTERY (Continued)
E4 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion.
pushed-out pins.
Possible Causes
Pinpoint Test F: The Ignition Key is
Inoperative/Hard to Turn
Ignition key
Normal Operation
Ignition lock cylinder
The ignition lock cylinder is the mechanical link to
Ignition switch
the ignition switch. When the ignition key is placed
in the ignition lock cylinder and rotated through the
ignition switch positions, the pinion rotates, moving
the ignition switch to the desired position.
PINPOINT TEST F: THE IGNITION KEY IS INOPERATIVE/HARD TO TURN
F1 CHECK THE STEERING WHEEL POSITION
Check to see if the steering wheel is turned and locked full left Yes
or full right. APPLY turning effort to the steering wheel
Is the steering wheel locked full left or full right? in the direction of lock while turning the
key to the ON position. TEST the system
No
GO to F2.
F2 CHECK THE IGNITION LOCK CYLINDER KEY
Check the ignition lock cylinder key for burrs, damaged key or Yes
incorrect key cut. GO to F3.
Is the key OK?
No
INSTALL a new ignition key. TEST the
F3 CHECK THE IGNITION LOCK CYLINDER
Remove the ignition lock cylinder. Refer to Section 501-14. Yes
Check the ignition lock cylinder by rotating the ignition lock INSTALL a new ignition lock cylinder.
cylinder through all of the switch positions. REFER to Section 501-14.
Does the ignition lock cylinder stick or bind in any of the
No
positions?
GO to F4.
F4 CHECK THE IGNITION LOCK CYLINDER HOUSING
Check for a binding or sticking ignition switch in the steering Yes
column lock module or insufficient lube. INSTALL a new ignition switch. REFER to
Is the steering column lock module and lubrication OK? Ignition Switch in this section. TEST the
No
REPAIR or LUBRICATE as necessary.
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303-00-1 303-00-1 Engine System General Information
SPECIFICATIONS
Item Specification
Motorcraft SAE 5W-50 WSS-M2C931-A
Item Specification Full Synthetic Motor Oil
XO-5W50-QGT or
Lubricants and Sealants
equivalent 5.4L (4V)
Gasoline Engine Oil Dye
Premium Synthetic Blend
164-R3705
Motor Oil XO-5W20-QSP
(US); Motorcraft SAE Threadlock 262 TA-26 WSK-M2G351-A6
5W-20 Super Premium
Motor Oil
CXO-5W20-LSP12
(Canada); or equivalent
4.6L (3V)
(US); Motorcraft SAE
5W-30 Super Premium
Motor Oil
CXO-5W30-LSP12
4.0L SOHC
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an exhaust emission control system. Refer to
Engine
Section 303-08.
CAUTION: When repairing engines, all
an evaporative emission control system. Refer to
parts must be contamination free. If
Section 303-13.
contamination/foreign material is present when
Some engines incorporate a fail-safe cooling system.
repairing an engine, premature engine failure
Refer to the appropriate section in Group 303 for
can occur.
the procedure.
NOTE: This section contains information, steps and
The engine, fuel system, ignition system, emissions
procedures that may not be specific to your engine.
system and exhaust system all affect exhaust
This section covers general procedures and
emission levels and must be maintained according
diagnosis and testing of the engine system, except
to the maintenance schedule. Refer to the scheduled
for exhaust emission control devices, which are
Maintenance Guide.
covered in the Powertrain Control/Emissions
Correct engine identification is required to order
Diagnosis (PC/ED) manual.
parts. Refer to the appropriate section in Group 303
The engine incorporates:
for the procedure.
a closed positive crankcase ventilation (PCV)
For complete vehicle and engine identification
system. Refer to Section 303-08.
codes, refer to Section 100-01.
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Special Tool(s)
Engine
UV Leak Detector Kit
Special Tool(s)
Commercially Available
Hydraulic Lash Adjuster
Leakdown Tester

Vacuum/Pressure Tester
Quick Disconnect Compression
Tester
Material
Item Specification
Dial Indicator Gauge Adapter
303-007 (TOOL-6565-AB) or
Gasoline Engine Oil Dye
equivalent
164-R3705
Motor Oil
XO-5W20-QSP (US);
Motorcraft SAE 5W-20
Super Premium Motor Oil
Holding Fixture
CXO-5W20-LSP12
100-002 (TOOL-4201-C) or
equivalent
4.6L (3V)
Motor Oil
XO-5W30-QSP (US);
Engine Cylinder Leak
Detection/Air Pressurization Kit
CXO-5W30-LSP12
4.0L SOHC
Full Synthetic Motor Oil
XO-5W50-QGT or
Oil Pressure Gauge
303-088 (T73L-6600-A)
(Continued)
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Inspection and Verification 2. Visually inspect for obvious signs of
mechanical damage. Refer to the following
WARNING: To avoid the possibility of
chart.
personal injury or damage to the vehicle, do not
operate the engine with the hood open until the
fan blade has been examined for possible cracks
Mechanical
and separation.
Engine coolant leaks
NOTE: Specifications show the expected minimum
Engine oil leaks
or maximum condition. Refer to the appropriate
Fuel leaks
section in Group 303 for the procedure.
Damaged or severely worn parts
Loose mounting bolts, studs and nuts
NOTE: If a component fails to meet the
specifications, it is necessary to install a new
component or refinish. If the component can be
3. If the inspection reveals obvious concerns that
refinished, wear limits are provided as an aid to
can be readily identified, repair as necessary.
making a decision. A new component must be
4. If the concerns remain after the inspection,
installed for any component that fails to meet
determine the symptoms. GO to Symptom
specifications and cannot be refinished.
Chart.
1. Verify the customer concern by operating the
engine to duplicate the condition.
Symptom Chart
Symptom Chart
Difficult starting Damaged ignition system Refer to the appropriate
Damaged fuel system section in Group 303 for the
Damaged starting system procedure. REFER to the
Powertrain Control/Emissions
Damaged charging REFER to Section 414-00.
system/battery
Burnt valve INSTALL a new valve.
Worn piston For 4.0L engines, INSTALL
a new piston and connecting
rod assembly. For 4.6L and
5.4L engines, INSTALL a
new piston.
Worn piston rings INSTALL new piston rings.
Worn cylinder REPAIR or INSTALL a new
cylinder block.
Damaged head gasket INSTALL a new head gasket.
Damaged cooling system Refer to the appropriate
section in Group 303 for the
procedure. REFER to the
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Poor idling Vacuum leaks Refer to the appropriate
Malfunctioning or damaged section in Group 303 for the
ignition system procedure. REFER to the
Malfunctioning or damaged Powertrain Control/Emissions
fuel system Diagnosis (PC/ED) manual.
Damaged valve tappet or lash INSTALL a new valve tappet
adjuster or lash adjuster.
Damaged valve tappet guide INSTALL a new valve tappet
or lash adjuster guide or valve tappet.
Incorrect valve-to-valve seat REPAIR or INSTALL a new
contact valve or valve seat.
Worn or damaged engine INSTALL a new engine
support brackets support brackets.
Worn or damaged engine INSTALL a new engine
support insulators support insulator.
Worn or damaged INSTALL a new transmission
transmission insulator and insulator and retainer.
retainer
Abnormal combustion Malfunctioning or damaged Refer to the appropriate
fuel system section in Group 303 for the
Malfunctioning or damaged procedure. REFER to the
ignition system Powertrain Control/Emissions
Malfunctioning or damaged Diagnosis (PC/ED) manual.
air intake system
Damaged valve tappet or lash INSTALL a new valve tappet
adjuster or lash adjuster.
or valve tappet guide or valve tappet.
Burnt or sticking valve REPAIR or INSTALL a new
valve.
Weak or broken valve spring INSTALL a new valve
spring.
Carbon accumulation in ELIMINATE carbon buildup.
combustion chamber
Excessive oil consumption Leaking oil REPAIR oil leakage.
Malfunctioning PCV system REPAIR or INSTALL new
necessary components.
Worn valve stem seal INSTALL a new valve stem
seal.
Worn valve stem or valve INSTALL a new valve and
guide valve guide.
Sticking piston rings For 4.0L engines, INSTALL
a new piston and connecting
5.4L engines, REPAIR or
INSTALL new piston rings.
Worn piston ring groove For 4.0L engine, INSTALL a
new piston and connecting
5.4L engines, INSTALL a
new piston and piston pin.
Worn piston or cylinder REPAIR or INSTALL a new
piston or cylinder block.
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Engine noise Leaking exhaust system REPAIR exhaust leakage.
Incorrect drive belt tension REFER to Section 303-05.
Malfunctioning generator Refer to the appropriate
bearing section in Group 414 for the
procedure.
Malfunctioning coolant pump REFER to Section 303-03A.
bearing
Malfunctioning or damaged
cooling system
Malfunctioning or damaged Refer to the appropriate
fuel system section in Group 303 for the
procedure. REFER to the
Loose timing chain/belt ADJUST or INSTALL a new
timing chain/belt.
Damaged timing chain INSTALL a new timing chain
tensioner tensioner.
Excessive main bearing CAUTION: Remove the
clearance cylinder heads before
removing the crankshaft.
Failure to do so can result
in engine damage.
ADJUST clearance or
INSTALL new crankshaft
main bearings.
Seized or heat-damaged INSTALL new crankshaft
crankshaft main bearing main bearings.
Excessive crankshaft end play INSTALL a new thrust
bearing or crankshaft.
Excessive connecting rod INSTALL new connecting
bearing clearance rod bearings or connecting
rods.
Heat damaged connecting rod INSTALL new connecting
bearing rod bearings.
Damaged connecting rod
bushing
Worn cylinder REPAIR or INSTALL a new
cylinder block.
Worn piston or piston pin INSTALL a new piston or
piston pin.
Damaged piston rings INSTALL new piston rings.
Bent connecting rod INSTALL a new connecting
rod.
Malfunctioning valve tappet INSTALL a new valve tappet
or lash adjuster or lash adjuster.
Excessive valve tappet or lash ADJUST clearance or
adjuster clearance INSTALL a new valve tappet
guide or valve tappet.
Broken valve spring INSTALL a new valve
spring.
Excessive valve guide ADJUST clearance or
clearance INSTALL a new valve guide
or valve.
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Insufficient power Malfunctioning or damaged Refer to the appropriate
ignition system section in Group 303 for the
Electronic throttle control procedure. REFER to the
(ETC) system concerns Powertrain Control/Emissions
Malfunctioning or damaged Diagnosis (PC/ED) manual.
fuel system
Malfunctioning or damaged
air intake system
Damaged or plugged exhaust INSPECT exhaust system.
system
Incorrect tire size REFER to Section 204-00.
Dragging brakes REFER to Section 206-00.
Slipping transmission Refer to the appropriate
section in Group 307 for the
procedure.
Malfunctioning valve tappet INSTALL a new valve tappet
or lash adjuster or lash adjuster.
or valve tappet guide or valve tappet.
Compression leakage at valve REPAIR or INSTALL a new
seat valve, valve seat or cylinder
head.
Seized valve stem INSTALL a new valve.
Weak or broken valve spring INSTALL a new valve
spring.
Worn or damaged camshaft INSTALL a new camshaft.
Cracked or distorted cylinder INSTALL a new cylinder
head head.
Damaged, worn or sticking REPAIR or INSTALL a new
piston ring(s) piston ring(s).
Worn or damaged piston INSTALL a new piston and
piston pin.
Component Tests 1. Add 29.6 ml (1 oz) of fluorescent additive to a
minimum of 0.47L (1/2 qt) and a maximum of
Engine Oil Leaks
0.95L (1 qt) engine oil and fill through the
engine oil fill. If the oil is not premixed, the
CAUTION: If an overnight drive is done,
fluorescent additive will not have enough time
the fan air or road air blast can cause erroneous
to reach the crankcase, oil galleries and seal
readings.
surfaces during this particular 15 minute test.
NOTE: When diagnosing engine oil leaks, the
The additive must be mixed with oil and added
source and location of the leak must be positively
through the oil fill. Check the level on the oil
identified prior to repair.
level indicator to determine what amount of oil
Prior to carrying out this procedure, clean all
to premix. If it is in the middle of the
sealing surface areas with a suitable solvent to
crosshatch area or below the full mark, use
remove all traces of oil.
0.95L (1 qt). If it is at the full mark, use 0.47L
(1/2 qt).
Engine Oil Leaks Fluorescent Oil Additive
2. Run the engine for 15 minutes. Stop the engine
Method
and inspect all seal and gasket areas for leaks
Use the UV Leak Detector Kit to carry out the
using the UV Leak Detector Kit. A clear bright
following procedure for oil leak diagnosis.
yellow or orange area will identify the leak. For
extremely small leaks, several hours may be
required for the leak to appear.
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3. At the end of test, make sure the oil level is Rear main bearing cap and seals
within the upper and lower oil indicator marks.
Flywheel mounting bolt holes (with flywheel
Remove oil as necessary if it registers above
installed)
the full mark.
Camshaft rear bearing covers or pipe plugs at the
end of oil passages
Leakage Points Underhood
Oil leaks at crimped seams in sheet metal parts and
Examine the following areas for oil leakage:
cracks in cast or stamped parts can be detected
Valve cover gaskets
when using the dye method.
Intake manifold gaskets
Compression Test Compression
Cylinder head gaskets
Gauge Check
Oil bypass filter
1. Make sure the oil in the crankcase is of the
Oil filter adapter
correct viscosity and at the correct level and
that the battery is correctly charged. Operate the
Engine front cover
vehicle until the engine is at normal operating
Oil filter adapter and filter body
temperature. Turn the ignition switch to the
Oil level indicator tube connection
OFF position, then remove all the spark plugs.
Oil pressure sensor
2. Set the throttle plates in the wide-open position.
3. Install a compression gauge such as the
Leakage Points Under Engine With
Compression Tester in the No. 1 cylinder.
Vehicle on Hoist
4. Install an auxiliary starter switch in the starting
circuit. With the ignition switch in the OFF
Oil pan gaskets
position, and using the auxiliary starter switch,
Oil pan sealer crank the engine a minimum of 5 compression
strokes and record the highest reading. Note the
Oil pan rear seal
approximate number of compression strokes
Engine front cover gasket
required to obtain the highest reading.
Crankshaft front seal
5. Repeat the test on each cylinder, cranking the
Crankshaft rear oil seal
engine approximately the same number of
compression strokes.
Crankshaft main bearing cap side bolts
Oil filter adapter and filter body
Compression Test Test Results
Oil cooler, if equipped
The indicated compression pressures are considered
within specification if the lowest reading cylinder is
Leakage Points With Transmission and
at least 75 percent of the highest reading. Refer to
Flywheel Removed
the Compression Pressure Limit Chart.
Crankshaft rear oil seal
Rear main bearing cap parting line
Compression Pressure Limit Chart
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
924 kPa 696 kPa 1131 kPa 848 kPa 1338 kPa 1000 kPa 1544 kPa 1158 kPa
(134 psi) (101 psi) (164 psi) (123 psi) (194 psi) (146 psi) (224 psi) (168 psi)
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Compression Pressure Limit Chart (Continued)
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
1110 kPa 834 kPa 1324 kPa 993 kPa 1631 kPa 1145 kPa
(161 psi) (121 psi) (192 psi) (144 psi) (222 psi) (166 psi)
If one or more cylinders reads low, squirt 3. If 2 adjacent cylinders indicate low compression
approximately one tablespoon of engine oil on top pressures and squirting oil on each piston does
of the pistons in the low-reading cylinders. Repeat not increase compression, the head gasket may
the compression pressure check on these cylinders. be leaking between cylinders. Engine oil or
coolant in cylinders could result from this
Compression Test Interpreting
condition.
Compression Readings
Use the Compression Pressure Limit Chart
1. If compression improves considerably, piston
when checking cylinder compression so that the
rings are faulty.
lowest reading is at least 75 percent of the
2. If compression does not improve, valves are
highest reading.
sticking or seating incorrectly.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the
Engine Cylinder Leak Detection/Air Pressurization
Kit will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug
hole, the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
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Once the combustion chamber is pressurized, a
special gauge included in the kit will read the
percentage of leakage. Leakage exceeding 20
percent is excessive.
While the air pressure is retained in the cylinder,
listen for the hiss of escaping air. A leak at the
intake valve will be heard in the throttle body. A
leak at the exhaust valve can be heard at the tail
pipe. Leakage past the piston rings will be audible
at the positive crankcase ventilation (PCV)
connection. If air is passing through a blown head
gasket to an adjacent cylinder, the noise will be
evident at the spark plug hole of the cylinder into
which the air is leaking. Cracks in the cylinder
block or gasket leakage into the cooling system may
be detected by a stream of bubbles in the radiator.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature.
Connect the Vacuum/Pressure Tester to the intake
manifold. Run the engine at the specified idle speed.
The vacuum gauge should read between 51-74 kPa
(15-22 in-Hg), depending upon the engine condition
and the altitude at which the test is performed.
Subtract 4.0193 kPa (1 in-Hg) from the specified
reading for every 304.8 m (1,000 feet) of elevation
1. NORMAL READING: Needle between 51-74
above sea level.
kPa (15-22 in-Hg) and holding steady.
The reading should be steady. If necessary, adjust
2. NORMAL READING DURING RAPID
the gauge damper control (where used) if the needle
ACCELERATION AND DECELERATION:
is fluttering rapidly. Adjust the damper until the
When the engine is rapidly accelerated (dotted
needle moves easily without excessive flutter.
needle), the needle will drop to a low reading
(not to zero). When the throttle is suddenly
Intake Manifold Vacuum Test Interpreting
released, the needle will snap back up to a
Vacuum Gauge Readings
higher than normal figure.
A careful study of the vacuum gauge reading while
3. NORMAL FOR HIGH-LIFT CAMSHAFT
the engine is idling will help pinpoint trouble areas.
WITH LARGE OVERLAP: The needle will
Always conduct other appropriate tests before
register as low as 51 kPa (15 in-Hg) but will be
arriving at a final diagnostic decision. Vacuum
relatively steady. Some oscillation is normal.
gauge readings, although helpful, must be
4. WORN RINGS OR DILUTED OIL: When the
interpreted carefully.
engine is accelerated (dotted needle), the needle
Most vacuum gauges have a normal band indicated
drops to 0 kPa (0 in-Hg). Upon deceleration,
on the gauge face.
the needle runs slightly above 74 kPa (22
The following are potential gauge readings. Some
in-Hg).
are normal; others should be investigated further.
5. STICKING VALVES: When the needle (dotted)
remains steady at a normal vacuum but
occasionally flicks (sharp, fast movement) down
and back about 13 kPa (4 in-Hg), one or more
valves may be sticking.
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6. BURNED OR WARPED VALVES: A regular, 16. When vacuum leaks are indicated, search out
evenly-spaced, downscale flicking of the needle and correct the cause. Excess air leaking into
indicates one or more burned or warped valves. the system will upset the fuel mixture and cause
Insufficient hydraulic lash adjuster (HLA) or concerns such as rough idle, missing on
HLA clearance will also cause this reaction. acceleration or burned valves. If the leak exists
in an accessory unit such as the power brake
7. POOR VALVE SEATING: A small but regular
booster, the unit will not function correctly.
downscale flicking can mean one or more
Always fix vacuum leaks.
valves are not seating.
8. WORN VALVE GUIDES: When the needle
Excessive Engine Oil Consumption
oscillates over about a 13 kPa (4 in-Hg) range
Nearly all engines consume oil, which is essential
at idle speed, the valve guides could be worn.
for normal lubrication of the cylinder bore walls and
As engine speed increases, the needle will
pistons and rings. Determining the level of oil
become steady if guides are responsible.
consumption may require testing by recording how
9. WEAK VALVE SPRINGS: When the needle
much oil is being added over a given set of miles.
oscillation becomes more violent as engine rpm
Customer driving habits greatly influence oil
is increased, weak valve springs are indicated.
consumption. Mileage accumulated during towing or
The reading at idle could be relatively steady.
heavy loading generates extra heat. Frequent short
10. LATE VALVE TIMING: A steady but low
trips, stop-and-go type traffic or extensive idling,
reading could be caused by late valve timing.
prevent the engine from reaching normal operating
temperature. This prevents component clearances
11. IGNITION TIMING RETARDING: Retarded
from reaching specified operating ranges.
ignition timing will produce a steady but
somewhat low reading.
The following diagnostic procedure may be utilized
to determine internal oil consumption. Make sure
12. INSUFFICIENT SPARK PLUG GAP: When
that the concern is related to internal oil
spark plugs are gapped too close, a regular,
consumption, and not external leakage, which also
small pulsation of the needle can occur.
consumes oil. Verify there are no leaks before
13. INTAKE LEAK: A low, steady reading can be
carrying out the test. Once verified, the rate of
caused by an intake manifold or throttle body
internal oil consumption can be tested.
gasket leak.
A new engine may require extra oil in the early
14. BLOWN HEAD GASKET: A regular drop of
stages of operation. Internal piston-to-bore
fair magnitude can be caused by a blown head
clearances and sealing characteristics improve as the
gasket or warped cylinder head-to-cylinder
engine breaks in. Engines are designed for close
block surface.
tolerances and do not require break-in oils or
15. RESTRICTED EXHAUST SYSTEM: When the
additives. Use the oil specified in the owner guide.
engine is first started and is idled, the reading
Ambient temperatures may determine the oil
may be normal, but as the engine rpm is
viscosity specification. Verify that the correct oil is
increased, the back pressure caused by a
being used for the vehicle in the geographic region
clogged muffler, kinked tail pipe or other
in which it is driven.
concerns will cause the needle to slowly drop
to 0 kPa (0 in-Hg). The needle then may slowly
rise. Excessive exhaust clogging will cause the
needle to drop to a low point even if the engine
is only idling.
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Basic Pre-checks
6. Inspect the air filter for dirt, sludge or damage.
A hole in the filter element will allow unfiltered
1. For persistent complaints of oil consumption,
air to bypass into the air induction system. This
interview the customer to determine the oil
can cause premature internal wear (engine
consumption characteristics. If possible,
dusting), allowing oil to escape past rings,
determine the brand and grade of oil currently
pistons, valves and guides.
in the oil pan. Look at the oil filter or
oil-change station tags to determine if
7. If the engine is hot or was recently shut down,
Ford-recommended maintenance schedules have
wait at least 5 minutes to allow the oil to drain
been followed. Make sure that the oil has been
back. Ask the customer if this requirement has
changed at the specified mileage intervals. If
been followed. Adding oil without this wait
vehicle mileage is past the first recommended
period can cause an overfill condition, leading
drain interval, the OEM production filter should
to excessive oil consumption and foaming
have been changed.
which may cause engine damage.
2. Ask how the most current mileage was
8. Make sure the oil level indicator (dipstick) is
accumulated. That is, determine whether the
correctly and fully seated in the indicator tube.
vehicle was driven under the following
Remove the oil level indicator and record the
conditions:
oil level.
Extended idling or curbside engine operation
Detailed Pre-checks
Stop-and-go traffic or taxi operation
1. Check the thermostat opening temperature to
Towing a trailer or vehicle loaded heavily
make sure that the cooling system is operating
at the specified temperature. If it is low,
Frequent short trips (engine not up to
internal engine parts are not running at
normal operating temperature)
specified internal operating clearances.
Excessive throttling or high engine-rpm
2. Verify the spark plugs are not oil saturated. Oil
driving
leaking into one or more cylinders will appear
3. Verify that there are no external leaks. If
as an oil soaked condition on the plug. If a
necessary, review the diagnostic procedure
plug is saturated, a compression check may be
under Engine Oil Leaks in the Diagnosis and
necessary at the conclusion of the oil
Testing portion of this section.
consumption test.
4. Inspect the crankcase ventilation system for the
Oil Consumption Test
following:
Once all of the previous conditions are met, carry
Disconnected hoses at the valve cover or
out an oil consumption test.
throttle body
1. Drain the engine oil and remove the oil filter.
Loose or missing valve cover fill cap
Install a new manufacturer-specified oil filter.
Missing or incorrectly seated engine oil
Make sure the vehicle is positioned on a level
level indicator
surface. Refill the oil pan to a level one quart
Incorrect or dirty PCV valve
(liter) less than the specified fill level, using
A PCV valve grommet unseated in the valve manufacturer-specified oil.
cover (if so equipped)
2. Run the engine for 3 minutes (if hot) or 10
5. Inspect for signs of sludge. Sludge affects PCV minutes (if cold). Allow for a minimum
performance and can plug or restrict cylinder 5-minute drainback period and then record the
head drainback wells. It can also increase oil oil level shown on the oil level indicator. Place
pressure by restricting passages and reducing a mark on the backside of the oil level indicator
the drainback capability of piston oil control noting the oil level location.
rings. Sludge can result from either excessive
3. Add the final 1 quart (liter) to complete the
water ingestion in the crankcase or operation at
normal oil fill. Restart the engine and allow it
extremely high crankcase temperatures.
to idle for 2 minutes. Shut the engine down.
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4. After a 5-minute drainback period, record the 3. A cylinder leak detection test can be carried out
location of the oil level again. Mark the oil using an Engine Cylinder Leak Detection/Air
level indicator with the new oil level location. Pressurization Kit. This can help identify
(Note: Both marks should be very close to the valves, piston rings, or worn valve guides/valve
MIN-MAX upper and lower limits or the upper stems, inoperative valve stem seals or other
and lower holes on the oil level indicator. related areas as the source of oil consumption.
These marks will exactly measure the engines
NOTE: An oil-soaked appearance on the porcelain
use of oil, with a one quart differential between
tips of the spark plugs also indicates excessive oil
the new marks.) Demonstrate to the customer
use. A typical engine with normal oil consumption
that the factory-calibrated marks on the dipstick
will exhibit a light tan to brown appearance. See
are where the oil should fall after an oil
Spark Plug Analysis in this section for details. A
change with the specified fill amount. Explain
single or adjoining, multiple cylinder leak can be
however, that this may vary slightly between
traced by viewing the tips.
MIN-MAX or the upper and lower holes on the
4. If an internal engine part is isolated as the root
oil level indicator.
cause, determine if the repair will exceed cost
5. Record the vehicle mileage.
limits and proceed with a repair strategy as
6. Advise the customer that oil level indicator required.
readings must be taken every 320 km (200
5. Once corrective action to engine is complete
miles) or weekly, using the revised marks as
and verifying that all pre-check items were
drawn. Remind the customer that the engine
eliminated in the original diagnosis, repeat the
needs a minimum 5-minute drainback for an
Oil Consumption Test as described above and
accurate reading and that the oil level indicator
verify consumption results.
must be firmly seated in the tube prior to taking
the reading. Oil Pressure Test
7. When the subsequent indicator readings 1. Disconnect and remove the oil pressure sensor
demonstrate a full quart (liter) has been used, from the engine.
record the vehicle mileage. The mileage driven
2. Connect the Oil Pressure Gauge to the oil
between the 2 readings should not be less than
pressure sender oil galley port.
1,500 miles. The drive cycle the vehicle has
3. Run the engine until normal operating
been operated under must be considered when
temperature is reached.
making this calculation. It may be necessary to
4. Run the engine at the specified rpm and record
have the customer bring the vehicle in for a
the gauge reading.
periodic oil level indicator reading to closely
monitor oil usage.
5. The oil pressure should be within specifications;
refer to the specification chart in the appropriate
Post Checks, Evaluation and Corrective
engine section.
Action
6. If the pressure is not within specification, check
1. If test results indicate excessive oil
the following possible sources:
consumption, carry out a cylinder compression
Insufficient oil
test. The cylinder compression test should be
carried out with a fully charged battery and all
Oil leakage
spark plugs removed. See the Compression Test
Worn or damaged oil pump
Chart in this section for pressure range limits.
Oil pump screen cover and tube
2. Compression should be consistent across all
Excessive main bearing clearance
cylinders. For additional information, refer to
the Compression Testing portion of this section.
Excessive connecting rod bearing clearance
If compression tested within the specifications
found in this section, the excessive oil
consumption may be due to wear on the valve
guides, valves or valve seals.
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Valve Train Analysis Engine Off Valve Valve Train Analysis Engine Running
Cover Removed
Start the engine and, while idling, check for
Check for damaged or severely worn parts and
correct operation of all parts. Check the
correct assembly. Make sure correct parts are used
following:
with the static engine analysis as follows.
Valve Train Analysis Engine Running,
Valve Train Analysis Engine Off, Rocker
Valves and Cylinder Head
Arm
Check for plugged oil drain back holes.
Check for loose mounting bolts, studs and nuts.
Check for missing or damaged valve stem seals or
Check for plugged oil feed in the rocker arms or
guide-mounted valve stem seals.
cylinder head.
Check for a plugged oil metering orifice for thrust
groove oil supply in the cylinder head thrust cap
Valve Train Analysis Engine Off,
Camshaft Roller Followers and Hydraulic (4.6L engine only).
Lash Adjusters, Overhead Camshaft
If insufficient oiling is suspected, check oil passages
for blockage, then accelerate the engine to 1,200
Check for loose mounting bolts on camshaft
rpm with the transmission in NEUTRAL and the
carriers.
engine at normal operating temperature. Oil should
Check for plugged oil feed in the camshaft roller
spurt from the rocker arm oil holes such that valve
followers, lash adjusters or cylinder heads.
tips and camshaft roller followers are well oiled.
With the valve covers off, some oil splash may
Valve Train Analysis Engine Off,
overshoot camshaft roller followers.
Camshaft Engines
Check for broken or damaged parts.
Camshaft Lobe Lift OHC Engines
Valve Train Analysis Valve Springs
Check the lift of each camshaft lobe in consecutive
Check for broken or damaged parts.
order and make a note of the readings.
1. Remove the valve covers.
Valve Train Analysis Engine Off, Valve
Spring Retainer and Valve Spring Retainer
2. Remove the spark plugs.
Keys
3. Install the Dial Indicator Gauge with Holding
Fixture so the rounded tip of indicator is on top
Check for correct seating of the valve spring
of the camshaft lobe and on the same plane as
retainer key on the valve stem and in valve spring
the valve tappet.
retainer.
4. Rotate the crankshaft using a breaker bar and
Check for correct seating on the valve stem.
socket attached to the crankshaft pulley retainer
Valve Train Analysis Engine Off, Valves
bolt. Rotate the crankshaft until the base circle
and Cylinder Head
of the camshaft lobe is reached.
Check for plugged oil drain back holes.
Check for worn or damaged valve tips.
Check for missing or damaged guide-mounted
valve stem seal.
Check collapsed valve tappet gap.
Check installed valve spring height.
Check for missing or worn valve spring seats.
Check for plugged oil metering orifice in cylinder
head oil reservoir (if equipped).
Static checks (engine off) are to be made on the
engine prior to the dynamic procedure.
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5. Zero the dial indicator. Continue to rotate the Excessive collapsed valve tappet gap can be caused
crankshaft until the (1) high-lift point of the by loose rocker arm seat bolts/nuts, incorrect initial
camshaft lobe is in the fully-raised position adjustment or wear of valve tappet face, or worn
(highest indicator reading). roller valve tappets, push rod, rocker arm, rocker
arm seat or valve tip. With valve tappet collapsed,
6. To check the accuracy of the original indicator
check gap between the valve tip and the rocker arm
reading, continue to rotate crankshaft until the
to determine if any other valve train parts are
(2) base circle is reached. The indicator reading
damaged, worn or out of adjustment.
should be zero. If zero reading is not obtained,
repeat Steps 1 through 6. An incorrectly functioning valve tappet can be
sticking, caused by contaminants or varnish inside
7. NOTE: If the lift on any lobe is below
the tappet. The tappet can have a check valve that is
specified service limits, install a new camshaft,
not functioning correctly, which can be caused by
and new camshaft roller followers.
an obstruction, such as dirt or chips that prevent
Remove the Dial Indicator Gauge with Holding
the check valve from closing, or a broken check
Fixture.
valve spring. A tappet with a leakdown time out of
8. Install the spark plugs.
specification can cause tappet noise. If no other
cause for noisy valve tappets can be found, the
9. Install the valve covers.
leakdown rate should be checked and new valve
tappets installed if found to be out of specification.
Valve Tappet
Assembled valve tappets can be tested with
Valve tappet noise can be caused by any of the
Hydraulic Lash Adjuster Leakdown Tester to check
following:
the leakdown rate. The leakdown rate specification
is the time in seconds for the plunger to move a
Excessive valve tappet gap (collapsed)
specified distance while under a 22.7 kg (50 lb)
Incorrectly functioning valve tappet
load.
Air in lubrication system
Air bubbles in the lubrication system will prevent
Excessive valve guide wear the valve tappet from supporting the valve spring
load. This can be caused by too high or too low an
Low oil pressure
oil level in the oil pan or by air being drawn into
the system through a hole, crack or leaking gasket
on the oil pump screen cover and tube.
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GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects:
1 Cratering fatigue failure
2 Spot polishing incorrect seating
3 Imbedded dirty engine oil
4 Scratching dirty engine oil
5 Base exposed poor lubrication
6 Both edges worn journal damaged
7 One edge worn journal tapered or
bearing not seated
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GENERAL PROCEDURES
Camshaft Bearing Journal Clearance
NOTE: The camshaft journals must meet
specifications before checking camshaft journal
clearance.
1. Remove the camshaft bearing cap and lay
Plastigage across the surface. Refer to the
appropriate section in Group 303 for the
procedure.
2. NOTE: Do not turn the camshaft while
carrying out this procedure.
3. Use Plastigage to verify the camshaft journal
Position the camshaft bearing cap and install
clearance.
the bolts. Refer to the appropriate section in
If out of specification, install new
components as necessary. Refer to the
procedure.
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GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
1. Measure each camshaft journal diameter in 2
directions.
procedure.
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GENERAL PROCEDURES
5. Move the camshaft to the front of the cylinder
Camshaft End Play
head. Note and record the camshaft end play.
Special Tool(s) If camshaft end play exceeds specifications,
install new camshaft and recheck end play.
Dial Indicator with Bracketry
Refer to the appropriate section in Group
100-002 (TOOL-4201-C) or
303 for the procedure.
equivalent
If camshaft end play exceeds specification
after camshaft installation, install a new
cylinder head. Refer to the appropriate
section in Group 303 for the procedure.
1. Remove the roller followers. Refer to the
procedure.
2. Use the special tool to measure camshaft end
play.
3. Position the camshaft to the rear of the cylinder
head.
4. Zero the indicator.
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GENERAL PROCEDURES
Camshaft Lobe Lift
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. Use the special tool to measure camshaft
intake/exhaust lobe lift.
Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading to figure the camshaft lobe lift.
For additional information, refer to
Specifications in the appropriate section in
Group 303.
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GENERAL PROCEDURES
Camshaft Runout
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Camshaft journals must be within
specifications before checking runout.
Use the special tool to measure the camshaft
runout.
Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading.
For additional information, refer to the
specification chart in the appropriate engine
section.
procedure.
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GENERAL PROCEDURES
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in
the contact area. Minor pitting is acceptable
outside the contact area.
If excessive pitting or damage is present,
install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.
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GENERAL PROCEDURES
Connecting Rod Bearing Journal
Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal
diameters in 2 directions perpendicular to one
another at each end of the connecting rod
journal. The difference in the measurements
from one end to the other is the taper. Verify
measurement is within the wear limit.
procedure.
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GENERAL PROCEDURES
4. Measure the Plastigage to get the connecting
Connecting Rod Bearing
rod bearing journal clearance. The Plastigage
Journal-to-Bearing Clearance
should be smooth and flat. A changing width
indicates a tapered or damaged connecting rod
NOTE: The crankshaft connecting rod journals
or connecting rod bearing.
must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing
surface.
procedure.
3. NOTE: Do not turn the crankshaft during this
step.
Install and tighten to specifications, then
remove the connecting rod bearing cap.
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GENERAL PROCEDURES
Connecting Rod Bend
1. Measure the connecting rod bend on a suitable
alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the bend
measurement is within specification.
procedure.
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GENERAL PROCEDURES
2. Measure the telescoping gauge with a
Connecting Rod Bushing Diameter
micrometer. Verify the diameter is within
specification.
1. Use a telescoping gauge to determine the inner
diameter of the connecting rod bushing, if
303 for the specification.
equipped.
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GENERAL PROCEDURES
Connecting Rod Cleaning
CAUTION: Do not use a caustic cleaning
solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a
matched set. The connecting rod cap must be
installed on the original connecting rod in the
original position. Do not reverse the cap. Parts
are not interchangeable.
Mark and separate the parts and clean with
solvent. Clean the oil passages.
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GENERAL PROCEDURES
Connecting Rod Large End Bore
1. Tighten the bolts to specification, then measure
the bore in 2 directions. The difference is the
connecting rod bore out-of-round. Verify the
out-of-round is within specification.
procedure.
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GENERAL PROCEDURES
Connecting Rod Twist
1. Measure the connecting rod twist on a suitable
alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the measurement is
within specification.
procedure.
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GENERAL PROCEDURES
4. Move the crankshaft to the front of the cylinder
Crankshaft End Play
block. Note and record the crankshaft end play.
Special Tool(s) If crankshaft end play exceeds
specifications, install a new crankshaft thrust
washer or crankshaft thrust main bearing.
100-002 (TOOL-4201-C) or
equivalent
1. Measure the crankshaft end play. Use the
special tool to measure crankshaft end play.
2. Position the crankshaft to the rear of the
cylinder block.
3. Zero the indicator.
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GENERAL PROCEDURES
Crankshaft Main Bearing Journal
Diameter
1. Measure each of the crankshaft main bearing
journal diameters in at least 2 directions.
procedure.
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GENERAL PROCEDURES
Crankshaft Main Bearing Journal
Taper and Out-of-Round
1. Measure each of the crankshaft main bearing
journal diameters in at least 2 directions at each
end of the main bearing journal.
procedure.
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GENERAL PROCEDURES
3. NOTE: Do not turn the crankshaft while
Crankshaft Main Bearing
Journal-to-Bearing Clearance
Install and remove the crankshaft main bearing
cap.
NOTE: Crankshaft main bearing journals must be
within specifications before checking journal
4. Verify the crankshaft journal clearance.
clearance.
1. Remove the crankshaft main bearing caps and
crankshaft main bearing.
2. Lay a piece of Plastigage across the face of
each crankshaft main bearing surface.
procedure.
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GENERAL PROCEDURES
Crankshaft Runout
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Crankshaft main bearing journals must
be within specifications before checking runout.
Use the special tool to measure the crankshaft
runout.
Group 303.
Rotate the crankshaft and subtract the lowest
dial indicator reading from the highest dial
indicator reading to figure the crankshaft
runout. If it is out of specification, install
new components as necessary. Refer to the
procedure.
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GENERAL PROCEDURES
Cup-Type
Cylinder Block Core Plug
Replacement
1. CAUTION: Use care during this
procedure so as not to disturb or distort the Special Tool(s)
cup sealing surface.
Impact Slide Hammer
100-001 (T50T-100-A)
CAUTION: When installed, the flanged
edge must be below the chamfered edge of
the bore to effectively seal the bore.
Use a tool suitable to seat the cup-type cylinder
block core plug.
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
1. Use a slide hammer or tools suitable to remove
the cylinder block core plug.
Expansion-Type
1. CAUTION: Do not contact the crown
when installing an expansion-type cylinder
block core plug. This could expand the plug
before seating and result in leakage.
Use tool suitable to seat the expansion-type
cylinder block core plug.
2. Inspect the cylinder block plug bore for any
damage that would interfere with the correct
sealing of the plug. If the cylinder block plug
bore is damaged, bore for the next oversize
plug.
3. NOTE: Oversize plugs are identified by the OS
stamped in the flat located on the cup side of
the plug.
Coat the cylinder block core plug and bore
lightly with Threadlock 262 and install the
cylinder block core plug.
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GENERAL PROCEDURES
2. Thoroughly rinse with clean water and wipe dry
Cylinder Bore Cleaning
with a clean, lint-free cloth.
1. CAUTION: If these procedures are not
3. Use a clean, lint-free cloth and lubricate the
followed, rusting of the cylinder bores may
cylinder bores.
occur.
Use clean engine oil meeting Ford
Clean the cylinder bores with soap or detergent
specification.
and water.
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GENERAL PROCEDURES
Cylinder Bore Out-of-Round
1. Measure the cylinder bore in 2 directions. The
difference is the out-of-round. Verify the
out-of-round is within the wear limit and bore
the cylinder to the next oversize limit.
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GENERAL PROCEDURES
Cylinder Bore Taper
1. Measure the cylinder bore at the top, middle
and bottom of piston ring travel in 2 directions
as indicated. Verify the cylinder bore is within
the wear limit. The difference indicates the
cylinder bore taper. Bore the cylinder to the
next oversize limit.
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GENERAL PROCEDURES
Cylinder Head Distortion
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
Straight Edge
303-D039 (D83L-4201-a) or
equivalent
1. NOTE: Make sure all cylinder head surfaces
are clear of any gasket material, RTV, oil and
coolant. The cylinder head surface must be
clean and dry before running a flatness check.
NOTE: Use a straight edge that is calibrated by
the manufacturer to be flat with 0.005 mm
(0.0002 in) per running foot length. For
example, if the straight edge is 61 cm (24 in)
long, the machined edge must be flat with
0.010 mm (0.0004 in) from end to end.
Using a straight edge and a feeler gauge,
inspect the cylinder head for flatness in the
sequence shown. If the cylinder head is
distorted, install a new cylinder head.
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GENERAL PROCEDURES
Exhaust Manifold Cleaning and
Inspection
Special Tool(s)
Straight Edge
303-D039 (D83L-4201-A) or
equivalent
1. Clean the exhaust manifold using a suitable
solvent. Use a plastic scraping tool to clean the
gasket sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs,
nuts and/or bolts must be installed when an
exhaust manifold is serviced.
Using the special tool (or a precision straight
edge) and a feeler gauge, check the exhaust
manifold sealing surface for warpage. If the
warpage is greater than 0.76 mm (0.0299 in),
install a new exhaust manifold.
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GENERAL PROCEDURES
Piston Diameter
1. Measure the piston diameter 90 degrees from
the piston pin and 42 mm (1.65 in) down from
the top of the piston at the point indicated.
Refer to the appropriate section in Group 303
for the procedure.
procedure.
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GENERAL PROCEDURES
Piston Inspection
Special Tool(s)
Piston Ring Groove Cleaner
303-D033 (D81L-6002-D) or
equivalent
CAUTION: Do not use a caustic cleaning
solution or a wire brush to clean the pistons or
2. Use the special tool to clean the piston ring
damage can occur.
grooves.
Make sure the oil ring holes are clean.
1. Clean and inspect the (1) ring lands, (2) skirts,
(3) pin bosses, and the (4) tops of the pistons.
If wear marks, scores or glazing is found on the
piston skirt, check for a bent or twisted
connecting rod.
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GENERAL PROCEDURES
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions
at the points shown. Verify the diameter is
procedure.
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GENERAL PROCEDURES
Piston Pin to Bore Diameter
1. WARNING: Cover the end of the pin
bore with a hand or shop rag when removing
the retainer ring, since it has a tendency to
spring out. Wear eye protection. Failure to
follow instructions may result in personal
injury.
NOTE: Piston and piston pins are a matched
set and should not be interchanged.
Measure the piston pin bore diameter in 2
directions on each side. Verify the diameter is
procedure.
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GENERAL PROCEDURES
2. Use a feeler gauge to measure the top piston
Piston Ring End Gap
ring end gap and the second piston ring end
gap.
CAUTION: Use care when fitting piston
rings to avoid possible damage to the piston ring
or the cylinder bore.
CAUTION: Piston rings should not be
transferred from one piston to another.
NOTE: Cylinder bore must be within specification
for taper and out-of-round.
1. Use a piston without rings to push a piston ring
in a cylinder to the bottom of ring travel.
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GENERAL PROCEDURES
Piston Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or
accelerated wear.
2. Measure the piston ring-to-groove clearance.
procedure.
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GENERAL PROCEDURES
2. NOTE: For precision fit, new pistons are
Piston Selection
divided into 3 categories (grade sizes). A paint
spot on the new pistons indicates the grade size.
NOTE: The cylinder bore must be within the
Choose the piston with the correct paint color
specifications for taper and out-of-round before
after measuring the cylinder bore diameter.
fitting a piston.
Choose the piston with the correct paint color.
1. Select a piston size based on the cylinder bore.
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GENERAL PROCEDURES
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder
bore diameter to find the piston-to-cylinder bore
clearance.
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GENERAL PROCEDURES
Piston Wrist Pin Side Clearance
1. Measure the clearance between the connecting
rod and the piston. Verify the measurement is
procedure.
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GENERAL PROCEDURES
OHC engines
Roller Follower Inspection
Push rod engines
1. Inspect the roller for flat spots or scoring. If
any damage is found, inspect the camshaft
lobes and valve tappet for damage.
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GENERAL PROCEDURES
3. Inspect for carbon fouling. Look for black, dry,
Spark Plug Inspection
fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by
1. Inspect the spark plug for a bridged gap.
a spark plug with an incorrect heat range, dirty
Check for deposit build-up closing the gap
air cleaner, too rich a fuel mixture or excessive
between the electrodes. Deposits are caused
idling.
by oil or carbon fouling.
Clean the spark plug.
4. Inspect for normal burning.
2. Check for oil fouling.
Check for light tan or gray deposits on the
Check for wet, black deposits on the
firing tip.
insulator shell bore electrodes, caused by
excessive oil entering the combustion
chamber through worn rings and pistons,
excessive valve-to-guide clearance or worn
or loose bearings.
Correct the oil leak concern.
Install a new spark plug.
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5. Inspect for pre-ignition, identified by melted
electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate
engine damage. This may be caused by
incorrect ignition timing, wrong type of fuel or
the unauthorized installation of a heli-coil
insert in place of the spark plug threads.
7. Inspect for fused deposits, identified by melted
or spotty deposits resembling bubbles or
blisters. These are caused by sudden
acceleration.
6. Inspect for overheating, identified by white or
light gray spots and with bluish-burnt
appearance of electrodes. This is caused by
engine overheating, wrong type of fuel, loose
spark plugs, spark plugs with an incorrect heat
range, low fuel pump pressure or incorrect
ignition timing.
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GENERAL PROCEDURES
Sprockets
1. WARNING: To avoid the possibility of
personal injury or damage to the vehicle, do
not operate the engine with the hood open
until the fan blade has been examined for
possible cracks and separation. Failure to
follow these instructions may result in
personal injury.
NOTE: Specifications show the expected
minimum or maximum condition.
NOTE: If a component fails to meet the
specifications, it is necessary to install a new
component or refinish the component. If the
component can be refinished, wear limits are
provided as an aid to making a decision. If a
component fails to meet specifications and
cannot be refinished, a new component must be
installed.
Inspect the timing chain/belt and the sprocket.
Install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.
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GENERAL PROCEDURES
2. Measure the ball gauge with a micrometer.
Valve Guide Inner Diameter
303 for the specification.
1. NOTE: Valve guides tend to wear in an
hourglass pattern. The ball gauge can be
inserted into the combustion chamber side of
the valve guide if necessary.
Use a ball gauge to determine the inner
diameter of the valve guides in 2 directions at
the top, middle and bottom of the valve guide.
3. If the valve guide is not within specifications,
ream the valve guide and install a valve with an
oversize stem or remove the valve guide and
install a new valve guide.
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GENERAL PROCEDURES
3. Clean the sharp edges left by reaming.
Valve Guide Reaming
1. Use a hand-reaming kit to ream the valve
guide.
2. Reface the valve seat.
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GENERAL PROCEDURES
Valve Inspection
1. Inspect the following valve areas:
1 The end of the stem for grooves or scoring.
2 The valve face and the edge for pits,
grooves or scores.
3 The valve head for signs of burning,
erosion, warpage and cracking.
4 The valve margin for wear.
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GENERAL PROCEDURES
Valve Seat Inspection
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve
seats, check valve clearance.
1. Check the valve head and seat.
Check valve angles.
Check margin width.
2. Inspect for abnormalities on the valve face and
Be sure margin width is within specification.
seat.
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GENERAL PROCEDURES
Valve Seat Width
1. Measure the valve seat width. If necessary,
grind the valve seat to specification.
Measure the intake valve seat width.
Measure the exhaust valve seat width.
Recheck the valve spring installed length
after the seats have been ground, and shim
the valve springs as necessary to achieve the
correct installed spring length.
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GENERAL PROCEDURES
Valve Seat Width
1. Measure the valve seat width. If necessary,
grind the valve seat to specification.
Measure the intake valve seat width.
Measure the exhaust valve seat width.
Recheck the valve spring installed length
after the seats have been ground, and shim
the valve springs as necessary to achieve the
correct installed spring length.
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GENERAL PROCEDURES
Valve Spring Free Length
1. Measure the free length of each valve spring.
procedure.
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GENERAL PROCEDURES
Valve Spring Installed Length
1. Measure the installed length of each valve
spring.
components. Refer to the appropriate section
in Group 303 for the procedure.
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GENERAL PROCEDURES
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.
Turn the valve spring and observe the space
between the top of the valve spring and the
square. Install a new valve spring if out of
square. Refer to the appropriate section in
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GENERAL PROCEDURES
Valve Spring Strength
Special Tool(s)
Valve/Clutch Spring Tester
303-006 (TOOL-6513-DD) or
equivalent
1. Use a spring tester to check the valve spring for
correct strength at the specified valve spring
length.
Group 303.
procedure.
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GENERAL PROCEDURES
Valve Stem Diameter
1. Measure the diameter of each intake and
exhaust valve stem at the points shown. Verify
the diameter is within specification.
procedure.
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GENERAL PROCEDURES
Valve Stem to Valve Guide Clearance
Special Tool(s)
100-002 (TOOL-4201-C) or
equivalent
Valve Guide Clearance Gauge
303-004 (TOOL-6505-E) or
equivalent
2. Move the valve clearance gauge toward the
indicator and zero the indicator. Move the valve
clearance gauge away from the indicator and
note the reading. The reading will be DOUBLE
the valve stem-to-valve guide clearance. Valves
with oversize stems will need to be installed if
NOTE: Valve stem diameter must be within
out of specification.
specifications before checking valve stem to valve
guide clearance.
1. NOTE: If necessary, use a magnetic base.
Install a valve clearance gauge on the valve
stem and install a dial indicator. Lower the
valve until the valve clearance gauge contacts
the upper surface of the valve guide.
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GENERAL PROCEDURES
OHC engines
Valve Tappet Inspection
Push rod engines
1. Inspect the hydraulic valve tappet and roller for
damage. If any damage is found, inspect the
camshaft lobes and valves for damage.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
For quick identification, refer to the vehicle control
Engine
information decal mounted under the hood.
The 4.0L SOHC engine consists of the following:
Single overhead camshafts
An engine identification label is attached to the
Sequential multiport fuel injection (SFI)
engine. The label:
Distributorless ignition system
identifies the symbol code for determining parts
Aluminum cylinder heads
usage. Refer to Section 100-01.
Cast iron, 60-degree V cylinder block
Balance shaft (manual transmission only)
Jackshaft
Unique engine timing configuration
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303-01A-1 303-01A-1 Engine 4.0L SOHC
Engine
For basic mechanical concerns, refer to Section
303-00.
For driveability concerns, refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
DISASSEMBLY
Special Tool(s)
Engine
Crankshaft Socket
303-674
Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-101 (T74P-3616-A)
Remover, Crankshaft Front Oil
Seal
303-107 (T74P-6700-A)
Damper
303-773
General Equipment
8 mm x 1.25 x 100 mm bolts (2 required)
Compressor, Valve Spring
303-581 (T97T-6565-A)
CAUTION: During engine repair
procedures, cleanliness is extremely important.
Any foreign material, including any material
created while cleaning gasket surfaces that enters
the oil passages, coolant passages or the oil pan,
can cause engine failure.
Holding Tool, Camshaft
Sprocket
CAUTION: Remove the cylinder heads
303-564 (T97T-6256-B)
before removing the crankshaft. Failure to do so
can result in engine damage.
CAUTION: If the fuel rail is used as a
leverage device, damage may occur to the fuel
Adapter for 303-564
rail. Care must be taken when working around
303-578 (T97T-6256-A)
the fuel rail.
NOTE: For additional information, refer to the
exploded views under Engine in the Assembly
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
DISASSEMBLY (Continued)
1. Remove the 8 bolts and the flexplate or 5. Disconnect the generator and throttle body (TB)
flywheel. electrical connectors.
2. Remove the spacer plate and if equipped, the 6. Remove the nut and detach the B+ terminal
flexplate-to-crankshaft spacer. from the generator.
Detach the wiring retainer from the coolant
tube bracket.
3. NOTE: The crankshaft rear seal may have a
metal speedy sleeve. This sleeve must be
removed before engine disassembly.
7. Disconnect the vacuum tube and the fuel rail
If necessary, remove the speedy sleeve using 2 pressure and temperature sensor electrical
screwdrivers or small pry bars. connector.
4. Mount the engine on a suitable engine stand.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
8. Disconnect the exhaust gas recirculation (EGR) 11. Disconnect the positive crankcase ventilation
system module and throttle position (TP) sensor (PCV) tube fittings and remove the tube.
12. Disconnect the knock sensor (KS) electrical
9. Disconnect the EGR tube fitting from the EGR connector and detach the wiring retainer.
system module.
13. Remove the 8 bolts and the intake manifold.
10. Disconnect the EGR tube fitting from the LH
exhaust manifold and remove the tube.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
14. Remove the 2 fuel supply tube bracket bolts.
18. Remove the 2 bolts, the nut and the generator
and bracket.
15. Disconnect the camshaft position (CMP)
19. Disconnect the crankshaft position (CKP) sensor
electrical connector and detach the 2 wiring
16. Disconnect the oil pressure sensor electrical
retainers.
connector and detach the wiring retainer.
17. Remove the bolt and the belt tensioner.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
20. Disconnect the engine coolant temperature
(ECT) sensor electrical connector.
24. Remove the 3 bolts, detach the wiring retainers
and remove the main engine wiring harness.
21. Disconnect the PCV valve electrical connector.
25. Remove the 4 bolts and then remove the fuel
rail and injectors.
22. Disconnect the 3 LH fuel injector electrical
connectors and detach the wiring retainer from
the valve cover stud bolt.
23. Disconnect the 3 RH fuel injector electrical
connectors and detach the wiring retainer from
the valve cover stud bolt.
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303-01A-6 303-01A-6 Engine 4.0L SOHC
26. Remove the bolt and the KS.
30. Remove the 2 bolts, the 4 stud bolts and the
RH valve cover.
27. Remove the bolt and then disconnect the
coolant bypass hose and the heater hose from
the coolant pump.
31. Remove the bolt and the oil level indicator
tube.
Discard the oil level indicator tube O-ring
28. Remove the 3 bolts and then remove the
seal.
thermostat housing, hoses and coolant tube.
LH valve cover.
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303-01A-7 303-01A-7 Engine 4.0L SOHC
32. Remove the 6 nuts and the LH exhaust 35. Remove the 4 bolts and the RH engine mount
manifold. bracket.
Remove and discard the LH exhaust
manifold gasket.
36. Rotate the crankshaft until the cam lobe is in
the up position.
33. Remove the 3 bolts and the LH engine mount
bracket.
37. NOTE: Mark each camshaft roller follower to
make sure it is installed in its original position
during reassembly.
34. Remove the 6 nuts and the RH exhaust
manifold. Using the special tool, remove the camshaft
roller followers.
Remove and discard the RH exhaust
manifold gasket.
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303-01A-8 303-01A-8 Engine 4.0L SOHC
38. Remove the RH hydraulic chain tensioner.
42. CAUTION: Remove the camshaft
sprocket from the timing chain to gain
39. Install the special tools on the RH cylinder head
clearance to remove the cylinder head.
and tighten the top 2 clamp bolts to 10 Nm (89
NOTE: Hold the timing chain and cassette with
lb-in).
a rubber band to aid in removal and to prevent
the timing chain from falling into the cylinder
block.
Remove the RH camshaft sprocket from the
timing chain. Install a rubber band around the
cassette and the timing chain.
40. CAUTION: The RH camshaft sprocket
bolt is a LH-threaded bolt.
Remove the RH camshaft sprocket bolt.
43. Remove the LH hydraulic chain tensioner.
41. Remove the RH cassette bolt.
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303-01A-9 303-01A-9 Engine 4.0L SOHC
44. Install the special tools on the LH cylinder head
and tighten the top 2 clamp bolts to 10 Nm (89
lb-in).
block.
Remove the LH camshaft sprocket from the
45. Remove the LH camshaft sprocket bolt.
48. NOTE: New cylinder head bolts must be
installed. They are a torque-to-yield design and
cannot be reused.
Remove the bolts in the sequence shown and
remove the cylinder heads.
Discard the gaskets and the bolts.
46. Remove the LH cassette bolt.
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303-01A-10 303-01A-10 Engine 4.0L SOHC
49. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces.
These tools cause scratches and gouges that
make leak paths. Use a plastic scraping tool
to remove all traces of the head gasket.
Clean and inspect the sealing surfaces. For
50. Remove the 2 bolts and the CKP.
53. Using the special tool, remove the crankshaft
front oil seal.
51. Using the special tool to hold the crankshaft
pulley, remove the bolt and washer.
54. Remove the 5 cylinder block cradle-to-engine
front cover bolts.
pulley.
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303-01A-11 303-01A-11 Engine 4.0L SOHC
engine front cover.
59. NOTE: Note the location of the 2
silver-colored bolts with the washer seals. These
bolts must be installed in the same position
56. Remove and discard the engine oil filter.
from which they were removed with new
washer seals.
Remove the cylinder block cradle inner bolts.
Remove and discard the 2 washer seals.
57. Remove the bolts and the oil pan.
60. Remove the 2 cylinder block cradle Torx
bolts.
58. Remove the bolt and the oil pump screen cover
and tube.
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303-01A-12 303-01A-12 Engine 4.0L SOHC
61. Remove the 15 bolts and the 2 nuts. Remove 63. Remove the oil filter adapter.
the cylinder block cradle.
64. Remove the rear jackshaft plug.
62. Remove the 2 bolts, the oil pump pickup tube
and the oil pump intermediate shaft.
65. Using the special tool, hold the crankshaft.
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303-01A-13 303-01A-13 Engine 4.0L SOHC
66. Remove the rear jackshaft sprocket-retaining
bolt and the spacer.
70. Using the special tool, loosen the front sprocket
retaining bolt.
67. Remove the RH cassette bolt.
71. Remove the bolts and the chain tensioner.
68. Remove the RH cassette.
69. Remove the oil pump bolt and retainer and then
remove the oil pump drive.
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303-01A-14 303-01A-14 Engine 4.0L SOHC
72. Remove the chain guide. 75. Remove the LH cassette bolt.
73. Remove the bolt. 76. Remove the LH cassette.
74. Remove the jackshaft sprocket and chain. 77. Remove the jackshaft thrust plate.
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303-01A-15 303-01A-15 Engine 4.0L SOHC
78. Remove the jackshaft.
82. If equipped, remove the balance shaft.
1 Remove the 2 bolts.
79. If equipped, remove the balance shaft
2 Remove the balance shaft.
tensioner.
1 Install a pin in the balance shaft tensioner.
2 Remove the 2 bolts.
3 Remove the balance shaft tensioner.
83. Before removing the pistons, inspect the top of
the cylinder bores. If necessary, remove the
ridge or carbon deposits from each cylinder
using an abrasive pad or equivalent, following
the manufacturers instructions.
80. If equipped, remove the 2 bolts and the balance
shaft chain guide.
81. NOTE: DO NOT remove the balance shaft
sprocket bolt.
If equipped, remove the balance shaft chain and
crankshaft sprocket.
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303-01A-16 303-01A-16 Engine 4.0L SOHC
84. NOTE: Clearly mark the connecting rods and
rod caps in numerical order for correct
reassembly.
Remove the connecting rod caps.
1 Remove the connecting rod nuts.
2 Remove the connecting rod caps.
88. Clean and inspect the pistons. For additional
89. CAUTION: Remove the cylinder heads
before removing the crankshaft. Failure to
do so can result in engine damage.
NOTE: Number (or mark) the crankshaft
bearing caps before removing them.
85. Install rubber hose pieces on the bolts to protect
Remove the bolts and the crankshaft main
the crankshaft and remove the pistons.
bearing caps.
86. Remove the connecting rod bearings.
90. Remove the crankshaft rear oil seal from the
crankshaft.
87. Remove the piston rings.
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303-01A-17 303-01A-17 Engine 4.0L SOHC
91. Remove the crankshaft. 92. Remove the crankshaft main bearings and the
thrust bearing.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
OF SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-581 (T97T-6565-A)
Installer, Valve Stem Oil Seal
303-370 (T90T-6571-A)
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
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303-01A-2 303-01A-2 Engine 4.0L SOHC
Disassembly
1 12405 Spark plugs (3 required)
1. Remove the spark plugs.
2 6529 Camshaft roller follower
3 6C501 Hydraulic lash adjuster (6
2. NOTE: Mark each hydraulic lash adjuster to
required)
make sure it is installed in its original position.
4 6518 Valve spring retainer key (12
Remove the hydraulic lash adjusters.
required)
5 6A536 Valve spring retainer (6
required)
6 6513 Valve spring (6 required)
7 6571 Valve seal (6 required)
8 6505 Exhaust valve (3 required)
9 6507 Intake valve (3 required)
10 W702341 Camshaft bearing cap
mounting bolt (8 required)
11 6578 Oil supply tube
12 6A528 Camshaft bearing cap (4
required)
13 6A258 LH camshaft
14 6050 LH cylinder head
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303-01A-3 303-01A-3 Engine 4.0L SOHC
3. NOTE: Keep the valves, valve springs, 6. Remove the camshaft.
retainers and retainer keys in order so they can
Assembly
be installed in their original positions.
Using the special tool, remove the valve spring
NOTE: Lubricate all parts with clean engine oil
retainer keys, the valve spring and the retainer.
prior to assembly.
Remove the valve.
NOTE: Install the camshaft roller followers only
Repeat the procedure until all of the valves
after the cylinder head is installed in the vehicle and
are removed.
the timing procedure has been carried out.
1. Inspect the cylinder head. For additional
2. Position the camshaft.
3. NOTE: The camshaft bearing caps must be
installed in their original positions.
NOTE: After installing the bolts, check the
camshaft for free rotation.
Position the camshaft bearing caps, the oil
supply tube and the bolts. Tighten the bolts in
the sequence shown in 2 stages.
4. Remove and discard the valve seals.
Stage 1: Tighten to 6 Nm (53 lb-in).
5. NOTE: Mark the position of the camshaft
Stage 2: Tighten to 16 Nm (12 lb-ft).
bearing caps so they can be installed in their
original positions.
remove the oil supply tube and the camshaft
bearing caps.
4. NOTE: Valves must be installed in the position
from which they were removed.
Install the valve.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
5. Using the special tool, install new valve stem
seals.
7. NOTE: Install the hydraulic lash adjusters in
the same positions from which they were
removed.
6. NOTE: The valve springs, retainers and
Install the hydraulic lash adjusters.
retainer keys must be installed in the position
from which they were removed.
Using the special tool, install the valve spring,
the retainer and the retainer keys.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
OF SUBASSEMBLIES
Material
Piston
Item Specification
Special Tool(s) Motorcraft SAE 5W-30 WSS-M2C929-A
Service Set, Piston Pin
Motor Oil
303-S024 (T68P-6135-A)
XO-5W30-QSP (US);
CXO-5W30-LSP12
Disassembly
1 6150 Piston compression upper ring
NOTE: The connecting rod bolts and nuts cannot
2 6152 Piston compression lower ring
be reused.
3 6159 Piston oil control upper
segment ring
NOTE: Mark the position of the parts, so they can
4 6161 Piston oil control spacer be installed in their original positions.
5 6159 Piston oil control lower
segment ring 1. Remove the connecting rod bearings from the
connecting rod and cap.
6 6135 Piston pin
7 6200 Connecting rod
2. Remove the piston rings from the piston.
8 6110 Piston
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303-01A-2 303-01A-2 Engine 4.0L SOHC
3. Using the special tool, press the piston pin out
of the connecting rod and piston assembly.
3. Install the piston rings.
4. Make sure the ring gaps (oil spacer-A, oil
Assembly
ring-B, compression ring-C) are correctly
spaced around the circumference of the piston.
NOTE: Lubricate all parts with clean engine oil.
NOTE: Install the piston in the connecting rod with
the cylinder number side of the rod and the
indentation notch in the piston on the same side.
NOTE: The oil hole in the connecting rod must
face the RH side of the cylinder block and the
arrow on the piston must face the front of the
engine block.
1. NOTE: If the piston pin is removed from the
piston, a new piston and piston pin must be
used. Do not reuse the piston or the piston pin.
Gradually heat the pin bore side of the
5. Install the connecting rod bearings in the
connecting rod to approximately 232C-316C
connecting rod and cap.
(467F-626F) and immediately install the
piston pin.
2. Using the special tool, press the piston pin into
the piston and connecting rod assembly.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
GENERAL PROCEDURES
Special Tool(s)
Camshaft Timing
303-577 (T97T-6303-C)
Special Tool(s)
Sprocket
303-564 (T97T-6256-B)
Adapter for 303-564
303-578 (T97T-6256-C)
Tensioner, Timing Chain
303-571 (T97T-6K254-A)
Material
Item Specification
Timing Tool, Crankshaft TDC
303-573 (T97T-6303-A)
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
Extension, Torque Wrench
303-575 (T97T-6256-F)
1. Remove the camshaft roller followers. For
additional information, refer to Camshaft Roller
Follower in this section.
2. Remove the generator. For additional
Adapter for 303-577
303-576 (T97T-6256-D)
3. Remove the engine coolant temperature (ECT)
sensor. For additional information, refer to
Section 303-14.
4. NOTE: The LH and RH camshafts must be
retimed when either camshaft is disturbed.
Socket, Camshaft Sprocket Nut
Turn the crankshaft clockwise to position the
303-565 (T97T-6256-G) or
No. 1 cylinder at top dead center (TDC).
equivalent
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
5. CAUTION: Do not rotate the engine
counterclockwise. Rotating the engine
counterclockwise will result in incorrect
timing of the engine.
NOTE: The special tool must be installed on
the damper and should contact the engine
block, this positions the engine at TDC.
Install the special tool.
8. Loosen the top 2 special tool clamp bolts.
6. Install the special tools to the RH cylinder head
and tighten the 2 top clamp bolts.
9. NOTE: The camshaft timing slots are
off-center.
Position the camshaft timing slots below the
centerline of the camshaft to correctly fit the
special tools and install the special tools on the
front of the RH cylinder head.
Using the special tool with the Camshaft
Sprocket Nut Socket 303-565, loosen the RH
camshaft sprocket bolt.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
10. Remove the RH camshaft tensioner. 13. Remove the special tool.
11. Install the special tool. 14. NOTE: Install a new O-ring seal on the
tensioner and lubricate with clean engine oil.
Install the RH camshaft tensioner.
Tighten the bolts.
15. Remove the special tools from the RH cylinder
1 Tighten the special tool top 2 clamp bolts to
head.
10 Nm (89 lb-in).
2 Using the special tool with the Camshaft
16. Install the special tools on the front of the LH
Sprocket Nut Socket 303-565, tighten the
cylinder head and tighten the top 2 clamp bolts.
camshaft bolt.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
17. Loosen the LH camshaft sprocket bolt. 20. Remove the LH camshaft tensioner.
18. Loosen the top 2 clamp bolts on the special 21. Install the special tool.
tool to allow the camshaft sprocket to rotate
freely.
22. Tighten the bolts.
10 Nm (89 lb-in).
off-center.
2 Tighten the LH camshaft bolt to 85 Nm (63
lb-ft).
special tools, and install the special tools on the
rear of the LH cylinder head.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
23. Remove the special tool.
25. Remove the special tools from the LH cylinder
head.
24. NOTE: Install a new O-ring seal on the
tensioner and lubricate with clean engine oil. 26. Install the engine coolant temperature (ECT)
Install the LH camshaft tensioner.
Section 303-14.
27. Install the generator. For additional information,
28. Install the camshaft roller followers. For
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303-01A-1 303-01A-1 Engine 4.0L SOHC
INSTALLATION
Engine
Special Tool(s)
303-050 (D70P-6000) or
equivalent
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
3. Install the LH engine mount nut.
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
Installation
4. Attach the ground cable to the RH strut tower
and install the bolt.
All vehicles
1. Using the special tools, position the engine in
the vehicle.
2. Install the RH engine mount nut.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
INSTALLATION (Continued)
5. Attach the battery cable harness pin-type
retainer to the cowl.
8. Install the power distribution box cover.
9. Attach the 3 wiring harness retainers.
6. Connect the 68-pin connector to the power
distribution box and tighten the bolt.
Attach the power distribution box upper
housing to the lower housing.
10. Connect the 16-pin electrical connector and
attach the 2 wiring retainers.
7. Attach the B+ terminal to the power distribution
box and install the bolt.
Attach the pin-type retainer from the strut
tower.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
11. Connect the upper and lower powertrain control
module (PCM) electrical connectors.
15. Position the ignition coil and spark plug wires
and install the 2 bolts.
Tighten the M8 bolt to 9 Nm (80 lb-in).
12. Connect the fuel vapor vent tube to the intake
Tighten the M12 bolt to 23 Nm (17 lb-ft).
manifold.
16. Install the 2 upper ignition coil bracket bolts.
13. Connect the brake booster vacuum hose to the
upper intake manifold. Tighten to 9 Nm (80 lb-in).
14. Attach the crankcase vent tube to the LH valve
cover.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
17. Connect the ignition coil electrical connector. 20. NOTE: Apply a light film of silicone brake
caliper grease and dielectric compound to the
inside of the spark plug wire boots before
installation.
Connect the 6 spark plug wires to the spark
plugs.
Attach the retainers to the valve cover stud
bolts and the ignition coil bracket.
18. Connect the radio ignition interference capacitor
21. Install the 2 coolant tube bracket bolts.
19. Attach the spark plug wire retainer to the intake
manifold.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
22. Connect the 2 heater hoses to the coolant tube. 25. Position the power steering pump pulley and
install the 3 bolts.
23. Position the front engine accessory drive
(FEAD) bracket and A/C compressor. Install the
3 bolts and the nut.
26. Rotate the accessory drive belt tensioner
Tighten to 48 Nm (35 lb-ft). counterclockwise and install the accessory drive
belt.
24. Position the power steering pump and install the
3 bolts. 27. Connect the fuel supply tube coupling. For
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303-01A-6 303-01A-6 Engine 4.0L SOHC
28. Attach the 2 wiring retainers to the FEAD
bracket.
32. Position the power steering pressure tube
bracket on the A/C compressor and install the
nut.
29. Connect the A/C compressor and A/C high
pressure switch electrical connectors.
33. Connect the lower radiator hose to the coolant
30. Connect the power steering pressure (PSP)
pump.
switch electrical connector.
31. Attach the power steering supply hose bracket
to the FEAD bracket and install the bolt.
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303-01A-7 303-01A-7 Engine 4.0L SOHC
34. Connect the upper radiator hose to the
thermostat housing.
39. Connect the 2 heated oxygen sensor (HO2S)
and the 2 catalyst monitor sensor electrical
connectors.
35. Position the ground strap and install the stud
bolt.
40. NOTE: Use the index marks made during the
removal procedure for correct hood alignment.
Position the hood and install the 4 bolts.
Vehicles with manual transmission
36. Install the clutch. For additional information,
41. Connect the windshield washer hose and
position the hood insulation.
Vehicles with automatic transmission
37. Install the transmission. For additional
All vehicles
38. NOTE: LH side shown, RH side similar.
Install the 4 catalytic converter-to-exhaust
manifold nuts.
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303-01A-8 303-01A-8 Engine 4.0L SOHC
42. Install the 1 hood insulation pin-type retainer 43. Install the air cleaner and air cleaner outlet
and attach the 2 windshield washer hose pipe. For additional information, refer to
retainers. Section 303-12.
44. Fill the engine with clean engine oil.
45. Connect the battery ground and positive cables.
414-01.
46. Fill and bleed the cooling system. For
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Camshaft Roller Follower
Special Tool(s)
303-581 (T97T-6565-A)
Material
Item Specification
roller followers so they can be installed in their Motorcraft SAE 5W-30 WSS-M2C929-A
Premium Synthetic Blend original positions.
Motor Oil
Using the special tool, remove the camshaft
XO-5W30-QSP (US);
roller followers.
CXO-5W30-LSP12
1. Remove the fuel rail. For additional
2. Remove the LH and RH valve covers. For
additional information, refer to Valve Cover
RH and Valve Cover LH in this section.
3. Rotate the crankshaft until the camshaft for the
cylinder being serviced is at base circle.
5. NOTE: The camshaft roller followers must be
NOTE: Lubricate the camshaft roller followers
with clean engine oil.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Removal
Camshafts
Both sides
Special Tool(s)
Sprocket
303-564 (T97T-6256-B) or
equivalent Follower in this section.
2. NOTE: The RH and LH camshaft timing
procedure must be carried out when either
camshaft is serviced.
Adapter for 303-564
Rotate the crankshaft clockwise to position the
303-578 (T97T-6256-A) or
equivalent No. 1 cylinder at TDC.
303-573 (T97T-6303-A) or
equivalent
block. This positions the piston at TDC.
Extension, Torque Wrench
303-575 (T97T-6256-F) or
equivalent
303-565 (T97T-6256-G)
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
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303-01A-2 303-01A-2 Engine 4.0L SOHC
RH side
4. Install the special tools on the rear of the RH
cylinder head and tighten the top 2 clamp bolts
to 10 Nm (89 lb-in).
LH side
7. Install the special tools on the front of the LH
camshaft and tighten the 2 top clamp bolts to
10 Nm (89 lb-in).
is a LH-threaded bolt.
Using the special tool and the Camshaft
Sprocket Nut Socket, loosen the camshaft
sprocket bolt.
8. Loosen the bolt.
6. Remove the bolt and position the RH camshaft
sprocket aside.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
9. Remove the bolt and position the LH camshaft 2. NOTE: Lubricate the camshaft bearing caps
sprocket aside. with clean engine oil.
NOTE: The camshaft bearing caps must be
NOTE: After installing the bolts, check the
camshaft for free rotation.
Position the oil supply tube, the camshaft
bearing caps and the bolts.
Tighten the bolts in the sequence shown in
2 stages.
X Stage 1: Tighten to 6 Nm (53 lb-in).
X Stage 2: Tighten to 16 Nm (12 lb-ft).
Both sides
bearing caps so they can be installed in their
original positions.
remove the camshaft bearing caps and the oil
supply tube.
RH side
3. CAUTION: The camshaft gear must
turn freely on the camshaft. DO NOT tighten
the bolt at this time.
Install the RH camshaft sprocket and loosely
install the bolt.
11. Remove the camshaft.
Installation
Both sides
1. NOTE: Lubricate the camshafts with clean
engine oil.
Install the camshaft.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
LH side Both sides
5. Retime the camshafts. For additional
information, refer to Camshaft Timing in this
section.
Install the LH camshaft sprocket and loosely
install the bolt.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Crankshaft Front Seal
crankshaft front seal.
Special Tool(s)
Remover, Crankshaft Front Oil
Seal
303-107 (T74P-6700-A)
Aligner, Front Cover
303-093 (T74P-6019-A)
Installation
1. NOTE: Lubricate the new front seal with clean Installer, Crankshaft Vibration
Damper engine oil.
303-102 (T74P-6316-B)
Using the special tools, install a new crankshaft
front seal.
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
Removal
2. Install the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this
1. Remove the crankshaft pulley. For additional section.
section.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Crankshaft Pulley
Special Tool(s)
Damper
303-101 (T74P-3616-A)
Damper
303-773
5. Using the special tools and two 8-mm bolts,
remove the crankshaft pulley.
Discard the crankshaft pulley bolt.
Installer, Crankshaft Vibration
Damper
303-102 (T74P-6316-B)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Installation
1. Using the special tool, install the crankshaft
Removal
pulley.
Section 100-02.
3. Remove the accessory drive belt. For additional
4. NOTE: This bolt is torque-to-yield and cannot
be reused.
Using the special tool to hold the crankshaft
pulley, remove the bolt.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. Using the special tool to hold the crankshaft 3. Install the accessory drive belt. For additional
pulley, install a new crankshaft pulley bolt. information, refer to Section 303-05.
Tighten the bolt in 2 stages.
Stage 2: Tighten an additional 85 degrees.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
3. NOTE: The crankshaft rear seal may have a
Crankshaft Rear Seal
metal speedy sleeve. This sleeve must be
removed before attempting to remove the seal.
Special Tool(s)
If necessary, remove the speedy sleeve using 2
Remover, Oil Seal
screwdrivers or small pry bars.
303-409 (T92C-6700-CH)
Service Set, Crankshaft Rear Oil
Seal
303-S524 (T95T-6701-AR)
Installer, Crankshaft Rear Oil
Seal
4. CAUTION: Avoid scratching or
303-579 (T97T-6701-A)
damaging the crankshaft rear seal running
surface during removal of the crankshaft
rear seal.
Using the special tool, remove the crankshaft
rear seal.
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
Motorcraft Metal Surface
Prep
ZC-31
Removal
Installation
1. Remove the flexplate or flywheel. For
1. NOTE: Be sure the crankshaft rear sealing
additional information, refer to Flexplate or
surface is clean and free from any rust or
Flywheel in this section.
corrosion. To clean the crankshaft rear seal
surface area, use extra-fine emery cloth or
2. Remove the spacer plate.
extra-fine 0000 steel wool with metal surface
prep.
Lubricate the crankshaft rear oil seal with clean
engine oil.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. Install the special tools. 4. Using the special tool, install the crankshaft
rear seal.
3. Position the crankshaft rear seal.
5. Install the flexplate-to-crankshaft spacer.
6. Install the spacer plate.
7. Install the flexplate or flywheel. For additional
information, refer to Flexplate or Flywheel in
this section.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Cylinder Block Cradle
Special Tool(s)
303-050 (D70P-6000) or
equivalent
3-Bar Engine Support Kit
303-F072
5. Remove the 6 pin-type retainers and the
radiator sight shield.
Material
Item Specification
Silicone Gasket Remover
ZC-30
Prep
ZC-31
Sealant
TA-30
6. Install the special tools.
Removal
Section 100-02.
7. Remove the RH engine mount nut.
3. Remove the throttle body (TB). For additional
9. Remove the oil pump screen and pickup tube.
4. Remove the front end accessory drive (FEAD)
For additional information, refer to Oil Pump
bracket bolt and install the special tool.
Screen and Pickup Tube in this section.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
16. Using the special tools, raise the engine and
then remove the lower block cradle.
wheel to rotate while the steering column
intermediate shaft is disconnected or damage
to the clockspring can result. If there is
evidence that the wheel has rotated, the
clockspring must be removed and recentered.
501-20B.
Remove the bolt and detach the steering column
intermediate shaft from the steering gear.
11. Remove the 2 steering gear-to-crossmember
bolts and detach the gear from the
crossmember.
12. Remove the 2 bolts and position the starter
Installation
motor aside.
1. CAUTION: Failure to back off the set
13. NOTE: The cylinder block cradle is shown
screws can result in damage to the cylinder
removed for clarity. Note the location of the 2
block cradle.
Torx head bolts at the rear of the cylinder
block cradle.
Back the set screws off until they are below the
cylinder block cradle boss.
Remove the 2 cylinder block cradle rear Torx
bolts.
14. Remove the 20 bolts and 2 nuts along the
outside of the cylinder block cradle.
15. NOTE: Note the location of the 2
silver-colored bolts that have washer seals.
They must be installed in the same position
with new washer seals.
Remove the 8 cylinder block cradle inner bolts
and the 2 washer seals.
Discard the washer seals.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
These tools cause scratches and gouges which
to remove all traces of old sealant.
NOTE: Gasket material as well as silicone
sealant may be present in the cavities in the
main bearing cap. This material must be
removed completely prior to assembly.
Clean the gasket mating surfaces, making sure
all the sealant is removed from the cavities on
the rear main bearing cap. To clean the sealing
3. NOTE: If not secured within 4 minutes, the
area, use silicone gasket remover and metal
sealant must be removed and the sealing area
surface prep. Follow the directions on the
cleaned. To clean the sealing area, use silicone
packaging.
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to
follow this procedure can cause future oil
leakage.
Apply silicone in the 6 places shown.
4. Position a new gasket and the cylinder block 5. Install the outer 20 bolts and 2 nuts finger tight.
cradle. Install the outer bolts and nuts finger
tight.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
6. Install the 2 cylinder block cradle rear Torx
bolts finger tight.
12. Install the 6 remaining inner bolts finger tight.
13. Tighten the 8 inner bolts in the sequence shown
7. Install the 2 bell housing-to-cylinder block in 2 stages.
cradle bolts.
8. Tighten the outer 20 bolts and 2 nuts.
Tighten the bolts with washers and both
nuts to 10 Nm (89 lb-in).
Tighten the bolts without washers to 14 Nm
(10 lb-ft).
9. Tighten the 2 cylinder block cradle rear Torx
bolts.
10. Tighten the 8 inserts.
14. Position the starter motor and install the 2 bolts.
15. Position the steering gear and install the 2 bolts.
11. Install the 2 silver-colored bolts and new 501-20B.
washer seals finger tight.
Attach the steering column intermediate shaft to
the steering gear and install the bolt.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
17. Install the oil pump screen and pickup tube. For
additional information, refer to Oil Pump
Screen and Pickup Tube in this section.
18. Lower the engine and install the LH engine
mount nut.
19. Install the RH engine mount nut.
20. Remove the engine lifting bracket and install
the FEAD bracket bolt.
22. Install the throttle body (TB). For additional
21. Position the radiator sight shield and install the
23. Connect the battery ground cable. For additional
6 pin-type retainers.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Special Tool(s)
Cylinder Head
303-573 (T97T-6303-A) or
Special Tool(s)
equivalent
Torque Wrench Extension
303-575 (T97T-6256-F) or
equivalent
Adapter for 303-577
303-576 (T97T-6256-D) or
equivalent
303-565 (T97T-6256-G) or
equivalent
Remover, Spark Plug Wire
303-106 (T74P-6666A)
Sprocket
303-564 (T97T-6256-B) or
equivalent
Material
Item Specification
Adapter for 303-564
303-578 (T97T-6256-A) or
equivalent
Compound
XG-3-A
Motor Oil
XO-5W30-QSP (US);
303-571 (T97T-6K254-A) or
equivalent
CXO-5W30-LSP12
303-577 (T97T-6256-C) or
equivalent
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
5 6065 RH cylinder head bolt (M8) 1 6065 LH cylinder head bolt (M8)
6 6065 RH cylinder head bolt (M12) 2 6065 LH cylinder head bolt (M12)
7 6049 RH cylinder head 3 6M099 LH cylinder head
8 6051 RH cylinder head gasket 4 6083 LH cylinder head gasket
(Continued)
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303-01A-3 303-01A-3 Engine 4.0L SOHC
RH side
Removal
8. Remove the 2 coolant tube bracket bolts. CAUTION: During engine repair
Both sides
Section 100-02.
2. Drain the engine cooling system. For additional
9. Disconnect the generator electrical connector,
remove the nut and detach the B+ terminal.
3. Release the fuel system pressure. For additional
Detach the pin-type retainer.
4. Remove the engine coolant temperature (ECT)
Section 303-14.
5. Remove the intake manifold. For additional
information, refer to Intake Manifold in this
section.
6. Remove the hydraulic lash adjusters. For
additional information, refer to Hydraulic Lash
Adjuster in this section.
counterclockwise and remove the accessory
10. Remove the bolt and the accessory drive belt
drive belt.
tensioner.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
11. Remove the nut, the 2 bolts and the generator
mounting bracket assembly.
15. Remove the 3 bolts and the thermostat housing.
12. Disconnect the heater hose from the thermostat
housing.
LH side
tube.
13. Disconnect the upper radiator hose.
14. Position the coolant bypass hose clamp aside.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
17. Remove the stud bolt and detach the ground 20. Remove the 3 bolts and the power steering
strap. pump pulley.
Position the ground strap aside.
21. Remove the 3 bolts and position the power
steering pump aside.
18. Remove the bolt and detach the power steering
supply hose bracket from the front engine
accessory drive (FEAD) bracket.
22. Remove the 3 bolts, the nut and position the
FEAD bracket and A/C compressor aside.
pressure (PSP) tube bracket from the
crossmember.
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303-01A-6 303-01A-6 Engine 4.0L SOHC
23. Remove the bolt and detach the starter motor
wiring retainer bracket.
26. Remove the 4 bolts and the fuel rail and
injectors.
24. Remove the ground strap bolt and detach the
wiring harness retainer from the backside of the
cylinder head.
27. Separate the 6 fuel injectors from the fuel rail
and discard the O-ring seals.
Both sides
Remove the 4 catalytic converter-to-manifold
nuts.
25. CAUTION: It is important to twist the
spark plug wire boots while pulling upward
to avoid possible damage to the spark plug
wires.
Using the special tool, disconnect the 6 spark
plug wires from the spark plugs.
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303-01A-7 303-01A-7 Engine 4.0L SOHC
Remove the 12 nuts and the exhaust manifolds
and gaskets.
Sprocket Nut Socket 303-565, remove the RH
Discard the gaskets.
camshaft bolt.
RH side
33. Remove the RH side cassette bolt.
30. Remove the RH side hydraulic chain tensioner.
Tighten the top clamp bolts to 10 Nm (89
lb-in).
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303-01A-8 303-01A-8 Engine 4.0L SOHC
block.
Remove the RH camshaft sprocket from the
37. Remove the LH side camshaft sprocket bolt.
LH side
35. Remove the LH side hydraulic chain tensioner.
38. Remove the LH side cassette bolt.
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303-01A-9 303-01A-9 Engine 4.0L SOHC
block.
Remove the LH camshaft sprocket from the
Clean and inspect the mating surfaces.
42. Inspect the cylinder head and the cylinder block
for flatness. For additional information, refer to
Section 303-00.
Both sides
Installation
40. CAUTION: To avoid damage to the Both sides
timing chain cassette, an assistant will be
required to help lift the cylinder head from
1. Position the cylinder head gaskets on the block.
the vehicle.
CAUTION: On the RH side, when
lifting the cylinder head, be careful to avoid
contacting the A/C tube.
NOTE: New cylinder head bolts must be
cannot be reused.
Remove the cylinder heads.
Remove the cylinder head bolts in the
sequence shown. Discard all the bolts.
Remove and discard the head gaskets.
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303-01A-10 303-01A-10 Engine 4.0L SOHC
RH side
2. CAUTION: To avoid damage to the
required to help position the cylinder head in
the vehicle.
cannot be reused.
Position the RH cylinder head. Install 8 new
M12 bolts and tighten in the sequence shown in
2 stages.
CAUTION: The right-hand camshaft
sprocket bolt is a left-hand threaded bolt.
Remove the rubber band, position the camshaft
sprocket and chain. Loosely install the bolt.
3. Install 2 new M8 bolts.
6. Install the RH side cassette bolt.
4. Tighten the 8 M12 bolts in the sequence shown
in 2 stages.
Stage 1: Tighten 90 degrees.
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303-01A-11 303-01A-11 Engine 4.0L SOHC
LH side
the vehicle.
cannot be reused.
Position the LH cylinder head. Install 8 new
2 stages.
Remove the rubber band, position the camshaft
sprocket and chain. Loosely install the bolt.
11. Install the LH side cassette bolt.
in 2 stages.
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303-01A-12 303-01A-12 Engine 4.0L SOHC
Both sides
Position new gaskets and the exhaust manifolds.
Install the 12 nuts.
15. NOTE: Lubricate the new O-ring seals with
clean engine oil.
Install the 6 fuel injectors.
Install new O-ring seals on the injectors.
Install the injectors.
16. Position the fuel rail and injectors and install
13. NOTE: Apply dielectric compound to the
the 4 bolts.
inside of the spark plug wire boots.
plugs.
Install the 4 catalytic converter-to-exhaust
manifold nuts.
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303-01A-13 303-01A-13 Engine 4.0L SOHC
block, this positions the engine at TDC.
21. Tighten the top clamp bolts to 10 Nm (89
lb-in).
19. NOTE: Leave the top 2 special tool clamp
bolts loose.
Install the special tools on the rear of the RH
cylinder head.
off-center.
front of the RH cylinder head.
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303-01A-14 303-01A-14 Engine 4.0L SOHC
off-center.
Sprocket Nut Socket 303-565, tighten the
camshaft bolt to 85 Nm (63 lb-ft).
24. Install the RH camshaft tensioner.
bolts loose.
Install the special tools on the front of the LH
cylinder head.
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303-01A-15 303-01A-15 Engine 4.0L SOHC
28. Tighten the bolts.
10 Nm (89 lb-in).
2 Tighten the camshaft bolt to 85 Nm (63
lb-ft).
31. Position the starter motor wiring retainer
bracket and install the bolt.
29. Install the LH camshaft tensioner.
32. Position the front engine accessory drive
(FEAD) bracket and A/C compressor. Install the
3 bolts and the nut.
LH side
30. Position the ground strap and install the bolt.
Attach the wiring harness retainer to the
backside of the cylinder head.
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303-01A-16 303-01A-16 Engine 4.0L SOHC
33. Position the power steering pump and install the 36. Attach the power steering supply hose bracket
3 bolts. to the FEAD bracket and install the bolt.
34. Position the power steering pump pulley and 37. Position the ground strap and install the stud
install the 3 bolts. bolt.
Tighten to 25 Nm (18 lb-ft). Tighten to 10 Nm (89 lb-in).
35. Attach PSP tube bracket to the crossmember 38. Install the oil level indicator tube and bolt.
and install the bolt.
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303-01A-17 303-01A-17 Engine 4.0L SOHC
RH side
42. Connect the heater hose to the thermostat
housing.
39. NOTE: Inspect the O-ring seal. Install a new
O-ring seal if necessary.
Position the thermostat housing and install the 3
bolts.
43. Position the generator mounting bracket
assembly and install the 2 bolts and the nut.
40. Position the coolant bypass hose clamp.
44. Install the accessory drive belt tensioner and
bolt.
41. Install the upper radiator hose.
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303-01A-18 303-01A-18 Engine 4.0L SOHC
Both sides
45. Connect the generator electrical connector.
Position the B+ terminal and install the nut.
counterclockwise and install the accessory drive
Attach the pin-type retainer.
belt.
46. Install the 2 coolant tube bracket bolts.
48. Install the hydraulic lash adjusters. For
additional information, refer to Hydraulic Lash
Adjuster in this section. Tighten the M8 bolt to 23 Nm (17 lb-ft).
49. Install the intake manifold. For additional
section.
50. Install the engine coolant temperature (ECT)
Section 303-14.
51. Fill and bleed the engine cooling system. For
303-03A.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Material
Engine Front Cover
Item Specification
Special Tool(s) Silicone Gasket and WSE-M4G323-A4
Sealant
TA-30
303-093 (T74P-6019-A)
ZC-30
Prep
ZC-31
Thread Sealant with PTFE WSK-M2G350-A2
TA-24
6 W500024 Engine front cover bolt (5 1 14A464 Crankshaft position (CKP)
required) sensor electrical connector
(part of 12B637)
7 15161 Clamp
2 Wiring retainer (part of
8 8286 Lower radiator hose
12B637)
9 E802185 Block cradle-to-engine front
3 E804541 Engine front cover stud bolt
cover bolt (5 required)
(4 required)
10 Accessory drive belt idler
4 8287 Clamp
pulley bolt (part of 6C348)
5 18C266 Coolant hose (Continued)
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
Item Part Number Description 12. CAUTION: Make sure that any
coolant that drains into the front corners of 11 6C348 Accessory drive belt idler
pulley the engine block cradle is removed.
12 15161 Clamp
Remove the oil pan drain plug and drain the
13 8620 Upper radiator hose engine oil.
14 6019 Engine front cover
Install the drain plug and tighten to 26 Nm
15 Engine front cover gasket (19 lb-ft).
Installation
Removal
1. CAUTION: Do not use metal scrapers, CAUTION: During engine repair
abrasive means to clean sealing surfaces.
make leak paths.
Clean and inspect the gasket mating surfaces.
Use silicone gasket remover and metal surface
prep and a plastic or wooden scraping tool.
Follow the directions on the packaging.
2. Drain the cooling system. For additional
2. Position a new front cover gasket.
CAUTION: If not secured within 4
3. Remove the crankshaft front oil seal. For
minutes, the sealant must be removed and the
additional information, refer to Crankshaft Front
sealing area cleaned. To clean the sealing area,
Seal in this section.
use silicone gasket remover and metal surface
prep. Follow the directions on the packaging.
4. Disconnect the upper radiator hose.
Failure to follow this procedure can cause future
oil leakage.
5. Disconnect the heater hose from the coolant
pump.
3. Apply silicone gasket and sealant to the oil pan
and engine block mating surfaces.
6. Disconnect the lower radiator hose from the
coolant pump.
idler pulley.
and detach the 2 wiring retainers.
9. Remove the 5 engine block cradle-to-engine
front cover bolts.
10. Remove the 5 bolts and the 4 stud bolts from
the engine front cover.
11. Disconnect the coolant bypass hose from the
coolant pump and remove the engine front
cover.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
4. Apply silicone gasket and sealant to the front 7. Install the 5 engine block cradle-to-engine front
cover in 2 places. cover bolts.
8. Connect the CKP sensor and attach the 2 wiring
retainers.
9. Install the accessory drive belt idler pulley and
the bolt.
10. Connect the lower radiator hose to the coolant
pump.
11. Connect the heater hose to the coolant pump.
5. NOTE: Apply thread sealant to the stud bolts
12. Connect the upper radiator hose.
and make sure that the stud bolts are installed
in their original positions.
13. Install the crankshaft front oil seal. For
Position the front cover and connect the coolant additional information, refer to Crankshaft Front
bypass hose to the thermostat housing. Seal in this section.
Loosely install the 5 bolts and the 4 stud
bolts.
6. Use the special tool to align the front cover and
tighten the bolts and stud bolts to 19 Nm (14
lb-ft).
303-03A.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Engine Lubrication Components
Exploded View
11 E822125 Cylinder block cradle nut (2 1 E802185 Oil pan bolt (10 required)
required)
2 6675 Oil pan
12 W702323 Cylinder block cradle bolt (2
3 6710-A Oil pan gasket
required)
4 W500214 Oil pump pickup tube bolt
13 6734 Washer (2 required)
5 6617 Oil pump pickup tube
14 W702323 Cylinder block cradle bolt (6
6 E804588 Cylinder block cradle bolt
required)
7 W709198-S437 Cylinder block cradle bolt
15 6F092 Cylinder block cradle
8 E802185 Bell housing-to-cylinder block
16 6710 Cylinder block cradle gasket
cradle bolt (2 required)
17 E804387 Oil pump bolt (2 required)
9 6C629 Bell housing-to-cylinder block
18 6600 Oil pump
cradle spacer (2 required)
10 E802185 Cylinder block cradle bolt (20
required)
(Continued)
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Engine Mount LH
Special Tool(s)
303-050 (D70P-6000) or
equivalent
303-F072
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303-01A-2 303-01A-2 Engine 4.0L SOHC
1 W710565 LH engine mount bracket bolt
(3 required)
2 N621943 LH engine mount
bracket-to-engine mount nut
3 6B033 LH engine mount bracket
4 W707641 LH engine mount bolt (2
required)
5 6038 LH engine mount
Section 100-02.
7. Remove the engine mount bracket-to-engine
mount nut.
8. Remove the 3 engine mount bracket nuts and
remove the bracket.
9. Remove the 2 engine mount bolts and the
engine mount.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Engine Mount RH
Special Tool(s)
303-050 (D70P-6000) or
equivalent
303-F072
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303-01A-2 303-01A-2 Engine 4.0L SOHC
1 W710565 RH engine mount bracket bolt
(3 required)
2 N621943 RH engine mount
bracket-to-engine mount nut
3 6037 RH engine mount bracket
4 W707641 RH engine mount bolt (2
required)
5 6038 RH engine mount
Section 100-02.
7. Remove the engine mount-to-engine bracket
mount nut.
8. Remove the 3 engine mount bracket nuts and
remove the bracket.
9. Remove the 2 engine mount bolts and the
engine mount.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Exhaust Manifold LH
2. Remove the 2 catalytic converter-to-exhaust
manifold nuts.
1 W701706 LH catalytic
converter-to-exhaust manifold To install, tighten to 40 Nm (30 lb-ft).
nut (2 required)
2 Exhaust gas recirculation 3. Disconnect the exhaust gas recirculation (EGR)
(EGR) system module tube
system module tube from the exhaust manifold.
fitting (part of 9E649)
3 W701706 LH exhaust manifold nut (6
required)
4. Remove the 6 nuts, the LH exhaust manifold
4 9431 LH exhaust manifold
and the gasket.
5 9448 LH exhaust manifold gasket
Remove and discard the gasket.
5. NOTE: Install a new LH exhaust manifold
gasket.
Section 100-02.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Exhaust Manifold RH
2. Remove the 2 catalytic converter-to-exhaust
manifold nuts.
1 W701706 RH catalytic
converter-to-exhaust manifold To install, tighten to 40 Nm (30 lb-ft).
nut (2 required)
2 W701706 RH exhaust manifold nut (6 3. Remove the nuts, the RH exhaust manifold and
required)
the gasket.
3 9430 RH exhaust manifold
4 9448 RH exhaust manifold gasket
Discard the gasket.
4. NOTE: Install a new RH exhaust manifold
gasket.
Section 100-02.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Flexplate
Removal
1. Remove the transmission. For additional
2. Remove the 8 bolts, the flexplate and the
flexplate-to-crankshaft spacer.
Installation
1. NOTE: Special bolts are used for flexplate
installation. Do not use standard bolts.
Position the spacer and the flexplate. Install the
8 bolts and tighten in the sequence shown in 2
stages.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Flywheel
Removal
1. Remove the clutch. For additional information,
2. Remove the 8 bolts and the flywheel.
Installation
1. NOTE: Special bolts are used for flywheel
installation. Do not use standard bolts.
Position the flywheel. Install the 8 bolts and
tighten in the sequence shown in 2 stages.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
2. NOTE: Mark the position of the hydraulic lash
adjusters so they can be installed in their
original positions.
Material
Item Specification
3. NOTE: The hydraulic lash adjusters must be
Motor Oil
XO-5W30-QSP (US); NOTE: Lubricate the hydraulic lash adjusters
CXO-5W30-LSP12
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Intake Manifold
9 Exhaust gas recirculation 1 W500214 Ignition coil bracket upper
(EGR) system module tube bolts (2 required)
fitting (part of 9E469)
2 12280 RH spark plug
10 14A464 EGR system module electrical wire-to-ignition coil connector
connector (part of 12B637) (3 required)
11 14A464 Throttle position (TP) sensor 3 12A310 Ignition coil and bracket
electrical connector (part of assembly
12B637)
4 W500041 Ignition coil bracket lower
12 14A464 TB electrical connector (part bolt (M12)
of 12B637)
13 6K817 Positive crankcase ventilation bolt (M8)
(PCV) tube
6 2C053 Brake booster vacuum hose
14 14A624 Knock sensor (KS) electrical
7 Vacuum harness fitting (part
connector (part of 12B637)
of 9E498)
15 12280 RH spark plug wire retainer
8 9G271 Vapor tube
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
4. Disconnect the RH spark plug wires from the
ignition coil.
16 9Y450 Intake manifold bolt (8
required)
5. Detach the RH spark plug wire retainer from
17 9424 Intake manifold
the intake manifold.
18 9439 Intake manifold gasket (6
required)
6. Remove the 2 ignition coil bracket upper bolts.
Removal
7. Remove the 2 ignition coil lower bolts.
Position the ignition coil and bracket
assembly aside.
8. Disconnect the exhaust gas recirculation (EGR)
system module electrical connector.
9. Disconnect the EGR system module tube from
the EGR system module.
11. Disconnect the vacuum tube from the fuel rail
pressure and temperature sensor.
12. Disconnect the vapor tube from the intake
manifold.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
13. Remove the positive crankcase ventilation 5. Connect the vapor tube to the intake manifold.
(PCV) tube.
6. Connect the vacuum tube to the fuel rail
14. Detach the knock sensor (KS) electrical pressure and temperature sensor.
connector retainer from the intake manifold.
15. Disconnect the throttle position (TP) sensor and intake manifold.
throttle body (TB) electrical connectors.
8. Connect the EGR system module tube to the
16. Remove the 8 bolts and the intake manifold. EGR system module.
Installation
9. Connect the EGR system module electrical
1. NOTE: Clean and inspect all sealing surfaces.
connector.
Inspect and install new gaskets as necessary.
10. Position the ignition coil and bracket assembly.
Position the intake manifold and install the 8
Install the 2 lower bolts.
bolts.
Tighten in the sequence shown to 10 Nm
(89 lb-in).
11. Install the 2 ignition coil bracket upper bolts.
12. Attach the RH spark plug wire retainer to the
intake manifold.
13. Connect the RH spark plug wires to the ignition
coil.
2. Connect the TP sensor and TB electrical
connectors.
3. Attach the KS electrical connector retainer to
303-03A.
4. Install the PCV tube.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Lower End Components Exploded
View, Crankshaft Pulley and
1 E800511 Crankshaft pulley bolt
2 Washer
3 6B321 Crankshaft pulley
4 6700 Crankshaft front oil seal
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303-01A-1 303-01A-1 Engine 4.0L SOHC
SPECIFICATIONS
Item Specification
Valve arrangement (front I-E-I-E-I-E
Item Specification to rear) LH
Lubricants and Sealants Valve arrangement (front E-I-E-I-E-I
to rear) RH
Premium Synthetic Blend Valve guide bore diameter 7.00-7.018 mm (0.276 in)
Valve stem diameter 6.965-6.98 mm
intake (0.274-0.275 in)
5W-30 Super Premium
Motor Oil Valve stem diameter 6.95-6.965 mm
CXO-5W30-LSP12 exhaust (0.27-0.274 in)
Valve stem-to-guide 0.020-0.053 mm
Motorcraft Premium Gold WSS-M97B51-A1 clearance intake (0.001-0.002 in)
Engine Coolant with
Valve stem-to-guide 0.035-0.068 mm
Bittering Agent (US only)
clearance exhaust (0.001-0.003 in)
VC-7-B (US); CVC-7-A
Valve head diameter 45.9-46.1 mm (Canada); or equivalent
intake (1.807-1.815 in)
(yellow color)
Valve head diameter 38.9-39.1 mm Motorcraft Metal Surface
exhaust (1.531-1.539 in)
Prep ZC-31
Valve face runout 0.03 mm (0.001 in) Silicone Gasket Remover
ZC-30
Valve face angle 45 degrees
Valve seat width 1.273-2.121 mm
Sealant TA-30
intake (0.05-0.083 in)
exhaust (0.061-0.095 in)
Compound XG-3-A
Valve seat runout 0.059 mm (0.002 in)
Valve seat angle 45 degrees
TA-25
Valve spring free length 43.1 mm (1.7 in)
TA-24
Valve spring squareness 1.5 deg
Engine
Valve spring compression 275-305 Nm at 35.9-36.7
pressure at specified mm (202.84-224.968 lb-ft
Displacement 4.0L (244 CID)
height (lbs) at 1.413-1.445 in)
Number of cylinders 6
Valve spring installed 39.86-40.86 mm
Bore 100.4 mm (3.953 in)
height (1.569-1.609 in)
Stroke 84.4 mm (3.32 in)
Valve spring installed 320 newtons (72 lb)
pressure Firing order 1-4-2-5-3-6
Roller follower ratio 1.98:1
Oil pressure minimum at 103 kPa (15 psi)
2,000 rpm (engine at
Camshaft
normal operating
Theoretical valve lift @ 0 11.93 mm (0.472 in)
temperature)
lash
Oil capacity 4.73 liters (5 quarts) with
Lobe lift 6.584 mm (0.259 in)
filter
Allowable lobe lift loss 0.127 mm (0.005 in)
Cylinder Head and Valve Train
Journal diameter 27.935-27.96 mm
Cylinder head gasket 0.08 mm (0.003 in) total
(1.099-1.101 in)
surface flatness
Camshaft journal bore 28.0-28.03 mm
Combustion chamber 65.197 2.068-2.018 cc
inside diameter (1.102-1.104 in)
volume
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303-01A-2 303-01A-2 Engine 4.0L SOHC
General Specifications (Continued) General Specifications (Continued)
Item Specification Item Specification
Camshaft 0.04-0.095 mm Piston diameter coded 101.350-101.370 mm
journal-to-bearing (0.002-0.004 in) 1.0 (3.990-3.991 in)
clearance
Piston-to-cylinder bore 0.030-0.050 mm
Runout 0.05 mm (0.002 in) clearance (0.0012-0.002 in)
End play 0.075-0.185 mm Piston ring end gap top 0.200-0.450 mm
(0.003-0.007 in) (0.008-0.018 in)
Cylinder Block Piston ring end gap 0.40-0.60 mm
bottom (0.016-0.024 in)
Cylinder bore diameter 100.4 mm (3.953 in)
Piston ring groove width 1.23-1.25 mm
Cylinder bore maximum 0.025 mm (0.001 in)
top (0.0484-0.0492 in)
taper
bottom (0.0598-0.0606 in)
out-of-round
Main bearing bore inside 60.620-60.634 mm
oil ring (0.1185-0.1193 in)
diameter (2.387-2.387 in)
Piston ring width top 1.175-1.190 mm
Head gasket surface 0.1 mm (0.004 in) overall
(0.0463-0.0469 in)
flatness
Piston ring width 1.475-1.490 mm
Crankshaft
bottom (0.0581-0.0587 in)
Main bearing journal 56.980-57.0 mm
Piston ring-to-groove 0.040-0.075 mm
clearance top (0.0016-0.0030 in)
Main bearing journal 0.008 mm (0.0003 in)
maximum taper
clearance bottom (0.0012-0.0026 in)
Piston pin bore diameter 23.958-23.976 mm
maximum out-of-round
(0.943-0.944 in)
Main bearing 0.008-0.062 mm
Piston pin diameter (red) 23.994-23.997 mm
journal-to-cylinder block (0.0003-0.0024 in)
(0.9446-0.9448 in)
clearance
Piston pin diameter (blue) 23.997-24.000 mm
Connecting rod journal 53.98-54.0 mm
(0.9448-0.9449 in)
Piston pin length 72.0-72.8 mm
Connecting rod journal 0.008 mm (0.0003 in)
(2.835-2.866 in)
maximum taper
Piston pin-to-piston fit 0.01-0.016 mm
(0.0004-0.0006 in)
maximum out-of-round
Piston pin-to-connecting 0.01-0.016 mm
Crankshaft maximum end 0.05-0.32 mm
rod clearance (0.0004-0.0006 in)
play (0.002-0.0126 in)
Connecting rod pin bore 23.958-23.976 mm
Main Bearings
Clearance to crankshaft 0.021-0.039 mm
Connecting rod length 145.965-146.035 mm
(0.0008-0.0015 in)
(center-to-center) (5.747-5.749 in)
Clearance to crankshaft 0.013-0.048 mm
Connecting rod maximum mm (0.0005 in) per 25.4
allowable (0.0005-0.002 in)
allowed bend mm (1.000 in)
Bearing wall thickness 1.8-1.806 mm
Connecting rod maximum 0.038 mm (0.0015 in) per
(0.0709-0.0711 in)
allowed twist 25.4 mm (1.000 in)
Piston and Connecting Rod
Connecting rod bearing 56.82 mm-56.84 mm
Piston diameter coded 100.380-100.400 mm
bore diameter (2.237 in-2.238 in)
standard (3.952-3.9528 in)
Piston diameter coded 100.880-100.900 mm
0.5 (3.971-3.972 in)
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303-01A-3 303-01A-3 Engine 4.0L SOHC
General Specifications (Continued) Torque Specifications (Continued)
Item Specification Description Nm lb-ft lb-in
Connecting rod 0.008-0.061 mm Cylinder block cradle
bearing-to-crankshaft (0.0003-0.0024 in) bolts (inside)
a
clearance
Cylinder block cradle 10 89
Connecting rod side 0.092-0.268 mm Torx bolts
clearance (0.0036-0.0106 in)
rear Torx bolts
Cylinder block cradle 3 27 Torque Specifications
inserts
Cylinder head bolts
Accessory drive belt 47 35
(M8)
a
tensioner bolt
Cylinder head bolts
(M12)
a
idler pulley bolt
Engine wiring 40 30
Balance shaft bolts 27 20
harness-to-cylinder
head bolts
Balance shaft chain 10 89
guide bolts
Engine front cover 19 14
bolts
Balance shaft chain 29 21
tensioner bolts
Engine mount bracket 80 59
bolts
Bell 47 35
housing-to-cylinder
Engine mount nut 63 46
block cradle bolts
Engine mount bolts 70 52
Camshaft bearing cap
Exhaust 39 29
bolts
a
manifold-to-exhaust gas
Camshaft position 6 53
recirculation (EGR)
(CMP) sensor bolt
system module tube
fittings
Camshaft sprocket bolt 85 63
Exhaust manifold nuts 23 17
Camshaft tensioners 44 32
Flexplate/flywheel
Catalytic 40 30
bolts
a
converter-to-exhaust
manifold nuts
Front engine accessory 48 35
drive (FEAD) bracket
Connecting rod bolts
bolts
and nuts
a
Fuel rail bolts 23 17
Coolant hose bracket 45 33
Fuel rail supply tube 6 53
Coolant pump bolts 10 89
bracket-to-LH valve
Coolant tube bracket 23 17
cover bolt
bolt (M8)
bracket-to-LH cylinder
bolt (M12)
head bolt
Crankshaft position 10 89
Generator bracket bolts 47 35
(CKP) sensor bolts
and nut
Crankshaft pulley bolt
a

Generator B+ terminal 8 71
nut
Crankshaft main
bearing cap bolts
a
Ground 10 89
strap-to-cylinder block
stud bolt
bolts and nuts (outside)
Ground wire-to-LH 40 30
cylinder head bolt
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303-01A-4 303-01A-4 Engine 4.0L SOHC
Hood hinge bolts 12 9 Oil pump screen and 10 89
pickup tube bolt
Hydraulic camshaft
tensioner, LH
a
Power distribution box 12 9
B+ terminal bolt
Hydraulic camshaft
tensioner, RH
a
electrical connector
Ignition coil bracket 9 80
bolt
upper bolts
Ignition coil bracket 34 25
(PSP)
lower bolts (M12)
tube-to-crossmember
Ignition coil bracket 24 18 bolt
lower bolt (M8)
Power steering supply 11 8
Intake manifold bolts
a
hose bracket-to-FEAD
bracket bolt
Jackshaft chain guide 19 14
bolts Power steering pump 25 18
bolts
Jackshaft chain 9 80
tensioner bolts Power steering pump 25 18
pulley bolts
Jackshaft rear sprocket
bolt
a
Pressure tube bracket 7 62
nut
Jackshaft front sprocket
bolt
a
RH cassette-to-cylinder 12 9
block bolt
Jackshaft thrust plate 11 8
bolts RH cassette-to-cylinder 10 89
head bolt
Knock sensor (KS) bolt 20 15
Spark plug 17 13
LH cassette-to-cylinder 12 9
head bolt Steering column 25 18
intermediate
LH cassette-to-cylinder 19 14
shaft-to-steering gear
block bolt
bolt
Oil filter adapter bolt 57 42
Steering 115 85
Oil level indicator tube 11 8
gear-to-crossmember
bracket bolt
bolts
Oil pan bolts 11 8
Suction hose bracket 8 71
bolt
Oil pan drain plug 26 19
Thermostat housing 11 8
Oil pump pickup tube 11 8
bolts
bolt
Throttle body (TB) 10 89
Oil pump intermediate 19 14
bolts
shaft bolts
Valve cover bolts and 10 89
Oil pump bolts 19 14
stud bolts
Oil pump drive bolt 19 14
a Refer to the procedure in this section.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
REMOVAL
Engine
Special Tool(s)
303-106 (T74P-6666A)
303-050 (D70P-6000) or
equivalent
6. Position the hood insulation aside and
disconnect the windshield washer hose.
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Removal
All vehicles
7. NOTE: Index-mark the hood hinge location to
aid in hood installation.
Remove the 4 bolts and the hood.
Section 100-02.
3. Disconnect the battery ground and positive
cables. For additional information, refer to
Section 414-01.
4. Remove the air cleaner and air cleaner outlet
pipe. For additional information, refer to
Section 303-12.
5. Release the 2 windshield washer hose retainers
and the one hood insulation pin-type retainer.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
REMOVAL (Continued)
All vehicles
14. Remove the oil pan drain plug and drain the
engine oil.
11. Disconnect the 2 heated oxygen sensor (HO2S)
and the 2 catalyst monitor sensor electrical
(19 lb-ft).
connectors.
15. Disconnect the upper radiator hose from the
thermostat housing.
Remove the 4 catalytic converter-to-exhaust
manifold nuts.
coolant pump.
13. Remove the stud bolt and detach the ground
17. Remove the nut and power steering pressure
strap.
tube bracket from the A/C compressor.
Position the ground strap aside.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
REMOVAL (Continued)
supply hose bracket from the front engine
accessory drive (FEAD) bracket.
22. Disconnect the fuel supply tube coupling. For
19. Disconnect the PSP switch electrical connector.
drive belt.
20. Disconnect the A/C compressor and A/C high
pressure switch electrical connectors.
21. Detach the 2 wiring retainers from the FEAD
bracket.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
REMOVAL (Continued)
pump pulley.
28. Remove the 2 coolant tube bracket bolts.
29. NOTE: When removing the ignition wires, a
slight twisting motion will break the seal and
ease removal.
Using the special tool, disconnect the 6 spark
26. Remove the 3 bolts, the nut and position the
plug wires from the spark plugs.
FEAD bracket and A/C compressor aside.
Detach the retainers from the valve cover
stud bolts and the ignition coil bracket.
27. Disconnect the 2 heater hoses from the coolant
tube.
Detach the heater hose bracket from the RH
valve cover.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
REMOVAL (Continued)
30. Detach the spark plug wire retainer from the
intake manifold.
34. Remove the 2 lower ignition coil bracket bolts
and then remove the ignition coil and spark
plug wires.
31. Disconnect the radio ignition interference
capacitor electrical connector.
35. Detach the crankcase vent tube from the LH
valve cover and remove the tube.
32. Disconnect the ignition coil electrical connector.
33. Remove the 2 upper ignition coil bracket bolts.
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303-01A-6 303-01A-6 Engine 4.0L SOHC
REMOVAL (Continued)
the upper intake manifold.
40. Detach the 3 wiring harness retainers.
37. Disconnect the fuel vapor vent tube from the
intake manifold.
41. Remove the power distribution box cover.
42. Remove the bolt and detach the B+ terminal
from the power distribution box.
38. Disconnect the upper and lower powertrain
Detach the pin-type retainer from the strut
control module (PCM) electrical connectors.
tower.
39. Disconnect the 16-pin electrical connector and
detach the 2 wiring retainers.
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303-01A-7 303-01A-7 Engine 4.0L SOHC
REMOVAL (Continued)
43. Detach the power distribution box upper 46. Install the special tool to the RH cylinder head.
housing from the lower housing, loosen the bolt
and then disconnect the 68-pin connector from
the power distribution box.
47. Install the special tool to the LH cylinder head.
44. Remove the bolt and detach the ground cable
from the RH strut tower.
45. Detach the battery cable harness pin-type
retainer from the cowl.
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303-01A-8 303-01A-8 Engine 4.0L SOHC
REMOVAL (Continued)
49. Remove the RH engine mount nut. 50. Using the special tools, remove the engine.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
ASSEMBLY
Special Tool(s)
Engine
Damper
Special Tool(s)
303-102 (T74P-6316-B)
303-571 (T97T-6K254-A)
303-573 (T97T-6303-A)
Sprocket
303-564 (T97T-6256-B)
Compressor, Piston Ring
303-D032 (D81L-6002-C)
Adapter for 303-564
303-578 (T97T-6256-A)
303-581 (T97T-6565-A)
303-577 (T97T-6256-C)
Crankshaft Socket
303-674
Adapter for 303-577
303-576 (T97T-6256-D)
Lifting Eyes
303-050
Strap Wrench
303-D055 (85L-6000-A) or
equivalent
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
(Continued)
(Continued)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
ASSEMBLY (Continued)
Service Set, Crankshaft Rear Oil Item Specification
Seal
303-S524 (T95T-6701-AR)
Prep
ZC-31
Sealant
TA-30
303-093 (T74P-6019-A)
Compound
XG-3-A
TA-24
Seal
303-579 (T97T-6701-A)
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
ZC-30
(Continued)
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303-01A-3 303-01A-3 Engine 4.0L SOHC
8 8A586 Thermostat housing 1 6582 RH valve cover
9 9E469 Exhaust gas recirculation 2 6769 Electric positive crankcase
(EGR) system module tube ventilation (PCV) valve
10 6K817 PCV tube 3 9D280 RH fuel rail
11 9K479 Intake manifold 4 9F593 Fuel injector (6 required)
12 9E498 Vacuum harness 5 9G512 Fuel injector insert adapter (6
required)
13 9E964 Fuel supply tube
6 6A258 RH camshaft thrust bearing
14 9G756 Fuel rail pressure and
cap
temperature sensor
7 6250 RH camshaft
15 9D280 LH fuel rail
(Continued)
(Continued)
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303-01A-4 303-01A-4 Engine 4.0L SOHC
16 6A505 LH valve cover 27 9448 LH exhaust manifold gasket
17 6K254 LH hydraulic chain tensioner 28 9431 LH exhaust manifold
18 6A258 LH camshaft thrust bearing 29 6507 Intake valve (6 required)
cap
30 6083 LH cylinder head gasket
19 6A258 LH camshaft bearing cap (3
required)
32 12405 Spark plug (6 required)
21 6529 Roller follower (12 required)
34 6049 RH cylinder head
22 6518 Valve spring retainer keys (12
35 6051 RH cylinder head gasket
required)
36 6K254 RH hydraulic chain tensioner
required) 37 9448 RH exhaust manifold gasket
24 6C501 Hydraulic lash adjuster (12 38 9430 RH exhaust manifold
required)
39 18696 Coolant tube
40 6A258 RH camshaft bearing cap (3
26 6571 Valve stem seal (12 required)
required)
(Continued)
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303-01A-5 303-01A-5 Engine 4.0L SOHC
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303-01A-6 303-01A-6 Engine 4.0L SOHC
36 6A338 Crankshaft main bearing (3 1 6B321 Crankshaft pulley
required)
2 6C315 Crankshaft position (CKP)
37 6303 Crankshaft sensor
38 6A339 Crankshaft main bearing cap 3 8501 Coolant pump
39 6325 Crankshaft main thrust 4 6700 Crankshaft front oil seal
bearing
5 8507 Coolant pump gasket
40 6A605 Oil pump drive shaft
41 6621 Oil pump
7 6020 Engine front cover gasket
42 6C629 Shim (2 required)
8 6M270 Jackshaft chain
43 6675 Oil pan
9 6M264 Jackshaft chain sprocket
44 6617 Oil pump screen and pickup
10 6M271 Jackshaft chain tensioner
tube
11 6M272 Jackshaft chain guide
45 6F092 Cylinder block cradle
12 6714 Oil filter
46 6710 Cylinder block cradle gasket
13 6884 Oil filter adapter
47 6210 Connecting rod cap
14 6L621 Oil filter adapter O-ring seal
48 6211 Connecting rod bearings
15 12A699 Knock sensor (KS)
16 6M290 RH camshaft drive cassette
50 6135 Piston pin
17 6M289 LH camshaft drive cassette
51 6159 Oil control rings
18 6846 Oil pump drive assembly
52 6152 Lower compression ring
19 6754 Oil level indicator tube
53 6150 Upper compression ring
20 6750 Oil level indicator
54 6161 Oil control ring spacer
21 6M296 Jackshaft seal
55 6110 Piston
22 6M052 Jackshaft plug
23 6375 Flexplate
24 6434 Flexplate-to-crankshaft spacer
25 6701 Crankshaft rear oil seal
26 9278 Oil pressure sensor
27 6A311 Balance shaft (if equipped)
28 6K355 Balance shaft chain tensioner
(if equipped)
29 6A364 Balance shaft chain (if
CAUTION: If the fuel rail is used as a
equipped)
leverage device, damage may occur to the fuel
30 6375 Flywheel (manual
rail. Care must be taken when working around
transmission only)
the fuel rail.
31 6333 Crankshaft main bearing (3
required)
1. Install the crankshaft main bearings and the
32 6337 Crankshaft main bearing cap thrust bearing.
33 W702979 Woodruff key
Lubricate the crankshaft main bearings with
34 6306 Jackshaft chain sprocket clean engine oil.
35 6K350 Balance shaft chain sprocket
(if equipped)
(Continued)
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303-01A-7 303-01A-7 Engine 4.0L SOHC
2. Install the lower main bearings in the bearing
caps.
5. Install the main bearing caps in the order in
which they were removed.
3. NOTE: The crankshaft main bearings are
precision selective fit. Inspect the bearing
clearance. For additional information, refer to
Section 303-00.
Install the crankshaft.
6. Tighten the bolts in the sequence shown to 35
Nm (26 lb-ft) and then rotate an additional 57
degrees.
leakage.
Apply silicone gasket and sealant to the rear
main bearing cap to cylinder block parting line.
7. Check the piston to cylinder bore and ring
clearance. For additional information, refer to
Section 303-00.
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303-01A-8 303-01A-8 Engine 4.0L SOHC
8. NOTE: Lubricate the piston rings with clean 12. NOTE: Position the piston with the indentation
engine oil. arrow toward the front of the cylinder block.
Install the piston rings. Using the special tool, install the pistons.
Rotate the crankshaft as necessary.
13. NOTE: The old nuts and bolts are used for
checking clearances. New nuts and bolts must
be used for reassembly.
10. Install the connecting rod bearings.
Check the clearance of each connecting rod
bearing. For additional information, refer to
Section 303-00.
14. Rotate the crankshaft until the piston is at the
bottom of its stroke.
15. NOTE: For cylinders 1, 2 and 3, remove the
connecting rod nut at the oil split hole side
first. For cylinders 4, 5 and 6, remove the
opposite nut first.
Loosen the first nut until the face is
approximately 2 mm (0.08 in) over the end of
the bolt.
11. Install rubber hose pieces on the connecting rod
bolts to protect the crankshaft.
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303-01A-9 303-01A-9 Engine 4.0L SOHC
16. Tap on the nut until the bolt can be removed by
hand.
21. Tighten the connecting rod nuts simultaneously
in 2 stages:
17. Repeat the previous 2 steps for the opposite
bolt.
22. Repeat the previous 4 steps for the remaining
18. Install the new bolts making certain that the
connecting rods.
bolt head is parallel to the sideward face of the
connecting rod.
23. Rotate crankshaft until the No. 1 piston is at
top dead center.
24. If equipped, install the balance shaft.
1 Position the balance shaft assembly.
2 Install the bolts and tighten to 27 Nm (20
lb-ft).
19. Install the connecting rod cap in its original
position.
20. Install and tighten the connecting rod nuts
finger-tight.
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303-01A-10 303-01A-10 Engine 4.0L SOHC
25. NOTE: Due to the gear ratio between the
reversal shaft and the balance shaft, up to 7
complete turns of the balance shaft may be
required to find the correct position.
Align the timing marks.
Install a 4 mm (0.16 in) pin to hold the
shaft in place.
28. Position the oil pump intermediate shaft and the
oil pump. Install the 2 bolts.
26. If equipped, install the balance shaft chain and
27. If equipped, install the balance shaft tensioner.
1 Position the balance shaft tensioner.
2 Install the 2 bolts and tighten to 29 Nm (21
lb-ft).
3 Position the balance shaft chain guide,
install the 2 bolts and tighten to 10 Nm (89
lb-in).
Remove the pin from the tensioner.
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303-01A-11 303-01A-11 Engine 4.0L SOHC
29. Install the jackshaft.
33. Position the jackshaft sprocket and chain.
30. Install the jackshaft thrust plate and bolts.
34. Install the jackshaft chain guide and the 2 bolts.
31. Position the LH cassette.
32. Install the front cassette and the bolt.
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303-01A-12 303-01A-12 Engine 4.0L SOHC
35. Install the jackshaft chain tensioner and the 2 38. Install the oil pump drive and the bolt.
bolts.
39. Position the RH cassette.
40. Position the rear jackshaft sprocket and the
37. Install the jackshaft sprocket bolt and tighten in spacer on the jackshaft.
2 stages.
Loosely install the bolt.
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303-01A-13 303-01A-13 Engine 4.0L SOHC
41. Install the RH cassette bolt.
45. Position a new engine front cover gasket on the
cylinder block.
46. NOTE: Apply thread sealant to the stud bolts
and make sure that the stud bolts are installed
in their original positions.
Position the front cover and loosely install the 5
bolts and the 5 stud bolts.
43. Tighten the rear jackshaft sprocket bolt in 2
stages.
47. Use the special tool to align the front cover and
tighten the bolts and stud bolts to 19 Nm (14
lb-ft).
44. Install the jackshaft plug.
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303-01A-14 303-01A-14 Engine 4.0L SOHC
48. NOTE: Lubricate the seal lip with clean engine
51. CAUTION: Failure to back off the set
oil.
screws can result in damage to the cylinder
block cradle.
Using the special tools, install the crankshaft
front oil seal.
Back the set screws off until they are below the
cylinder block cradle boss.
49. Apply silicone gasket and sealant to the front
cover in 4 places.
52. Position the lower block cradle and a new
gasket.
50. Apply silicone gasket and sealant to the rear
main bearing cap as shown.
53. Install and hand-tighten the 20 bolts and 2 nuts.
Position the lower block cradle gasket.
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303-01A-15 303-01A-15 Engine 4.0L SOHC
54. Install and hand-tighten the bolts.
57. Install the 2 block cradle bolts.
55. NOTE: The lower block cradle to the cylinder
block alignment must be within a maximum
mismatch of 0.25 mm (0.01 in) lower block
cradle underflush or 0.05 mm (0.00196 in)
lower block cradle protrusion.
Using a straightedge, align the transmission face
of the lower block cradle with the rear face of
the cylinder block.
58. Tighten the lower block cradle inserts to 3 Nm
(27 lb-in).
56. Tighten the 20 bolts and the 2 nuts.
Tighten the bolts with washers and both
nuts to 10 Nm (89 lb-in).
Tighten the bolts without washers to 14 Nm
(10 lb-ft).
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303-01A-16 303-01A-16 Engine 4.0L SOHC
59. Install new seals on the 2 silver bolts and 62. NOTE: Assemblies that measured out of
loosely install them in the cylinder block cradle. specification must have the entire assembly
procedure repeated.
Measure the step between the rear face of the
cylinder block and the transmission face of the
lower block cradle.
60. Loosely install the 6 remaining lower block
cradle bolts.
63. Repair all assemblies that exceed underflush
specification by installing shims on 1 or both
sides of the cylinder block cradle.
61. Tighten the cylinder block cradle bolts in 2
stages.
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303-01A-17 303-01A-17 Engine 4.0L SOHC
64. Install the oil pump screen and pickup tube and
the bolt.
68. Install a new oil filter.
Tighten until the oil filter seal is flush with
the adapter and the tighten an additional 270
degrees.
65. Install the gasket, oil pan and the 10 bolts.
pulley.
66. Inspect and install new oil filter adapter O-ring
seals if necessary.
67. Install the oil filter adapter and the bolt.
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303-01A-18 303-01A-18 Engine 4.0L SOHC
70. CAUTION: A new bolt must be used
each time it is removed.
Using the special tool, tighten the bolt in 2
stages.
Stage 2: Rotate an additional 90 degrees.
the vehicle.
cannot be reused.
Position the RH cylinder head. Install 8 new
71. Position the crankshaft position (CKP) sensor
and install the 2 bolts.
2 stages.
Position the cylinder head gaskets.
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303-01A-19 303-01A-19 Engine 4.0L SOHC
77. CAUTION: The camshaft sprocket
must turn freely on the camshaft. DO NOT
tighten the bolt.
Install and hand-tighten the RH rear camshaft
sprocket bolt.
in 2 stages.
78. Install the RH cassette bolt.
76. Position the RH cassette and camshaft sprocket.
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303-01A-20 303-01A-20 Engine 4.0L SOHC
the vehicle.
cannot be reused.
Position the LH cylinder head. Install 8 new
2 stages.
82. Position the LH cassette and camshaft sprocket.
83. CAUTION: The camshaft sprocket
must turn freely on the camshaft. DO NOT
tighten the bolt.
Install and hand-tighten the LH camshaft
sprocket bolt.
in 2 stages.
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303-01A-21 303-01A-21 Engine 4.0L SOHC
84. Install the LH cassette bolt.
bolts loose.
Install the special tools on the rear of the RH
85. Turn the crankshaft one revolution clockwise.
cylinder head.
86. NOTE: The special tool must be installed on
block, this positions the engine at top dead
center (TDC).
87. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots
below centerline of camshaft to correctly fit the
special tools.
Install the special tools on the front of the RH
cylinder head.
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303-01A-22 303-01A-22 Engine 4.0L SOHC
90. CAUTION: The right-hand camshaft
sprocket bolt is a left-hand threaded bolt.
Tighten the bolts.
10 Nm (89 lb-in).
lb-ft).
93. NOTE: Camshaft timing slots are off-center.
NOTE: Position the camshaft timing slots
below centerline of camshaft to correctly fit the
special tools.
Install the special tools on the rear of the LH
cylinder head.
91. Remove the special tool and install the RH
camshaft tensioner.
92. NOTE: Do not tighten the special tool top 2
clamp bolts. Camshaft sprocket must rotate
freely.
Install the special tools on the front of the LH
cylinder head.
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303-01A-23 303-01A-23 Engine 4.0L SOHC
95. Tighten the bolts. 98. NOTE: Lubricate the roller followers with
clean engine oil.
10 Nm (89 lb-in). Using the special tool, install the roller
followers in their original positions.
lb-ft).
99. Position the RH engine mount bracket and
96. Install the LH camshaft tensioner.
97. Rotate the crankshaft until the cam lobe is in
the up position. 100. Position a new RH exhaust manifold gasket
and the RH exhaust manifold. Install the 6
nuts.
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303-01A-24 303-01A-24 Engine 4.0L SOHC
101. Position the LH engine mount bracket and
104. Clean the valve covers and cylinder head
sealing surfaces with metal surface prep.
Inspect and install new gaskets as necessary.
105. Position the RH valve cover and install the 2
102. Position a new LH exhaust manifold gasket
and the LH exhaust manifold. Install the 6
nuts. Tighten in the sequence shown to 10 Nm
(89 lb-in).
106. Position the LH valve cover and install the 3
103. NOTE: Install a new O-ring seal on the oil
level indicator tube and lubricate with clean
engine oil. Tighten in the sequence shown to 10 Nm
(89 lb-in).
Position the oil level indicator tube and install
the bolt.
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303-01A-25 303-01A-25 Engine 4.0L SOHC
107. Position the thermostat housing, hoses and
110. CAUTION: Use O-ring seals that are
coolant tube. Install the 3 bolts.
made of special fuel-resistant material. Use
of ordinary O-rings seals can cause the fuel
system to leak. Do not reuse the O-ring
seals.
NOTE: Lubricate the O-ring seals with clean
engine oil.
Install new O-ring seals on the 6 fuel
injectors.
108. Connect the coolant hose to the coolant pump,
position the bracket and install the bolt.
111. Position the fuel rail and injectors and install
the 4 bolts.
109. Position the knock sensor and install the bolt.
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303-01A-26 303-01A-26 Engine 4.0L SOHC
112. Position the main engine wiring harness on the 115. Connect the PCV valve electrical connector.
engine and install the 3 bolts.
Attach the wiring retainers.
116. Connect the engine coolant temperature (ECT)
sensor electrical connector.
113. Connect the 3 RH fuel injector electrical
connectors and attach the wiring retainer to the
valve cover stud bolt.
117. Connect the crankshaft position (CKP) sensor
electrical connector and attach the 2 wiring
retainers.
114. Connect the 3 LH fuel injector electrical
connectors and attach the wiring retainer to the
valve cover stud bolt.
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303-01A-27 303-01A-27 Engine 4.0L SOHC
118. Position the generator and bracket. Install the 121. Connect the camshaft position (CMP)
2 bolts and the nut. electrical connector.
122. Position the fuel rail supply tube brackets and
119. Install the belt tensioner and the bolt.
Tighten the bolt for the upper bracket to 6
Nm (53 lb-in).
Tighten the bolt for the lower bracket to 10
Nm (89 lb-in).
120. Connect the oil pressure sensor electrical
connector and attach the wiring retainer.
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303-01A-28 303-01A-28 Engine 4.0L SOHC
123. NOTE: Clean and inspect all sealing surfaces. 126. Position the exhaust gas recirculation (EGR)
Inspect and install new intake manifold tube. Connect the fitting to the LH exhaust
gaskets as necessary. manifold.
Position the intake manifold and install the 8 Tighten to 39 Nm (29 lb-ft).
bolts.
(89 lb-in).
127. Connect the EGR tube fitting to the EGR
system module.
124. Connect the KS electrical connector and attach
the wiring retainer.
128. Connect the EGR system module and throttle
position (TP) sensor electrical connectors.
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303-01A-29 303-01A-29 Engine 4.0L SOHC
129. Connect the fuel rail pressure and temperature 132. Install the special tool to the RH cylinder
sensor electrical connector and the vacuum head.
tube.
133. Install the special tool to the LH cylinder
130. Attach the B+ terminal to the generator and head.
install the nut.
Attach the wiring retainer to the generator.
134. Using the special tools, remove the engine
from the engine stand.
131. Connect the generator and throttle body
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303-01A-30 303-01A-30 Engine 4.0L SOHC
135. NOTE: Be sure the crankshaft rear sealing 138. Using the special tool, install the crankshaft
surface is clean and free from any rust or rear oil seal.
corrosion. To clean the crankshaft rear seal
surface area, use extra-fine emery cloth or
extra-fine 0000 steel wool with metal surface
prep.
Lubricate the crankshaft rear oil seal with
clean engine oil.
139. Install the spacer plate and if equipped, the
flexplate-to-crankshaft spacer.
137. Position the crankshaft rear oil seal.
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303-01A-31 303-01A-31 Engine 4.0L SOHC
140. NOTE: Special bolts are used for flexplate
and flywheel installation. Do not use standard
bolts.
Install the flexplate or flywheel.
2 stages.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
View, Flexplate, Flywheel and
NOTE: Flexplate shown, flywheel similar.
4 6434 Flexplate-to-crankshaft spacer 1 6379 Flexplate/flywheel bolt (8
(automatic transmission only) required)
5 6701 Crankshaft rear oil seal 2 6375 Flexplate/flywheel
3 6A373 Spacer plate
(Continued) 1. For additional information, refer to the
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Oil Level Indicator and Tube
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
1 W500213 Oil level indicator tube bolt
tube.
3 Oil level indicator tube
To install, tighten to 11 Nm (8 lb-ft). O-ring seal
Remove and discard the O-ring seal.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. NOTE: Lubricate the O-ring seal with clean
engine oil.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
3. Remove the 2 power steering gear bolts and
Oil Pan
position aside the steering gear.
Material To install tighten to 115 Nm (85 lb-ft).
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
4. Remove the oil drain plug and drain the engine
oil.
5. Remove the bolts, the oil pan and the gasket.
Discard the gasket.
Section 100-02.
pressure (PSP) tube bracket from the
crossmember.
make leak paths.
Clean and inspect the sealing surfaces.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
2. Remove the bolt and the oil pump screen and
Oil Pump Screen and Pickup Tube
pickup tube.
1. Remove the oil pan. For additional information,
refer to Oil Pan in this section.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Oil Pump
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
1. Remove the cylinder block cradle. For
additional information, refer to Cylinder Block
Cradle in this section.
2. Remove the 2 bolts and the oil pump.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Timing Drive Components
Camshaft Drive Cassette, LH
Special Tool(s)
Sprocket
303-564 (T97T-6256)
Adapter for 303-564
303-578 (T97T-6256-A)
Holding Tool, Crankshaft
303-674
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303-01A-2 303-01A-2 Engine 4.0L SOHC
9 6M276 Jackshaft sprocket bolt 1 W520101 Pressure tube bracket nut
10 W500011 Primary chain tensioner bolts 2 N605784 Power steering pump pulley
(2 required) bolt (3 required)
11 6M271 Primary chain tensioner 3 3A733 Power steering pump pulley
12 Primary chain and sprocket 4 W500213 Suction hose bracket bolt
assembly
5 W700839 Power steering pump bolt (3
13 6U001 Chain guide bolt required)
14 W500110 Chain guide bolt 6 3A674 Power steering pump
15 6M289 Timing chain and guide 7 6K254 Hydraulic chain tensioner
assembly
8 6M276 Camshaft sprocket bolt
(Continued)
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303-01A-3 303-01A-3 Engine 4.0L SOHC
Removal
section.
4. Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
5. Remove all of the roller followers. For
9. Using the special tool to prevent the crankshaft
8. Remove the LH camshaft sprocket bolt.
from turning, remove the jackshaft sprocket
Install the special tools and tighten to 10
bolt.
Nm (89 lb-in).
Remove the LH camshaft sprocket bolt.
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303-01A-4 303-01A-4 Engine 4.0L SOHC
10. Remove the 2 bolts and the primary chain 15. Remove the 3 bolts and position the power
tensioner. steering pump aside.
16. Remove the LH cassette upper bolt.
11. Remove the primary chain and sprockets as an
assembly.
17. Remove the LH cassette lower bolt and the LH
cassette.
12. Remove the suction hose bracket bolt.
13. Remove the pressure tube bracket nut.
pump pulley.
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303-01A-5 303-01A-5 Engine 4.0L SOHC
Installation
3. Install the LH cassette upper bolt.
1. NOTE: The camshaft chain sprockets must be
oriented correctly.
Position the LH cassette.
3 bolts.
5. Install the power steering pump pulley and the
3 bolts.
6. Install the pressure tube bracket nut.
7. Install the suction hose bracket bolt.
8. Install the primary chain and sprockets as an
assembly.
2. Install the LH cassette lower bolt.
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303-01A-6 303-01A-6 Engine 4.0L SOHC
9. Install the primary chain tensioner and the 2 11. Loosely install the camshaft sprocket bolt.
bolts.
NOTE: The LH hydraulic chain tensioner will
be installed during camshaft timing.
Retime the LH and RH camshafts. For
additional information, refer to Camshaft
Timing in this section.
14. Install the engine front cover. For additional
section.
10. Using the special tool to prevent the crankshaft
from turning, tighten the jackshaft sprocket bolt
in 2 stages.
section.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Hydraulic Chain Tensioner, LH
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
2. Remove the engine coolant temperature sensor.
1 6K254 LH hydraulic chain tensioner
303-14.
2 LH hydraulic chain tensioner
O-ring seal
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303-01A-2 303-01A-2 Engine 4.0L SOHC
4. NOTE: Lubricate the new O-ring seal with 5. To install, reverse the removal procedure.
clean engine oil.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Hydraulic Chain Tensioner, RH
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
1 6K254 RH hydraulic chain tensioner
2 RH hydraulic chain tensioner
O-ring seal
1. Remove the RH hydraulic chain tensioner.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. NOTE: Lubricate the new O-ring seal with 3. To install, reverse the removal procedure.
clean engine oil.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Valve Cover LH
Material
Item Specification
Prep
ZC-31
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. Disconnect the 6 spark plug wires from the
igniton coil.
1 W500213 Fuel rail supply tube
bracket-to-cylinder head bolt
3. Remove the 2 upper ignition coil bracket bolts.
2 12280 Spark plug wire-to-ignition
coil connector (6 required)
4. Remove the 2 lower ignition coil bracket bolts
3 W500214 Ignition coil bracket upper
and remove the ignition coil and bracket
bolts (2 required)
assembly.
bolt (M12)
5. Remove the fuel rail supply tube
bracket-to-cylinder head bolt.
bolt (M8)
6 12A310 Ignition coil and bracket
6. Remove the fuel rail supply tube
assembly
bracket-to-valve cover bolt.
7 14A464 Fuel rail pressure and
Position the fuel rail supply tube aside.
temperature sensor electrical
7. Disconnect the crankcase ventilation tube from
8 13A506 Wiring harness retainer (part
the valve cover and position the tube aside.
of 12B637)
9 14A464 Fuel injector electrical
8. Disconnect the camshaft position (CMP) sensor
connector (3 required) (part
electrical connector. of 12B637)
10 Fuel rail supply tube bracket
9. Disconnect the fuel rail pressure and
(part of 9E964)
temperature sensor electrical connector.
11 W500213 Fuel rail supply tube
bracket-to-valve cover bolt
12 14A464 Camshaft position (CMP)
connectors.
sensor electrical connector
(part of 12B637)
Detach the wiring retainer from the valve
13 6758 Crankcase ventilation tube cover stud bolt and position the wiring
harness aside. 14 6C519 LH valve cover stud bolt (3
required)
11. Detach the spark plug wire retainer from the
15 6C519 LH valve cover bolt (3
required) valve cover stud bolt.
16 6A505 LH valve cover assembly
17 6584 LH valve cover gasket
LH valve cover.
Removal
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303-01A-3 303-01A-3 Engine 4.0L SOHC
Installation
4. Connect the fuel rail pressure and temperature
1. NOTE: Clean the valve cover and cylinder
5. Connect the camshaft position (CMP) sensor
head sealing surfaces with metal surface prep.
Inspect and install a new gasket as necessary.
Position the LH valve cover and install the 3
6. Connect the crankcase ventilation tube to the
valve cover.
(89 lb-in). 7. Position the fuel rail supply tube and install the
fuel rail supply tube bracket-to-valve cover bolt.
8. Install the fuel rail supply tube
bracket-to-cylinder head bolt.
9. Install the ignition coil and bracket assembly
and the lower bolts.
Tighten the M8 bolts to 24 Nm (18 lb-ft).
10. Install the upper ignition coil bracket bolts.
2. Attach the spark plug wire retainer to the valve
cover stud bolt.
11. Connect the 6 spark plug wire to the ignition
3. Position the wiring harness, attach the wiring
coil.
retainer to the valve cover stud bolt and then
connect the 3 LH fuel injector electrical
connectors.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Valve Cover RH
Material
Item Specification
Prep
ZC-31
1 6K817 Positive crankcase ventilation
(PCV) tube
2 PCV valve electrical
connector (part of 12A580)
3 8W287 Heater hose retainer bracket
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. Remove the positive crankcase ventilation
(PCV) tube.
4 W506031 Wiring harness bracket bolt
5 14536 Wiring harness bracket (part
of 12B637)
6 6C519 RH valve cover stud bolt (4
4. Detach the heater hose retainer from the valve
required)
cover.
7 13A506 Wiring retainer (part of
12B637)
5. Remove the wiring harness bracket bolt from
8 6C519 RH valve cover bolt (2
the back of the RH cylinder head and detach
required)
the bracket from the valve cover stud bolt.
9 6582 RH valve cover assembly
10 6584 RH valve cover gasket 6. Detach the engine wiring and spark plug wiring
retainers from the 2 valve cover stud bolts.
Removal
RH valve cover.
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303-01A-3 303-01A-3 Engine 4.0L SOHC
Installation
2. Attach the engine wiring and spark plug wiring
retainers to the 2 valve cover stud bolts.
1. NOTE: Clean the valve cover and cylinder
3. Position the wiring harness bracket on the valve
head sealing surfaces with metal surface prep.
cover stud bolt and install the wiring harness
Inspect and install a new gasket as necessary.
bracket bolt to the back of the RH cylinder
Position the RH valve cover and install the 2
head.
(89 lb-in).
4. Attach the heater hose retainer to the valve
cover.
5. Connect the PCV valve electrical connector.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
4. Using the special tool, remove the valve spring
Valve Spring, Retainer, and Seal
retainer keys, valve spring retainers and the
valve springs.
Special Tool(s)
303-581 (T97T-6565-A)
Installer, Valve Stem Seal
303-370 (T90T-6571-A)
5. Remove the valve seals.
Material Installation
Item Specification
1. NOTE: Lubricate the valve seals with clean
engine oil.
Motor Oil
Using the special tool, install the valve seal.
XO-5W30-QSP (US);
CXO-5W30-LSP12
Removal
2. Position the piston of the cylinder being
serviced at top dead center (TDC).
3. CAUTION: If air pressure has forced
the piston to the bottom of the cylinder, any
loss of air pressure will allow the valve to
fall into the cylinder. If air pressure must be
removed, support the valve prior to removal.
Hold the valves in the cylinder head.
Remove the spark plug of the cylinder being
serviced.
Use a suitable tool to apply air pressure to
the cylinder.
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303-01A-2 303-01A-2 Engine 4.0L SOHC
2. NOTE: Lubricate the valve springs, retainers 3. Install the camshaft roller followers. For
and retainer keys with clean engine oil. additional information, refer to Camshaft Roller
Using the special tool, install the valve springs
the valve spring retainers and the valve spring
retainer keys.
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303-01A-1 303-01A-1 Engine 4.0L SOHC
IN-VEHICLE REPAIR
Valve Train Components Exploded
View
RH Side
4 6518 Valve spring retainer key (12 1 6K254 RH hydraulic chain tensioner
required)
2 6529 Camshaft roller follower (6
5 6A536 Valve spring retainer (6 required)
required)
6 6513 Valve spring (6 required) required)
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303-01A-2 303-01A-2 Engine 4.0L SOHC
7 6571 Valve seal (6 required) 11 6578 Oil supply tube
8 6M276 RH camshaft sprocket bolt 12 6A258 Camshaft bearing cap (4
required)
9 6256 RH camshaft sprocket
13 6250 RH camshaft
10 W702341 Camshaft bearing cap bolt (8
required)
(Continued)
LH Side
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303-01A-3 303-01A-3 Engine 4.0L SOHC
21 6M276 LH camshaft sprocket bolt 14 6K254 LH hydraulic chain tensioner
22 6M267 LH camshaft sprocket 15 6529 Camshaft roller follower (6
required)
23 W702341 Camshaft bearing cap bolt (8
required) 16 6C501 Hydraulic lash adjuster (6
required)
24 6578 Oil supply tube
25 6A258 Camshaft bearing cap (4
required)
required)
required)
20 6571 Valve seal (6 required)
(Continued)
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303-01B-1 303-01B-1 Engine 4.6L (3V)
Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, refer to
the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
DISASSEMBLY
Special Tool(s)
Engine
Locking Tool, Camshaft Phaser
Sprocket
Special Tool(s)
303-1046
Remover, Crankshaft Rear
Slinger
303-514 (T95P-6701-AH)
Remover/Installer, Cylinder
Head
303-572 (T97T-6000-A)
Remover, Crankshaft Rear Seal
303-519 (T95P-6701-EH)
303-1039
Slide Hammer
100-001 (T50T-100-A)
Installer, Connecting Rod
303-442 (T93P-6136-A)
Modular Engine Lift Bracket
303-F047 (014-00073)
Material
Item Specification
3-Jaw Puller
303-D121
ZC-30
Prep
ZC-31
Remover, Crankshaft Front Seal
303-107 (T74P-6700-A)
(Continued)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
3. Using the special tools, remove the crankshaft
rear seal.
Discard the crankshaft rear seal.
NOTE: The flexplate, crankshaft rear seal and the
crankshaft rear oil slinger must be removed before
mounting the engine on the engine stand.
exploded view under the assembly procedure in this
section.
4. Remove the 8 bolts and the crankshaft rear seal
retainer plate.
1. NOTE: Flexplate shown, flywheel similar.
CAUTION: Do not use metal
Remove the 6 bolts and the flexplate or
scrapers, wire brushes, power abrasive
flywheel.
discs or other abrasive means to clean the
sealing surfaces. These tools cause
scratches and gouges which make leak
paths. Use a plastic scraping tool to
remove all traces of old sealant.
rear oil slinger.
Discard the crankshaft rear oil slinger.
5. Mount the engine on a suitable work stand.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
6. Remove the special tool. 9. Detach the engine wiring harness pin-type
retainers.
7. NOTE: RH shown, LH similar.
10. Remove the nut and the RH radio ignition
Disconnect the RH and LH camshaft position
interference capacitor.
(CMP) sensor electrical connectors.
Disconnect the RH and LH variable camshaft
timing (VCT) solenoid electrical connectors.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
11. CAUTION: When reusing liquid or
vapor tube connectors, make sure to use
compressed air to remove any foreign
material from the connector retaining clip
area before separating from the tube.
Remove the positive crankcase ventilation
(PCV) tubes from the LH and RH valve covers.
Disconnect the quick connect fittings.
X Push the connector toward the valve
cover to release pressure.
X Push the release tab clockwise.
14. Disconnect the 2 engine wiring harness
retainers from the LH valve cover studs.
X Disconnect the quick connect fitting.
15. Detach the engine wiring harness pin-type
retainers.
Disconnect the 4 RH and 4 LH ignition coil
13. Disconnect the 3 engine wiring harness
retainers from the RH valve cover studs.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
16. Disconnect the cylinder head temperature
(CHT) sensor electrical connector.
20. Disconnect the engine oil pressure sensor
17. Detach the CHT sensor jumper harness
electrical connector pin-type retainer.
21. Remove the engine wiring harness from the
engine.
18. Disconnect the knock sensor (KS) electrical 22. Remove the nut and ground strap from the stud
connector and pin-type retainer. bolt.
19. Disconnect the LH heated oxygen sensor
(HO2S) electrical connector.
Detach the engine wiring harness retainer
from the stud bolt.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
23. NOTE: LH shown, RH similar.
Remove the 8 bolts and the 8 ignition coils.
CAUTION: When removing the valve
cover, make sure to avoid damaging the
variable camshaft timing (VCT) solenoid.
NOTE: The bolts are part of the valve cover
and should not be removed.
Loosen the 29 bolts and remove the valve
covers.
Clean the valve cover mating surface of the
cylinder head with silicone gasket remover
tube.
and metal surface prep. Follow the
directions on the packaging.
Inspect the valve cover gasket. If the gasket
is damaged, remove and discard the gasket.
Clean the valve cover gasket groove with
soap and water or a suitable solvent.
26. Remove and discard the oil filter.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
27. Remove the 4 bolts and the oil filter adapter.
Discard the gasket.
30. Remove the 2 bolts, 2 stud bolts and the RH
motor mount bracket.
28. Remove the 4 bolts and the LH motor mount
manifold.
bracket.
Discard the nuts and gasket.
29. Remove the 8 nuts and the LH exhaust
manifold.
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303-01B-8 303-01B-8 Engine 4.6L (3V)
32. Remove the 2 bolts and the KS.
36. Remove the 7 bolts, the coolant pump pulley
and the 3 accessory drive belt idler pulleys.
33. Remove the bolt and the RH CMP sensor.
37. Remove the 3 bolts and the accessory drive belt
34. Remove the bolt and the LH CMP sensor.
tensioner.
35. Remove the bolt and the CKP sensor.
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303-01B-9 303-01B-9 Engine 4.6L (3V)
38. Remove the 4 coolant pump housing bolts.
front oil seal.
39. Remove the coolant pump housing from the
cylinder block.
43. Remove the bolts, oil pan and oil pan gasket.
Discard the oil pan gasket.
40. Remove the stud bolt and the coolant tube
assembly.
41. Remove and discard the crankshaft pulley bolt.
pulley.
http://vnx.su
303-01B-10 303-01B-10 Engine 4.6L (3V)
44. NOTE: Correct fastener location is essential for 47. Position the crankshaft keyway at the 12
the assembly procedure. Record fastener oclock position.
location.
Remove the engine front cover fasteners.
48. NOTE: If the camshaft lobes are not exactly
positioned as shown, the crankshaft will require
one full additional rotation to the 12 oclock
45. Remove the engine front cover from the
position.
cylinder block.
The No. 1 cylinder camshaft exhaust lobe must
be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake lobes and the
exhaust lobe on the No. 1 cylinder.
46. Remove the crankshaft sensor ring from the
crankshaft.
http://vnx.su
303-01B-11 303-01B-11 Engine 4.6L (3V)
49. CAUTION: If the components are to
be reinstalled, they must be installed in the
same positions. Mark the components for
installation into their original locations.
Remove only the 3 roller followers shown in
the illustration from the RH cylinder head.
the illustration from the LH cylinder head.
50. CAUTION: Do not allow the valve
keepers to fall off the valve or the valve may
drop into the cylinder.
NOTE: It may be necessary to push the valve
down while compressing the spring.
Using the special tool, remove the 3 roller
followers designated in the previous step from
the RH cylinder head.
http://vnx.su
303-01B-12 303-01B-12 Engine 4.6L (3V)
the LH cylinder head.
54. Remove the 2 bolts, the LH timing chain
tensioner and tensioner arm.
55. Remove the 2 bolts, the RH timing chain
53. CAUTION: The crankshaft cannot be
moved past the 6 oclock position once set.
Rotate the crankshaft clockwise and position the
crankshaft keyway at the 6 oclock position.
http://vnx.su
303-01B-13 303-01B-13 Engine 4.6L (3V)
56. Remove the RH and LH timing chains and the
Remove the RH timing chain from the
camshaft sprocket.
Remove the LH timing chain from the
camshaft sprocket.
Remove the LH timing chain and crankshaft
sprocket.
Remove the LH and RH timing chain guides.
Remove the 2 bolts.
Remove both timing chain guides.
http://vnx.su
303-01B-14 303-01B-14 Engine 4.6L (3V)
60. Install the special tool onto the LH cylinder
58. CAUTION: Damage to the camshaft
head.
phaser sprocket assembly will occur if
mishandled or used as a lifting or leveraging
device.
CAUTION: Only use hand tools to
remove the camshaft phaser sprocket
assembly or damage may occur to the
camshaft or camshaft phaser unit.
Using the special tool, remove the bolt and the
RH camshaft phaser sprocket assembly.
Discard the camshaft phaser sprocket bolt.
61. Install the special tool onto the RH cylinder
head.
device.
LH camshaft phaser sprocket assembly.
http://vnx.su
303-01B-15 303-01B-15 Engine 4.6L (3V)
63. Clean and inspect the RH camshaft bearing
62. CAUTION: Remove the front thrust
caps.
camshaft bearing cap straight upward from
the bearing towers, or the bearing cap may
The camshaft front thrust bearing cap
be damaged from sideloading.
contains an oil metering groove. Make sure
the groove is free of foreign material.
installed in their original locations. Record
camshaft bearing cap locations.
Remove the bolts in the sequence shown.
Remove the RH cylinder head front camshaft
bearing cap, then the remaining bearing caps.
64. Remove the RH camshaft.
Remove the remaining roller followers from the
RH cylinder head.
Remove the hydraulic lash adjusters from the
RH cylinder head.
http://vnx.su
303-01B-16 303-01B-16 Engine 4.6L (3V)
68. Clean and inspect the LH camshaft bearing
caps.
Remove the LH cylinder head front camshaft
69. Remove the LH camshaft.
Remove the remaining roller followers from the
LH cylinder head.
LH cylinder head.
http://vnx.su
303-01B-17 303-01B-17 Engine 4.6L (3V)
72. CAUTION: The cylinder head must be
cool before removing it from the engine.
Cylinder head warpage can result if a warm
or hot cylinder head is removed.
CAUTION: Place clean shop towels
over exposed engine cavities. Carefully
remove the towels so foreign material is not
dropped into the engine.
CAUTION: The cylinder head bolts
must be discarded and new bolts must be
installed. They are tighten-to-yield designed
and cannot be reused.
CAUTION: Do not use metal scrapers,
CAUTION: Aluminum surfaces are
soft and can be scratched easily. Never place
the cylinder head gasket surface,
unprotected, on a bench surface.
NOTE: RH shown, LH similar.
Remove the 20 bolts and the cylinder heads.
Discard the cylinder head gaskets.
Discard the cylinder head bolts.
http://vnx.su
303-01B-18 303-01B-18 Engine 4.6L (3V)
CAUTION: Observe all warnings or
cautions and follow all application directions
contained on the packaging of the silicone
gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material
present, metal surface prep can be used to clean
and prepare the surfaces.
Clean the cylinder head-to-cylinder block
mating surfaces of both the cylinder head and
the cylinder block.
1 Remove any large deposits of silicone or
gasket material with a plastic scraper.
2 Apply silicone gasket remover, following
package directions and allow to set for
several minutes.
3 Remove the silicone gasket remover with a
plastic scraper. A second application of
silicone gasket remover may be required if
residual traces of silicone or gasket material
remain.
4 Apply metal surface prep, following
package directions, to remove any
remaining traces of oil or coolant and to
prepare the surfaces to bond with the new
gasket. Do not attempt to make the metal
shiny. Some staining of the metal surfaces
is normal.
http://vnx.su
303-01B-19 303-01B-19 Engine 4.6L (3V)
NOTE: Use a straightedge that is calibrated by
the manufacturer to be flat within 0.005 mm
example, if the straightedge is 61 cm (24 in)
long, the machined edge must be flat within
Support the cylinder heads on a bench with the
head gasket side up. Inspect all areas of the
deck face with a straightedge, paying particular
attention to the oil pressure feed area. The
cylinder heads must not have depressions
deeper than 0.0254 mm (0.001 in) across a
38.1 mm (1.5 in) square area, or scratches
longer than 0.0254 mm (0.001 in).
http://vnx.su
303-01B-20 303-01B-20 Engine 4.6L (3V)
75. Remove the bolts, the oil pump screen and
pickup tube and the spacer.
76. Remove the 7 nuts and the windage tray.
the manufacturers instructions.
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303-01B-21 303-01B-21 Engine 4.6L (3V)
79. CAUTION: Verify that the connecting
rods and rod caps have orientation numbers
cast into them. If not, number the connecting
rods and rod caps for correct orientation.
Remove the bolts and the connecting rod caps.
Discard the bolts.
81. Disassemble the 8 pistons. For additional
information, refer to Piston in this section.
80. CAUTION: Do not scratch the cylinder
walls or crankshaft journals with the
connecting rod.
Use the special tool to push the piston through
the top of the cylinder block.
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303-01B-22 303-01B-22 Engine 4.6L (3V)
82. Remove the fasteners. 83. Remove the 5 main bearing caps, the lower
crankshaft main bearings and the lower thrust
1 Remove and discard the cross-mounted
washer.
main cap bolts.
2 Remove and discard the main bearing cap
bolts and stud bolts.
84. Remove the crankshaft, the upper crankshaft
main bearings and the upper thrust washers
from the cylinder block.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
OF SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-1039
303-383 (T91T-6571-A)
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
6 6C255 LH/ Camshaft 1 W701520 Variable camshaft timing
6251 RH (VCT) housing assembly
bolts (2 required)
required) 2 6C261 LH/ VCT housing assembly
6C260 RH
8 6514 Valve spring retainer (12
required) 3 N807834 Camshaft bearing cap bolt (10
required)
4 6B284 Camshaft front bearing cap
10 6A517 Valve seal (12 required)
5 6B280 Camshaft bearing cap (4
11 6507 Intake valves (8 required)
required)
(Continued)
(Continued)
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303-01B-3 303-01B-3 Engine 4.6L (3V)
6. Remove the valve from the cylinder head.
13 6050 LH/ 6049 Cylinder head
7. Repeat the previous 3 steps for each valve.
RH
8. Inspect the components. For additional
Disassembly
1. Remove the bolts and the variable camshaft
timing (VCT) housing.
Discard the gasket.
2. Lubricate the camshaft and camshaft journals
Remove the bolts and the front camshaft
with clean engine oil and install the camshaft.
bearing cap and then the remaining bearing
caps.
3. NOTE: The camshaft must be installed in the
head to use the special tool necessary to
compress the valve springs.
NOTE: Lubricate the camshaft bearing caps
11. Check the cylinder head for distortion. For
Install the camshaft bearing caps in their
Assembly
original locations.
Position the front camshaft bearing cap.
Position the remaining camshaft bearing
with clean engine oil and install the camshaft.
caps.
2. NOTE: Lubricate the camshaft bearing caps
Install the bolts finger-tight.
4. Using the special tool, compress the valve
spring and remove the valve spring retainer
original locations.
keys.
caps.
Install the bolts finger-tight.
3. NOTE: Lubricate the valve stem with clean
engine oil prior to installation.
Install the valve into the cylinder head.
4. NOTE: Lubricate the valve seal and valve stem
with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
5. Remove the valve spring retainer, the valve
spring and the valve seal.
Discard the valve seal.
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
5. Using the special tool, install the new valve
seal.
7. Repeat the previous 2 steps for each valve.
8. Remove the bolts and the front camshaft
6. Using the special tool, install the valve spring, bearing cap and then the remaining bearing
the valve spring retainer and the valve spring caps.
retainer keys.
10. Install a new gasket, the variable camshaft
timing (VCT) housing and the bolts.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
OF SUBASSEMBLIES
Piston
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
5 6159 Piston oil control segment 1 6150 Piston compression ring,
ring, lower upper
6 6140 Piston pin retainer 2 6152 Piston compression ring,
lower
7 6140 Piston pin retainer
3 6159 Piston oil control segment
8 6135 Piston pin
ring, upper
4 6161 Piston oil control spacer
10 6110 Piston
(Continued)
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
Disassembly
Discard the piston rings.
2. Remove the piston pin retainers and the piston
pin.
3. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting
rod. For additional information, refer to Section
303-00.
Assembly
1. NOTE: The connecting rod must be installed
into the piston with identification markings
toward the front.
Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean
engine oil.
3. Install the piston pin in the piston and
connecting rod assembly.
4. Install the piston pin retaining clips in the
piston.
5. Lubricate the piston and the new piston rings
6. Install the piston rings onto the piston.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
INSTALLATION
Special Tool(s)
Cylinder Head
Installer, Front Cover Seal
303-335 (T88T-6701-A)
Special Tool(s)
Head
303-572 (T97T-6000-A)
303-F047 (014-00073) or
equivalent
Alignment Pins, Cylinder Head
303-1040 (SR-015486)
Material
Item Specification
303-1039
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Motorcraft Premium Gold WSS-M97B51-A1
Sprocket
Engine Coolant with
303-1046
(yellow color)
Sealant
TA-30
Damper
303-102 (T74P-6316-B) Motorcraft Metal Surface
Prep
ZC-31
ZC-30
Hydraulic Chain Tensioner
Installer, Crankshaft Front Seal
Retaining Clip
303-635
1L3Z-6P250-AA
(Continued)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
All cylinder heads
1. CAUTION: Make sure all coolant
residue and foreign material are cleaned
from the block surface and cylinder bore.
CAUTION: The use of sealing aids
(aviation cement, copper spray and glue) is
not permitted. The gasket must be installed
dry.
must be discarded and new bolts installed.
They are tighten-to-yield designed and
cannot be reused.
NOTE: Do not turn the crankshaft until
instructed to do so.
Using the special tools, position the cylinder
head gaskets and cylinder heads over the
dowels and install the cylinder head bolts
loosely.
LH cylinder head
3. Remove the special tool from the LH cylinder
head.
Tighten the bolts in 3 stages, in the sequence
shown.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
4. NOTE: Lubricate the hydraulic lash adjusters
NOTE: The hydraulic lash adjusters must be
installed in their original locations.
Install the hydraulic lash adjusters into the LH
cylinder head.
RH cylinder head
7. Remove the special tool from the RH cylinder
head.
5. Position a new gasket, the LH exhaust manifold
and tighten the 8 new nuts in the sequence
shown.
NOTE: The hydraulic lash adjusters must be
installed in their original locations.
Install the hydraulic lash adjusters into the RH
cylinder head.
6. Install the ground strap and nut to the stud bolt.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
All cylinder heads
9. Position a new gasket, the RH exhaust manifold
shown.
12. NOTE: Lubricate the camshaft and camshaft
journals with clean engine oil prior to
installation.
Install the LH and RH camshafts.
Install the LH and RH camshaft bearing caps in
their original locations.
caps.
Install the bolts loosely.
10. NOTE: Do not reuse the O-ring seals.
Tighten to 10 Nm (89 lb-in) in the sequence
shown.
engine coolant prior to installation.
Slide the coolant tube forward with the new
O-ring seals into the cylinder block.
11. Install the coolant tube stud bolt.
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
device.
NOTE: The RH and LH camshaft phaser
sprockets are similar. Refer to the single timing
mark to identify the RH camshaft phaser
sprocket and the L timing mark to identify the
LH camshaft phaser sprocket.
Install the camshaft phaser sprockets and new
camshaft phaser bolts finger tight.
16. Install the crankshaft sprocket, making sure the
flange faces forward.
17. Rotate the crankshaft to position the crankshaft
sprocket timing mark in the 6 oclock position.
device.
CAUTION: Damage to the camshaft
device.
Using the special tool, tighten the LH and RH
camshaft phaser sprocket bolts in 2 stages.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
18. Rotate the camshaft sprockets to position the 21. Install a retaining clip on the tensioner to hold
RH camshaft sprocket timing mark in the 11 the plunger in during installation.
oclock position and the LH camshaft sprocket
timing mark in the 12 oclock position.
22. Remove the tensioner from the vise.
23. If the copper links are not visible, mark one
19. CAUTION: If one or both tensioner
link on one end and one link on the other end
mounting bolts are loosened or removed, the
and use as timing marks.
tensioner-sealing bead must be inspected for
seal integrity. Any cracks, tears, cuts or
separation from the tensioner body, or
permanent compression of the seal bead, will
require replacement of the tensioner.
Inspect the RH and LH timing chain tensioners.
Install new tensioners, as necessary.
20. CAUTION: Timing chain procedures
must be followed exactly or damage to valves
and pistons will result.
Compress the tensioner plunger, using a vise.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
24. Install the 4 bolts and the LH and RH timing
chain guides.
25. Position the lower end of the LH (inner) timing 26. NOTE: Make sure the upper half of the timing
chain on the crankshaft sprocket, aligning the chain is below the tensioner arm dowel.
timing mark on the outer flange of the
Position the LH timing chain on the camshaft
crankshaft sprocket with the single copper
sprocket. Make sure the camshaft sprocket
(marked) link on the chain.
timing mark is aligned with the copper
(marked) chain link.
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303-01B-8 303-01B-8 Engine 4.6L (3V)
27. NOTE: The LH timing chain tensioner arm has
a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on
the dowel pin and install the LH timing chain
tensioner and 2 bolts.
30. NOTE: The camshaft phaser and sprocket will
be stamped with one of the illustrated timing
marks for the RH camshaft.
NOTE: The lower half of the timing chain
must be positioned above the tensioner arm
dowel.
Position the RH timing chain on the camshaft
28. Remove the retaining clip from the LH timing
chain tensioner.
29. Position the lower end of the RH (outer) timing
chain on the crankshaft sprocket, aligning the
timing mark on the sprocket with the single
copper (marked) chain link.
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303-01B-9 303-01B-9 Engine 4.6L (3V)
31. Position the RH timing chain tensioner arm on
the dowel pin and install the RH timing chain
32. Remove the retaining clip from the RH timing
chain tensioner.
34. Install the crankshaft sensor ring on the
crankshaft.
33. NOTE: The RH and LH camshaft phaser
sprockets are similar. Refer to the single timing
As a post-check, verify correct alignment of all
timing marks. Make sure the timing marks on
the sprockets correspond to the above note.
http://vnx.su
303-01B-10 303-01B-10 Engine 4.6L (3V)
35. NOTE: Lubricate the roller followers with
clean engine oil prior to installation.
Using the special tool, install all of the
camshaft roller followers.
http://vnx.su
303-01B-11 303-01B-11 Engine 4.6L (3V)
NOTE: If the engine front cover is not secured
within 4 minutes, the sealant must be removed
and the sealing area cleaned. To clean the
sealing area, use silicone gasket remover and
metal surface prep. Follow the directions on the
packaging. Failure to follow this procedure can
cause future oil leakage.
NOTE: Make sure that the engine front cover
gasket is in place on the engine front cover
before installation.
Apply a bead of silicone gasket and sealant
along the cylinder head-to-cylinder block
surface at the locations shown.
http://vnx.su
303-01B-12 303-01B-12 Engine 4.6L (3V)
Part
37. Install a new engine front cover gasket on the
Item Number Description
engine front cover. Position the engine front
14 N806300 Stud, Hex Shoulder Pilot, M8 cover onto the dowels. Install the 15 fasteners
x 1.25 x 1.25 x 91.1
finger-tight.
15 N806300 Stud, Hex Shoulder Pilot, M8
x 1.25 x 1.25 x 91.1
38. Tighten the 15 engine front cover fasteners in
the sequence shown to 25 Nm (18 lb-ft).
Part
1 N806177 Bolt, Hex Flange Head Pilot,
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
6 W706508 Stud, Hex Shoulder Pilot, M8
x 1.25 x 50 - M6 x 1 x 10 39. Loosely install the 4 bolts, then tighten the
bolts in 2 stages, in the sequence shown.
7 N808586 Stud and Washer, Hex Head
Pilot, M8 x 1.25 - M6 x 1 x
86.35
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
x 1.25 x 1.25 x 91.1
x 1.25 x 1.25 x 91.1
http://vnx.su
303-01B-13 303-01B-13 Engine 4.6L (3V)
40. Lubricate the engine front cover and the
crankshaft seal inner lip with clean engine oil.
pulley.
41. Using the special tools, install the crankshaft
front oil seal into the engine front cover.
44. Using a new crankshaft pulley bolt, install the
bolt and washer and tighten the bolt in 4 stages.
Stage 2: Loosen 360 degrees.
cleaned with metal surface prep and silicone Stage 3: Tighten to 50 Nm (37 lb-ft).
gasket remover. Allow to dry until there is no
sign of wetness, or 4 minutes, whichever is
longer. Failure to follow this procedure can
Apply silicone gasket and sealant to the
Woodruff key slot in the crankshaft pulley.
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303-01B-14 303-01B-14 Engine 4.6L (3V)
45. Install the RH side accessory drive belt idler 48. NOTE: Lubricate the new O-ring seal with
pulley, the coolant pump pulley and the 5 bolts. clean engine oil prior to installation.
Tighten to 25 Nm (18 lb-ft). Install the RH CMP sensor and the bolt.
46. Install the crankshaft position (CKP) sensor and
the bolt.
Clean the valve cover mating surface with
silicone gasket remover and metal surface prep.
47. NOTE: Lubricate the new O-ring seal with
leakage.
Apply silicone gasket and sealant in 2 places
Install the LH camshaft position (CMP) sensor
where the engine front cover meets the cylinder
and the bolt.
head.
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303-01B-15 303-01B-15 Engine 4.6L (3V)
51. CAUTION: When installing the valve 52. CAUTION: Do not use metal scrapers,
cover, make sure to avoid damaging the wire brushes, power abrasive discs or other
variable camshaft timing (VCT) solenoid. abrasive means to clean sealing surfaces.
Position the RH valve cover and gasket on the
cylinder head and tighten the bolts in the
sequence shown.
leakage.
head.
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303-01B-16 303-01B-16 Engine 4.6L (3V)
54. CAUTION: When installing the valve
Position the LH valve cover and gasket on the
cylinder head and tighten the bolts in the
sequence shown.
Install the 8 ignition coils and the 8 bolts.
58. Position the engine wiring harness on the
engine.
55. Install the oil level indicator tube and the bolt.
59. Connect the engine oil pressure sensor electrical
connector.
Install a new O-ring seal and lubricate the
O-ring seal with clean engine oil prior to
installation.
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303-01B-17 303-01B-17 Engine 4.6L (3V)
60. Attach the engine wiring harness retainer to the 63. Connect the CHT sensor electrical connector.
stud bolt.
Connect the LH heated oxygen sensor
64. Attach the engine wiring harness pin-type
retainers.
61. Connect the knock sensor (KS) electrical
connector and pin-type retainer.
65. Connect the 2 engine wiring harness retainers to
the LH valve cover studs.
62. Attach the cylinder head temperature (CHT)
sensor jumper harness electrical connector
pin-type retainer.
http://vnx.su
303-01B-18 303-01B-18 Engine 4.6L (3V)
the RH valve cover studs.
retainers.
Connect the 4 RH and 4 LH ignition coil
Connect the RH and LH variable camshaft
68. Connect the positive crankcase ventilation
(PCV) tubes to the RH and LH valve covers.
69. Install the RH radio ignition interference
capacitor and nut.
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303-01B-19 303-01B-19 Engine 4.6L (3V)
Connect the RH and LH camshaft position
74. Using a suitable floor crane, remove the engine
from the engine stand.
75. Install the engine. For additional information,
refer to Engine in this section
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
INSTALLATION
Engine
Special Tool(s)
303-F072
Lifting Brackets, Engine
303-050 (T70P-6000)
2. CAUTION: Do not remove the engine
crane until the special tool (3-bar support) is
installed in the next step. The rear of the
engine must be supported to prevent damage
to the engine or cowl panel.
Using a suitable engine crane, position the
303-F047 (014-00073) or
engine in the vehicle.
equivalent
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
All vehicles
1. Install the special tool to the threaded hole
located at the LH side of the engine block.
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
3. CAUTION: Do not position the legs of
the special tool (3-bar support) on the
Install the RH and LH engine support insulator
fenders. Instead, the legs should be
nuts.
positioned on the body structure near the
suspension strut tower.
Install the 3-bar support and a suitable length of
chain to the engine lifting bracket installed in
the previous step.
Remove the engine crane.
6. Install the LH radio interference capacitor and
nut onto the engine front cover stud bolt.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
7. Connect the 68-pin connector to the power 11. Connect the generator jumper harness electrical
distribution box and tighten the bolt. connector.
12. Install the ground strap and bolt to the cowl.
Attach the pin-type retainer.
attach the 2 wiring retainers.
13. Connect the heater hoses.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
14. Install the engine-to-transmission spacer plate.
19. Install the transmission cooler tube bracket and
nut.
Connect the RH and LH catalyst monitor sensor
(CMS).
All vehicles
20. Remove the 3-bar support, chain and lifting eye
from the engine.
3 stud bolts.
16. Connect the RH heated oxygen sensor (HO2S)
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
22. Install the wiring retainer on the power steering 25. Install the ground wire onto the stud bolt.
stud bolt.
Attach the pin-type retainer from the A/C
compressor.
23. Position the A/C compressor, bolt and install
the 3 nuts.
26. Attach the 2 pin-type retainers.
24. Connect the A/C clutch and crankshaft position
27. Connect the coolant hose to the oil filter
(CKP) sensor electrical connectors.
adapter.
Attach the wiring harness retainers.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
28. Connect the A/C pressure transducer electrical 34. Install the cowl vent screen. For additional
connector. information, refer to Section 501-02.
35. NOTE: Use the hood hinge location index
marks made during removal to aid in hood
installation.
Install the hood and 4 bolts.
29. Install the accessory drive belt. For additional
30. Install the radiator sight shield and the 6
pin-type retainers.
37. Install the hood insulation pin-type retainer and
attach the 2 windshield washer hose retainers.
31. Install the engine coolant crossover. For
303-03A.
32. Install the degas bottle. For additional
33. Install the air cleaner and outlet pipe. For
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
2. Remove the LH valve cover. For additional
Camshaft LH
information, refer to Valve Cover LH in this
section.
Special Tool(s)
303-1039
phaser and sprocket assembly will occur if
device.
Loosen and back off the LH camshaft phaser
and sprocket bolt one full turn.
Wedge, Timing Chain
4. Disconnect the LH camshaft position (CMP)
303-1175
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
5. Remove the LH CMP sensor and the bolt.
Removal
CAUTION: The camshaft procedure must
be followed exactly or damage to the valves and
pistons will result.
1. Position the crankshaft damper spoke at the 12
oclock position and the timing mark
indentation at the 1 oclock position.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
positioned as shown, the crankshaft keyway will
require one full additional rotation to 12
oclock.
NOTE: The camshaft roller followers must be
The No. 5 cylinder camshaft lobe must be
coming up on the exhaust stroke. Verify by
camshaft roller follower locations.
noting the position of the 2 intake camshaft
lobes and the exhaust lobe on the No. 5
cylinder.
Using the special tool, remove only the 3
designated camshaft roller followers from the
previous step.
7. Remove only the 3 camshaft roller followers
shown in the illustration.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
Rotate the crankshaft clockwise, as viewed from
the front, positioning the crankshaft damper
spoke at the 6 oclock position and the timing
mark indentation at the 7 oclock position.
10. CAUTION: Engine is not freewheeling.
Camshaft procedure must be followed exactly
or damage to valves and pistons will result.
CAUTION: The Timing Chain Wedge
tool must be installed square to the timing
chain and the engine block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the LH timing chain
as shown.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
11. CAUTION: Do not remove the Timing
Chain Wedge tool at any time during
assembly. If the special tool is removed or
out of placement, the engine front cover
must be removed and the engine must be
retimed. For additional information, refer to
Timing Drive Components in this section.
CAUTION: The timing chain must be
installed in its original position onto the
camshaft phaser and sprocket using the
scribed marks, or damage to valves and
Scribe a location mark on the timing chain and
the camshaft phaser and sprocket assembly.
caps.
remove the front camshaft bearing cap and then
the remaining bearing caps.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
Installation
device.
remove the camshaft phaser and sprocket
bolt or damage may occur to the camshaft or
camshaft phaser and sprocket.
CAUTION: Do not remove the Timing must be removed and the engine must be
Chain Wedge tool at any time during retimed. For additional information, refer to
assembly. If the special tool is removed or Timing Drive Components in this section.
device.
Remove the bolt and withdraw the camshaft
CAUTION: Do not allow the camshaft
from the camshaft phaser and sprocket
roller followers to move out of position when
assembly, leaving the camshaft phaser and
installing the camshaft.
sprocket assembly in place.
Install the camshaft into the camshaft phaser
Discard the bolt and washer.
and sprocket assembly and onto the head.
Install a new camshaft phaser and sprocket bolt
finger-tight.
15. Inspect the camshaft phaser and sprocket for
damage. For additional information, refer to
Camshaft Phaser and Sprocket in this section.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
5. Tighten the bolts in the sequence shown.
Verify the camshaft phaser and sprocket and
timing chain scribe marks are still in alignment.
4. CAUTION: Do not allow the camshaft
original locations.
Lubricate the camshaft bearing caps with
clean engine oil.
caps.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
6. NOTE: Engine front cover removed for clarity. 8. Verify correct camshaft position by noting the
position of the No. 5 cylinder intake and
Remove the special tools.
exhaust camshaft lobes.
9. Using the special tool, install the 3 originally
removed camshaft roller followers.
7. Rotate the crankshaft a half turn
counterclockwise and position the crankshaft
damper spoke at the 12 oclock position and the
timing mark indentation at the 1 oclock
position.
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303-01B-8 303-01B-8 Engine 4.6L (3V)
10. Install the CMP sensor and the bolt.
12. CAUTION: Only use hand tools to
install the camshaft phaser and sprocket
camshaft or camshaft phaser and sprocket.
device.
Tighten the camshaft phaser and sprocket bolt
in 2 stages:
11. Connect the CMP electrical connector.
13. Install the LH valve cover. For additional
section.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
2. Remove the RH valve cover. For additional
Camshaft RH
information, refer to Valve Cover RH in this
section.
Special Tool(s)
303-1039
device.
Loosen and backoff the RH camshaft phaser
and sprocket bolt one full turn.
Wedge, Timing Chain
4. Disconnect the RH camshaft position (CMP)
303-1175
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
CAUTION: The camshaft procedure must
be followed exactly or damage to the valves and
1. Position the crankshaft damper spoke at the 12
oclock position and the timing mark
indentation at the 1 oclock position.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
one full additional rotation to 12 oclock.
NOTE: The camshaft roller followers must be
noting the position of the 2 intake camshaft
camshaft roller follower locations.
lobes and the exhaust lobe on the No. 1
cylinder.
Using the special tool, remove only the 3
designated camshaft roller followers from the
previous step.
7. Remove only the 3 camshaft roller followers
shown in the illustration.
Rotate the crankshaft clockwise, as viewed from
the front, positioning the crankshaft damper
spoke at the 6 oclock position and the timing
mark indentation at the 7 oclock position.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
10. CAUTION: Engine is not freewheeling. 11. CAUTION: Do not remove the Timing
Camshaft procedure must be followed exactly Chain Wedge tool at any time during
or damage to valves and pistons will result. assembly. If the special tool is removed or
CAUTION: The Timing Chain Wedge
tool must be installed square to the timing
chain and the engine block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the RH timing chain
as shown.
Scribe a location mark on the timing chain and
the camshaft phaser and sprocket assembly.
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
remove the front camshaft bearing cap and then
the remaining bearing caps.
device.
remove the camshaft phaser and sprocket
bolt or damage may occur to the camshaft or
camshaft phaser and sprocket.
CAUTION: Do not remove the Timing
Remove the bolt and withdraw the camshaft
from the camshaft phaser and sprocket
assembly, leaving the camshaft phaser and
sprocket assembly in place.
Discard the bolt and washer.
caps.
15. Inspect the camshaft phaser and sprocket for
damage. For additional information, refer to
Camshaft Phaser and Sprocket in this section.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
Installation
Verify the camshaft phaser and sprocket and
timing chain scribe marks are still in alignment.
device.
CAUTION: Do not allow the camshaft
Install the camshaft into the camshaft phaser
and sprocket assembly and onto the head.
Install a new camshaft phaser and sprocket bolt
finger-tight.
4. CAUTION: Do not allow the camshaft
original locations.
clean engine oil.
caps.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
5. Tighten the bolts in the sequence shown.
7. Rotate the crankshaft a half turn
counterclockwise and position the crankshaft
damper spoke at the 12 oclock position and the
timing mark indentation at the 1 oclock
6. NOTE: Engine front cover removed for clarity.
position.
Remove the special tool.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
8. Verify correct camshaft position by noting the 11. Connect the CMP electrical connector.
position of the No. 1 cylinder intake and
exhaust camshaft lobes.
12. CAUTION: Only use hand tools to
install the camshaft phaser and sprocket
9. Using the special tool, install the 3 originally
removed camshaft roller followers.
camshaft or camshaft phaser and sprocket.
device.
Tighten the new camshaft phaser and sprocket
bolt in 2 stages:
10. Install the CMP sensor and the bolt.
13. Install the RH valve cover. For additional
section.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Camshaft Phaser and Sprocket
Special Tool(s)
Wedge, Timing Chain
303-1175
Removal
5. Inspect the rear of the camshaft phaser and
1. If servicing the RH camshaft phaser and
sprocket for a deformed or damaged location
sprocket, remove the RH camshaft. For
pin.
additional information, refer to Camshaft RH
If the location pin is deformed or damaged a
in this section.
new camshaft phaser and sprocket must be
installed.
2. If servicing the LH camshaft phaser and
sprocket, remove the LH camshaft. For
additional information, refer to Camshaft LH
in this section.
device.
CAUTION: Do not remove the Timing
Remove the camshaft phaser and sprocket from
the timing chain.
4. Inspect the front of the camshaft phaser and
sprocket for missing or damaged roll pins.
If the roll pins are missing or damaged, a
new camshaft phaser and sprocket must be
installed.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
6. Visually inspect the camshaft phaser and
2. CAUTION: The timing chain must be
sprocket for squareness (A). If the trigger wheel
or spring is deformed or damaged (B), install a
new camshaft phaser and sprocket.
device.
Align the scribe marks and position the
camshaft phaser and sprocket into the timing
chain.
3. If servicing the RH camshaft phaser and
sprocket, install the RH camshaft. For
additional information, refer to Camshaft RH
in this section.
Installation
4. If servicing the LH camshaft phaser and
sprocket, install the LH camshaft. For additional
information, refer to Camshaft LH in this
section.
device.
If installing a new camshaft phaser and
sprocket, transfer the original scribe mark to the
new camshaft phaser and sprocket.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Camshaft Roller Follower
Special Tool(s)
303-1039
Material
Item Specification
4. Repeat the previous 2 steps for each roller
follower being serviced. Motorcraft SAE 5W-20 WSS-M2C930-A
Motor Oil
5. Inspect the roller follower. For additional
XO-5W20-QSP (US);
Installation
CXO-5W20-LSP12
Removal
1. Depending on the roller follower being
serviced, remove the LH or RH valve cover.
NOTE: Lubricate the roller follower with clean
For additional information, refer to Valve Cover
engine oil.
LH or Valve Cover RH in this section.
Using the special tool, compress the valve
spring and install the camshaft roller follower.
2. Rotate the crankshaft until the piston for the
valve being serviced is at the top of its stroke
with the intake valve and the exhaust valves
closed.
spring and remove the camshaft roller follower.
2. Repeat the previous step for each roller
follower being serviced.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
3. Depending on the valve being serviced, install
the LH or RH valve cover. For additional
information, refer to Valve Cover LH or
Valve Cover RH in this section.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Special Tool(s)
303-107 (T74P-6700-A)
303-635
Installation
crankshaft front seal inner lip with clean engine
oil.
303-335 (T88T-6701-A)
Damper
303-102 (T74P-6316-B)
Material
front seal.
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
1. Remove the crankshaft pulley. For additional
section.
front seal.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
section.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Crankshaft Pulley
Special Tool(s)
3-Jaw Puller
303-D121
Damper
303-102 (T74P-6316-B)
Installation
Material
Item Specification follow this procedure can cause future oil
leakage.
Prep
ZC-31
ZC-30
Sealant
TA-30
Removal
Section 100-02.
4. Remove the crankshaft pulley bolt and washer.
pulley.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
2. Using the special tool, install the crankshaft 3. Using a new crankshaft pulley bolt, install the
pulley. bolt and washer and tighten the bolt in 4 stages.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Material
Crankshaft Rear Seal with Retainer
Item Specification
Plate
Prep
Special Tool(s)
ZC-31
Installer, Crankshaft Rear Seal
303-518 (T95P-6701-DH)
ZC-30
Sealant
TA-30
Gasket Maker WSK-M2G348-A5
TA-16
Remover, Crankshaft Rear Seal Motorcraft SAE 5W-20 WSS-M2C930-A
303-519 (T95P-6701-EH) Premium Synthetic Blend
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
303-516 (T95P-6701-BH)
1. Remove the flywheel or flexplate. For
additional information, refer to Lower End
Components Exploded View, Flexplate,
Flywheel and Crankshaft Rear Seal and
Flexplate or Flywheel in this section.
Remover, Crankshaft Rear Oil
Slinger
303-514 (T95P-6701-AH) 2. Remove the engine-to-transmission spacer plate.
3. Remove the power steering pressure tube
bracket-to-crossmember bolt and position the
bracket aside.
Slinger
303-517 (T95P-6701-CH) intermediate shaft to rotate while it is
and re-centered. For additional information,
Impact Slide Hammer
100-001 (T50T-100-A)
Remove the steering column
coupling-to-steering gear pinch bolt.
Discard the pinch bolt.
5. Remove the 2 steering gear bolts and
disconnect the coupling from the steering gear
while positioning the steering gear forward.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
6. Drain the engine oil.
Install the drain plug when finished.
7. Detach the 2 pin-type wire harness retainers.
8. Remove the 16 oil pan bolts and remove the oil
pan.
retainer plate.
Installation
NOTE: Clean the sealing surfaces with silicone
oil slinger.
Discard the crankshaft oil slinger.
leakage.
Clean and inspect the mating surfaces.
2. NOTE: The rear crankshaft seal retainer plate
does not have a sealant groove. Gasket maker
must be applied to the rear crankshaft seal
retainer mating surface on the engine block.
Apply a bead of gasket maker to the rear
crankshaft seal retainer mating surface on the
engine block.
rear seal.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
3. Install the crankshaft rear seal retainer plate and
the 6 bolts in the sequence shown.
These tools cause scratches and gouges,
which make leak paths. Use a plastic
scraping tool to remove all traces of old
sealant.
Inspect the oil pan. Clean the mating surface
for the oil pan with silicone gasket remover and
packaging.
4. NOTE: Lubricate the inner lip of the crankshaft
rear seal with clean engine oil.
leakage.
Apply silicone gasket and sealant at the
rear seal.
crankshaft rear seal retainer plate-to-cylinder
block sealing surface.
rear oil slinger.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
8. NOTE: If not secured within 4 minutes, the 10. Tighten the bolts in 3 stages, in the sequence
sealant must be removed and the sealing area shown.
leakage.
Apply silicone gasket and sealant at the engine
front cover-to-cylinder block sealing surface.
11. Attach the 2 pin-type wire harness retainers.
intermediate shaft to rotate while it is
9. Install the new oil pan gasket and the oil pan
and loosely install the 16 bolts.
and re-centered. For additional information,
Position the steering gear while connecting the
steering column coupling to the steering gear
and install the 2 steering gear bolts.
13. Install the new steering column
coupling-to-steering gear pinch bolt.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
14. Position the power steering pressure tube 16. Install the flywheel or flexplate. For additional
bracket and install the pressure tube information, refer to Lower End Components
bracket-to-crossmember bolt. Exploded View, Flexplate, Flywheel and
Crankshaft Rear Seal and Flexplate or
18. Start the engine and check for leaks.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Material
Item Specification
Motor Oil
303-518 (T95P-6701-DH)
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
303-519 (T95P-6701-EH)
1. Remove the flywheel or flexplate. For
additional information, refer to Lower End
Components Exploded View, Flexplate,
Flywheel and Crankshaft Rear Seal and
Flexplate or Flywheel in this section.
303-516 (T95P-6701-BH)
oil slinger.
Discard the crankshaft oil slinger.
Slinger
303-514 (T95P-6701-AH)
Slinger
303-517 (T95P-6701-CH)
rear seal.
Impact Slide Hammer
100-001 (T50T-100-A)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
Installation
rear seal.
3. Install the flywheel or flexplate. For additional
information, refer to Lower End Components
Exploded View, Flexplate, Flywheel and
Crankshaft Rear Seal and Flexplate or
rear oil slinger.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Material
Engine Front Cover
Item Specification
3-Jaw Puller
Motor Oil
303-D121
XO-5W20-QSP (US);
CXO-5W20-LSP12
Sealant
TA-30
303-107 (T74P-6700-A)
Prep
ZC-31
ZC-30
303-335 (T88T-6701-A)
303-635
Damper
303-102 (T74P-6316-B)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
7 18801 LH radio ignition interference 1 RH camshaft position (CMP)
capacitor sensor electrical connector
(part of 12B637)
8 LH CMP sensor electrical
connector (part of 12B637) 2 N804758 RH radio ignition interference
capacitor nut
9 W705023 Power steering pump stud
bolt (3 required) 3 18801 RH radio ignition interference
capacitor
4 8620 Upper coolant hose
11 N806282 Coolant pump pulley bolts (4
required) 5 15161 Hose clamp
12 8A528 Coolant pump pulley 6 N804758 LH radio ignition interference
capacitor nut (Continued)
(Continued)
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303-01B-3 303-01B-3 Engine 4.6L (3V)
13 W701512 Crankshaft pulley bolt 15 6316 Crankshaft pulley
14 N806165 Crankshaft pulley bolt washer 16 6700 Crankshaft front oil seal
(Continued)
Install the drain plug and tighten to 26 Nm 17 Crankshaft position (CKP)
sensor electrical connector (19 lb-ft).
(part of 12B637)
18 W701605 Oil pan bolt (4 required) 3. Remove the engine coolant degas bottle. For
19 N806177 Engine front cover bolt (9
required) 303-03A.
20 N806300 Engine front cover stud (4
4. Remove the RH side idler pulley. For additional required)
21 N808586 Engine front cover stud bolt
22 W706508 Engine front cover stud bolt
5. Remove the RH valve cover. For additional
23 6C086 Engine front cover
24 6D081 Engine front cover gasket (3
section.
required)
6. Remove the LH valve cover. For additional
Removal
section.
hoist. For additional information, refer to 7. Disconnect the upper coolant hose from the
Section 100-02. engine.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
8. Remove the nut and position aside the RH radio
ignition interference capacitor.
9. Disconnect the RH camshaft position (CMP)
10. Remove the nut and position aside the LH radio
ignition interference capacitor.
11. Disconnect the LH CMP sensor electrical
connector.
12. Remove the 4 bolts and the coolant pump
pulley.
front oil seal.
13. Remove the wiring harness retainer from the
power steering stud bolt.
19. Remove the 4 front oil pan bolts.
14. Remove the 3 stud bolts and position the power
20. Remove the bolts and the stud bolts.
Support the power steering pump with a
length of mechanics wire.
16. Remove the crankshaft pulley bolt and washer.
pulley.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
Remove the engine front cover from the front
cover to cylinder block dowel.
Remove the engine front cover gaskets.
Clean the mating surfaces with silicone
gasket remover and metal surface prep.
Inspect the mating surfaces.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
Installation
surface and the oil pan-to-cylinder block
surface, at the locations shown.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
Part
14 N806300 Stud, Hex Shoulder Pilot, M8 cover onto the dowels. Install the fasteners
x 1.25 x 1.25 x 91.1
finger tight.
x 1.25 x 1.25 x 91.1
3. Tighten the engine front cover fasteners in the
sequence shown to 25 Nm (18 lb-ft).
Part
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
x 1.25 x 50 - M6 x 1 x 10 4. Loosely install the bolts, then tighten the bolts
in 2 stages, in the sequence shown.
Pilot, M8 x 1.25 - M6 x 1 x
86.35
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
x 1.25 x 1.25 x 91.1
x 1.25 x 1.25 x 91.1
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303-01B-8 303-01B-8 Engine 4.6L (3V)
crankshaft front oil seal inner lip with clean
engine oil.
pulley.
front oil seal.
sealant must be removed and the sealing area Stage 3: Tighten to 50 Nm (37 lb-ft).
cleaned with metal surface prep and silicone
10. Connect the CKP sensor electrical connector.
11. Position the power steering pump assembly and
install the stud bolts.
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303-01B-9 303-01B-9 Engine 4.6L (3V)
12. Install the wiring retainer on the power steering 16. Connect the RH CMP sensor electrical
stud bolt. connector.
capacitor and the nut.
18. Connect the upper coolant hose to the engine.
19. Install the RH valve cover. For additional
section.
20. Install the LH valve cover. For additional
section.
13. Install the coolant pump pulley and the 4 bolts.
21. Install the accessory drive belt tensioner and 3
idler pulleys. For additional information, refer
to Section 303-05.
14. Connect the LH CMP sensor electrical
connector.
22. Install the engine coolant degas bottle. For
15. Install the LH radio ignition interference
303-03A.
capacitor and nut onto the engine front cover
stud bolt.
23. Fill the crankcase with clean engine oil.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Exploded View
6 Wiring harness pin-type 1 Pin-type retainer
retainer (part of 14305)
2 8C291 Radiator sight shield
7 N804758 Generator nut (2 required)
3 W705790 B+ terminal nut
8 N807309 Generator bracket bolt
4 B+ terminal cover (part of
9 W704682 Generator bracket bolt 14305)
10 10300 Generator 5 14A4644 Generator electrical connector
(part of 14305)
(Continued)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
14 N621943 Engine support insulator nut 11 W711075 Subframe bolt (4 required)
(2 required)
12 W707246 Subframe nut (4 required)
13 5025 Subframe
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
21 N806155 Oil pump screen and pickup 15 Pin-type retainer (2 required)
tube-to-oil pump bolts (2 (part of 12B637)
required)
16 W701605 Oil pan bolt (16 required)
22 N806183 Oil pump bolt (3 required)
17 6675 Oil pan
23 6621 Oil pump
18 6710 Oil pan gasket
19 N605904 Oil pump screen and pickup
tube-to-spacer bolt
tube
(Continued)
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Engine Support Insulators
Special Tool(s)
303-F072
303-050 (T70P-6000)
Material
Item Specification
Prep
ZC-31
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
(part of 14305)
(Continued)
11 N621943 RH engine support insulator
nut
12 W707641 RH engine support insulator
bolt (2 required)
13 6038 RH engine support insulator
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
5. Disconnect the evaporative emissions (EVAP)
canister purge valve vapor tube quick connect
14 N621943 LH engine support insulator
coupling from the intake manifold and position
nut
aside. For additional information, refer to
15 W500721 LH engine support bracket
Section 310-00.
bolt (4 required)
16 6B033 LH engine support bracket
17 W707641 LH engine support insulator
bolt (2 required)
18 6038 LH engine support insulator
Removal
All engine support insulators
Section 100-02.
6. Remove the 6 pin-type retainers and the 2. Disconnect the battery ground cable. For
radiator sight shield. additional information, refer to Section 414-01.
7. Remove the 2 outer generator bracket bolts. 3. Remove the air cleaner assembly. For additional
8. Remove the 2 lower generator nuts.
4. Remove the throttle body. For additional
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
9. Disconnect the generator electrical connector
and pin-type retainer.
10. Position the B+ terminal cover aside and
remove the B+ terminal nut.
Remove the generator.
14. Using the special tool, raise the engine 40 mm
(1.57 in).
RH engine support insulator
15. Remove the 2 engine support
insulator-to-subframe bolts.
Remove the RH engine support insulator.
LH engine support insulator
13. NOTE: Both the RH and LH engine support
16. Remove the 4 bolts and the LH engine support
insulator nuts must be removed to allow the
bracket.
engine to be raised.
17. Remove the 2 engine support
insulator-to-subframe bolts.
Remove the RH and LH engine support
insulator nuts.
Remove the LH engine support insulator.
Installation
1. Install the LH engine support insulator and 2
engine support insulator-to-subframe bolts.
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
2. Install the LH engine support bracket and 4 6. NOTE: Make sure the B+ cable is positioned
bolts. close to the generator when the nut is being
tightened.
Position the generator and install the B+
terminal and nut.
3. Install the RH engine support insulator and 2
engine support insulator-to-subframe bolts.
7. Connect the generator electrical connector and
pin-type retainer.
8. Install the 2 lower generator nuts. All engine support insulators
4. Using the special tool, lower the engine.
9. Install the 2 outer generator bracket bolts.
10. Install the radiator sight shield and 6 pin-type
retainers.
11. Connect the EVAP canister purge valve vapor
tube to the intake manifold. For additional
nuts.
12. Install the throttle body. For additional
13. Install the air cleaner assembly. For additional
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Exhaust Manifold LH
Special Tool(s)
303-F072
303-050 (T70P-6000)
Material
Item Specification
Prep
ZC-31
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
(part of 14305)
(Continued)
14 W500721 LH engine support insulator 11 W701706 RH catalytic
bracket bolt (4 required) converter-to-exhaust manifold
nut (2 required)
15 6B033 LH engine support insulator
bracket 12 W701706 LH catalytic
converter-to-exhaust manifold
nut (2 required)
13 N621943 LH engine support insulator
nut
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
required)
18 9Y431 LH exhaust manifold gasket
(2 required)
Removal
Section 100-02.
6. Remove the 2 RH catalytic converter-to-exhaust
manifold nuts.
7. Remove the 2 LH catalytic converter-to-exhaust
manifold nuts.
(HO2S) electrical connector and wiring retainer.
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
9. Using a suitable belt tensioner release tool,
rotate the accessory drive belt tensioner
clockwise and position the accessory drive belt
aside from the generator pulley.
10. Remove the 2 outer generator bracket bolts.
insulator nuts.
(1.57 in).
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
Installation
1. Install new exhaust manifold gaskets.
2. Install the exhaust manifold and 8 new nuts.
Tighten the nuts in the sequence shown to
25 Nm (18 lb-ft).
501-20B.
Remove the bolt and disconnect the steering
coupling.
Discard the bolt.
3. Install the LH engine support insulator bracket
and the 4 bolts.
19. Remove the 4 bolts and the LH engine support 4. CAUTION: Do not allow the steering
insulator bracket. wheel to rotate while the steering column
20. Remove the 8 nuts and the exhaust manifold.
Discard the nuts.
501-20B
Connect the steering coupling and install the
new bolt.
These may cause scratches and gouges
resulting in leak paths. Use a plastic scraper
to clean the sealing surfaces.
NOTE: Clean the sealing surfaces with metal
packaging.
Remove and discard the exhaust manifold
gaskets.
Clean the sealing surfaces with metal
surface prep.
http://vnx.su
303-01B-6 303-01B-6 Engine 4.6L (3V)
10. NOTE: Make sure the B+ cable is positioned
close to the generator when the nut is being
tightened.
nuts.
terminal and nut.
pin-type retainer.
12. Install the 2 lower generator nuts.
onto the generator pulley.
7. Install the 2 LH catalytic converter-to-exhaust
manifold nuts.
8. Install the 2 RH catalytic converter-to-exhaust
manifold nuts.
9. Connect the LH HO2S electrical connector and
wiring retainer.
retainers.
http://vnx.su
303-01B-7 303-01B-7 Engine 4.6L (3V)
17. Install the air cleaner assembly. For additional 18. Connect the battery ground cable. For additional
information, refer to Section 303-12. information, refer to Section 414-01.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Exhaust Manifold RH
Special Tool(s)
303-F072
303-050 (T70P-6000)
Material
Item Specification
Prep
ZC-31
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
(part of 14305)
(Continued)
14 W500721 RH engine support bracket 11 W701706 LH catalytic
bolt (2 required) converter-to-exhaust manifold
nuts (2 required)
bracket stud bolt (2 required) 12 W701706 RH catalytic
converter-to-exhaust manifold
nut (2 required)
bracket
13 N621943 RH engine support insulator
nut
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
6. Remove the 2 RH catalytic converter-to-exhaust
manifold nuts.
17 W701706 RH exhaust manifold nut (8
required)
7. Remove the 2 LH catalytic converter-to-exhaust
manifold nuts.
19 9Y431 RH exhaust manifold gasket
(2 required)
Removal
All vehicles
aside from the generator pulley. 1. With the vehicle in NEUTRAL, position it on a
Section 100-02.
5. Remove the starter. For additional information,
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
(1.57 in).
18. Remove the nut and the ground wire from the
stud bolt.
insulator nuts.
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
2. Install the exhaust manifold and 8 new nuts.
Tighten the nuts in the sequence shown to
19. Remove the nut and position aside the
25 Nm (18 lb-ft).
transmission cooler tube bracket.
3. Install the RH engine support insulator bracket,
All vehicles
the 2 bolts and 2 stud bolts.
20. Remove the 2 bolts, 2 stud bolts and the RH
engine support bracket. Vehicles with automatic transmission
21. Remove the 8 nuts and the exhaust manifold.
Discard the nuts.
nut.
These may cause scratches and gouges
NOTE: Clean the sealing surfaces with metal
packaging.
Remove and discard the exhaust manifold
gaskets.
Clean the sealing surfaces with metal
surface prep.
Installation
All vehicles
1. Install new exhaust manifold gaskets.
http://vnx.su
303-01B-6 303-01B-6 Engine 4.6L (3V)
All vehicles
8. Install the 2 LH catalytic converter-to-exhaust
manifold nuts.
5. Install the ground wire and nut onto the stud
bolt.
9. Install the 2 RH catalytic converter-to-exhaust
manifold nuts.
tightened.
terminal and nut.
pin-type retainer.
onto the generator pulley.
nuts.
retainers.
16. Install the starter. For additional information,
http://vnx.su
303-01B-7 303-01B-7 Engine 4.6L (3V)
18. Install the air cleaner assembly. For additional 19. Connect the battery ground cable. For additional
information, refer to Section 303-12. information, refer to Section 414-01.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Flexplate
2. Remove the 6 bolts and the flexplate.
To install, tighten to 80 Nm (59 lb-ft) in the
sequence shown.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Flywheel
sequence shown.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
2. Remove the remaining roller followers from the
cylinder head being serviced.
Material
Item Specification
Motor Oil
XO-5W20-QSP (US); Remove the hydraulic lash adjusters that are
being serviced.
CXO-5W20-LSP12
4. Inspect the hydraulic lash adjusters. For
5. NOTE: Lubricate each of the hydraulic lash
adjusters with clean engine oil prior to
1. Remove the camshafts. For additional
installation.
information, refer to Valve Train Components
Exploded View and Camshaft LH and
Camshaft RH in this section.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Intake Manifold
Material
Item Specification
Prep
ZC-31
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
tube from the intake manifold and position the
1 14A464 Charge motion control valve
tube aside.
(CMCV) electrical connector
(part of 12B637)
5. Disconnect the positive crankcase ventilation
2 9F792 Vacuum hose T-fitting
(PCV) tube from the intake manifold, LH valve
3 Wiring harness retainer (part
cover and remove.
of 12B637)
4 Wiring harness pin-type
6. Disconnect the throttle position (TP) sensor and
retainer (part of 12B637)
electronic throttle body electrical connectors.
5 9G271 Evaporative emissions
(EVAP) tube
7. Disconnect the charge motion control valve
(CMCV) electrical connector.
(PCV) tube
7 14A464 Electronic throttle body
8. Detach the wiring retainers from the intake
manifold stud bolt and the CMCV bracket and
12B637)
then position the wiring harness aside.
8 14A464 Throttle position (TP) sensor
9. Disconnect the vacuum hose from the T-fitting.
12B637)
9 W709552 Intake manifold bolt (9
required)
10 W710464 Intake manifold stud bolt
11 9425 Intake manifold
required)
NOTE: Clean and inspect the sealing surfaces
Removal
with metal surface prep. Follow the directions
on the packaging.
WARNING: Do not smoke or carry lighted
Remove the 9 bolts, the stud bolt and the intake
tobacco or open flame of any type when working
manifold.
on or near any fuel-related component. Highly
flammable mixtures are always present and may
be ignited. Failure to follow these instructions
WARNING: Fuel in the fuel system
remains under high pressure even when the
engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.
3. Remove the fuel rail and injectors. For
303-04B.
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
Installation
3. Connect the vacuum hose to the T-fitting.
4. Position the wiring harness and attach the
1. NOTE: Electrical and vacuum harnesses must
wiring retainers to the intake manifold stud bolt
not restrict movement of the charge motion
and the CMCV bracket.
control valve (CMCV) control rods at rear of
the intake manifold. Use extreme care on
5. Connect the CMCV electrical connector.
installation of the intake manifold to prevent
any pinching of electrical and vacuum
6. Connect the TP sensor and electronic throttle
harnesses.
body electrical connectors.
Using new intake manifold gaskets, position the
intake manifold.
7. Connect the PCV tube to the intake manifold.
2. Install the intake manifold bolts and stud bolt.
8. Connect the EVAP tube to the intake manifold.
9. Install the fuel rail and injectors. For additional
(89 lb-in).
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
1 W701512 Crankshaft pulley bolt
2 N806165 Crankshaft pulley bolt washer
3 6316 Crankshaft pulley
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
View, Flexplate, Flywheel and
3 3N725 Steering column coupling 1 W505255 Power steering pressure tube
4 W710909 Steering gear bolt (2 required)
5 3200 Steering gear
coupling-to-steering gear
pinch bolt
(Continued)
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
12 6675 Oil pan 6 N808139/ Flywheel/flexplate bolt (6
N806168 required)
7 6375 Flywheel/flexplate
14 6310 Crankshaft oil slinger
8 6A373 Engine-to-transmission spacer
15 6701 Crankshaft rear seal
plate
16 N806155 Crankshaft rear seal retainer
9 6730 Oil pan drain plug
plate bolt (6 required)
10 Pin-type retainer (2 required)
17 6K318 Crankshaft rear seal retainer
(part of 12B637)
plate
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Oil Filter Adapter
Material
Item Specification
Prep
ZC-31
ZC-30
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
3 15161 Hose clamp 1 6714 Oil filter
4 8B273 Thermostat housing-to-oil 2 14A464 Engine oil pressure (EOP)
filter adapter hose sensor electrical connector
(part of 12B637) (Continued)
(Continued)
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
5 N806156 Oil filter adapter bolt (4 To install, tighten to 25 Nm (18 lb-ft).
required)
7 6A636 Oil filter adapter gasket wire brushes, power abrasive discs or other
Removal and Installation These may cause scratches and gouges
Remove and discard the oil filter adapter
Section 100-02.
gasket.
Clean the sealing surfaces with silicone
(19 lb-ft).
Fill the engine with clean engine oil.
4. Disconnect the engine oil pressure (EOP) sensor
303-03A.
5. Disconnect the lower radiator-to-oil filter
adapter hose and position it aside.
To install, lubricate the oil filter gasket with
clean engine oil and tighten until the seal
makes contact.
X Using an oil filter strap wrench, tighten
the filter an additional 270 degrees.
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
SPECIFICATIONS
Item Specification
Item Specification exhaust (0.234-0.235 in)
Lubricants and Sealants Valve stem-to-guide 0.020-0.069 mm
clearance intake (0.001-0.003 in)
Premium Synthetic Blend Valve stem-to-guide 0.045-0.094 mm
Motor Oil XO-5W20-QSP clearance exhaust (0.002-0.004 in)
Valve head diameter 33.62-33.98 mm
5W-20 Super Premium
intake (1.324-1.338 in)
Motor Oil
CXO-5W20-LSP12 Valve head diameter 37.32-37.68 mm
(Canada); or equivalent exhaust (1.469-1.483 in)
Motorcraft Premium Gold WSS-M97B51-A1 Valve face runout 0.05 mm (0.002 in)
Engine Coolant with
Valve face angle 45.5 degrees
Valve seat width 1.2-1.4 mm VC-7-B (US); CVC-7-A
intake (0.047-0.055 in) (Canada); or equivalent
(yellow color)
exhaust (0.055-0.063 in) Motorcraft Metal Surface
Prep ZC-31
Valve seat angle 44.5-45.0 degrees
Valve spring free length 56.5 mm (2.22 in)
ZC-30
Valve spring compression 760 N (79 lbs) 39.0 N
pressure (maximum lift) (4 lbs) @ 31.04 mm (1.22
Sealant TA-30
in)
Engine
Valve spring installed 42.04 mm (1.66 in)
height Displacement 4.6L (281 CID)
Valve spring installed 350 N (79 lbs) 17.5 N Number of cylinders 8
pressure (4 lbs) @ 42.04 mm (1.66
Bore 90.2 mm (3.55 in)
in)
Stroke 90.0 mm (3.54 in)
Firing order 1-3-7-2-6-5-4-8
Diameter 15.988-16.000 mm
Oil pressure minimum at 517 kPa (75 psi) (0.6294-0.6299 in)
2,000 rpm (engine at
Clearance-to-bore 0.018-0.069
normal operating
(0.0007-0.0027 in)
temperature)
Service limit
Oil capacity 5.7 liters (6 quarts) with
Collapsed lash adjuster 0.45-0.85 (0.018-0.033) filter
gap
Compression ratio 9.8:1
Camshaft
Combustion chamber 48.1-51.1 cc
lash intake
volume (2.94-3.12 cu in)
Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I
lash exhaust
to rear) LH
Lobe lift intake 5.520 mm (0.217 in)
Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I
Lobe lift exhaust 5.506 mm (0.217 in) to rear) RH
Allowable lobe lift loss 0.00127 mm (0.005 in) Valve guide bore diameter 6.015-6.044 mm
(0.237-0.238 in)
(1.126-1.127 in) Valve stem diameter 5.975-5.995 mm
intake (0.235-0.236 in)
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
Camshaft journal bore 28.657-28.682 mm Piston diameter grade 90.208-90.193 mm
inside diameter (1.128-1.129 in) 3 (at right angle to pin (3.5515-3.551 in)
bore) (uncoated)
Camshaft 0.024-0.075 mm
journal-to-bearing (0.001-0.003 in) Piston-to-cylinder bore 0.017-0.047 mm
clearance clearance (at grade size) (0.0007-0.0019 in)
Runout 0.03 mm (0.001 in) Piston ring end gap top 0.15-0.30 mm
(0.006-0.012 in)
End play 0.0050-0.250 mm
(0.0002-0.009 in) Piston ring end gap 0.25-0.50 mm
intermediate (0.0098-0.0197 in)
Cylinder Block
Piston ring end gap oil 0.15-0.65 mm
Cylinder bore diameter 90.200-90.210 mm
control (0.0059-0.0256 in)
grade 1 (3.5512-3.5516 in)
top (0.0598-0.0606 in)
grade 2 (3.5516-3.5520 in)
grade 3 (3.5520-3.5524 in)
oil control (0.1193-0.1203 in)
taper
Piston ring width top 1.50-1.48 mm
and intermediate (0.0590-0.0582 in)
out-of-round
Main bearing bore inside 72.400-72.424 mm
clearance top (0.0008-0.0020 in)
Crankshaft
clearance intermediate (0.0008-0.0020 in)
diameter (2.6567-2.6576 in)
(0.8666-0.8668 in)
Piston pin diameter 22.0010-22.0030 mm
maximum taper
(0.8662-0.8663 in)
Piston pin length 61.8 mm (2.433 in)
maximum out-of-round between cross sections
Main bearing 0.048-0.024 mm
(0.0004-0.0009 in)
journal-to-cylinder block (0.0019-0.0009 in)
clearance Connecting rod-to-pin 0.009-0.023 mm
clearance (0.0004-0.0009 in)
Connecting rod journal 53.003-52.983 mm
diameter (2.0867-2.0859 in) Connecting rod pin bore 22.012-22.024 mm
diameter (0.8666-0.8671 in)
maximum taper Connecting rod length 150.7 mm (5.933 in)
(center-to-center)
maximum out-of-round between cross sections Connecting rod maximum 0.038 mm (0.0015 in)
allowed bend
Crankshaft maximum end 0.075-0.377 mm
play (0.0030-0.0148 in) Connecting rod maximum 0.05 mm (0.0020 in)
allowed twist
a
Piston and Connecting Rod
Connecting rod bearing 53.049-53.027 mm
Piston diameter grade 90.182-90.167 mm
bore diameter (with (2.0885-2.0877 in)
1 (at right angle to pin (3.5504-3.5499 in)
assembled liners)
bore) (uncoated)
Piston diameter grade 90.196-90.179 mm
2 (at right angle to pin (3.551-3.5503 in)
bore) (uncoated)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
Connecting rod 0.024-0.066 mm Cylinder head 26 19
bearing-to-crankshaft (0.0009-0.0026 in) temperature sensor
clearance (CHT)
Connecting rod side 0.5-0.15 mm Cylinder heads bolts
a

clearance (0.02-0.006 in)
Engine front cover
bolts
a
a The pin bore and crank bearing bore must be
parallel and in the same vertical plane within the Engine support bracket 55 41
specified total difference when measured at the ends bolts
of a 203 mm bar, 105.5 mm on each side of rod
Engine support 63 46
centerline.
insulator nuts
Exhaust manifold nuts
a

Flexplate bolts 80 59
A/C compressor bolts 25 18
nut
Generator lower 25 18
idler pulley bolts
mounting bolts
Generator lower 25 18
tensioner bolts
mounting nuts
Camshaft bearing cap
Generator mounting 10 89
bolts
a
bracket bolts
Camshaft phaser
Ground strap-to-cowl 6 53
sprocket assembly
bolt
bolts
a
Ground 10 89
strap-to-cylinder head
(CMP) sensor bolt
stud bolt
Catalytic 40 30
Ground strap-to-engine 25 18
converter-to-exhaust
support bracket nut
manifold nuts
Ignition coil bolts 6 53
Connecting rod bolts
a

Intake manifold bolts
a

Knock sensor (KS) 20 15
Coolant pump pulley 25 18
Oil filter adapter bolts 25 18
bolts
Oil level indicator tube 10 89
Coolant tube stud bolt 10 89
bolt
Crankshaft main
Oil pan drain plug 26 19
bearing bolts
a
Oil pan bolts
a

Crankshaft main
bearing bolts Oil pump bolts 10 89
(cross-mounted)
a
Oil pump screen and 25 18
Crankshaft main pickup tube spacer
bearing stud bolts
a
Crankshaft position 10 89 pickup tube-to-oil
(CKP) sensor bolt pump bolts
Crankshaft pulley bolt
a
pickup tube-to-spacer
Crankshaft rear seal
bolt
retainer plate bolts
a
connector bolt
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
Power steering pressure 9 80 Transmission cooler 25 18
tube line bracket nut
bracket-to-crossmember
Throttle body bolts 10 89
bolt
Throttle body nuts 10 89
Timing chain guide 10 89 stud bolts
bolts
Power steering tube 10 89
Timing chain hydraulic 25 18 retaining clip nut
tensioner bolts
Radio interference 25 18
Timing chain tensioner 10 89 capacitor nuts
arm bolts
Spark plugs 34 25
Valve cover bolts
a

Variable camshaft 10 89 coupling pinch bolt
timing (VCT) housing
bolts
Subframe bolts 115 85
Windage tray nuts 25 18
Subframe nuts 115 85
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
ASSEMBLY
Special Tool(s)
Engine
303-D032 (D81L-6002-C) or
Special Tool(s)
equivalent
Head
303-572 (T97T-6000-A)
303-518 (T95P-6701-DH)
303-442 (T93P-6136-A)
Installer, Crankshaft Oil Slinger
303-517 (T95P-6701-CH)
303-1039
303-516 (T95P-6701-EH)
Damper
303-102 (T74P-6316-B)
Alignment Pins, Cylinder Head
303-1040 (SR-015486)
303-635
303-F047 (014-00073) or
equivalent
303-335 (T88T-6701-A)
Sprocket
303-1046
(Continued)
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
Material Material
Motorcraft Premium Gold WSS-M97B51-A1 Motorcraft Metal Surface
Engine Coolant with Prep
Bittering Agent (US only) ZC-31
ZC-30
(yellow color)
Sealant
Retaining Clip
TA-30
1L3Z-6P250-AA
Gasket Maker WSK-M2G348-A5
TA-16
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
Engine Upper End
7 14B102 Cylinder head temperature 1 6582 RH valve cover
(CHT) sensor jumper harness
2 6B284 RH camshaft thrust bearing
8 6G004 CHT sensor cap
9 6049 RH cylinder head 3 6C524 RH camshaft phaser sprocket
10 6051 RH cylinder head gasket 4 6250 RH camshaft
11 6C260 RH variable camshaft timing 5 6B280 Camshaft bearing cap (8
(VCT) oil control solenoid required)
assembly
(Continued)
(Continued)
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303-01B-4 303-01B-4 Engine 4.6L (3V)
12 9Y431 Exhaust manifold gasket (2 28 6518 Valve spring retainer key (48
required) required)
13 9430 Exhaust manifold RH 29 6514 Valve spring retainer (24
required)
14 6C261 LH VCT oil control solenoid
assembly 30 6513 Valve spring (24 required)
15 6505 Exhaust valve (8 required) 31 6A517 Valve stem seal (24 required)
16 6083 LH cylinder head gasket 32 9Y431 Exhaust manifold gasket (2
required)
17 6507 Intake valve (16 required)
34 18B402 Coolant tube
19 6C524 LH camshaft phaser sprocket
20 6C255 LH camshaft
36 6K873 Oil level indicator tube
21 6B284 LH camshaft thrust bearing
cap 37 W706175 Ignition coil bolt (8 required)
22 N807834 Camshaft bearing cap bolt (20 38 9F792 Fuel rail assembly
required)
39 9424 Intake manifold assembly
23 6A505 LH valve cover
40 8C369 Engine coolant crossover
41 9F991 Electronic throttle body
(PCV) tube
42 9F860 Fuel injector (8 required)
25 12A366 Ignition coil (8 required)
43 9C995 Fuel injector clip (8 required)
26 6529 Roller follower (24 required)
44 9F798 D-ring seal (16 required)
required)
(Continued)
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303-01B-5 303-01B-5 Engine 4.6L (3V)
Engine Lower End
8 6B288 Camshaft position (CMP) 1 8A528 Coolant pump pulley
sensor (2 required)
2 8501 Coolant pump
9 6C315 Crankshaft position (CKP)
sensor
5 12A216 Accessory drive belt idler
11 6L266 RH timing chain tensioner
pulley (2 required)
12 12A227 Ignition pulse wheel
6 6C348 Accessory drive belt idler
13 6K255 RH tensioner arm pulley
14 6306 Crankshaft sprocket 7 6B209 Accessory drive belt tensioner
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303-01B-6 303-01B-6 Engine 4.6L (3V)
15 6268 RH timing chain 46 6211 Connecting rod upper bearing
(8 required)
16 6M256 RH timing chain guide
47 6110 Piston (8 required)
17 6M269 LH timing chain tensioner
48 6159 Outer oil control ring (8
18 6M274 LH tensioner arm
required)
19 6268 LH timing chain
49 6159 Outer oil control ring (8
20 6B274 LH timing chain guide
required)
21 6375 Flexplate
50 6150 Upper compression ring (8
required) 22 6701 Crankshaft oil slinger
51 6152 Lower compression ring (8 23 6310 Crankshaft rear seal
required)
52 6161 Inner oil control ring (8 plate
required)
25 7B546 Pressure plate
26 6375 Flywheel
1. Record the main bearing code found on the
front of the engine block.
28 6714 Oil filter
29 6675 Oil pan
tube
tube spacer
33 6687 Windage tray
34 6A636 Oil filter adapter gasket
35 6325 Crankshaft main bearing cap
(5 required)
36 6A338 Lower crankshaft bearing (4
required)
37 6210 Connecting rod cap (8
2. Record the main bearing code found on the
required)
back of the crankshaft.
38 6211 Connecting rod lower bearing
(8 required)
39 6K302 Lower crankshaft thrust
washer
40 6303 Crankshaft
41 6333 Upper crankshaft bearing (5
required)
42 6A341 Upper crankshaft thrust
washer
43 6621 Oil pump
44 12A699 Knock sensor
45 6010 Cylinder block
(Continued)
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303-01B-7 303-01B-7 Engine 4.6L (3V)
3. Using the data recorded earlier and the Bearing
Select Fit Chart, Standard Bearings, determine
the required bearing grade for each main
bearing.
Read the first letter of the engine block
main bearing code and the first letter of the
crankshaft main bearing code.
Read down the column below the engine
block main bearing code letter and across
the row next to the crankshaft main bearing
code letter, until the 2 intersect. This is the
required bearing grade for the No. 1
crankshaft main bearing.
As an example, if the engine block code
letter is F and the crankshaft code letter
is D, the correct bearing grade for this
main bearing is a 2.
Repeat this process for the remaining 4
main bearings.
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303-01B-8 303-01B-8 Engine 4.6L (3V)
4. If oversize bearings are being used, use the
procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine
the required bearing grade for each main
bearing.
5. NOTE: Before assembling the cylinder block,
all sealing surfaces must be free of chips, dirt,
paint and foreign material. Also, make sure the
coolant and oil passages are clear.
Install the crankshaft main bearings.
Install the crankshaft upper main bearings
into the cylinder block.
Install the crankshaft lower main bearings
into the bearing caps.
Make sure all oil passages are aligned.
Lubricate all main bearings with clean
engine oil.
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303-01B-9 303-01B-9 Engine 4.6L (3V)
6. Lubricate the crankshaft bearing journals with
clean engine oil. Install the crankshaft onto the
upper crankshaft main bearings.
8. Install the rear (No. 5) main bearing cap.
9. Install the crankshaft lower main bearings into
the main bearing caps and lubricate them with
clean engine oil. Locate the main bearing cap
on the cylinder block and, keeping the cap as
square as possible, alternately draw the cap
down evenly using the cap fasteners.
10. Push the crankshaft forward to seat the
crankshaft thrust washer. Hold the crankshaft in
the forward position.
7. NOTE: The oil groove on the thrust washer
must face toward the rear of the engine (against
the crankshaft thrust surface).
Push the crankshaft rearward and install the rear
crankshaft upper thrust washer at the back of
the No. 5 main boss.
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303-01B-10 303-01B-10 Engine 4.6L (3V)
11. Install the vertical main bearing cap fasteners
and tighten in the sequence shown, in 4 stages.
Stage 1: Tighten fasteners 1 through 20 to
10 Nm (89 lb-in).
25 Nm (18 lb-ft).
40 Nm (30 lb-ft).
Stage 4: Tighten fasteners 1 through 20 an
additional 90 degrees.
13. Check the crankshaft end play. For additional
14. Check that crankshaft torque-to-turn does not
exceed 6 Nm (53 lb-in).
15. Check the piston-to-cylinder block and piston
ring clearances. For additional information, refer
to Section 303-00.
16. Assemble the pistons. For additional
information, refer to Piston in this section.
12. Install the cross-mounted main bearing cap
fasteners and tighten in the sequence shown, in
2 stages.
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303-01B-11 303-01B-11 Engine 4.6L (3V)
connecting rod.
Once the connecting rod is seated on the
crankshaft journal, remove the special tools.
connecting rod.
20. CAUTION: The rod cap installation
NOTE: The following piston installation steps
must keep the same orientation as marked
are for all 8 connecting rods, rod bearings and
during disassembly.
pistons. Only 1 connecting rod, rod bearing and
NOTE: The connecting rod caps are of the
piston is shown.
cracked design and must mate with the
Use the special tools to install the connecting
connecting rod ends. Excessive bearing
rod with the upper connecting rod bearing in
clearance will result if not mated correctly.
place.
Position the lower bearing and connecting rod
Lubricate the piston and ring with clean
and install the new bolts loosely.
engine oil
Lubricate the rod bearings with clean engine
oil.
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303-01B-12 303-01B-12 Engine 4.6L (3V)
21. NOTE: Main bearing caps are removed for 23. Install the windage tray and the 7 nuts.
clarity.
shown.
22. Position the oil pump and install the 3 bolts.
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303-01B-13 303-01B-13 Engine 4.6L (3V)
24. CAUTION: Make sure the O-ring is in 25. CAUTION: Make sure all coolant
place and not damaged. A missing or residue and foreign material are cleaned
damaged O-ring can cause foam in the from the block surface and cylinder bore.
lubrication system, low oil pressure and
severe engine damage.
NOTE: Clean and inspect the mating surfaces
and install a new O-ring. Lubricate the O-ring
dry.
Install the spacer, oil pump screen and pickup
must be discarded and new bolts installed.
tube and the 3 bolts.
They are tighten-to-yield designed and
Tighten the spacer and the oil pump screen
cannot be reused.
and pickup tube-to-spacer bolt to 25 Nm (18
NOTE: Do not turn the crankshaft until
lb-ft).
instructed to do so.
Tighten the oil pump screen and pickup
tube-to-oil pump bolts to 10 Nm (89 lb-in).
Using the special tools, position the cylinder
head gaskets and cylinder heads over the
dowels and install the 20 cylinder head bolts
loosely.
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303-01B-14 303-01B-14 Engine 4.6L (3V)
26. NOTE: LH shown, RH similar. 28. Remove the special tool from the RH cylinder
head.
shown.
Install the hydraulic lash adjusters into the RH
and LH cylinder heads.
30. NOTE: Lubricate the camshaft and camshaft
27. Remove the special tool from the LH cylinder
head.
installation.
Install the LH and RH camshafts.
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303-01B-15 303-01B-15 Engine 4.6L (3V)
caps.
shown.
device.
device.
Position the camshaft phaser sprockets and
install new camshaft phaser bolts finger tight.
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303-01B-16 303-01B-16 Engine 4.6L (3V)
Install new tensioners as necessary.
39. Install a retaining clip on the tensioner to hold
the plunger in during installation.
36. Rotate the camshaft sprockets to position the
RH camshaft sprocket timing mark in the 11
oclock position and the LH camshaft sprocket
timing mark in the 12 oclock position.
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303-01B-17 303-01B-17 Engine 4.6L (3V)
41. If the copper links are not visible, mark one 42. Install the 4 bolts and the LH and RH timing
link on one end and one link on the other end chain guides.
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303-01B-18 303-01B-18 Engine 4.6L (3V)
43. Position the lower end of the LH (inner) timing
chain tensioner.
44. NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.
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303-01B-19 303-01B-19 Engine 4.6L (3V)
48. NOTE: The camshaft phaser and sprocket will 49. Position the RH timing chain tensioner arm on
be stamped with one of the illustrated timing the dowel pin and install the RH timing chain
marks fo the RH camshaft. tensioner and 2 bolts.
NOTE: The lower half of the timing chain Tighten to 25 Nm (18 lb-ft).
dowel.
chain tensioner.
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303-01B-20 303-01B-20 Engine 4.6L (3V)
51. NOTE: The RH and LH camshaft phaser 53. NOTE: Lubricate the roller followers with
sprockets are similar. Refer to the single timing clean engine oil prior to installation.
crankshaft.
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303-01B-21 303-01B-21 Engine 4.6L (3V)
surface at the locations shown.
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303-01B-22 303-01B-22 Engine 4.6L (3V)
Part
14 N806300 Stud, Hex Shoulder Pilot, M8 cover onto the dowels. Install the 15 fasteners
x 1.25 x 1.25 x 91.1
finger-tight.
x 1.25 x 1.25 x 91.1
56. Tighten the 15 engine front cover fasteners in
the sequence shown to 25 Nm (18 lb-ft).
Part
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
x 1.25 x 50 - M6 x 1 x 10 57. Lubricate the engine front cover and the
crankshaft front oil seal inner lip with clean
engine oil. Pilot, M8 x 1.25 - M6 x 1 x
86.35
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
M8 x 1.25 x 53
x 1.25 x 1.25 x 91.1
x 1.25 x 1.25 x 91.1
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303-01B-23 303-01B-23 Engine 4.6L (3V)
front oil seal into the engine front cover.
cleaned with metal surface prep and silicone Stage 3: Tighten to 50 Nm (37 lb-ft).
62. NOTE: Do not reuse the O-ring seals.
engine coolant prior to installation.
Slide the coolant tube forward with the new
O-ring seals into the cylinder block.
pulley.
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303-01B-24 303-01B-24 Engine 4.6L (3V)
63. Install the coolant tube stud bolt.
66. Position the accessory drive belt tensioner and
64. CAUTION: Do not rotate the coolant
pump housing once the coolant pump
housing has been positioned in the cylinder
block. Damage to the O-ring seal will occur.
NOTE: Lubricate the new O-ring seal using
clean engine coolant and install the O-ring seal
onto the coolant pump.
Position the coolant pump and install the 4
bolts loosely.
67. Install the 3 accessory drive belt idler pulleys,
the coolant pump pulley and the 7 bolts.
65. Tighten the 4 coolant pump bolts.
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303-01B-25 303-01B-25 Engine 4.6L (3V)
the bolt.
71. Install the knock sensor (KS) and the bolts.
Install the LH camshaft position (CMP) sensor
and the bolt.
70. NOTE: Lubricate the new O-ring seal with silicone gasket remover and metal surface prep.
clean engine oil prior to installation. Follow the directions on the packaging.
Install the RH CMP sensor and the bolt.
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303-01B-26 303-01B-26 Engine 4.6L (3V)
leakage.
head.
Position the RH valve cover and gasket on the
cylinder head and tighten the 14 bolts in the
sequence shown.
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303-01B-27 303-01B-27 Engine 4.6L (3V)
leakage.
head.
78. Position a new gasket, the RH exhaust manifold
Position the LH valve cover and gasket on the
shown.
cylinder head and tighten the 15 bolts in the
sequence shown.
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303-01B-28 303-01B-28 Engine 4.6L (3V)
79. Install the RH motor mount bracket, 2 bolts and 81. Position a new gasket, the LH exhaust manifold
2 stud bolts. and tighten the 8 new nuts in the sequence
shown.
80. Install the oil level indicator tube and the bolt.
82. Install the LH motor mount bracket and 4 bolts.
Install a new O-ring seal and lubricate the
O-ring seal with clean engine oil prior to Tighten to 55 Nm (41 lb-ft).
installation.
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303-01B-29 303-01B-29 Engine 4.6L (3V)
and install new gaskets.
Position the oil filter adapter and install the 4
bolts.
86. Install the ground strap and nut to the stud bolt.
87. Position the engine wiring harness on the
engine.
88. Connect the engine oil pressure sensor electrical
connector.
Install the 8 ignition coils and the 8 bolts.
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303-01B-30 303-01B-30 Engine 4.6L (3V)
89. Attach the engine wiring harness retainer to the 92. Connect the CHT sensor electrical connector.
stud bolt.
Connect the LH heated oxygen sensor
retainers.
90. Connect the knock sensor (KS) electrical
connector and pin-type retainer.
the LH valve cover studs.
91. Attach the CHT sensor jumper harness
electrical connector pin-type retainer.
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303-01B-31 303-01B-31 Engine 4.6L (3V)
the RH valve cover studs.
retainers.
Connect the 4 RH and 4 LH ignition coil
Connect the RH and LH variable camshaft
(PCV) tubes from the RH and LH valve covers.
capacitor and nut.
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303-01B-32 303-01B-32 Engine 4.6L (3V)
Connect the RH and LH camshaft position
105. Install the crankshaft rear seal retainer plate
106. Tighten the 6 bolts in the sequence shown.
103. Using a suitable floor crane, remove the
engine from the engine stand.
104. NOTE: The rear crankshaft seal retainer plate
does not have a sealant groove. Gasket maker
must be applied to the rear crankshaft seal
Apply a bead of gasket maker to the rear
crankshaft seal retainer mating surface on the
engine block.
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303-01B-33 303-01B-33 Engine 4.6L (3V)
107. CAUTION: Do not use metal
scrapers, wire brushes, power abrasive discs
or other abrasive means to clean the sealing
surfaces. These tools cause scratches and
gouges, which make leak paths. Use a
plastic scraping tool to remove all traces of
old sealant.
for the oil pan with silicone gasket remover
and metal surface prep. Follow the directions
on the packaging.
leakage.
leakage.
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303-01B-34 303-01B-34 Engine 4.6L (3V)
110. Install the new oil pan gasket and the oil pan 112. NOTE: Lubricate the inner lip of the
and loosely install the 16 bolts. crankshaft rear seal with clean engine oil.
Using the special tools, install a new
crankshaft rear seal.
111. Tighten the 16 bolts in 3 stages, in the
sequence shown.
Stage 1: Tighten to 2 Nm (18 lb-in). 113. Using the special tools, install a new
crankshaft rear oil slinger.
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303-01B-35 303-01B-35 Engine 4.6L (3V)
114. NOTE: Flexplate shown, flywheel similar.
Install the flexplate or flywheel and the 6 bolts
in the sequence shown.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
REMOVAL
Engine
Special Tool(s)
303-050 (D70P-6000) or
equivalent
303-F072
303-F047 (014-00073) or
equivalent
be ignited, resulting in possible personal injury.
engine is not running. Before repairing or
disconnecting any of the fuel system components,
the fuel system pressure must be relieved to
7. Remove the cowl vent screen. For additional
prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
8. Remove the air cleaner and outlet pipe. For
All vehicles
9. Remove the engine coolant crossover manifold
Section 303-03A.
Section 100-02.
10. Remove the degas bottle. For additional
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303-01B-2 303-01B-2 Engine 4.6L (3V)
REMOVAL (Continued)
15. Remove the oil pan drain plug and drain the
engine oil.
(19 lb-ft).
clockwise and remove the accessory drive belt.
16. Detach the 2 pin-type retainers.
13. Disconnect the A/C pressure transducer
stud bolt.
Detach the pin-type retainer from the A/C
compressor.
14. Disconnect the coolant hose from the oil filter
adapter.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
REMOVAL (Continued)
18. Disconnect the A/C clutch and crankshaft 21. Remove the 3 stud bolts and position the power
position (CKP) sensor electrical connectors. steering pump aside.
Detach the wiring harness retainers and Support the power steering pump with a
position the harness aside. length of mechanics wire.
19. Remove the bolt, 3 nuts and position the A/C 22. Install the special tool (lifting bracket) to the
compressor aside. threaded hole located at the LH side of the
engine block.
Support the A/C compressor with a length
of mechanics wire.
power steering stud bolt.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
REMOVAL (Continued)
23. CAUTION: The rear of the engine
must be supported before removing the
transmission to prevent damage to the engine
or cowl.
CAUTION: Do not position the legs of
the special tool (3-bar engine support) on the
fenders. Instead, the legs should be
positioned on the body structure near the
suspension strut tower.
Install the 3-bar engine support and a suitable
length of chain to the engine lifting bracket
installed in the previous step.
All vehicles
27. Disconnect the RH heated oxygen sensor
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303-01B-5 303-01B-5 Engine 4.6L (3V)
REMOVAL (Continued)
Disconnect the RH and LH catalyst monitor
sensor (CMS).
32. Disconnect the generator jumper harness
29. Remove the engine-to-transmission spacer plate.
33. Disconnect the upper and lower powertrain
30. Disconnect the heater hoses.
31. Remove the bolt and the ground strap from the
cowl.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
REMOVAL (Continued)
34. Disconnect the 16-pin electrical connector and 38. NOTE: RH shown, LH similar.
insulator nuts.
36. Detach the power distribution box upper
housing from the lower housing, loosen the
bolt, then disconnect the 68-pin connector from
40. Attach a suitable floor crane to the engine
lifting bracket installed in the previous step.
Remove the 3-bar support from the vehicle.
37. Remove the nut and LH radio interference Remove the engine from the vehicle.
capacitor from the engine front cover stud bolt.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
are positioned so that their tips direct fuel just
Engine
ahead of the engine intake valves.
are connected in series with the fuel rail pressure
and temperature sensor.
section.
supply fuel from the fuel tank with a fuel pump
The 4.6L (3V) is a V-8 engine with the following
mounted in the fuel tank.
features:
A constant fuel pressure is maintained across the
Single overhead camshafts
fuel injectors by the fuel rail pressure and
Three valves per cylinder
temperature sensor. The fuel rail pressure and
Sequential multiport fuel injection (SFI) temperature sensor:
is positioned upstream from the fuel injectors on
the fuel rail.
Aluminum cylinder block
Variable camshaft timing (VCT)
Valve Train
Individually chain-driven camshafts with a
The valve train operates as follows:
hydraulic timing chain tensioner on each timing
Ball-tip hydraulic lash adjusters provide automatic
chain
lash adjustment.
Distributorless ignition system
Roller followers ride on the camshaft lobe,
Electronic returnless fuel system
transferring the up-and-down motion of the
camshafts to the valves in the cylinder heads.
Identification
Always refer to these labels when installation of
Positive Crankcase Ventilation System
new parts is necessary or when checking engine
All engines are equipped with a closed-type positive
calibrations. The engine parts often differ within a
crankcase ventilation system recycling the crankcase
CID family. Verification of the identification codes
vapors to the upper intake manifold.
will make sure that the correct parts are obtained.
These codes contain all of the pertinent information
Lubrication System
relating to the dates, optional equipment and
The engine lubrication system operates as follows:
revisions. The Ford Master Parts Catalog contains a
complete listing of the codes and their applications.
Oil is drawn into the oil pump through the oil
pump screen cover and tube in the sump of the
Code Information
oil pan.
The engine code information label, located on the
Oil is pumped through the oil filter on the left
side of the valve cover and the front side of the
front side of the cylinder block.
valve cover, contains the following:
Oil enters the main gallery where it is distributed
Engine build date
to the crankshaft main journals and to both
cylinder heads.
Engine plant code
From the main journals, the oil is routed through
Engine code
cross-drilled passages in the crankshaft to
Induction System
lubricate the connecting rod bearings. Controlled
leakage through the crankshaft main bearings and
The sequential multiport fuel injection (SFI)
connecting rod bearings is slung radially outward
provides the fuel/air mixture needed for combustion
to cool and lubricate the cylinder walls as well as
in the cylinders. The 8 solenoid-operated fuel
the entire connecting rod, piston and piston ring
injectors:
assembly.
are mounted in the intake manifold.
meter fuel into the air intake stream in accordance
with engine demand.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
The left cylinder head is fed from a drilling into The inner rotor is piloted on the crankshaft post
the supply passage feeding the main gallery at the and is driven through flats on the crankshaft
front of the cylinder block. The right cylinder
System pressure is limited by an integral,
head is fed from a drilling into the rear of the
internally-vented relief valve which directs the
main gallery. Main gallery pressure is reduced as
bypassed oil back to the inlet side of the oil pump
it enters the cylinder head galleries through fixed
Oil pump displacement has been selected to
non-serviceable orifices, located at the upper part
provide adequate volume to make sure of correct
of the feed passages. It is this reduced pressure in
oil pressure, both at hot idle and maximum speed
the cylinder head galleries which feeds the
The relief valve calibration protects the system
camshaft journals, the hydraulic lash adjusters
from excessive pressure during high viscosity
and the primary and secondary timing chain
conditions
tensioners.
The relief valve is designed to provide adequate
The camshaft lobe and roller followers are
connecting rod bearing lubrication under
lubricated by splash created through valve train
high-temperature and high-speed conditions
operation.
Oil Pump
The lubrication system of the 4.6L (3V) engine is
designed to provide optimum oil flow to critical
components of the engine through its entire
operating range. The heart of the system is a
positive displacement internal gear oil pump using
top seal rotors. Generically this design is known as
a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the
cylinder block
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
1. With the vehicle in NEUTRAL, position it on a (EVAP) canister purge valve
2 EVAP canister purge valve
Section 100-02. bracket (part of 9G641)
3 N605891 Oil level indicator and tube
2. Detach the evaporative emissions (EVAP)
bolt
canister purge valve from the bracket and
4 6754 Oil level indicator and tube
position aside.
5 O-ring seal
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303-01B-2 303-01B-2 Engine 4.6L (3V)
3. Remove the oil level indicator and tube bolt. 5. NOTE: Lubricate the new oil level indicator
tube O-ring seal with clean engine oil prior to
installation.
4. Remove the oil level indicator and tube from
the cylinder block.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Oil Pan
Special Tool(s)
303-F072
clockwise and remove the accessory drive belt Lifting Brackets, Engine
303-050 (T70P-6000) from the generator pulley.
Material
Item Specification
Prep
ZC-31
ZC-30
Sealant
TA-30
Motor Oil 10. Disconnect the generator electrical connector
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
Section 100-02.
(19 lb-ft).
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303-01B-2 303-01B-2 Engine 4.6L (3V)
13. Install the special tool. 16. Position a suitable adjustable jack stand under
the subframe.
17. Mark the position of the 4 subframe nuts and 4
subframe bolts for referencing during assembly.
18. Remove the 4 subframe nuts and 4 subframe
bolts.
insulator nuts.
19. Using the adjustable jackstand, lower the
subframe 50 mm (1.96 in).
20. Detach the 2 pin-type retainers.
21. NOTE: Be careful when removing the oil pan
gasket. It is reusable.
Remove the 16 bolts, the oil pan and the
gasket.
(1.57 in).
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303-01B-3 303-01B-3 Engine 4.6L (3V)
Installation
These tools cause scratches and gouges,
sealant.
Inspect the oil pan. Clean the mating surface of
the oil pan with silicone gasket remover and
packaging.
leakage.
leakage.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
4. Install the new oil pan gasket and the oil pan 6. Attach the 2 pin-type retainers.
7. Using the adjustable jackstand, raise the
subframe.
8. NOTE: Do not tighten the subframe nuts and
bolts at this time.
Install the 4 subframe nuts and 4 subframe
bolts.
9. Align the subframe nuts and bolts with the
reference marks made during removal.
Tighten nuts to 115 Nm (85 lb-ft).
Tighten bolts to 115 Nm (85 lb-ft).
5. Tighten the bolts in 3 stages, in the sequence
shown.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
11. NOTE: RH shown, LH similar. 16. Using a suitable belt tensioner release tool,
clockwise and install the accessory drive belt on
nuts.
the generator pulley.
retainers.
tightened.
Position the generator and install the B+ information, refer to Section 303-04B.
terminal and nut.
19. Install the air cleaner assembly. For additional
20. Fill the crankcase with clean engine oil.
pin-type retainer.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Installation
Material 1. CAUTION: Make sure the O-ring is in
place and not damaged. A missing or
Item Specification
damaged O-ring can cause foam in the
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Position the oil pump screen and pickup tube
and install the bolts.
Removal
refer to Engine Lubrication Components
tube-to-spacer bolt to 25 Nm (18 lb-ft).
Exploded View and Oil Pan in this section.
2. Remove the bolts and the oil pump screen and
pickup tube.
2. Install the oil pan. For additional information,
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Oil Pump
Material
Item Specification
Prep
ZC-31
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal
2. Remove the timing drive components. For
additional information, refer to Timing Drive
Components in this section.
3. Remove the bolts and the oil pump screen and
pickup tube.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
Installation
Clean the sealing surfaces with metal surface
prep. Follow the directions on the packaging.
2. Position the oil pump and install the bolts.
4. Install the timing drive components. For
3. CAUTION: Make sure the O-ring is in
5. Install the oil pan. For additional information,
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303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Special Tool(s)
303-1039
Sprocket
303-1046
3. Position the crankshaft keyway at the 12
oclock position.
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Retaining Clip
positioned as shown, the crankshaft will require 1L3Z-6P250-AA
one full additional rotation to 12 oclock.
Removal
The No. 1 cylinder must be coming up on the
exhaust stroke with the crankshaft keyway at
the 12 oclock position. Verify by noting the
position of the 2 intake lobes and the exhaust
section.
lobe on the No. 1 cylinder.
crankshaft.
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303-01B-2 303-01B-2 Engine 4.6L (3V)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
10. Remove the bolts, the LH timing chain
11. Remove the bolts, the RH timing chain
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303-01B-4 303-01B-4 Engine 4.6L (3V)
camshaft sprocket.
camshaft sprocket.
sprocket.
Remove the bolts.
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303-01B-5 303-01B-5 Engine 4.6L (3V)
14. CAUTION: Damage to the camshaft 16. CAUTION: Remove the front thrust
phaser sprocket assembly will occur if camshaft bearing cap straight upward from
mishandled or used as a lifting or leveraging the bearing towers, or the bearing cap may
device. be damaged from sideloading.
remove the RH cylinder head front camshaft
caps.
device.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
caps.
caps.
remove the LH cylinder head front camshaft
caps.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
Remove all of the remaining roller followers
from the cylinder heads.
Installation
1. Install the LH and RH camshafts.
Lubricate the camshaft and camshaft
installation.
clean engine oil.
caps.
shown. 3. CAUTION: Damage to the camshaft
device.
Install the camshaft phaser sprockets and new
camshaft phaser bolts finger-tight.
http://vnx.su
303-01B-8 303-01B-8 Engine 4.6L (3V)
device.
Install new tensioners as necessary.
http://vnx.su
303-01B-9 303-01B-9 Engine 4.6L (3V)
9. Install a retaining clip on the tensioner to hold
the plunger in during installation.
12. Install the 4 bolts and the LH and RH timing
chain guides.
11. If the copper links are not visible, mark one
link on one end and one link on the other end
http://vnx.su
303-01B-10 303-01B-10 Engine 4.6L (3V)
13. Position the lower end of the LH (inner) timing
chain tensioner.
14. NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.
tensioner and bolts.
http://vnx.su
303-01B-11 303-01B-11 Engine 4.6L (3V)
18. NOTE: The camshaft phaser and sprocket will 19. Position the RH timing chain tensioner arm on
be stamped with one of the illustrated timing the dowel pin and install the RH timing chain
marks for the RH camshaft. tensioner and bolts.
NOTE: The lower half of the timing chain Tighten to 25 Nm (18 lb-ft).
dowel.
chain tensioner.
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303-01B-12 303-01B-12 Engine 4.6L (3V)
21. NOTE: The RH and LH camshaft phaser 23. NOTE: It is necessary to rotate the engine to
sprockets are similar. Refer to the single timing position the camshaft lobes at base circle to
mark to identify the RH camshaft phaser install the roller followers.
Lubricate the roller followers with clean
crankshaft.
section.
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303-01B-1 303-01B-1 Engine 4.6L (3V)
REMOVAL
Material
Cylinder Head
Item Specification
Special Tool(s) Motorcraft Metal Surface
Prep
ZC-31
303-F047 (014-00073) or
equivalent
ZC-30
All cylinder heads
1. Remove the engine. For additional information,
3-Jaw Puller
refer to Engine in this section.
303-D121
303-107 (T74P-6700-A)
Head
303-572 (T97T-6000-A)
Disconnect the RH and LH camshaft position
Sprocket
303-1046
303-1039
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303-01B-2 303-01B-2 Engine 4.6L (3V)
REMOVAL (Continued)
8. CAUTION: When reusing liquid or
vapor tube connectors, make sure to use
Disconnect the RH and LH variable camshaft
compressed air to remove any foreign
material from the connector retaining clip
area before separating it from the tube.
Remove the positive crankcase ventilation
(PCV) tubes from the RH and LH valve covers.
Disconnect the quick connect fittings.
X Push the connector toward the valve
cover to release pressure.
X Push the release tab clockwise.
X Disconnect the quick connect fitting.
retainers.
Disconnect the 4 RH and 4 LH ignition coil
7. Remove the nut and the RH radio ignition
interference capacitor.
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303-01B-3 303-01B-3 Engine 4.6L (3V)
REMOVAL (Continued)
10. Disconnect the 3 engine wiring harness 13. Disconnect the cylinder head temperature
retainers from the RH valve cover studs. (CHT) sensor electrical connector.
11. Disconnect the 2 engine wiring harness 14. Detach the CHT sensor jumper harness
retainers from the LH valve cover studs. electrical connector pin-type retainer.
12. Detach the engine wiring harness pin-type 15. Disconnect the knock sensor (KS) electrical
retainers. connector and pin-type retainer.
http://vnx.su
303-01B-4 303-01B-4 Engine 4.6L (3V)
REMOVAL (Continued)
Detach the engine wiring harness retainer
from the stud bolt.
17. Disconnect the engine oil pressure sensor
22. Remove the bolt and the LH CMP sensor.
18. Remove the engine wiring harness from the
engine.
19. Remove and discard the oil filter.
tube.
http://vnx.su
303-01B-5 303-01B-5 Engine 4.6L (3V)
REMOVAL (Continued)
23. Remove the bolt and the CKP sensor.
CAUTION: When removing the valve
NOTE: The bolts are part of the valve cover
and should not be removed.
Loosen the 29 bolts and remove the valve
covers.
Remove the 8 bolts and the 8 ignition coils.
Inspect the valve cover gasket. If the gasket
is damaged, remove and discard the gasket.
Clean the valve cover gasket groove with
soap and water or a suitable solvent.
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303-01B-6 303-01B-6 Engine 4.6L (3V)
REMOVAL (Continued)
26. Remove the 5 bolts, the coolant pump pulley
and the RH side accessory drive belt idler
pulley.
30. NOTE: Correct fastener location is essential for
the assembly procedure. Record fastener
location.
Remove the engine front cover fasteners.
27. Remove and discard the crankshaft pulley bolt.
pulley.
31. Remove the engine front cover from the
cylinder block.
seal.
29. Remove the 4 oil pan-to-engine front cover
bolts.
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303-01B-7 303-01B-7 Engine 4.6L (3V)
REMOVAL (Continued)
crankshaft.
33. Position the crankshaft keyway at the 12
oclock position.
one full additional rotation to the 12 oclock
position.
noting the position of the 2 intake lobes and the
exhaust lobe on the No. 1 cylinder.
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303-01B-8 303-01B-8 Engine 4.6L (3V)
REMOVAL (Continued)
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303-01B-9 303-01B-9 Engine 4.6L (3V)
REMOVAL (Continued)
40. Remove the 2 bolts, the LH timing chain
41. Remove the 2 bolts, the RH timing chain
http://vnx.su
303-01B-10 303-01B-10 Engine 4.6L (3V)
REMOVAL (Continued)
camshaft sprocket.
camshaft sprocket.
sprocket.
Remove the 2 bolts.
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303-01B-11 303-01B-11 Engine 4.6L (3V)
REMOVAL (Continued)
44. CAUTION: Damage to the camshaft 46. CAUTION: Remove the front thrust
phaser sprocket assembly will occur if camshaft bearing cap straight upward from
mishandled or used as a lifting or leveraging the bearing towers, or the bearing cap may
device. be damaged from sideloading.
Remove the RH cylinder head front camshaft
device.
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303-01B-12 303-01B-12 Engine 4.6L (3V)
REMOVAL (Continued)
caps.
caps.
Remove the LH cylinder head front camshaft
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303-01B-13 303-01B-13 Engine 4.6L (3V)
REMOVAL (Continued)
56. Remove the nut and ground strap from the stud
bolt.
Remove all of the remaining roller followers
from the cylinder heads.
LH cylinder head
LH cylinder head.
RH cylinder head
54. Install the special tool onto the LH cylinder
head.
RH cylinder heads.
58. Install the special tool onto the RH cylinder
head.
55. Remove the 8 nuts and the LH exhaust
manifold.
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303-01B-14 303-01B-14 Engine 4.6L (3V)
REMOVAL (Continued)
59. Remove the 8 nuts and the RH exhaust 60. Remove the stud bolt and the coolant tube.
manifold.
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303-01B-15 303-01B-15 Engine 4.6L (3V)
REMOVAL (Continued)
All cylinder heads
Remove the 20 bolts and the cylinder heads.
Discard the cylinder head gaskets.
Discard the cylinder head bolts.
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303-01B-16 303-01B-16 Engine 4.6L (3V)
REMOVAL (Continued)
the cylinder block.
several minutes.
remain.
is normal.
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303-01B-17 303-01B-17 Engine 4.6L (3V)
REMOVAL (Continued)
long, the machined edge must be flat within
cylinder heads must not have depressions
deeper than 0.0254 mm (0.001 in) across a
38.1 mm (1.5 in) square area, or scratches
longer than 0.0254 mm (0.001 in).
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Valve Cover LH
Material
Item Specification
Prep
ZC-31
ZC-30
Sealant
TA-30
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
6 6C519 LH valve cover bolt (15 1 14A464 LH variable camshaft timing
required) (part of 6582) (VCT) solenoid electrical
7 6A559 LH valve cover gasket
2 Engine wiring harness
8 Engine wiring harness
retainer (2 required) (part of
retainer (2 required) (part of
12B637)
12B637)
3 9J274 Evaporative emissions
(EVAP) tube
Removal
(PCV) tube
1. Remove the air cleaner assembly and outlet
(Continued)
Section 303-12.
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
2. Remove the LH ignition coils. For additional
3. Remove the oil level indicator and tube. For
additional information, refer to Oil Level
Indicator and Tube in this section.
tube from the intake manifold.
5. Remove the positive crankcase ventilation
(PCV) tube.
6. Disconnect the LH variable camshaft timing
2. Position the LH valve cover and new gasket on
(VCT) solenoid electrical connector and detach
the cylinder head and tighten the bolts in the
the 2 wiring harness pin-type retainers.
sequence shown.
7. Detach the 2 wiring harness retainers from the
valve cover stud bolts.
Loosen the 15 fasteners and remove the LH
valve cover and gasket.
Discard the valve cover gasket. Clean the
valve cover gasket groove with soap and
water or a suitable solvent.
Installation
1. NOTE: If the valve cover is not secured within
4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Failure to follow this procedure can cause
future oil leakage.
Apply a bead of silicone gasket and sealant in 2
3. Attach the 2 wiring harness retainers to the
places where the engine front cover meets the
cylinder head.
4. Connect the LH VCT solenoid electrical
connector and attach the 2 wiring harness
pin-type retainers.
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303-01B-4 303-01B-4 Engine 4.6L (3V)
6. Connect the EVAP tube to the intake manifold. 9. Install the air cleaner assembly and outlet pipe.
7. Install the oil level indicator and tube. For
303-12.
additional information, refer to Oil Level
Indicator and Tube in this section.
8. Install the LH ignition coils. For additional
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Valve Cover RH
Material
Item Specification
Prep
ZC-31
ZC-30
Sealant
TA-30
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
7 Engine wiring harness 1 Engine wiring harness (part
retainer (3 required) (part of of 12B637)
12B637)
2 14A464 RH variable camshaft timing
(VCT) solenoid electrical
Removal connector (part of 12B637)
3 6758 Positive crankcase ventilation
(PCV) tube
1. Remove the RH ignition coils. For additional
4 6582 RH valve cover information, refer to Section 303-07B.
5 6C519 RH valve cover bolt (14
2. Detach the wiring harness retainer from the required) (part of 6582)
engine front cover stud bolt.
6 6584 RH valve cover gasket
(Continued)
http://vnx.su
303-01B-3 303-01B-3 Engine 4.6L (3V)
3. Disconnect the RH variable camshaft timing 2. Position the RH valve cover and new gasket on
(VCT) solenoid electrical connector. the cylinder head and tighten the bolts in the
sequence shown.
(PCV) tube from the RH valve cover.
Loosen the 14 fasteners and remove the RH
valve cover and gasket.
Discard the valve cover gasket. Clean the
valve cover gasket groove with soap and
water or a suitable solvent.
Installation
3. Attach the 4 wiring harness retainers to the
future oil leakage.
4. Connect the PCV tube to the RH valve cover.
cylinder head.
5. Connect the RH VCT solenoid electrical
connector.
6. Attach the wiring harness retainer to the engine
front cover stud bolt.
7. Install the RH ignition coils. For additional
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Valve Seals
Special Tool(s)
303-1039
303-383 (T91P-6571-A)
5. Use compressed air in the cylinder to hold both
valves in position.
Apply a minimum of 965 kPa (140 psi) of
compressed air into the cylinder.
6. CAUTION: If air pressure has forced Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CAUTION: If the components are to
CXO-5W20-LSP12
installation into their original locations. (Canada); or equivalent
Removal
keys.
1. Depending on the valve seal being serviced,
remove the LH or RH valve cover. For
2. Remove the spark plug. For additional
valve seal being serviced is at the top of its
stroke with the intake valve and the exhaust
valves closed.
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
Installation
4. Relieve the air pressure from the cylinder.
1. NOTE: Lubricate the valve seal and valve stem 5. CAUTION: If the components are to
with clean engine oil prior to installation. be reinstalled, they must be installed in the
Position a new valve seal onto the valve stem.
2. Using the special tool, install the new valve
seal.
3. Using the special tool, install the valve spring,
6. Install the spark plug. For additional
the valve spring retainer and the valve spring
retainer keys.
7. Depending on the valve seal being serviced,
install the LH or RH valve cover. For
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Valve Springs 6. CAUTION: If air pressure has forced
loss of air pressure will allow the valve to Special Tool(s)
303-1039
Removal
keys.
1. Depending on the valve spring being serviced,
remove the LH or RH valve cover. For
valve spring being serviced is at the top of its
stroke with the intake valve and the exhaust
valves closed.
7. Remove the valve spring retainer and the valve
spring.
8. Inspect the valve spring. For additional
Installation
1. Using the special tool, install the valve spring,
retainer keys.
5. Use compressed air in the cylinder to hold both
valves in position.
http://vnx.su
303-01B-2 303-01B-2 Engine 4.6L (3V)
2. Relieve the air pressure from the cylinder. 4. Install the spark plug. For additional
5. Depending on the valve spring being serviced,
install the LH or RH valve cover. For
http://vnx.su
303-01B-1 303-01B-1 Engine 4.6L (3V)
IN-VEHICLE REPAIR
Valve Train Components Exploded Item Part Number Description
View 11 6279 Camshaft phaser and sprocket
bolt
12 6C524 Camshaft phaser and sprocket
1 N807834 Camshaft bearing cap bolt (10
required)
2 6B284 Camshaft front bearing cap
3 6B280 Camshaft bearing cap (4
required)
4 6C255 LH/ Camshaft
6251 RH
required)
required)
required)
required)
(Continued)
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303-01B-2 303-01B-2 Engine 4.6L (3V)
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303-01C-1 303-01C-1 Engine 5.4L (4V)
SPECIFICATIONS
Item Specification
Item Specification exhaust (0.2756-0.2748 in)
Lubricants and Sealants Valve stem-to-guide 0.057-0.023 mm
clearance intake (0.0022-0.0009 in)
Motorcraft Metal Surface WSE-M5B392-A
Cleaner ZC-21 Valve stem-to-guide 0.072-0.038 mm
clearance exhaust (0.0028-0.0015 in)
Prep ZC-31 Valve head diameter 37.13-36.87 mm
intake (1.462-1.4516 in)
Engine Coolant with Valve head diameter 32.13-31.87 mm
Bittering Agent (US only) exhaust (1.2650-1.2547 in)
Valve face runout 0.05 mm (0.0019 in)
(yellow color) Valve face angle 45.75-45.25 degrees
Motorcraft SAE 5W-50 WSS-M2C931-A Valve seat width 1.4-1.2 mm
Full Synthetic Motor Oil intake (0.0551-0.0472 in)
XO-5W50-QGT or
equivalent
exhaust (0.0630-0.0551 in)
Valve face runout 0.05 mm (0.0019 in)
Valve seat angle 45.00-44.50 degrees Compound XG-3-A
Valve spring free length 54.4 mm (2.1417 in) Silicone Gasket and WSE-M4G323-A4
intake Sealant TA-30
Valve spring free length 50.9 mm (2.0039 in) Silicone Gasket Remover
exhaust
ZC-30
Valve spring 1.2 mm (0.0472 in) Thread Sealant with PTFE WSK-M2G350-A2
perpendicularity intake TA-24
Valve spring 1.2 mm (0.0472 in)
perpendicularity TA-25
exhaust
Engine
Valve spring compression 815 N @ 31.82 mm
Displacement 5.4L (330 CID)
force intake (1.2528 in)
Number of cylinders 8
Valve spring compression 760 N @ 25.5 mm
Bore 90.215 mm (3.552 in) force exhaust (1.0827 in)
Stroke 105.8 mm (4.23 in) Valve spring installed 43.00 mm (1.692 in)
height intake
Firing order 1-3-7-2-6-5-4-8
Valve spring installed 39.5 mm (1.555 in)
Oil pressure at 2000 rpm 276-414 kPa (40-60 psi)
height exhaust
(engine at normal
operating temperature) Valve spring installed 310 N @ 43.00 mm
force intake (1.6929 in)
Engine oil capacity (with 6.0 liters (6.5 quarts)
filter change) with filter Valve spring installed 320 N @ 39.5 mm (1.555
force exhaust in)
Compression ratio 8.4:1
Roller follower ratio 1.81:1
Combustion chamber 42.45-45.45 cc (2.59-2.77
volume cu in) Diameter intake 12.000-11.989 mm
(0.4724-0.4720 in)
intake (0.2762-0.2754 in) Diameter exhaust 16.000-15.9888 mm
(0.6299-0.6295 in)
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
Clearance-to-bore 0.018-0.069 mm Main bearing 0.048-0.024 mm
(0.0007-0.0027 in) journal-to-main bearing (0.001891-0.0009 in)
clearance
Service limit intake 12.000-11.989 mm
(0.4724-0.4720 in) Connecting rod journal 53.003-52.983 mm
diameter (2.0867-2.0859 in)
Service limit exhaust 16.000-15.9888 mm
(0.6299-0.6295 in) Connecting rod journal 0.004 mm (0.0002 in)
maximum taper
Hydraulic leakdown rate 0.45-3 seconds
a
intake Crankshaft maximum end 0.075-0.377 mm
play (0.003-0.0148 in)
Hydraulic leakdown rate 0.60-4 seconds
a
exhaust Piston and Connecting Rod
Collapsed lash adjuster 0.450-0.850 mm Piston diameter 90.180 0.005 mm
gap (0.0177-0.0335 in) (3.5504 0.0002 in)
Camshaft Piston-to-cylinder bore -0.005 to +0.025 mm
clearance (-0.0002-0.001 in)
Lobe lift intake 6.15674 mm (0.242391 in)
Piston ring end gap top 0.13-0.28 mm
Lobe lift exhaust 6.5958 mm (0.2597 in)
(0.0051-0.0111 in)
Piston ring end gap 0.25-0.40 mm
(1.0615-1.0605 in)
Journal bore inside 27.012-26.987 mm
Piston ring gap oil 0.15-0.65 mm
diameter (1.0635-1.0625 in)
control (0.0059-0.0256 in)
Journal-to-bearing 0.076-0.025 mm
clearance (0.0030-0.0010 in)
top (0.0602-0.061 in)
Runout 0.09 mm (0.0035 in) (4
places)
End play 0.027-0.190 mm
(0.0011-0.0075 in)
oil control (0.1193-0.1201 in)
Cylinder Block
Piston ring width 1.49-1.46 mm
(0.0587-0.0575 in)
(3.5511-3.5515 in)
Cylinder bore maximum 0.006 mm (0.0002 in) clearance top (0.0012-0.0020 in)
taper
Cylinder bore maximum 0.020 mm (0.0008 in) clearance intermediate (0.0012-0.0031 in)
out-of-round
Main bearing bore inside 72.400-72.424 mm (0.8665-0.8667 in)
Piston pin diameter 22.0005-22.0030 mm
Head gasket surface 0.0254 mm (0.001 in)
(0.8662-0.8663 in)
flatness across any 38.1 mm (1.5
Piston pin length 61.8 mm (2.433 in)
in) square
Crankshaft
(clearance) (0.0002-0.0005 in)
Connecting rod-to-pin 0.009-0.0235 mm
diameter (2.6567-2.6577 in)
clearance (0.0004-0.0093 in)
Connecting rod pin bore 22.012-22.024 mm
maximum taper
diameter (0.8666-0.8671 in)
Connecting rod length 169.1 mm (6.6575 in)
maximum out-of-round between cross sections
(centerline bore-to-bore)
Connecting rod maximum 0.038 mm (0.0015 in)
allowed bend
http://vnx.su
303-01C-3 303-01C-3 Engine 5.4L (4V)
Connecting rod maximum 0.05 mm (0.0021 in) Crankshaft position 10 89
allowed twist (CKP) sensor bolt
Connecting rod bearing 53.049-53.027 mm Crankshaft pulley bolt
a

bore diameter (with (2.0885-2.0877 in)
Crankshaft rear seal
assembled liners)
retainer plate bolts
a
Connecting rod 0.064-0.026 mm
Cylinder head bolts
a

bearing-to-crankshaft (0.0025-0.001 in)
Engine block drain 14 10 clearance
plugs
Connecting rod side 0.300 0.175 mm
Engine front cover clearance (as assembled to (0.0118 0.0069 in)
bolts
a
crank) standard play
Engine support 55 41 Connecting rod side 0.475 mm (0.0187 in)
insulator bolts clearance (as assembled to
crank) max. play
Engine support 80 59
insulator bracket bolts
a Time required for the plunger to leak down 1.6 mm
of travel with 222 N force and leak-down fluid in Engine support 63 46
the lash adjuster. insulator nuts
Exhaust gas 25 18
recirculation (EGR) Torque Specifications
system module bolts
EGR tube 39 29
A/C compressor stud 25 18
Exhaust manifold nuts
a

bolts
Flywheel
a

idler pulley (smooth Fuel rail bolts 10 89
and grooved) bolt
Generator bolts and 50 37
Accessory drive belt 25 18 stud bolt
tensioner bolt
Generator B+ wire 8 71
Alternator bolts 50 37 terminal nut
Camshaft bearing cap Ground wire-to-LH 10 89
bolts
a
cylinder head bolt
Camshaft drive Ground wire-to-RH 25 18
sprocket bolts
a
engine support
insulator nut
(CMP) sensor bolt Ignition coil-on-plug 10 89
cover bolts
Charge air cooler
(CAC) bolts
a
Intake air temperature 15 11
(IAT) sensor
CAC coolant tube 10 89
assembly bolts Intake manifold
assembly bolts
a
Connecting rod cap
bolts
a
Intake manifold wiring 10 89
harness bracket bolts
Cooling fan assembly 9 80
bolts Intermediate steering 47 35
shaft bolt
Lower intake manifold
cover bolts
a
bolt
Main bearing cap bolts
a

Coolant tube assembly 10 89
bolts
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303-01C-4 303-01C-4 Engine 5.4L (4V)
Main bearing cap side Supercharger (SC)
bolts
a
bolts
a
Oil cooler bolts
a
SC drive belt idler 25 18
(smooth and grooved)
Oil filter
a

bolts
Oil filter adapter bolts
a

SC drive belt heavy 48 35
Oil level indicator tube 10 89 load idler (closest to
bolt centerline of engine)
bolt
Oil pan bolts
a

SC drive belt tensioner 48 35
Oil pan-to-engine front 25 15
bolt
cover bolts
Starter bolts
a

Oil pan-to-engine front 25 18
cover stud bolt Starter B+ terminal nut 12 9
Oil pan drain plug 26 19 Starter S-terminal nut 5 44
Oil pump bolts
a
Steering column dash 9 80
boot nuts
pickup tube (large Subframe bolts 115 85
bolts)
Subframe nuts 115 85
Subframe cross brace 48 35
pickup tube (small
nut
bolts)
nuts
connector bolt
Throttle body and 10 89
spacer bolts
(PSP) tube fitting
Timing chain guide 10 89
bolts
bolts
Timing chain tensioner 25 18
Power steering 25 18
bolts (primary)
reservoir bracket bolts
Timing chain tensioner 10 89
bolts (secondary)
bracket bolt
Valve cover bolts
a

bracket nut Windage tray nuts
a

Radio interference 10 89
capacitor nuts
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
ASSEMBLY
Special Tool(s)
Engine
303-335 (T88T-6701-A)
Special Tool(s)
303-D032 (D81L-6002-C) or
equivalent
Strap Wrench
303-D055 (D85L-6000-A)
303-442 (T93P-6136-A)
303-518 (T95P-6701-DH)
303-448 (T93P-6303-A)
303-516 (T95P-6701-BH)
303-452 (T93P-6565-AR)
Slinger
303-517 (T95P-6701-CH)
Damper
303-102 (T74P-6316-B)
Lifting Bracket, Engine (2
required)
303-D087 (D93P-6001-A1)
303-635
(Continued)
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
Spreader Bar Item Specification
303-D089 (D93P-6001-A3) or
equivalent
Prep
ZC-31
Cleaner
ZC-21
Heavy Duty Floor Crane
Sealant
TA-30
Compound
XG-3-A
Material
Item Specification
XO-5W50-QGT or
equivalent
ZC-30
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
Upper End Components and Front Engine Accessory Drive (FEAD) Components
7 6C348 SC drive belt grooved idler 1 10300 Generator
pulley
8 8620 Engine accessory drive belt
3 8620 Supercharger (SC) drive belt
9 19A216 Engine accessory drive belt
4 6B209 SC drive belt tensioner
grooved idler pulley
5 19A216 SC drive belt heavy load idler
10 19A216 Engine accessory drive belt
pulley
smooth idler pulley
6 19A216 SC drive belt smooth idler
11 6B209 Engine accessory drive belt
pulley
tensioner
(Continued)
(Continued)
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303-01C-4 303-01C-4 Engine 5.4L (4V)
12 6584 RH valve cover gasket 18 9E822 Throttle body assembly
13 6582 RH valve cover 19 18801 LH radio interference
capacitor
14 6P067 RH ignition coil-on-plug
cover 20 6P067 LH ignition coil-on-plug
cover
15 18801 RH radio interference
capacitor 21 12A366 Ignition coil-on-plug (8
required)
16 9H487 Intake manifold assembly
17 9439 Intake manifold assembly
gasket (2 required) 23 6584 LH valve cover gasket
(Continued)
Lower End Components and Coolant Pump
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303-01C-5 303-01C-5 Engine 5.4L (4V)
8 6A341 Crankshaft upper thrust 1 6675 Oil pan
washers (2 required)
9 6621 Oil pump
10 6333 Crankshaft upper main tube
bearing (5 required)
4 6325 Main bearing cap
11 8501 Coolant pump
5 6A338 Crankshaft lower main
12 8A528 Coolant pump pulley bearing (5 required)
13 6010 Cylinder block 6 6K302 Crankshaft lower thrust
washer
7 6303 Crankshaft
(Continued)
http://vnx.su
303-01C-6 303-01C-6 Engine 5.4L (4V)
Oil Filter Adapter Assembly
4 6714 Engine oil filter 1 18663 Coolant tube assembly
5 6A642 Oil cooler 2 6884 Oil filter adapter
6 6N818 Oil cooler gasket (4 required) 3 6A636 Oil filter adapter gasket
(Continued)
http://vnx.su
303-01C-7 303-01C-7 Engine 5.4L (4V)
Timing Drive Components and Cylinder Heads
9 6L266 LH primary timing chain 1 12A227 Crankshaft sensor ring
tensioner
2 6K255 RH timing chain tensioner
10 6M274 LH timing chain tensioner arm
arm
3 6306 Crankshaft timing sprocket
4 6268 LH primary timing chain
12 6700 Crankshaft front seal
5 6B274 LH primary timing chain
13 6C086 Engine front cover guide
14 6D081 Engine front cover gasket 6 6L266 RH primary timing chain
tensioner
15 6F093 RH cylinder head assembly
7 6268 RH primary timing chain
16 6M099 LH cylinder head assembly
8 6M256 RH primary timing chain
guide
(Continued)
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303-01C-8 303-01C-8 Engine 5.4L (4V)
Flywheel and Exhaust Manifolds
7 6701 Crankshaft rear seal 1 9D477 Exhaust gas recirculation
(EGR) tube
plate 2 9428 RH exhaust manifold
9 18C553 Coolant tube assembly 3 9Y431 RH exhaust manifold gasket
(2 required)
4 6375 Flywheel
(2 required) 5 6A373 Engine-to-transmission spacer
plate
assembly 6 6310 Crankshaft oil slinger
(Continued)
http://vnx.su
303-01C-9 303-01C-9 Engine 5.4L (4V)
2. Note the first character on the No. 7 crankshaft
counterweight.
created while cleaning gasket surfaces, that
enters the oil passages, coolant passages or the
oil pan, can cause engine failure.
NOTE: During engine assembly it may become
necessary to check bearing clearances and end play.
For additional information, refer to Section 303-00.
1. Record the first character code information on
the cylinder block.
3. Using the data recorded in the previous 2 steps,
cross-reference using the chart to obtain bearing
grade.
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303-01C-10 303-01C-10 Engine 5.4L (4V)
4. NOTE: Before assembling the cylinder block,
6. CAUTION: Make sure the side of the
all sealing surfaces must be free of chips, dirt,
thrust washer, with three 5-mm wide oil
paint and foreign material. Also, make sure the
grooves, faces the crankshaft thrust surface.
coolant and oil passages are clear.
Push the crankshaft rearward and install the rear
Lubricate the upper crankshaft main bearings
crankshaft upper thrust washer at the back of
with clean engine oil and install into the
cylinder block.
5. NOTE: Do not install the upper thrust bearings
until the crankshaft is installed.
NOTE: Lubricate the thrust surfaces of the
Push the crankshaft forward and install the front
crankshaft with clean engine oil.
crankshaft upper thrust washer at the front of
Install the crankshaft onto the upper main
bearings.
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303-01C-11 303-01C-11 Engine 5.4L (4V)
10. NOTE: Crankshaft not shown for clarity.
Install the main bearing cap dowel pins so the
flat sides face the crankshaft.
NOTE: To aid in assembly, apply petroleum
jelly to the back of the crankshaft thrust
washer.
Install the lower crankshaft thrust washer to the
back side of the No. 5 main bearing cap, with
the tab aligned with the cutout in the main
bearing cap.
9. Lubricate the crankshaft lower main bearings
and install them into the main bearing caps.
Locate the main bearing caps on the cylinder
block and, keeping the caps as square as
possible, alternately draw the caps down evenly
using the new cap fasteners.
http://vnx.su
303-01C-12 303-01C-12 Engine 5.4L (4V)
11. Push the crankshaft forward to seat the
crankshaft thrust washer. Hold the crankshaft in
the forward position.
12. Tighten the vertical main bearing cap fasteners
in the sequence shown, in 3 stages.
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303-01C-13 303-01C-13 Engine 5.4L (4V)
13. NOTE: Crankshaft not shown for clarity.
Install the new side bolts and tighten them in
the sequence shown, in 2 stages.
connecting rod.
NOTE: The next 3 steps are for all 8
connecting rods, rod caps and pistons. Only 1
connecting rod, rod cap and piston is shown.
NOTE: Make sure the identification marks on
the piston and connecting rod face toward the
front of the engine.
Using the special tools, install the No. 1 and
No. 6 piston and the connecting rod assemblies.
Lubricate the piston and rings with clean
engine oil.
Lubricate the rod bearings with clean engine
oil.
Lubricate the cylinder bores with clean
engine oil.
14. Check that crankshaft torque-to-turn does not
exceed 6 Nm (53 lb-in).
15. Check the crankshaft end play. For additional
16. NOTE: Verify correct orientation of connecting
rod and rod cap.
Prepare the connecting rod and cap.
Insert the bolts in the rod cap.
Insert the upper and lower rod bearings into
the rod and cap.
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303-01C-14 303-01C-14 Engine 5.4L (4V)
18. Seat the connecting rods on the crankshaft
journals and remove the special tool.
22. Install the oil pump and 3 bolts.
Tighten the bolts in the sequence shown to
10 Nm (89 lb-in).
19. CAUTION: The rod cap installation
must keep the same orientation as marked
during disassembly.
NOTE: Rotate the crankshaft after each
connecting rod is installed and tightened, to
check for assembly binding.
Install the rod bearing caps and tighten the bolts
in 2 stages.
23. NOTE: Install a new O-ring seal on the oil
pump screen and pickup tube.
Install the oil pump screen and pickup tube and
the 3 bolts.
Tighten the 2 small bolts to 10 Nm (89
lb-in).
Tighten the large bolt to 25 Nm (18 lb-ft).
20. Install the piston assemblies 3 and 5, 4 and 7, 2
and 8, by turning the crankshaft 90 degrees and
repeating the previous steps.
21. Install the windage tray, the 7 nuts and the
spacer.
(18 lb-ft).
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303-01C-15 303-01C-15 Engine 5.4L (4V)
24. CAUTION: The gasket sealing surfaces 25. CAUTION: Cylinder head machining
on the cylinder head and the cylinder block or milling is not authorized by the Ford
must be clean. For additional information, Motor Company. Cylinder head flatness
refer to Cylinder Head in the Removal must be within 0.0254 mm (0.001 in) across a
portion of this section. 38.1 mm (1.5 in) square area.
CAUTION: The use of sealing aids CAUTION: The gasket sealing surfaces
(aviation cement, copper spray and glue) is on the cylinder head and the cylinder block
not permitted. The gasket must be installed must be clean. Do not use metal scrapers,
dry. wire brushes, power abrasive discs or other
CAUTION: The new gasket has a film
These tools cause scratches and gouges
coating which is crucial to the gaskets
ability to seal correctly. Do not scratch the
gasket.
sealant.
NOTE: RH head gasket shown, LH head
gasket similar.
Install the RH and LH head gasket over the
dowel pins.
dry.
CAUTION: Do not allow the dowels to
scratch the sealing surface of the cylinder
head during cylinder head installation.
NOTE: The new cylinder head bolts must be
lightly oiled with a rag and allowed to drain for
a few minutes prior to installation.
Install the RH and LH cylinder heads on the
dowels and the head gaskets.
Loosely install new bolts.
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303-01C-16 303-01C-16 Engine 5.4L (4V)
26. Tighten the new RH cylinder head bolts in 5
stages in the sequence shown.
28. CAUTION: Do not compress the
ratchet assembly. This will damage the
ratchet assembly
Compress each tensioner plunger, using an edge
of a vise.
27. Tighten the new LH cylinder head bolts in 5
stages in the sequence shown.
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303-01C-17 303-01C-17 Engine 5.4L (4V)
29. Using a small screwdriver or pick, push back 32. If the colored links are not visible, mark one
and hold the ratchet mechanism link on one end and 2 links on the other end,
30. While holding the ratchet mechanism, push the
ratchet arm back into the tensioner housing. 33. Using the special tool, position the crankshaft.
31. Install a suitable pin into the hole of each 34. Install the crankshaft sprocket with the flange
tensioner housing to hold the ratchet assembly facing forward.
and plunger in place during installation.
Remove the tensioner from the vise.
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303-01C-18 303-01C-18 Engine 5.4L (4V)
35. Position the camshaft sprocket timing marks as 38. Install the LH timing chain on the camshaft
shown. sprocket, aligning the 2 colored links with the
timing mark on the sprocket.
36. Install the LH primary timing chain guide and
the 2 bolts. 39. Install the LH primary timing chain tensioner
arm.
40. Install the LH primary timing chain tensioner
37. Position the LH (inner) timing chain onto the
and the 2 bolts.
crankshaft sprocket, aligning the one colored
link on the timing chain with the slot on the Tighten to 25 Nm (18 lb-ft).
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303-01C-19 303-01C-19 Engine 5.4L (4V)
41. Install the RH primary timing chain guide and 44. Install the RH primary timing chain tensioner
the 2 bolts. arm.
45. Install the RH primary timing chain tensioner
and the 2 bolts.
42. Position the RH (outer) timing chain on the
crankshaft sprocket, aligning the colored link Tighten to 25 Nm (18 lb-ft).
with the timing marks on the sprocket.
43. Install the RH timing chain on the camshaft
46. As a post-check, verify correct alignment of all
sprocket, aligning the 2 colored links with the
timing marks. Make sure that the colored links
are lined up with the marks on the crankshaft
sprocket and the camshaft sprockets.
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303-01C-20 303-01C-20 Engine 5.4L (4V)
47. Install the crankshaft sensor ring. 50. Repeat the previous step to install all the roller
followers.
Install the 8 spark plugs.
52. NOTE: If the engine front cover is not secured
and the sealing area cleaned with metal surface
cleaner. Allow to dry until there is no sign of
wetness or 4 minutes, whichever is longer.
Failure to follow this procedure can result in
future oil leakage.
Apply silicone gasket and sealant in the
locations shown.
be reinstalled, they must be installed in their
original positions.
spring and install the roller follower.
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303-01C-21 303-01C-21 Engine 5.4L (4V)
53. Install the engine front cover and the 16 bolts.
Tighten the bolts in the sequence shown:
Bolts 1 through 14 to 25 Nm (18 lb-ft).
Bolts 15 and 16 to 50 Nm (37 lb-ft).
13 N806177 Bolt, hex head pilot, M8 x 1 N806177 Bolt, hex head pilot, M8 x
1.25 x 53 1.25 x 53
1.25 x 53 1.25 x 53
15 N606063 Bolt, hex flange head pilot, 3 N806177 Bolt, hex head pilot, M8 x
M10 x 1.50 x 55 1.25 x 53
M10 x 1.50 x 55 1.25 x 53
5 N806177 Bolt, hex head pilot, M8 x
1.25 x 53
oil.
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
(Continued)
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303-01C-22 303-01C-22 Engine 5.4L (4V)
front seal.
pulley.
leakage.
Woodruff key slot on the crankshaft pulley.
59. Using the special tool, install a new crankshaft
pulley bolt and the original washer, tighten the
bolt in 4 stages:
Stage 2: Loosen one full turn.
57. Lubricate the crankshaft pulley sealing surface
with clean engine oil prior to installation
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303-01C-23 303-01C-23 Engine 5.4L (4V)
60. Install the coolant pump and the 4 bolts.
63. NOTE: If the valve covers are not secured
61. Install the camshaft position (CMP) sensor and
the bolt.
future oil leakage.
Apply silicone gasket and sealant to the engine
front cover-to-cylinder block joints.
the bolt.
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303-01C-24 303-01C-24 Engine 5.4L (4V)
future oil leakage.
Install the valve covers, bolts and stud bolts.
(89 lb-in).
66. NOTE: Lubricate the new oil level indicator
installation.
Using a new O-ring seal, install the oil level
indicator tube, bolt and oil level indicator.
Install the LH and RH block drain plugs.
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303-01C-25 303-01C-25 Engine 5.4L (4V)
67. NOTE: Clean and inspect the sealing surfaces
on the packaging.
Using a new gasket, install the oil filter adapter
and the 8 bolts.
Tighten in the sequence shown:
X Bolts 1 through 6 to 25 Nm (18 lb-ft).
X Bolts 7 and 8 to 50 Nm (37 lb-ft).
70. Install the 3 coolant tube assembly bolts.
68. CAUTION: A new cooler must be
installed or severe damage to the engine can
occur.
NOTE: Clean and inspect the sealing surfaces
on the packaging.
71. Install new gaskets, the LH exhaust manifold
Using new gaskets, install a new oil cooler and
and 8 new nuts.
the 6 bolts.
(15 lb-ft).
(89 lb-in).
69. Install the coolant tube assembly and the 3
bolts.
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303-01C-26 303-01C-26 Engine 5.4L (4V)
72. Install the LH engine support insulator bracket 75. NOTE: Clean and inspect the sealing surfaces
and the 4 bolts. with metal surface prep. Follow the directions
on the packaging.
Using new intake manifold gaskets, install the
intake manifold and the 14 bolts.
(89 lb-in).
73. Install new gaskets, the RH exhaust manifold
and 8 new nuts.
(15 lb-ft).
76. Connect the intake manifold-to-coolant tube
assembly hose.
74. Install the RH engine support insulator bracket,
the stud bolt, and the 3 bolts.
77. Position the wiring harness assembly onto the
engine.
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303-01C-27 303-01C-27 Engine 5.4L (4V)
78. NOTE: Apply a light film of brake dielectric 81. Install the LH radio interference capacitor and
grease to the inside of the coil boots before the nut.
installation.
Install the 4 LH coil-on-plugs.
Connect the 4 LH coil-on-plug electrical
connectors.
connectors.
79. Install the LH coil-on-plug cover and the 2
bolts.
83. Connect the intake air temperature (IAT) sensor
80. Attach the wiring harness retainers to the LH
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303-01C-28 303-01C-28 Engine 5.4L (4V)
84. Connect the CMP sensor electrical connector. 87. Install the RH coil-on-plug cover, bolt and stud
bolt.
85. Connect the engine oil pressure (EOP) sensor
electrical connector and the 2 wiring harness
pin-type retainers.
88. Attach the wiring harness retainers to the RH
86. NOTE: Apply a light film of brake dielectric
grease to the inside of the coil boots before
89. Attach the wiring harness to the RH
installation.
coil-on-plug cover stud bolt.
Install the 4 RH coil-on-plugs.
Connect the 4 RH coil-on-plug electrical
connectors.
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303-01C-29 303-01C-29 Engine 5.4L (4V)
90. Connect the exhaust gas recirculation (EGR) 93. Connect the 4 RH fuel injector electrical
valve electrical connector. connectors.
91. Install the RH radio interference capacitor and 94. Connect the positive crankcase ventilation
the nut. (PCV) valve electrical connector.
95. Attach the 3 wiring harness pin-type retainers.
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303-01C-30 303-01C-30 Engine 5.4L (4V)
96. Install the wiring harness retaining bracket and 99. Connect the LH heated oxygen sensor (HO2S)
the 2 bolts. electrical connector and pin-type retainer.
100. Attach the wiring harness pin-type retainer to
the coolant tube assembly bracket.
97. Connect the bubbler tube from the supercharger
(SC).
101. Connect the cylinder head temperature (CHT)
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303-01C-31 303-01C-31 Engine 5.4L (4V)
102. Install a new gasket, the throttle (TB) and
spacer assembly and the 4 bolts.
106. Install the EGR tube.
103. Connect the electronic throttle control
107. Install the 3 SC drive belt idler pulleys and
the 3 bolts.
Tighten the heavy load idler pulley (closest
to centerline of engine) to 48 Nm (35 lb-ft).
104. Connect the throttle position (TP) sensor
Tighten the smooth idler pulley and the
grooved idler pulley to 25 Nm (18 lb-ft).
105. Install and connect the crankcase ventilation
tube.
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303-01C-32 303-01C-32 Engine 5.4L (4V)
108. Install the coolant pump pulley and install the 111. Install the accessory drive belt tensioner and
4 bolts hand-tight. the bolt.
109. Install the accessory drive belt idler pulley
(grooved) and the bolt.
112. Install the generator, 2 bolts and the stud bolt.
(smooth) and the stud bolt.
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303-01C-33 303-01C-33 Engine 5.4L (4V)
113. Attach the 2 wiring harness pin-type retainers
to the generator.
117. Install the power steering tube bracket bolt.
115. Install the power steering pump and reservoir
assembly and the 3 bolts.
116. Install the power steering reservoir bracket
bolts.
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303-01C-34 303-01C-34 Engine 5.4L (4V)
119. Install the power steering tube bracket nut.
120. Position the SC drive belt and install the SC
drive belt tensioner and bolt.
122. Tighten the 4 coolant pump pulley bolts to 25
Nm (18 lb-ft).
clockwise and install the accessory drive belt.
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303-01C-35 303-01C-35 Engine 5.4L (4V)
123. Connect the coolant hose from the charge air 126. Connect the 2 upper radiator hoses to the
cooler (CAC). intake manifold.
124. Install the thermostat housing assembly and 127. Connect the 2 coolant vent hoses to the intake
the 2 nuts. manifold.
128. Install the coolant tube bracket nut.
125. Connect the electronic coolant temperature Tighten to 9 Nm (80 lb-in).
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303-01C-36 303-01C-36 Engine 5.4L (4V)
129. Connect the coolant hose to the thermostat 132. Using the special tools, remove the engine
housing. from the work stand.
130. Install the special tool. 133. Apply a 4 mm (0.15 in) bead of silicone
gasket and sealant to the rear crankshaft seal
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303-01C-37 303-01C-37 Engine 5.4L (4V)
134. CAUTION: If not secured within 4
minutes, the sealant must be removed and
the sealing area cleaned. To clean the
sealing area, use silicone gasket remover
directions on the packaging. Failure to
leakage.
Install the crankshaft rear seal retainer plate
and the 6 bolts.
(89 lb-in) .
gouges, which make leak paths. Use a
plastic scraping tool to remove all traces of
old sealant.
for the oil pan with silicone gasket remover
and metal surface prep. Follow the directions
on the packaging.
135. NOTE: Lubricate the inner lip of the
the sealing area cleaned. To clean the
crankshaft rear seal with clean engine oil.
sealing area, use silicone gasket remover
rear seal.
directions on the packaging. Failure to
leakage.
front cover-to-cylinder block sealing joints and
the crankshaft rear seal retainer
plate-to-cylinder block sealing joints.
rear seal.
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303-01C-38 303-01C-38 Engine 5.4L (4V)
139. Using a new gasket, install the oil pan, 14 140. Install the engine/transmission spacer plate.
bolts and 2 stud bolts.
(18 lb-ft).
141. Install the flywheel and the 8 bolts.
Tighten to 80 Nm (59 lb-ft) in the sequence
shown.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
Emission Calibration Label
Engine
NOTE: The engine codes and the calibration
The 5.4L (330 CID) is a V-8 engine with the
numbers must be used when making inquiries or
following features:
ordering parts.
Dual overhead camshafts
The emission calibration number label is located on
Four valves per cylinder
the LH side door or LH door post pillar. It
identifies:
Sequential mult-port fuel injection (SFI)
the engine calibration number.
Cast iron, 90-degree V-cylinder block
the engine code number.
Individually chain-driven camshafts with a
the revision level.
hydraulic timing chain tensioner on each timing
These numbers are used to determine if parts are
chain
unique to specific engines.
Electronic ignition system with 8 ignition coils
Supercharger
Supercharger (SC)
The supercharger (SC) is a positive displacement
Charge air cooler (CAC)
pump. Its purpose is to supply an excess volume of
intake air to the engine by increasing air pressure
Identification
and density in the intake manifold. The SC is
For quick identification refer to the safety
matched to the engine by its displacement and belt
certification decal.
ratio, and can provide excess airflow at any engine
The decal is located on the LH front door lock speed.
face panel.
NOTE: The supercharger (SC) is repaired only as
Find the engine code (letter or number) on the an assembly. Disassembly of the SC unit may void
decal, then refer to the Engine Identification Chart the warranty.
to determine engine type and size. Refer to
NOTE: The supercharger (SC) is not a bolt-on
Section 100-01.
option. It is part of a integrated engine system.
The symbol code on the identification tag Many components of the supercharged engine are
identifies each engine for determining parts usage; not interchangeable with similar parts from a
for example, engine displacement in liters or non-supercharged engine.
cubic inch displacement and model year.
The SC contains two 3-lobed rotors. The helical
shape and specialized porting provide a smooth
Engine Code Information
discharge flow and low level of noise during
The engine code information label is located on the
operation. The rotors are supported by ball bearings
engine front cover. The label contains, among other
in front and needle bearings at the rear. The drive
information:
gears are pressed into place, therefore the SC is
installed new as a unit, and is not repairable.
the engine calibration number.
The SC system is a blow-through type with the fuel
the engine build date.
injected directly into the intake ports. The SC is belt
the engine plant code.
driven off the crankshaft through an idler pulley.
the engine code.
The throttle body controls the amount of intake air
to the SC through the intake plenum. Air from the
SC is routed through the charge air cooler (CAC),
then to the intake manifold. The resulting denser air
charge in the combustion chamber provides for a
higher power output of the engine over a
non-supercharged engine or the same displacement.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
Valve Train NOTE: It is not possible to increase manifold
pressure or engine power output by altering the
The valves are actuated by a direct acting hydraulic
bypass valve or the actuator.
lash adjuster and roller follower. The direct acting
hydraulic lash adjusters and roller followers:
At partial-throttle opening or when vacuum is
present in the intake system, a vacuum controlled
provide hydraulic lash adjustment.
bypass valve reroutes some discharged air from the
ride on the camshaft lobes.
SC back through the intake plenum. This prevents
the SC from cavitating, causing reduced
Engine Lubrication System
performance, increased temperatures and poor
The engine lubrication system is of the force-feed
economy.
type in which oil is supplied under full pressure to
The SC has a self-contained oiling system that does
the:
not require a fluid change for the life of the vehicle.
crankshaft main bearings.
Induction System
crankshaft thrust main bearing.
The sequential multi-port fuel injection (SFI)
connecting rod bearings.
provides the fuel/air mixture needed for combustion
oil galleries.
in the cylinders. The 8 solenoid-operated fuel
injectors:
All other parts are lubricated by splash of the oil.
are mounted in the fuel injection supply manifold
Oil Pump
and the intake manifold above the cylinder heads.
The lubrication system of the 5.4L (4V) engine is
meter fuel into the air intake stream in accordance
designed to provide optimum oil flow to critical
with engine demand.
components of the engine through its entire
are positioned so that their tips direct fuel just
operating range. The heart of the system is a
ahead of the engine intake valves.
positive displacement internal gear oil pump using
top seal rotors.
are connected in series with the fuel pressure
regulator.
Generically, this design is known as a gerotor
pump, which operates as follows:
supply fuel from the fuel tank by a fuel pump
mounted in the fuel tank.
The oil pump is mounted on the front face of the
A constant fuel pressure drop is maintained across cylinder block.
the fuel injectors by the fuel pressure regulator. The
The inner rotor is piloted on the crankshaft post
fuel pressure regulator:
and is driven through flats on the crankshaft.
is positioned upstream from the fuel injectors on
System pressure is limited by an integral,
the fuel injection supply manifold.
internally-vented relief valve which directs the
bypassed oil back to the inlet side of the oil
Crankshaft
pump.
The crankshaft is supported on the bottom of the
Oil pump displacement has been selected to
cylinder block by 5 crankshaft main bearings.
provide adequate volume to make sure of correct
oil pressure both at hot idle and maximum speed.
Camshafts
The relief valve calibration protects the system
The camshafts:
from excessive pressure during high viscosity
are arranged in pairs, one each (intake and
conditions.
exhaust) on each cylinder head.
The relief valve is designed to provide adequate
are synchronized through a secondary timing
connecting rod bearing lubrication under
chain.
high-temperature and high-speed conditions.
depress the roller followers to actuate the valves.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, refer to
(PC/ED) manual.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
DISASSEMBLY
Special Tool(s)
Engine
303-452 (T93P-6565-AR)
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
303-442 (T93P-6136-A)
Slinger
303-514 (T95P-6701-AH)
Material
Item Specification
303-519 (T95P-6701-EH)
Prep
ZC-31
ZC-30
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Remover, Crankshaft Vibration the oil passages, coolant passages or the oil pan,
Damper
303-009 (T58P-6316-D)
NOTE: The flywheel, crankshaft rear oil slinger,
crankshaft rear seal and the crankshaft rear seal
retainer plate must be removed before mounting the
engine on the engine stand.
303-107 (T74P-6700-A)
section.
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
1. Remove the 8 bolts and the flywheel. 4. Using the special tools, remove the crankshaft
rear seal.
2. Remove the engine/transmission spacer plate.
5. Remove the 8 bolts and the rear seal retainer
plate.
rear oil slinger.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
10. Disconnect the 2 upper radiator hoses from the
intake manifold.
7. Disconnect the coolant hose from the thermostat
housing.
8. Remove the coolant tube bracket nut.
9. Disconnect the 2 coolant vent hoses from the
intake manifold.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
12. Remove the 2 nuts and the thermostat housing 15. Rotate the accessory drive belt tensioner
assembly. clockwise and remove the accessory drive belt.
13. Disconnect the coolant hose from the charge air
cooler (CAC).
16. Remove the bolt, supercharger (SC) drive belt
tensioner and the SC drive belt.
14. Loosen the 4 coolant pump pulley bolts.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
17. Remove the power steering tube bracket nut.
pump and reservoir assembly.
18. Disconnect the power steering pressure (PSP)
22. Disconnect the generator electrical connector.
19. Remove the power steering tube bracket bolt.
20. Remove the 2 power steering reservoir bracket
bolts.
http://vnx.su
303-01C-6 303-01C-6 Engine 5.4L (4V)
23. Detach the 2 wiring harness pin-type retainers
from the generator.
26. Remove the stud bolt and the accessory drive
belt idler pulley (smooth).
24. Remove the stud bolt, 2 bolts and the generator.
idler pulley (grooved).
tensioner.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
28. Remove the 4 bolts and the coolant pump 31. Disconnect and remove the crankcase
pulley. ventilation tube.
29. Remove the 3 bolts and the 3 SC drive belt 32. Disconnect the throttle position (TP) sensor
idler pulleys. electrical connector.
30. Disconnect the 2 exhaust gas recirculation 33. Disconnect the electronic throttle control
(EGR) tube fittings. electrical connector.
Remove the EGR tube.
http://vnx.su
303-01C-8 303-01C-8 Engine 5.4L (4V)
34. Remove the 4 bolts and the TB and spacer 37. Disconnect the LH heated oxygen sensor
assembly. (HO2S) electrical connector and pin-type
retainer.
(CHT) sensor electrical connector. 38. Detach the wiring harness pin-type retainer
from the LH cylinder head.
36. Detach the wiring harness pin-type retainer
from the coolant tube assembly bracket. 39. Disconnect the bubbler tube from the SC.
http://vnx.su
303-01C-9 303-01C-9 Engine 5.4L (4V)
40. Remove the 2 bolts and the wiring harness
retaining bracket.
41. Detach the 3 wiring harness pin-type retainers.
45. Remove the nut and the RH radio interference
capacitor.
(PCV) valve electrical connector.
connectors.
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303-01C-10 303-01C-10 Engine 5.4L (4V)
46. Disconnect the EGR valve electrical connector.
50. Disconnect the 4 RH coil-on-plug electrical
connectors.
47. Detach the wiring harness from the RH
Remove the 4 RH coil-on-plugs.
48. Detach the wiring harness retainers from the
RH valve cover stud bolts.
pin-type retainers.
49. Remove the bolt, stud bolt and the RH
coil-on-plug cover.
http://vnx.su
303-01C-11 303-01C-11 Engine 5.4L (4V)
52. Disconnect the camshaft position (CMP) sensor 55. Remove the nut and the LH radio interference
electrical connector. capacitor.
53. Disconnect the intake air temperature (IAT) 56. Detach the wiring harness retainers from the
sensor electrical connector. LH valve cover stud bolts.
54. Disconnect the 4 LH fuel injector electrical 57. Remove the 2 bolts and the LH coil-on-plug
connectors. cover.
http://vnx.su
303-01C-12 303-01C-12 Engine 5.4L (4V)
58. Disconnect the 4 LH coil-on-plug electrical
connectors.
Remove the 4 LH coil-on-plugs.
62. Remove the stud bolt, 3 bolts and the RH
engine support insulator bracket.
59. Remove the wiring harness assembly from the
engine.
60. Disconnect the intake manifold-to-coolant tube
assembly hose.
63. Remove 8 nuts and the RH exhaust manifold.
Discard the nuts and gaskets.
Clean and inspect the RH exhaust manifold.
303-00.
61. Remove the 14 bolts and the intake manifold
assembly.
Remove and discard the 2 intake manifold
gaskets.
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303-01C-13 303-01C-13 Engine 5.4L (4V)
64. Remove the 4 bolts and the LH engine support 67. Remove the oil level indicator, the bolt and the
insulator bracket. oil level indicator tube.
Remove and discard the oil level indicator
tube O-ring seal.
65. Remove 8 nuts and the LH exhaust manifold.
Clean and inspect the LH exhaust manifold.
303-00.
68. Remove the coolant tube assembly-to-LH
cylinder head bolt.
66. Remove the 3 coolant tube assembly bolts.
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303-01C-14 303-01C-14 Engine 5.4L (4V)
69. Remove the 3 bolts and the coolant tube 72. NOTE: LH shown, RH similar.
assembly.
Remove the LH and RH block drain plugs.
70. CAUTION: A new oil cooler must be
73. Remove the 14 bolts, 2 stud bolts and the oil
installed or severe damage to the engine can
pan.
occur.
Remove and discard the oil pan gasket.
Remove the 6 bolts and the oil cooler.
Discard the oil cooler and the gaskets.
Discard the oil filter adapter gasket.
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303-01C-15 303-01C-15 Engine 5.4L (4V)
74. Remove the 3 bolts and the oil pump screen
and pickup tube assembly.
77. Remove the bolts, stud bolts and LH valve
cover.
Remove and discard the gaskets.
75. Remove the spacer, 7 nuts and the windage
tray.
76. Remove the bolts, stud bolts and RH valve
cover.
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303-01C-16 303-01C-16 Engine 5.4L (4V)
78. Remove the bolt and the crankshaft position
(CKP) sensor.
pulley.
79. Remove the bolt and the CMP sensor.
front seal.
80. Remove the 4 bolts and the coolant pump.
pulley bolt and the washer.
Discard the bolt.
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303-01C-17 303-01C-17 Engine 5.4L (4V)
84. Remove the 16 bolts and the engine front
cover.
Remove and discard the engine front cover
gaskets.
Remove the 8 spark plugs.
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303-01C-18 303-01C-18 Engine 5.4L (4V)
89. Remove the crankshaft sensor ring.
spring and remove the roller follower.
90. Remove the 2 bolts and the RH primary timing
chain tensioner.
87. Repeat the previous step to remove each of the
roller followers. Inspect roller followers. For
Inspect the hydraulic lash adjusters. For
91. Remove the RH primary timing chain tensioner
arm.
303-00.
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303-01C-19 303-01C-19 Engine 5.4L (4V)
92. Remove the RH primary timing chain. 95. Remove the LH primary timing chain tensioner
arm.
chain guide. 96. Remove the LH primary timing chain.
94. Remove the 2 bolts and the LH primary timing 97. Remove the 2 bolts and the LH primary timing
chain tensioner. chain guide.
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303-01C-20 303-01C-20 Engine 5.4L (4V)
98. Remove the crankshaft sprocket.
100. CAUTION: The cylinder head must
be cool before removing it from the engine.
99. Remove the 3 bolts and the oil pump. scrapers, wire brushes, power abrasive discs
gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the
head gasket.
soft and can be scratched easily. Never
place the cylinder head gasket surface,
Remove the bolts, the RH cylinder head and
Discard the bolts.
Remove and discard the cylinder head
gaskets
http://vnx.su
303-01C-21 303-01C-21 Engine 5.4L (4V)
gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the
head gasket.
cautions and follow all application
directions contained on the packaging of the
silicone gasket remover and the metal
surface prep.
present, metal surface prep can be used to
clean and prepare the surfaces.
the cylinder block.
several minutes.
remain.
is normal.
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303-01C-22 303-01C-22 Engine 5.4L (4V)
NOTE: Use a straightedge that is calibrated
by the manufacturer to be flat within 0.005
mm (0.0002 in) per running foot length. For
long, the machine edge must be flat within
Support the cylinder heads on a bench with
the head gasket side up. Inspect all areas of
the deck face with a straightedge, paying
particular attention to the oil pressure feed
area. The cylinder head must not have
depressions deeper than 0.0254 mm (0.001 in)
across a 38.1 mm (1.5 in) square area, or
scratches more than 0.0254 mm (0.001 in).
manufacturers instructions.
http://vnx.su
303-01C-23 303-01C-23 Engine 5.4L (4V)
104. NOTE: Verify that the connecting rods and
rod caps have orientation numbers cast into
them. If not, number the connecting rods and
rod caps for correct orientation
Remove the bolts and the connecting rod caps
for pistons No. 1 and No. 6.
Carefully tap the connecting rod bolts out of
the connecting rod caps. Avoid damaging
the rod caps.
105. CAUTION: Do not scratch the
cylinder walls or crankshaft journals with
the connecting rod.
106. To remove pistons 2, 3, 4, 5, 7 and 8, turn the
Using the special tools, push the pistons 1
crankshaft 90 degrees and repeat the previous
through 6 through the top of the cylinder
steps.
block.
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303-01C-24 303-01C-24 Engine 5.4L (4V)
108. Remove the main bearing caps, the lower
107. CAUTION: Remove the cylinder
crankshaft main bearings and the lower thrust
heads before removing the crankshaft.
washer.
Failure to do so can result in engine
damage.
Remove the crankshaft main bearing cap
fasteners.
1 Remove and discard the side bolts.
2 Remove and discard the main bearing cap
bolts.
3 Remove the dowel pins.
109. Remove the crankshaft, the upper crankshaft
main bearings and the upper thrust washers
from the cylinder block.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
OF SUBASSEMBLIES
Cylinder Head
Special Tool(s)
303-446 (T93P-6256-AHR)
303-452 (T93P-6565-AR)
Compressor Spacer, Valve
Spring
303-382 (T91P-6565-AH)
303-383 (T91P-6571-A)
Material
Item Specification
XO-5W50-QGT or
equivalent
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303-01C-2 303-01C-2 Engine 5.4L (4V)
7 6268 Secondary timing chain 1 N811085 Camshaft drive sprocket bolt
8 6256 Exhaust camshaft drive 2 N806164 Camshaft drive sprocket
sprocket washer
9 6256 Intake camshaft drive 3 6C252 RH/ Camshaft drive sprocket
sprocket 6C253 LH
10 W500304 RH/ Secondary timing chain 4 N811085 Camshaft drive sprocket bolt
W500215 LH tensioner bolt (2 required)
5 N806164 Camshaft drive sprocket
11 6C270 RH/ Secondary timing chain washer
6C271 LH tensioner
6 6265 Camshaft drive sprocket
spacer
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
17 W710991 Exhaust camshaft bearing cap 12 W710990 Intake camshaft bearing cap
bolt bolt
18 W705438 Exhaust camshaft bearing cap 13 N807352 Intake/Exhaust camshaft
bolt bearing cap bolt (22 required)
19 6B278 Exhaust camshaft bearing cap 14 6B277 Intake/Exhaust camshaft
bearing cap (8 required)
20 6B278 Exhaust camshaft bearing cap
15 6B277 Intake camshaft bearing cap
21 6A272 RH/ Exhaust camshaft
(2 required)
6A273 LH
16 6A270 RH/ Intake camshaft
6A271 LH
(Continued)
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303-01C-4 303-01C-4 Engine 5.4L (4V)
22 6518 Retainer key (32 required)
required)
24 6513 Valve spring
25 6A517 Valve seal
26 6507 Intake valve
27 6505 Exhaust valve
Disassembly
1. CAUTION: Before disassembly begins,
mark the valve position on the face of each
valve being removed. The valves must be
reinstalled into the same positions.
http://vnx.su
303-01C-5 303-01C-5 Engine 5.4L (4V)
Remove the bolt, washer and camshaft drive
sprocket.
Remove the 2 bolts and the secondary timing
chain tensioner.
Remove the bolt, washer and spacer.
spring and remove the retainer keys.
4. Compress the secondary timing chain tensioner
and install a lockpin.
Remove the timing chain and the 2 camshaft
sprockets.
http://vnx.su
303-01C-6 303-01C-6 Engine 5.4L (4V)
8. Remove the valve, spring retainer, valve spring
and the valve seal.
Remove the valve.
9. Repeat the previous 2 steps and remove all of
the retainer keys, spring retainers, valve springs,
valve seals and valves.
10. CAUTION: The cam bearing cap bolts
vary in length and head design and must be
installed in their original positions. Camshaft
bearing caps are not interchangeable and
must be installed in their original positions.
NOTE: The camshaft bearing cap with 3 bolts
is located at the front of the LH cylinder head
and at the rear of the RH cylinder head.
Remove the camshaft bearing cap bolts in the
sequence shown.
Remove the camshaft bearing caps.
Remove the camshafts.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
Assembly
Install the camshafts.
Using the special tools, install a new valve seal.
Repeat step to install all of the new valve
seals.
installed in their original positions. Camshaft
must be installed in their original positions.
NOTE: The camshaft bearing cap with 3 bolts
is located at the front of the LH cylinder head
and at the rear of the RH cylinder head.
NOTE: Lubricate the camshaft bearing cap
bearing surfaces with clean engine oil prior to
installation.
Install the camshaft bearing caps.
Install the bearing cap bolts and tighten in
the sequence shown to 10 Nm (89 lb-in).
http://vnx.su
303-01C-8 303-01C-8 Engine 5.4L (4V)
4. Position the valve, the valve spring and the 7. Repeat the 3 previous steps and install all of
spring retainer into the cylinder head. the valves, valve springs, valve spring retainers
and retainer keys.
Install the secondary timing chain tensioner and
the bolts.
5. Install the special tool between the valve spring
coils to protect the valve seal from damage.
Index the keyways on the camshafts to the 6
oclock position.
spring and install the retainer keys.
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303-01C-9 303-01C-9 Engine 5.4L (4V)
10. CAUTION: Timing marks must be at
12 oclock position.
Install the camshaft sprockets and the chain as
an assembly.
Remove the lockpin from the secondary
timing chain tensioner.
Install the camshaft sprocket, washer and bolt,
and hand-tighten the bolt.
Tighten the bolts in 2 stages:
Install the camshaft spacer, washer and bolt,
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
INSTALLATION
Special Tool(s)
Cylinder Head
required)
Special Tool(s)
303-D087 (D93P-6001-A1)
303-448 (T93P-6303-A)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Installer, Crankshaft Front Oil
Seal
303-635
Installer, Crankshaft Front Oil
Seal
303-335 (T88T-6701-A)
Material
Item Specification
Strap Wrench
303-D055 (D85L-6000-A)
XO-5W50-QGT or
equivalent
Sealant
TA-30
Installer, Crankshaft Vibration Motorcraft Metal Surface
Damper Prep
303-102 (T74P-6316-B) ZC-31
ZC-30
Compound
XG-3-A
303-452 (T93P-6565-AR)
Cleaner
ZC-21
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
Both cylinder heads
2. CAUTION: Cylinder head machining
or milling is not authorized by the Ford
Motor Company. Cylinder head flatness
1. CAUTION: The gasket sealing surfaces
must be within 0.0254 mm (0.001 in) across a
on the cylinder head and the cylinder block
38.1 mm (1.5 in) square area.
must be clean. For additional information,
refer to Cylinder Head in the Removal
CAUTION: The gasket sealing surfaces
on the cylinder head and the cylinder block
must be clean. Do not use metal scrapers,
These tools cause scratches and gouges
dry.
CAUTION: The new gasket has a film
coating which is crucial to the gaskets
sealant.
ability to seal correctly. Do not scratch the
gasket.
NOTE: RH head gasket shown, LH head
gasket similar.
dry.
Install the head gasket over the dowel pins.
CAUTION: Do not allow the dowels to
scratch the sealing surface of the cylinder
head during cylinder head installation.
NOTE: The new cylinder head bolts must be
lightly oiled with a rag, and allowed to drain
for a few minutes prior to installation.
Install the cylinder head on the dowels and the
head gasket.
Loosely install the new bolts.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
RH cylinder head
Tighten 10 Nm (89 lb-in).
3. Tighten the new cylinder head bolts in 5 stages
5. Install new RH exhaust manifold gaskets, the
RH exhaust manifold and 8 new nuts.
(15 lb-ft).
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303-01C-4 303-01C-4 Engine 5.4L (4V)
LH cylinder head
6. Tighten the new cylinder head bolts in 5 stages
Both cylinder heads
ratchet assembly
of a vise.
9. Using a small screwdriver or pick, push back
and hold the ratchet mechanism
7. Install new LH exhaust manifold gaskets, the
LH exhaust manifold and 8 new nuts.
(15 lb-ft).
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303-01C-5 303-01C-5 Engine 5.4L (4V)
10. While holding the ratchet mechanism, push the 13. Using the special tool, position the crankshaft.
ratchet arm back into the tensioner housing.
14. Install the crankshaft sprocket with the flange
11. Install a suitable pin into the hole of each facing forward.
tensioner housing to hold the ratchet assembly
and plunger in place during installation.
the 2 bolts.
12. If the colored links are not visible, mark one
link on one end and 2 links on the other end,
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303-01C-6 303-01C-6 Engine 5.4L (4V)
16. Position the camshaft sprocket timing marks as
shown.
and the 2 bolts.
link on the timing chain with the slot on the
21. Install the RH primary timing chain guide and
the 2 bolts.
Tighten to 10 Nm (89 lb-in). 18. Install the LH timing chain on the camshaft
arm.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
22. Position the RH (outer) timing chain on the 25. Install the RH primary timing chain tensioner
crankshaft sprocket, aligning the colored link and the 2 bolts.
23. Install the RH timing chain on the camshaft
arm.
27. Install the crankshaft sensor ring.
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303-01C-8 303-01C-8 Engine 5.4L (4V)
30. Repeat the previous step to install all the roller
followers.
be reinstalled, they must be installed in their
original positions.
Install the 8 spark plugs.
future oil leakage.
locations shown.
spring and install the roller follower.
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303-01C-9 303-01C-9 Engine 5.4L (4V)
1.25 x 53 1.25 x 53
1.25 x 53 1.25 x 53
M10 x 1.50 x 55 1.25 x 53
M10 x 1.50 x 55 1.25 x 53
34. Install the 2 oil pan-to-engine front cover bolts
1.25 x 53
and the 2 oil pan-to-engine front cover stud
bolts.
1.25 x 53
7 N806177 Bolt, hex head pilot, M8 x Tighten to 25 Nm (18 lb-ft).
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
1.25 x 53
(Continued)
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303-01C-10 303-01C-10 Engine 5.4L (4V)
oil.
front seal.
pulley.
leakage.
http://vnx.su
303-01C-11 303-01C-11 Engine 5.4L (4V)
40. Using the special tool, install a new crankshaft 42. Install the camshaft position (CMP) sensor and
pulley bolt and the original washer, tighten the the bolt.
bolt in 4 stages:
the bolt.
41. Install the coolant pump and the 4 bolts.
http://vnx.su
303-01C-12 303-01C-12 Engine 5.4L (4V)
future oil leakage.
Apply silicone gasket sealant in the locations
shown.
Install the LH and RH block drain plugs.
future oil leakage.
Install the valve covers and the bolts.
(89 lb-in).
http://vnx.su
303-01C-13 303-01C-13 Engine 5.4L (4V)
47. Install the RH engine insulator bracket, the stud
bolt, and the 3 bolts.
on the packaging.
Using a new gasket, install the oil cooler and
48. NOTE: Lubricate the new oil level indicator
the 6 bolts.
installation.
(89 lb-in).
Using a new O-ring seal, install the oil level
indicator tube, bolt and oil level indicator.
on the packaging.
and the 8 bolts.
http://vnx.su
303-01C-14 303-01C-14 Engine 5.4L (4V)
on the packaging.
Using new intake manifold gaskets, install the
intake manifold and the 14 bolts.
(89 lb-in).
56. Install the LH coil-on-plug cover and the 2
bolts.
53. Connect the intake manifold-to-coolant tube
assembly hose.
57. Attach the wiring harness retainers to the LH
54. Position the wiring harness assembly onto the
engine.
installation.
Install the 4 LH coil-on-plugs.
Connect the 4 LH coil-on-plug electrical
connectors.
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303-01C-15 303-01C-15 Engine 5.4L (4V)
the nut.
62. Connect the engine oil pressure (EOP) sensor
connectors.
installation.
Install the 4 RH coil-on-plugs.
60. Connect the intake air temperature (IAT) sensor
Connect the 4 RH coil-on-plug electrical
connectors.
61. Connect the CMP sensor electrical connector.
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303-01C-16 303-01C-16 Engine 5.4L (4V)
64. Install the RH coil-on-plug cover, bolt and stud 67. Connect the EGR valve electrical connector.
bolt.
68. Install the RH radio interference capacitor and
the nut.
65. Attach the wiring harness retainers to the RH Tighten to 10 Nm (89 lb-in).
66. Attach the wiring harness to the RH sensor electrical connector.
http://vnx.su
303-01C-17 303-01C-17 Engine 5.4L (4V)
connectors.
74. Connect the bubbler tube from the supercharger
(SC).
73. Install the wiring harness retaining bracket and
the 2 bolts.
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303-01C-18 303-01C-18 Engine 5.4L (4V)
76. Connect the LH heated oxygen sensor (HO2S)
electrical connector and pin-type retainer.
80. Connect the TB control electrical connector.
the coolant tube assembly bracket.
81. Connect the throttle position (TP) sensor
78. Connect the cylinder head temperature (CHT)
79. Install a new gasket, the throttle (TB) and
spacer assembly and the 4 bolts.
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303-01C-19 303-01C-19 Engine 5.4L (4V)
82. Install and connect the crankcase ventilation 85. Install the coolant pump pulley and the 4 bolts.
tube.
Do not tighten the bolts at this time.
83. Install the exhaust gas recirculation (EGR) tube.
Tighten to 39 Nm (29 lb-ft). (grooved) and the bolt.
84. Install the 3 SC drive belt idler pulleys and the
3 bolts.
Tighten the heavy load idler pulley (closest (smooth) and the stud bolt.
to centerline of engine) to 48 Nm (35 lb-ft).
Tighten the smooth idler pulley and the
grooved idler pulley to 25 Nm (18 lb-ft).
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303-01C-20 303-01C-20 Engine 5.4L (4V)
88. Install the accessory drive belt tensioner and the
bolt.
89. Install the alternator, 2 bolts and the stud bolt.
90. Attach the 2 wiring harness pin-type retainers to
the generator.
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303-01C-21 303-01C-21 Engine 5.4L (4V)
93. Install the power steering reservoir bracket 96. Install the power steering tube bracket nut.
bolts.
97. Position the SC drive belt and install the SC
94. Install the power steering tube bracket bolt. drive belt tensioner and bolt.
Tighten to 10 Nm (89 lb-in). Tighten to 48 Nm (35 lb-ft).
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303-01C-22 303-01C-22 Engine 5.4L (4V)
clockwise and install the accessory drive belt.
101. Install the thermostat housing assembly and
the 2 nuts.
102. Connect the engine coolant temperature (ECT)
Nm (18 lb-ft).
100. Connect the coolant hose from the charge air
cooler (CAC).
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303-01C-23 303-01C-23 Engine 5.4L (4V)
103. Connect the 2 upper radiator hoses to the 106. Connect the coolant hose to the thermostat
intake manifold. housing.
104. Connect the 2 coolant vent hoses to the intake 107. Install the special tool.
manifold.
105. Install the coolant tube bracket nut.
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303-01C-24 303-01C-24 Engine 5.4L (4V)
109. Using the special tools, remove the engine 111. Install the flywheel and the 8 bolts.
from the work stand.
Tighten to 80 Nm (59 lb-ft) in the sequence
shown.
110. Install the engine/transmission spacer plate.
112. Install the engine into the vehicle. For
additional information, refer to Engine in this
section.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
OF SUBASSEMBLIES
Piston
Material
Item Specification
XO-5W50-QGT or
equivalent
9 6200 Connecting rod 1 6150 Piston compression upper ring
10 6110 Piston 2 6152 Piston compression lower ring
3 6159 Piston oil control upper
Disassembly segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower
segment ring
Discard the piston rings.
6 6140 Piston pin retainer
2. Remove the piston pin retainers and the piston 7 6140 Piston pin retainer
pin.
8 6135 Piston pin
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
3. Separate the piston from the connecting rod. 2. Lubricate the piston pin and pin bore with clean
engine oil.
4. Clean and inspect the piston and connecting
rod. For additional information, refer to Section 3. Install the piston pin in the piston and
303-00. connecting rod assembly.
Assembly
4. Install the piston pin retaining clips in the
piston.
1. NOTE: The connecting rod must be installed
5. Lubricate the piston and the new piston rings
into the piston with identification markings
toward the front.
Position the connecting rod in the piston.
6. Install the piston rings onto the piston.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
INSTALLATION
Engine
Special Tool(s)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
2. Install the LH engine insulator nut.
211-D027 (D90P-3517-A) or
equivalent
Material
Item Specification
Full Synthetic Motor Oil 3. Install the RH engine insulator nut.
XO-5W50-QGT or
equivalent
1. Using the special tools, install the engine into
the vehicle.
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
4. Install the ground wire and the bolt to the rear
of the LH cylinder head.
8. CAUTION: For correct starter
installation, the upper bolt must be tightened
first
Install the starter and the 3 bolts finger tight.
5. Install the clutch disc and pressure plate. For
1 Tighten the upper bolt to 25 Nm (18 lb-ft).
2 Tighten the 2 lower bolts to 25 Nm (18
lb-ft).
501-20B.
Install the intermediate steering shaft and the
upper bolt.
9. Connect the 2 wires and install the 2 nuts on
the starter solenoid.
Tighten the B+ terminal to 12 Nm (9 lb-ft).
Tighten the S-terminal to 5 Nm (44 lb-in).
7. Install a new engine oil filter.
1 Lubricate the oil filter gasket with clean
engine oil and tighten until the seal makes
contact.
2 Using an oil filter strap wrench, tighten the
filter an additional 270 degrees.
http://vnx.su
303-01C-3 303-01C-3 Engine 5.4L (4V)
10. Install the starter solenoid terminal cover.
14. Position the SC drive onto the A/C compressor
and attach the 2 wiring harness retainers onto
the A/C compressor stud bolts.
the oil pan.
12. Install the ground wire and the nut to the RH
the back of the A/C compressor.
engine insulator bracket stud bolt.
13. Install the A/C compressor and the 3 stud bolts.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
16. Connect the A/C compressor electrical
connector.
20. Connect the power steering return hose.
17. Connect the crankshaft position (CKP) sensor
21. NOTE: A new Teflon seal must be installed.
seal on the power steering pressure (PSP) tube
fitting.
18. Attach the 2 wiring harness retainers to the oil
pan stud bolts.
19. Connect the B+ wire to the generator and
install the nut.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
22. Connect the pressure PSP tube fitting. 25. Rotate the supercharger (SC) drive belt
tensioner clockwise and install the drive belt
onto the SC drive pulley.
23. Position the lower radiator hose assembly into
the vehicle.
Connect the lower radiator hose to the
radiator.
26. Connect the A/C pressure transducer electrical
connector.
24. Connect the coolant hose to the oil cooler.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
27. Connect the hose to the power steering
reservoir.
31. Connect the 68-pin connector to the power
distribution box.
attach the 2 wiring retainers
30. Connect the jumper harness electrical connector.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
34. Connect the 2 heater hoses to the coolant tube 37. Connect the fuel supply tube. For additional
assembly at the rear of the engine. information, refer to Section 310-00.
35. Install the evaporative emissions (EVAP) 38. Connect the coolant hose to the coolant pump.
canister purge valve.
Connect the lower EVAP tube and electrical
connector to the EVAP canister purge valve.
39. Connect the coolant hose to the thermostat
housing.
36. Connect the EVAP tube and brake booster
vacuum supply tube to the throttle body (TB)
spacer.
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303-01C-8 303-01C-8 Engine 5.4L (4V)
40. Connect the coolant hose to the coolant tube
assembly (above the generator).
44. Connect the upper radiator hose from the
thermostat housing.
41. Connect the coolant hose from the charge air
cooler (CAC).
45. Install the SC coolant degas bottle. For
303-03B.
42. NOTE: RH bolt shown, LH similar.
Install the cooling fan assembly and the 2 bolts.
303-03A.
47. Install the 2 steering column dash boot nuts.
43. Connect the cooling fan electrical connector.
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303-01C-9 303-01C-9 Engine 5.4L (4V)
48. Install the air cleaner and air cleaner outlet
Section 303-12.
49. Install the battery tray and battery. For
50. NOTE: Use the hood hinge location index
marks made during removal to aid in hood
installation.
Install the hood and 4 bolts.
54. Install the battery and tray. For additional
303-03A.
56. Fill and bleed the SC cooling system. For
303-03B.
information Section 211-00.
52. Install the hood insulation pin-type retainer and
attach the 2 windshield washer hose retainers.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Camshaft LH
Special Tool(s)
303-446 (T93P-6256-AHR)
Material
Item Specification
XO-5W50-QGT or
equivalent
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
sprocket washer
9 6256 Intake camshaft drive 3 6C253 Camshaft drive sprocket
sprocket
4 N811085 Camshaft drive sprocket bolt
10 W500215 LH secondary timing chain
tensioner bolt (2 required)
washer
11 6C271 LH secondary timing chain
tensioner
spacer
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
12 W710990 Intake camshaft bearing cap
bolt
13 N807352 Intake/exhaust camshaft
bearing cap bolt (22 required)
14 6B277 Intake/exhaust camshaft
(2 required)
16 6A271 LH intake camshaft
17 W710991 Exhaust camshaft bearing cap
bolt
bolt
3. Remove the bolt, washer and camshaft drive
sprocket.
21 6A273 LH exhaust camshaft
4. Remove the bolt washer and camshaft sprocket
spacer.
Removal
Components.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
6. Remove the timing chain and the 2 camshaft
sprockets.
7. Remove the 2 bolts and the secondary timing
chain tensioner.
installed in their original position. Camshaft
must be installed in their original position.
Installation
sequence shown.
http://vnx.su
303-01C-5 303-01C-5 Engine 5.4L (4V)
.
installation.
12 oclock position.
Install the camshaft sprockets and the chain as
an assembly.
3. Install the secondary timing chain tensioner and
the bolts.
4. Index the keyways on the camshafts to the 6
oclock position.
7. Install the camshaft sprocket spacer, washer and
bolt, and hand-tighten the bolt.
8. Install the camshaft drive sprocket, washer and
bolt, and hand-tighten the bolt.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
9. Tighten the bolts in 2 stages: 10. Install the timing drive components. For
Components.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Camshaft RH
Special Tool(s)
303-446 (T93P-6256-AHR)
Material
Item Specification
XO-5W50-QGT or
equivalent
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
sprocket washer
9 6256 Intake camshaft drive 3 6C253 Camshaft drive sprocket
sprocket
4 N811085 Camshaft drive sprocket bolt
10 W500304 RH secondary timing chain
tensioner bolt (2 required)
washer
11 6C270 RH secondary timing chain
tensioner
spacer
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
12 W710990 Intake camshaft bearing cap
bolt
13 N807352 Intake/exhaust camshaft
bearing cap bolt (22 required)
14 6B277 Intake/exhaust camshaft
(2 required)
16 6A270 RH intake camshaft
bolt
bolt
3. Remove the bolt, washer and camshaft drive
sprocket.
21 6A272 RH exhaust camshaft
4. Remove the bolt, washer and camshaft sprocket
spacer.
Removal
additional information refer to, Timing Drive
http://vnx.su
303-01C-4 303-01C-4 Engine 5.4L (4V)
6. Remove the secondary timing chain and the 2
camshaft sprockets.
7. Remove the 2 bolts and the secondary timing
chain tensioner.
Installation
sequence shown.
http://vnx.su
303-01C-5 303-01C-5 Engine 5.4L (4V)
.
installation.
12 oclock position.
Install the camshaft sprockets and the secondary
timing chain as an assembly.
Remove the lockpin from the secondary
timing chain tensioner.
3. Install the secondary timing chain tensioner and
the bolts.
4. Index the keyways on the camshafts to the 6
oclock position.
7. Install the camshaft drive sprocket spacer,
washer and bolt, and hand-tighten the bolt.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
8. Install the camshaft sprocket, washer and bolt,
9. Tighten the bolts in 2 stages:
10. Install the timing drive components. For
additional information refer to, Timing Drive
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Camshaft Roller Follower 3. CAUTION: If the roller followers are
to be reinstalled, they must be installed in
the same positions. Mark the roller followers Special Tool(s)
for installation into their original locations.
Using the special tool, compress the valve 303-452 (T93P-6565-AR)
Material
Item Specification
XO-5W50-QGT or
equivalent
4. Repeat the previous 2 steps to remove each of
the roller followers.
Inspect the roller followers. For additional
Lubricate each of the roller followers with
1. Remove the RH or LH valve cover. For
RH or Valve Cover LH in this section.
2. NOTE: If the engine is difficult to rotate while
positioning the piston to the bottom of the
cylinder, remove the spark plugs.
Position the camshaft lobe at base circle.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Special Tool(s)
303-635
303-335 (T88T-6701-A)
Installation
oil.
303-107 (T74P-6700-A)
Damper
303-102 (T74P-6316-B)
Material
front seal.
Item Specification
XO-5W50-QGT or
equivalent
Removal
1. Remove the crankshaft pulley. For additional
section.
front seal.
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
section.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
3. Rotate the supercharger (SC) drive belt
Crankshaft Pulley
tensioner clockwise and remove the drive belt
from the SC drive pulley.
Special Tool(s)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Damper
303-009 (T58P-6316-D)
Damper
303-102 (T74P-6316-B)
Material
Item Specification
ZC-30
Prep
ZC-31
Sealant
TA-30
XO-5W50-QGT or
equivalent
Removal
Section 100-02.
2. Remove the cooling fan assembly. For
303-03A.
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
clockwise and remove the accessory drive belt
from the power steering pump pulley.
Installation
leakage.
5. Position the accessory drive belt and SC drive
belt away from the crankshaft pulley.
Discard the bolt.
pulley.
http://vnx.su
303-01C-3 303-01C-3 Engine 5.4L (4V)
3. Using the special tool, install the crankshaft 5. Position the accessory drive belt and SC drive
pulley. belt onto the crankshaft pulley.
clockwise and install the accessory drive belt
onto the power steering pump pulley.
4. Using the special tool, install a new crankshaft
pulley bolt and the original washer, tighten the
bolt in 4 stages:
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303-01C-4 303-01C-4 Engine 5.4L (4V)
7. Rotate the SC drive belt tensioner clockwise 8. Install the cooling fan assembly. For additional
and install the drive belt onto the SC drive information, refer to Section 303-03A.
pulley.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Special Tool(s)
Crankshaft Rear Seal with Retainer
Plate
303-516 (T95P-6701-BH)
Special Tool(s)
required)
303-D087 (D93P-6001-A1)
303-518 (T95P-6701-DH)
303-F072
Slinger
303-517 (T95P-6701-CH)
3-Bar Engine Support
303-F070
Material
Item Specification
Impact Slide Hammer
100-001 (T50T-100-A)
XO-5W50-QGT or
equivalent
Prep
ZC-31
ZC-30
Slinger
Removal
303-514 (T95P-6701-AH)
Section 100-02.
2. Remove the battery and tray. For additional
303-519 (T95P-6701-EH)
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
Tighten the drain plug to 26 Nm (19 lb-ft).
11. Remove the 4 nuts and the subframe cross
brace.
oil pan.
oil pan stud bolts.
pan.
Discard the gasket.
6. Remove the flywheel. For additional
rear seal oil slinger.
information, refer to Flywheel in this section.
7. Remove the engine-to-transmission spacer plate.
8. Remove the LH and RH engine support
insulator nuts.
9. NOTE: The heavy duty 3-bar support
(303-F070) must be used with the draw screws
from the light duty 3-bar support (303-F072).
This will provide enough clearance between the
supercharger (SC) and the 3-bar support, and
enough clearance between the draw screw and
the vehicle hood.
Install the special tools and raise the engine.
http://vnx.su
303-01C-3 303-01C-3 Engine 5.4L (4V)
rear seal.
3. Install the crankshaft rear seal retainer plate and
the 6 bolts.
(89 lb-in).
retainer plate.
Installation
leakage.
Clean and inspect the mating surfaces of the
engine block, rear seal retainer plate and oil
rear seal.
pan.
the sealing area cleaned. To clean the sealing
packaging. Failure to follow this procedure
can cause future oil leakage.
Apply a 4 mm (0.15 in) bead of silicone gasket
and sealant to the rear crankshaft seal retainer
mating surface on the engine block.
http://vnx.su
303-01C-4 303-01C-4 Engine 5.4L (4V)
rear oil slinger.
the crankshaft rear seal retainer plate-to-cylinder
block sealing joints.
pan stud bolts.
pan.
10. Install the subframe cross brace and the 4 nuts.
11. Using the special tools, lower the engine onto
the engine support insulators.
7. Using a new gasket, install the oil pan, 14 bolts
and 2 stud bolts.
(18 lb-ft).
http://vnx.su
303-01C-5 303-01C-5 Engine 5.4L (4V)
12. Install the LH and RH engine support insulator 15. Install the air cleaner outlet pipe. For additional
nuts. information, refer to Section 303-12.
14. Install the flywheel. For additional information,
refer to Flywheel in this section.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Material
Item Specification
Impact Slide Hammer
XO-5W50-QGT or
100-001 (T50T-100-A)
equivalent
Removal
1. Remove the flywheel. For additional
information, refer to Flywheel in this section.
Slinger 2. Using the special tools, remove the crankshaft
303-514 (T95P-6701-AH)
rear seal oil slinger.
303-519 (T95P-6701-EH)
303-516 (T95P-6701-BH)
rear seal.
303-518 (T95P-6701-DH)
Slinger
303-517 (T95P-6701-CH)
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
Installation
rear oil slinger.
rear seal.
3. Install the flywheel. For additional information,
refer to Flywheel in this section.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Engine Front Cover
Special Tool(s)
required)
303-D087 (D93P-6001-A1)
303-F072
303-F070
Material
Item Specification
Prep
ZC-31
ZC-30
Sealant
TA-30
XO-5W50-QGT or
equivalent
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
5 8B273 Lower radiator hose 1 15161 Lower radiator hose
assembly-to-coolant pump assembly-to-radiator clamp
6 15161 Lower radiator hose 2 8B273 Lower radiator hose
assembly-to-coolant pump assembly-to-radiator
clamp
3 8B273 Lower radiator hose
7 14A464 Power steering pressure (PSP) assembly-to-coolant tube
switch electrical connector assembly
(part of 12B637)
4 15161 Lower radiator hose
8 8A586 Upper radiator hose assembly-to-coolant tube
assembly clamp
9 15161 Upper radiator hose clamp
(Continued)
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
10 8D031 Charge air cooler (CAC) 15 W527352 Coolant vent hose clamp
coolant hose
16 8A586 Upper radiator hose
11 W527362 CAC coolant hose clamp
12 8D030 CAC coolant hose
18 8276 Coolant vent hose
13 W527362 CAC coolant hose clamp
19 W527352 Coolant vent hose clamp
(Continued)
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303-01C-4 303-01C-4 Engine 5.4L (4V)
28 14A464 A/C pressure transducer 20 14A464 Crankshaft position (CKP)
electrical connector (part of sensor electrical connector
12B637) (12B637)
29 Wiring harness retainer (2 21 Wiring harness retainer (2
required) (part of 12B637) required) (part of 14305)
30 N805424 Generator bolt (2 required) 22 520111 Power steering tube bracket
nut
31 W704893 Generator stud bolt
23 N806282 Coolant pump pulley bolt (4
32 10300 Generator
required)
33 B+ wire terminal (part of
24 8A528 Coolant pump pulley
14305)
25 W500212 Power steering tube bracket
34 W705790 B+ wire terminal nut
bolt
35 14A464 Generator electrical connector
26 W706447 Power steering pump bolt (3
(part of 12B637)
required)
(Continued)
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303-01C-5 303-01C-5 Engine 5.4L (4V)
42 N807724 Oil filter adapter bolt (6 36 N605891 Coolant tube assembly-to-oil
required) filter adapter bolt (3 required)
43 6A636 Oil filter adapter gasket 37 18663 Coolant tube assembly
44 6B850 Coolant hose-to-oil filter 38 Wiring harness retainer (2
adapter required) (part of 12B637)
45 15161 Coolant hose-to-oil filter 39 14A464 Engine oil pressure (EOP)
adapter clamp sensor electrical connector
(part of 12B637)
assembly-to-oil filter adapter 40 N606063 Oil filter adapter bolt (2
required) (Continued)
(Continued)
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303-01C-6 303-01C-6 Engine 5.4L (4V)
47 15161 Lower radiator hose 49 N605893 Oil cooler bolt (6 required)
assembly-to-oil filter adapter
50 6A642 Oil cooler
clamp
51 6N818 Oil cooler gasket (4 required)
48 6714 Engine oil filter
(Continued)
Removal
52 N806177 Coolant pump bolt (4
1. With the vehicle in NEUTRAL, position it on a required)
Section 100-02.
required)
required)
3. Remove the engine coolant degas bottle. For
57 6D081 Engine front cover gasket
additional information, refer to Section 303-03A
58 W701605 Oil pan-to-engine front cover
bolt (2 required)
4. Remove the supercharger (SC) coolant degas
59 W701606 Oil pan-to-engine front cover bottle. For additional information, refer to
stud bolt (2 required)
Section 303-03B.
60 W712530 Engine support insulator nut
(2 required)
http://vnx.su
303-01C-7 303-01C-7 Engine 5.4L (4V)
6. Remove the RH and LH valve covers. For 15. Disconnect the coolant hoses from the charge
additional information, refer toValve Cover air cooler (CAC).
16. Disconnect the lower radiator hose assembly
7. Loosen the 4 coolant pump pulley bolts. from the coolant pump, radiator, oil filter
adapter and the coolant tube assembly (located
above the generator).
Remove the lower radiator hose assembly
from the vehicle.
19. Remove the power steering tube bracket nut
from the generator stud bolt.
8. Remove the accessory drive belt, the 2
20. Remove the power steering tube bracket bolt
accessory drive belt idler pulleys and the
from the engine front cover.
accessory drive belt tensioner. For additional
steering pump and reservoir assembly aside.
9. Remove the 4 bolts and the coolant pump
pulley.
10. Remove the SC drive belt, SC drive belt
tensioner and the 3 SC drive belt idler pulleys.
303-05.
11. Remove the thermostat housing. For additional
12. Remove the crankshaft front seal. For additional
information, refer to Crankshaft Front Seal in
this section.
intake manifold.
intake manifold.
http://vnx.su
303-01C-8 303-01C-8 Engine 5.4L (4V)
24. Install the special tool. 28. Detach the 2 wiring harness retainers from the
oil pan stud bolts.
from the generator.
30. Remove the stud bolt, 2 bolts and the generator.
31. Disconnect the coolant hose from the oil filter
adapter.
32. CAUTION: If metal or aluminum
foreign material is present in the oil cooler,
mechanical concerns exist. To diagnose
mechanical concerns, refer to Section 303-00.
This will provide enough clearance between the Inspect the oil cooler.
the vehicle hood.
Install the special tools.
1 Remove the LH and RH engine support
insulator nuts.
35. Remove the 2 coolant tube assembly-to-oil filter
2 Using the special tools, raise the engine.
adapter bolts.
pin-type retainers.
Discard the gasket.
38. Remove the 2 oil pan-to-engine front cover
bolts and the 2 oil pan-to-engine front cover
stud bolts.
Discard the gasket.
26. Remove the nut and disconnect the B+ wire
terminal from the generator.
http://vnx.su
303-01C-9 303-01C-9 Engine 5.4L (4V)
cover.
gaskets.
Installation
future oil leakage.
locations shown.
http://vnx.su
303-01C-10 303-01C-10 Engine 5.4L (4V)
1.25 x 53 1.25 x 53
1.25 x 53 1.25 x 53
1.25 x 53 1.25 x 53
1.25 x 53 1.25 x 53
M10 x 1.50 x 55 1.25 x 53
M10 x 1.50 x 55 1.25 x 53
3. Install the 2 oil pan-to-engine front cover bolts
1.25 x 53
and the 2 oil pan-to-engine front cover stud
bolts.
1.25 x 53
9 N806177 Bolt, hex head pilot, M8 x Tighten to 25 Nm (18 lb-ft).
1.25 x 53
4. Install the coolant pump and the 4 bolts. 10 N806177 Bolt, hex head pilot, M8 x
1.25 x 53
(Continued)
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303-01C-11 303-01C-11 Engine 5.4L (4V)
on the packaging.
and the 8 bolts.
10. Connect the coolant hose to the oil filter
adapter.
11. Install the generator, 2 bolts and the stud bolt.
the generator.
pan stud bolts.
6. Connect the EOP sensor electrical connector
and the 2 wiring harness pin-type retainers.
7. Install the 2 coolant tube assembly-to-oil filter
15. Connect the B+ wire terminal to the generator
adapter bolts.
and install the nut.
8. Install a new engine oil filter.
contact.
9. NOTE: Clean the sealing surfaces with metal
packaging. Inspect the mating surfaces.
Using new gaskets, install the oil cooler and the
6 bolts.
(89 lb-in).
17. Install the LH and RH engine support insulator
nuts.
18. Connect the CKP sensor electrical connector.
http://vnx.su
303-01C-12 303-01C-12 Engine 5.4L (4V)
19. Remove the 3 bolts and position the power 31. Install the 3 supercharger (SC) drive belt idler
steering pump and reservoir assembly aside. pulleys, SC drive belt and the SC drive belt
tensioner. For additional information, refer to
Section 303-05.
32. Install the coolant pump pulley and the 4 bolts.
33. Install the 2 accessory drive belt idler pulleys,
21. Install the power steering tube bracket bolt.
the accessory drive belt tensioner and the
accessory drive belt. For additional information,
22. Install the power steering tube bracket nut to
the generator stud bolt.
Nm (18 lb-ft).
23. Connect the PSP switch electrical connector.
35. Install the RH and LH valve covers. For
additional information, refer toValve Cover
24. Connect the A/C pressure transducer electrical
connector.
36. Install the SC coolant degas bottle. For
25. Install the lower radiator hose assembly to the
coolant pump, radiator, oil filter adapter and the
303-03B.
coolant tube assembly (located above the
generator).
26. Connect the coolant hoses from the CAC.
27. Connect the 2 upper radiator hoses to the intake
manifold.
28. Connect the 2 coolant vent hoses to the intake
manifold.
303-03B.
29. Install the crankshaft front seal. For additional
information, refer to Crankshaft Front Seal in
this section.
303-03A.
30. Install the thermostat housing. For additional
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Exploded View
4 5025 Subframe 1 W711075 Subframe bolt (4 required)
5 W711553 Subframe cross brace nut (4 2 W707246 Subframe nut (4 required)
required)
3 W712530 Engine support insulator nut
6 5A095 Subframe cross brace (2 required)
(Continued)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
11 6B033 LH engine support insulator 7 W702600 Intermediate steering shaft
bracket bolt
12 6714 Engine oil filter 8 3C662 Intermediate steering shaft
9 W707137 Dash boot nut (2 required)
bracket bolt (4 required)
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
19 N807724 Oil filter adapter bolt (6 13 N605891 Coolant tube assembly-to-oil
required) filter adapter bolt (3 required)
20 6A636 Oil filter adapter gasket 14 18663 Coolant tube assembly
21 6B850 Coolant hose-to-oil filter 15 Wiring harness retainer (2
adapter required) (part of 12B637)
22 15161 Coolant hose-to-oil filter 16 14A464 Engine oil pressure (EOP)
adapter clamp sensor electrical connector
(part of 12B637)
assembly-to-oil filter adapter 17 N606063 Oil filter adapter bolt (2
(Continued)
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303-01C-4 303-01C-4 Engine 5.4L (4V)
24 15161 Lower radiator hose 26 6A642 Oil cooler
assembly-to-oil filter adapter
27 6N818 Oil cooler gasket (4 required)
clamp
25 N605893 Oil cooler bolt (6 required)
(Continued)
30 6675 Oil pan 28 Wiring harness retainer (2
29 Wiring harness retainer (2
32 W701606 Oil pan stud bolt (2 required)
(Continued)
(Continued)
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303-01C-5 303-01C-5 Engine 5.4L (4V)
33 W701605 Oil pan bolt (14 required) 37 6622 Oil pump screen and pickup
tube
38 N806183 Oil pump bolt (3 required)
tube bolt (large) 39 6621 Oil pump
tube bolt (small) (2 required)
(Continued)
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Engine Support Insulators
Special Tool(s)
required)
303-D087 (D93P-6001-A1)
303-F072
303-F070
Material
Item Specification
nut Motorcraft SAE 5W-50 WSS-M2C931-A
XO-5W50-QGT or
bolt (2 required)
equivalent
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
7 W710565 LH engine support insulator 4 W702600 Intermediate steering shaft
bracket bolt (4 required) bolt
8 6B033 LH engine support insulator 5 3C662 Intermediate steering shaft
bracket
6 W707137 Dash boot nut (2 required)
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
2. Remove the 2 dash boot nuts.
nut
bolt (2 required)
12 6038 LH engine support insulator
Section 100-02.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
the vehicle hood.
1 Remove the LH and RH engine support
insulator nuts.
X To install, tighten to 63 Nm (46 lb-ft).
2 Using the special tools, raise the engine.
bracket.
To install, lubricate the oil filter gasket with
clean engine oil and tighten until the seal
makes contact.
X Using a suitable oil filter strap wrench,
tighten the filter an additional 270
degrees.
12. Remove the 2 LH engine support
insulator-to-subframe bolts and the LH engine
support insulator.
8. Remove the 2 RH engine support
insulator-to-subframe bolts and the RH engine
support insulator.
501-20B.
Remove the upper bolt from the intermediate
steering shaft and position the intermediate
steering shaft aside.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Exhaust Manifold LH
Material
Item Specification
Prep
ZC-31
XO-5W50-QGT or
equivalent
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
3 W707137 Dash boot nut (2 required) 1 W702600 Intermediate steering shaft
bolt
2 3C662 Intermediate steering shaft
(Continued)
2. Remove the evaporative emissions (EVAP)
canister purge valve. For additional information,
required)
3. Remove the 2 dash boot nuts.
7 14A464 LH heated oxygen sensor
(HO2S) electrical connector
(part of 12B637)
4. Remove the catalytic convertor. For additional
information, refer to Section 309-00. (2 required)
Removal
Section 100-02.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
2. Install new gaskets, the LH exhaust manifold
and 8 new nuts.
(15 lb-ft).
501-20B.
steering shaft and position the intermediate
steering shaft aside.
8. Remove the 8 nuts and the LH exhaust 501-20B.
manifold.
Install the intermediate steering shaft and the
Discard the nuts and gaskets. upper bolt.
Clean and inspect the LH exhaust manifold. Tighten to 47 Nm (35 lb-ft).
303-00.
Installation
Clean the exhaust manifold mating surface of
the cylinder head with metal surface prep.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
4. Install a new engine oil filter. 5. Connect the LH HO2S electrical connector.
6. Install the 2 dash boot nuts.
contact.
7. Install the EVAP canister purge valve. For
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Exhaust Manifold RH
Special Tool(s)
303-D087 (D93P-6001-A1)
303-F072
303-F070
Material
Item Specification
Prep
ZC-31
http://vnx.su
303-01C-2 303-01C-2 Engine 5.4L (4V)
2. Remove the exhaust gas recirculation (EGR)
tube. For additional information, refer to
1 W701706 RH exhaust manifold nut (8
Section 303-08.
required)
3. Remove the catalytic convertor. For additional
3 9Y431 RH exhaust manifold gasket
(2 required)
nut
6 8620 Supercharger (SC) drive belt
7 W707821 A/C compressor stud bolt (3
required)
Removal
Section 100-02.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
5. Rotate the supercharger (SC) drive belt 7. NOTE: The heavy duty 3-bar support
tensioner clockwise and remove the drive belt (303-F070) must be used with the draw screws
from the SC drive pulley. from the light duty 3-bar support (303-F072).
the vehicle hood.
1 Remove the RH engine support insulator
nut.
2 Using the special tools, raise the RH side of
the engine.
8. Remove the SC drive belt from the A/C
compressor pulley.
9. Remove the 2 wiring harness retainers from the
A/C compressor stud bolts and position the
wiring harness aside.
10. NOTE: The A/C compressor stud bolts must be
loosened to gain access to the RH exhaust
manifold nuts.
Loosen the A/C compressor stud bolts 25 mm
(0.98 in).
manifold.
303-00.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
Installation
Clean the exhaust manifold mating surface of
the cylinder head with metal surface prep.
2. Install new gaskets, the RH exhaust manifold
7. Install the RH engine support insulator nut.
and 8 new nuts.
(15 lb-ft).
8. Rotate the SC drive belt tensioner clockwise
and install the drive belt onto the SC drive
pulley.
3. Tighten the A/C compressor stud bolts to 25
Nm (18 lb-ft).
4. Install the 2 wiring harness retainers onto the
A/C compressor stud bolts.
5. Position the SC drive belt onto the A/C
compressor pulley.
the engine support insulator.
10. Install the catalytic converter. For additional
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303-01C-5 303-01C-5 Engine 5.4L (4V)
11. Install the EGR tube. For additional
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Flywheel
2. Remove the bolts and the flywheel.
sequence shown.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Hydraulic Lash Adjuster 2. CAUTION: If the hydraulic lash
adjusters are to be reinstalled, they must be
installed in the same position. Mark the Material
hydraulic lash adjusters for installation into
Item Specification
the original location.
XO-5W50-QGT or
equivalent
303-00.
Lubricate each of the hydraulic lash
adjusters with clean engine oil prior to
installation.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Intake Manifold
Material
Item Specification
Prep
ZC-31
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303-01C-2 303-01C-2 Engine 5.4L (4V)
12 W527352 Supercharger (SC) bubbler 1 15161 Upper radiator hose clamp
hose clamp (part of 6C324)
13 6C324 SC bubbler hose
14 14A464 Exhaust gas recirculation
(EGR) system module
12B637)
15 6K817 Crankcase ventilation tube
9 14A464 Fuel injector electrical
17 9J280 Fuel supply tube
of 12B637)
18 N806154 Throttle body (TB) spacer
bolt (4 required)
12B637)
19 9E822 TB and spacer assembly
11 14A464 Intake air temperature (IAT)
20 9L437 TB spacer gasket
(part of 12B637)
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
28 Wiring harness pin-type 21 W527362 Charge air cooler (CAC) hose
retainer (3 required) (part of clamp
12B637)
22 8D030 CAC hose
29 Wiring harness retainer bolt
23 W527362 CAC hose clamp
(2 required)
24 8D031 CAC hose
30 14K060 Wiring harness retainer
25 8620 SC drive belt
26 8287 Heater hose clamp
required)
27 18C553 Heater hose
(Continued) required)
33 9H487 Intake manifold
(Continued)
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303-01C-4 303-01C-4 Engine 5.4L (4V)
tube. For additional information, refer to
Section 303-08.
required)
7. Disconnect the throttle position (TP) sensor
Removal
8. Remove the 4 bolts and position the throttle
body (TB) and spacer assembly aside.
9. Disconnect the intake air temperature (IAT)
10. Disconnect the fuel supply tube. For additional
connectors.
retainer from the rear of the intake manifold.
procedures, cleanliness is extremely important. 13. Detach the 3 wiring harness pin-type retainers
Any foreign material, including any material from the rare of the intake manifold.
connectors.
16. Disconnect the EGR system module electrical
connector.
17. Disconnect the crankcase ventilation tube from
3. Drain the supercharger (SC) cooling system.
the RH side of the SC.
303-03B.
18. Disconnect the SC bubbler hose from the rear
of the SC.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
19. Rotate the SC drive belt tensioner clockwise 23. Remove the 14 bolts and the intake manifold
and remove the drive belt from the SC drive assembly.
pulley.
Installation
Using new intake manifold gaskets, position the
intake manifold.
2. Install the 14 bolts.
(89 lb-in).
3. Connect the heater hose located below the rear
20. Disconnect the 2 upper radiator hoses and the 2
of the intake manifold.
coolant vent hoses from the intake manifold.
4. Connect the 2 coolant hoses to the (CAC).
21. Disconnect the 2 coolant hoses from the charge
air cooler (CAC).
5. Connect the 2 upper radiator hoses and the 2
coolant vent hoses to the intake manifold.
22. Disconnect the heater hose located below the
rear of the intake manifold.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
6. Rotate the SC drive belt tensioner clockwise 11. Connect the fuel rail pressure and temperature
and install the drive belt onto the SC drive sensor electrical connector.
pulley.
the rear of the intake manifold.
13. Install the wiring harness retainer and the 2
bolts onto the rear of the intake manifold.
connectors.
15. Connect the fuel supply tube. For additional
16. Connect the IAT sensor electrical connector.
17. Install the TB and spacer assembly and the 4
bolts.
18. Connect the TP sensor electrical connector.
19. Install the EGR tube. For additional
7. Connect the SC bubbler hose to the rear of the
303-03B.
SC.
8. Connect the crankcase ventilation tube to the
RH side of the SC.
303-03A.
9. Connect the EGR system module electrical
connector.
connectors.
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
OF SUBASSEMBLIES
Intake Manifold Assembly
Material
Item Specification
Engine Coolant with
(yellow color)
XO-5W50-QGT or
equivalent
TA-25
3 W527352 Supercharger (SC) bubbler 1 18C553 Heater hose
hose clamp
2 Heater hose clamp (part of
4 6C324 SC bubbler hose 18C553)
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303-01C-2 303-01C-2 Engine 5.4L (4V)
5 9E498 Lower SC bypass vacuum 7 W701232 Exhaust gas recirculation
actuator tube (EGR) system module bolt (2
required)
6 9E498 Upper SC bypass vacuum
actuator tube 8 9Y456 EGR system module
(Continued)
9 9D476 EGR system module gasket
12 9F907 Fuel injector clip (8 required) 10 N804394 Fuel rail bolt (4 required)
13 9F593 Fuel injector (8 required) 11 9F792 Fuel rail
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303-01C-3 303-01C-3 Engine 5.4L (4V)
14 9229 Fuel injector O-ring (16 18 9E498 Fuel rail and pressure and
required) temperature sensor vacuum
tube
15 N806177 SC bolt (10 required)
16 6F066 SC
sensor
17 9H486 SC gasket
(Continued)
28 N605892 CAC bolt (10 required) 20 N807071 Charge air cooler (CAC)
coolant tube assembly bolt (5
29 6K775 CAC
required)
30 9424 Upper intake manifold
21 9N491 CAC coolant tube assembly
22 9L438 CAC coolant tube assembly
Disassembly
gasket
23 N802927 CAC tube O-ring seal (4
1. Remove the heater hose.
required)
24 9L442 CAC coolant connector tube
2. Remove the supercharger (SC) bubbler hose.
(2 required)
25 W704682 Lower intake manifold cover
3. Remove the upper and lower SC bypass
bolt (13 required)
vacuum actuator tubes.
26 9S455 Lower intake manifold cover
27 9E436 Lower intake manifold cover 4. Remove the 2 bolts and the exhaust gas
gasket
recirculation (EGR) system module.
(Continued)
Discard the gasket.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
5. Disconnect the vacuum tube from the fuel rail
and pressure temperature sensor.
6. Remove the 4 fuel rail bolts.
Remove the fuel rail and injectors as an
assembly.
7. NOTE: The fuel injector clip can be reused if
it is not damaged during removal.
Remove the clips and the fuel injectors from
the fuel rail.
2. Install a new gasket, the lower intake manifold
made of special fuel-resistant material. Use of
cover and the 13 bolts.
ordinary O-ring seals can cause the fuel
system to leak. Do not reuse the O-ring seals.
(89 lb-in).
Remove and discard the fuel injector O-ring
seals.
9. Remove the 10 bolts and the SC.
Discard the gasket.
10. Remove the vacuum tube.
11. Remove the intake air temperature (IAT)
sensor.
12. Remove the 5 bolts and the charge air cooler
(CAC) tube assembly.
Discard the gasket.
3. NOTE: Apply clean engine coolant to the new
CAC coolant connector tube O-ring seals.
13. Remove the 2 CAC coolant connector tubes.
Install new O-ring seals on the CAC coolant
connector tubes.
14. Remove the 13 bolts and the lower intake
Install the CAC coolant connector tubes.
manifold cover.
4. Install a new gasket, the CAC coolant tube
Discard the gasket.
15. Remove the 10 bolts and the CAC.
Assembly
5. Install the IAT sensor.
1. NOTE: Apply threadlock and sealer to the
CAC bolts prior to installation.
6. Install the vacuum tube.
Position the CAC and install the bolts.
2 stages:
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303-01C-5 303-01C-5 Engine 5.4L (4V)
7. Install a new gasket, the SC and the 10 bolts. 9. Install the fuel injectors onto the fuel rail and
install the locking clips.
2 stages:
10. Install the fuel rail and fuel injector assembly
X Tighten to 5 Nm (44 lb-in).
onto the intake manifold.
11. Install the 4 fuel rail bolts.
12. Connect the vacuum tube to the fuel rail and
pressure temperature sensor.
13. Install a new gasket, the EGR system module
and the 2 bolts.
14. Install the upper and lower SC bypass vacuum
actuator tubes.
15. Install the SC bubbler hose.
16. Install the heater hose.
Install new O-ring seals on each of the fuel
injectors.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
5 8620 Supercharger (SC) drive belt 1 6A340 Crankshaft pulley bolt
6 6700 Crankshaft front seal 2 N806165 Crankshaft pulley washer
4 8620 Accessory drive belt
(Continued)
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
View, Flywheel and Crankshaft Rear
Seal with Retainer Plate
4 6310 Crankshaft oil slinger 1 N808139 Flywheel bolts (8 required)
5 6701 Crankshaft rear seal 2 6375 Flywheel
6 6K318 Crankshaft rear seal retainer 3 6A373 Engine-to-transmission spacer
plate plate
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303-01C-2 303-01C-2 Engine 5.4L (4V)
7 N806155 Crankshaft rear seal retainer 13 W12530 Engine support insulator nut
plate bolts (6 required) (2 required)
8 6710 Oil pan gasket 14 Wiring harness retainer (2
9 6675 Oil pan
12 W701606 Oil pan stud bolt (2 required)
(Continued)
16 W711553 Subframe cross brace nut (4
required)
17 5A095 Subframe cross brace
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Installation
Oil Cooler
Material
Item Specification
Using new gaskets, install the oil cooler and the
Prep
6 bolts.
ZC-31
Removal
(89 lb-in).
Section 100-02.
information, refer to, Section 414-02.
4. CAUTION: If metal or aluminum
foreign material is present in the oil cooler,
mechanical concerns exist. To diagnose
mechanical concerns, refer to Section 303-00.
2. Install the generator. For additional information,
3. Fill and bleed engine cooling system. For
Inspect the oil cooler.
303-03A.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
5. Remove the oil cooler. For additional
Oil Filter Adapter
information, refer to Engine Lubrication
Components Exploded View and Oil Cooler
Special Tool(s)
in this section.
required)
303-D087 (D93P-6001-A1)
303-F072
303-F070
Material
Item Specification
XO-5W50-QGT or
equivalent
Prep
ZC-31
Removal
insulator nuts.
Section 100-02.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
the vehicle hood.
12. Position a suitable adjustable jack stand under
the subframe.
bolts.
bracket.
501-20B.
18. Remove the 2 coolant tube assembly-to-oil filter
adapter bolts.
steering shaft.
19. Disconnect the 2 coolant hoses from the oil
filter adapter.
pin-type retainers.
Discard the gasket.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
Installation
on the packaging.
and the 8 bolts.
501-20B.
Position the intermediate steering shaft and
install the upper bolt.
2. Connect the EOP sensor electrical connector
and the 2 wiring harness pin-type retainers.
bolts at this time.
3. Connect the 2 coolant hoses to the oil filter
bolts.
adapter.
4. Install the 2 coolant tube assembly-to-oil filter
adapter bolts.
1 Tighten the nuts to 115 Nm (85 lb-ft).
2 Tighten the bolts to 115 Nm (85 lb-ft).
5. Install the LH engine support bracket and the 4
bolts.
subframe.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
10. Install a new engine oil filter. 12. Install the LH and RH engine support insulator
nuts.
engine oil and tighten until the seal makes Tighten to 63 Nm (46 lb-ft).
contact.
13. Install the oil cooler. For additional information,
2 Using a suitable oil filter strap wrench,
tighten the filter an additional 270 degrees.
Exploded View and Oil Cooler in this section.
303-03A.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Material
Item Specification
Motorcraft Full Synthetic WSS-M2C931-A
SAE 5W-50 Motor Oil
XO-5W50-QSP or
equivalent
2. Remove the LH exhaust manifold. For
additional information, refer to Exhaust
Manifold LH in this section.
2 N806155 Oil level indicator tube bolt
3. Remove the oil level indicator.
4 O-ring seal
4. Remove the oil level indicator tube bolt.
1. With the vehicle in NEUTRAL, position it on a 5. Remove the oil level indicator tube.
Section 100-02.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
Lubricate the new oil level indicator tube
O-ring seal with clean engine oil prior to
installation.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Oil Pan
Special Tool(s)
required)
303-D087 (D93P-6001-A1)
303-F072
303-F070
Material
Item Specification
Prep
ZC-31
insulator nuts.
ZC-30
Sealant
TA-30
XO-5W50-QGT or
equivalent
Removal
Section 100-02.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
the vehicle hood.
9. Remove the 4 nuts and the subframe cross
brace.
10. Position a suitable adjustable jackstand under
the subframe.
bolts.
oil pan.
501-20B.
oil pan stud bolts.
steering shaft.
pan.
Discard the gasket.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
Installation
leakage.
Clean and inspect the mating surfaces of the
engine block and oil pan.
the crankshaft rear seal retainer plate-to-cylinder
pan stud bolts.
block sealing joints.
pan.
subframe.
Install the steering intermediate shaft into
the steering coupler.
3. Using a new gasket, install the oil pan, 14 bolts
and 2 stud bolts.
(18 lb-ft).
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303-01C-4 303-01C-4 Engine 5.4L (4V)
501-20B.
Position the intermediate steering shaft and
install the upper bolt.
10. Install the subframe cross brace and the 4 nuts.
bolts at this time.
bolts.
12. Install the LH and RH engine support insulator
nuts.
1 Tighten the nuts to 115 Nm (85 lb-ft).
2 Tighten the bolts to 115 Nm (85 lb-ft).
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Material
Item Specification
XO-5W50-QGT or
equivalent
Removal
Installation
1. CAUTION: Make sure the O-ring is in
Section 100-02.
3. Remove the 3 bolts and the oil pump screen
and pickup tube assembly.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Installation
Oil Pump
Material 1. CAUTION: Do not use metal scrapers,
Item Specification
Prep
make leak paths.
ZC-31
Clean the sealing surfaces with metal surface Motorcraft SAE 5W-50 WSS-M2C931-A
Full Synthetic Motor Oil prep. Follow the directions on the packaging.
XO-5W50-QGT or
equivalent
2. Install the oil pump and 3 bolts. Removal
Tighten the bolts in the sequence shown to
10 Nm (89 lb-in). CAUTION: During engine repair
Section 100-02.
3. Remove the oil pump screen and pickup tube. 3. Install the oil pump screen and pickup tube. For
For additional information, refer to Engine additional information, refer to Engine
Lubrication Components Exploded View and Lubrication Components Exploded View and
Oil Pump Screen and Pickup Tube in this Oil Pump Screen and Pickup Tube in this
section. section.
4. Remove the 3 bolts and the oil pump. 4. Install the timing drive components. For
http://vnx.su
303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Valve Cover LH
Material
Item Specification
Prep
ZC-31
ZC-30
Sealant
TA-30
Cleaner
ZC-21
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303-01C-2 303-01C-2 Engine 5.4L (4V)
7 3R700 Power steering reservoir 1 14A464 LH fuel injector electrical
8 W500223 Power steering reservoir bolt
of 12B637)
(2 required)
2 9J280 Fuel supply tube
sensor electrical connector 3 14A464 Throttle position (TP) sensor
(part of 12B637) electrical connector (part of
12B637)
required) (part of 12B637) 4 N806154 Throttle body (TB) spacer
bolt (4 required)
11 N806155 Oil level indicator tube bolt
5 9E822 TB and spacer (Continued)
6 9L437 TB spacer gasket
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
12 14A464 Electronic throttle control 14 2B432 Brake booster vacuum hose
12B637)
(EVAP) hose
(Continued)
15 W520111 LH radio interference
capacitor nut
3. Remove the power brake booster. For additional
16 18801 LH radio interference
capacitor
17 W708442 LH valve cover stud bolt (2
4. Remove the air cleaner assembly and air
required)
cleaner outlet pipe. For additional information,
19 W708441 LH valve cover bolt (8
required)
5. Remove the LH ignition coils. For additional
20 6584 LH valve cover gasket
information, refer to Section 303-07C.
Removal
7. Disconnect the electronic throttle control
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303-01C-4 303-01C-4 Engine 5.4L (4V)
Installation
the throttle body (TB) spacer.
1. Install new gaskets. Make sure the gaskets are
correctly seated on the valve cover.
hose from the TB spacer.
10. Remove the 4 bolts and the TB and spacer
assembly.
Discard the gasket.
connectors.
13. Remove the nut and the LH radio interference
capacitor.
Allow to dry until there is no sign of wetness,
or 4 minutes, whichever is longer. Failure to
bolts and position the reservoir aside.
follow this procedure can result in future oil
leakage.
LH valve cover studs.
cylinder head.
17. Remove the bolt and position the oil level
indicator tube aside.
18. Remove the 8 bolts, 2 stud bolts and LH valve
cover.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
3. Install the RH valve cover, the 8 bolts and 2 7. Connect the CMP sensor electrical connector.
stud bolts.
nut.
(89 lb-in).
9. Connect the fuel supply tube. For additional
connectors.
11. Using a new gasket, install the TB and spacer
12. Connect the EVAP hose to the TB spacer.
TB spacer.
14. Connect the electronic throttle control electrical
connector.
16. Install the LH ignition coils. For additional
17. Install the air cleaner assembly and air cleaner
outlet pipe. For additional information, refer to
Section 303-12.
4. Position the oil level indicator tube and install
the bolt.
18. Install the power brake booster. For additional
5. Attach the 3 wiring harness retainers to the LH
valve cover studs.
6. Position the power steering reservoir and install
the 2 power steering reservoir bracket bolts.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Valve Cover RH
Material
Item Specification
ZC-30
Prep
ZC-31
Sealant
TA-30
Cleaner
ZC-21
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303-01C-2 303-01C-2 Engine 5.4L (4V)
4 14A464 Fuel rail pressure and 1 Wiring harness retainer (3
temperature sensor electrical required ) (part of 12B637)
2 14A464 Engine coolant temperature
5 14A464 RH fuel injector electrical (ECT) sensor electrical
connector (4 required) (part connector (part of 12B637)
of 12B637)
3 14A464 Positive crankcase ventilation
6 Wiring harness retainer (part (PCV) valve electrical
of 12B637) connector (part of 12B637)
(Continued)
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303-01C-3 303-01C-3 Engine 5.4L (4V)
7 W520111 RH radio interference
capacitor nut
8 18801 RH radio interference
capacitor.
capacitor
9 W708442 RH valve cover stud bolt (2
required)
connectors.
10 64817 Crankcase ventilation hose
11 6582 RH valve cover assembly
12 W708441 RH valve cover bolt (8 temperature sensor electrical connector.
required)
13 6584 RH valve cover gasket 8. Disconnect the engine coolant temperature
Removal
RH valve cover studs.
from the rear of the intake manifold.
2. Remove the RH ignition coils. For additional
3. Remove the crankcase ventilation tube.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
11. Remove the 8 bolts, 2 stud bolts and RH valve
cover.
3. Install the RH valve cover, the 8 bolts and 2
stud bolts.
Installation
(89 lb-in).
1. Install new gaskets. Make sure the gaskets are
correctly seated on the valve cover.
Allow to dry until there is no sign of wetness,
or 4 minutes, whichever is longer. Failure to
follow this procedure can result in future oil
leakage.
cylinder head.
the rear of the intake manifold.
5. Attach the 3 wiring harness retainers to the RH
valve cover studs.
6. Connect the ECT sensor electrical connector.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
7. Connect the fuel rail pressure and temperature 10. Connect the PCV valve electrical connector.
11. Install the crankcase ventilation tube.
12. Install the RH ignition coils. For additional
connectors.
9. Install the RH radio interference capacitor and
the nut.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Valve Seals
with both the intake valve and the exhaust
Special Tool(s)
valve closed.
303-452 (T93P-6565-AR)
same position. Mark the components for
installation into the original location.
Spring
303-382 (T91P-6565-AH)
303-383 (T91P-6571-A)
5. Use compressed air in the cylinder to hold the
Material
valves in position.
Item Specification
XO-5W50-QGT or
equivalent
1. Depending on the valve being serviced, remove
the RH or LH valve cover. For additional
information, refer to Valve Cover RH or
Valve Cover LH in this section.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
location.
NOTE: If a valve drops into the cylinder,
remove the cylinder head. For additional
information, refer to Cylinder Head in this
section.
coils to protect the valve stem seal from
damage.
keys.
same position.
Using the special tool, install the valve spring,
retainer keys.
Installation
Using the special tools, install a new valve seal.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
5. Install the spark plug. For additional
same position.
6. Depending on the valve being serviced, install
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Valve Springs
Special Tool(s)
303-452 (T93P-6565-AR)
Spring
303-382 (T91P-6565-AH)
5. Use compressed air in the cylinder to hold the
valves in position.
1. Depending on the valve being serviced, remove
coils to protect the valve seal from damage.
with both the intake valve and the exhaust
valve closed.
installation into the original location.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
location.
NOTE: If a valve drops into the cylinder,
remove the cylinder head. For additional
information, refer to Cylinder Head in this
section.
NOTE: Valve stem seals should be visually
inspected if new seals are not installed.
keys, the valve spring retainer and the valve
spring.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Valve Train Components Exploded
View
5 6513 Valve spring (32 required) 1 6C501 Hydraulic lash adjuster (32
required)
required)
required)
required)
(Continued)
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303-01C-1 303-01C-1 Engine 5.4L (4V)
IN-VEHICLE REPAIR
Special Tool(s)
303-448 (T93P-6303-A)
Removal
arm.
additional information, refer to Valve Train
Components Exploded View and Camshaft
Roller Follower in this section.
section.
6. Remove the RH primary timing chain.
chain tensioner.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
7. Remove the 2 bolts and the RH primary timing 10. Remove the LH primary timing chain.
chain guide.
11. Remove the 2 bolts and the LH primary timing
8. Remove the 2 bolts and the LH primary timing chain guide.
chain tensioner.
9. Remove the LH primary timing chain tensioner
arm.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
Installation
ratchet assembly
of a vise.
4. Install a suitable pin into the hole of each
tensioner housing to hold the ratchet assembly
and plunger in place during installation
2. Using a small screwdriver or pick, push back
and hold the ratchet mechanism
5. If the colored links are not visible, mark one
link on one end and 2 links on the other end,
3. While holding the ratchet mechanism, push the
ratchet arm back into the tensioner housing.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
6. Using the special tool, position the crankshaft.
7. Install the crankshaft sprocket with the flange
link on the timing chain with the slot on the
facing forward.
11. Install the LH timing chain on the camshaft
the 2 bolts.
9. Position the camshaft sprocket timing marks as
shown.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
12. Install the LH primary timing chain tensioner 15. Position the RH (outer) timing chain on the
arm. crankshaft sprocket, aligning the colored link
and the 2 bolts. 16. Install the RH timing chain on the camshaft
14. Install the RH primary timing chain guide and
arm.
the 2 bolts.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
18. Install the RH primary timing chain tensioner 20. Install the crankshaft sensor ring.
and the 2 bolts.
section.
additional information, refer to Valve Train
Components Exploded View and Camshaft
Roller Follower in this section.
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303-01C-1 303-01C-1 Engine 5.4L (4V)
REMOVAL
Cylinder Head CAUTION: During engine repair
Any foreign material, including any material Special Tool(s)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Both cylinder heads
1. Remove the engine from the vehicle. For
additional information, refer to Engine in this
section.
Damper
303-009 (T58P-6316-D)
303-107 (T74P-6700-A)
303-452 (T93P-6565-AR)
3. Remove the engine/transmission spacer plate.
Material
Item Specification
Prep
ZC-31
ZC-30
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303-01C-2 303-01C-2 Engine 5.4L (4V)
REMOVAL (Continued)
intake manifold.
housing.
6. Remove the coolant tube bracket nut.
intake manifold.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
REMOVAL (Continued)
10. Remove the 2 nuts and the thermostat housing 13. Rotate the accessory drive belt tensioner
assembly. clockwise and remove the accessory drive belt.
cooler (CAC).
14. Remove the bolt, supercharger (SC) drive belt
tensioner and the SC drive belt.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
REMOVAL (Continued)
15. Remove the power steering tube bracket nut.
pump and reservoir assembly.
17. Remove the power steering tube bracket bolt.
bolts.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
REMOVAL (Continued)
from the generator.
24. Remove the stud bolt and the accessory drive
belt idler pulley (smooth).
22. Remove the stud bolt, 2 bolts and the alternator.
idler pulley (grooved).
tensioner.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
REMOVAL (Continued)
26. Remove the 4 bolts and the coolant pump 29. Disconnect and remove the crankcase
pulley. ventilation tube.
27. Remove the 3 bolts and the 3 SC drive belt 30. Disconnect the throttle position (TP) sensor
idler pulleys. electrical connector.
28. Disconnect the 2 exhaust gas recirculation 31. Disconnect the throttle body (TB) control
(EGR) tube fittings. electrical connector.
Remove the EGR tube.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
REMOVAL (Continued)
32. Remove the 4 bolts and the TB and spacer 35. Disconnect the LH heated oxygen sensor
assembly. (HO2S) electrical connector and pin-type
retainer.
Discard the gasket.
from the LH cylinder head.
37. Disconnect the bubbler tube from the SC.
from the coolant tube assembly bracket.
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303-01C-8 303-01C-8 Engine 5.4L (4V)
REMOVAL (Continued)
retaining bracket.
39. Detach the 3 wiring harness pin-type retainers.
capacitor.
connectors.
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303-01C-9 303-01C-9 Engine 5.4L (4V)
REMOVAL (Continued)
44. Disconnect the EGR valve electrical connector.
48. Disconnect the 4 RH coil-on-plug electrical
connectors.
45. Detach the wiring harness from the RH
Remove the 4 RH coil-on-plugs.
RH valve cover stud bolts.
47. Remove the bolt, stud bolt and the RH
coil-on-plug cover.
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303-01C-10 303-01C-10 Engine 5.4L (4V)
REMOVAL (Continued)
50. Disconnect the camshaft position (CMP) sensor 53. Remove the nut and the LH radio interference
electrical connector. capacitor.
51. Disconnect the intake air temperature (IAT) 54. Detach the wiring harness retainers from the
sensor electrical connector. LH valve cover stud bolts.
52. Disconnect the 4 LH fuel injector electrical 55. Remove the 2 bolts and the LH coil-on-plug
connectors. cover.
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303-01C-11 303-01C-11 Engine 5.4L (4V)
REMOVAL (Continued)
56. Disconnect the 4 LH coil-on-plug electrical
connectors.
Remove the 4 LH coil-on-plugs.
60. Remove the 3 coolant tube assembly bolts.
57. Remove the wiring harness assembly from the
engine.
58. Disconnect the intake manifold-to-coolant tube
assembly hose.
61. Remove the 6 bolts and the oil cooler.
Remove and discard the oil cooler gasket.
59. Remove the 14 bolts and the intake manifold
assembly.
Remove and discard the 2 intake manifold
gaskets.
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303-01C-12 303-01C-12 Engine 5.4L (4V)
REMOVAL (Continued)
62. Remove the 8 bolts and the oil filter adapter. 64. NOTE: The RH engine support insulator
bracket must be removed to access the RH
Remove and discard the oil filter adapter
block drain plug.
gasket.
Remove the stud bolt, 3 bolts and the RH
engine support insulator bracket.
63. Remove the oil level indicator, the bolt and the
oil level indicator tube.
Remove and discard the oil level indicator
tube O-ring seal. Remove the LH and RH block drain plugs.
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303-01C-13 303-01C-13 Engine 5.4L (4V)
REMOVAL (Continued)
Remove the 8 bolts, 2 stud bolts and the valve
covers.
Discard the bolt.
67. Remove the bolt and the crankshaft position
(CKP) sensor.
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303-01C-14 303-01C-14 Engine 5.4L (4V)
REMOVAL (Continued)
71. Using the special tool, remove the crankshaft 73. Remove the 2 oil pan-to-engine front cover
pulley. bolts and the 2 oil pan-to-engine front cover
stud bolts.
front seal.
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303-01C-15 303-01C-15 Engine 5.4L (4V)
REMOVAL (Continued)
cover.
gaskets.
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303-01C-16 303-01C-16 Engine 5.4L (4V)
REMOVAL (Continued)
chain tensioner.
77. Repeat the previous step to remove all the roller
followers. Inspect roller followers. For
arm.
303-00.
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303-01C-17 303-01C-17 Engine 5.4L (4V)
REMOVAL (Continued)
82. Remove the RH primary timing chain. 85. Remove the LH primary timing chain tensioner
arm.
chain guide. 86. Remove the LH primary timing chain.
84. Remove the 2 bolts and the LH primary timing 87. Remove the 2 bolts and the LH primary timing
chain tensioner. chain guide.
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303-01C-18 303-01C-18 Engine 5.4L (4V)
REMOVAL (Continued)
RH cylinder heads
90. Remove 8 nuts and the RH exhaust manifold.
303-00.
LH cylinder heads
89. Remove 8 nuts and the LH exhaust manifold.
Clean and inspect the LH exhaust manifold.
303-00. 91. Remove the 3 coolant tube assembly bolts.
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303-01C-19 303-01C-19 Engine 5.4L (4V)
REMOVAL (Continued)
Both cylinder heads
the cylinder block.
2 Apply silicone gasket remover, following make leak paths. Use a plastic scraping tool
package directions and allow to set for to remove all traces of the head gasket.
several minutes.
remain.
Remove the 10 bolts and the cylinder head.
Discard the bolts.
Remove and discard the cylinder head
gaskets.
is normal.
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303-01C-20 303-01C-20 Engine 5.4L (4V)
REMOVAL (Continued)
long, the machine edge must be flat within
cylinder head must not have depressions deeper
than 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area, or scratches more than
0.0254 mm (0.001 in).
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303-01C-1 303-01C-1 Engine 5.4L (4V)
REMOVAL
Engine
Special Tool(s)
required)
303-D087 (D93P-6001-A1)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
7. Remove the air cleaner and air cleaner outlet
Section 303-12.
Section 100-02.
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303-01C-2 303-01C-2 Engine 5.4L (4V)
REMOVAL (Continued)
8. Remove the 2 steering column dash boot nuts. 13. NOTE: RH bolt shown, LH similar.
Remove the 2 bolts and the cooling fan
assembly.
9. Remove the engine coolant degas bottle. For
303-03A.
cooler (CAC).
10. Remove the supercharger (SC) coolant degas
bottle. For additional information, refer to
Section 303-03B.
thermostat housing.
15. Disconnect the coolant hose from the coolant
tube assembly (above the generator).
12. Disconnect the cooling fan electrical connector.
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303-01C-3 303-01C-3 Engine 5.4L (4V)
REMOVAL (Continued)
housing.
20. Disconnect the lower EVAP tube and electrical
connector from the EVAP canister purge valve.
Remove the EVAP canister purge valve.
17. Disconnect the coolant hose from the coolant
pump.
21. Disconnect the 2 heater hoses from the coolant
tube assembly at the rear of the engine.
tube and brake booster vacuum supply tube
from the throttle body (TB) spacer.
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303-01C-4 303-01C-4 Engine 5.4L (4V)
REMOVAL (Continued)
22. Detach the 2 wiring harness pin-type retainers. 26. Disconnect the upper and lower powertrain
27. Disconnect the 16-pin electrical connector and
24. Detach the power distribution box upper
housing from the lower housing, loosen the
bolt, then disconnect the 68-pin connector from
28. Disconnect the hose from the power steering
reservoir.
Drain the power steering fluid into a
25. Disconnect the jumper harness electrical
suitable container.
connector.
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303-01C-5 303-01C-5 Engine 5.4L (4V)
REMOVAL (Continued)
radiator.
Remove the lower radiator hose assembly
30. Rotate the SC drive belt tensioner clockwise
from the vehicle.
and remove the drive belt from the SC drive
pulley.
tube fitting.
Discard the Teflon seal.
31. Disconnect the coolant hose from the oil cooler.
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303-01C-6 303-01C-6 Engine 5.4L (4V)
REMOVAL (Continued)
34. Disconnect the power steering return hose.
38. Disconnect the A/C compressor electrical
connector.
35. Remove the nut and disconnect the B+ wire
from the generator.
from the back of the A/C compressor.
oil pan stud bolts.
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303-01C-7 303-01C-7 Engine 5.4L (4V)
REMOVAL (Continued)
40. Position the SC drive belt away from the A/C 43. Detach the 2 wiring harness pin-type retainers
compressor and detach the 2 wiring harness from the oil pan.
retainers from the A/C compressor stud bolts.
44. Remove the starter solenoid terminal cover.
41. Remove the 3 stud bolts and position the A/C
compressor aside.
45. Remove the 2 nuts and disconnect the 2 wires
from the starter solenoid.
RH engine support insulator bracket stud bolt.
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303-01C-8 303-01C-8 Engine 5.4L (4V)
REMOVAL (Continued)
46. Remove the 3 bolts and the starter.
50. Remove the clutch disc and pressure plate. For
51. Remove the bolt and the ground wire from the
install the drain plug and tighten to 26 Nm
(19 lb-ft).
501-20B.
steering shaft.
Position the intermediate steering shaft
aside.
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303-01C-9 303-01C-9 Engine 5.4L (4V)
REMOVAL (Continued)
Remove the engine from the vehicle.
54. Remove the RH engine support insulator nut.
55. Remove the LH engine support insulator nut.
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303-03A-1 303-03A-1 Engine Cooling
Block Heater
information, refer to Cooling System Draining,
Filling and Bleeding in this section.
3. Disconnect the block heater electrical connector
and position aside.
4. CAUTION: Do not loosen the block
heater retaining screw more than necessary
for removal.
Loosen the block heater retaining screw and
remove the block heater.
Lubricate the block heater seal and the
cylinder block hole with clean engine
coolant to ease installation.
Make sure the block heater electrical
connector is routed and secured away from
rotating or hot components or damage to the
cable can occur.
1 6B019 Block heater electrical
additional information, refer to Cooling System
connector
Draining, Filling and Bleeding in this section.
2 6A051 Block heater retaining screw
3 6A051 Block heater
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Coolant Crossover Manifold
Assembly 4.6L (3V)
1 N807309 Generator support bracket
1. Drain the engine cooling system. For additional bolt (4 required)
2 10153 Generator support bracket
3 15161 Hose clamp
4 8A594 Coolant crossover
assembly-to-radiator hose
5 18B402 Heater return and supply hose
6 W710925 Coolant crossover assembly
bolt (2 required)
7 8C387 Gasket
4. Remove the 4 bolts and position aside the 8 8C388 Gasket
generator support bracket.
9 8C369 Coolant crossover assembly
To install, tighten to 10 Nm (89 lb-in). 10 N804758 Generator nut (2 required)
11 10300 Generator
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5. Remove the 2 nuts and position aside the 7. Disconnect the quick connect fitting for the
generator and wiring harness. heater return and supply hose and position
aside.
8. Remove the 2 coolant crossover assembly bolts
and the coolant crossover assembly.
Remove and discard the coolant crossover
assembly gaskets.
Clean the sealing surfaces and install new
coolant crossover assembly gaskets.
6. Disconnect the coolant crossover
assembly-to-radiator hose and position aside.
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Coolant Pump 4.0L SOHC
Material
Item Specification
Cleaner
ZC-21
1. Drain the engine coolant. For additional required)
2 8509 Coolant pump pulley
3 W525966 Hose clamp
4 8548 Thermostat housing-to-coolant
pump hose
5 8287 Hose clamp
6 18C266 Heater hose
7 8287 Hose clamp
8 8286 Radiator-to-coolant pump
information, refer to Section 303-05. hose
9 500014 Coolant pump bolt (12
required)
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5. Remove the 4 coolant pump pulley bolts and 9. Remove the 12 coolant pump bolts and the
the coolant pump pulley. coolant pump.
To install, tighten to 25 Nm (18 lb-ft). Discard the coolant pump gasket.
Use metal surface cleaner and a suitable
6. Disconnect the thermostat housing-to-coolant
plastic or wooden scraper to clean the
pump hose.
sealing surfaces.
7. Disconnect the heater hose and position aside.
8. Disconnect the radiator-to-coolant pump hose
and position aside.
Install a new coolant pump gasket.
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Coolant Pump 4.6L (3V)
Material
Item Specification
Engine Coolant with
(yellow color)
1. Drain the engine cooling system. For additional required)
2 A8528 Coolant pump pulley
required)
4 8501 Coolant pump
5 Coolant pump O-ring seal
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5. Remove the 4 coolant pump pulley bolts and 7. To install, reverse the removal procedure.
the coolant pump pulley.
Install a new coolant pump O-ring seal and
To install, tighten to 25 Nm (18 lb-ft). lubricate with clean engine coolant.
6. Remove the 4 coolant pump bolts and the 8. Fill and bleed the cooling system. For
coolant pump. additional information, refer to Cooling System
Discard the coolant pump O-ring seal.
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Coolant Pump 5.4L (4V)
Material
Item Specification
Engine Coolant with
(yellow color)
4 W503924 Degas bottle bolt (2 required) 1 8276 Upper degas bottle hose
5 8D028 Supercharger degas bottle 2 8D031 Upper supercharger degas
bottle hose
6 8A080 Degas bottle
3 W503924 Supercharger degas bottle bolt
(Continued)
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3. Disconnect the upper degas bottle hose, remove
the 2 bolts and position aside the degas bottle.
required) To install, tighten to 8 Nm (71 lb-in).
4. Disconnect the upper supercharger degas bottle
9 8B550 Coolant pump-to-lower
hose, remove the bolt and position aside the
radiator hose assembly
supercharger degas bottle.
required)
11 Coolant pump O-ring seal
2. Drain the supercharger cooling system. For
303-03B.
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7. Rotate the supercharger belt tensioner clockwise 8. Remove the 4 coolant pump pulley bolts and
and remove the supercharger belt off the the coolant pump pulley.
supercharger.
9. Disconnect the coolant pump-to-lower radiator
hose assembly.
Discard the coolant pump O-ring seal.
Install a new coolant pump O-ring seal and
lubricate with clean engine coolant.
13. Fill and bleed the supercharger cooling system.
303-03B.
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Cooling Fan Motor and Shroud
4.0L and 4.6L (3V)
4 8C633 Upper degas bottle hose 1 W503924 Power steering reservoir bolt
5 W503924 Degas bottle bolt (2 required) 2 3R700 Power steering reservoir
6 8A080 Degas bottle 3 W527383 Upper degas bottle hose
clamp
(Continued)
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5.4L (4V)
4 W503924 Degas bottle bolt (2 required) 1 8276 Upper degas bottle hose
5 8D028 Supercharger degas bottle 2 8D031 Upper supercharger degas
bottle hose
3 W503924 Supercharger degas bottle bolt
(Continued)
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All engines
4.0L and 4.6L (3V) Engines
7 8C350 Lower degas bottle hose
4. Remove the air cleaner outlet pipe. For (4.0L and 4.6L (3V) only)
8 14A464 Cooling fan motor and shroud
5. Remove the bolt and position aside the power
9 N606676 Cooling fan motor and shroud
steering reservoir.
bolt (2 required)
10 8C607 Cooling fan motor and shroud To install, tighten to 8 Nm (71 lb-in).
5.4L (4V) Engine
6. Detach the lower degas bottle hose and position
it aside.
5.4L (4V) Engines
7. Disconnect the upper supercharger degas bottle
hose and position it aside.
8. Remove the bolt and position aside the
303-03B.
supercharger degas bottle.
All Engines
9. Disconnect the upper degas bottle hose and
position it aside.
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All Engines
5.4L (4V) Engines
10. Remove the 2 bolts and position aside the degas
bottle.
11. Disconnect the cooling fan motor and shroud
12. Remove the 2 bolts and the cooling fan motor
303-03B.
and shroud.
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GENERAL PROCEDURES
1. Release the pressure in the cooling system by
Cooling System Draining, Filling and
slowly turning the pressure relief cap one half
Bleeding
turn counterclockwise or the radiator cap
counterclockwise to the first stop. When the
Special Tool(s)
pressure is released, remove the pressure relief
RADKITPLUS cap/radiator cap.
078-00497
2. Place a suitable container below the radiator
draincock. Open the draincock and drain the
engine coolant.
Close the radiator draincock.
Filling and Bleeding with RADKITPLUS
Material
Item Specification
1. Using the special tool, install the
Motorcraft Premium Gold WSS-M97B51-A1 RADKITPLUS and follow the RADKITPLUS
Engine Coolant with
manufacturers instructions to fill and bleed the
cooling system.
Filling and Bleeding without
(yellow color)
RADKITPLUS
Draining
CAUTION: Vehicle cooling systems are
filled with Motorcraft Premium Gold Engine
WARNING: Never remove the pressure
Coolant or equivalent meeting Ford specification
relief cap while the engine is operating or when
WSS-M97B51-A1 (yellow color). Always fill the
the cooling system is hot. Failure to follow these
cooling system with the same coolant that is
instructions can result in damage to the cooling
present in the system. Do not mix coolant types.
system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of
CAUTION: Engine coolant provides freeze
the degas bottle when removing the pressure
protection, boil protection, cooling efficiency, and
relief cap, wait until the engine is cooled, then
corrosion protection to the engine and cooling
wrap a thick cloth around the pressure relief cap
components. In order to obtain these protections,
and turn it slowly. Step back while the pressure
the engine coolant must be maintained at the
is released from the cooling system. When you
correct concentration and fluid level in the
are sure all the pressure has been released, turn
degas bottle.
and remove the pressure relief cap (still with a
cloth). When adding engine coolant, use a 50/50 mixture
of engine coolant and deionized water.
CAUTION: The coolant must be recovered
To maintain the integrity of the coolant and the
in a suitable, clean container for reuse. If the
cooling system:
coolant is contaminated, it must be recycled or
Add Motorcraft Premium Gold Engine Coolant
disposed of correctly.
or equivalent meeting Ford specification
NOTE: Less than 80% of coolant capacity can be
WSS-M97B51-A1 (yellow color). Use the same
recovered with the engine in the vehicle. Dirty,
coolant that was drained from the cooling
rusty or contaminated coolant should be drained and
system. Do not mix coolant types.
filled with new coolant.
Do not add/mix orange-colored Motorcraft
Speciality Orange Engine Coolant or equivalent
meeting Ford specification WSS-M97B44-D.
Mixing coolants may degrade the coolants
corrosion protection.
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Do not add alcohol, methanol, or brine, or any
4. CAUTION: If the air discharge
engine coolants mixed with alcohol or methanol
remains cool and the engine coolant
antifreeze. These can cause engine damage
temperature gauge does not move, the engine
from overheating or freezing.
coolant level is low and must be filled. Stop
the engine, allow the engine to cool and fill
Ford Motor Company does NOT recommend
cooling system.
the use of recycled engine coolant in vehicles
originally equipped with Motorcraft Premium
Start the engine and allow it to idle until
Gold Engine Coolant since a Ford-approved
normal operating temperature is reached. Hot
recycling process is not yet available.
air should discharge from A/C vents. The
engine coolant temperature gauge should
1. Fill the radiator through the degas bottle until
maintain a stabilized reading in the middle of
the coolant level is between the COOLANT
the NORMAL range. The upper radiator hose
FILL LEVEL marks.
should feel hot to the touch.
2. Select the maximum heater temperature and
5. Shut the engine off and allow the engine to
blower motor speed settings. Position the
cool.
control to discharge air at A/C vents in
instrument panel.
6. Check the engine for coolant leaks.
3. Start the engine and allow to idle. While engine
7. Check the engine coolant level in the degas
is idling, feel for hot air at A/C vents.
bottle and fill as necessary.
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Degas Bottle
position aside.
1 W527383 Upper degas bottle hose
clamp
3. Disconnect the lower degas bottle hose and
2 8C633 Upper degas bottle hose
position aside.
3 15161 Lower degas bottle hose
clamp
4. Remove the 2 degas bottle bolts and the degas
4 8C350 Lower degas bottle hose
bottle.
5 W503924 Degas bottle bolt (2 required)
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GENERAL PROCEDURES
Engine and Radiator Flushing 1. WARNING: Never remove the
pressure relief cap while the engine is
operating or when the cooling system is hot. Special Tool(s)
Failure to follow these instructions can result
Coolant System Drain/Flush/Fill
in damage to the cooling system or engine or
personal injury. To avoid having scalding hot
coolant or steam blow out of the degas bottle
when removing the pressure relief cap, wait
until the engine has cooled, then wrap a
thick cloth around the pressure relief cap
and turn it slowly. Step back while the
Flush Kit
pressure is released from the cooling system.
When you are sure all the pressure has been
released, turn and remove the pressure relief
cap (still with a cloth).
Once pressure is released, remove the pressure
relief cap/radiator cap.
Drain Kit
3. Remove the coolant thermostat. For additional
information, refer to Thermostat and Thermostat
Housing Exploded View, Thermostat
4.0L SOHC, Thermostat 4.6L (3V) or
Material
Thermostat 5.4L (4V) in this section.
Item Specification
Premium Cooling System ESR-M14P7-A
4. Install the coolant hose connection without the
Flush
thermostat.
VC-1
5. NOTE: Refer to the cooling system flusher
Engine Coolant with
manufacturers operating instructions for
specific vehicle hook-up.
Using an appropriate cooling system flusher,
(yellow color)
flush the engine and radiator.
Use Premium Cooling System Flush or
equivalent meeting Ford specification
ESR-M14P7-A. Always flush the cooling
system with water thoroughly after using the
VC-1 flush and prior to filling the cooling
system with the same coolant that was present
in the system. Do not mix coolant types.
6. Install the thermostat. For additional
information, refer to Thermostat and Thermostat
Housing Exploded View and Thermostat
4.0L SOHC, Thermostat 4.6L (3V) or
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7. Backflush the heater core. For additional 8. Fill and bleed the cooling system. For
information, refer to Heater Core Backflushing additional information, refer to Cooling System
in this section. Draining, Filling and Bleeding in this section.
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The 4.6L (3V) and 5.4L (4V) cooling system
Engine Cooling
components include the:
block heater.
Coolant or equivalent (yellow color) meeting
cylinder head temperature (CHT) sensor.
Ford specification WSS-M97B51-A1. Always fill
fan motor and shroud assembly.
the cooling system with the same coolant that is
radiator.
present in the system. Do not mix coolant types.
radiator cap.
The 4.0L (SOHC) cooling system components
include the:
radiator draincock.
coolant pump.
block heater.
coolant thermostat.
engine coolant temperature (ECT) sensor.
oil filter adapter.
cooling fan motor and shroud assembly.
radiator overflow hose.
radiator.
degas bottle.
heater tube assembly.
upper radiator hose.
pressure relief cap.
lower radiator hose.
thermostat housing assembly.
ECT sensor (5.4L (4V) only).
radiator draincock.
The fan blade draws air through the radiator to help
coolant pump.
cool the engine coolant.
coolant thermostat.
The fan motor:
oil filter adapter.
operates only when the ignition switch is in the
radiator overflow hose.
RUN position.
degas bottle.
will not operate with the switch in the OFF
upper radiator hose.
position.
lower radiator hose.
The engine coolant:
The coolant thermostat:
flows from the thermostat through the radiator
controls the engine coolant temperature.
tubes and is cooled by passing air over the
cooling fins. allows for quicker engine warm-up.
is then circulated from the radiator outlet tank The degas bottle:
through the oil adapter and into the cylinder block
provides a location for service fill.
to complete the circuit.
contains coolant expansion and system
A closed coolant thermostat returns the engine
pressurization.
coolant to the coolant pump. An open coolant
provides air separation during operation.
thermostat allows the engine coolant to flow to the
radiator.
replenishes the engine coolant to the system.
The engine coolant flows:
protection, boil protection, cooling efficiency, and
from the lower radiator hose to the coolant pump.
from the coolant pump to the engine block and
the cylinder heads.
degas bottle.
When adding engine coolant, use a 50/50 mixture of
engine coolant and deionized water.
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To maintain the integrity of the coolant and the Ford Motor Company does NOT recommend the
cooling system: use of recycled engine coolant in vehicles
originally equipped with Motorcraft Premium
add Motorcraft Premium Gold Engine Coolant or
Gold Engine Coolant since a Ford-approved
equivalent (yellow color) meeting Ford
recycling process is not yet available.
specification WSS-M97B51-A1. Use the same
The engine coolant temperature (ECT) sensor
coolant that is present in the cooling system. Do
(4.0L), (5.4L) or cylinder head temperature (CHT)
not mix coolant types.
sensor (4.6L), (5.4L) provides a signal to the
do not add/mix orange-colored Motorcraft
temperature gauge.
Speciality Orange Engine Coolant or equivalent
The optional block heater:
meeting Ford specification WSS-M97B44-D.
Mixing coolants may degrade the coolants
electrical heating element is installed in the core
corrosion protection.
plug opening.
do not add alcohol, methanol or brine, or any
uses a standard 110V electrical supply
engine coolants mixed with alcohol or methanol
keeps the engine coolant warm during cold
antifreeze. These can cause engine damage from
weather.
overheating or freezing.
Coolant Flow Diagram, 4.0L
NOTE: Black arrows indicate hot, white arrows indicate cold.
4 8005 Radiator 1 8A080 Degas bottle
5 8B273 Lower radiator hose 2 8276 Upper degas bottle hose
(Continued)
3 8B274 Upper radiator hose
(Continued)
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6 18C266 Coolant inlet tube-to-coolant 13 18465 Coolant inlet tube-to-throttle
pump hose body hose
7 8501 Coolant pump 14 18K579 Heater inlet hose
8 8548 Coolant pump-to-thermostat 15 18K580 Heater outlet hose
housing hose
16 19B555 Heater assembly
9 8A586 Thermostat housing
17 6C064 Cylinder head
10 18465 Coolant inlet tube-to-throttle
18 6083 Cylinder head gasket
body hose
19 6015 Engine block
11 9F991 Throttle body
12 18696 Coolant inlet tube
(Continued)
Coolant Flow Diagram, 4.6L (3V)
NOTE: Black arrows indicate hot, white arrows indicate cold.
7 6881 Oil filter adapter 1 8A080 Degas bottle
8 6015 Engine block 2 8B273 Lower radiator hose
9 6083 Cylinder head gasket 3 8276 Upper degas bottle hose
10 6050 Cylinder head 4 8005 Radiator
11 19B555 Heater assembly 5 8C369 Coolant crossover manifold
assembly
12 18B402 Coolant tube heater assembly
6 8501 Coolant pump
13 18K580 Heater inlet hose
(Continued)
(Continued)
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14 18K579 Heater outlet hose 15 8B274 Upper radiator hose
(Continued)
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Engine Cooling
Special Tool(s)
Pressure Tester
73III Automotive Meter and turn it slowly. Step back while the pressure
cloth).
CAUTION: Check the coolant level, engine
oil and transmission fluid, top off the coolant if
needed. If there is engine coolant in the engine
oil or transmission fluid, the cause must be
corrected and oil/fluid changed or major
component damage may occur. hardware, or equivalent scan
tool
1. Verify the customers concern by operating the
2. Inspect to determine if any of the following
Battery/Anti-Freeze Tester
014-R1060 or equivalent mechanical or electrical concerns apply.
Mechanical
Leaks
Hoses
Hose clamps
Head gaskets
Intake manifold gasket
The cooling fan motor and shroud is serviced as an
Coolant pump
assembly. If DTC P0480 or P0481 is present, refer
Radiator
to the Powertrain Control/Emissions Diagnosis
Degas bottle
(PC/ED) manual. Heater core
Cooling fan motor and shroud
Engine coolant temperature (ECT) sensor
Cylinder head temperature (CHT) sensor
Circuitry
symptom and go to the Symptom Chart.
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X Minimum coolant concentration is 40
5. CAUTION: Some vehicle cooling
percent coolant/60 percent water.
systems are filled with Motorcraft Premium
Gold Engine Coolant or equivalent (yellow
3 Adjust coolant range and level, if necessary.
color) meeting Ford specification
X If coolant is low, add specified coolant
WSS-M97B51-A1. Always fill the cooling
mixture only.
system with the same coolant that is present
X If the engine coolant tests too weak, add
in the system. Do not mix coolant types.
straight engine coolant until the readings
Inspect the coolant condition.
are within acceptable levels.
1 Inspect the coolant color.
X If the engine coolant tests strong, remove
X If or equivalent meeting Motorcraft
some of the engine coolant and add water
Premium Gold Engine Coolant Ford
until the readings are within acceptable
specification WSS-M97B51-A1 has a
levels.
clear or pale yellow color, this indicates
6. If the concern remains after the inspection,
higher water content than required.
determine the symptom(s) and GO to Symptom
X Dark brown can indicate unauthorized
Chart.
stop leak may have been used. Use
Diagnostic Trouble Code (DTC) Index
Cooling System Stop Leak Pellets or
Powertrain Control Module Diagnostic Trouble
WSS-M99B37-B6.
Code (DTC) Index
X A light or reddish brown color indicates
DTC Description Action
that rust may be present in the cooling
P0480 Low Fan Control Refer to the
system. Flush the system and refill with
(LFC)/Fan Control 1 Powertrain
the correct mixture of water and engine
(FC1) Primary Control/Emissions
coolant.
Circuit Malfunction Diagnosis (PC/ED)
manual.
X An iridescent sheen on top of the coolant
P0481 High Fan Control Refer to the can indicate a trace of oil is entering the
(HFC)/Fan Control 3 Powertrain
system. For information on engine
(FC3) Primary Control/Emissions
diagnosis, refer to Section 303-00.
Circuit Malfunction Diagnosis (PC/ED)
X A milky brown color may indicate that manual.
engine oil is entering the cooling system.
If engine oil is suspected, the cause of
the leak may be internal to the engine.
2 If the engine coolant appearance is
acceptable, test the engine coolant freezing
point range with the battery and anti-freeze
tester. The freezing point should be in the
range -40C to -20C (-50F to -10F). If
the vehicle is driven in cold climates less
than -32C (-34F), it may be necessary to
increase the coolant concentration to get
adequate freeze protection.
X Maximum coolant concentration is 60
percent coolant/40 percent water.
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Symptom Chart
Symptom Chart
Loss of coolant Radiator GO to Pinpoint Test A.
Coolant pump seal
Radiator hoses
Heater hoses
Heater core
Engine gaskets
Degas bottle
The engine overheats Thermostat GO to Pinpoint Test B.
Coolant pump
Internal engine coolant leak
Radiator
Cooling fan
Pressure relief cap or radiator
cap
The engine does not reach Thermostat GO to Pinpoint Test C.
normal operating temperature
Pinpoint Tests Radiator hoses
Heater hoses
Pinpoint Test A: Loss Of Coolant
Heater core
Possible Causes
Engine gaskets
Radiator
Degas bottle
Coolant pump seal
PINPOINT TEST A: LOSS OF COOLANT
A1 CHECK THE ENGINE COOLANT LEVEL
WARNING: Never remove the pressure relief cap while
the engine is operating or when the cooling system is hot.
Failure to follow these instructions can result in damage to the
cooling system or engine or personal injury. To avoid having
scalding hot coolant or steam blow out of the degas bottle
when removing the pressure relief cap, wait until the engine is
cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly. Step back while the pressure is released
from the cooling system. When you are sure all the pressure
has been released, turn and remove the pressure relief cap
(still with a cloth).
Yes
NOTE: Allow the engine to cool before checking the engine coolant
GO to A2.
level.
Visually check the engine coolant level at the degas bottle. REFILL the engine coolant as necessary.
Is the engine coolant level within specification? GO to A2.
A2 CHECK THE PRESSURE RELIEF CAP
Carry out the cap test. Go to Component Tests in this section. Yes
Is pressure relief cap/radiator cap OK? GO to A3.
No
INSTALL a new pressure relief
cap/radiator cap. TEST the system for
normal operation.
(Continued)
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PINPOINT TEST A: LOSS OF COOLANT (Continued)
A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK
Inspect the engine coolant in the degas bottle for signs of If engine oil is evident, REFER to Section
engine oil. 303-00.
Is oil evident in the coolant?
No
GO to A4.
A4 CHECK THE ENGINE FOR COOLANT
Remove the oil level indicator from the engine. Yes
Is coolant evident in the oil? If coolant is in the engine, REFER to
Section 303-00.
No
GO to A5.
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
Pressure test the engine cooling system. Go to Component Yes
Tests in this section. REPAIR or install new components. TEST
Does the engine cooling system leak? the system for normal operation.
No
The cooling system is operational. GO to
Symptom Chart.
Pinpoint Test B: The Engine Overheats
Internal engine coolant leak
Radiator
Normal Operation
Cooling fan
Possible Causes
Pressure relief cap or radiator cap
Thermostat
Coolant pump
PINPOINT TEST B: THE ENGINE OVERHEATS
B1 CHECK THE ENGINE COOLANT LEVEL
WARNING: Never remove the pressure relief cap while
the engine is operating or when the cooling system is hot.
Failure to follow these instructions can result in damage to the
cooling system or engine or personal injury. To avoid having
scalding hot coolant or steam blow out of the degas bottle
when removing the pressure relief cap, wait until the engine is
cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly. Step back while the pressure is released
from the cooling system. When you are sure all the pressure
has been released, turn and remove the pressure relief cap
(still with a cloth).
Yes
NOTE: If the engine is hot, allow the engine to cool before
GO to B2.
proceeding.
Check the engine coolant level at the degas bottle. REFILL the engine coolant at the degas
Is the engine coolant OK? bottle. GO to Pinpoint Test A.
B2 CHECK THE COOLANT CONDITION
Check the coolant for dirt, rust or contamination. Yes
Is the coolant condition OK? GO to B3.
No
FLUSH the engine cooling system.
REFER to Engine and Radiator Flushing
normal operation.
(Continued)
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PINPOINT TEST B: THE ENGINE OVERHEATS (Continued)
B3 CHECK FOR AN AIRFLOW OBSTRUCTION
Inspect the A/C condenser core and radiator for obstructions Yes
such as leaves or dirt. REMOVE the obstruction. CLEAN the A/C
Is there an obstruction? condenser core and radiator. TEST the
No
For 4.0L and 5.4L (4V) engines GO to B4.
For 4.6L (3V) engines, GO to B5.
B4 CHECK THE THERMOSTAT OPERATION (4.0L ENGINES) and
(5.4L (4V) ENGINES)
While observing the ECT sensor reading, start the engine and Yes
allow the engine to run for 10 minutes. INSTALL a new thermostat. REFER to
Feel the upper radiator hose. Thermostat and Thermostat Housing
Does the upper radiator hose remain at ambient Exploded View and Thermostat 4.0L
temperature when the ECT sensor is reading between 88C - SOHC or Thermostat 5.4L (4V) in this
93C (190F and 205F)? section. TEST the system for normal
operation.
No
For diagnosis and testing of the engine,
B5 CHECK THE THERMOSTAT OPERATION (4.6L (3V) ENGINES)
Start the engine and allow the engine to run for 10 minutes. Yes
Feel the upper radiator hose. INSTALL a new thermostat. REFER to
Does the upper radiator hose remain at ambient Thermostat 4.6L (3V) in this section.
temperature? TEST the system for normal operation.
No
For diagnosis and testing of the engine,
Pinpoint Test C: The Engine Does Not Reach
Normal Operating Temperature
Possible Causes
Thermostat
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
C1 CHECK THE ENGINE TEMPERATURE
Start the engine and allow the engine to idle for 10 minutes. Yes
Feel the upper radiator hose. INSTALL a new thermostat. REFER to
Does the upper radiator hose start to get hot before idling Thermostat and Thermostat Housing
for 10 minutes? Exploded View and Thermostat 4.0L
SOHC, Thermostat 4.6L (3V) or
No
For diagnosis and testing of the engine
coolant temperature gauge, REFER to
Section 413-00.
Component Tests
Pressure Test
1. Turn the engine OFF.
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2. WARNING: Never remove the 7. CAUTION: If the pressure drops,
pressure relief cap while the engine is check for leaks at the engine-to-heater core
operating or when the cooling system is hot. hoses, engine-to-radiator hoses, water valve
Failure to follow these instructions can result hose (if applicable), oil cooler return tube
in damage to the cooling system or engine or gasket, radiator and heater core or other
personal injury. To avoid having scalding hot system components and connections. Any
coolant or steam blow out of the degas bottle leaks which are found must be corrected
when removing the pressure relief cap, wait and the system rechecked.
until the engine is cooled, then wrap a thick
Pressurize the engine cooling system as
cloth around the pressure relief cap and turn
described in Step 4 (using a pressure relief cap
it slowly. Step back while the pressure is
that operates within the specified upper and
released from the cooling system. When you
lower pressure limits). Observe the gauge
are sure all the pressure has been released,
reading for approximately 2 minutes. Refer to
turn and remove the pressure relief cap (still
General Specifications. Pressure should not
with a cloth).
drop during this time.
Check the engine coolant level. Refer to
8. Release the system pressure by loosening the
Cooling System Draining, Filling and Bleeding
pressure relief cap. Check the engine coolant
in this section.
level and replenish, if necessary, with the
3. Connect the Radiator Heater Core Pressure correct engine coolant mixture. Refer to
Tester to the degas bottle nipple and vent hose. Cooling System Draining, Filling and Bleeding
Install a pressure test pump to the quick in this section.
connect fitting of the test adapter.
Cap
4. CAUTION: Do not pressurize the
cooling system beyond 152 kPa (22 psi).
NOTE: If the plunger of the pump is depressed
too quickly, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing and note the highest pressure reading
obtained.
5. If the pressure relief cap does not hold pressure,
remove and wash the pressure relief cap in
clean water to dislodge all foreign material
from the gaskets. Check the sealing surface in
cloth).
the filler neck.
1. Remove the pressure relief cap from the degas
6. If 110 kPa (16 psi) cannot be reached, install a
bottle.
new pressure relief cap. If more than 124 kPa
(18 psi) shows on the gauge, install a new
2. Follow the instructions from the pressure tester
manufacturer.
3. NOTE: If the plunger of the pump is depressed
too quickly, an erroneous pressure reading will
result.
obtained.
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4. If the pressure test gauge readings are not 4. Start the engine and allow the engine to idle
within specifications, install a new pressure throughout this test. Allow the engine to run for
relief cap. If the pressure test gauge readings 2 minutes, then record the ECT or CHT
are within specifications, carry out the cooling voltage. Record the ECT or CHT voltage every
system Pressure Test. 60 seconds. When the ECT or CHT voltage
trend changes direction or only changes
Thermostat
slightly (0.03 volts or less) from the previous
A new thermostat should be installed only after the reading, record this as the thermostat opening
following electrical and mechanical tests have been voltage. Use the voltage and corresponding
carried out. coolant temperature chart listed below for 4.6L
(3V) engines only.
Thermostat Electrical Test
Coolant Temperature CHT (Volts)
CAUTION: Always vent the exhaust to the
22C (71F) 3.00
outside when carrying out this test.
43C (109F) 2.01
NOTE: The electrical thermostat test is most
71C (159F) 1.01 accurate if carried out at less than 37.8C (100F)
ambient air. This test may be carried out with or
82C (180F) 0.75
without the hood open and with the engine warm or
91C (195F) 0.59
cold.
97C (206F) 0.50
1. Check the engine coolant level. Fill as needed.
105C (221F) 0.40
2. With the ignition OFF, remove the engine
coolant temperature (ECT) or cylinder head
5. If the thermostat opening voltage is greater than
temperature (CHT) sensor harness connector
0.70 volts and less than 85C (185F), install a
and attach ECT or CHT sensor T cable as a
new thermostat.
jumper between the powertrain control module
(PCM) and the ECT or CHT sensor. Attach the 6. If the thermostat opening voltage is less than
73III Automotive Meter to the ECT or CHT 0.70 volts and greater than 85C (185F), the
sensor T cable. Voltage values (0-5 V) may thermostat is good and a new thermostat should
now be monitored while the sensor retains its not be installed. GO to Symptom Chart for
connection to the wiring harness. further instructions.
An appropriate scan tool may be used to
Radiator Leak Test, Removed From the
monitor the ECT on vehicles equipped with
Vehicle
data link connector (DLC).
CAUTION: Never leak test an aluminum
3. NOTE: Running this test with the vehicle in
radiator in the same water that copper/brass
gear or with the A/C compressor clutch
radiators are tested in. Flux and caustic cleaners
engaged (running) will cause incorrect
may be present in the cleaning tank and they will
diagnosis.
damage aluminum radiators.
Place the transmission in PARK (P) or
NOTE: Always install plugs in the oil cooler
NEUTRAL (N).
fittings before leak-testing or cleaning any radiator.
NOTE: Clean the radiator before leak-testing to
avoid contamination of tank.
1. Leak-test the radiator in clean water with 138
kPa (20 psi) air pressure.
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GENERAL PROCEDURES
Heater Core Backflushing 1. WARNING: Never remove the
operating or when the cooling system is hot. Special Tool(s)
Flush Kit
until the engine is cooled, then wrap a thick
cloth around the pressure relief cap and turn
it slowly. Step back while the pressure is
Drain Kit
released from the cooling system. When you
are sure all the pressure has been released,
turn and remove the pressure relief cap (still
with a cloth).
relief cap.
Material 2. Partially drain the cooling system. For
Item Specification
Flush
3. NOTE: For additional information, refer to the
VC-1
cooling system flusher manufacturers operating
instructions for particular vehicle hook-up.
Engine Coolant with
Bittering Agent (US only) Use an appropriate cooling system flusher to
backflush the heater core. Use Premium
Cooling System Flush or equivalent meeting
(yellow color)
Ford specification ESR-M14P7-A. Flush with
water thoroughly after using VC-1 or equivalent
prior to refilling the cooling system
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Radiator
6 8286 Lower radiator hose 1 W527383 Hose clamp
7 W505424 Radiator support bracket bolt 2 8C633 Degas bottle-to-radiator hose
(4 required)
3 8287 Hose clamp
8 8226 Radiator support bracket (2
4 8260 Upper radiator hose
required)
5 8287 Hose clamp
(Continued)
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15 7A095 Transmission cooler (if 9 N606676 A/C condenser bolt (2
equipped) required)
10 Power steering tubes and A/C
Removal and Installation condenser retaining nut (2
required)
11 3F780 Power steering tubes
12 19710 A/C condenser information, refer to Cooling System Draining,
13 8005 Radiator
14 Transmission cooler bolts (if
2. Remove the lower radiator air deflector.
equipped)
(Continued)
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3. Remove the 6 pushpin retainers and the air 8. Remove the 4 bolts and the radiator support
deflector. brackets.
9. Remove the 2 power steering tubes and A/C
condenser retaining nuts and position aside the
power steering tubes.
10. Remove the 2 A/C condenser bolts.
11. If equipped, remove the 2 bolts and the
transmission cooler and position aside.
4. Remove the cooling fan motor and shroud. For
additional information, refer to Cooling Fan
12. Remove the radiator.
Motor and Shroud in this section.
5. Disconnect the degas bottle-to-radiator hose and
position aside. 14. Fill and bleed the cooling system. For
radiator and position aside.
radiator and position aside.
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SPECIFICATIONS
Thermostat cover bolts 10 89
Item Specification 4.6L (3V)
Cooling System Capacity 15.2 L (4.0 gal) Thermostat housing 25 18
nuts 5.4L (4V)
Coolant Type
cover bolts 5.4L
Engine Coolant with
(4V)
VC-7-B (US); CVC-7-A Generator support 10 89
(Canada); or equivalent bracket bolts 4.6L
(yellow color) (3V)
Other Chemicals Generator nuts 4.6L 25 18
(3V)
Flush VC-1 Coolant crossover 10 89
assembly bolts 4.6L
(3V)
Cleaner ZC-21
Cooling System Stop Leak WSS-M99B37-B6
bolts 4.0L (SOHC)
Pellets VC-6
Cooling System Pressure 138 kPa (20 psi)
4.0L (SOHC)
Test Specifications
Radiator Cap Pressure 110 kPa (16 psi)
bolts 4.6L (3V),
Test Specifications
5.4L (4V)
Thermostat Opening Temperatures
Starts to open (4.0L) 90-94C (194-201F)
4.6L (3V), 5.4L (4V)
Fully open (4.0L) 106C (223F)
Radiator support 10 89
brackets
A/C condenser bolts 10 89
Fully open (4.6L) 94.5C (202F)
Power steering tubes 8 71
and A/C condenser nut
Fully open (5.4L) 95C (203F)
Power steering 8 71
reservoir bolt 4.0L
(SOHC), 4.6L (3V)
Degas bottle bolts 8 71
Supercharger degas 8 71
Block heater retaining 2 18
bottle bolt 5.4L
screw
(4V)
Upper thermostat 10 89
Cooling fan motor and 9 80
housing bolts 4.0L
shroud bolts
(SOHC)
Transmission cooler 10 89
Lower thermostat 12 9
bolts (if equipped)
housing bolts 4.0L
(SOHC)
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Thermostat 4.0L SOHC
Material
4. Remove the 3 upper thermostat housing bolts
Item Specification
and position aside the thermostat housing.
Discard the thermostat O-ring seal.
Engine Coolant with
To install, tighten to 10 Nm (89 lb-in). Bittering Agent (US only)
5. Remove the thermostat.
(yellow color)
Install a new thermostat O-ring seal and
lubricate with clean engine coolant.
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8. Remove the thermostat O-ring seal and the
Thermostat 4.6L (3V)
thermostat.
Material Discard the thermostat O-ring seal.
Item Specification
Installation
Engine Coolant with
1. NOTE: Lubricate the O-ring seal with clean
engine coolant.
Install the thermostat with the smaller plate
(yellow color)
facing upward and a new O-ring seal.
Removal
2. Position the thermostat cover and install the 2
bolts.
3. Position the generator and wiring harness and
install the 2 nuts.
additional information, refer to Section 303-12. Tighten to 25 Nm (18 lb-ft).
3. Remove the accessory drive belt. For additional 4. Install the 2 outer generator support bracket
information, refer to Section 303-05. bolts.
4. Disconnect the crankcase vent tube from the
intake manifold and position it aside.
5. Connect the crankcase vent tube to the intake
manifold.
5. Remove the 2 generator support bracket outer
bolts.
6. Remove the 2 lower generator nuts and position
aside the generator and wiring harness.
7. NOTE: RH thermostat cover bolt has a slotted
flange.
Remove the LH thermostat cover bolt and additional information, refer to Cooling System
loosen the RH bolt. Draining, Filling and Bleeding in this section.
Position aside the thermostat cover and hose
assembly.
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2. Remove the 2 bolts and position aside the
Thermostat 5.4L (4V)
thermostat housing cover and hose assembly.
Material To install, tighten to 10 Nm (89 lb-in).
Item Specification
3. Remove the O-ring seal and the thermostat.
Engine Coolant with
VC-7-B (US); CVC-7-A 4. To install, reverse the removal procedure.
Lubricate the new O-ring seal with clean
(yellow color)
engine coolant.
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Thermostat and Thermostat Housing
Exploded View
4.0L (SOHC)
4 8A586 Thermostat housing cover and 1 W525966 Upper radiator hose clamp
gasket
2 8260 Upper radiator hose
5 8575 Thermostat
3 W500015 Upper thermostat housing
6 Heater inlet hose clamp (part bolts (3 required)
of 18472)
(Continued)
(Continued)
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7 18472 Heater inlet hose 9 W525966 Bypass hose clamp
8 W702527 Lower thermostat housing 10 8A586 Thermostat housing
bolts (3 required)
(Continued)
4.6L (3V)
3 10300 Generator 1 N807309 Generator support bracket
outer bolt (2 required)
4 W503279 LH thermostat cover bolt
5 W503279 RH thermostat cover bolt
(Continued)
(Continued)
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6 8594 Thermostat cover 8 8575 Thermostat
7 N806807 Thermostat O-ring seal
(Continued)
5.4L (4V)
4 8575 Thermostat 1 N605893 Thermostat housing cover
bolt (2 required)
(ECT) sensor electrical 2 8594 Thermostat housing cover
connector
3 O-ring seal
(Continued)
(Continued)
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6 8A595 Thermostat housing-to-intake 10 8B274 Thermostat
manifold hose housing-to-radiator hose
7 8A595 Thermostat housing-to-intake 11 W520413 Thermostat housing nut (2
manifold hose required)
8 8A594 Thermostat housing-to-lower 12 9K478 Thermostat housing
radiator hose assembly
9 6B851 Thermostat housing-to-oil
filter adapter hose
(Continued)
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6. Disconnect the heater inlet hose from the
Thermostat Housing 4.0L SOHC
thermostat housing and position aside.
7. Disconnect the bypass hose from the thermostat
housing and position aside.
8. Remove the 3 lower thermostat housing bolts
and the thermostat housing.
thermostat housing and position aside.
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6. Disconnect the thermostat housing-to-lower
Thermostat Housing 5.4L (4V)
radiator hose assembly and position it aside.
7. Disconnect the thermostat housing-to-oil filter
adapter hose and position it aside.
8. Disconnect the thermostat housing-to-radiator
hose and position it aside.
9. Remove the 2 nuts and the thermostat housing.
3. Remove the degas bottle. For additional
10. NOTE: Upon installation, make sure all the
information, refer to Degas Bottle in this
hoses are fully seated against the stops.
section.
5. Disconnect the 2 thermostat housing-to-intake Draining, Filling and Bleeding in this section.
manifold hoses and position them aside.
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303-03B-1 303-03B-1 Supercharger Cooling
Coolant Pump
3. Remove the radiator grille. For additional
1 14A464 Coolant pump electrical
connector
4. Disconnect the coolant pump electrical
2 8D029 Coolant pump-to-degas bottle
connector.
hose
3 N621939 Coolant pump nut (2
5. Disconnect the coolant pump-to-degas bottle
required)
hose from the coolant pump and position aside.
4 8K236 Coolant pump-to-radiator
hose
6. Disconnect the coolant pump-to-radiator hose
5 8K232 Coolant pump
from the radiator.
7. Remove the 2 coolant pump nuts and the
coolant pump.
additional information, refer to Supercharger
in this section.
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Supercharger Cooling System Draining, Filling
and Bleeding in this section.
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Degas Bottle
3. Disconnect the lower degas bottle hose and
position aside.
1 8D031 Upper degas bottle hose
2 8D029 Lower degas bottle hose
4. Remove the degas bottle bolt and remove the
3 W503924 Degas bottle bolt
degas bottle.
4 8D028 Degas bottle
1. Drain the supercharger cooling system. For 6. Fill and bleed the supercharger cooling system.
additional information, refer to Supercharger For additional information, refer to
Cooling System Draining, Filling and Bleeding Supercharger Cooling System Draining, Filling
in this section. and Bleeding in this section.
position aside.
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Radiator
2. Disconnect the radiator-to-charge air cooler
(CAC) hose from the radiator and position
1 W505424 Radiator bracket bolt (4
aside.
required)
2 8K243 Radiator bracket (2 required)
3. Disconnect the radiator-to-coolant pump hose
3 8D030 Radiator-to-charge air cooler
from the radiator.
(CAC) hose
4 8K236 Radiator-to-coolant pump
4. Remove the 4 radiator bracket bolts and the
hose
radiator.
5 8K229 Radiator
additional information, refer to Supercharger
in this section.
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SPECIFICATIONS
Item Specification
System (radiator) kPa 138 (20)
Item Specification (psi)
Cooling System Capacity Cap (relief opening 110 (16)
pressure) kPa (psi)
System capacity 3.75L (4.0 qt)
Coolant Type a The addition of Cooling System Stop Leak Pellets,
VC-6, darkens Motorcraft Premium Gold Engine
Coolant from yellow to golden tan.
Engine Coolant with
VC-7-B (US); CVC-7-A Torque Specifications
(yellow color)
a
Lower splash shield 5 44
Other Chemicals
bolts
Coolant pump nuts 25 18
Flush VC-1
Radiator bracket bolts 9 80
Cooling System Pressure Test Specifications
Degas bottle bolt 9 80
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GENERAL PROCEDURES
NOTE: Less than 80% of coolant capacity can be
Supercharger Cooling System
recovered with the engine in the vehicle. Dirty,
Draining, Filling and Bleeding
rusty or contaminated coolant requires replacement.
Special Tool(s)
hoist. For additional information, refer to RADKITPLUS
078-00497
Section 100-02.
2. Remove the 6 bolts and the lower splash shield.
3. Disconnect the radiator-to-charge air cooler
(CAC) hose from the radiator and allow the
coolant to drain in a suitable container.
Material
Connect the hose.
Item Specification
4. Install the lower splash shield and the 6 bolts.
Engine Coolant with
Tighten the bolts to 5 Nm (44 lb-in).
Filling and Bleeding with RADKITPLUS
(yellow color)
1. Using the special tool, install the
Draining
RADKITPLUS and follow the manufacturers
instructions to fill and bleed the cooling system.
Filling and Bleeding without
RADKITPLUS
protection, boil protection, cooling efficiency and
relief cap, wait until the engine has cooled, then
degas bottle.
is released from the cooling system. When
certain all the pressure has been released, (still
with a cloth) turn and remove the pressure relief
cap.
Coolant with Bittering Agent (US only) VC-7-B
(US); CVC-7-A (Canada); or equivalent meeting
CAUTION: The coolant must be recovered
Ford specification WSS-M97B51-A1 (yellow
in a suitable, clean container for reuse. If the
color). Always fill the cooling system with the
coolant is contaminated, it must be recycled or
same coolant that is present in the system. Do
disposed of correctly and replaced.
NOTE: When adding engine coolant, use a 50/50
mixture of engine coolant and clean, drinkable
water.
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1. To maintain the integrity of the coolant and the 2. Fill the degas bottle.
cooling system:
3. Start the engine and allow to run until coolant
1 Add Motorcraft Premium Gold Engine
circulation is observed in the degas bottle.
Coolant with Bittering Agent (US only)
Absence of circulation indicates air is trapped
VC-7-B (US); CVC-7-A (Canada); or
in the system.
Turn the engine off.
WSS-M97B51-A1 (yellow color). Use the
same coolant that was drained from the
4. Add coolant as needed.
cooling system. Do not mix coolant types.
2 Do not add/mix orange-colored Motorcraft
5. Repeat the above procedure to make sure all
Speciality Orange Engine Coolant VC-2 or
entrapped air is released.
WSS-M97B44-D. Mixing coolants may
degrade the coolants corrosion protection.
3 Do not add alcohol, methanol, brine or any
engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine
damage from overheating or freezing.
4 Do not mix with recycled coolant. Use of
such coolants can harm the engine and
cooling system components.
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GENERAL PROCEDURES
Supercharger Cooling System
information, refer to Supercharger Cooling
Flushing
System Draining, Filling and Bleeding in this
section.
Material
Item Specification 3. NOTE: Refer to the cooling system flusher
manufacturers operating instructions for
Flush specific vehicle hook-up.
VC-1
Using an appropriate cooling system flusher,
flush the intercooler cooling system.
1. WARNING: Never remove the
Use Premium Cooling System Flush VC-1
meeting Ford specification ESR-M14P7-A.
operating or when the cooling system is hot.
4. Fill the cooling system. For additional
information, refer to Supercharger Cooling
System Draining, Filling and Bleeding in this
section.
when you are sure all the pressure has been
released, (still with a cloth) turn and remove
the pressure relief cap.
relief cap.
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Engine coolant provides freeze protection, boil
Supercharger Cooling
protection, cooling efficiency and corrosion
protection to the engine and cooling components. In
order to obtain these protections, the engine coolant
must be maintained at the correct concentration and
fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of
engine coolant and clean, drinkable water.
To maintain the integrity of the coolant and the
cooling system:
NOTE: The air that is produced from the
supercharger is cooled by the intercooler.
Add Motorcraft Premium Gold Engine Coolant
with Bittering Agent (US only) VC-7-B (US);
The cooling system components include the:
CVC-7-A (Canada); or equivalent meeting Ford
intercooler.
specification WSS-M97B51-A1 (yellow color).
intercooler radiator. Use the same coolant that was drained from the
cooling system. Do not mix coolant types.
Do not add/mix orange-colored Motorcraft
degas bottle.
Speciality Orange Engine Coolant VC-2 or
electric coolant pump.
The degas bottle:
WSS-M97B44-D. Mixing coolants may degrade
the coolants corrosion protection.
provides a location for system fill.
Do not add alcohol, methanol, brine or any engine
contains coolant expansion and system
coolants mixed with alcohol or methanol
pressurization.
antifreeze. These can cause engine damage from
provides air separation during operation.
overheating or freezing.
replenishes the intercooler coolant to the system.
Do not mix with recycled coolant unless it meets
the requirements of Ford specification or
The intercooler coolant flows:
WSS-M97B51-A1. Not all coolant recycling
from the intercooler to the degas bottle.
processes meet these Ford specifications. Use of
from the degas bottle to the coolant pump.
such coolants can harm the engine and cooling
system components.
from the coolant pump to the intercooler radiator.
from the intercooler radiator to the intercooler.
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Supercharger Cooling CAUTION: Vehicle cooling systems are
Special Tool(s)
(US); CVC-7-A (Canada) or equivalent meeting Pressure Test Kit
014-R1072 or equivalent Ford specification WSS-M97B51-A1 (yellow
Battery/Antifreeze Tester
mechanical or electrical concerns apply.
Mechanical Electrical
Radiator attachments Damaged coolant pump
Leaks wiring
Damaged hoses Material
Hose clamps
Item Specification
Coolant pump
Radiator
Degas bottle
Engine Coolant with
Coolant pump bracket
3. If the inspection reveals an obvious concern
(yellow color)
that can be readily identified, repair it as
Inspection and Verification necessary.
4. Inspect the coolant condition.
1 WARNING: Never remove the
operating or when the cooling system is
hot. Failure to follow these instructions
can result in damage to the cooling
system or engine or personal injury. To
relief cap, wait until the engine has cooled, then
avoid having scalding hot coolant or
steam blow out of the degas bottle when
removing the pressure relief cap, wait
are sure all the pressure has been released, (still
with a cloth) turn and remove the pressure relief
cap.
pressure is released from the cooling
system. When you are sure all the
CAUTION: Check the coolant and engine
pressure has been released, (still with a
oil levels. Top off the coolant level if needed. If
cloth) turn and remove the pressure relief
there is engine coolant in the engine oil, the
cap.
cause must be corrected and the oil changed or
major component damage can occur.
Allow the engine to cool. Once pressure is
released, remove the pressure relief cap.
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3 If the engine coolant appearance is
2 CAUTION: Check the coolant and
acceptable, test the engine coolant freezing
engine oil level and top off the coolant if
point range with the special tool. The
needed. If there is engine coolant in the
freezing point should be in the range -45C
engine oil, the cause must be corrected
(-50F) to -23C (-10F). If the vehicle is
and oil/fluid changed or major
driven in cold climates less than -36C
component damage can occur.
(-34F), it may be necessary to increase the
CAUTION: Vehicle cooling systems
coolant concentration to get adequate freeze
are filled with Motorcraft Premium Gold
protection.
Engine Coolant with Bittering Agent (US
X Maximum coolant concentration is 60/40.
only) VC-7-B (US); CVC-7-A (Canada);
X Minimum coolant concentration is 40/60.
or equivalent meeting Ford specification
WSS-M97B51-A1 (yellow color). Always
4 Check the coolant system conditions:
fill the cooling system with the same
X If the intercooler fluid is low, add the
coolant that is present in the system. Do
specified coolant mixture only.
X If the intercooler coolant fluid tests weak,
Inspect the coolant color:
add straight engine coolant until the
X If Motorcraft Premium Gold Engine
readings are within acceptable levels.
Coolant with Bittering Agent (US only)
X If the engine coolant tests strong, remove
VC-7-B (US); CVC-7-A (Canada);
some of the engine coolant and add water
(yellow color) VC-7-A or equivalent
until readings are within acceptable
meeting Ford specification
levels.
WSS-M97B51-A1 has a clear or pale
yellow color, this indicates higher water
determine the symptom(s). GO to Symptom
content than required.
Chart.
X A light or reddish brown color indicates
6. Verify the cooling system is correctly filled and
that rust may be present in the cooling
bled. Refer to Supercharger Cooling System
system. Flush the system and refill with
the correct mixture of water and engine
coolant.
X An iridescent sheen on top of the coolant
or a milky brown color can indicate a
trace of oil is entering the system. For
additional information on engine
diagnosis, refer to Section 303-00.
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Symptom Chart
SYMPTOM CHART
Loss of intercooler coolant Intercooler GO to Pinpoint Test A.
Intercooler radiator
Coolant pump
Coolant hoses
Degas bottle
Pinpoint Tests
PINPOINT TEST A: LOSS OF COOLANT
A1 CHECK THE INTERCOOLER COOLANT LEVEL
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling
system or engine and/or personal injury. To avoid having
scalding hot coolant or steam blow out of the cooling system,
use extreme care when removing the pressure relief cap from a
hot degas bottle. Wait until the engine has cooled, then wrap a
thick cloth around the pressure relief cap and turn it slowly
one turn (counterclockwise). Step back while the pressure is
released from the cooling system. When you are sure all the
pressure has been released, (still with a cloth) turn and remove
Yes
NOTE: Allow the engine to cool before checking the engine coolant
GO to A2.
level. The engine must be off to check the coolant.
Visually check the intercooler coolant level at the degas bottle. REFILL the coolant as necessary. GO to
Is the coolant level within specification? A2.
A2 CHECK THE DEGAS BOTTLE PRESSURE RELIEF CAP
WARNING: Never remove the pressure relief cap
under any conditions while the engine is operating. Failure
to follow these instructions could result in damage to the
cooling system or engine and/or personal injury. To avoid
having scalding hot coolant or steam blow out of the
cooling system, use extreme care when removing the
pressure relief cap from a hot degas bottle. Wait until the
engine has cooled, then wrap a thick cloth around the
pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is
released from the cooling system. When you are sure all the
Yes
pressure has been released, (still with a cloth) turn and
GO to A3.
remove the pressure relief cap.
Remove the pressure relief cap. No
Inspect the pressure relief cap for foreign material between the CLEAN or INSTALL a new pressure relief
sealing gasket and the diaphragm. cap. TEST the system for normal
Is the pressure relief cap OK? operation.
(Continued)
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PINPOINT TEST A: LOSS OF COOLANT (Continued)
A3 CHECK THE DEGAS BOTTLE
WARNING: Never remove the pressure relief cap
under any conditions while the engine is operating. Failure
to follow these instructions could result in damage to the
cooling system or engine and/or personal injury. To avoid
having scalding hot coolant or steam blow out of the
cooling system, use extreme care when removing the
pressure relief cap from a hot degas bottle. Wait until the
engine has cooled, then wrap a thick cloth around the
pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is
released from the cooling system. When you are sure all the Yes
pressure has been released, (still with a cloth) turn and INSTALL a new degas bottle. TEST the
remove the pressure relief cap. system for normal operation.
NOTE: The engine must be cool when coolant is added to the
No
degas bottle.
CARRY OUT the cooling system pressure
Add coolant to the degas bottle until fluid is between the coolant test. REFER to the Component Tests in
fill level marks. this section. REPAIR as necessary. TEST
Does the degas bottle leak? the system for normal operation.
Component Tests 3. Connect the Radiator/Heater Core Pressure
Tester to the degas bottle nipple. Install a
Pressure Test
pressure test pump to the quick-connect fitting
1. Turn the engine OFF.
of the test adapter.
2. WARNING: Never remove the
too fast, an erroneous pressure reading will
pressure relief cap under any conditions
result.
while the engine is operating. Failure to
follow these instructions could result in
damage to the cooling system or engine
and/or personal injury. To avoid having
scalding hot coolant or steam blow out of
obtained.
the cooling system, never remove the
5. If the pressure relief cap does not hold pressure,
pressure relief cap from a hot degas bottle.
remove and wash the pressure relief cap in
Wait until the engine has cooled, then wrap
clean water to dislodge all foreign particles
a thick cloth around the pressure relief cap
from the gaskets. Check the sealing surface in
and turn it slowly one turn
the filler neck.
(counterclockwise). Step back while the
6. If 110 kPa (16 psi) cannot be reached, install a
new pressure relief cap. If more than 165 kPa
When you are sure all the pressure has been
(24 psi) shows on the gauge, install a new
released, (still with a cloth) turn and remove
Check the intercooler coolant level. Refer to
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2. Immerse the filler neck seal in water and install
7. CAUTION: If the pressure drops,
it in the filler neck adapter.
check for leaks at the intercooler hoses or
other system components and connections.
3. Install the filler neck adapter with the filler
Any leaks which are found must be corrected
neck seal to the Radiator Cap Adapter.
and the system rechecked.
4. Connect the female quick-connect fitting of the
NOTE: Intercooler system is not connected to
pressure test pump to the male quick-connect
the main engine cooling system.
fitting of the filler neck adapter.
Pressurize the intercooler cooling system as
described in Step 4 (using a pressure relief cap
too fast, an erroneous pressure reading will
that operates within the specified upper and
result.
lower pressure limits). Observe the gauge
reading for approximately 2 minutes; refer to
General Specifications. Pressure should not
drop during this time.
obtained.
If the pressure drops and no external leak is
6. Release the pressure by turning the relief screw
found, the intercooler may be the cause.
counterclockwise.
Remove and inspect the intercooler. Install a
7. Tighten the pressure relief screw and repeat
new intercooler if necessary.
Step 6 (at least twice) to make sure the reading
8. Release the system pressure by loosening the
is repeatable within the specifications of the
pressure relief cap. Check the coolant level and
replenish, if necessary, with the correct coolant
8. If the pressure test gauge readings are not
mixture. Refer to Supercharger Cooling System
within specifications, install a new pressure
relief cap. If the pressure test gauge readings
Cap are within specifications, carry out the cooling
system pressure test.
relief cap under any conditions while the engine
Radiator Leak Test, Removed From the
is operating. Failure to follow these instructions
Vehicle
could result in damage to the cooling system or
CAUTION: Never leak test an aluminum
engine and/or personal injury. To avoid having
radiator or intercooler in the same water that
scalding hot coolant or steam blow out of the
copper/brass radiators are tested in. Flux and
cooling system, use extreme care when removing
caustic cleaners may be present in the cleaning
the pressure relief cap from a hot degas bottle.
tank and they will damage aluminum radiators
Wait until the engine has cooled, then wrap a
and intercoolers.
thick cloth around the pressure relief cap and
NOTE: Clean the radiator or intercooler before leak
turn it slowly one turn (counterclockwise). Step
testing to avoid contamination of tank.
back while the pressure is released from the
cooling system. When you are sure all the
1. Leak test the radiator or intercooler in clean
pressure has been released, (still with a cloth)
water with 138 kPa (20 psi) air pressure.
turn and remove pressure relief cap.
1. Immerse the pressure relief cap in water and
install it on the shallow filler neck of
Radiator/Heater Core Pressure Tester and
Radiator Cap Adapter, part of Radiator/Heater
Core Pressure Tester.
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303-04A-1 303-04A-1 Fuel Charging and Controls 4.0L SOHC
For additional information, refer to Throttle Body in
Fuel Charging and Controls
this section.
Sequential Multiport Fuel Injection (SFI)
Fuel Injectors
The fuel injectors:
are electronically operated by the PCM.
atomize the fuel as the fuel is delivered.
each have an internal solenoid that opens a needle
valve, which injects fuel into the intake port in
The fuel charging and controls system consists of
the cylinder head.
the:
are deposit resistant.
electronic throttle body.
For removal and installation, refer to Fuel Rail and
fuel injectors.
Fuel Injector Exploded View and Fuel Rail in
this section.
fuel rail.
fuel rail pressure and temperature sensor.
Fuel Rail
fuel pump driver module.
CAUTION: The fuel injectors and the fuel
The fuel charging and controls system is:
rail must be handled with extreme care to
prevent damage to sealing areas and sensitive
a sequential multiport fuel injection (SFI) system.
fuel-metering orifices.
pulse width modulated.
The fuel rail:
mass air flow-controlled.
receives fuel from the fuel supply tube.
Fuel is metered into each intake port in a sequential
delivers fuel to the fuel injectors.
firing order. Fuel injectors pulse to follow engine
firing order, in accordance with engine demand on a
tuned intake manifold.
this section.
The powertrain control module (PCM) controls the
fuel injection system. Injector pulse width is varied
Fuel Rail Pressure and Temperature
to control the amount of fuel flow. Varying fuel
Sensor
pump output controls fuel pressure. The PCM
The fuel rail pressure and temperature sensor:
commands the fuel pump driver module, which
directly controls the fuel pump. The throttle body is
measures the pressure and temperature of the fuel
electronically controlled by the engine management
rail and sends these signals to the PCM.
system (EMS). Throttle plate angle is changed
uses intake manifold vacuum as a pressure
electronically in response to throttle pedal
reference.
movements initiated by the driver.
For removal and installation, refer to Section
Throttle Body 303-14.
CAUTION: Do not hold the throttle plate
Fuel Pump Driver Module (FPDM)
open with any object that could scratch the bore
The FPDM:
or plate while servicing or cleaning the throttle
body. Refer to Throttle Body in this section. receives signals from the PCM.
The throttle body: duty cycles the fuel pump.
controls air supply to the intake manifold by
electronically positioning the throttle plate.
is not adjustable.
must be removed from the vehicle to be cleaned.
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For removal and installation, refer to Fuel Pump
Driver Module (FPDM) in this section.
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Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
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1 14A464 Fuel pump driver module
(FPDM) electrical connector
(part of 14A005)
2 W504755 FPDM bolt (2 required)
3 9D370 FPDM
NOTE: The fuel pump driver module (FPDM) is
located in the spare tire stowage compartment.
2. Disconnect the FPDM electrical connector.
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3. Remove the 2 bolts and the FPDM. 4. To install, reverse the removal procedure.
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Fuel Rail and Fuel Injector
Exploded View
4 W711782 Fuel rail supply tube bolt (4 1 W500213 Lower fuel rail supply tube
required) bracket bolt
5 O-ring seal (2 required) 2 834551 Fuel rail supply tube quick
connect coupling
6 9E964 Fuel rail supply tube
3 W500204 Upper fuel rail supply tube (Continued)
bracket bolt
(Continued)
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7 9E498 Fuel rail pressure and 11 9D280 RH fuel rail
temperature sensor vacuum
12 9D280 LH fuel rail
hose
14 O-ring seals (12 required)
connector
9 14A464 Fuel injector electrical 1. For additional information, refer to the
connector (6 required)
10 W500023 Fuel rail bolt (4 required)
(Continued)
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Fuel Rail Supply Tube
Material
3. Disconnect the fuel rail supply tube quick
Item Specification
connect coupling. For additional information,
Motorcraft SAE 5W-30 WSS-M2C929-A refer to Section 310-00.
Motor Oil
4. Remove the lower fuel rail supply tube bracket
XO-5W30-QSP (US);
bolt.
Super Premium Motor Oil To install, tighten to 10 Nm (89 lb-in).
CXO-5W30-LSP12
5. Remove the upper fuel rail supply tube bracket
bolt.
6. Remove the 4 bolts and the fuel rail supply
tube.
on or near any fuel-related components. Highly
flammable mixtures are always present and can
made of special fuel-resistant material. The
use of ordinary O-ring seals can cause the WARNING: Fuel in the fuel system
fuel system to leak. Do not reuse the O-ring
remains under high pressure, even when the
seals.
engine is not running. Before working on or
Remove and discard the fuel rail supply tube
O-ring seals.
relieved. Failure to follow these instructions can
Lubricate the new O-ring seals with clean
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Fuel Rail 6. CAUTION: Use O-ring seals that are
use of ordinary O-ring seals can cause the Material
Item Specification
seals.
O-ring seal. Motor Oil
XO-5W30-QSP (US);
7. Remove the 2 bolts and the RH side fuel rail.
CXO-5W30-LSP12
8. Remove the 3 fuel injectors from the fuel rail.
WARNING: Do not smoke or carry lighted made of special fuel-resistant material. The
tobacco or open flame of any type when working use of ordinary O-ring seals can cause the
on or near any fuel-related components. Highly fuel system to leak. Do not reuse the O-ring
flammable mixtures are always present and can seals.
seals.
LH side
temperature sensor vacuum hose.
Both Sides
LH valve cover stud bolt and position it aside.
13. Disconnect the 3 fuel injector electrical
connectors.
14. Remove the 2 fuel rail supply tube bolts from
the LH side fuel rail.
RH side
RH valve cover stud bolt and position it aside.
use of ordinary O-ring seals can cause the
connectors.
seals.
5. Remove the 2 fuel rail supply tube bolts from
O-ring seal.
the RH side fuel rail.
16. Remove the 2 bolts and the LH side fuel rail.
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Both Sides
17. Remove the 3 fuel injectors from the fuel rail.
18. CAUTION: Use O-ring seals that are 19. To install reverse the removal procedure.
Lubricate the new O-ring seals with clean
use of ordinary O-ring seals can cause the
seals.
seals.
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SPECIFICATIONS
Throttle body bolts 10 89
Item Specification
Lower fuel rail supply 10 89
Lubricants and Chemicals tube bracket bolt
Motorcraft SAE 5W-30 WSS-M2C929-A Upper fuel rail supply 6 53
Premium Synthetic Blend tube bracket bolt
bolts
5W-30 Super Premium
Motor Oil Fuel rail bolts 23 17
CXO-5W30-LSP12
Fuel rail pressure and 6 53
temperature sensor
bolts
Fuel rail end cover 6 53
bolts
Fuel pump driver 10 89
module (FPDM) bolt
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3. Disconnect the 2 throttle body (TB) electrical
Throttle Body
connectors.
1 14A464 Throttle body (TB) electrical
connector
3 W503280 TB bolt (4 required)
4 9F991 TB
5 TB gasket
CAUTION: The throttle body must be
removed from the vehicle to be cleaned. Do not
hold the throttle plate open with any object that
could scratch the bore or plate while servicing or
cleaning the throttle body.
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4. NOTE: Inspect and install a new throttle body 5. To install, reverse the removal procedure.
gasket as necessary.
Remove the 4 bolts and the TB.
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303-04B-1 303-04B-1 Fuel Charging and Controls 4.6L (3V)
Refer to Throttle Body in this section.
Fuel Injectors
The fuel injectors:
each have an internal solenoid that opens a needle
valve, which injects fuel into the intake port in
the cylinder head.
are deposit resistant.
the:
throttle body.
fuel injectors.
this section.
fuel rail.
Fuel Rail
fuel pump driver module.
prevent damage to sealing areas and sensitive
The fuel rail:
pulse width modulated.
mass air flow-controlled.
firing order, in accordance with engine demand on a
tuned intake manifold.
this section.
fuel injection system. Injector pulse width is varied
Sensor
to control the amount of fuel flow. Varying fuel
pump output controls fuel pressure. The PCM
commands the fuel pump driver module, which
directly controls the fuel pump. The throttle body is
electronically controlled by the engine management
system (EMS). Throttle plate angle is changed
reference.
electronically in response to throttle pedal
For removal and installation, refer to Section
movements initiated by the driver.
303-14.
Throttle Body
The FPDM:
or plate while servicing or cleaning the throttle receives signals from the PCM.
body. Refer to Throttle Body in this section.
duty cycles the fuel pump.
The throttle body:
electronically positioning the throttle plate.
is not adjustable.
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For removal and installation, refer to Fuel Pump
Driver Module (FPDM) in this section.
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(PC/ED) manual.
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1 14A464 Fuel pump driver module
(part of 14A005)
2 W504755 FPDM bolt (2 required)
3 9D370 FPDM
NOTE: The fuel pump driver module (FPDM) is
located in the spare tire stowage compartment.
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3. Remove the 2 bolts and the FPDM. 4. To install, reverse the removal procedure.
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Exploded View
3 9C482 Fuel rail pressure and 1 14A163 Wiring harness retainer (2
temperature sensor vacuum required) (part of 12B637)
hose
4 Fuel rail pressure and temperature sensor electrical
temperature sensor vacuum connector (part of 12B637)
hose retainer (part of 9C482)
(Continued)
(Continued)
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5 14A464 Fuel injector electrical 9 9F860 Fuel injector
10 9F798 O-ring seal (16 required)
of 12B637)
6 N8111425 Fuel rail stud bolt (4
required)
7 9F792 Fuel rail
8 9C995 Fuel injector retaining clip (8
required)
(Continued)
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Fuel Rail
temperature sensor vacuum hose retainer from
the fuel rail stud bolt.
Material
Item Specification
6. Remove the engine appearance cover.
Premium Synthetic Blend 7. Disconnect the fuel rail pressure and
Motor
temperature sensor electrical connector and
Oil XO-5W20-QSP (US);
vacuum hose.
Super Premium Synthetic
Motor Oil
connectors. CXO-5W20-LSP12
9. Remove the 4 fuel rail stud bolts.
10. Remove the fuel rail and fuel injectors as an
assembly from the intake manifold.
it is not damaged during removal. If the clip is
reused, the 2 sides of the clip should be
squeezed back into shape by placing it between
index finger and thumb.
Remove the retaining clips and fuel injectors
from the fuel rail.
made of special fuel-resistant material. Use of
ordinary O-ring seals can cause the fuel
system to leak. Do not reuse the O-ring seals.
information, refer to Section 310-00. Remove and discard the fuel injector O-ring
seals.
additional information, refer to Section 414-01. 13. To install, reverse the removal procedure.
Lubricate the new upper and lower fuel
3. Disconnect the fuel supply tube spring lock
injector O-ring seals with clean engine oil
coupling. For additional information, refer to
prior to installation.
Section 310-00.
fuel rail stud bolts and position the harness
aside.
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SPECIFICATIONS
Description Nm lb-in
Throttle body (TB) stud bolts 10 89
Item Specification
TB nuts 10 89
Lubricants and Chemicals
Fuel rail stud bolts 10 89
Fuel pump driver module 10 89
(FPDM) bolts
5W-20 Super Premium
Synthetic Motor Oil
CXO-5W20-LSP12
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Throttle Body
1 14A464 Electronic throttle control
electrical connector (part of CAUTION: The throttle body must be
12B637)
2 14A464 Throttle position (TP) sensor hold the throttle plate open with any object that
could scratch the bore or plate while servicing or
12B637)
3 N806154 Throttle body (TB) stud bolt
(2 required)
4 N805320 TB nut (2 required) additional information, refer to Section 414-01.
5 9F991 TB
6 9E936 TB gasket
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5. NOTE: Discard the throttle body gasket. 6. To install, reverse the removal procedure.
Remove the 2 stud bolts, 2 nuts and the throttle
body.
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303-04C-1 303-04C-1 Fuel Charging and Controls 5.4L (4V)
Throttle Body (TB)
or plate while servicing or cleaning the throttle
body. Refer to Throttle Body in this section.
The TB:
electronically positioning the throttle plates.
is not adjustable.
the:
throttle body. Refer to Throttle Body in this section.
fuel injectors.
Fuel Rail
fuel rail.
fuel pump driver module. prevent damage to sealing areas and sensitive
The fuel rail:
pulse-width modulated (PWM).
mass air flow (MAF) controlled.
this section.
firing order, in accordance with engine demand, on
a tuned intake manifold.
Fuel Injectors
The basic fuel requirement of the engine is
The fuel injectors:
determined from the data supplied to the powertrain
control module (PCM) by the MAF sensor, which
measures the amount of air being drawn into the
engine.
each have an internal solenoid which opens a
The various sensors detect any changes in the
needle valve to inject fuel into the intake
operating conditions and send signals to the PCM.
manifold.
This permits the PCM to control the opening
are deposit-resistant.
duration (pulse width) of the fuel injectors and
maintain optimum exhaust emission control and
engine performance for all operating conditions.
this section.
Sensor
maintains constant fuel pressure to the fuel
injectors and throughout the fuel system.
is spring-loaded and operated by intake manifold
vacuum.
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For removal and installation, refer to Section For removal and installation, refer to Fuel Pump
303-14. Driver Module (FPDM) in this section.
Fuel Pump Driver Modules (FPDM)
The FPDM(S):
each controls one fuel pump.
receives signals from the PCM.
duty cycles the fuel pumps.
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(PC/ED) manual.
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1 14A464 RH fuel pump driver module
NOTE: The fuel pump driver modules (FPDM) are
located in the spare tire stowage compartment and (part of 14A005)
are serviced separately.
2 W504755 RH FPDM bolt (2 required)
3 9D370 RH FPDM
4 14A464 LH FPDM electrical
5 W504755 LH FPDM bolt (2 required)
6 9D370 LH FPDM
3. Remove the 2 bolts and the FPDM.
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Exploded View
5 N806154 Throttle body (TB) spacer 1 9G271 Evaporative emission (EVAP)
bolt (4 required) canister purge valve vapor
tube-to-throttle body spacer
6 9E822 TB spacer assembly
quick connect coupling
7 9L437 TB spacer-to-supercharger
2 2B432 Brake booster-to-throttle body
gasket
spacer quick connect coupling
(part of 12B637)
12B637)
9 9J280 Fuel supply tube-to-fuel rail
12B637)
(Continued)
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12 14A464 Fuel rail pressure and 10 6K817 Positive crankcase ventilation
temperature sensor electrical (PCV) valve-to-supercharger
connector (part of 12B637) tube
13 14A464 Fuel injector electrical 11 9E498 Fuel rail pressure and
connector (8 required) (part temperature sensor vacuum
of 12B637) hose
(Continued)
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19 Lower fuel injector O-ring (8 14 N804394 Fuel rail bolt (4 required)
required) (part of 9F593)
15 9F792 Fuel rail
17 9F907 Fuel injector clip (8 required)
18 Upper fuel injector O-ring (8
required) (part of 9F593)
(Continued)
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Fuel Rail
Material
8. Remove the 4 throttle body (TB) spacer
Item Specification
assembly-to-supercharger bolts and the TB
Motorcraft SAE 5W-50 WSS-M2C931-A spacer assembly.
Discard the gasket.
XO-5W50-QGT or
equivalent To install, tighten to 10 Nm (89 lb-in).
9. Disconnect the intake air temperature (IAT)
10. Disconnect the fuel supply tube quick connect
coupling from the fuel rail. For additional
(PCV) valve tube-to-supercharger quick connect
coupling and position aside. For additional
temperature sensor electrical and vacuum
relieved. Failure to do so can result in personal
connectors.
injury.
connectors.
14. Remove the 4 fuel rail bolts.
15. Remove the fuel rail and the 8 fuel injectors.
4. Disconnect the evaporative emission (EVAP)
it is not damaged during removal.
canister purge valve vapor tube-to-throttle body
Remove the fuel injector clips from the fuel
spacer quick connect coupling. For additional
injectors.
17. Inspect the fuel injector O-rings for damage.
5. Disconnect the brake booster-to-throttle body
spacer quick connect coupling. For additional
Lubricate the upper and lower fuel injector
O-ring seals with clean engine oil prior to
installation.
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SPECIFICATIONS
Throttle body (TB) bolts 10 89
Item Specification
TB spacer bolts 10 89
Lubricants
Fuel rail bolts 10 89
Fuel pump driver module 10 89
(FPDM) bolts
XO-5W50-QGT or
equivalent
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Throttle Body
12B637)
4. Disconnect the electronic throttle control 12B637)
3 N806154 Throttle body (TB) bolt (4
required)
5. Remove the 4 bolts and the throttle body (TB)
4 9F991 TB
and discard the gasket.
5 9E936 TB-to-TB spacer gasket
CAUTION: The throttle body must be
hold the throttle plate open with any object that
could scratch the bote or plate while servicing or
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Install a new TB gasket.
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303-05-1 303-05-1 Accessory Drive
Accessory Drive Belt 4.0L SOHC
drive belt.
2. NOTE: Refer to the illustration for correct
drive belt routing.
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Accessory Drive Belt 4.6L (3V)
drive belt routing.
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Accessory Drive Belt 5.4L (4V)
drive belt routing.
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Accessory Drive Belt Idler Pulley
drive belt routing.
4.0L SOHC
drive belt from the accessory drive belt idler
pulley.
idler pulley.
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drive belt routing.
4.6L (3V)
from the accessory drive belt idler pulley.
idler pulley.
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4. Remove the stud bolt and smooth idler pulley.
5.4L (4V) To install, tighten to 25 Nm (18 lb-ft).
All vehicles
All vehicles
drive belt routing.
from the coolant pump pulley.
Grooved idler pulley
2. Remove the bolt and the grooved idler pulley.
Smooth idler pulley
3. Remove the coolant tube bracket nut and
position the coolant tube aside.
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Accessory Drive Belt Tensioner
drive belt routing.
4.0L SOHC
drive belt from the accessory drive belt
tensioner.
tensioner.
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drive belt routing.
4.6L (3V)
from the accessory drive belt tensioner.
2. Remove the 3 bolts and the accessory drive belt
tensioner.
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drive belt routing.
5.4L (4V)
from the accessory drive belt tensioner.
tensioner.
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Accessory Drive Item Part Number Description
6 6C348 Accessory drive belt idler Accessory Drive Belt Routing 4.0L SOHC
pulley
9 6B209 Accessory drive belt tensioner
pulley
10 19D784 A/C compressor pulley
Accessory Drive Belt Routing 5.4L (4V)
1 10300 Generator pulley
4 8509 Coolant pump pulley
5 6B321 Crankshaft pulley
pulley Item Part Number Description
7 6C348 Accessory drive belt idler
pulley
pulley
Accessory Drive Belt Routing 4.6L (3V)
pulley
pulley
8 3D673 Power steering pump pulley
pulley
pulley
(Continued)
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Supercharger Belt Routing 5.4L (4V)
4 6B209 Supercharger belt tensioner
pulley
6 6C348 Supercharger belt grooved
idler pulley
7 19A216 Supercharger belt smooth
idler pulley
8 8620 Supercharger belt
1 6F066 Supercharger pulley
2 19A216 Supercharger belt heavy load
idler pulley
(Continued)
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5. NOTE: Up to 15 cracks in a rib over a
Accessory Drive
distance of 100 mm (4.0 in) can be considered
acceptable. If damage exceeds the acceptable
limit or any chunks are found to be missing
CAUTION: Under no circumstances should
from the ribs, a new belt must be installed.
the accessory drive belt, tensioner or pulleys be
Check the belt for cracks. Up to 15 cracks in a
lubricated as potential damage to the belt
rib over a distance of 100 mm (4.0 in) can be
material and tensioner damping mechanism will
considered acceptable. If cracks exceed this
occur. Do not apply any fluids or belt dressing to
standard, install a new belt.
the accessory drive belt or pulleys.
6. The condition of the V-ribbed drive belt should
be compared against the illustration and
system.
appropriate action taken.
1 Small scattered deposits of rubber material.
mechanical damage.
This is not a concern, therefore, installation
of a new belt is not required.
Mechanical 2 Longer deposit areas building up to 50% of
the rib height. This is not considered a
Drive belt cracking/chunking/wear
Belt/pulley contamination concern but it can result in excessive noise.
Incorrectly routed belt
If noise is apparent, install a new belt.
Pulley misalignment or excessive pulley runout
3 Heavy deposits building up along the
Loose or mislocated hardware
grooves resulting in a possible noise and Incorrectly routed power steering tubes (rubbing)
belt stability concern. If heavy deposits are
apparent, install a new belt.
3. Eliminate all other non-belt related noises that
could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable
camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition
V-Ribbed Serpentine Drive Belt With Cracks Across
Ribs
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V-Ribbed Serpentine Belt With Piling
7. There should be no chunks missing from the
belt ribs. If the belt shows any evidence of this, NOTE: Piling is an excessive buildup in the
install a new accessory drive belt.
V-grooves of the belt.
V-Ribbed Serpentine Belt With Chunks of Rib
Missing
8. If the concern is not visually evident, verify the
Symptom Chart
Symptom Chart
Accessory drive belt cracking Accessory drive belt INSPECT the accessory drive
(over 15 cracks in a rib over belt. REFER to Inspection
a distance of 100 mm [4.0 and Verification in this
in]) section. INSTALL a new
accessory drive belt as
necessary.
Accessory drive belt chunking Accessory drive belt INSPECT the accessory drive
belt. REFER to Inspection
and Verification in this
section. INSTALL a new
accessory drive belt as
necessary.
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Accessory drive belt noise, Defective/worn or incorrect REFER to Component Tests,
squeal, chirping or flutter accessory drive belt Drive Belt, Noise/Flutter in
Misaligned pulley(s) this section. REPAIR or
Pulley runout INSTALL new parts as
Damaged or worn accessories necessary.
Fluid contamination of
accessory drive belt or
pulleys
Damaged or worn accessory REFER to Component Tests,
drive belt tensioner Belt Tensioner Mechanical
and Belt Tensioner
Dynamics in this section.
INSTALL a new accessory
drive belt tensioner as
necessary.
Premature accessory drive Defective accessory drive belt REFER to Component Tests,
belt wear Misaligned pulley(s) Drive Belt Noise/Flutter and
Pulley runout Incorrect Drive Belt
Damaged accessories Installation in this section.
Incorrectly installed drive belt REPAIR or INSTALL new
Fluid contamination parts as necessary.
Accessory drive belt does not Accessory drive belt has INSPECT the drive belt.
hold correct tension excessive cracking, damage or REFER to Inspection and
is worn Verification in this section.
INSTALL a new drive belt as
necessary.
Drive belt tensioner worn or CHECK the drive belt
damaged tensioner for damage and
correct operation. REFER to
the Component Tests, Belt
Tensioner Mechanical and
Belt Tensioner Dynamics
in this section. INSTALL a
new drive belt tensioner as
necessary.
Incorrect accessory drive belt VERIFY the correct
accessory drive belt is
installed.
Accessory drive component CHECK the accessory drive
failure components. INSTALL new
Accessory drive belt idler INSPECT the accessory drive
pulley bearing failure belt idler pulley for freedom
of rotation and damage.
INSTALL a new accessory
drive belt idler pulley as
necessary.
Component Tests
To correct, determine the area where the noise
comes from. Check each of the pulleys in that area
Drive Belt Noise/Flutter
with a straightedge to the crankshaft pulley. Look
Drive belt chirp occurs due to pulley misalignment
for accessory pulleys out of position in the fore/aft
or excessive pulley runout. It can be the result of a
direction or at an angle to the straightedge.
damaged or incorrectly aligned grooved pulley.
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if the accessory drive belt is too long. A drive
CAUTION: Do not apply any fluids or belt
belt that is too long will allow the accessory drive
dressing to the accessory drive belt or pulleys.
belt tensioner arm to go all the way to the arm
Drive belt squeal may be an intermittent or constant
travel stop under certain load conditions, which
noise that occurs when the drive belt slips on an
will release tension to the drive belt. If the
accessory pulley under certain conditions.
accessory drive belt tensioner indicator is outside
A short intermittent squeal may occur during engine
the normal installation wear range window, install
start-up and shut down or during very rapid engine
a new accessory drive belt.
acceleration and decelerations, such as:
NOTE: The accessory drive belt tensioner arm
should rotate freely without binding.
wide open throttle 1-2 and 2-3 shifts or 2-3 and
3-4 back out shifts on automatic transmissions.
Install a new accessory drive belt tensioner if the
drive belt tensioner is worn or damaged.
wide open throttle 1-2 and 2-3 shifts and any
combination of rapid downshifting on manual
Drive Belt Incorrect Installation
transmissions.
CAUTION: Incorrect accessory drive belt
These special short-term transient events are
installation will cause excessive drive belt wear
expected, and are due to the higher system inertias
and can cause the drive belt to come off the
required to meet the electrical and cooling demands
pulleys.
on todays vehicle systems. Constant or reoccurring
drive belt squeal can occur:
Non-standard accessory drive belts can track
differently or incorrectly. If an accessory drive belt
if the A/C discharge pressure goes above
tracks incorrectly, install a new accessory drive belt
specifications:
to avoid performance failure or loss of the drive
the A/C system is overcharged.
belt.
the A/C condenser core airflow is blocked.
Incorrect Installation
if the A/C off equalized pressure (the common
discharged and suction pressure that occurs after
several minutes) exceeds specifications.
if any of the accessories are damaged or have a
worn or damaged bearing. All accessories should
be rotatable by hand in the unloaded condition. If
not, inspect the accessory.
if there is evidence of fluid contamination on the
accessory drive belt. When the drive belt has been
exposed to fluid contamination during vehicle
operation, such as leaks from the power steering
system, A/C system or cooling system, clean all
pulleys with soap and water, rinse with clean
Correct Installation
water and install a new accessory drive belt. If the
drive belt has been exposed to fluids in a
localized area during routine vehicle service, such
as replacement of hoses or fluids, the drive belt
and pulleys should be washed with soap and
water immediately (prior to starting the engine),
and rinsed with clean water.
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With the engine running, check accessory drive belt 3. Using a suitable, commercially available
tracking on all pulleys. If the edge of the accessory serpentine belt tensioner release tool, move the
drive belt rides beyond the edge of the pulleys, tensioner from its relaxed position, through its
noise and premature wear will occur. Make sure the full stroke and back to the relaxed position to
accessory drive belt rides correctly on the pulley. If make sure there is no stick, grab or bind, and to
an accessory drive belt tracking condition exists, make sure that there is tension on the tensioner
proceed with the following: spring.
4. Rotate the tensioner pulley by hand and check
Visually check the accessory drive belt tensioner
for a binding, contaminated or seized condition.
for damage, especially the mounting pad surface.
Install a new accessory drive belt tensioner if
If the accessory drive belt tensioner is not
necessary.
installed correctly, the mounting surface pad will
be out of position. This will result in chirp and
5. Inspect the area surrounding the accessory drive
squeal noises.
belt tensioner for oil leaks or contamination and
repair any leaks. Install a new accessory drive
With the engine running, visually observe the
belt tensioner as necessary.
grooves in the pulleys (not the pulley flanges or
the pulley forward faces) for excessive wobble.
6. If the accessory drive belt tensioner meets the
Install new components as necessary.
above criteria, proceed to testing the tensioner
dynamically. If the accessory drive belt
Check all accessories, mounting brackets and the
tensioner does not meet the above criteria,
accessory drive belt tensioner for any interference
install a new tensioner.
that would prevent the component from mounting
correctly. Correct any interference condition and
Belt Tensioner Dynamics
recheck the accessory drive belt tracking.
The accessory drive belt tensioner can be checked
Tighten all accessories, mounting brackets and
dynamically as follows:
accessory drive belt tensioner retaining hardware
1. With the engine running, observe the accessory
to specification. Recheck the accessory drive belt
drive belt tensioner movement. The accessory
tracking.
drive tensioner should move (respond) when the
Belt Tensioner Mechanical
air conditioning clutch cycles (if equipped), or
when the engine is accelerated rapidly. If the
The only mechanical check that needs to be made is
accessory drive belt tensioner movement is
a check for tensioner stick, grab or bind.
excessive without air conditioning clutch
1. With the engine off, check routing of the
cycling or engine acceleration, check belt
accessory drive belt. Refer to the illustrations
rideout. Excessive belt rideout (uneven depth of
under Description and Operation in this section.
grooves in the belt) can cause excessive
2. NOTE: The accessory drive belt tensioner
accessory drive belt tensioner movement.
spring is very strong and requires substantial
Check rideout condition by installing a new
force to release.
belt. If excessive accessory drive belt tensioner
movement still exists, install a new accessory
Using a suitable, commercially available
drive belt tensioner.
serpentine belt tensioner release tool, release the
tension on the belt and detach the accessory
drive belt in the area of the tensioner.
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Front End Accessory Drive (FEAD)
Exploded View
4.0L SOHC
4 Accessory drive belt idler 1 8620 Accessory drive belt
pulley bolt (part of 6C348)
2 W500325 Accessory drive belt tensioner
5 6C348 Accessory drive belt idler bolt
pulley
(Continued)
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4.6L (3V)
6 N808920 Accessory drive belt tensioner 1 8620 Accessory drive belt
bolt (3 required)
2 W707288 Accessory drive belt idler
7 6B209 Accessory drive belt tensioner pulley bolt
8 N808102 Accessory drive belt idler 3 6C348 Accessory drive belt idler
pulley bolt pulley
9 19A216 Accessory drive belt idler 4 N808102 Accessory drive belt idler
pulley pulley bolt
pulley
(Continued)
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5.4L (4V)
7 19A216 Accessory drive belt smooth 1 N621905 Coolant tube bracket nut
idler pulley
2 6B851 Coolant tube
8 N808102 Accessory drive belt grooved
idler pulley bolt
4 Accessory drive belt tensioner
9 19A216 Accessory drive belt grooved
bolt (part of 6B209)
idler pulley
6 W712808 Accessory drive belt smooth
idler pulley stud bolt
(Continued)
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SPECIFICATIONS
Item Specification grooved idler pulley
bolt 5.4L (4V)
Accessory drive belt 6 ribs
Supercharger drive belt 10 ribs
smooth idler pulley
stud bolt 5.4L (4V)
Torque Specifications Coolant pump pulley 25 18
bolts 5.4L (4V)
nut 5.4L (4V)
tensioner bolt 4.0L
Supercharger belt 48 35
SOHC
tensioner bolt 5.4L
(4V)
tensioner bolts 4.6L
(3V)
smooth idler pulley
bolt 5.4L (4V)
tensioner bolt 5.4L
(4V)
grooved idler pulley
bolt 5.4L (4V)
idler pulley bolt
4.0L SOHC
heavy load idler pulley
bolt 5.4L (4V)
idler pulley bolts
4.6L (3V)
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Supercharger Belt Idler Pulley
from the coolant pump pulley.
All idler pulleys
6. Remove the bolts and the coolant pump pulley.
rotate the supercharger belt tensioner clockwise
and remove the supercharger belt from the
supercharger pulley.
Smooth idler pulley
2. Remove the bolt and the supercharger belt
smooth idler pulley.
Grooved idler pulley
heavy load idler pulley.
grooved idler pulley.
All idler pulleys
Heavy load idler pulley
4. Loosen the coolant pump pulley bolts.
supercharger belt routing.
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Supercharger Belt Tensioner
Removal and Installation To install, reverse the removal procedure.
2. NOTE: The supercharger belt is routed behind
the supercharger belt tensioner.
Remove the supercharger belt tensioner bolt and
tensioner.
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Supercharger Belt, Tensioner and
Pulley Exploded View
7 6C348 Supercharger belt grooved 1 Supercharger belt tensioner
idler pulley bolt (part of 6B209)
8 N808296 Supercharger belt heavy load 2 6B209 Supercharger belt tensioner
idler pulley bolt
3 8620 Supercharger belt
9 19A216 Supercharger belt heavy load
4 W707288 Supercharger belt smooth
idler pulley
idler pulley bolt
5 19A216 Supercharger belt smooth
idler pulley
6 N808102 Supercharger belt grooved
idler pulley bolt
(Continued)
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Supercharger Belt
information, refer to Accessory Drive Belt
5.4L (4V) in this section.
3. NOTE: The supercharger belt is routed behind
the supercharger belt tensioner.
Remove the supercharger belt tensioner bolt, the
tensioner and the supercharger belt.
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303-06-1 303-06-1 Starting System
SPECIFICATIONS
Starter motor bolts 25 18
Item Specification
Starter motor solenoid 5 44
Normal engine cranking 100-140 rpm S-terminal nut
speed rpm
Starter motor solenoid 12 9
Starter motor no load 60-80 amps B+ terminal nut
current draw amperes
Starter motor normal load 130 amps
current draw
Starter motor maximum 400 amps
load current draw amperes
Maximum starting circuit 0.5 volt
voltage drop (engine at
normal engine
temperature)
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Starter Motor 4.0L SOHC
Removal
1 11N087 Starter solenoid terminal
cover WARNING: When servicing the starter
motor or carrying out other underhood work in
2 W705790 Starter solenoid S-terminal
nut the vicinity of the starter motor, be aware that
the heavy gauge battery input lead at the starter
3 14463 Starter solenoid S-terminal
eyelet solenoid is electrically hot at all times. A
protective cap or boot is provided over this
4 N805403 Starter solenoid B+ terminal
nut terminal that must be installed after servicing. Be
sure to disconnect the battery negative cable
5 14463 Starter solenoid B+ terminal
eyelet before servicing the starter. Failure to follow
these instructions can result in personal injury.
6 W709781 Starter motor mounting bolt
(2 required)
WARNING: When working in area of the
7 11000 Starter motor
starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these
Section 100-02.
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2. Disconnect the battery ground cable. For 2. Install the wires and the 2 starter solenoid
additional information, refer to Section 414-01. terminal nuts.
Tighten the B+ terminal nut to 12 Nm (9
3. Remove the starter solenoid terminal cap.
lb-ft) and the S-terminal nut to 5 Nm (44
lb-in).
4. Remove the 2 starter solenoid terminal nuts and
position aside the wires.
3. Install the starter solenoid terminal cap.
5. Remove the 2 bolts and the starter motor.
Installation
1. CAUTION: To make sure of proper
starter installation, the upper bolt must be
tightened first.
Position the starter motor and install the 2 bolts
finger tight.
Tighten the upper bolt to 25 Nm (18 lb-ft).
Tighten the lower bolt to 25 Nm (18 lb-ft).
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Starter Motor 4.6L (3V)
Removal
(3 required)
Section 100-02.
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additional information, refer to Section 414-01. terminal nuts
lb-in).
Installation
tightened first.
finger tight.
Tighten the 2 upper bolts to 25 Nm (18
lb-ft).
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Starter Motor 5.4L (4V)
Removal
(3 required)
Section 100-02.
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additional information, refer to Section 414-01. terminal nuts
lb-in).
Installation
tightened first.
finger tight.
Tighten the 2 upper bolts to 25 Nm (18
lb-ft).
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GENERAL PROCEDURES
3. If the starter drive gear and the flywheel ring
Starter Motor Drive Gear and
gear are not fully meshing and both of the
Flywheel Ring Gear Inspection
gears are scored or damaged, install a new
starter motor. For additional information, refer
1. Remove the starter motor. For additional
to Starter Motor 4.0L SOHC or Starter
information, refer to Starter Motor 4.0L
Motor 4.6L (3V) or Starter Motor 5.4L
SOHC or Starter Motor 4.6L (3V) or
(4V) in this section.
Starter Motor 5.4L (4V) in this section.
If necessary, install a new flywheel. For
2. Check the wear patterns on the starter drive
or Section 303-01B or Section 303-01C.
gear and the flywheel ring gear. If the wear
pattern is normal, install the starter motor. For
additional information, refer to Starter Motor
4.0L SOHC or Starter Motor 4.6L (3V)
or Starter Motor 5.4L (4V) in this section.
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When the ignition switch is in the START position:
Starting System
the pull-in coil is activated and pulls the contacts
Starting System Starter Motor
together.
The starter motor is a 12-volt unit that has the
current passes through the starter relay from the
starter solenoid mounted on the drive end housing
engine compartment bussed electrical center
and functions as follows:
(BEC) to the starter solenoid.
The current flows through the solenoid energizing
Starting System Clutch Pedal Position
coil until the solenoid plunger is at the end of its
(CPP) Switch
travel.
The clutch pedal position (CPP) switch for:
The plunger closes a set of contacts that bypass
the energizing coil, letting the holding coil engage
a manual transmission closes when the clutch
the starter drive and pass starting current to the
pedal is depressed, completing the starting circuit.
starter motor.
an automatic transmission is a jumper inserted in
The motor is energized when the starter solenoid
place of the CPP switch to complete the circuit.
contacts are closed.
Starter System Operation
The starter drive engages the flywheel ring gear
and starts the engine. When the ignition switch is turned to the START
position, the starter relay switches power to the
An overrunning clutch in the starter drive protects
starter solenoid causing the starter motor to engage
the starter motor from excessive speed when the
as long as:
engine starts.
the clutch pedal is depressed (manual transmission
Starting System Starter Relay
only).
The starter interrupt relay consists of:
the digital transmission range (TR) sensor is in
pull-in coil and contacts. PARK or NEUTRAL (automatic transmission
only).
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NOTE: When working on the starter system, make
Starting System
sure the anti-theft system is deactivated, if equipped.
Special Tool(s)
73 Digital Multimeter starting system.
mechanical and electrical damage. Refer to the
following chart:
SABRE Premium Battery and
Starter motor Battery
Electrical System Tester
Brackets Smart junction box
(SJB) fuse:
21 (10A)
Bussed electrical center
(BEC) fuse:
3 (30A)
Anti-theft system
Damaged wiring harness
Loose or corroded
connections
tool
software release. The starting system is electronically controlled by
the passive anti-theft system (PATS). The PATS
recognizes the correct electronically coded ignition
key and signals the instrument cluster to provide a
ground for the starter relay. The energized relay
provides voltage to the starter solenoid with the key
in the START position, thereby allowing the starter
VCM.
motor to activate.
VCM:
WARNING: When servicing the starter check the VCM connection to the vehicle.
the vicinity of the starter motor, be aware that
refer to Section 418-00, No power to the
scan tool, to diagnose no communication
solenoid is electrically hot at all times. A
with the scan tool.
protective cap or boot is provided over the
6. If the scan tool does not communicate with the terminal of this lead and must be installed after
vehicle: servicing. Failure to follow these instructions may
WARNING: When working in the area of verify the scan tool operation with a known
the starter motor, be careful to avoid touching good vehicle.
hot exhaust components. Failure to follow these
(PCM).
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7. Carry out the network test. 8. Clear the continuous DTCs and carry out the
self-test diagnostics for the powertrain control
module (PCM).
refer to Section 418-00. 9. If the DTCs retrieved are related to the concern,
go to Passive Anti-Theft System (PATS)
Diagnostic Trouble Code (DTC) Index. For all
other DTCs, refer to Section 419-10.
Passive Anti-Theft System (PATS) Diagnostic Trouble Code (DTC) Index
B1213 Anti-Theft Number Of Powertrain Control Module REFER to Section
Programmed Keys Is (PCM) 419-01B.
Below Minimum
B1342 ECU is Defective PCM CLEAR the DTCs.
REPEAT the self-test. If
DTC B1342 is retrieved
again, INSTALL a PCM.
CLEAR the DTCs.
B1600 Passive Anti-Theft System PCM REFER to Section
(PATS) Key Transponder 419-01B.
Is Not Received
Damaged Key Or
Non-PATS Key
B1601 PATS Received Incorrect PCM REFER to Section
Key-Code From Key 419-01B.
Transponder
(Unprogrammed PATS
Key)
B1602 or B2431 PATS Received Invalid PCM REFER to Section
Format Of Key-Code From 419-01B.
Key Transponder (Partial
Key Read)
B1681 PATS Transceiver Module PCM REFER to Section
Signal Is Not Received 419-01B.
(Damaged, Not Connected
Or Damaged Wiring)
B2103 Internal Transceiver PCM REFER to Section
Antenna Damaged 419-01B.
P1260 PCM Disabled Vehicle PCM REPAIR the PCM. REFER
Disabled to the Powertrain
Control/Emissions
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Symptom Chart
Symptom Chart
The engine does not crank/the Battery GO to Pinpoint Test A.
relay does not click Fuse
Starter relay
Ignition switch
Digital transmission range
(TR) sensor (automatic
transmission only)
Clutch pedal position (CPP)
switch (manual transmission
only)
Circuit
The engine does not crank/the Fuse GO to Pinpoint Test B.
relay does click Battery
Starter motor/solenoid
Ignition switch
Circuit
The engine cranks slowly Battery GO to Pinpoint Test C.
Starter motor/solenoid
Circuit
Unusual starter noise Starter mounting GO to Pinpoint Test D.
Flexplate or flywheel
Starter motor
The starter spins but the Starter motor INSPECT the starter motor
engine does not crank Damaged flexplate or mounting and engagement.
flywheel ring gear teeth INSTALL a new starter
motor. REFER to Starter
Motor 4.0L SOHC or
Starter Motor 4.6L (3V) or
Starter Motor 5.4L (4V) in
this section.
INSPECT the flexplate or
flywheel for damaged,
missing or worn teeth.
REPAIR as required.
Pinpoint Tests For automatic transmission equipped vehicles,
voltage is supplied from the SJB to the digital
Pinpoint Test A: The Engine Does Not
transmission range (TR) sensor through circuit 32
Crank/The Relay Does Not Click
(RD/LB). In PARK or NEUTRAL, voltage is
Refer to Wiring Diagrams Cell 20, Starting System
supplied from the TR sensor through circuit 33
for schematic and connector information.
(WH/PK) to the starter relay coil located in the
BEC. The starter relay coil is supplied ground from
Normal Operation
the PCM through circuit 1419 (LG/YE).
In normal operation, voltage from the bussed
For manual transmission equipped vehicles, voltage
electrical center (BEC) is supplied to the ignition
from the SJB is supplied to the clutch pedal position
switch through circuit 1050 (LG/PK). When the
switch (CPP) through circuit 32 (RD/LB). When the
ignition switch is placed in the START position,
clutch pedal is depressed, voltage is supplied from
voltage is supplied through circuit 1522 (DG) to the
the CPP to the starter relay coil located in the BEC
through circuit 32 (RD/LB). The starter relay coil is
supplied ground from the PCM through circuit 1419
(LG/YE).
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Possible Causes
When the starter relay is energized, voltage supplied
to the relay switch is sent to the starter motor
Fuse(s)
solenoid through circuit 113 (YE/LB). Battery
An open in battery voltage feed BEC, 2037 (RD)
voltage is supplied to the starter motor through
or 113 (YE/LB)
circuit 2037 (RD) at all times.
Starter motor relay
Starter
PINPOINT TEST A: THE ENGINE DOES NOT CRANK/THE RELAY DOES NOT CLICK
A1 CHECK THE BATTERY
Check the battery condition and charge if necessary. Refer to Yes
Section 414-01. GO to A2.
Is the battery OK?
No
CHARGE or INSTALL a new battery as
A2 CHECK FOR PATS DTCS
NOTE: The PATS DTCs are the only DTCs of concern in this Yes
step. Only repair retrieved non-PATS DTCs if a customer GO to Section 419-01B to diagnose the
concern is reported. PATS DTCs.
Check for PATS DTCs.
No
Were any PATS DTCs retrieved?
GO to A3.
A3 CHECK CIRCUIT 33 (WH/PK) (CIRCUIT 32 [RD/LB] MANUAL
TRANSMISSION ONLY) FOR VOLTAGE
Disconnect: Starter Motor Relay.
If equipped, fully depress the clutch pedal.
(Continued)
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PINPOINT TEST A: THE ENGINE DOES NOT CRANK/THE RELAY DOES NOT CLICK (Continued)
A3 CHECK CIRCUIT 33 (WH/PK) (CIRCUIT 32 [RD/LB] MANUAL
TRANSMISSION ONLY) FOR VOLTAGE (Continued)
Measure the voltage between the bussed electrical center (BEC)
starter motor relay C1017-85, circuit 33 (WH/PK) (circuit 32
[RD/LB] manual transmission only) and ground while holding the
key in the START position and with the clutch pedal, if
equipped, fully depressed.
Yes
GO to A12.
No
Vehicles equipped with an automatic
transmission, GO to A4. Vehicles
equipped with a manual transmission, GO
Is the voltage greater than 10 volts? to A7.
A4 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR (AUTOMATIC TRANSMISSION ONLY)
Disconnect: Digital TR Sensor C167.
(Continued)
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A4 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR (AUTOMATIC TRANSMISSION ONLY) (Continued)
Measure the voltage between digital TR sensor C167-10, circuit
32 (RD/LB) and ground while holding the key in the START
position.
Yes
GO to A5.
No
Is the voltage greater than 10 volts? GO to A8.
A5 CHECK CIRCUIT 33 (WH/PK) FOR AN OPEN
Measure the resistance between digital TR sensor C167-12,
circuit 33 (WH/PK) and the BEC starter motor relay C1017-85,
circuit 33 (WH/PK).
Yes
GO to A6.
No
REPAIR circuit 33 (WH/PK). TEST the
Is the resistance less than 5 ohms? system for normal operation.
(Continued)
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A6 CHECK DIGITAL TR SENSOR ADJUSTMENT
Carry out the digital TR sensor adjustment. Refer to Section Yes
307-01. INSTALL a new digital TR sensor. TEST
Is the digital TR sensor adjusted correctly? the system for normal operation.
No
ADJUST the digital TR sensor as
operation.
A7 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE CLUTCH
PEDAL POSITION (CPP) SWITCH
Disconnect: CPP Switch C257.
Measure the voltage between CPP switch C257-1, circuit 32
(RD/LB) and ground while holding the key in the START
position.
Yes
GO to A11.
No
A8 CHECK CIRCUIT 1522 (DG) FOR AN OPEN
Disconnect: SJB Fuse 21.
Measure the voltage between SJB fuse 21, circuit 1522 (DG)
and ground while holding the key in the START position.
Yes
REPAIR circuit 32 (RD/LB). TEST the
No
A9 CHECK CIRCUIT 1050 (LG/PK) FOR VOLTAGE
(Continued)
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A9 CHECK CIRCUIT 1050 (LG/PK) FOR VOLTAGE (Continued)
Measure the voltage between ignition switch C250-4, circuit
1050 (LG/PK) and ground.
Yes
GO to A10.
No
REPAIR circuit 1050 (LG/PK). TEST the
Is the voltage greater than 10 volts? system for normal operation.
Measure the resistance between ignition switch C250-7, circuit Yes
1522 (DG) and SJB fuse 21. INSTALL a new ignition switch. REFER to
Is the resistance less than 5 ohms? Section 211-05. TEST the system for
normal operation.
No
REPAIR circuit 1522 (DG). TEST the
A11 CHECK CIRCUIT 32 (RD/LB) FOR AN OPEN
(Continued)
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A11 CHECK CIRCUIT 32 (RD/LB) FOR AN OPEN (Continued)
Measure the resistance between CPP switch C257-2, circuit 32
(RD/LB) and the BEC starter motor relay C1017-85, circuit 32
(RD/LB).
Yes
INSTALL a new CPP switch. REFER to
normal operation.
No
REPAIR circuit 32 (RD/LB). TEST the
A12 CHECK THE STARTER MOTOR RELAY GROUND CIRCUIT FOR
AN OPEN
(Continued)
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A12 CHECK THE STARTER MOTOR RELAY GROUND CIRCUIT FOR
AN OPEN (Continued)
Measure the voltage between the BEC starter motor relay
C1017-86, circuit 1419 (LG/YE) and starter motor relay
C1017-85, circuit 33 (WH/PK) (circuit 32 [RD/LB] manual
transmission only) while holding the key in the START position
and clutch pedal, if equipped, fully depressed.
Yes
INSTALL a new starter motor relay. TEST
No
A13 CHECK CIRCUIT 1419 (LG/YE) FOR AN OPEN
Disconnect: PCM C175B.
(Continued)
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A13 CHECK CIRCUIT 1419 (LG/YE) FOR AN OPEN (Continued)
Measure the resistance between PCM C175B-2, circuit 1419
(LG/YE) and the BEC starter relay C1017-86, circuit 1419
(LG/YE).
Yes
INSTALL a new PCM. REFER to Section
operation.
No
REPAIR circuit 1419 (LG/YE). TEST the
Pinpoint Test B: The Engine Does Not
Crank/The Relay Does Click
Normal Operation
(LG/YE).
For automatic transmission equipped vehicles,
Possible Causes
Fuse(s) (RD/LB). In PARK or NEUTRAL, voltage is
An open in circuit 1050 (LG/PK), 1522 (DG), 32
(RD/LB), 33 (WH/PK) or 1419 (LG/YE)
Powertrain control module (PCM)
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Digital transmission range (TR) switch
Ignition switch
Starter motor relay
Clutch pedal position (CPP) switch
PINPOINT TEST B: THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK
B1 CHECK THE VOLTAGE TO THE STARTER RELAY
Measure the voltage between the BEC starter relay C1017-30
and ground.
Yes
GO to B2.
No
INSTALL a new BEC. TEST the system
Is the voltage greater than 10 volts? for normal operation.
(Continued)
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PINPOINT TEST B: THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK (Continued)
B2 CHECK THE VOLTAGE TO THE STARTER MOTOR SOLENOID
Measure the voltage between starter motor solenoid positive
terminal and ground.
Yes
GO to B3.
No
REPAIR circuit 2037 (RD) for an open.
Is the voltage 10 volts or greater? TEST the system for normal operation.
B3 MANUALLY JUMP THE STARTER MOTOR
Connect one end of a fused (15A) jumper wire to the positive
terminal of the battery and touch the other end to the starter
solenoid S-terminal.
Yes
GO to B4.
No
INSTALL a new starter motor. REFER to
Starter Motor 4.0L SOHC or Starter
Motor 4.6L (3V) or Starter Motor
5.4L (4V) in this section. TEST the system
Does the starter solenoid engage? for normal operation.
B4 TEST THE STARTER MOTOR RELAY
Carry out the relay component test on the starter motor relay. Yes
Refer to Wiring Diagrams Cell 149 for component testing. REPAIR circuit 113 (YE/LB) for an open.
Does the starter motor relay test good? TEST the system for normal operation.
No
INSTALL a new starter motor relay. TEST
Pinpoint Test C: The Engine Cranks Slowly
For automatic transmission equipped vehicles,
(RD/LB). In PARK or NEUTRAL, voltage is
Normal Operation
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Possible Causes
Fuse(s)
Circuit 2037 (RD)
Ground circuit
Starter motor
(LG/YE).
PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
C1 CHECK THE VOLTAGE TO THE STARTER
Measure the voltage between starter motor solenoid positive
terminal and ground.
Yes
GO to C2.
No
REPAIR circuit 2037 (RD). CLEAN and
TIGHTEN the connections at the battery
terminals. TEST the system for normal
Is the voltage 12.5 volts or greater? operation.
C2 CHECK MOTOR GROUND CIRCUIT
Carry out the Motor Ground Circuit test. Refer to Component Yes
Tests in this section. INSTALL a new starter motor. TEST the
Is the ground OK? system for normal operation.
No
REPAIR the ground circuit as necessary.
Pinpoint Test D: Unusual Starter Noise
Starter motor drive
Possible Causes Flywheel or flexplate ring gear
Starter motor
Starter motor mounting
Starter motor mounting bolts
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PINPOINT TEST D: UNUSUAL STARTER NOISE
D1 CHECK THE STARTER MOTOR MOUNTING
Inspect the starter motor mounting for cracks. Yes
Check the starter motor mounting bolts for looseness. GO to D2.
Is the starter motor mounted correctly?
No
REINSTALL the starter motor correctly.
REFER to Starter Motor 4.0L SOHC or
Starter Motor 4.6L (3V) or Starter
Motor 5.4L (4V) in this section.
D2 INSPECT THE STARTER MOTOR
Remove the starter motor. Refer to Starter Motor 4.0L SOHC Yes
or Starter Motor 4.6L (3V) or Starter Motor 5.4L (4V) in INSTALL a new starter motor. TEST the
this section. system for normal operation.
Inspect the starter motor for damage.
No
Is the starter motor damaged?
CHECK the starter drive. REFER to
Component Tests, Starter Drive Test in
this section. INSTALL a new starter motor.
Component Tests Starter Motor Motor Feed Circuit
NOTE: Make all multimeter connections at the
Starter Motor Load Test
component terminal rather than the cable or wiring
WARNING: When servicing the starter
terminal.
1. Disconnect the ignition coil connector from the
the vicinity of the starter motor, be aware that
ignition coil.
2. Connect a remote starter switch between the
solenoid is electrically hot at all times.
starter solenoid S-terminal and the battery
CAUTION: A protective cap or boot is
positive (+) post.
provided over the battery input terminal on all
3. Connect the positive (+) lead of the 73 Digital
car lines and must be installed after repair. Be
Multimeter to the battery positive (+) post.
sure to disconnect the battery ground cable
Connect the negative (-) lead of the multimeter
before repairing the starter motor.
to the starter solenoid M-terminal.
1. Before carrying out this test inspection, check
4. Engage the remote starter switch. The
the battery to determine its state of charge.
multimeter reading should be 0.5 volt or less.
Carry out a load test of the battery using the
5. If the voltage at the M-terminal is greater than
Starter, Alternator, Battery, Regulator and
0.5 volt, move the multimeter negative (-) lead
Electrical Tester (SABRE). Refer to Section
to the starter solenoid B-terminal and repeat the
414-00 for the test procedure.
test.
2. Disconnect the ignition coil connector from the
6. If the voltage reading at the B-terminal is less
ignition coil.
than 0.5 volt, the problem is either in the
3. Connect the SABRE tester to the vehicle using
connections at the starter solenoid or the starter
the amperage lead clipped around the positive
solenoid.
battery cable.
7. Remove the wires at the starter solenoid B-, S-
4. Measure the amperage of the starter motor
and M-terminals. Clean the connections and
while activating the starting system.
install the cables. Repeat Steps 1 through 5
5. A correctly operating starter motor will draw
above. If the reading is still higher than 0.5 volt
from 130 to 190 amps of current.
at the M-terminal and 0.5 volt or lower at the
B-terminal, the problem is in the starter
Starter Motor Voltage Drop Tests
solenoid. Install a new starter motor. Refer to
The following test procedures will be carried out
Starter Motor 4.0L SOHC or Starter Motor
with the starter motor on the vehicle.
4.6L (3V) or Starter Motor 5.4L (4V) in
this section.
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8. If the voltage taken at the starter solenoid 5. Remove the positive lead from the starter
B-terminal is greater than 0.5 volt, the problem motor. The ejected starter drive should return to
is either the positive (+) battery cable its original position.
connection or the positive (+) battery cable.
6. If the starter drive does not eject and return to
position, replace the starter motor.
Starter Motor Motor Ground Circuit
7. Check the starter drive. It should turn freely in
NOTE: Make all multimeter connections at the
one direction, and positively engage to the
component terminal rather than the cable or wiring
armature when turned in the opposite direction.
terminal.
If not as specified, install a new starter motor.
A slow cranking condition can be caused by
resistance in the ground or return portion of the Starter Motor No Load Test
cranking circuit. Check the voltage drop in the
The starter No Load Test will identify open or
ground circuit as follows:
shorted windings and a possible rubbing starter
1. Disconnect the ignition coil connector from the motor armature or bent starter motor armature shaft.
ignition coil.
1. WARNING: Make sure that the starter
2. Connect a remote starter switch between the
motor is securely mounted on a bench
starter solenoid S-terminal and the battery
because the starter motor may move or jump
positive (+) terminal.
when it is energized.
3. Connect the positive (+) lead of a 73 Digital
Connect a fully charged battery, a Starter,
Multimeter to the starter motor housing. The
Alternator, Battery, Regulator and Electrical
connection must be clean and free of rust or
Tester (SABRE) and a remote starter switch to
grease. Connect the negative (-) lead to the
the starter motor. Connect the remote starter
negative (-) battery terminal.
switch between the battery positive (+) post and
the starter motor S-terminal. Connect the
4. Engage the remote starter switch and read the
starter motor B-terminal to the battery positive
voltage. The reading should be 0.2 volt or less.
(+) post. Connect the SABRE positive (+)
5. If the voltage drop is greater than 0.2 volt,
terminal and negative (-) terminal to the
clean the negative (-) battery cable connections
corresponding battery post. Make sure that the
at the battery and chassis. Also, clean the
battery and starter motor are grounded.
engine ground cable connection at the cable
2. Engage the remote starter switch.
mounting bracket. If the voltage drop is still
excessive, repair or install a new battery
3. The starter motor should eject the starter drive
ground cable.
and run smoothly. If the starter motor does not
run smoothly, install a new starter motor.
Starter Motor Starter Drive Test
4. While the starter motor is running, check the
1. Remove the starter motor. Refer to Starter
voltmeter and ammeter.
Motor 4.0L SOHC or Starter Motor 4.6L
5. The voltage should be greater than 11.0 volts
(3V) or Starter Motor 5.4L (4V) in this
and the amperage should be no more than 70
section.
amps.
2. Secure the starter motor in a vise.
6. If the voltage is lower than the 11.0 volts, or
3. Connect the battery ground cable of a fully
the amperage is higher than 70 amps, install a
charged battery to the case of the starter motor.
new starter motor.
4. CAUTION: Do not leave the positive
lead of the battery connected to the starter
motor S-terminal for more than 10 seconds.
Touch the positive lead from the battery to the
S-terminal and verify that the starter drive
ejects.
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303-07A-1 303-07A-1 Engine Ignition 4.0L SOHC
Engine Ignition Components
Exploded View
4 12297 Spark plug wire retainer 1 14A464 Ignition coil electrical
connector
5 12286 Spark plug wire-to-spark plug
(6 required) 2 18801 Radio ignition interference
capacitor
3 12286 Spark plug wire-to-ignition
7 W706216 Ignition coil bolt (4 required)
coil
(Continued)
(Continued)
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8 12029 Ignition coil 11 W500041 Ignition coil
bracket-to-cylinder head bolt
9 W500214 Ignition coil bracket-to-intake
(2 required) (M12)
manifold bolt (2 required)
10 W500023 Ignition coil
1. For additional information, refer to the bracket-to-cylinder head bolt
(M8) procedures in this section.
(Continued)
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Coil Terminal-To-Cylinder Relationship
Engine Ignition
The ignition system consists of the:
crankshaft position (CKP) sensor.
ignition coil.
spark plug wire.
spark plug.
The ignition system is:
an electronic distributorless ignition system
(EDIS) controlled by an electronic engine control
integrated into the powertrain control module
(PCM).
set at 10 degrees before top dead center (BTDC)
for base timing, and is not adjustable.
The crankshaft position (CKP) sensor:
is a variable reluctance sensor.
senses a missing tooth on the crankshaft damper
pulse ring.
generates a crankshaft position signal which is
sent to the PCM. The PCM counts this signal for
engine rpm.
The ignition coil:
changes low voltage pulses from the PCM to high
voltage pulses.
has 3 transformers.
fires 2 spark plugs simultaneously.
Spark plug wires carry high voltage pulses from the
ignition coil to the spark plugs.
The spark plugs:
change high voltage pulses to spark at the gap,
which ignites the fuel and air mixture.
The firing order is: 1-4-2-5-3-6.
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Engine Ignition
(PC/ED) manual.
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4. Remove the 4 bolts and the ignition coil.
Ignition Coil
5. NOTE: Be sure to reinstall the radio ignition
interference capacitor under the correct
mounting bolt.
2. Disconnect the electrical connector from the
ignition coil.
3. CAUTION: It is important to twist the
wires.
CAUTION: Spark plug wires must be
connected to the correct ignition coil
terminal.
Disconnect the 6 spark plug wires from the
ignition coil.
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Spark Plug Wires 4. CAUTION: It is important to twist the
to avoid possible damage to the spark plug Special Tool(s)
wire.
Using the special tool, remove the spark plug 303-106 (T74P-6666A)
wire from the spark plug using a twisting
motion.
Material
Item Specification
Compound
XG-3-A
5. CAUTION: Make sure the spark plug
boots are positioned so that the spark plug
2. CAUTION: Spark plug wires must be wires do not contact the exhaust manifold, or
connected to the correct ignition coil any sharp edges.
terminal.
NOTE: Apply silicone brake caliper grease and
Disconnect the spark plug wires from the dielectric compound to the inside of the spark
ignition coil. plug wire-to-boots.
3. Detach the spark plug wire retainers.
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Spark Plugs
Special Tool(s)
303-106 (T74P-6666A)
Material
Item Specification
3. NOTE: Use compressed air to remove any
foreign material in the spark plug well before Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric removing the spark plugs.
Compound
XG-3-A
Installation
Removal
1. Install the 6 spark plugs.
additional information, refer to Section 414-01. Tighten to 17 Nm (13 lb-ft).
2. Apply silicone brake caliper grease and
2. CAUTION: Spark plug wires must be
dielectric compound to the inside of the spark
connected to the correct spark plug.
plug wire-to-boots.
CAUTION: It is important to twist the
3. CAUTION: Make sure the spark plug
boots are positioned so that the spark plug
wire.
wires do not contact the exhaust manifold, or
Using the special tool, remove the spark plug
any sharp edges.
wires from the spark plugs using a twisting
motion.
plugs.
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SPECIFICATIONS
Spark plugs 17 13
Item Specification
Ignition coil bolts 6 53
Base ignition timing
Ignition coil 23 17
Firing order 1-4-2-5-3-6 bracket-to-cylinder
head bolt (M8)
Spark plug gap 1.32-1.42 mm
(0.052-0.056 in) Ignition coil 80 59
bracket-to-cylinder
Spark plug type AGSF24N
head bolts (M12)
Ignition coil 8 71
bracket-to-intake
Compound XG-3-A
manifold bolts
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303-07B-1 303-07B-1 Engine Ignition 4.6L (3V)
Exploded View
1 14A464 Ignition coil-on-plug electrical
connector (8 required)
2 W706175 Ignition coil-on-plug bolt (8
required)
3 12A366 Ignition coil-on-plug (8
required)
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The 8 separate ignition coils:
Engine Ignition
The electronic ignition system is a coil-on-plug
change low voltage to high voltage pulses based
ignition system. The coil-on-plug ignition system
on signals from the PCM.
consists of the following components:
produce the high voltage pulses to the spark
plugs.
Crankshaft position (CKP) sensor
are connected directly to each spark plug.
Ignition coils
The spark plug:
Spark plugs
The CKP sensor:
change high voltage pulses into a spark which
ignites the fuel and air mixture.
originally equipped on the vehicle have a
is triggered by a 36-minus-1 tooth sensor ring
platinum-enhanced active electrode for long life.
mounted on the crankshaft.
provides base timing and crankshaft speed (rpm)
to the powertrain control module (PCM).
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Engine Ignition
(PC/ED) manual.
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3. Remove the ignition coil bolts.
Ignition Coil-On-Plug
Material
4. NOTE: When removing the ignition coils, a
Item Specification
ease removal.
Remove the ignition coils. Compound
XG-3-A
Apply a light film of brake caliper grease to
the inside of the coil boots before
installation.
2. Disconnect the ignition coil electrical
connectors.
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4. NOTE: When removing the ignition coils, a
Spark Plugs
ease removal.
Material
Remove the ignition coils.
Item Specification
foreign material from the spark plug well before
Compound
removing the spark plugs.
XG-3-A
Remove the spark plugs.
Apply a light film of silicone brake caliper
grease and dielectric compound to the inside
2. Disconnect the ignition coil electrical
of the coil boots before installation.
connectors.
3. Remove the ignition coil bolts.
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SPECIFICATIONS
Item Specification
Firing order 1-3-7-2-6-5-4-8
Item Specification
Spark plug type PZT1F
Lubricants and Chemicals
Compound XG-3-A
Engine Ignition
Spark plugs 34 25
Base ignition timing 10 degrees BTDC
Coil on plug bolts 5 44
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303-07C-1 303-07C-1 Engine Ignition 5.4L (4V)
Exploded View
LH Ignition Components
4 12A366 Ignition coil-on-plug (4 1 W701621 Ignition coil-on-plug cover
required) bolt (2 required)
5 12405 Spark plug (4 required) 2 6P067 Ignition coil-on-plug cover
3 14A464 Ignition coil-on-plug electrical
of 12B637)
(Continued)
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RH Ignition Components
5 14A464 Ignition coil-on-plug electrical 1 W706827 Wire harness retainer (part of
connector (4 required) (part 12B637)
of 12B637)
2 W712595 Ignition coil-on-plug cover
6 12A366 Ignition coil-on-plug (4 stud bolt
required)
3 W701624 Ignition coil-on-plug cover
7 12405 Spark plug (4 required) bolt
4 6P068 Ignition coil-on-plug cover
(Continued) 1. For additional information, refer to the
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The CMP sensor:
Engine Ignition
The electronic ignition (EI) system is a coil-on-plug
is mounted on the LH side of the front cover.
ignition system. The coil-on-plug ignition system
sends the PCM a signal indicating camshaft
consists of the following components:
position used for fuel and spark synchronization.
Crankshaft position (CKP) sensor
The 8 separate ignition coils:
Camshaft position (CMP) sensor
convert low voltage signals from the PCM to high
Ignition coils
voltage pulses.
Spark plugs
produce the high voltage pulses for the spark
plugs.
The CKP sensor:
are connected directly to each spark plug.
The spark plugs:
is mounted to the lower RH side of the front
cover.
convert a high voltage pulse into a spark which
ignites the fuel and air mixture.
is triggered by a 36-minus-1 tooth trigger wheel
mounted on the crankshaft.
originally installed on the vehicle have a
platinum-enhanced active electrode for long life.
provides base timing and crankshaft speed (rpm)
to the powertrain control module (PCM).
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Engine Ignition
(PC/ED) manual.
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RH ignition coil-on-plugs
Ignition Coil-On-Plug
6. Detach the wire harness retainer from the stud
Material
bolt and position the harness aside.
Item Specification
7. Remove the bolt, stud bolt and the RH ignition
coil-on-plug cover.
Compound
Inspect the gasket. Install a new gasket if XG-3-A
necessary.
All ignition coil-on-plugs
8. Disconnect the 4 RH ignition coil-on-plug
additional information, refer to Section 414-01. 9. Remove the 4 RH ignition coil-on-plugs, using
a twisting motion while pulling up on the
LH ignition coil-on-plugs
ignition coil-on-plug.
All ignition coil-on-plugs
2. Remove the air cleaner inlet tube. For
10. NOTE: Verify that the ignition coil-on-plug
3. Remove the 2 bolts and the LH ignition
spring is correctly located inside the ignition
coil-on-plug cover.
coil-on-plug boot and that there is no damage to
the tip of the boot.
Inspect the gasket. Install a new gasket if
necessary.
Apply a light coat of dielectric grease to the
inside of the ignition coil-on-plug boots.
4. Disconnect the 4 LH ignition coil-on-plug
5. Remove the 4 LH ignition coil-on-plugs, using
a twisting motion while pulling up on the
ignition coil-on-plug.
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3. Inspect the spark plugs. Install new spark plugs
Spark Plugs
as necessary. For additional information, refer
to Section 303-00.
4. Adjust the spark plug gap as necessary.
1. Remove the ignition coil-on-plugs. For
additional information, refer to Ignition
Coil-On-Plug in this section.
foreign material from the spark plug well before
removing the spark plugs.
NOTE: If an original spark plug is used, make
sure it is installed in the same cylinder from
which it was taken. New spark plugs can be
used in any cylinder.
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SPECIFICATIONS
Spark plugs 18 13
Item Specification
Ignition coil cover 10 89
Silicone Brake Caliper ESE-M1C171-A bolts
Compound XG-3-A
Base ignition timing 10 degrees BTDC
non-adjustable
Firing order 1-3-7-2-6-5-4-8
Spark plug gap 1.04-1.20 mm
(0.041-0.047 in)
Spark plug type AGSF-22FM1
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303-08-1 303-08-1 Engine Emission Control
The PCV valve:
Engine Emission Control
controls the amount of ventilating air and blow-by
CAUTION: Do not remove any part of the
gases going to the intake manifold.
engine emission control system. Operating the
engine without the engine emission control
The EGR system module-to-exhaust manifold tube:
system will reduce fuel economy and engine
connects the exhaust manifold to the EGR valve.
ventilation. This will weaken engine performance
and shorten engine life. The EGR system module transducer:
The engine emission control system consists of the:
monitors the EGR system module flow rate
through the EGR-to-exhaust manifold tube.
positive crankcase ventilation (PCV) system.
sends an EGR system module flow rate signal to
exhaust gas recirculation (EGR) system.
the PCM.
The EGR system returns a portion of the exhaust
The EGR vacuum regulator solenoid uses input
gas to the intake manifold to reduce the combustion
from the PCM to change the EGR system module
temperature. This results in lower nitrous oxide
operation.
formation.
EGR vacuum regulator solenoid. The EGR vacuum
regulator solenoid controls the vacuum to the EGR
valve. When the EGR valve opens, exhaust gas
flows to the intake manifold. The EGR transducer
measures the flow through the EGR system module
to exhaust manifold tube and sends a signal to the
powertrain control module.
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Engine Emission Control
(PC/ED) manual.
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Exhaust Gas Recirculation (EGR)
System Components Exploded
View
4.0L SOHC Engine
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4 EGR system 1 14A464 Exhaust gas recirculation
module-to-exhaust manifold (EGR) system module
tube lower fitting (part of electrical connector
9E469)
2 9E498 Engine vacuum harness
5 9D477 EGR system module tube connector-to-EGR system
module
6 W500224 EGR system module bolts (2
required) 3 EGR system
module-to-exhaust manifold
7 9Y456 EGR system module
tube upper fitting (part of
9E469)
(Continued)
5.4L 4V Engine
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5 9D477 EGR system module tube 1 14A464 EGR system module electrical
connector
6 W500224 EGR system module bolts (2
required) 2 9E498 Engine vacuum harness
connector-to-EGR system
7 9Y456 EGR system module
module
3 EGR system
1. For additional information, refer to the tube upper fitting (part of
9E469) procedures in this section.
4 EGR system
tube lower fitting (part of
9E469)
(Continued)
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3. Disconnect the EGR system module
Exhaust Gas Recirculation (EGR)
tube-to-exhaust manifold tube lower fitting and
System Module Tube
remove the tube.
To install, tighten to 39 Nm (29 lb-ft) (4.6L
3V).
Vehicles with 5.4L 4V engine
4V).
1. Remove the battery tray. For additional
All vehicles
system module-to-exhaust manifold tube upper
fitting.
3V).
4V).
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Exhaust Gas Recirculation (EGR) 5. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive disc or other System Module
to remove all traces of the old gasket.
NOTE: The EGR system module sealing
surfaces are soft metals.
Carefully clean the EGR system module sealing
system module vacuum tube and electrical
surfaces.
connector.
3. Disconnect the EGR system module-to-exhaust
Install a new gasket with the raised circle
manifold tube upper fitting.
facing away from the EGR system module.
3V).
4V).
4. NOTE: Upon installation, make sure to install
the correct EGR system module mounting
gasket. Even though varying gaskets may be
very similar, orifice sizes may differ thus
causing performance issues.
Remove the 2 bolts, the EGR system module
and the gasket. Discard the gasket.
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Positive Crankcase Ventilation (PCV)
Valve
4.0L SOHC engine
(PCV) valve electrical
connector
2 PCV valve tube-to-PCV valve
3 6A666 PCV valve
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5.4L 4V engine
4. CAUTION: A new PCV valve must be (PCV) valve electrical
connector installed if removed. Upon removal, the
plastic retaining ears of the PCV valve are 2 PCV valve tube-to-PCV valve
quick connect coupling (part sheared.
of 6K817)
Rotate the PCV valve counterclockwise to
3 6A666 PCV valve
remove from the valve cover.
Discard the PCV valve.
Install a new PCV valve.
2. Disconnect the PCV valve tube-to-PCV valve
quick connect coupling. For additional
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SPECIFICATIONS
EGR system 42 31
Description Nm lb-ft module-to-exhaust manifold
tube lower fitting (5.4L 4V)
Exhaust gas recirculation 25 18
(EGR) system module bolts EGR system 42 31
EGR system 39 29
tube upper fitting (5.4L 4V)
tube lower fitting (4.6L 3V)
EGR system 39 29
tube upper fitting (4.6L 3V)
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303-12-1 303-12-1 Intake Air Distribution and Filtering
All vehicles
Air Cleaner Outlet Pipe
3. Loosen the 2 clamps and remove the air cleaner
All vehicles
outlet pipe.
1. Disconnect the crankcase vent tube from the air
cleaner outlet pipe.
All vehicles with 5.4L (4V)
2. Disconnect the vacuum tube from the air
cleaner outlet pipe.
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5. NOTE: Make sure that the 2 air cleaner
Air Cleaner
assembly feet rubber grommets are seated into
the locating holes in the fender.
NOTE: The air cleaner outlet pipe should be
securely sealed to prevent unmetered air from
1. Loosen the clamp and disconnect the air cleaner
entering the engine.
outlet pipe from the air cleaner assembly.
2. Disconnect the mass air flow (MAF) sensor
3. Remove the air cleaner assembly bolt.
4. NOTE: Make sure that the 2 rubber grommets
are retained to the air cleaner assembly feet.
Remove the air cleaner assembly.
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Charge Air Cooler
Material
Item Specification
TA-25
Engine Coolant with
(yellow color)
6 9E436 Lower intake manifold cover 1 N807071 Charge air cooler (CAC)
gasket coolant tube assembly bolt (4
required)
7 N802927 CAC tube O-ring seal (4
required) 2 6F077 CAC coolant tube assembly
8 9L442 CAC coolant connector tube 3 9L438 CAC coolant tube assembly
(2 required) gasket
9 N605892 CAC bolt (10 required) 4 W704682 Lower intake manifold cover
bolt (13 required)
10 6K775 CAC
5 9K461 Lower intake manifold cover
(Continued)
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Removal
2. NOTE: Inspect the lower intake manifold cover
gasket. Install a new gasket if necessary.
Position the gasket and the lower intake
manifold cover, and install the bolts.
2. Remove the 4 bolts and the charge air cooler
(CAC) coolant tube assembly.
3. Remove the 2 CAC coolant connector tubes and
the 4 O-rings.
Discard the O-rings.
4. Remove the 13 bolts and the lower intake
manifold cover and gasket.
5. Remove the 10 bolts and the CAC.
Installation
1. NOTE: Apply threadlock and sealer to the
CAC bolts prior to installation.
3. Apply clean engine coolant to the new CAC
Position the CAC and install the bolts.
coolant connector tube O-rings, and install them
on the CAC coolant connector tubes.
2 stages:
4. Install the CAC coolant connector tubes.
5. NOTE: Inspect the CAC coolant tube assembly
and gasket. Install a new gasket if necessary.
Position the gasket and the CAC coolant tube
assembly, and install the bolts.
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The supercharger system is a blow-through type
Intake Air Distribution and Filtering
with the fuel injected directly into the intake ports.
Supercharger, Charge Air Cooler
The supercharger is belt driven off the crankshaft
The air intake system consists of the:
through an idler pulley. The throttle body controls
the amount of intake air to the supercharger
air cleaner (ACL).
through the intake plenum. Air from the
ACL element.
supercharger is routed through the charge air cooler
mass air flow (MAF) sensor.
(CAC), then to the intake manifold. The resulting
denser air charge in the combustion chamber
air cleaner outlet pipe.
provides for a higher power output of the engine
air cleaner and duct assembly.
over a non-supercharged engine or the same
The air intake system:
displacement.
cleans intake air with an air cleaner element.
NOTE: It is not possible to increase manifold
pressure or engine power output by altering the
measures air flow with a MAF sensor. For
bypass valve or the actuator.
At partial-throttle opening or when vacuum is
The supercharger (SC) is a positive displacement
present in the intake system, a vacuum controlled
pump. Its purpose is to supply an excess volume of
bypass valve reroutes some discharged air from the
intake air to the engine by increasing air pressure
supercharger back through the intake plenum. This
and density in the intake manifold. The supercharger
prevents the supercharger from cavitating, causing
is matched to the engine by its displacement and
reduced performance, increased temperatures and
belt ratio, and can provide excess airflow at any
poor economy.
engine speed.
The supercharger has a self-contained oiling system
NOTE: The supercharger is repaired only as an
that does not require a fluid change for the life of
assembly. Disassembly of the supercharger unit may
the vehicle. However, at every 30,000 mile interval,
void the warranty.
the supercharger fluid level should be checked. The
NOTE: The supercharger is not a bolt-on option. It
vehicle should be parked on a level surface, the
is part of a integrated engine system. Many
engine cool and not running. To check the oil,
components of the supercharged engine are not
remove the Allen head plug located at the front of
interchangeable with similar parts from a
the supercharger. The oil level should be at the
non-supercharged engine.
bottom of the fill plug threads when cold. If the
The supercharger contains two 3-lobed rotors. The
fluid level is low, add Synthetic Supercharger Fluid
helical shape and specialized porting provide a
Motorcraft XL-4 or equivalent meeting Ford
smooth discharge flow and low level of noise
specification ESE-M99C115-A. Supercharged
during operation. The rotors are supported by ball
vehicles are equipped with a CAC. The CAC cools
bearings in front and needle bearings at the rear.
the pressurized air from the supercharger, increasing
The drive gears are pressed into place, therefore the
the air density, which improves combustion
supercharger is installed new as a unit, and is not
efficiency, engine horsepower and torque.
repairable.
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The air intake system consists of the:
air cleaner (ACL).
ACL element.
air cleaner outlet pipe.
The air intake system:
cleans intake air with an ACL element.
measures air flow with a MAF sensor. For
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(PC/ED) manual.
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Intake Air System Components
Exploded View, 4.0L SOHC
5 14A464 Mass air flow (MAF) sensor 1 9C632 Air cleaner outlet pipe clamp
2 67582 Crankcase vent tube
6 9661 Air cleaner cover (part of
3 9B659 Air cleaner outlet pipe
9A600)
4 9C632 Air cleaner outlet pipe clamp
7 9601 Air cleaner element
(Continued)
8 W505427 Air cleaner assembly bolt
(Continued)
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9 9A600 Air cleaner assembly
10 9P686 Air cleaner assembly
grommet
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Exploded View, 4.6L (3V)
5 14A464 Mass air flow (MAF) sensor 1 9C632 Air cleaner outlet pipe clamp
2 6758 Crankcase vent tube
6 9661 Air cleaner cover (part of
3 9B659 Air cleaner outlet pipe
9A600)
4 9C632 Air cleaner outlet pipe clamp
(Continued)
8 W505427 Air cleaner assembly bolt
(Continued)
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10 9P686 Air cleaner assembly
grommet
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Exploded View, 5.4L (4V)
4 9C632 Air cleaner outlet pipe-to-air 1 9C632 Air cleaner outlet
cleaner clamp pipe-to-throttle body clamp
5 9E498 Vacuum tube-to-air cleaner 2 6758 Crankcase vent tube-to-air
outlet pipe cleaner outlet pipe
6 9643 Air cleaner cover (part of 3 9R504 Air cleaner outlet pipe
9A600)
(Continued)
(Continued)
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7 14A464 Mass air flow (MAF) sensor 11 9P686 Air cleaner assembly
electrical connector gronment
1. For additional information, refer to the 9 W505427 Air cleaner assembly bolt
(Continued)
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Torque Specifications Torque Specifications
SPECIFICATIONS
General Specifications Lubricants and
Air cleaner outlet pipe clamps 3 27 Sealants
Air cleaner bolt 8 71
Item Specification
Charge air cooler (CAC) 10 89
coolant tube assembly bolts
TA-25
Lower intake manifold cover
bolts
a
Engine Coolant with
Bittering Agent (US only) CAC bolts
a

Supercharger bolts
a

(yellow color)
Synthetic Supercharger ESE-M99C115-A
Fluid XL-4
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Supercharger
Removal
1 9E498 Supercharger bypass vacuum
1. Disconnect the battery ground cable. For actuator vacuum connector
2 6C324 Supercharger bubbler hose
3 N806177 Supercharger bolt (10
required)
4 6F066 Supercharger
5 9H486 Supercharger gasket
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2. Rotate the drive belt tensioner clockwise and 7. Remove and discard the supercharger gasket.
detach the drive belt from the supercharger
Cover the lower intake manifold with a shop
pulley.
towel to prevent foreign material from
falling into the engine.
Installation
1. NOTE: Install a new gasket.
Position the supercharger gasket on the lower
intake manifold dowels.
2. Position the supercharger and install the bolts.
2 stages:
system module. For additional information, refer 3. Connect the supercharger bubbler hose and the
to Section 303-08 supercharger bypass vacuum actuator vacuum
connector.
4. Remove the fuel rail. For additional
information, refer to Section 303-04C. 4. Install the fuel rail. For additional information,
refer to Section 303-04C.
5. Disconnect the supercharger bubbler hose and
the supercharger bypass vacuum actuator 5. Install the EGR system module. For additional
vacuum connector. information, refer to Section 303-08
6. Remove the 10 bolts and the supercharger.
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6. Rotate the drive belt tensioner clockwise and 7. Connect the battery ground cable. For additional
attach the drive belt to the supercharger pulley. information, refer to Section 414-01.
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303-13-1 303-13-1 Evaporative Emissions
Dust Separator
3 9K324 Dust separator outlet tube 1 Evaporative emission (EVAP)
canister vapor tube-to-EVAP
4 9K313B Dust separator inlet tube
canister quick connect
5 9B328 Dust separator
coupling (part of 9K313A)
2 9K313A EVAP canister vapor tube
(Continued)
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3. Remove the EVAP canister vapor tube.
4. Disconnect the dust separator inlet and outlet
WARNING: The evaporative emission
vapor tubes.
system contains fuel vapor and condensed fuel
vapor. Although not in large quantities, it still
5. Remove the EVAP canister dust separator from
presents the danger of explosion or fire.
the canister assembly.
Disconnect the battery ground cable from the
battery to minimize the possibility of an
electrical spark occurring, possibly causing a fire
or explosion if fuel vapor or liquid fuel is present
7. Carry out the evaporative emission system leak
in the area. Failure to follow these instructions
test. For additional information, refer to
Evaporative Emission System Leak Test in this
section.
1. Remove the evaporative emission (EVAP)
canister. For additional information, refer to
8. Carry out the evaporative emission repair
Evaporative Emission Canister in this section.
verification drive cycle. For additional
information, refer to Powertrain
2. Disconnect the EVAP canister vapor
Control/Emissions Diagnosis (PC/ED) manual
tube-to-EVAP canister quick connect coupling.
in this section.
310-00.
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Evaporative Emission Canister Purge
Valve
3 Vapor tube-to-EVAP canister 1 14A464 Evaporative emission (EVAP)
purge valve quick connect canister purge valve electrical
coupling (part of 9J280) connector
4 9G683 EVAP canister purge valve 2 Vapor tube-to-EVAP canister
purge valve quick connect
coupling (part of 9G271)
(Continued)
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4. Depress the release tab and remove the EVAP
canister purge valve from the mounting bracket.
canister purge valve electrical connector.
3. NOTE: The upper vapor tube has an
identification tag attached on the end of tube
section.
near the quick connect coupling. If this vapor
tube is removed or replaced make sure that the
end with the identification tag is reconnected to
the upper EVAP canister purge valve port.
information, refer to the Powertrain
Disconnect the 2 vapor tube-to-EVAP canister
purge valve quick connect couplings. For
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Evaporative Emission Canister Vent
Solenoid
3 9K318 EVAP canister vent solenoid 1 Evaporative emission (EVAP)
inlet vapor tube canister vapor tube-to-EVAP
canister quick connect
4 9K313B EVAP canister vent solenoid
coupling (part of 9K313A)
outlet vapor tube
2 9K313A EVAP canister vapor tube
5 9F945A EVAP canister vent solenoid
(Continued)
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3. Remove the EVAP canister vapor tube.
4. Disconnect the EVAP canister vent solenoid
inlet vapor tube.
5. Disconnect the EVAP canister vent solenoid
outlet vapor tube.
6. Remove the EVAP canister vent solenoid from
the canister assembly.
1. Remove the evaporative emission (EVAP)
canister. For additional information, refer to
Evaporative Emission Canister in this section.
section.
tube-to-EVAP canister quick connect coupling.
310-00.
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Evaporative Emission Canister
3 Fuel vapor control tube 1 14A464 Evaporative emission (EVAP)
assembly valve-to-EVAP canister vent solenoid
canister vapor tube quick electrical connector
connect coupling (part of
2 EVAP canister vapor
9E325)
tube-to-vapor tube quick
4 106463 Vapor tube pin-type retainer connect coupling (part of
clip (2 required) 9K313A)
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5. Disconnect the fuel vapor control tube assembly
valve-to-EVAP canister vapor tube quick
5 103435 Vapor tube retainer clip
6 N621906 EVAP canister retainer nuts
(2 required)
7 N811181S EVAP canister retainer bolts
6. If equipped, release the 2 vapor tube pin-type
(2 required)
retainers from the EVAP canister brackets.
8 9D653 EVAP canister
9 9E857 EVAP canister assembly
7. Release the vapor tube retainer clip and remove
the vapor tube from the frame.
8. Remove the 2 EVAP canister assembly
retaining nuts.
9. Remove the 2 EVAP canister assembly
retaining bolts.
10. Remove the EVAP canister assembly.
Section 100-02.
section.
canister vent solenoid electrical connector.
tube-to-vapor tube quick connect coupling. For
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GENERAL PROCEDURES
3. Connect the scan tool and energize the EVAP
Evaporative Emission System Leak
canister purge valve to the open position. For
Test
additional information, refer to the
Special Tool(s)
VACUTEC Smoke Machine 4. Using the scan tool, close the canister vent
Fuel Evaporative Emission
solenoid. For additional information, refer to the
System Tester
5. Using the smoke machine, pressurize the EVAP
system. For additional information, refer to the
6. Monitor the indicator flag on the smoke (VCM) and Integrated
Diagnostic System (IDS) machine leak tester. If the measurement is
below the indicator flag, the system has passed
the leak test and the test procedure is complete.
tool
If the measurement is above the indicator flag,
the system has failed the leak test. Proceed to
Phase 2.
Phase 1 Leak Verification
Phase 2 System Leak Check
1. Disconnect the upper vapor tube-to-evaporative
1. Introduce smoke from the smoke machine into
emission (EVAP) canister purge valve quick
the EVAP system. For additional information,
refer to the manufacturers instructions.
2. Use the halogen light provided with the smoke
2. Connect the smoke machine leak tester to the
machine to look for smoke coming from the
upper EVAP canister purge valve fitting. For
EVAP system. This would indicate a leak point.
additional information, refer to the
3. Repair any leaks as necessary.
4. Repeat the leak test until the system passes.
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The fuel tank filler cap:
Evaporative Emissions
The evaporative emission system:
relieves system vacuum below 3.8 kPa (15.26
inches H
2
O).
is equipped with an on-board refueling vapor
The canister vent solenoid:
recovery (ORVR) system.
prevents hydrocarbon emissions from reaching the
is normally open.
atmosphere.
seals the EVAP system for the inspection and
stores fuel vapors in the evaporative emission
maintenance (I/M 240) test and OBDII leak and
(EVAP) canister that are generated during vehicle
pressure tests.
operation or hot soak, or vehicle refueling, until
is mounted to the evaporative emission canister.
they can be consumed by the engine.
is repaired as a separate item.
routes the stored fuel vapors to the engine during
The evaporative emission (EVAP) canister purge
engine operation.
valve:
is controlled by the powertrain control module
is normally closed.
(PCM) which uses various sensor inputs to
calculate the desired amount of purge flow. The
regulates purging of the EVAP canister.
PCM regulates the purge flow, induced by the
is controlled by the PCM.
application of intake manifold vacuum, by varying
is located on the left front inner fender well.
the duty cycle applied to the EVAP canister
purge valve.
The fuel vapor control valve tube assembly:
The fuel vapors are routed:
consists of the fuel vapor control valve and an
in-line fuel tank pressure sensor.
from the fuel tank through the fuel vapor control
valve.
prevents suspended liquid fuel from being drawn
into the evaporative emission canister along with
to the EVAP canister through a vapor tube.
the fuel vapors.
to the engine when the EVAP canister purge
returns the liquid to the fuel tank.
valve is opened by the PCM.
includes a fresh air transfer tube routing fresh air
The fuel tank pressure (FTP) sensor:
between the canister vent solenoid hose and the
monitors the pressure levels in the fuel tank.
fuel tank filler pipe assembly.
communicates the pressure reading to the PCM
The evaporative emission (EVAP) system monitor:
during the OBDII leak test.
is a self-test strategy within the PCM, which tests
is located in-line above the fuel tank and is
the integrity of the EVAP system.
serviced as part of the fuel vapor control valve
monitors the EVAP system for leaks.
tube assembly.
monitors electronic EVAP components for
The evaporative emission canister:
irrationally high or low voltages.
is located in the center rear of the vehicle behind
monitors for correct EVAP system operation.
the fuel tank.
utilizes intake manifold vacuum to test the EVAP
contains activated carbon.
system and involves several stages.
stores fuel vapor.
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Evaporative Emissions
(PC/ED) manual.
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Fuel Vapor Tube Assembly
1 14A464 Fuel vapor control tube
assembly valve electrical WARNING: The evaporative emission
connector
2 Fuel vapor control tube vapor. Although not in large quantities, it still
assembly valve-to-fuel tank
quick connect coupling (part
of 9E325)
3 Fuel vapor control tube
assembly valve-to-EVAP
canister vapor tube quick
connect coupling (part of
may result in personal injury. 9E325)
4 106250 Pin-type retainer clip
5 106245 Separator clip
6 W504081 Fuel vapor control tube
Section 100-02.
assembly valve bracket bolt
7 9E325 Fuel vapor control tube
assembly valve
valve electrical connector.
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4. Disconnect the fuel vapor control tube assembly 8. Remove the fuel vapor control tube assembly
valve-to-fuel tank quick connect coupling. For valve.
9. To install, reverse the removal procedure
valve-to-EVAP canister vapor tube quick
section.
6. Remove the fuel vapor control tube assembly
valve bracket bolt.
7. Release the 2 fuel vapor control tube assembly
valve clips.
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SPECIFICATIONS
Evaporative emissions 9 80
(EVAP) canister bolts
EVAP canister nuts 9 80
Fuel vapor control tube 5 44
assembly valve retainer bolt
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303-14-1 303-14-1 Electronic Engine Controls
Camshaft Position (CMP) Sensor
4.0L SOHC
1 14A464 Camshaft position sensor
(CMP) electrical connector
2 W500204 CMP sensor bolt
3 6B288 CMP sensor
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4.6L (3V)
LH side
1 14A464 Camshaft position sensor
2. Remove the air cleaner outlet pipe. For (CMP) electrical connector
(part of 12B637)
2 N806155 CMP sensor bolt
Both sides
3 6B288 CMP sensor
Both sides
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5.4L (4V)
2. Disconnect the CMP sensor electrical connector.
2 N806155 CMP sensor bolt
3 6B288 CMP sensor
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Material
Catalyst Monitor Sensor 4.0L
Item Specification
SOHC
Penetrating and Lock
Lubricant
Special Tool(s)
XL-1 (US); CXC-51-A
Socket, Exhaust Gas Oxygen (Canada)
Sensor
303-476 (T94P-9472-A)
XL-2 (US); CXG-2-B
(Canada)
1 14A464 Catalyst monitor sensor
(CMS) electrical connector (2
3. Disconnect the catalyst monitor sensor (CMS)
required)
2 9F472 CMS (2 required)
Section 100-02.
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4. NOTE: If necessary, lubricate the CMS with 5. To install, reverse the removal procedure.
lock lubricant to aid in removal.
Apply a light coat of anti-seize lubricant to
Using the special tool, remove the CMS. the threads of the CMS before installing.
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Material
Catalyst Monitor Sensor 4.6L (3V),
Item Specification
5.4L (4V)
Lubricant
Special Tool(s)
XL-1 (US); CXC-51-A
Sensor
303-476 (T94P-9472-A)
XL-2 (US); CXG-2-B
(Canada)
NOTE: 4.6L (3V) shown, 5.4L (4V) similiar.
1 14A464 Catalyst monitor sensor
(CMS) electrical connector
3. Disconnect the catalyst monitor sensor (CMS)
2 9F472 CMS (2 required)
Section 100-02.
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4. NOTE: If necessary, lubricate the CMS with 5. To install, reverse the removal procedure.
penetrating and lock lubricant to aid in removal.
Using the special tool, remove the CMS. the threads of the CMS before installing.
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Charge Motion Control Valve (CMCV)
4.6L (3V)
3. NOTE: Bent shaft or damaged components will
require the intake manifold to be replaced.
1 14A464 Charge motion control valve
(CMCV) electrical connector Rotate each CMCV shaft by hand to verify that
they do not stick or bind. 2 W710420 E-clip (2 required)
3 W708165 CMCV bolt (3 required)
4. Disconnect the CMCV electrical connector.
4 CMCV bracket
5 9B841 CMCV linkage
5. Remove the 3 bolts, bracket and the CMCV.
6 9G730 CMCV
Installation
Removal
1. Position the CMCV, bracket and install the 3
bolts loosely.
Do not tighten the bolts at this time.
2. Remove and discard the 2 E-clips and
2. Rotate each CMCV shaft so that the plates are
disconnect the charge motion control valve
in the closed position.
(CMCV) linkages.
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3. Install the RH and LH CMCV plate alignment 5. Verify that the CMCV plate alignment locks are
locks. still properly located and tighten the 3 CMCV
bolts.
6. Remove the RH and LH alignment locks.
7. NOTE: Make sure that the wiring harness is
routed away from the CMCV system.
Connect the CMCV electrical connector
9. Perform the KOEO self test. For additional
4. Connect the RH and LH CMCV linkages and
install 2 new E-clips.
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Clutch Pedal Position (CPP) Switch
1 11A152 Clutch pedal position (CPP)
switch electrical connector
(part of 12638)
2 14489 CPP switch
2. Disconnect the clutch pedal position (CPP)
3. Release the CPP switch from the clutch pedal
bracket.
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Crankshaft Position (CKP) Sensor
4.0L SOHC
1 14A464 Crankshaft position (CKP)
2 W500213 CKP sensor bolt (2 required)
3 6C315 CKP sensor
4. Remove the 2 bolts and the CKP sensor.
Section 100-02.
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4.6L (3V)
of 12B637)
2 14A464 A/C compressor electrical
3 N806184 A/C compressor stud bolt (3
required)
4 19703 A/C compressor
5. Disconnect the A/C compressor field coil and
the crankshaft position (CKP) sensor electrical
(part of 12B637)
connectors.
6 N806155 CKP sensor bolt
7 6C315 CKP sensor
6. Remove the stud bolts and position the A/C
compressor aside.
1. With vehicle in NEUTRAL, position it on a
Section 100-02.
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7. Remove the CKP sensor bolt and sensor. 8. To install, reverse the removal procedure.
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5.4L (4V)
of 12B637)
3. Remove the supercharger belt. For additional
2 14A464 A/C compressor electrical
connector
3 W707821 A/C compressor stud bolt (3
required)
5. Disconnect the A/C compressor field coil and
the crankshaft position (CKP) sensor electrical
6 N806155 CKP sensor bolt
connectors.
7 6C315 CKP sensor
6. Remove the 3 studbolts and position the A/C
Removal and Installation compressor aside.
Section 100-02.
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7. Remove the CKP sensor bolt and sensor. 8. To install, reverse the removal procedure.
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Cylinder Head Temperature (CHT)
Sensor 4.6L (3V)
5. Remove and discard the CHT sensor.
1 14A464 Cylinder head temperature
(CHT) sensor electrical Do not reuse the CHT sensor, install a new
sensor.
2 6G004 CHT
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Cylinder Head Temperature (CHT)
Sensor 5.4L (4V)
1 14A464 Cylinder head temperature
(CHT) sensor electrical
3. Remove and discard the CHT sensor.
connector
2 6G004 CHT sensor To install, tighten to 26 Nm (19 lb-ft).
Do not reuse the CHT sensor, install a new
1. Remove the battery tray. For additional sensor.
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The MAF sensor:
Electronic Engine Controls
The electronic engine controls consist of the:
uses a hot wire sensing element to measure the
amount of air entering the engine. Air passing
powertrain control module (PCM).
over the hot wire causes it to cool.
throttle position (TP) sensor.
The HO2S:
camshaft position (CMP) sensor.
creates a voltage signal dependent on exhaust
crankshaft position (CKP) sensor.
oxygen content.
provides feedback information to the PCM used to
heated oxygen sensors (HO2S).
calculate fuel delivery.
catalyst monitor sensors (CMS).
The CMS:
knock sensor (KS) 4.0L SOHC and 4.6L (3V).
monitors oxygen content after it flows through the
catalytic converter.
engine coolant temperature (ECT) sensor 4.0L
provides a voltage to the PCM used to calculate
SOHC and 5.4L (4V).
catalytic converter integrity.
cylinder head temperature (CHT) sensor 4.6L
The KS:
(3V) and 5.4L (4V).
is used to detect engine detonation.
charge motion control valve (CMCV) 4.6L
sends a voltage signal to the PCM.
(3V) only.
is able to provide a signal which retards the
variable camshaft timing (VCT) oil control
ignition timing, as necessary.
solenoid 4.6L (3V) only.
manifold intake air temperature 2 (IAT2) sensor
5.4L (4V) only.
The PCM carries out the following:
accepts input from various engine sensors to
reference.
compute the fuel flow rate necessary to maintain a
The ECT sensor:
prescribed air/fuel ratio throughout the entire
engine operational range.
sends the PCM a signal indicating engine coolant
outputs a command to the fuel injectors to meter
temperature.
the appropriate quantity of fuel.
voltage decreases as coolant temperature
The TP sensor:
increases.
The CHT sensor:
sends the PCM a signal indicating the throttle
plate angle.
is mounted into the wall of the cylinder head and
is the main input to the PCM from the driver.
is not connected to any coolant passages.
The CMP sensor:
sends the PCM a signal indicating camshaft
position used for fuel synchronization.
The CKP sensor:
sends the PCM a signal indicating crankshaft
position.
is essential for calculating spark timing.
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sends the PCM a signal indicating cylinder head The CMCV assemblies are located between the
temperature. intake manifold and cylinder heads, providing 2
air passages for each cylinder.
If the temperature exceeds approximately
121C (250F) (4.6L [3V] only)/176C One air passage is always open and the other
(348F) (5.4L [4V] only), the PCM disables passage switches from closed to open by means of
half of the fuel injectors at a time. The PCM a valve plate.
will alternate which fuel injectors are disabled
The valve plates are opened and closed by the
every 32 engine cycles. The cylinders that are
CMCV electric actuator, which is controlled by
not being fuel injected act as air pumps to aid
the PCM.
in engine cooling.
The variable camshaft timing (VCT) oil control
If the temperature exceeds approximately
solenoid:
166C (330F) (4.6L [3V] only)/260C
is an electrically controlled hydraulic valve that
(500F) (5.4L [4V] only), the PCM disables
directs engine oil to the variable camshaft. Once
all of the fuel injectors until the engine
the PCM transmits a signal, the solenoid moves a
temperature drops below approximately 154C
valve spool, directing oil into the camshaft phaser
(310F) (4.6L [3V] only)/164C (328F) (5.4L
cavity. This action changes valve timing by
[4V] only).
either inducing an advance or retard condition.
The coolant temperature gauge pointer will
The camshaft is, thereby repositioned in relation
read fully hot.
to crankshaft timing and allows for optimum
The check gauge warning indicator will
engine performance and lower emissions.
illuminate and DTCs are set.
The IAT2 sensor mounted in the intake manifold:
The 4.6L air induction system improves engine
sends the PCM a signal indicating the temperature
performance by using the CMCV assemblies as
of the air entering the cylinders after passing over
follows:
the charge air cooler.
The intake manifold has 2 runners per cylinder,
feeding each of the intake ports in the cylinder
heads.
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Electronic Engine Controls
(PC/ED) manual.
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Engine Coolant Temperature (ECT)
Sensor 4.0L SOHC
(ECT) sensor electrical
connector
2 ECT sensor retaining clip
3 12A648 ECT sensor
4. Remove the retaining clip and the ECT sensor.
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303-03A.
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Sensor 5.4L (4V)
(ECT) sensor
2 12A648 ECT sensor
4. Remove the ECT sensor.
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303-03A.
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Sensor 4.0L SOHC
Material
Item Specification
Motor Oil
XO-5W30-QSP (US);
CXO-5W30-LSP12
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3 Fuel rail pressure and 1 9E498 Fuel rail pressure and
temperature sensor bolt (2 temperature sensor vacuum
required) hose
4 9G756 O-ring seal (part of 9G756) 2 14A464 Fuel rail pressure and
connector
temperature sensor
(Continued)
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4. Disconnect the vacuum hose from the fuel rail
5. Remove the 2 bolts and the fuel rail pressure
disconnecting any of the fuel tubes or fuel system
Inspect the O-ring seal and install new as
necessary.
Lubricate the O-ring seal with clean engine
oil.
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Fuel Rail Pressure and Temperature Item Part Number Description
Sensor 4.6L (3V), 5.4L (4V) 1 14A464 Fuel rail pressure and
connector
Material
2 9C482/9E498 Vacuum hose (4.6L [3V]/
Item Specification
5.4L [4V])
3 W705870 Fuel rail pressure and
temperature sensor bolts (2
Motor Oil
required)
XO-5W20-QSP (US);
temperature sensor
5 O-ring seal CXO-5W20-LSP12
4.6L (3V)
XO-5W50-QGT or
flammable mixtures are always present and may NOTE: 4.6L (3V) shown, 5.4L (4V) similiar.
4. Disconnect the vacuum hose from the fuel rail
5. Remove the 2 bolts and the fuel rail pressure
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Inspect the O-ring seal and install new as
necessary.
Lubricate the O-ring seal with clean engine
oil.
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Material
Heated Oxygen Sensor (HO2S)
Item Specification
4.0L SOHC
Lubricant
Special Tool(s)
XL-1 (US); CXC-51-A
Sensor
303-476 (T94P-9472-A)
XL-2 (US); CXG-2-B
(Canada)
1 14A464 Heated oxygen sensor
3. Disconnect the heated oxygen sensor (HO2S)
(2 required)
2 9G444 HO2S (2 required)
Section 100-02.
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4. NOTE: If necessary, lubricate the HO2S with 5. To install, reverse the removal procedure.
Using the special tool, remove the HO2S. the threads of the HO2S before installing.
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Material
Item Specification
4.6L (3V), 5.4L (4V)
Lubricant
Special Tool(s)
XL-1 (US); CXC-51-A
Sensor
303-476 (T94P-9472-A)
XL-2 (US); CXG-2-B
(Canada)
NOTE: 4.6L (3V) shown, 5.4L (4V) similiar.
1 14A464 Heated oxygen sensor (H02S)
electrical connector (2
required)
2 9G444 H02S
Section 100-02.
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4. NOTE: If necessary, lubricate the HO2S with 5. To install, reverse the removal procedure.
Using the special tool, remove the HO2S. the threads of the HO2S before installing.
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2. Disconnect the intake air temperature 2 (IAT2)
Intake Air Temperature 2 (IAT2)
Sensor 5.4L (4V)
3. Remove the IAT2 sensor.
Installation
1. Install the IAT2 sensor. Tighten the IAT2
sensor in 2 stages:
Stage 1: Tighten the IAT2 sensor to 15 Nm
(11 lb-ft).
CAUTION: During Stage 2, do not
tighten the IAT2 sensor more than 1 full
turn and do not rotate the IAT2 sensor
counter clockwise after tightening.
Stage 2: Tighten the IAT2 sensor until it is
aligned as shown.
1 14A464 Intake air temperature 2
(IAT2) sensor electrical 2. Connect the IAT2 sensor electrical connector.
connector
2 12A697 IAT2 sensor 3. Connect the battery ground cable. For additional
Removal
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Knock Sensor (KS) 4.0L SOHC
2 W500225 KS bolt
connector.
3 12A699 KS
4. Remove the bolt and the KS.
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Knock Sensor (KS) 4.6L (3V)
2 Pin-type retainer (part of
connector.
12A699)
3 W500110 KS bolt (2 required)
4 12A699 KS
4. Remove the 2 bolts and the KS.
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Mass Air Flow (MAF) Sensor
2. Disconnect the mass air flow (MAF) sensor
1 14A464 Mass air flow (MAF) sensor
3. Remove the 2 screws and the MAF sensor.
12B637)
2 W709287 MAF sensor screw (2 To install, tighten to 2 Nm (18 lb-in).
required)
4. To install, reverse the removal procedure. 3 12B579 MAF sensor
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Powertrain Control Module (PCM)
3. Remove the 2 bolts and the PCM.
1 14A464 Powertrain control module
Installation
(PCM) electrical connector (3
required)
1. Install the PCM and the 2 bolts.
2 W505423 PCM bolt
3 12A650 PCM
2. Connect the 3 PCM electrical connectors.
Removal
3. Restore the module configuration. Carry out the
1. NOTE: Any PCM replacement will require that
module configuration restore steps of the
ALL customer keys are available to be
Programmable Module Installation procedure.
programmed at the time of installation. PCM
replacement DOES NOT require new keys.
418-01.
Retrieve the module configuration. Carry out
the module configuration retrieval steps of the
4. Reprogram the passive anti-theft system
Programmable Module Installation procedure.
(PATS). Carry out the Key Programming Using
Two Programmed Keys procedure. For
418-01.
419-01B.
2. Disconnect the 3 PCM electrical connectors.
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SPECIFICATIONS
Catalyst monitor 48 35
Item Specification sensors (CMS)
Lubricants Charge motion control 10 89
valve (CMCV) 4.6L
(3V)
Lubricant XL-1 (US);
CXC-51-A (Canada) CHT sensor 5.4L 26 19
(4V)
Anti-Seize Lubricant XL-2 CMP sensor bolt 10 89
(US); CXG-2-B (Canada) 4.6L (3V), 5.4L (4V)
Lubricants 4.0L SOHC Only Crankshaft position 10 89
(CKP) sensor bolts
Premium Synthetic Blend Cylinder head 10 89
Motor Oil XO-5W30-QSP temperature (CHT)
(US); Motorcraft SAE sensor 4.6L (3V)
5W-30 Super Premium
Engine coolant 15 11
Motor Oil
temperature (ECT)
CXO-5W30-LSP12
sensor 5.4L (4V)
Fuel rail pressure and 6 53
Lubricants 4.6L (3V) Only
temperature sensor
Motorcraft SAE 5W-20 WSS-M2C930-A bolts
Heated oxygen sensors 48 35
(HO2S)
5W-20 Super Premium Intake air temperature
Motor Oil 2 (IAT2) sensor
CXO-5W20-LSP12 5.4L (4V)
a
Knock sensor (KS) 20 15
Lubricants 5.4L (4V) Only bolts
Motorcraft SAE 5W-50 WSS-M2C931-A Mass air flow (MAF) 2 18
Full Synthetic Motor Oil sensor screws
XO-5W50-QGT or
Powertrain control 8 71
equivalent
module (PCM) bolts
Supercharger bypass 20 15
vacuum actuator Torque Specifications
5.4L (4V)
Throttle position (TP) 3 27
A/C compressor stud 25 18
sensor screws
bolts 4.6L (3V),
Variable camshaft 5 44
5.4L (4V)
timing (VCT) solenoid
4.6L (3V)
(CMP) sensor bolt
4.0L a Refer to the procedure in this section.
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Supercharger Bypass Vacuum
Actuator
4. Rotate the supercharger bypass vacuum actuator
to align the actuator rod with the slot in the
1 9E499 Supercharger bypass vacuum
linkage, and remove the actuator.
actuator vacuum connectors
2 Supercharger bypass vacuum
actuator bolts (2 required)
3 6F066 Supercharger bypass vacuum
actuator
Removal
2. Disconnect the 2 supercharger bypass vacuum
actuator vacuum connectors.
3. Remove the 2 supercharger bypass vacuum
actuator bolts.
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Installation
1. CAUTION: The actuator adjustment
tool included with the new actuator kit must
be used when installing the supercharger
bypass vacuum actuator. Failure to correctly
adjust the actuator will result in incorrect
operation of the supercharger assembly.
Install the adjustment tool on the motor, making
sure the tool is correctly attached to the actuator
rod.
3. Install the 2 supercharger bypass vacuum
actuator bolts.
4. Connect the 2 supercharger bypass vacuum
actuator vacuum connectors.
5. Remove the adjustment tool.
2. Align the actuator rod with the slot in the
linkage, and rotate the supercharger bypass
vacuum actuator into position.
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Throttle Position (TP) Sensor
Installation
1. CAUTION: Do not reuse the TP sensor
2 W707535 TP screw (2 required) and screws. A new TP sensor and screws
must be installed.
3 9E928 TP sensor
CAUTION: Do not use a high-speed
Removal
driver to install the new screws or damage to
the TP sensor can occur.
NOTE: When installing the new TP sensor,
make sure that the radial locator tab on the TP
sensor is aligned with the radial locator hole on
the throttle body.
Position the new TP sensor and install the 2
new screws.
3. CAUTION: Failure to remove the TP
sensor screws in the following manner will Tighten to 3 Nm (27 lb-in).
result in damage to the screws. First loosen
the screws 1-2 full turns using a hand tool
and then use a suitable high-speed driver to
complete the removal.
Remove and discard the 2 screws and the TP
sensor.
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Variable Camshaft Timing (VCT) Oil
Control Solenoid 4.6L (3V)
Early Build
3 6C260 VCT oil control solenoid bolt 1 14A464 Variable camshaft timing
(VCT) oil control solenoid
4 6B297 VCT oil control solenoid
12B637)
2 6C535 Grommet
(Continued)
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Late Build
All vehicles
Early build
2. Disconnect the variable camshaft timing (VCT)
oil control solenoid electrical connector.
3. Remove the grommet.
Late build
4. Remove the LH or RH valve cover. For
303-01B.
All vehicles
5. Remove the bolt and the VCT oil control
solenoid.
1 6C260 VCT oil control solenoid bolt
2 6B297 VCT oil control solenoid
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307-01-1 307-01-1 Automatic Transaxle/Transmission
The direct clutch is a multi-disc clutch made up of
Apply Components
steel and friction plates.
Band Overdrive
The direct clutch is applied with hydraulic
For component location, refer to Transmission in
pressure and disengaged by return springs and the
this section.
exhaust of the hydraulic pressure.
During 2nd and 5th gear operation, hydraulic
It is housed in the direct clutch drum.
pressure is applied to the overdrive servo.
During 4th, 5th and REVERSE gear application,
This pressure causes the piston to move and apply
the direct clutch is applied transferring torque
force to the band.
from the forward clutch cylinder to the direct
clutch drum.
This action causes the overdrive band to hold the
overdrive drum.
This action causes the forward sun gear to drive
the pinions of the low/reverse planetary carrier.
This causes the overdrive sun gear to be held
stationary through the adapter plate and the
Clutches Forward
overdrive drum.
Band Low/Reverse
this section.
The forward clutch is a multi-disc clutch made up
this section.
of steel and friction plates.
During 2nd gear, 1st gear and reverse operation,
The forward clutch is applied with hydraulic
hydraulic pressure is applied to the low/reverse
servo.
This pressure causes the servo to move and apply
The forward clutch is applied in all forward gears.
force to the low/reverse band.
When applied, the forward clutch provides a
This action causes the low/reverse brake drum to
direct mechanical coupling between the center
be held.
shaft and the forward ring gear and hub.
This action causes the low/reverse planetary
Clutches Coast
assembly to be held stationary.
Band Intermediate
this section.
The coast clutch is a multi-disc clutch made up of
this section.
steel and friction plates.
During 3rd gear operation, hydraulic pressure is
The coast clutch is applied with hydraulic
applied to the intermediate servo.
This pressure causes the servo to move and apply
force to the intermediate band.
The coast clutch is housed in the overdrive drum.
This action causes the direct clutch drum to be
The coast clutch is applied when in 1st, 3rd,
held.
DRIVE and REVERSE positions.
The intermediate band holds the intermediate
When applied, the coast clutch locks the overdrive
brake and direct clutch drum to the case in 3rd
sun gear to the overdrive planetary carrier, thus
gear.
preventing the one-way clutch from overrunning
when the vehicle is coasting.
This causes the input shell and forward sun gear
to be held stationary.
This allows the use of engine compression to
help slow the vehicle and provide engine
Clutches Direct
braking.
this section.
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One-Way Clutch Direct One-Way Clutch Low/Reverse
For component location, refer to Transmission in For component location, refer to Transmission in
this section. this section.
The direct one-way clutch is a sprag-type one-way The low/reverse one-way clutch is a sprag-type
clutch that is pressed into the center shaft. one-way clutch.
The direct one-way clutch is driven by the ring The low/reverse one-way clutch holds the
gear of the overdrive planetary carrier. low/reverse drum and low/reverse planetary
assembly to the case in 1st and 2nd gear.
The direct one-way clutch holds and drives the
outer splines of the center shaft in 1st, 3rd, 4th In all other gears the low/reverse one-way clutch
and REVERSE gears. overruns.
The direct one-way clutch overruns during all
coast operations and at all times in 2nd and 5th
gear.
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c. checking the fluid levels.
Diagnosis By Symptom
d. carrying out other test procedures as
Special Tool(s)
directed.
4. NOTE: Not all concerns and conditions with
electrical components will set a diagnostic
trouble code (DTC). Be aware that the
components listed may still be the cause. hardware, or equivalent scan
tool
NOTE: When the battery is disconnected or a
new battery is installed, certain transmission
operating parameters can be lost. The
The Diagnosis by Symptom Index gives the
powertrain control module (PCM) must relearn
technician diagnostic information and direction, and
these parameters. During this learning process,
suggests possible components, using a symptom as a
you may experience slightly firm shifts,
starting point.
delayed or early shifts. This operation is
considered normal and will not affect the
Diagnosis by Symptom Index
function of the transmission. Normal operation
Directions
will return once these parameters are stored by
1. Using the Symptom Index, select the
the PCM.
Concern/Symptom that best describes the
Begin with the ROUTINE, if indicated. Follow
condition.
the reference or action statements. Always carry
2. Refer to the routine indicated in the Diagnosis
out the on-board diagnostic tests as necessary.
by Symptom Index.
Never skip steps. Repair as necessary.
3. Always begin diagnosis of a symptom with:
5. These components are listed in the removal
sequence and by most probable cause. All
a. preliminary inspections.
components listed must be inspected to make
b. verification of conditions.
sure that the repairs are complete.
5R55S Routines
Engagement Concerns:
No Forward in D or D ((D) cancelled) Only 201A
No Forward Only (All Positions) 201B
No Reverse Only 202
Harsh Reverse Only 203
Harsh Forward Only 204A
Harsh Manual 1st Gear Only 204B
Delayed/Soft Reverse Only 205
Delayed/Soft Forward Only 206
No Forward and No Reverse 207
Harsh Forward and Harsh Reverse 208
Delayed Forward and Delayed Reverse 209
Shift Concerns:
Some/All Shifts Missing (Automatic Mode Only) 210
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Diagnosis by Symptom Index (Continued)
5R55S Routines
Timing Concern
Early/Late (Some/All) 211
Erratic/Hunting (Some/All) 212
Feel Concerns
Soft/Slipping (Some/All) 213
Harsh (Some/All) 214
No First Gear in Drive, Engages in a Higher Gear 215
No First Gear in Manual 1st 216
No Manual 2nd Gear 217
Torque Converter Clutch Operation Concerns:
Does Not Apply 240
Always Applied/Stalls Vehicle 241
Cycling/Shudder/Chatter 242
Other Concerns:
Shift Lever Efforts High 251
External Leaks 252
Noise/Vibration Forward or Reverse 254
Engine Will Not Crank 255
No Park Range 256
Transmission Overheating 257
No Engine Braking in Manual 2nd Position 258
No Engine Braking in Manual 1st Position 259
Fluid Venting or Foaming 261
Vehicle Movement with Gear Selector in N 262
Slips/Chatters in Manual 1st Gear 263
Slips/Chatters in Manual 2nd Gear 264
No Engine Braking in Manual 3rd Position 280
No Engine Braking in Manual 4th (D (D) cancelled) Position 281
Slips/Chatters in Manual 3rd Gear 282
Engine Braking in ALL Gears 283
No 2nd and 5th Gears (manual 2nd is ok) 284
No 3rd, 4th and 5th gears 285
Diagnostic Routines
Engagement Concern: No Forward in D or D ((D) Cancelled) Only
201A ROUTINE
Powertrain Control System
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Engagement Concern: No Forward in D or D ((D) Cancelled) Only (Continued)
PCM, vehicle wiring harnesses, pressure control Carry out on-board diagnostic tests. Refer to the
solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
GO to Pinpoint Test D.
Repair as required. Clear DTCs, road test and rerun
on-board diagnostic test.
Main Control
Screw not tightened to specification Tighten to specification.
Separator plate damaged Inspect for damage. If damaged, install a new
separator plate.
Contamination Disassemble and clean.
Valves, springs damaged, misassembled, missing, If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
Filter damaged, missing Inspect for damage, repair as necessary.
Center Support
Seal rings or bearing damaged Inspect for damage. Repair as necessary.
Outside diameter of case bore damaged Inspect for damage. Repair as necessary.
Support damaged or leaking Inspect for damage. Repair as necessary.
Forward Clutch Assembly
Seals, piston damaged Inspect for damage. Repair as necessary.
Check ball damaged, missing, not seating, off location Inspect for mislocation, poor seating, damage. Install
a new cylinder.
Friction elements damaged or worn Inspect for damage. Repair as necessary.
Return springs damaged Inspect for damage. Repair as necessary.
Bronze seal ring or bearing damaged Inspect for damage. Repair as necessary.
Forward Planetary Assembly
Planetary damage Inspect for damage. Repair as necessary.
Low One-Way Clutch
Worn, damaged or assembled incorrectly Inspect for damage. Repair as necessary.
Engagement Concern: No Forward
201B ROUTINE
solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
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Engagement Concern: No Forward (Continued)
Fluid
Incorrect level Adjust fluid to the correct level. Refer to
Transmission Fluid Level Check in this section.
Condition Carry out the fluid condition check. Refer to
Preliminary Inspection in this section.
Main Control
separator plate.
a new cylinder.
Overdrive Servo
Servo retaining screws damaged Inspect for damage. Repair as necessary.
Seals (piston and cover) damaged Inspect for damage. Repair as necessary.
Overdrive Band
Band damaged Inspect for damage. Repair as necessary.
Servo worn or damaged Inspect for damage. Repair as necessary.
Not adjusted correctly Inspect for damage. Repair as necessary.
Case
Damaged Inspect for damage. Repair as necessary.
Engagement Concern: No Reverse
202 ROUTINE
PCM, vehicle wiring harnesses, Pressure Control Carry out on-board diagnostic tests. Refer to the
Solenoid C (PC C), Shift Solenoid B (SSB) Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test A and GO to Pinpoint Test D.
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Engagement Concern: No Reverse (Continued)
Main Control
Screws not tightened to specification Tighten to specification.
separator plate.
stuck or bore damage control assembly. If misassembled, reassemble
Direct Clutch Assembly
Seals, piston damaged Inspect or damage. Repair as necessary.
a new cylinder.
Reverse Servo
Reverse Band
Reverse Drum Assembly
One-way clutch damaged Inspect for damage. Install a new drum assembly.
Bearing damaged Inspect for damage. Install a new drum assembly.
Torque Converter Assembly
Torque converter internal failure preventing Remove the transmission. Inspect for damage. Refer
engagement, piston release to Torque Converter in this section. If the torque
converter fails to pass the criteria or is damaged,
install a new or remanufactured torque converter.
Engagement Concern: Harsh Reverse ONLY
203 ROUTINE
solenoid C (PC C) Powertrain Control/Emissions Diagnosis (PC/ED)
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Engagement Concern: Harsh Reverse ONLY (Continued)
Incorrect Pressures
High pressures Check pressure at line and PC C taps. Carry out Line
Pressure Test. Refer to Special Testing Procedures in
this section.
Main Control
separator plate.
Valves, spring damaged, misassembled, missing, stuck If damaged or parts are missing, install a new main
or bore damaged control assembly. If misassembled, reassemble
Check ball damaged, missing not seating, off location Inspect for mislocation, poor seating, damage. Install
a new cylinder.
a new cylinder.
Reverse Servo
Reverse Band
Reverse Drum Assembly
One-way clutch damaged Inspect for damage. Install a new drum assembly.
Bearing damaged Inspect for damage. Install a new drum assembly.
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Engagement Concern: Harsh Forward ONLY
204A ROUTINE
solenoid A (PC A), pressure control solenoid C (PC Powertrain Control/Emissions Diagnosis (PC/ED)
C) manual for diagnosis and testing of the PCM.
Incorrect Pressures
this section.
Main Control
separator plate.
Center Support
Seal rings or bearing damage Inspect for damage. Repair as necessary.
Outside diameter of case bore damage Inspect for damage. Repair as necessary.
a new cylinder.
Engagement Concern: Harsh Manual 1st Gear ONLY
204B ROUTINE
solenoid B (PC B), Turbine Shaft Speed (TSS) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
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Engagement Concern: Harsh Manual 1st Gear ONLY (Continued)
GO to Pinpoint Test D and GO to Pinpoint Test E.
Repair as necessary. Clear DTCs, road test and rerun
Engagement Concern: Delayed or Soft Reverse ONLY
205 ROUTINE
solenoid C (PC C) Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
Low pressure Check pressure at line and PC C taps. Carry out Line
this section.
Main Control
separator plate.
Check ball damaged, missing not seating, off location Inspect for mislocation, poor seating, damage. Install
a new cylinder.
Reverse Servo
Reverse Band
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Engagement Concern: Delayed/Soft Forward ONLY
206 ROUTINE
solenoid B (PC B) Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
Low pressures Check pressure at line and PC C taps. Carry out Line
this section.
Main Control
separator plate.
Valves, spring damaged, misassembled, missing, stuck If damaged or parts are missing, install a new main
Overdrive Servo
Overdrive Band
Band damaged. Inspect for damage. Repair as necessary.
Center Support
a new cylinder.
Friction element damaged or worn Inspect for damage. Repair as necessary.
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Engagement Concern: No Forward and No Reverse
207 ROUTINE
solenoid B (PC B) Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Incorrect level Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
Condition Carry out Fluid Condition Check. Refer to
Shift Cable/Digital TR Sensor
Cable system or digital transmission range (TR) Inspect and repair as necessary. Refer to Transmission
sensor damaged, misaligned Range (TR) Sensor Adjustment in this section.
Main Control
Screws not tightened to specification Tighten screws to specification.
separator plate.
Valve, springs damaged, misassembled, missing, stuck If damaged or parts are missing, install new main
Input Shaft
Fluid Pump Assembly
Gasket damaged Inspect for damage. If damaged, install a new gasket.
Porosity, cross leaks, ball missing, plugged hole Inspect for damage. If damaged, repair as necessary.
Pump gears cracked and/or seized Inspect for damage. Install a new pump.
Flow control valves, springs, or seals damaged, stuck Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Overdrive Planetary Assembly
Planetary damaged Inspect for damage. Repair as necessary.
Center Shaft Assembly
Damaged. One-way clutch damaged Inspect for damage. Repair as necessary.
a new cylinder.
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Engagement Concern: No Forward and No Reverse (Continued)
Forward Planetary Assembly
Reverse Planetary Assembly
Output Shaft
Damage Inspect for damage. Repair as necessary.
Torque Converter
Damaged flexplate or adapter plate Remove the transmission. Inspect for damage. Refer
to Torque Converter in this section. If the torque
Damaged impeller hub
Damaged turbine hub
Direct One-Way Clutch
Engagement Concern: Harsh Forward and Harsh Reverse
208 ROUTINE
PCM, vehicle wring harnesses, digital TR sensor, Carry out on-board diagnostic tests. Refer to the
transmission fluid temperature (TFT) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test B and GO to Pinpoint Test C.
Fluid
Preliminary Inspection.
Incorrect Pressures
this section.
Main Control
separator plate.
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Engagement Concern: Harsh Forward and Harsh Reverse (Continued)
Valves, springs damaged, misassembled, missing, If damaged or parts are missing, install new main
a new cylinder.
Engagement Concern: Delayed Forward and Delayed Reverse
209 ROUTINE
PCM, vehicle wiring harnesses, TFT sensor Carry out on-board diagnostic tests. Refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Preliminary Inspection.
Incorrect Pressures
this section.
Main Control
separator plate.
Valves and springs damaged, misassembled, missing, If damaged or parts are missing, install a new main
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Engagement Concern: Delayed Forward and Delayed Reverse (Continued)
Fluid Pump Assembly
Shift Concern: Some/All Shifts Missing (Automatic Mode Only)
210 ROUTINE
PCM, vehicle wiring harnesses, shift solenoids A, B, Carry out on-board diagnostic tests. Refer to the
C, torque converter clutch (TCC) solenoid, pressure Powertrain Control/Emissions Diagnosis (PC/ED)
control solenoids A, B, C, output shaft speed (OSS) manual for diagnosis and testing of the PCM, IAT
sensor, digital TR sensor, intake air temperature (IAT) and VSS.
sensor, vehicle speed sensor (VSS) input
GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
Some Shifts Missing ONLY
If only some shifts are missing, determine which
shift(s) is missing.
Refer to the following routine(s) for further No Shift
concerns:
No 1-2 Shift, Routine 220
Fluid
Incorrect level Adjust fluid to correct level, refer to the in this
section.
Cable system or digital TR sensor damaged, Inspect and repair as necessary. Refer to Transmission
misaligned Range (TR) Sensor Adjustment in this section.
Incorrect Pressures
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Shift Concern: Some/All Shifts Missing (Automatic Mode Only) (Continued)
High/low pressures Check pressure at line and PC C taps. Carry out Line
this section.
Main Control
separator plate.
Fluid Pump Assembly
Center Support
a new cylinder.
Shift Concern: Timing ConcernsEarly/Late
211 ROUTINE
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Shift Concern: Timing ConcernsEarly/Late (Continued)
PCM, vehicle wiring harnesses, OSS sensor, IAT Carry out on-board diagnostic tests. Refer to the
sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM and
IAT.
GO to Pinpoint Test E.
Some Shifts Early/Late ONLY
If only some shifts are early/late, determine which
concerns:
Soft/Slipping 1-2 Shift, Routine 226
Fluid
Main Control
separator plate.
Overdrive Servo
Overdrive Band
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Shift Concern: Timing ConcernsErratic/Hunting (Some/All)
212 ROUTINE
PCM, vehicle wiring harnesses, OSS sensor, IAT Carry out on-board diagnostic tests. Refer to the
sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM and
IAT.
Fluid
Main Control
separator plate.
Overdrive Servo
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Shift Concern: Timing ConcernsErratic/Hunting (Some/All) (Continued)
Further Diagnosis
For further diagnosis for timing issues, refer to Refer to the following routine(s) for specific
Reference/Action diagnosis:
Soft/Slip 1-2 Shift, Routine 226
Harsh 1-2 Shift, Routine 232
Engagement Concern: FeelSoft/Slipping (Some/All)
213 ROUTINE
C, pressure control solenoids A, B, C, D, intermediate Powertrain Control/Emissions Diagnosis (PC/ED)
shaft speed sensor, TFT sensor, IAT sensor, VSS manual for diagnosis and testing of the PCM, IAT
input and VSS.
GO to Pinpoint Test A, GO to Pinpoint Test B, GO
Some Shifts Soft/Slipping ONLY
If only some of the shifts are soft/slipping, determine
which shift(s) is missing.
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Engagement Concern: FeelSoft/Slipping (Some/All) (Continued)
Refer to the following routine(s) for further
Soft/Slipping concerns:
Fluid
Incorrect Pressures
High/low pressures Check pressure at line and PC C taps.
Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
separator plate.
Fluid Pump Assembly
Coast Clutch Assembly
a new cylinder.
Center Support
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Engagement Concern: FeelSoft/Slipping (Some/All) (Continued)
Seal rings or bearings damaged Inspect for damage. Repair as necessary.
Outside diameter of case bore damage Inspect for damage. Repair as necessary.
Intermediate Servo
Intermediate Band
a new cylinder.
a new cylinder.
Reverse Servo
Reverse Band
Case
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Shift Concern: FeelHarsh (Some/All)
214 ROUTINE
C, pressure control solenoids A, B, C, D, intermediate Powertrain Control/Emissions Diagnosis (PC/ED)
shaft speed sensor, digital TR sensor, TFT sensor, manual for diagnosis and testing of the PCM, IAT
IAT sensor, VSS input and VSS.
Some Shifts Harsh ONLY
If only some of the shifts are harsh, determine which
concerns:
Fluid
Incorrect Pressures
this section.
Main Control
separator plate.
stuck, or bore damaged control assembly. If misassembled, reassemble
Input Shaft
Damaged Inspect for damage. Install new as necessary.
Overdrive Servo
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Shift Concern: FeelHarsh (Some/All) (Continued)
Overdrive Band
Center Shaft Assembly
Center shaft assembly damaged Inspect for damage. Repair as necessary.
One-way clutch damaged Inspect for damage. Repair as necessary.
Center Support
Intermediate Servo
Intermediate Band
a new cylinder.
Reverse Servo
Reverse Band
Output Shaft
Damaged Inspect for damage. Install new as necessary.
Case
Shift Concern: No 1st and 2nd Gear in Drive, Engages in a Higher Gear
215 ROUTINE
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Shift Concern: No 1st and 2nd Gear in Drive, Engages in a Higher Gear (Continued)
C, digital TR sensor Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test A and GO to Pinpoint Test C.
Incorrect Pressures
this section.
Main Control
separator plate.
Valves/springs damaged, misassembled, missing, stuck If damaged or parts are missing, install new main
Overdrive Servo
Low One-Way Clutch
Engagement Concern: No 1st Gear in Manual 1 Position
216 ROUTINE
pressure control solenoids B, C Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
High/low pressures Carry out Line Pressure Test. Refer to Special Testing
Main Control
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Engagement Concern: No 1st Gear in Manual 1 Position (Continued)
separator plate.
Low One-Way Clutch
Shift Concern: No 2nd Gear in Manual 2 Position
217 ROUTINE
PCM, vehicle wiring harnesses, shift solenoids A, B, Carry out on-board diagnostic tests. For additional
C, pressure control solenoid B information, refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing
of the PCM.
Incorrect Pressures
Main Control
separator plate.
Overdrive Servo
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Shift Concern: No 2nd Gear in Manual 2 Position (Continued)
Overdrive Band
Low One-Way Clutch
Torque Converter Operation Concerns: Does Not Apply
240 ROUTINE
PCM, vehicle wiring harnesses, TCC solenoid, TFT Carry out on-board diagnostic tests. Refer to the
sensor and engine coolant temperature (ECT) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test A and GO to Pinpoint Test B.
Incorrect Pressures
this section.
Main Control
separator plate.
Fluid Pump Assembly
Flow control valves, springs or seals damaged, stuck Inspect for damage. Install a new seal or flow control
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Torque Converter Operation Concerns: Does Not Apply (Continued)
engagement, piston application to Torque Converter in this section. If the torque
Torque Converter Operation Concern: Always Applied/Stalls Vehicle
241 ROUTINE
PCM, vehicle wiring harnesses, TCC solenoid Carry out on-board diagnostic tests. Refer to the
GO to Pinpoint Test A.
Main Control
separator plate.
Low One-Way Clutch
Worn, damaged or assembled incorrectly. Inspect for damage. Repair as necessary.
Torque Converter Operation Concern: Cycling/Shudder/Chatter
242 ROUTINE
PCM, vehicle wiring harnesses, TCC solenoid Carry out on-board diagnostic tests. Refer to the
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Torque Converter Operation Concern: Cycling/Shudder/Chatter (Continued)
Fluid
Conditioncontaminated, degraded Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section. If
contaminated, locate source of contamination. If
burnt, inspect mechanical bands, clutches. Repair as
necessary. Change fluid. Carry out drain and refill
procedure. Refer to Transmission Fluid Drain and
Refill Without Torque Converter Drain Plug in
this section. Carry out fluid cooler and torque
converter cleaning procedure. Refer to Transmission
Fluid Cooler Backflushing and Cleaning in this
section.
Main Control
separator plate.
Torque converter internal leakage, clutch material Remove the transmission. Inspect for damage. Refer
damaged to Torque Converter in this section. If the torque
Other Concerns: Shift Lever Efforts High
251 ROUTINE
PCM, vehicle wiring harnesses, digital TR sensor Carry out on-board diagnostic tests. Refer to the
GO to Pinpoint Test C.
Shift Cable, Digital TR Sensor
Main Control
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Other Concerns: Shift Lever Efforts High (Continued)
separator plate.
Valve/springs damaged, misassembled, missing, stuck If damaged or parts are missing, install new main
Case
Manual control lever assembly damage, manual valve Inspect for damage. If damaged, install a new part.
inner lever pin bent, manual valve inner lever
damaged, spring rod damaged
Manual valve lever shaft retaining pin damaged Inspect for damage. If damaged, repair as necessary.
Other Concerns: External Leaks
252 ROUTINE
OSS sensor, intermediate shaft speed, TSS sensor, Inspect for leakage. If areas around sensor show signs
digital TR sensor of leakage, install a new sensor O-ring seal. If area
behind digital TR sensor shows signs of a leak, a new
manual lever shaft seal may need to be installed.
Fluid
Incorrect level Adjust to correct level. Refer to Transmission Fluid
Level Check in this section.
Case
Case vent damaged Inspect for damage. If damaged, repair as necessary.
Output shaft flange damage Inspect for damage. If damaged, repair as necessary.
Seals/Gaskets
Leakage at gaskets, seals, cooler lines, torque Refer to Leakage Inspection in this section for
converter studs, etc. potential leak locations.
Remove all traces of lubricant on exposed surfaces of
the transmission. Check vent for free breathing.
Operate the vehicle at normal temperatures and carry
out leak check test, refer to Leakage Inspection in this
section. Repair as necessary.
Vents
Fluid leakage through the vent system into the Incorrect fluid level may cause the transmission fluid
bellhousing to vent. If not already carried out verify and adjust
the fluid to the correct level. Refer to Transmission
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Other Concerns: External Leaks (Continued)
Verify the transmission operating temperature by
monitoring the TFT while driving the vehicle for 32
km (20 miles) or 20 minutes. If the TFT exceeds
102C (215F) during the drive, refer to Routine No.
257 Transmission Overheating, Main Control,
Thermostatic bypass valve.
Remove all traces of fluid on exposed surfaces of the
transmission.
Check the vent for damage and obstructions. Verify
that the vent is operating correctly by applying air
through the vent tubes. If the vent is damage or
obstructed, repair as necessary.
Other Concern: Noise/VibrationForward or Reverse
254 ROUTINE
PCM, vehicle wiring harnesses, TCC solenoid, Carry out on-board diagnostic tests. Refer to the
pressure control solenoids A, B, C Powertrain Control/Emissions Diagnosis (PC/ED)
Cable or digital TR sensor damaged, misaligned Inspect and repair as necessary. Refer to Transmission
Range (TR) Sensor Adjustment in this section.
Main Control
separator plate.
Valves/springs damaged, misassembled, missing, If damaged or parts are missing, install new main
stuck, or bore damaged, thermostatic bypass valve control assembly. If misassembled, reassemble
damaged correctly. DO NOT stone, file or sand valves. This
Fluid Pump Assembly
Low One-Way Clutch
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Other Concern: Noise/VibrationForward or Reverse (Continued)
Flexplate or Adapter Plate
Nuts not tightened to specification Tighten to specification.
Adapter plate not aligned correctly Remove transmission and using special service tool
and procedure in this section, align adapter plate.
Clutch Assemblies
Check ball damaged, missing, not seating, off location Inspect for damage, mislocation, poor seating. Install
a new cylinder as necessary.
Torque converter hub damaged Inspect for damage. Repair as necessary.
Other Concern: Engine Will Not Crank
255 ROUTINE
PCM, vehicle wiring harnesses, digital TR sensor Carry out on-board diagnostic tests. Refer to the
Cable or digital TR sensor damaged, misaligned Inspect and repair as necessary. Refer to Transmission
Range (TR) Sensor Adjustment in this section.
Main Control/Park System/TR Sensor Alignment
Detent spring, rooster comb, manual lever and TR Disconnect TR sensor electrical connector. Remove
sensor are not correctly aligned together outer manual lever nut. Loosen TR sensor screws.
Loosen detent spring screw. Move manual lever
through all gear ranges. Place manual lever into the
NEUTRAL position. Tighten the detent spring screw
to correct specification. Install TR sensor alignment
tool. Tighten the TR sensor screws alternating
sequence until correct tightening specification is
obtained. Remove tool. Install outer manual lever and
nut. Tighten nut to correct specification. Install TR
sensor connector. Verify that the vehicle will start in
PARK and NEUTRAL. Verify that the reverse
backup lamps illuminate in REVERSE.
Fluid Pump Assembly
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Other Concern: Engine Will Not Crank (Continued)
Flexplate or Adapter Plate
Other Concern: No Park Range
256 ROUTINE
Case
Manual control lever assembly damage, manual valve Inspect for damage. If damaged, repair as necessary.
Park System
Park gear, parking pawl, parking pawl return spring, Inspect for damage. If damaged, repair as necessary.
park or guide plate, parking actuating rod, parking
pawl shaft, manual lever, manual lever detent spring
damaged or misassembled
External linkages/brackets damaged Inspect for damage. If damaged, repair as necessary.
Other Concern: Transmission Overheating
257 ROUTINE
PCM, vehicle wiring harnesses, TCC solenoid, Carry out on-board diagnostic tests. Refer to the
pressure control solenoids A, B, C, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test A, GO to Pinpoint Test B and
Fluid
Hydraulic/Mechanical
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Other Concern: Transmission Overheating (Continued)
Thermostatic bypass valve in the main control valve Verify correct thermal valve function, while
body assembly monitoring the TFT. Drive the vehicle for about 32
km (20 miles) or 20 minutes. If the temperature
exceeds 102C (215F) during the drive, install a new
main control valve body assembly.
Incorrect Pressures
this section.
Main Control
separator plate.
or bore damaged, thermostatic bypass valve damaged control assembly. If misassembled, reassemble
Thermostatic bypass valve damaged or malfunctioning If the verification procedure confirms the malfunction,
install a new main control valve body assembly. If
not malfunctioning, inspect for damage. If damaged,
install a new main control valve body assembly.
Fluid Pump Assembly
Case
Seized torque converter one-way clutch Remove the transmission. Inspect for damage. Refer
to Torque Converter in this section. If the torque
Excessive slip detected
Other
Restriction in the transmission cooling system Refer to Section 307-02 for information and diagnosis
of cooling system.
Excessive trailer tow load Refer to the owner guide for specifications on trailer
towing.
Engine driveability concerns Check engine. Refer to Section 303-00.
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Other Concern: No Engine Braking in Manual 3rd Position
280 ROUTINE
C, reverse pressure (RP) switch, pressure control Powertrain Control/Emissions Diagnosis (PC/ED)
solenoids A, B manual for diagnosis and testing of the PCM.
GO to Pinpoint Test A, GO to Pinpoint Test D.
Fluid
Incorrect level Adjust fluid to correct level. Refer to Transmission
Incorrect Pressures
High/low pressures Check pressure at Line and PC C taps. Carry out Line
this section.
Main Control
separator plate.
a new cylinder.
Center Support
Seals rings or bearing damaged Inspect for damage. Repair as necessary.
Intermediate Servo
Intermediate Band
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Other Concern: No Engine Braking in Manual 4th (D (D) Cancelled) Position
281 ROUTINE
PCM, vehicle wiring harnesses, shift solenoid D, RP Carry out on-board diagnostic tests. Refer to the
switch, pressure control solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
GO to Pinpoint Test A, GO to Pinpoint Test D.
Fluid
Main Control
separator plate.
a new cylinder.
Other Concerns: No Engine Braking in Manual 2nd Position
258 ROUTINE
PCM, vehicle wiring harnesses, shift solenoids A, C, Carry out on-board diagnostic tests. Refer to the
D, pressure control solenoid A Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Incorrect Pressures
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Other Concerns: No Engine Braking in Manual 2nd Position (Continued)
this section.
Overdrive Servo
Overdrive Band
Other Concern: No Engine Braking in Manual 1st Position
259 ROUTINE
PCM, vehicle wiring harnesses, shift solenoids A, C, Carry out on-board diagnostic tests. Refer to the
D, pressure control solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Incorrect level Adjust fluid to the correct level, refer to Transmission
Incorrect pressures
this section.
Reverse Servo
Reverse Band
Other Concerns: Fluid Venting/Foaming
261 ROUTINE
Fluid
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Other Concerns: Fluid Venting/Foaming (Continued)
Fluid Pump Assembly
Case
Other
Transmission overheating Refer to 257 routine in this section.
Other Concern: Vehicle Movement with Gear Selector in N Position
262 ROUTINE
Fluid
Incorrect Pressures
this section.
Main Control
separator plate.
Clutch Assemblies
Check ball damaged, missing, not seating, off location Inspect for damage, mislocation, poor seating. Install
a new cylinder as necessary.
Friction elements damaged or worn. Inspect for damage. Repair as necessary.
Case
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Other Concern: Vehicle Movement with Gear Selector in N Position (Continued)
Manual control lever assembly damage, manual valve Inspect for damage. If damaged, repair as necessary.
Other Concern: Slips/Chatters in Manual 1st Position
263 ROUTINE
solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Incorrect Pressures
this section.
Main Control
separator plate.
Fluid Pump Assembly
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Other Concern: Slips/Chatters in Manual 1st Position (Continued)
a new cylinder.
Reverse Servo
Reverse Band
Other Concern: Slips/Chatters in Manual 2nd Position
264 ROUTINE
Fluid
Incorrect Pressures
this section.
Overdrive Servo
Overdrive Band
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Other Concern: Slips/Chatters in Manual 2nd Position (Continued)
a new cylinder.
Other Concern: Slip/Chatters in Manual 3rd Position
282 ROUTINE
Fluid
Incorrect Pressures
this section.
Overdrive Servo
Overdrive Band
Intermediate Servo
Intermediate Band
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Other Concern: Slip/Chatters in Manual 3rd Position (Continued)
a new cylinder.
Low One-Way Clutch
Other Concern: Engine Braking in ALL Gears
283 ROUTINE
PCM, vehicle wiring harnesses, shift solenoid D Carry out on-board diagnostic tests. Refer to the
Other Concern: No 2nd and 5th Gears (Manual 2nd is Ok)
284 ROUTINE
Hydraulic/Mechanical
Verify that Manual 2 is present and functions
correctly. If Manual 2 is not operating correctly go to
Shift Concerns: Routine 210 - Some/All Shifts
Missing (Automatic Mode) and continue diagnosis. If
Manual 2 is operating correctly continue with this
routine.
solenoids B, C Powertrain Control/Emissions Diagnosis (PC/ED)
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Other Concern: No 3rd, 4th and 5th Gears
285 ROUTINE
Overdrive Servo
Overdrive Band
Intermediate Servo
Intermediate Band
Shift Concern: Harsh 1-2 Shift
232 ROUTINE
PCM, vehicle wiring harnesses, shift control solenoid Carry out on-board diagnostic tests. Refer to the
C, pressure control solenoids B, TSS sensor, digital Powertrain Control/Emissions Diagnosis (PC/ED)
TR sensor, TFT sensor manual for diagnosis and testing of the PCM.
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
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Shift Concern: Harsh 1-2 Shift (Continued)
separator plate.
Overdrive Servo
Overdrive Band
233 ROUTINE
B, pressure control solenoids A, TSS sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
intermediate shaft speed sensor, digital TR sensor, manual for diagnosis and testing of the PCM.
TFT sensor
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
separator plate.
http://vnx.su
Overdrive Servo
Overdrive Band
a new cylinder.
Intermediate Servo
Intermediate Band
234 ROUTINE
A, pressure control solenoids C, digital TR sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
TFT sensor manual for diagnosis and testing of the PCM.
to Pinpoint Test C and GO to Pinpoint Test D.
Incorrect Pressures
this section.
Main Control
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separator.
Center Support
a new cylinder.
Intermediate Servo
Shift Concerns: Harsh 4-5 Shift
274 ROUTINE
PCM, vehicle wiring harnesses, shift solenoid C, Carry out on-board diagnostic tests. Refer to the
pressure control solenoid B, TSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, TFT sensor manual for diagnosis and testing of the PCM.
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
separator.
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Shift Concerns: Harsh 4-5 Shift (Continued)
Overdrive Servo
Seal (piston and cover) damaged Inspect for damage. Repair as necessary.
Overdrive Band
275 ROUTINE
C, pressure control solenoid C, TSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
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Overdrive Band
235 ROUTINE
PCM, vehicle wiring harnesses, shift solenoid A, Carry out on-board diagnostic tests. Refer to the
pressure control solenoid A, digital TR sensor, TFT Powertrain Control/Emissions Diagnosis (PC/ED)
sensor manual for diagnosis and testing of the PCM.
to Pinpoint Test C and GO to Pinpoint Test D.
Incorrect Pressures
this section.
Main Control
separator plate.
a new cylinder.
Intermediate Servo
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Intermediate Band
236 ROUTINE
C, pressure control solenoid B, TSS sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
intermediate shaft speed sensor, digital TR sensor, manual for diagnosis and testing of the PCM.
TFT sensor
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
Intermediate Servo
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Intermediate Band
237 ROUTINE
C, pressure control solenoid B, TSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
Pinpoint Test E.
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
Direct Clutch One-Way Clutch
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Shift Concern: No 1-2 Shift
220 ROUTINE
pressure control solenoid B, OSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, VSS input manual for diagnosis and testing of the PCM and
VSS.
Fluid
Incorrect Pressures
Main Control
separator plate.
Overdrive Servo
Overdrive Band
221 ROUTINE
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Shift Concern: No 2-3 Shift (Continued)
PCM, vehicle wiring harnesses, shift solenoid B, TCC Carry out on-board diagnostic tests. Refer to the
solenoid, pressure control solenoid A, OSS sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
digital TR sensor manual for diagnosis and testing of the PCM.
Incorrect Pressures
this section.
Main Control
separator plate.
Check ball, damaged, missing, not seating, off Inspect for mislocation, poor seating, damage. Install
location a new cylinder.
Intermediate Servo
Seals (piston and cover) damaged Inspect for mislocation, poor seating, damage. Install
a new cylinder.
Intermediate Band
222 ROUTINE
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pressure control solenoid C, OSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
Center Support
a new cylinder.
a new cylinder.
Intermediate Servo
a new cylinder.
http://vnx.su
270 ROUTINE
Transmission control (TC) switch GO to Pinpoint Test A, GO to Pinpoint Test C, GO
TC switch For TC switch diagnosis, refer to Section 307-05.
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
271 ROUTINE
pressure control solenoid C, OSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
http://vnx.su
TC switch For TC switch diagnosis, refer to Section 307-05.
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
223 ROUTINE
PCM, vehicle wiring harnesses, shift solenoid A, B, Carry out on-board diagnostic tests. Refer to the
pressure control solenoid A, OSS sensor, digital TR Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
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Intermediate Servo
Intermediate Band
224 ROUTINE
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
http://vnx.su
a new cylinder.
225 ROUTINE
Incorrect Pressures
this section.
Main Control
separator plate.
a new cylinder.
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Overdrive Servo
Overdrive Band
Shift Concern: Soft/Slipping 1-2 Shift
226 ROUTINE
pressure control solenoid B, TFT sensor, VSS input Powertrain Control/Emissions Diagnosis (PC/ED)
Fluid
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
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Shift Concern: Soft/Slipping 1-2 Shift (Continued)
Overdrive Band
227 ROUTINE
pressure control solenoid A, intermediate shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
Intermediate Servo
a new cylinder.
Intermediate Band
http://vnx.su
228 ROUTINE
pressure control solenoid C, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
Center Support
a new cylinder.
Intermediate Servo
272 ROUTINE
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pressure control solenoid B, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
Shift Concern: Feel Soft/Slipping 5-4 Shift
273 ROUTINE
pressure control solenoid C, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
http://vnx.su
Shift Concern: Feel Soft/Slipping 5-4 Shift (Continued)
this section.
Main Control
separator plate.
a new cylinder.
229 ROUTINE
pressure control solenoid A, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
http://vnx.su
Shift Concern: Feel Soft/Slipping 4-3 Shift (Continued)
Intermediate Servo
Intermediate Band
230 ROUTINE
pressure control solenoid B, intermediate shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
Overdrive Servo
Overdrive Band
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231 ROUTINE
pressure control solenoid B, TFT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
Incorrect Pressures
this section.
Main Control
separator plate.
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Diagnostic Trouble Code (DTC)
Charts
Diagnostic Trouble Code Chart
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Com-
DTC ponent Description Condition Symptom Action
P0102, MAF MAF concerns MAF system High/low EPC REFER to the
P0103, inoperative which pressure, incorrect Powertrain
P1100, may cause a shift schedule. Control/Emissions
P1101 transmission Incorrect torque Diagnosis (PC/ED)
concern. converter clutch manual.
engagement
scheduling.
Symptoms similar
to a TP failure.
P0112 IAT IAT indicates Voltage drop across Incorrect EPC REFER to the
125C (254F) IAT exceeds scale pressure. Either Powertrain
(grounded) set for temperature high or low which Control/Emissions
125C (254F). will result in harsh Diagnosis (PC/ED)
or soft shifts. manual.
P0113 IAT IAT indicates -40C Voltage drop across Incorrect EPC REFER to the
(-40F) (open IAT exceeds scale pressure. Either Powertrain
circuit) set for temperature high or low which Control/Emissions
-40C (-40F). will result in harsh Diagnosis (PC/ED)
or soft shifts. manual.
P0114 IAT IAT out of IAT temperature Rerun on-board REFER to the
on-board diagnostic higher or lower diagnostic at normal Powertrain
range than expected operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
P1116 ECT ECT out of ECT temperature Rerun on-board REFER to the
on-board diagnostic higher or lower diagnostic at normal Powertrain
range than expected operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
P0117 ECT ECT indicates Voltage drop across Torque converter REFER to the
125C (254F) ECT exceeds scale clutch will always Powertrain
set for temperature be off, resulting in Control/Emissions
125C (254F) reduced fuel Diagnosis (PC/ED)
(grounded). economy. manual.
P0118 ECT ECT indicates Voltage drop across Torque converter REFER to the
-40C (-40F) ECT exceeds scale clutch will always Powertrain
set for temperature be off, resulting in Control/Emissions
-40C (-40F) (open reduced fuel Diagnosis (PC/ED)
circuit). economy. manual.
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Diagnostic Trouble Code Chart (Continued)
Five
Digit Com-
P0121, TP TP concern PCM has detected Harsh engagements, REFER to the
P0122, an error. This error firm shift feel, Powertrain
P0123, may cause a abnormal shift Control/Emissions
P1120, transmission schedule, torque Diagnosis (PC/ED)
P1121, concern. converter clutch manual.
P1125, does not engage.
P1124 Torque converter
clutch cycling.
P0121- APP APP concern PCM has detected Harsh engagements, REFER to the
P0124, an error. This error firm shift feel, Powertrain
P0221- may cause a abnormal shift Control/Emissions
P0224, transmission schedule, torque Diagnosis (PC/ED)
P2100- concern. converter clutch manual.
P2107, does not engage.
P2110- Torque converter
P2112, clutch cycling.
P2121-
P2124,
P2126-
P2129,
P2121-
P2135,
P2138-
P2140
P0300- EI EI concerns EI system is Harsh engagements REFER to the
P0308, inoperative which and shifts, late Powertrain
P0320, may cause a WOT shifts, no Control/Emissions
P0340, transmission torque converter Diagnosis (PC/ED)
P1351- concern. clutch engagement. manual.
P1364
P0503, ABS Insufficient VSS PCM detected a No transmission REFER to the
P0500, input from ABS loss of vehicle symptom. IP Powertrain
U1039 through the speed signal speedometer may Control/Emissions
communication link through the be affected. Diagnosis (PC/ED)
communication link manual.
from ABS.
P0705 Digital Digital TR circuit Digital TR circuits, Harsh engagements GO to Pinpoint Test C.
TR sensor failure indicating an or wrong gear
invalid pattern in commanded.
TR D. Condition Defaults to (D) or
caused by a short to invalid position.
ground or an open
in TR4, TR3A, TR2
and/or TR1 circuits.
This DTC cannot
be set by an
incorrectly adjusted
digital TR sensor.
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Five
Digit Com-
P0708 Digital Digital TR sensor Digital TR sensor Harsh engagements GO to Pinpoint Test C.
TR sensor circuit TR3A open circuit TR3A or wrong gear
reading 2.6v - 5.0v commanded.
(open circuit). This Defaults to (D) or
DTC cannot be set invalid position.
by an incorrectly
adjusted digital TR
sensor.
P1702 Digital Digital TR signal See P0705, P0708 See P0705, P0708 GO to Pinpoint Test C.
TR sensor intermittent, code conditions. symptoms.
P0705, P0708 are
set
P1704 Digital Digital TR not in P Digital TR sensor DTC is set. GO to Pinpoint Test C.
TR sensor or N positions or shift cable
during incorrectly adjusted
KOEO/KOER or digital TR circuit
failure.
P1705 Digital Digital TR not in P KOEO/KOER not DTC is set. RERUN KOEO/KOER
TR sensor or N during run in park or in P or N or GO to
KOEO/KOER neutral, or digital Pinpoint Test C.
TR circuit failure.
P0712 TFT 157C (315F) Voltage drop across DTC set. GO to Pinpoint Test B.
indicated TFT TFT sensor exceeds
sensor circuit scale set for
grounded temperature of
157C (315F).
P0713 TFT -40C (-40F) Voltage drop across DTC set. GO to Pinpoint Test B.
indicated TFT TFT sensor exceeds
sensor circuit open scale set for
temperature -40C
(-40F).
P1711 TFT TFT out of Transmission not at DTC set vehicle Warm or cool vehicle
on-board diagnostic operating cold or overheated. to normal operating
range temperature during temperature. GO to
on-board diagnostic. Pinpoint Test B.
P0711 TFT No change in TFT PCM has detected DTC is set. GO to Pinpoint Test B.
no TFT change
during operation.
P1783 TFT Transmission Transmission fluid Increase in control GO to Pinpoint Test B.
overtemp condition temperature pressure.
indicated exceeded 127C
(270F).
P0715 TSS Insufficient input PCM detected a GO to Pinpoint Test E.
from turbine shaft loss of TSS signal
speed sensor during operation.
P0717 TSS Insufficient input PCM detected a GO to Pinpoint Test E.
from turbine shaft loss of TSS signal
speed sensor during operation.
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Five
Digit Com-
P0718 TSS Turbine shaft speed PCM has detected a GO to Pinpoint Test E.
sensor signal noisy noisy TSS signal.
P0720 OSS Insufficient input PCM detected a Abnormal shift GO to Pinpoint Test E.
from OSS sensor loss of OSS signal schedule, harsh
during operation. shifts.
P0721 OSS Output shaft speed PCM has detected Abnormal shift GO to Pinpoint Test E.
sensor signal noisy an erratic OSS schedule, harsh
signal. shifts.
P0722 OSS Insufficient input PCM detected a Abnormal shift GO to Pinpoint Test E.
from OSS sensor loss of OSS signal schedule, harsh
during operation. shifts.
P0731** SSA, 1st gear ratio error No 1st gear. Correct gear ratio REFER to the Solenoid
SSB, SSC not achieved for On/Off Charts. GO to
or commanded gear. Pinpoint Test A.
internal Shift errors may
parts also be due to other
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0732** SSA, 2nd gear ratio error No 2nd gear. Correct gear ratio REFER to the Solenoid
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0733** SSA, 3rd gear ratio error No 3rd gear. Correct gear ratio REFER to the Solenoid
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
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Five
Digit Com-
P0734** SSA, 4th gear ratio error No 4th gear. Correct gear ratio REFER to the Solenoid
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0735 SSA, 5th gear ratio error No 5th gear. Correct gear ratio REFER to the Solenoid
SSB, not achieved for On/Off Chart. GO to
SSC, commanded gear. Pinpoint Test A.
SSD or Shift errors may
internal also be due to other
parts transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected.
P0741** TCC TCC solenoid The PCM picked up Stuck OFF: harsh GO to Pinpoint Test A.
circuit error or an excessive shifts or
stuck OFF amount of TCC engagements.
slippage during Engine RPM may
normal vehicle be higher than
operation. expected.
P0743* TCC TCC solenoid TCC solenoid Open or short to GO to Pinpoint Test A.
circuit failure circuit fails to battery power:
during on-board provide voltage harsh shifts or
diagnostics drop across engagements,
solenoid. Circuit engine rpm higher
open or shorted or than expected. Short
PCM driver failure to ground: vehicle
during on-board stalls when in drive
diagnostics. gear at idle, harsh
shifts or
engagements or
engine rpm lower
than expected.
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Five
Digit Com-
P1740** TCC TCC solenoid TCC not Stuck OFF: harsh GO to Pinpoint Test F.
inoperative commanded. shifts or
Mechanical failure engagements,
of the solenoid engine rpm higher
detected. than expected.
Stuck ON: vehicle
stalls when in drive
gear at idle, harsh
shifts or
engagements or
engine rpm lower
than expected.
P0740* TCC TCC solenoid TCC solenoid Open or short to GO to Pinpoint Test A.
circuit failure circuit fails to battery power:
during on-board provide voltage harsh shifts or
diagnostic drop across engagements,
solenoid. Circuit engine rpm higher
open or shorted or than expected. Short
PCM driver failure to ground: vehicle
during on-board stalls when in drive
diagnostics. May gear at idle, harsh
flash TCIL. shifts or
engagements or
engine rpm lower
than expected.
P0962** PCA PCA solenoid Voltage through Short circuit GO to Pinpoint Test D.
circuit failure, short PCA solenoid is causes minimum
to ground checked. An error PCA pressure
will be noted if (minimum capacity)
tolerance is and limits engine
exceeded. torque (alternate
firm). Slips in gear
and 3rd gear
incorrect.
P0745 PCA PCA solenoid or PCA functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault-low pressure pattern indicating
mechanical or
hydraulic failure of
the transmission.
P0748 PCA PCA solenoid Electrical failure of Possible slip in gear GO to Pinpoint Test D.
inoperative the solenoid and/or 3rd gear
detected. ratio.
P0960 PCA PCA solenoid Voltage through Open circuit GO to Pinpoint Test D.
circuit open PCA solenoid is causes maximum
checked. Error is PCA pressure, harsh
noted if tolerance is engagements and
exceeded. shifts.
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Five
Digit Com-
P0963 PCA PCA solenoid short Voltage through Short to power GO to Pinpoint Test D.
to battery power or PCA solenoid is causes maximum
short to ground checked. An error PCA pressure, harsh
will be noted if engagements and
tolerance is shifts. Short to
exceeded. ground No 3rd
gear.
P0966 PCB PCB solenoid Voltage through Short to ground. No GO to Pinpoint Test D.
circuit failure, short PCB solenoid is 2nd and 5th gear.
to ground checked. An error
will be noted if
tolerance is
exceeded.
P0775 PCB PCB solenoid or PCB functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault low pattern indicating
pressure. mechanical or
the transmission.
P0778 PCB PCB solenoid Electrical failure of No 2nd and 5th GO to Pinpoint Test D.
inoperative the solenoid gear.
detected.
P0967 PCB PCB solenoid short Voltage through Short to battery GO to Pinpoint Test D.
to battery voltage, PCB solenoid is power: harsh shift
short to ground checked. An error and engagements.
will be noted if Short to ground
tolerance is No 2nd and 4th
exceeded. gear.
P0964 PCB PCB solenoid Voltage through Open circuit GO to Pinpoint Test D.
circuit open PCB solenoid is causes maximum
checked. Error is PCB pressure, harsh
exceeded. shifts.
P0795 PCC PCC solenoid or PCC functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault low pattern indicating
pressure. mechanical or
the transmission.
P0798 PCC PCC solenoid Electrical failure of Incorrect gear ratio GO to Pinpoint Test D.
inoperative the solenoid in 4th and 5th gear.
detected.
P0968 PCC PCC solenoid Voltage through Open circuit GO to Pinpoint Test D.
circuit open PCC solenoid is causes maximum
checked. Error is PCC pressure, harsh
exceeded. shifts.
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Five
Digit Com-
P0970 PCC PCC solenoid Voltage through No 4th and 5th GO to Pinpoint Test D.
circuit failure, short PCC solenoid is gear.
to ground checked. An error
will be noted if
tolerance is
exceeded.
P0971 PCC PCC solenoid short Voltage through Short to battery GO to Pinpoint Test D.
to power, short to PCC solenoid is power: harsh shift
ground checked. An error and engagements.
will be noted if Short to ground
tolerance is No 4th and 5th
exceeded. gear.
P0750* SSA SSA solenoid SSA circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 1st
drop across gear ratio incorrect
solenoid. Circuit or no gear ratio
open or shorted or errors, no 1st gear.
PCM driver failure Short to ground: no
during on-board 4th or 5th gear.
diagnostic.
P0753* SSA SSA solenoid SSA circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 1st
drop across gear ratio incorrect
solenoid. Circuit or no gear ratio
open or shorted or errors, no 1st gear.
PCM driver failure Short to ground: no
during on-board 4th or 5th gear.
diagnostic.
P1714 SSA SSA inoperative Mechanical failure Stuck OFF. Open GO to Pinpoint Test F.
of the solenoid or short to battery
detected. power: 1st gear
ratio incorrect or no
gear ratio errors, no
1st gear. May turn
on MIL. Stuck ON.
No 4th or 5th gear.
P0755* SSB SSB solenoid SSB circuit fails to Open or short to GO to Pinpoint Test A.
circuit failure provide voltage battery power: no
drop across 3rd gear. Short to
solenoid. Circuit ground: no 1st gear.
open or shorted or
PCM driver failure
during on-board
diagnostic.
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Five
Digit Com-
P0758* SSB SSB solenoid SSB circuit fails to Open or short to GO to Pinpoint Test A.
circuit failure provide voltage battery power: no
drop across 3rd gear. Short to
solenoid. Circuit ground: no 1st gear.
open or shorted or
PCM driver failure
during on-board
diagnostic.
P1715 SSB SSB inoperative Mechanical failure Stuck OFF: 3rd GO to Pinpoint Test F.
of the solenoid gear ratio incorrect,
detected. no 3rd gear. Stuck
ON: 1st gear ratio
incorrect or no 1st
gear.
P0760* SSC SSC solenoid SSC circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 2nd
drop across and 5th gear ratio
solenoid. Circuit incorrect. Short to
open or shorted or ground: 1st gear
PCM driver failure ratio incorrect or no
during on-board gear ratio errors.
diagnostic.
P0763* SSC SSC solenoid SSC circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 2nd
drop across and 5th gear ratio
solenoid. Circuit incorrect. Short to
open or shorted or ground: 1st gear
PCM driver failure ratio incorrect or no
during on-board gear ratio errors.
diagnostic.
P1716 SSC SSC inoperative Mechanical failure Stuck OFF: 2nd and GO to Pinpoint Test F.
of the solenoid 5th gear ratio
detected. incorrect. Stuck
ON: 1st gear ratio
incorrect or no gear
ratio errors.
P0765 SSD SSD solenoid SSD circuit failed Short to ground: no GO to Pinpoint Test A.
circuit failure to provide voltage engine braking.
drop across
solenoid. Circuit
shorted to ground.
P0768 SSD SSD solenoid SSD circuit failed Short to ground: no GO to Pinpoint Test A.
circuit failure to provide voltage engine braking.
drop across
solenoid. Circuit
shorted to ground.
P1717 SSD SSD inoperative Mechanical failure Stuck ON: no GO to Pinpoint Test F.
of the solenoid engine braking.
detected.
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Five
Digit Com-
P0791 Intermed- Intermediate shaft PCM has detected a Harsh shifts. GO to Pinpoint Test E.
iate shaft speed sensor signal loss of the
speed failure intermediate shaft
sensor speed sensor signal.
P0794 Intermed- Intermediate shaft PCM has detected Harsh shifts. GO to Pinpoint Test E.
iate shaft speed sensor signal an intermittent
speed intermittent intermediate shaft
sensor speed sensor signal.
P1124 TP TP voltage high/low TP was not in the Rerun at REFER to the
for on-board correct position for appropriate throttle Powertrain
diagnostic on-board diagnostic. position per Control/Emissions
application. Diagnosis (PC/ED)
manual.
P1460 A/C A/C clutch cycling A/C or defrost ON DTC set during REFER to the
pressure switch condition may on-board diagnostic Powertrain
error result from A/C rerun with A/C Control/Emissions
clutch being ON OFF. Failed ON Diagnosis (PC/ED)
during on-board EPC pressure manual.
diagnostic. slightly low with
A/C OFF.
P1636 SSx SSx ISIG PCM has detected INSTALL a new PCM.
communication an error with the
error ISIG chip.
P1700 TRANS Transmission Internal component FMEM becomes If other solenoid DTCs
indeterminate failure. Direct active engine are present, diagnose
failure one-way clutch rpm limited to and repair them first.
failure. 4,000 rpm. Failed a CLEAR DTCs and
neutral condition in drive vehicle. If P1700
1st, 3rd or 4th gear returns, disassemble
in automatic Mode. transmission and inspect
Only 2nd and 5th the direct one-way
gear available. clutch. Repair as
Other DTCs that required. CLEAR DTC.
may set P1700: Drive vehicle and verify
P0745, P1747, repair.
P1760, P1714,
P1715, P0750,
P0755.
P1703 BPP Brake not actuated Brake not cycled Failed ON or not REFER to the
during on-board during KOER. connected torque Powertrain
diagnostic KOER converter clutch Control/Emissions
will not engage at Diagnosis (PC/ED)
less than 1/3 manual.
throttle. Failed OFF
or not connected
torque converter
clutch will not
disengage when
brake is applied.
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Five
Digit Com-
P1703 BPP BPP switch circuit Brake ON circuit Failed ON or not REFER to the
failed failure during connected torque Powertrain
KOEO. converter clutch Control/Emissions
or not connected
torque converter
clutch will not
disengage when
brake is applied.
P1572 BPP BPP switch circuit Brake ON circuit Failed ON or not REFER to the
failed failure during connected torque Powertrain
normal operation. converter clutch Control/Emissions
or not connected
torque converter
clutch will not
disengage when
brake is applied.
P1780 TCS TCS not changing TCS not cycled No overdrive cancel RERUN on-board
switch states during self-test. when cycled during diagnostics and cycle
TCS circuit or KOER. switch. REFER to
switch open or Section 307-05 for
shorted. further diagnosis and
repair.
Rotunda Transmission Tester
The Rotunda Transmission Tester is used to
diagnose electronically controlled transmissions and
is used in conjunction with the pinpoint tests. The
tests should be carried out in order. Installing the
Rotunda Transmission Tester allows separation of
the vehicle electronics from transmission electronics.
Refer to the Rotunda Transmission Tester manual
for these tests.
Digital Transmission Range (TR) Sensor Testing
Resistance/Continuity Test
Switch Test Park/Neutral, Backup Lamp and
Optional Circuits
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Special Tool(s)
Diagnostics
Special Tool(s)
100W/12 Volt DC UV Lamp
tool
MLP-TR Cable
418-F107 (007-00111) or
equivalent
Transmission Fluid Pressure
Gauge
307-004 (T57L-77820-A)
Transmission Tester
307-F016 (007-00130) or
equivalent
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
Diagnosing electronically controlled automatic
transmissions is simplified using the following
Air Test Plate and Gaskets, procedures. It is important to remember that there is
Transmission
a definite procedure to follow. Do not take shortcuts
307-433-01, 307-433-02,
or assume that critical checks or adjustments have
307-433-03
already been made. Follow the procedures as written
to avoid missing critical components or steps. By
following the diagnostic sequence, the technician
will be able to diagnose and repair the concern the
first time. 73 III Automotive Meter
On-Board Diagnostics with Scan Tool
NOTE: For detailed instruction and other diagnostic
methods using the scan tool, refer to the scan tool
tester and the Powertrain Control/Emissions
Trans Tester TR/MLP Overlay
These quick tests should be used to diagnose the
and Manual
powertrain control module (PCM) and should be
carried out in order.
Quick Test 1.0 Visual Inspection
Quick Test 2.0 Set Up
Quick Test 3.0 Key On, Engine Off
(Continued)
Quick Test 4.0 Continuous Memory
Quick Test 5.0 Key On, Engine Running
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Special Test Mode For further information on other diagnostic testing
features using the VCM or generic scan tool, refer
Wiggle Test Mode
to the Powertrain Control/Emissions Diagnosis
Output Test Mode
(PC/ED) manual.
PCM Reset Mode
Clearing DTCs
OBD II Drive Cycle
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IN-VEHICLE REPAIR
Digital Transmission Range (TR)
Sensor
Special Tool(s)
307-351 (T97L-70010-A)
Removal
1 W704971 Transmission
1. With the vehicle in NEUTRAL, position it on a crossmember-to-floor pan
screws hoist. For additional information, refer to
Section 100-02. 2 7E395 Transmission selector lever
cable
3 W500015 Digital transmission range
(TR) sensor screws
4 7F293 Digital TR sensor
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2. WARNING: Secure the transmission to
the transmission jack with a safety chain.
Failure to follow these instructions may
Using a suitable transmission jack, support the
transmission.
3. Remove the transmission crossmember-to-floor
pan screws and lower the transmission enough
to gain access to the TR sensor.
6. Remove the digital TR sensor screws and
remove the digital TR sensor.
4. Disconnect the digital TR sensor connector.
Installation
1. CAUTION: The digital TR sensor
must fit flush against the boss on the case to
prevent damage to the sensor.
Install the digital TR sensor and loosely install
the screws.
5. Disconnect the transmission shift cable from the
manual control lever.
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4. Connect the digital TR sensor connector.
2. CAUTION: Tightening one screw
before tightening the other may cause the
sensor to bind or become damaged.
NOTE: The manual lever must be in the
NEUTRAL position.
Using the special tool, align the digital TR
sensor and tighten the screws in an alternating
sequence.
5. Install the transmission crossmember-to-floor
pan screws.
3. Connect the transmission shift cable to the
manual control lever.
6. Verify that the shift cable is adjusted correctly.
307-05.
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OF SUBASSEMBLIES
Direct Clutch Drum Assembly
Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)
Protector, Piston Seal
307-049 (T74P-77404-A)
Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM (or XT-5-QMC)
(US); CXT-5-LM12
(Canada)
Direct Clutch Drum Assembly
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1 7D044 Intermediate brake drum
assembly
2 7A548 Direct piston outer seal ring
3 7D404 Direct piston inner seal ring
4 7A262 Direct clutch piston
5 7A480 Direct piston spring (20
required)
6 7A527 Direct clutch piston spring
retainer
7 E860125-S Retaining ring
8 7B442 Direct clutch external spline
plates
9 7B164 Direct clutch internal spline
plates
10 7B066 Direct clutch pressure plate
11 E860126S/129S Retaining ring (select fit)
Disassembly
1. Remove the direct clutch retaining ring and the
direct clutch pressure plate.
1 Remove the direct clutch retaining ring.
2 Remove the direct clutch pressure plate.
3. WARNING: After removing the
retaining ring, use care when releasing the
pressure on the springs. Failure to follow
these instructions may result in personal
injury.
CAUTION: Do not fully compress the
special tool or damage to the spring retainer
may occur.
Using the special tool, remove the direct clutch
piston retaining ring.
2. Remove the direct clutch disc pack.
Inspect and install new friction plates if
worn, damaged or overheated.
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4. Relieve the direct clutch spring tension and 7. Remove and discard the direct clutch piston
remove the special tool. inner and outer seal.
1 Remove and discard the direct clutch piston
5. Remove the direct clutch piston spring retainer
inner seal.
and the direct clutch piston springs.
2 Remove and discard the direct clutch piston
1 Remove the direct clutch piston spring
outer seal.
retainer.
Clean the components as necessary.
2 Remove the direct clutch piston springs.
Assembly
6. WARNING: Air pressure must not
exceed 138 kPa (20 psi). Wear safety glasses
1. Inspect the clutch components for damage or
when using compressed air, and make sure
wear. Install new components as necessary.
the drum is facing down as shown. Failure to
Inspect the drum surface for damage.
Inspect the clutch piston bore and piston.
personal injury.
Check the fluid passages for obstructions.
Using compressed air, remove the direct clutch
All fluid passages must be clean and free of
piston from the direct clutch drum.
obstructions.
Apply air pressure to the hole in the drum
Inspect the clutch plates for damage.
while blocking the other hole with a finger.
Inspect the clutch springs.
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2. CAUTION: The lip seals must be
positioned as shown. Care must be taken to
prevent rollover of the lip seal.
NOTE: Use new seals to help prevent seal
failures.
Install the new direct clutch piston inner seal
and the direct clutch piston outer seal.
5. Install the direct clutch piston springs and the
retainer.
3. Verify the check ball is free to move.
6. WARNING: After removing the
retaining ring, use care when releasing the
pressure on the springs. Failure to follow
these instructions may result in personal
injury.
may occur.
4. CAUTION: Care must be taken to
prevent damage to the seals during
Using the special tool, install the direct clutch
installation.
Using the special tool, install the direct clutch
piston.
Lubricate the seals with transmission fluid
before installing.
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7. CAUTION: The direct clutch friction
plates are directional and must be installed
correctly. Alternate the internally splined
(clockwise) and the externally splined
(counterclockwise) clutch plates.
CAUTION: If new plates are used,
they should be soaked in clean automatic
transmission fluid before assembly.
When installing friction plates, alternate the
internally splined (clockwise) and the externally
splined (counterclockwise) clutch plates. Install
the direct clutch disc pack.
9. CAUTION: The retaining ring is a
8. Install the friction plates alternating the
select fit.
internally splined (clockwise) and the externally
Install the direct clutch pressure plate using the
splined (counterclockwise) clutch plates starting
original direct clutch retaining ring.
with an externally splined (counterclockwise)
clutch plate.
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11. Push down on the direct clutch disc pack and
check the gap between the direct clutch
retaining ring and the direct clutch pressure
plate with a feeler gauge.
drum is facing down as shown. Failure to
If the specifications do not match, use a
personal injury.
select fit direct clutch retaining ring to
match specifications and verify with a feeler
Air check the assembly.
gauge.
Direct Clutch
Thickness Diameter
mm In mm In Part Number
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122
E860128-S 2.08 0.0819 130.1 5.122
E860129-S 2.44 0.0961 130.1 5.122
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IN-VEHICLE REPAIR
Extension Housing Gasket
Special Tool(s)
205-479
Installer, Output Shaft Flange
307-404
Remover, Output Shaft Flange
307-523
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1 W701357 Transmission output shaft
flange coupler bolt (4
3. Remove the catalytic converter assembly. For
required)
insulator-to-extension housing
4. NOTE: Use a suitable transmission jack to center screw
support the transmission.
crossmember-to-floor pan
Remove the 4 transmission
screws
crossmember-to-floor pan screws.
flange nut
5 7089 Transmission output shaft
flange
6 W500311 Extension housing-to-case
screw
7 7A039 Extension housing
8 7086 Extension housing gasket
Removal
Section 100-02.
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5. Remove the transmission insulator-to-extension
8. CAUTION: The parking pawl, parking
housing center screw and remove the
pawl return and parking pawl shaft could
transmission crossmember.
fall out during removal of the extension
housing.
Remove the 7 extension housing screws and the
extension housing.
6. Remove and discard the nut.
9. Remove and discard the extension housing
gasket.
7. Using the special tool, remove the output shaft
flange.
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Installation
4. Install a new nut.
1. Clean the extension housing and install a new
extension housing gasket. Make sure the park
pawl is installed correctly.
5. Loosely install the transmission
insulator-to-extension housing center screw.
2. CAUTION: Make sure the parking
lever actuating rod is correctly seated into
the case parking rod guide cup.
Install the extension housing and screws.
6. Position the transmission crossmember in the
vehicle and loosely install the transmission
3. Using the special tools, install the output flange.
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7. NOTE: The transmission support insulator must 9. With the transmission support insulator
be neutralized. neutralized, tighten the transmission
Slide the transmission support insulator forward,
rearward and side-to-side until the gaps between Tighten to 70 Nm (52 lb-ft).
the transmission support insulator snubber and
crossmember are equal.
8. With the transmission support insulator
neutralized, tighten the transmission
10. Install the catalytic converter assembly. For
11. Install the driveshaft. For additional
12. Check the transmission fluid level. For
additional information, refer to Transmission
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IN-VEHICLE REPAIR
Extension Housing Seal
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Remover, Torque Converter
Fluid Seal
307-309 (T94P-77001-BH)
205-115
205-479
Installer, Output Shaft Flange
307-404
307-523
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3. Using a suitable transmission jack, support the
transmission.
flange coupler bolts (4
4. Remove the 4 transmission
required)
crossmember-to-floor pan screws only and
lower the transmission enough to gain access to
screws the extension housing seal.
flange nut
4 7089 Transmission output shaft
flange
5 7052 Extension housing seal
Removal
Section 100-02.
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Installation
1. NOTE: Make sure the extension housing seal is
correctly installed onto the special tool and the
garter spring is in the correct position.
Using the special tool, install the new extension
housing seal.
flange.
2. Using the special tools, install the output flange.
7. Using the special tools, remove and discard the
extension housing seal.
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4. Install the 4 transmission crossmember-to-floor 5. Install the driveshaft. For additional
pan screws only. information, refer to Section 205-01.
6. Check the transmission fluid level. For
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IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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connectors and retaining clip from the RH pan
1 7A010 Transmission fluid pan drain
rail and then position the connectors aside.
plug
2 6734 Transmission fluid pan drain
plug gasket
3 W500213 Transmission fluid
pan-to-case screw (16
required)
4 7A194 Transmission fluid pan
5 7A191 Transmission fluid pan gasket
6 W705559 Transmission fluid filter
screw (2 required)
7 7A098 Transmission fluid filter
Removal
CAUTION: Lubricate the fluid filter seals 4. Remove the HO2S connector from the front of
with clean automatic transmission fluid or they the transmission pan rail.
may be damaged.
NOTE: Make sure that the fluid filter seals are
correctly seated on the filter.
NOTE: The transmission fluid pan gasket is
reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
NOTE: Install a new transmission fluid filter.
Section 100-02.
5. NOTE: The transmission fluid pan gasket is
2. Remove the drain plug and drain the
reusable, clean and inspect for damage. If not
transmission fluid.
Discard the gasket.
Remove the transmission fluid pan and gasket.
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6. Remove and discard the transmission fluid
filter.
3. Install the fluid pan magnet in the transmission
fluid pan.
Installation
1. Clean and inspect the transmission fluid pan
and magnet.
Install the transmission fluid pan and gasket and
loosely install the screws.
2. CAUTION: Lubricate the transmission
fluid filter O-ring seals with clean automatic
transmission fluid or the seals may be
damaged.
NOTE: Make sure the transmission fluid filter
seals are correctly seated on the filter.
Lubricate the seals and install the transmission
fluid filter and screws.
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5. Tighten the screws in a crisscross sequence. 8. Install the drain plug.
Tighten to 11 Nm (8 lb-ft). Install a new gasket onto the drain plug
assembly.
6. Install the HO2S connector to the front of the
transmission pan rail.
9. NOTE: It will be necessary to hold the drain
plug with a wrench when removing the fluid
level indicator plug.
NOTE: Use a 3/16-inch Allen key to remove
the fluid level indicator plug.
Remove the fluid level indicator plug.
7. Connect the HO2S connector and install the
sensor wire retaining clip to the RH side of the
10. Carry out the fluid level check. Refer to
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OF SUBASSEMBLIES
Special Tool(s)
Fluid Pump
Transmission Fluid Pump Seal
Aligner
Special Tool(s)
307-451/1
Installer, Torque Converter
Fluid Seal
307-349 (T97T-77000-A)
Sizer
307-451/2
Alignment Set, Fluid Pump
307-S039 (T74P-77103-X)
Installer
307-451/3
Aligner, Fluid Pump Handle
307-431
Material
Item Specification
Aligner, Fluid Pump Pilot
Multi-Purpose Grease ESB-M1C93-B
307-432
XG-4 and/or XL-5
Disassembly
1. Remove the fluid pump gasket, fluid pump seal
ring and the No. 1 thrust washer.
Sizer, Piston Seal
1 Remove and discard the fluid pump gasket.
307-338 (T95L-70010-G)
2 Remove and discard the fluid pump seal
ring (square cut).
3 Remove and tag the No. 1 thrust washer.
Alignment Pins, Transmission
Pump
307-398
(Continued)
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2. Remove the fluid pump support seal ring.
6. Remove the drive gear O-ring seal and discard.
Inspect the fluid pump gears for cracks and
3. Remove the seal rings.
scoring.
4. Remove the fluid pump housing.
7. Inspect the overdrive pump.
Inspect the overdrive pump support gear
pockets for scoring and wear.
Clean and inspect the overdrive and rear
input shaft bushings.
5. NOTE: A rough casting on the pump surface
crescent is not a flaw.
NOTE: The fluid pump gears are part of the
pump assembly and are not repaired separately.
Remove the fluid pump gears.
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Assembly
8. Inspect the fluid pump adapter plate for scoring
and wear.
1. NOTE: Minor burrs and scoring may be
removed with crocus cloth. If damage is found,
install a new assembly.
Inspect the fluid pump components for the
following:
Pump body and case for burrs.
Fluid passages for obstructions.
2. NOTE: Check and make sure that the garter
spring in the seal has not popped off of the
converter hub seal.
Install a new seal onto the special tool.
9. Remove and discard the valve.
3. Using the special tool, install the converter hub
seal.
10. Inspect the fluid pump to converter housing
bushing.
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4. Install a new O-ring seal in the fluid pump
drive gear.
7. Install a new seal on the new valve.
5. CAUTION: Lubricate the special tool
with multi-purpose grease.
Using the special tool, seat the O-ring seal in
the pump gear.
8. Install a new valve with the tab facing down.
6. CAUTION: The chamber on the inside
edge of the small gear must be UP when in
the pump housing gear pocket. The dimple
on the larger gear must be DOWN when in
the pump housing gear pocket.
Install the pump gears into the fluid pump
housing. Apply multi-purpose grease to the
pump gear to prevent scoring at start up.
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9. First, install the fluid pump adapter plate, then 12. Loosely install the fluid pump housing screws
install the alignment pins in their correct in their correct location and remove the special
location. tools.
13. Install the 2 remaining screws.
10. CAUTION: The special tools must be
used to correctly align the pump with the
adapter plate to reduce gear noise, bushing
failure and leakage.
Using the special tool, align the fluid pump to
the adapter plate.
14. Tighten all of the fluid pump screws in a star
pattern.
11. Using the special tools, assemble the pump.
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15. Install a new fluid pump seal ring.
18. CAUTION: Verify correct seal
installation. Make sure seal grooves are clean
and free of burrs.
NOTE: Make sure seal grooves are clean and
free of burrs. Make sure that the seal is seated
into the groove.
Verify the seal is installed correctly.
16. Install the 2 new seal rings.
19. CAUTION: Failure to correctly size
the seal will cause damage to the seal when
the torque converter is installed.
Using the special tool, size the seal to the
correct size. Leave the special tool on the seal
ring for 2 minutes to obtain the correct seal
size.
17. CAUTION: Be careful not to
overstretch the seal ring past the seal ring
groove. Damage to the seal will occur.
Using the special tools, install the fluid pump
seal ring.
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OF SUBASSEMBLIES
Forward Clutch
Special Tool(s)
307-015 (T65L-77515-A)
307-051 (T74P-77548-A)
Gauge, Forward Clutch Seal
307-434
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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1 7D483 Forward clutch retaining ring
(select fit)
2 7B066 Forward clutch pressure plate
3 7B164 Forward clutch internal plates
friction
(vehicle-dependent)
4 7B442 Forward clutch external plates
steel (vehicle-dependent)
5 E860109 Forward clutch retaining ring
6 7G229 Forward clutch spring
assembly
7 7A262 Forward clutch piston
8 7A360 Forward clutch cylinder
assembly
Disassembly
1. Remove the pressure plate.
1 Remove the forward clutch retaining ring.
2 Remove the pressure plate.
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2. Remove the forward clutch disc pack.
Inspect the forward clutch plates for wear,
damage or overheating.
4. Relieve the forward clutch spring tension and
remove the tool.
5. Remove the forward clutch piston spring
assembly.
3. WARNING: Use caution when
releasing tool pressure on the clutch piston
springs. Failure to follow these instructions
CAUTION: Do not fully depress the
may occur.
Using the special tool, remove the forward
clutch piston retaining ring.
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2. NOTE: If the seals on the forward clutch
piston show any signs of damage, a new
forward clutch piston will need to be installed.
when using compressed air. Make sure the
cylinder is facing down as shown. Failure to
Inspect the forward clutch piston and seals.
personal injury.
Remove the forward clutch piston.
1 Place the forward clutch cylinder with
forward clutch piston facing down.
2 Install the center support on the forward
clutch cylinder.
3 Apply air pressure to the left port of the
center support.
3. Inspect the forward clutch drum assembly.
1 Inspect the forward clutch cylinder surfaces
for scores or burrs.
2 Inspect the forward clutch piston for scores
or burrs.
3 Verify the check ball is free to move in the
piston.
Assembly
1. Inspect the clutch components for damage or
wear. Install new components as necessary.
Check the fluid passages for obstructions.
All fluid passages must be clean and free of
obstructions.
Inspect the clutch plates for damage.
Inspect the clutch springs.
Inspect the needle bearing and seal rings for
damage.
Check clutch hub thrust surfaces for
damage.
Check clutch plates for flatness and fit on
the clutch hub serrations.
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4. NOTE: The special tool must be installed on 6. Install the forward clutch piston spring
the forward clutch piston for a couple of assembly.
minutes prior to installing it into the forward
clutch cylinder.
Install the special tool on the forward clutch
piston.
7. CAUTION: Do not fully depress the
clutch spring compressor or damage to the
spring retainer may occur.
Using the special tool, install the forward clutch
5. CAUTION: Care must be taken to piston spring retaining ring.
prevent damage to the seals.
NOTE: Lubricate the forward clutch piston
inner and outer seal with clean automatic
transmission fluid.
Using the special tool, install the forward clutch
piston assembly into the forward clutch
cylinder.
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8. CAUTION: The forward clutch friction
plates are directional and must be installed
with grooves pointing counterclockwise.
CAUTION: If new plates are used,
they should be soaked in clean automatic
transmission fluid before assembly.
If reusing plates, grooves must be installed
counterclockwise. Install the direct clutch disc
pack.
9. Install the steel clutch plates and friction clutch
plates in alternating order starting with a steel
clutch plate.
10. CAUTION: The retaining ring is a
select fit.
Install the original selective retaining ring.
1 Install the forward clutch pressure plate.
2 Install the original selective retaining ring.
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12. Check the forward clutch disc pack free play.
1 Press down on the forward clutch disc pack.
when using compressed air. Make sure the
2 Using a feeler gauge, check the gap
cylinder is facing down as shown. Failure to
between the forward clutch retaining ring
and the forward clutch pressure plate.
personal injury.
If the clearance is not within specifications,
Air check the forward clutch piston.
install the correct size retaining ring.
1 Place the forward clutch cylinder with the
Thickness Diameter
forward clutch piston facing down.
2 Install the transmission center support on
the forward clutch cylinder. XW4Z-7D483-AB 1.73 0.0681 141.45 5.65
XW4Z-7D483-AC 2.08 0.0819 141.45 5.65 3 Apply air pressure to the left port of the
center support.
XW4Z-7D483-AD 2.44 0.0961 141.45 5.65
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The forward planetary gearset pinions drive the
Geartrain
forward sun gear.
Power is transmitted from the torque converter to
The forward sun gear is splined to the input shell.
the planetary gearsets through the input shaft. Bands
and clutches are used to hold and drive certain
The forward carrier is splined to the output shaft.
combinations of gearsets. This results in 5 forward
Planetary Gearset Low/Reverse
ratios and 1 reverse ratio, which are transmitted to
the output shaft and differential.
this section.
Gear Ratio
The low/reverse planetary gearset is connected to
1st 3.22 to 1
the reverse brake drum by lugs from the low/reverse
2nd 2.29 to 1
brake drum to the lugs of the low/reverse planetary
3rd 1.55 to 1 gearset.
4th 1.00 to 1
The low/reverse planetary gearset is driven by the
5th 0.71 to 1 forward sun gear which is splined to the input
shell.
Reverse 3.07 to 1
The forward sun gear drives the pinions in the
low/reverse planetary gearset.
Planetary Gearset Overdrive
The pinions of the low/reverse planetary gearset
drive the output shaft ring gear and output shaft
this section.
hub which is splined to the output shaft.
The planetary gear overdrive carrier is driven by the
The low/reverse planetary gearset can be held by
input shaft.
the low one-way clutch in the low/reverse brake
drum, or by the low/reverse band.
The overdrive planetary gearset carrier drives the
center shaft via the overdrive one-way clutch in
Input Shaft
1st, 3rd, 4th and REVERSE gears.
In 2nd and 5th gears, the overdrive sun gear is
this section.
held causing the pinion gears to rotate around the
overdrive sun gear. The radial positioning of the input shaft is
controlled by 2 bushings in the stator support.
The pinion gears, in turn, drive the overdrive ring
gear resulting in the 5th (overdrive) gear ratio. Axial positioning of the input shaft is controlled
by the splines in the converter turbine hub and the
The overdrive planetary gearset is internally
retaining ring in the overdrive planetary carrier.
splined to the coast clutch for engine braking.
Output Shaft
Planetary Gearset Forward
this section.
this section.
The output shaft is supported by a bearing in the
The forward planetary gearset is splined to the
case and by a bearing in the extension housing. End
output shaft.
positioning is controlled by the parking gear and by
The forward planetary gearset is driven by the
the reverse ring gear hub and snap ring.
forward ring gear when the forward clutch is
applied.
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Main Control
Hydraulic System
Fluid Pump
this section.
The main control assembly and related
this section.
components are part of the pressure side of the
The fluid pump provides the fluid pressure
hydraulic system.
necessary to charge the torque converter, main
The main control assembly consists of the
control assembly, transmission cooling system,
solenoids, the valve body assembly and the
lubrication system and apply devices.
separator plate.
The fluid pump is a positive displacement, gear
These components combine to convert electrical
type pump.
signals into hydraulic actions.
The fluid pump is driven by the torque
All valves in the main control assembly are an
converter impeller hub.
odized aluminum and cannot be sanded, filed
or dressed in any other way. If there is any
Filter
damage to the valves that prevents or restricts
their movement, install a new main control
this section.
assembly.
All fluid drawn from the transmission fluid pan
by the fluid pump passes through the fluid filter.
The transmission fluid filter and its accompanying
seals are part of the fluid path from the sump
(pan) to the fluid pump.
The transmission fluid filter has a bypass
section which allows fluid vented at the main
regulator valve to be recirculated to the fluid
pump, without passing through the
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Identification Tags
ID Tag Located on Transmission Case
Item Description
1 Transmission part number
2 Bar code 1
3 Transmission plant model code part 1
4 Transmission plant model code part 2
5 Bar code 2
6 Transmission serial number
7 Transmission build date (DD MM YY)
8 Assembly plant line shift
All vehicles are equipped with a vehicle
certification label, located on the driver side door
lock post. Refer to the code in the space marked
TR. For model, service ID level or build date
information, refer to the transmission service ID tag
located on the transmission case.
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Leak Check Test with A Black Light
Leakage Inspection
Automatic Transmission/Power Steering Dye
Special Tool(s) 164-R3701 or equivalent (specifically formulated for
ATF) is used to detect a transmission fluid leak.
100W/12 Volt DC UV Lamp
164-R0751 or equivalent 1. Add Automatic Transmission/Power Steering
Dye to the transmission fluid. Use one 30.0 mL
(1 oz) of dye solution for every 3.8L (4 quarts)
of transmission fluid.
2. Start and run the engine until the transaxle
reaches its normal operating temperature.
Observe the back of the cylinder block and top
Material
of the torque converter housing for evidence of
Item Specification
fluid leakage. Raise the vehicle on a hoist and
MERCON V Automatic MERCON V run the engine at fast idle, then at engine idle,
Transmission Fluid
occasionally shifting to the DRIVE and
REVERSE ranges to increase pressure within
(US); CXT-5-LM12
the transaxle. Observe the front of the flexplate,
(Canada)
back of the cylinder block (in as far as
Automatic
possible), inside the torque converter housing
Transmission/Power
and the entire case until fluid leakage is evident
Steering Dye
and the probable source of leakage can be 164-R3701 or equivalent
determined.
External Fluid Leaks
Leak Path Possible Source
Leaks at the fluid pan to case Pan bolts not tightened to specification.
Pan gasket damaged.
Case pan rail damaged.
Fluid cooler lines or fittings leaking Cooler line(s), cooler line fitting(s) damaged. Refer to
Section 307-02.
Cooler line fitting to case union damaged. Refer to
Section 307-02.
Case damage at case fitting.
Fluid cooler line nut-to-case fittings leaking Damaged or missing O-ring seals. Refer to Section
307-02.
Fitting(s) not tightened to specifications. Refer to
Section 307-02.
Leaks at the fluid cooler Fluid cooler damage. Refer to Section 307-02.
Fitting(s) damaged or not tightened to specifications.
Leaks at external sensors Damaged or missing O-ring seals.
Screw not tightened to specification.
Leaks at the manual control lever seal Damaged or missing lever seal.
Leaks at the solenoid body harness connector Solenoid body harness connector O-ring seal(s), either
on the harness end or the solenoid body, damaged or
missing.
Fluid leakage in torque converter area For possible sources, refer to Fluid Leakage in the
Torque Converter Area Chart.
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External Sealing O-ring seals
Seal rings
CAUTION: Do not try to stop a fluid leak
by increasing the torque beyond specifications.
Seal grommets
This may cause damage to the transmission case
Seal washers
threads.
Thread sealant
The transmission has the following parts to prevent
external fluid leakage:
Gaskets
Lip-type seals
External Sealing
9 W702969-S300 Seal intermediate servo 1 7902 Torque converter assembly
cover
2 7A248 Seal assembly front fluid
10 7D027 Cover intermediate servo pump
11 390318-S2 Plugs pipe (2 required) 3 7A248 Seal front fluid pump
12 W702981-S300 O-ring seals sensor-to-case 4 W704892-S300 Screw and washer assembly
13 7H103 Sensor assembly (3 5 7G187 Fluid pump
required)
6 7A136 Gasket fluid pump
14 6026 Plug case
7 7D027 Cover overdrive servo
15 7034 Vent assembly
8 W703119-S300 Seals overdrive servo
16 7060 Shaft output cover (2 required)
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17 7086 Gasket extension housing
18 7A039 Extension housing assembly
19 7052 Seal extension housing
20 W500311-S309 Screw extension housing
(7 required)
21 7005 Case assembly
22 7B498 Seal manual lever
23 7A256 Manual lever
24 7C492 Screw band adjuster (2
required)
25 71000-S100 Nuts band adjuster (2
required)
26 W705928-S300 O-ring seals (2 required)
27 7A191 Gasket fluid pan
28 7A194 Fluid pan
29 W500213-S309 Screw fluid pan (16
required)
30 W704999 Plug short hex
31 7A101 Plug fluid drain
External Sealing
CAUTION: Do not try to stop a fluid leak
by increasing the torque beyond specifications.
Possible
This may cause damage to the transmission case
Leak Path Symptom Source
threads.
1, 2 and 4 Leak at the front Pump lip seal
The transmission has the following parts to prevent
of the
external fluid leakage:
transmission
1, 2 and 4 Leak at the front Converter hub Gaskets
of the weld
Lip-type seals
transmission
O-ring seals
1, 2 and 4 Leak at the front External pump
of the seal (large)
Seal rings
transmission
Seal grommets
1, 2 and 4 Leak at the front Pump-to-case
Seal washers of the screws
transmission
Thread sealant
1, 2 and 4 Leak at the front Pump gasket
Fluid Leakage In Torque Converter Area of the
transmission
Leakage at the front of the transmission, as
3 Leak at the front Torque
evidenced by fluid around the torque converter
of the converter seal
housing part of the case, may have several sources.
transmission weld
By careful observation, it is possible in many
3 Leak at the front Torque
instances to pinpoint the source of the leak before
of the converter stud
removing the transmission from the vehicle.
transmission
The paths, which the fluid takes to reach the bottom
5 Leak at the front Engine oil leak;
of the torque converter housing part of the case, are
of the rear main seal
shown in the illustration. The 5 numbers in the transmission
illustration correspond with the 5 flow path steps.
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Possible Possible
Leak Path Symptom Source Leak Path Symptom Source
5 Leak at the front Engine valve 5 Leak at the front Engine oil
of the cover of the pressure sensor
transmission transmission
5 Leak at the front Oil galley 6 Leak between Venting
of the engine and
transmission transmission
case
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IN-VEHICLE REPAIR
Main Control Valve Body
Special Tool(s)
Aligner, Valve Body (2
required)
307-334 (T95L-70010-C)
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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7 W705559 Transmission fluid filter 1 7A010 Transmission fluid pan drain
screw (2 required) plug assembly
8 7A098 Transmission fluid filter 2 6734 Transmission fluid pan drain
plug gasket
9 W702359 Reverse servo screw (4
required) 3 Solenoid body electrical
connector screw
10 7B193 Reverse servo assembly
4 W500213 Transmission fluid
11 W703189 Solenoid body screw (7
pan-to-case screw (16
required)
required)
12 W702921 Solenoid body screw
13 7G391 Solenoid body
(Continued)
(Continued)
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3. NOTE: Clean the area around the solenoid
body connector to prevent contamination.
14 W705928 Solenoid body O-rings
Disconnect the solenoid body harness electrical
15 W500100 Manual valve detent spring
screw connector.
16 7E332 Manual valve detent spring
17 W500102 Main control valve body
screw (18 required)
screw
screw
20 7A100 Main control valve body
assembly
Removal
CAUTION: Lubricate the fluid filter seals
with clean automatic transmission fluid or they
may be damaged.
NOTE: Clean the area around the solenoid body
connector to prevent contamination.
NOTE: The transmission fluid pan gasket is
Section 100-02.
transmission fluid.
5. Remove the HO2S connector from the front of
the transmission pan rail.
Discard the drain plug gasket.
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6. NOTE: The transmission fluid pan gasket is 9. Remove the screws and the solenoid body.
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should be
reused.
Remove the transmission fluid pan and gasket.
10. Remove the manual control valve detent spring.
7. Remove the transmission fluid filter.
11. Remove the main control valve body bolts and
the main control valve body assembly.
8. Remove the 4 screws attaching the reverse
servo to the transmission case and remove the
servo.
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Installation
3. Remove the special tool and loosely install the
screw.
1. Install the special tools into the transmission
case.
2. Using the special tools, install the main control
valve body and loosely install the screws.
1 Install the short screw.
2 Install the screw with the larger head.
3 Install the remaining screws.
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4. Tighten the screws in the sequence shown.
5. Install the manual control valve detent spring.
6. Install the reverse servo and the 4 screws.
Tighten the screws in sequence in 2 stages.
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7. Install new O-ring seals on the solenoid body
connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
8. CAUTION: Inspect the transmission
case bore to make sure it is free of foreign
material and not damaged. If it is damaged,
transmission leak may occur.
Install the solenoid body. Tighten the screws in
sequence shown.
11. Tighten the screws in a crisscross sequence.
9. CAUTION: Lubricate the fluid filter
seals with clean automatic transmission fluid
or they may be damaged.
fluid filter.
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12. Install the drain plug.
Install a new gasket onto the drain plug
assembly.
15. CAUTION: Damage will occur to the
solenoid body assembly if the screw is
tightened above specification.
NOTE: Always install new O-ring seals on the
vehicle harness connector.
NOTE: Clean the area around the connector to
prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the
O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the
transmission connector and connect the
connector.
16. Fill the transmission to the correct level. For
Fluid Drain and Refill Without Torque
Converter Drain Plug in this section.
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OF SUBASSEMBLIES
Main Control Valve Body
Special Tool(s)
Aligner, Valve Body (2
required)
307-334 (T95L-70010-C)
8 Spring converter clutch 1 Clip retainer
control valve
2 Plug retainer
9 Valve converter clutch
3 Valve assembly thermo
control
4 Valve fluid cooler bypass
10 Plate
5 Spring fluid cooler bypass
11 Spring coast clutch control
6 Clip retainer
12 Valve coast clutch control
7 Plug retainer
13 Clip retainer
(Continued)
(Continued)
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14 Plug retainer 49 Plug retainer
15 Valve converter clutch 50 Spring converter limit
back pressure
51 Valve converter limit
16 Spring converter clutch
52 Plate
back pressure
53 Spring solenoid regulator
17 Clip retainer
valve
18 Plug retainer
54 Valve solenoid regulator
19 Valve VFS2 modulator
55 Valve manual
20 Spring VFS2 modulator
56 Clip retainer
valve
57 Plug retainer
21 Clip retainer
58 Spring rear servo control
22 Plug retainer
valve
23 Valve intermediate servo
59 Valve rear servo control
release
60 Clip retainer
24 Spring intermediate servo
61 Plug retainer
release valve
62 Spring RS ISA select
25 Plate
valve
26 Spring high clutch control
63 Valve RS ISA select
27 Valve high clutch control
64 Clip retainer
28 Plug retainer
65 Plug retainer
29 Clip retainer
66 Spring forward
30 Valve reverse modulator
engagement control valve
31 Spring reverse modulator
67 Valve forward engagement
valve
control
32 Clip retainer
68 Plate
33 Plug retainer
69 Spring Overdrive servo
34 Valve reverse engagement control
35 Spring reverse engagement 70 Valve Overdrive servo
valve control
36 Clip retainer 71 Retainer clip
37 Plug retainer 72 Sleeve converter clutch
modulator control
38 Valve VFS1 modulator
39 Spring VFS1 modulator
modulator control
valve
40 Clip retainer
modulator
41 Sleeve
75 Spring converter clutch
42 Valve booster
modulator control
43 Valve booster
76 7Z490 Plate assembly main
control valve body separator 44 Spring inner
77 7E195 Ball lubrication check 45 Spring outer
78 7E195 Ball shuttle valve 46 Spring retainer
79 7A101 Body control valve lower 47 Valve main regulator
80 W701099 Screws separator plate 48 Clip retainer
(Continued)
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Disassembly
2. CAUTION: Do not stone, file or sand
the valves. This will remove the anodized
1. NOTE: The valve body separator plate has a
finish and may result in further main control
bonded gasket. Do not reuse. Discard the plate.
or transmission damage.
Remove and discard the valve body separator
After cleaning the main control valve body,
plate.
carry out the following:
Inspect all valve and plug bores for scoring
or burrs.
Check all fluid passages for obstructions.
Inspect all valves and plugs for burrs.
Inspect all mating surfaces for burrs or
distortion.
Inspect all springs for distortion.
Check all valves and plugs for free
movement in their respective bores.
X Valves and plugs, when dry, must fall
from their own weight into their
respective bores.
2. Remove the check balls.
Roll the manual valve on a flat surface to
check for a bent condition.
3. Assemble the main control valve body.
4. Install the main control valve body check balls.
3. NOTE: Refer to the disassembled view.
Disassemble the main control valve body only
if cleaning is required.
Assembly
1. CAUTION: Do not lose parts when
cleaning or repairing.
Thoroughly clean all parts in solvent and blow
dry with moisture-free compressed air.
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5. NOTE: Use a new valve body separator plate
for main control valve body installation.
Using the special tools, install a new main
control valve body separator plate.
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OF SUBASSEMBLIES
Output Shaft Ring Gear and Hub
Shaft Assembly
Disassembly
Assembly
1. Install the output shaft ring gear onto the output
shaft hub.
1 Install the output shaft ring gear.
2 Install the retaining ring.
1 7A153 Output shaft ring gear
2 7D164 Output shaft hub
3 7C122 Retaining ring
4 7D019 Output shaft hub seal
1. Inspect the output shaft ring gear and hub shaft
assembly for damage. If repair is necessary, use
the following procedure.
2. Remove the seal.
3. Remove the output shaft ring gear from the
output shaft hub.
1 Remove the retaining ring.
2 Remove the output shaft ring gear.
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2. Install the seal.
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Select KOEO On-Demand Self Test and KOER
Output State Control (OSC) Mode
On-Demand Self Tests.
Output state control (OSC) mode allows the
Carry out test and record DTCs.
technician to take control of certain parameters to
function the transmission.
Repair all non-Transmission DTCs.
For example, OSC allows the technician to shift the
Repair all VSS and digital TR sensor DTCs.
transmission only when commanding a gear change.
Make sure that VSS and digital TR sensors are
If the technician commands 1st gear in OSC, the
functional.
transmission will remain in 1st gear until the
Select Active Command Modes.
technician commands the next gear.
Select Output State Control.
Another example of the OSC features is that a
technician can command a shift solenoid to turn ON
Select Trans - Bench Mode or Trans - Drive
or OFF when carrying out an electrical circuit
Mode.
check. OSC has 2 modes of operation for
OSC Transmission Bench Modes
transmission, the BENCH Mode and the DRIVE
Mode. Each mode/parameter has a unique set of
The following transmission BENCH Modes may be
vehicle operating requirements that the technician
used as necessary during diagnostics.
must meet before being allowed to operate OSC.
SSA, SSB, SSC, SSD and TCC in Bench
NOTE: To operate OSC, the digital transmission
Mode
range (TR) sensor and the vehicle speed sensor
CAUTION: The parking brake must be set
(VSS) must be operational. No diagnostic trouble
prior to carrying out this procedure.
codes (DTCs) related to the digital TR sensor or the
VSS can be present.
The BENCH Mode allows the technician to carry
out electrical circuit checks on the following
The vehicle requirements MUST BE MET when
components:
SENDING the OSC value. Refer to vehicle
requirements for each individual test.
SSA - Activates SS A OFF or ON.
If the vehicle requirements are NOT MET when
SSB - Activates SS B OFF or ON.
SENDING the OSC value, an ERROR
SSC - Activates SS C OFF or ON.
MESSAGE will appear. When the ERROR
SSD - Activates SS D OFF or ON.
MESSAGE is received, OSC is aborted and must
be restarted.
TCC - Activates TCC OFF or ON.
If after a sent value is substituted and the vehicle
OSC SSA, SSB, SSC, SSD, TCC BENCH Mode
requirements are no longer met, the powertrain
operates ONLY when:
control module (PCM) will cancel the OSC value
VSS and digital TR sensor are operational.
and resume normal operation. No error message
will be sent. No VSS and digital TR sensor DTCs.
The OSC value XXX may be sent anytime to Transmission range selector lever is in P or N.
cancel OSC.
Key ON.
Engine OFF. OSC Procedures
OSC Command Values:
Carry out visual inspection and vehicle
preparation as necessary.
OFF - Turns solenoid OFF.
Select Vehicle and Engine Selection menu.
ON - Turns solenoid ON.
Select appropriate vehicle and engine.
XXX - Cancels OSC value sent.
Select Diagnostic Data Link.
SEND - Sends the values to PCM.
Select Powertrain Control module.
Select Diagnostic Test Mode.
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Bench Mode Procedure for SSA, SSB, OSC PCx BENCH Mode should ONLY be
SSC, SSD and TCC
operated to check PRESSURE FUNCTIONALITY
using an installed pressure gauge (300 psi) when:
Follow operating instructions from the scan tool
menu screen:
No VSS and digital TR sensor DTCs.
Select Trans - Bench Mode.
Transmission range selector lever is in P or N.
Select PIDs to be monitored.
Pressure gauge installed.
Monitor all selected PIDs during test.
Key ON.
Select Parameters - SSA, SSB, SSC, SSD or
Engine ON.
TCC.
Engine rpm at least 1500.
Select ON to turn solenoid ON.
OSC PCx BENCH Mode should ONLY be
Press SEND to send command ON.
operated to complete PCx SOLENOID CIRCUIT
PINPOINT TESTS when:
Select OFF to turn solenoid OFF.
Press SEND to send command OFF.
Select XXX to cancel at any time.
No VSS and digital TR sensor DTCs are present.
Press SEND.
Transmission range selector lever is in P or N.
Key ON.
PCA, PCB, PCC in Bench Mode
Engine OFF.
CAUTION: The parking brake must be set
OSC Command Values:
prior to carrying out this procedure.
The BENCH Mode is also used to test the 00 - Sets PCx pressure to 00 psi.
functionality of the transmission electronic pressure
15 - Sets PCx pressure to 15 psi.
control. During BENCH Mode, the PCx solenoids
can be commanded in increments of 15 psi from 0
to 90 psi and 90 to 0 psi.
The line pressure tap is used to verify output
pressure from PC A or PC B by turning either one
OFF while verifying the output from the other
solenoid. The second pressure tap is used to verify
the output from the PC C solenoid.
SEND - Sends the values to PCM.
The OSC functions for the parameter PCx allows
the technician to choose the following options:
Bench Mode Procedure for PCx
PCx - Activates PCx to selected values.
Following operating instructions from the scan tool
00 - Sets PCx pressure to 00 psi. menu screen:
Select Trans - Bench Mode.
Select Parameters - PCx.
Select Value 0 - 90 psi.
Press SEND to send command.
Press SEND.
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OSC Transmission Drive Modes 5 - PCM selects 5th gear.
The DRIVE Mode allows control of 3 transmission
parameters. Each mode/parameter has a unique set
SEND - Sends the values to the PCM.
of vehicle operating requirements that the technician
must meet before being allowed to operate OSC. Drive Mode Procedure for GEAR
The recommended procedure, when using the
DRIVE Mode, is to control one parameter at a time.
menu screen.
The DRIVE Mode allows the technician to carry out
the following functions on the transmission:
Select Trans - Drive Mode.
GEAR - Allows upshifts or downshifts.
TCC - Engages or disengages the torque converter
clutch.
Select Parameters - GEAR.
FIRM SFT - Commands a higher control
pressure during upshift. Select Value 1-5.
The pressure control (PCx) solenoids for this Press SEND to send command.
transmission are not directly controlled during
Reselect Value 1-5.
DRIVE mode testing. Pressures may be raised
during an upshift via the harsh shift control channel
(FIRM SFT).
Press SEND.
GEAR in Drive Mode
TCC in Drive Mode
This OSC function is used to test the transmission
shift functions.
This OSC function is used to test whether the
torque converter clutch (TCC) is engaging and
The OSC functions for the GEAR parameter allow
disengaging correctly.
the technician to choose the following options:
The OSC functions for the TCC parameter allows
1 - PCM selects 1st gear.
the technician to choose the following:
2 - PCM selects 2nd gear.
TCC - Activates TCC OFF and ON.
3 - PCM selects 3rd gear.
ON - Turns TCC solenoid ON.
4 - PCM selects 4th gear.
OFF - Turns TCC solenoid OFF.
OSC TCC OFF DRIVE Mode operates ONLY
OSC GEAR mode operates ONLY when:
when:
VSS and digital TR sensors are operational.
No VSS and digital TR sensor DTCs present.
Engine ON.
Engine ON.
TCC OFF (TCC cannot be engaged).
Transmission range selector lever in (D).
Vehicle speed is greater than 3 km/h (2 mph).
OSC TCC ON DRIVE Mode operates ONLY
OSC Command Values:
when:
1 - PCM selects 1st gear.
VSS and digital TR sensors are operational.
2 - PCM selects 2nd gear.
No VSS and digital TR sensor DTCs present.
3 - PCM selects 3rd gear.
Engine ON.
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Transmission in 2nd gear or higher. OSC FIRM SFT DRIVE Mode operates ONLY
when:
TFT is between 33-153C (60-275F).
Brake not applied. OFF below 32 km/h (20
mph).
Maintain steady speed.
Transmission range selector lever in O/D.
OSC Command Values:
Pressure gauge installed (optional).
OFF - Turns TCC OFF. Key ON.
ON - Turns TCC ON. Engine ON.
XXX - Cancels OSC value sent. Vehicle speed greater than 3 km/h (2 mph).
SEND - Sends the values to PCM. TCC is OFF (TCC is not engaged).
OSC Command Values:
Drive Mode Procedures for TCC
ON - Sets control pressure high for all upshifts
(determined by the PCM).
menu screen.
OFF - Sets control pressure to normal for all
upshifts (determined by the PCM).
Select Trans-Drive Mode.
XXX - Cancel OSC for FIRM SFT.
SEND - Sends the values to the PCM.
DRIVE Mode procedure for FIRM SFT
Select Parameters - TCC.
Select ON to turn solenoid ON.
menu screen.
Press SEND to send command ON.
Select OFF to turn solenoid OFF.
Select Trans - Drive Mode.
Press SEND to send command OFF.
Press SEND.
Select Parameters - FIRM SFT.
FIRM SFT in Drive Mode
This OSC function is used to raise pressure during
an upshift to determine whether the pressure control
Press SEND.
system is functioning correctly. Harsher shifts
indicate that the pressure control system works at
Using Output State Control (OSC) and
higher pressure. The best test for isolating pressure Accessing PIDs
control system problems is to carry out the PCA,
To confirm that the OSC value was sent by the scan
PCB, PCC in BENCH Mode using a hydraulic
tool and the PCM has accepted the OSC
pressure gauge.
substitution, a corresponding PID for each OSC
The OSC functions for the parameter FIRM SFT
parameter must be monitored. Additional PIDs
allows the technician to choose the following
should be monitored to help the technician
options:
adequately diagnose the transmission.
The following is a list of OSC parameters and their
FIRM SFT - Activates the harsh shift channel.
corresponding PID:
ON - Sets control pressure higher for all
OFF - Sets control pressure to normal for all
XXX - Cancels OSC for FIRM SFT.
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Corres- Corres-
ponding ponding
PID PID Description PID PID Description
BPP Brake Pedal Position Switch On/Off SSC Shift Solenoid C Commanded ON
PCA Pressure Control Solenoid A SSD Shift Solenoid D Commanded ON
Commanded Pressure
TCC Torque Converter Commanded Duty
PCB Pressure Control Solenoid B Cycles (%)
Commanded Pressure
TCCRAT Torque Converter Speed Ratio (RPM
PCC Pressure Control Solenoid C and/or TSS)
Commanded Pressure
TFT Transmission Fluid Temperature
FIRMST Firm Shift Control (FMC) Status (degrees Fahrenheit)
Requested by OSC; 0 = FSC not
VSS Vehicle Speed (mph)
Commanded by OSC, NGS PID Output
= OFF; 1 = FSC Commanded by OSC,
NGS PID Output = ON
To confirm that the OSC substitution occurred,
GEAR Commanded Transmission Gear (use in SEND the OSC value and monitor the
DRIVE only)
corresponding PID value. If no ERROR MESSAGE
RPM Engine Revolutions Per Minute was received and the value of the corresponding
PID is the same as the value sent from OSC, then
SSA Shift Solenoid A Commanded ON
the OSC substitution was successful.
SSB Shift Solenoid B Commanded ON
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OF SUBASSEMBLIES
Overdrive Brake and Coast Clutch
Drum Assembly
Special Tool(s)
307-015 (T65L-77515-A)
307-049 (T74P-77404-A)
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
Overdrive Brake and Coast Clutch Drum Assembly
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1 7L669 Coast clutch drum
2 7A548 Overdrive piston outer seal
ring
3 7D404 Overdrive piston inner seal
ring
4 7A262 Overdrive clutch piston
5 7A480 Overdrive piston spring (20
required)
6 7A527 Coast clutch piston spring
retainer
7 E860125-S Retaining ring
8 7B442 Coast clutch external plates
3. WARNING: Use caution when
steel (2 required)
releasing tool pressure on the rear clutch
9 7B164 Coast clutch internal plates
piston spring. Failure to follow these
friction (2 required)
10 7B066 Coast clutch pressure plate
11 E860126S/129S Retaining ring (select fit)
may occur.
Disassembly
Using the special tool, remove the coast clutch
1. Remove the coast clutch pressure plate.
1 Remove the coast clutch retaining ring.
2 Remove the coast clutch pressure plate.
4. Relieve the coast clutch spring tension and
remove the special tool.
2. Remove the coast clutch disc pack.
Inspect for wear, install a new pack as
necessary.
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5. Remove the coast clutch piston springs.
1 Remove the coast clutch piston retainer.
2 Remove the clutch piston springs.
Assembly
1. CAUTION: The lip seals must be
positioned as shown. Care must be taken to
prevent rollover of the lip seal.
Install the new coast clutch piston inner and
outer seal.
the drum is facing down as shown. Failure to
personal injury.
Remove the coast clutch piston.
to remove the coast clutch piston while
blocking the other hole with a finger.
2. Verify the check ball is free to move.
7. Remove and discard the coast clutch piston
inner seal and the coast clutch piston outer seal.
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prevent damage to the seals during
installation.
Using the special tool, install the coast clutch
piston.
Lubricate the seals with transmission fluid.
6. CAUTION: Coast clutch friction plates
are directional and must be installed with
grooves clockwise (I.D. to O.D.). The word
TOP should face up.
CAUTION: If new clutch plates are
being used, they should be soaked in clean
automatic transmission fluid before assembly.
4. Install the coast clutch piston springs.
When installing friction plates, the word TOP
1 Install the coast clutch piston springs. should face up. If reusing plates, grooves must
be installed clockwise. Install the coast clutch
2 Install the coast clutch spring retainer.
disc pack.
5. CAUTION: Do not fully compress the
special tool or damage to the coast clutch
piston spring retainer may occur.
Using the special tool, install the coast clutch
piston spring retainer ring.
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7. Install the 2 steel clutch plates and 2 friction
clutch plates in alternating order starting with a
steel clutch plate.
10. Check the coast clutch disc pack free play.
1 Push down on the coast pressure plate.
2 Check clearance between the coast clutch
retaining ring and coast pressure plate.
8. CAUTION: The retaining ring is select
Clearance should be 1.3-2.0 mm
fit.
(0.051-0.079 in). If clearance is not within
Install the coast clutch pressure plate.
the specification, install a correct coast
clutch retaining ring that will provide the
1 Install the coast clutch pressure plate.
correct free play adjustment.
2 Install the original coast clutch retaining
ring.
Thickness Diameter
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122
E860128-S 2.08 0.0819 130.1 5.122
E860129-S 2.44 0.0961 130.1 5.122
drum is facing down as shown. Failure to
personal injury.
Air check the assembly.
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OF SUBASSEMBLIES
Overdrive Planetary and One-Way
Clutch Assembly
2. CAUTION: Do not remove the
overdrive one-way clutch. Damage to the
clutch may occur if it is removed.
Clean and inspect the overdrive one-way clutch
and center shaft. 1 W702037 Retaining ring
2 7A658 Center shaft Inspect for cracks in the roller cage and
wear on the roller clutch, and the press fit 3 7A153 Overdrive ring gear
of the one-way clutch to the center shaft.
4 7L495 No. 2 overdrive planetary
thrust bearing
5 7B446 Overdrive planetary gear
carrier assembly
6 7D063 Overdrive sun gear
7 7660 Coast clutch adapter
Disassembly
1. NOTE: The overdrive one-way clutch is
serviced with the center shaft assembly.
Remove the center shaft from the overdrive ring
gear.
1 Remove the overdrive center shaft retaining
ring.
2 While rotating counterclockwise remove the
center shaft from the ring gear.
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Assembly
3. Inspect the one-way clutch.
Temporarily insert the overdrive planetary
1. Install the center shaft and one-way clutch.
gear carrier assembly into the one-way
clutch rollers for verification of the one-way
1 Install the center shaft and one-way clutch.
clutch.
2 Install the center shaft retaining ring.
The planetary gear must rotate
counterclockwise and hold when rotated
clockwise.
Remove the planetary gear carrier assembly.
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OF SUBASSEMBLIES
Overdrive Planetary Gears
Disassembly
1. NOTE: Individual parts of the planetary
carriers are not serviceable.
Before installing a planetary assembly, the shaft
retaining pins should be checked for adequate
staking. Check the pins and shafts in the
planetary assemblies for loose fit and/or
complete disengagement. Install a new planetary
assembly if necessary.
4. Remove and inspect the No. 2 overdrive
planetary thrust bearing on the nose of the
overdrive planetary gear carrier assembly.
2. Inspect the pinion gears for damaged or
excessively worn teeth and for free rotation.
5. NOTE: Inspect the sun gear for damaged or
worn teeth.
Remove the coast clutch-to-overdrive carrier
adapter.
3. Inspect the overdrive one-way clutch inner race
and the inner and outer races for scored or
damaged surface areas where the rollers contact
the races.
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6. Remove and inspect the overdrive sun gear.
2. Install the overdrive planetary gear carrier into
the center shaft and overdrive.
7. CAUTION: Do not attempt to remove
the No. 12 bearing from behind the pinion
gears.
Inspect the No. 12 bearing for damage.
3. CAUTION: Make sure that the No. 12
bearing is in place in the overdrive planetary
prior to installing the overdrive sun gear.
Install the overdrive sun gear with the recessed
Assembly
gear teeth facing toward the adapter.
1. NOTE: Thoroughly clean all parts and blow
dry with moisture-free compressed air.
NOTE: Use petroleum jelly to hold the No. 2
overdrive planetary thrust bearing in place.
Install the No. 2 overdrive planetary thrust
bearing.
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4. CAUTION: Adapter part number must
not be visible after installation.
NOTE: Inspect the sun gear for damaged or
worn teeth.
Install the coast clutch-to-overdrive carrier
adapter.
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Special Tool(s)
Pinpoint Tests OSC Equipped
MLP-TR Cable
Vehicle
418-F107 (007-00111) or
equivalent
Special Tool(s)
Gauge
307-004 (T57L-77820-A)
Transmission Tester
307-F016 (007-00130) or
equivalent
73 III Automotive Meter
Shift Solenoid Pre-Diagnosis
Anytime an electrical connector or solenoid body is
disconnected, inspect the connector for terminal
Trans Tester TR/MLP Overlay
condition, corrosion and contamination. Also inspect
and Manual
the connector seal for damage. Clean, repair or
install new as necessary.
Use the following shift solenoid operation
information when carrying out Pinpoint Test A.
tool
(Continued)
Solenoid Operation Chart
5R55S Solenoid States
Gearshift PCM Comm-
SSA SSB SSC SSD PCA PCB PCC Selector Position anded Gear
P/N P/N ON OFF OFF ON L H/L L
R R ON OFF OFF ON L/H L H
D 1 ON OFF OFF ON H H/L L
2 ON OFF ON ON L/H H L
3 ON ON OFF ON H L/H L
4 OFF OFF OFF ON H H/L H
5 OFF OFF ON ON H H H
D Cancelled 1 ON OFF OFF ON H H/L L
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Solenoid Operation Chart (Continued)
Gearshift PCM Comm-
4 OFF OFF OFF OFF L/H H H
Manual 3 3 ON ON OFF OFF H L H/L
Manual 2 2 ON OFF ON OFF H L H/L
Manual 1 1 ON OFF OFF OFF H L H/L
H = HIGH Shift Solenoid Failure Mode Chart
L = LOW
Failed ON or OFF due to powertrain control module
H/L = PCM controlled (PCM) and/or vehicle wiring concerns, solenoid
electrically, mechanically or hydraulically stuck ON Manual = if equipped
or OFF.
Solenoid Failure Mode Chart A 5R55S
Actual Gear
SSA SSB SSC SSD
ON OFF ON OFF ON OFF ON OFF Gear
D Position
1 1 1 3 1 2 1 1 1/M1
2 2 2 2 2 2 1 2 M2
3 3 3 3 1 3 3 3 3/M3
4 1 4 4 4 4/5 4 4 4/M4
5 2 5 5 5 5 4 5 5
D Position (D) Cancelled
1M M1 M1 M3 M1 M2 M1 1 M1
2M M2 M2 1.1 M2 M2 M1 2 M2
3M M3 M3 M3 M1 1.1 M3 3 M3
4M M1 M4 M4 M4 5 M4 4 M4
R R R N R R R R R
Slip = Slip due to low line pressure
1.1 = Actual ratio with Forward Clutch, Intermediate and
Overdrive Band applied.
Solenoid Failure Mode Chart B 5R55S
Actual Gear
PC A PC B PC C
L H L H L H Gear
D Position
1/S 1 1 1 1 1 1
2 2 2 1 2 2 2
3 1/S 3 3 3 3 3
4 4 4 4 4 1 4
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Solenoid Failure Mode Chart B 5R55S (Continued)
Actual Gear
PC A PC B PC C
L H L H L H Gear
5 5 5 4 5 2 5
D Position (D) Cancelled
1M 1 M1 1 M1 1M M1
2M M2 M2 1 M2 2M M2
3M 1 M3 3 M3 3M M3
4M M4 M4 4 M4 1 M4
R R/S R R/S R R R
H = High
L = Low
Slip = Slip due to low line pressure
1.1 = Actual ratio with Forward Clutch, Intermediate and
Overdrive Band applied.
Pinpoint Tests
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS
NOTE: Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests.
NOTE: Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired
before entering output state control (OSC).
A1 ELECTRONIC DIAGNOSTICS
Select PARK.
Check to make sure the transmission harness connector is fully
seated, terminals are fully engaged in connector and in good
condition before proceeding.
Key in ON position.
Enter the following diagnostic mode on the scan tool: Diagnostic
Data Link.
Yes
Enter the following diagnostic mode on the scan tool: PCM.
REMAIN in Trans-Bench Mode. GO to A2.
Enter the following diagnostic mode on the scan tool: Active
Command Modes. No
Enter the following diagnostic mode on the scan tool: Output REPEAT procedure to enter Trans-Bench
State Control (OSC). Mode. If vehicle did not enter Trans-Bench
Enter the following diagnostic mode on the scan tool: Mode, REFER to the Powertrain
Trans-Bench Mode. Control/Emissions Diagnosis (PC/ED)
Does vehicle enter Trans-Bench Mode? manual for diagnosis of PCM or VCM.
A2 WIGGLE TEST
Remain in Trans-Bench Mode.
(Continued)
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PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (Continued)
A2 WIGGLE TEST (Continued)
PID Command PID Actual
SSA SSA
SSB SSB
SSC SSC
SSD SSD
TCC TCC
Select ON to turn suspect solenoid(s) ON.
Press SEND.
Wiggle all wiring and connectors to the transmission. Monitor the
Yes
solenoid state for changes.
REPAIR the circuit. TEST the system for
Select OFF to turn solenoid(s) OFF.
normal operation.
Press SEND.
Repeat steps for each solenoid. No
Does the suspect solenoid(s) fault state change? GO to A3.
A3 SOLENOID FUNCTIONAL CHECK
Monitor each solenoid state. Yes
Turn each solenoid ON and OFF. GO to A4.
Does the solenoid turn ON and OFF when commanded and
No
can solenoid activation be heard?
GO to A5.
A4 OSC TRANS-DRIVE MODE (GEAR OR TCC)
Carry out OSC Trans-Drive Mode. Yes
Select GEAR for shift solenoids or follow procedures for GEAR CLEAR all DTCs. ROAD TEST to verify if
as listed in this section. concern is still present. If concern is still
Select TCC for torque converter clutch solenoid. Follow present, REFER to Diagnosis By Symptom
procedures of TCC in Drive Mode as listed in this section. to diagnose shift or torque converter
Does the transmission upshift and downshift or torque concern.
converter engage/disengage when commanded?
No
GO to A5.
A5 CHECK FOR BATTERY VOLTAGE
Disconnect: Transmission Vehicle Harness Connector.
Visually inspect all wires and connectors for damage.
Key in ON position.
Measure the voltage on pin 3 harness side and ground.
Yes
GO to A6.
No
REPAIR the circuit. TEST for normal
Is the voltage greater than 10 volts? operation.
(Continued)
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A6 ELECTRICAL SIGNAL CHECK
Leave positive lead connected to pin 3 and connect negative
lead to pin 5, 6, 14, 15 and 16.
Enter the following diagnostic mode on the scan tool:
Trans-Bench Mode.
Select Parameter SSA, SSB, SSC, SSD or TCC.
Yes
Select ON.
GO to A7.
Press SEND.
Measure the voltage while cycling the solenoids ON and OFF. No
Select OFF, press SEND. REPAIR the circuit. TEST the system for
Does the voltage change? normal operation.
A7 CHECK SOLENOID RESISTANCE AT SOLENOID
Measure the resistance between pin 3 and pin 5, 6, 14, 15 and
16 solenoid side.
Solenoid Resistance (ohms)
SSA 16-45
SSB 16-45
SSC 16-45
SSD 16-45
TCC 9-16
Yes
GO to A8.
No
INSTALL a new solenoid body assembly.
Is the resistance within specification? TEST the system for normal operation.
(Continued)
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A8 CHECK SOLENOID FOR SHORT TO GROUND
Measure the resistance between pin 3 and pin 5, 6, 14, 15 and
16 solenoid side and ground.
Yes
No
REFER to Diagnosis By Symptom in this
section for diagnosis of shift or torque
Is the resistance less than 5 ohms? converter concerns.
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
pinpoint tests.
B1 ELECTRONIC DIAGNOSTICS
Select PARK.
seated, terminals are fully engaged in connector and in good
Yes
REMAIN in PID/Data Control. GO to B2.
Key in ON position.
Select Diagnostic Data Link. No
Select PCM. REPEAT procedure to enter PID. If vehicle
Select PID/Data Monitor and Record. did not enter PID, REFER to the
Enter the following diagnostic mode on the scan tool: PIDs; TFT, Powertrain Control/Emissions Diagnosis
TFTV. (PC/ED) manual for diagnosis of PCM and
Does the vehicle enter PID/Data Monitor and Record? VCM.
B2 WARM-UP/COOL-DOWN CYCLE
While monitoring the TFT PIDs, carry out the following test: If Yes
transmission is cold, run transmission to warm it up. If If the TFT PIDs increase as the
transmission is warm, allow transmission to cool down. transmission is warmed or decrease as
Do the TFT PIDs increase as the transmission is warmed up the transmission is cooled, CLEAR all
or decrease as the transmission is cooled or does the TFT DTCs. ROAD TEST to verify if concern is
or TFTV drop in and out of range? still present. If concern is still present,
section to diagnose transmission
overheating.
If the TFT or TFTV drop in and out of
range, INSPECT for intermittent concern in
the internal/external harness, sensor or
connector.
No
GO to B3.
B3 ELECTRICAL SIGNAL CHECK
Disconnect: Transmission Harness Connector.
(Continued)
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PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR (Continued)
B3 ELECTRICAL SIGNAL CHECK (Continued)
Measure the voltage between pin 2 harness side and ground.
Yes
GO to B4.
No
Is the voltage between 4.5 and 5.0 volts? normal operation.
B4 CHECK RESISTANCE OF THE TRANSMISSION FLUID
TEMPERATURE (TFT) SENSOR
Measure the resistance between pin 2 and 12 at the solenoid
body connector.
Record the resistance.
Resistance should be approximately in the following ranges:
Transmission Fluid Temperature
C F Resistance (Ohms)
-40 to -20 -40 to -4 967K - 284K
-19 to -1 -3 - 31 284K - 100K
0 - 20 32 - 68 100K - 37K
21 - 40 69 - 104 37K - 16K
41 - 70 105 - 158 16K - 5K
71 - 90 159 - 194 5K - 2.7K
91 - 110 195 - 230 2.7K - 1.5K
Yes
111 - 130 231 - 266 1.5K - 0.8K
section to diagnose an overheating
concern.
131 - 150 267 - 302 0.8K - 0.54K
No
Is the resistance in the range? INSTALL a new solenoid body assembly.
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PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR
NOTE: Refer to the Digital Transmission Range (TR) Sensor Connector illustration and Digital
Transmission Range (TR) Sensor Diagnosis Chart preceding these pinpoint tests.
C1 VERIFY DIAGNOSTIC TROUBLE CODES
Select PARK. GO to C4.
Carry out On-Board Diagnostic Test.
No
Are only DTC codes P0705, P0708 present?
GO to C2.
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR ALIGNMENT
Select PARK.
Check to make sure the digital TR sensor harness connector is
Yes
fully seated, terminals are fully engaged in connector and in
GO to C3.
good condition before proceeding.
Apply the parking brake. No
Select NEUTRAL. ADJUST the digital TR sensor. REFER to
Disconnect the shift cable/linkage from the manual lever. Digital Transmission Range (TR) Sensor in
Verify that the TR Sensor Alignment Gauge fits in the this section. PLACE transmission range
appropriate slots. selector lever into PARK and CLEAR
Is the digital TR sensor correctly adjusted? DTCs. RERUN OBD Tests. GO to C3.
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
Place the range selector in D. Yes
Connect the shift cable/linkage. GO to C4.
Verify that the shift cable/linkage is correctly adjusted. Refer to
No
Section 307-05.
ADJUST the shift cable/linkage. REFER to
Is the shift cable/linkage correctly adjusted?
Section 307-05. GO to C4.
C4 CHECK ELECTRICAL SIGNAL OPERATION
Select PARK.
Yes
Disconnect: Digital TR Sensor.
REPAIR as necessary. CLEAR DTCs and
RERUN OBD Tests.
CAUTION: Do not pry on connector. This will damage
No the connector and result in a transmission concern.
If diagnosing a DTC, GO to C5.
Inspect both ends of the connector for damage or pushed-out
pins, corrosion, loose wires and missing or damaged seals. If diagnosing a starting concern or a
Is there damage to the connector, pins or harness? backup lamp concern, GO to C10.
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL TR AND
PCM)
Connect: Digital TR Sensor.
Key in ON position.
Enter the following diagnostic mode on the scan tool: TR PIDS
TR D, TR V.
Move transmission range selector lever into each gear and stop.
Observe the PIDs, TR D, and TR V (vehicle-dependent) while
Yes
wiggling harness, tapping on sensor or driving the vehicle. Use
The problem is not in the digital TR sensor
PIDs TR D for DTCs P0705, P1704 and P1705. Use PIDs
system. REFER to Diagnosis By Symptom
TR V for DTC P0708.
in this section for further diagnosis.
Compare the PIDs to the Digital Transmission Range (TR)
Sensor Diagnosis Chart. No
Do the PIDs TR D and TR V match the Digital If TR D changes when wiggling harness,
Transmission Range (TR) Sensor Diagnosis chart, and does tapping on the sensor or driving the
the TR D PID remain steady when the harness is wiggled, vehicle, the problem may be intermittent.
the sensor is tapped on or the vehicle driven? GO to C6.
C6 CHECK DIGITAL TRANSMISSION RANGE SENSOR OPERATION
Disconnect: Digital TR Sensor. Yes
Connect: TR-E Cable to Transmission Tester. Concern is not in the digital TR sensor.
Connect: TR-E Cable to Digital TR Sensor. GO to C7.
Place the Digital TR Overlay onto the Transmission Tester.
No
Carry out Sensor Test as instructed on the digital TR Overlay.
INSTALL a new digital TR sensor and
Does the status lamp on the tester TRS-E cable match the
ADJUST. REFER to Digital Transmission
selected gear positions?
Range (TR) Sensor in this section. CLEAR
DTCs and RERUN OBD Tests.
(Continued)
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PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
C7 CHECK PCM HARNESS CIRCUITS FOR OPENS
Disconnect: 150-Pin PTEC Module Connector B.
Inspect for damaged or pushed-out pins, corrosion or loose
wires.
Disconnect: Digital TR Sensor.
CAUTION: Do not pry the connector. This will damage
the connector and result in a transmission concern.
Measure the resistance between TR pin 2 harness side and
signal return PCM pin 41 harness side.
Measure the resistance between PCM pin 16 and TR pin 4
harness side.
harness side.
(Continued)
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C7 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
harness side.
harness side.
Yes
GO to C8.
No
REPAIR the circuits. TEST the system for
Are the resistances less than 5 ohms? normal operation.
C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
OR POWER
Measure the resistance between PCM pin 41 and TR pins 10
and 12 harness side and ground.
(Continued)
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OR POWER (Continued)
Measure the resistance between pin 16 harness side and
ground; and pin 41 harness side and ground.
(Continued)
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OR POWER (Continued)
Yes
GO to C9.
No
normal operation. CLEAR DTCs. RERUN
Are the resistances greater than 10,000 ohms? OBD Tests.
C9 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL
CIRCUITS
Measure the resistance between pin 27 harness side; and
between pin 16, pin 17 and pin 28 harness side.
between pin 27, pin 17 and pin 28 harness side.
(Continued)
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C9 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL
CIRCUITS (Continued)
between pin 16, pin 27; pin 28 harness side.
between pin 16, pin 17; pin 27 harness side.
Yes
INSTALL a new PCM. TEST the system
No
Are the resistances greater than 10,000 ohms? normal operation.
C10 CHECK THE NON-PCM INTERNAL CIRCUITS OR SENSOR
Connect: TRS-E Cable to Transmission. Yes
Connect: TRS-E Cable to Digital TR Sensor. Concern is not in the digital TR sensor.
Place the Digital TR Overlay onto the Transmission Tester. For backup lamp concerns, REFER to
Carry out Switch Test as instructed on the Digital TR Overlay. Section 417-01.
Does the status lamp on the tester indicate RED for the
No
correct gear position?
INSTALL a new digital TR sensor and
ADJUST. REFER to Digital Transmission
Range (TR) Sensor in this section. CLEAR
DTCs and RERUN OBD Tests.
PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC)
pinpoint tests.
NOTE: Read and record all DTCs. All digital TR Sensor and VSS DTCs must be repaired
before entering output state control (OSC).
D1 ELECTRONIC DIAGNOSTICS
Select PARK.
seated, terminals are fully engaged in the connector and in good
(Continued)
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PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC) (Continued)
D1 ELECTRONIC DIAGNOSTICS (Continued)
Install 300 psi pressure gauges into Line and PC C tap.
Key in ON position.
Data Link.
Yes
Enter the following diagnostic mode on the scan tool: PCM.
REMAIN in Trans-Bench Mode. GO to D2.
Command Modes. No
Enter the following diagnostic mode on the scan tool: Output REPEAT procedure to enter Trans-Bench
State Control (OSC). Mode. If vehicle did not enter OSC,
Enter the following diagnostic mode on the scan tool: REFER to Powertrain Control/Emissions
Trans-Bench Mode. Diagnosis (PC/ED) manual for diagnosis of
Does the vehicle enter the Trans-Bench Mode? PCM or VCM.
D2 SOLENOID FUNCTIONAL TEST
Monitor pressure gauges.
Enter the following diagnostic mode on the scan tool: Parameter;
PCx.
NOTE: Make sure that the solenoids not being tested are off or
at zero.
Select PC A, PC B or PC C.
Select value - 15, 30, 45, 60, 70 or 90 psi.
Press SEND.
Select another value 0-90 psi.
Press SEND.
Enter the following diagnostic mode on the scan tool: XXX.
Press SEND.
For PC A and PC B: Does the pressure reading for A or B
Yes
follow the commanded pressure (actual A and B pressures
CLEAR DTCs.
will be higher than the commanded pressure)? For PC C:
Does the pressure reading match the commanded No
pressure? GO to D3.
D3 CHECK FOR BATTERY VOLTAGE
Disconnect: Transmission Harness Connector.
Key in ON position.
Measure the voltage between pin 3 harness side and ground.
Yes
GO to D4.
No
Is the voltage greater than 10 volts? normal operation.
(Continued)
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D4 ELECTRICAL SIGNAL CHECK
Leave positive lead connected to pin 3 and connect negative
lead to pin 1, 4 and 11 harness side.
Activate solenoids (ON and OFF) while monitoring the voltage
reading.
Enter the following diagnostic mode on the scan tool:
Trans-Bench Mode.
Enter the following diagnostic mode on the scan tool: Parameter;
PCx.
Select a value 0-90 psi.
Press SEND.
Yes
Select another value 0-90 psi.
GO to D5.
Press SEND.
Enter the following diagnostic mode on the scan tool: XXX. No
Press SEND. CHECK for open or short circuit in
Does the voltage and solenoid state change? harness or PCM.
D5 CHECK SOLENOID RESISTANCE AT SOLENOID
Measure and record the resistance between PC solenoid pin 3
and pins 1, 4 and 11. Resistance should be between 3.3 and
7.5 ohms.
Yes
GO to D6.
No
Is the resistance within specifications? INSTALL a new solenoid body assembly.
(Continued)
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D6 CHECK SOLENOID FOR SHORT TO GROUND
Measure and record the resistance between the PC solenoid
pins 1, 4, 11 and ground solenoid side.
Yes
No
section for diagnosis of pressure concerns.
Is the resistance less than 10,000 ohms? TEST the system for normal operation.
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED AND OUTPUT
SHAFT SPEED (OSS) SENSORS
NOTE: Refer to the Turbine Shaft Speed (TSS), Intermediate Shaft Speed and Output Shaft
Speed (OSS) Sensor Connector illustrations preceding these pinpoint tests.
E1 ELECTRONIC DIAGNOSTICS
Check to make sure the transmission harness connectors are
fully seated, terminals are fully engaged in connector and in
good condition before proceeding.
Yes
Key in ON position.
REMAIN in PID/Data. GO to E2.
Data Link. No
Enter the following diagnostic mode on the scan tool: PCM. REPEAT procedure to ENTER PID. If
Select PID/Data Monitor and Record. vehicle did not enter PID, REFER to the
Select the following PIDs: TSS, intermediate shaft speed or Powertrain Control/Emissions Diagnosis
OSS. (PC/ED) manual for diagnosis of PCM or
Does vehicle enter PID/Data Monitor and Record? VCM.
E2 DRIVE CYCLE TEST
While monitoring the appropriate sensor PID, drive the vehicle Yes
so that the transmission upshifts and downshifts through all GO to E3.
gears.
No
Does the TSS, intermediate shaft speed or OSS PID
If the TSS, intermediate shaft speed or
increase and decrease with engine and vehicle speed?
OSS PID does not increase and decrease
with engine and vehicle speed, INSPECT
for open or short in vehicle harness,
sensor a PCM concern or internal
hardware concern. GO to E4.
E3 DRIVE CYCLE TEST ERRATIC
While monitoring the appropriate sensor PID, drive the vehicle Yes
so that the transmission upshifts and downshifts through all If the sensor signal is erratic, INSPECT for
gears. intermittent concern in the harness, sensor
Is the TSS, intermediate shaft speed or OSS PID signal or connector. GO to E4.
erratic (drop to zero or near zero and return to normal
No
operation)?
CLEAR all DTCs. RERUN OBD.
E4 CHECK PCM HARNESS CIRCUITS FOR OPENS
Disconnect: 150-Pin PTEC Module Connector B.
Inspect for damaged or pushed-out pins, corrosion or loose
wires.
(Continued)
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SHAFT SPEED (OSS) SENSORS (Continued)
E4 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
For OSS, measure the resistance between pin 3 and the
appropriate sensor connector pin 2 harness side.
For intermediate shaft speed, measure the resistance between
pin 41 and the appropriate sensor connector pin 2 harness side.
For TSS, measure the resistance between pin 41 and the
(Continued)
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E4 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
pin 4 and the appropriate sensor connector pin 1 harness side.
For TSS, measure the resistance between pin 15 and the
For OSS, measure the resistance between pin 3 and the
Yes
GO to E5.
No
Are all resistances less than 5 ohms? normal operation.
(Continued)
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E5 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
For OSS, measure the resistance between pin 3 and sensor
connector pin 1 harness side and ground.
PCM pin 4 and sensor connector pin 1 harness side and
ground.
For TSS, measure the resistance between PCM pin 15 and
sensor connector pin 1 harness side and ground.
Yes
GO to E6.
No
normal operation. CLEAR DTCs. RERUN
Are the resistances greater than 10,000 ohms? OBD Tests.
E6 CHECK RESISTANCE OF TSS, INTERMEDIATE SHAFT SPEED
OR OSS SENSOR
Disconnect the appropriate vehicle harness connector from the
TSS, intermediate shaft speed or OSS sensor.
(Continued)
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E6 CHECK RESISTANCE OF TSS, INTERMEDIATE SHAFT SPEED
OR OSS SENSOR (Continued)
Connect ohmmeter negative lead to one pin of the sensor and
the positive lead to the other pin on the sensor.
Record the resistance. Resistance should be as follows:
Resistance (ohms) Temperature
266-390 -20C (4F)
325-485 21C (70F)
Yes
492-738 150C (302F)
GO to E7.
Is the resistance within specification for the appropriate No
sensor? INSTALL a new sensor.
E7 CHECK SENSORS FOR SHORT TO GROUND
Measure the resistance between pin 1 and 2 of each sensor and
ground.
Yes
INSTALL a new sensor.
No
REFER to Diagnosis By Symptom for
diagnosis of shift or torque converter
Is the resistance less than 10,000 ohms? concerns in this section.
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PINPOINT TEST F: SOLENOID MECHANICAL FAILURE
NOTE: Repair all other DTCs before repairing the following DTCs: P1714, P1715, P1716,
P1717 and P1740.
F1 ELECTRONIC DIAGNOSIS
Select PARK. REPAIR the DTCs for TFT or shift
Key in ON position. solenoids first. CLEAR DTCs and CARRY
Carry out Key ON Engine OFF (KOEO) Test until continuous OUT transmission Drive Cycle test.
DTCs have been displayed. RERUN Quick Test.
If any of the following DTCs are present, continue with this test:
No
P1714, P1715, P1716, P1717 and P1740.
INSTALL a new solenoid and/or body.
Are other DTCs present for TFT or shift solenoids?
REFER to the Diagnostic Trouble Code
(DTC) Charts for code description. GO to
F2.
F2 TRANSMISSION DRIVE CYCLE TEST
Carry out Transmission Drive Cycle Test. Refer to Transmission Yes
Drive Cycle Test in this section. GO to F3.
Does the vehicle upshift and downshift OK?
No
section to diagnose shift concerns.
F3 RETRIEVE DTCs
Select PARK. INSTALL a new PCM. ROAD TEST and
Key in ON position. RERUN Quick Test.
Carry out KOEO Test until continuous DTCs have been
No
displayed.
Testing completed. If a concern still exists,
Are DTCs P1714, P1715, P1716, P1717 and P1740 still
present?
section for concern diagnosis.
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Noise/vibration check for dependencies, either
Preliminary Inspection
rpm dependent, vehicle speed dependent, shift
The following items must be checked prior to
dependent, gear dependent, range dependent or
beginning the diagnostic procedures:
temperature dependent.
Know and Understand the Concern
Check Fluid Level and Condition
In order to correctly diagnose a concern, first
Fluid Level Check
understand the customer concern or condition.
Customer contact may be necessary in order to
CAUTION: The vehicle should not be
begin to verify the concern. Understand the
driven if the fluid level is low or internal failure
condition as to when the concern occurs, for
could result.
example:
NOTE: If the vehicle has been operated for an
hot or cold vehicle temperature.
extended period of time at highway speeds, in city
traffic, in hot weather, or pulling a trailer, the fluid
hot or cold ambient temperature.
must cool down 30 minutes to obtain an accurate
vehicle driving conditions.
reading.
vehicle loaded/unloaded.
This vehicle is not equipped with a fluid level
After understanding when and how the concern
indicator. An incorrect level may affect the
occurs, proceed to verify the concern.
transmission operation and can result in
transmission damage. To correctly check and add
Verification of Condition
fluid to the transmission, refer to Transmission
This section provides information that must be used
in both determining the actual cause of customer
concerns and executing the appropriate procedures. High Fluid Level
The following procedures must be used when A fluid level that is too high can cause the fluid to
verifying customer concerns for the engine. become aerated due to the churning action of the
rotating internal parts. This will cause erratic control
Determine Customer Concern
pressure, foaming, loss of fluid from the vent tube
NOTE: Some transmission conditions can cause and possible transmission damage. If an overfill
engine concerns. An electronic pressure control reading is indicated, refer to Transmission Fluid
short circuit can cause engine misfiring. The torque Level Check in this section.
converter clutch not disengaging will stall the
Low Fluid Level
engine.
A low fluid level can result in poor transmission
Determine customer concerns relative to vehicle use
engagement, slipping or damage. It can also indicate
and dependent driving conditions, paying attention
a leak in one of the transmission seals or gaskets.
to the following items:
Adding Fluid
Hot or cold vehicle operating temperature
Hot or cold ambient temperatures CAUTION: The use of any type of
transmission fluid other than specified can result
Type of terrain
in transmission damage.
Vehicle loaded/unloaded
If fluid must be added, add fluid in 0.25L (0.5 pint)
City/highway driving
increments through the fluid pan level check screw
Upshift
opening. Do not overfill the fluid, refer to
Transmission Fluid Level Check in this section. For
Downshift
fluid type, refer to the General Specification chart in
Coasting
this section.
Engagement
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Fluid Condition Check
4. If fluid contamination or transmission failure is
confirmed by the sediment in the bottom of the
1. Observe the color and the odor of the fluid.
transmission fluid pan, the transmission must be
Under normal circumstances, the color should
disassembled and completely cleaned.
be dark reddish, not brown or black.
5. Carry out diagnostic checks and adjustments.
2. Allow the fluid to drip onto a facial tissue and
Refer to Diagnosis By Symptom in this section.
examine the stain.
3. If evidence of solid material is found, the
transmission fluid pan should be removed for
further inspection.
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The D position provides:
Range Selection
Depending on the vehicle options selected, the
automatic shifts 1-5 and 5-1.
transmission range selector may have different range
apply and release of the torque converter clutch.
positions.
maximum fuel economy during normal operation.
The standard range selector has 7 positions: P, R,
engine braking in 5th gear.
N, D, 3, 2 and 1.
Drive Overdrive Canceled
Range Shifter
The D position provides:
activated by pressing the TC switch on the shifter
handle.
automatic shifts 1-4 and 4-1.
maximum fuel economy during normal operation.
engine braking in 4th gear.
for cancelling overdrive through TC switch.
illuminates the Overdrive OFF on the I.P.
Position 3 3rd Gear
Park
The position provides:
In the PARK position:
third gear start and hold.
there is no power flow through the transmission.
the parking pawl locks the output shaft to the
improved traction on slippery roads.
case.
engine braking.
the engine may be started.
Position 2 2nd Gear
the ignition key may be removed.
The position provides:
Reverse
second gear start and hold.
In the REVERSE position:
the vehicle may be operated in a rearward
improved traction on slippery roads.
direction, at a reduced gear ratio.
engine braking.
backup lamps are illuminated.
Position 1 1st Gear
Neutral
If this position is selected at normal road speeds,
In the NEUTRAL position:
the transmission will downshift into the next lower
gear and continue downshifting until the vehicle
there is no power flow through the transmission.
reaches 1st gear.
the output shaft is not held and is free to turn.
This position provides:
the engine may be started.
first gear operation only.
Drive Overdrive Enabled
engine braking for descending steep grades.
D is the normal position for most forward driving.
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Electronic Transmission Error Indicator
The vehicle is equipped with a redundant electronic
gearshift indicator. This character appears with the
key in the run position and displays the same gear
selection as shown on the range selector floor
console next to the range selector lever. A
transmission malfunction is indicated if an E
character flashes or remains on.
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OF SUBASSEMBLIES
Reverse Servo Assembly
Disassembly
1 7D321 Control valve spring retainer
2 7A270 Fluid pressure regulator valve
spring
3 7D488 Reverse servo check valve
4 7D372 Reverse servo plate
5 7D466 Reverse servo accumulator
spring
6 7D189 Reverse servo piston and seal
7 7423 Reverse servo piston O-ring
8 7D036 Reverse servo cover
1. Remove the control valve spring retainer.
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2. Remove the reverse servo spring and check
valve.
5. Remove the reverse servo piston and seal
assembly.
Inspect the seal for damage, install a new
3. WARNING: The upper and lower
reverse servo piston if necessary.
servo covers are under spring tension. Use
care when separating the two halves. Failure
to follow these instructions can result in
personal injury.
NOTE: Tabs on servo plate mate with slots on
cover every 120 degrees.
Remove the reverse servo plate by turning in
either direction to release.
Align the arrow on the servo plate with any
slot on the cover.
6. Remove and discard the reverse servo piston
seal.
4. Remove the reverse servo spring.
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Assembly
1. NOTE: Try not to roll the seal onto the
care when assembling the 2 halves. Failure to
housing when installing the seal, or damage to
follow these instructions can result in
the seal can occur.
personal injury.
Lubricate and install a new reverse servo piston
CAUTION: The arrow on the servo
seal.
plate must be aligned evenly between any 2
slots on the cover.
Install the reverse servo plate.
2. Lubricate and install the reverse servo piston
and seal assembly.
5. Install the reverse servo spring and check valve.
3. Install the reverse servo spring.
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6. Install the control valve spring retainer.
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Road Testing Vehicle
NOTE: Always drive the vehicle in a safe manner
according to driving conditions and obey all traffic
laws.
NOTE: When the battery has been disconnected or
a new battery installed, certain transmission
operating parameters may be lost. The powertrain
control module (PCM) must relearn these
parameters. During this learning process you may
experience slightly firm shifts, delayed or early
shifts. This operation is considered normal and will
not affect the function of the transmission. Normal
operation will return once these parameters are
stored by the PCM.
The Shift Point Road Test and Torque Converter
Operation Test provide diagnostic information on
transmission shift controls and torque converter
operation.
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Coastdown
Shift Patterns
The coastdown downshift occurs when the vehicle
Upshifts
is coasting down to a stop.
Transmission upshifting is controlled by the
Torque Demand
powertrain control module (PCM). The PCM
receives inputs from various engine or vehicle
The torque demand downshift occurs (automatically)
sensors and driver demands to control shift
during part throttle acceleration when the demand
scheduling, shift feel and torque converter clutch
for torque is greater than the engine can provide at
(TCC) operation.
that gear ratio. If applied, the transmission will
disengage the TCC to provide added acceleration.
The PCM has an adaptive learn strategy to
electronically control the transmission which will
Kickdown
automatically adjust the shift feel. When the battery
For maximum acceleration, the driver can force a
has been disconnected or a new battery installed,
downshift by pressing the accelerator pedal to the
certain transmission operating parameters may be
floor. A forced downshift into a lower gear is
lost. The PCM must relearn these parameters.
possible below calibrated speeds. Specifications for
During this learning process you may experience
downshift speeds are subject to variations due to
slightly firm shifts, delayed or early shifts. This
tire size and engine and transmission calibration
operation is considered normal and will not affect
requirements.
the function of the transmission. Normal operation
will return once these parameters are stored by the
PCM.
Downshifts
Under certain conditions the transmission will
downshift automatically to a lower gear range
(without moving the range selector lever). There are
3 categories of automatic downshifts: coastdown,
torque demand and forced (or kickdown) shifts.
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6. With the vehicle speed above 48 km/h (30
Shift Point Road Test
mph), move the transmission range selector
This test verifies that the shift control system is
lever from D4 position to manual 1 position
operating correctly.
and release the accelerator pedal. The
1. Bring the engine and transmission up to normal
transmission should immediately downshift to
operating temperature.
3rd gear. When vehicle speed drops below 32
km/h (20 mph), the transmission should
2. Operate the vehicle with the selector lever in
downshift into 1st gear.
the D position.
7. If transmission fails to upshift/downshift or the
3. Apply minimum throttle and observe the speeds
TCC does not apply/release, refer to Diagnosis
at which upshift occurs and the torque converter
By Symptom for possible causes.
engages. Refer to the following Shift Speeds
chart.
4. Stop the vehicle. Select the D position and
cancel overdrive by pressing the transmission
control (TC) switch. Repeat Step 3. The
transmission will make all upshifts except 4-5
and the torque converter clutch (TCC) should
apply above 46 km/h (27 mph).
5. Press the accelerator pedal to the floor, wide
open throttle (WOT). The transmission should
shift from 3rd to 2nd, or 3rd to 1st, depending
on vehicle speed, and the TCC should release.
Shift Speeds 4.0L Engine
CAUTION: Always obey local traffic laws, do not exceed posted limits.
Overdrive Position D Axle Ratio
Shift Shift Speed Throttle Position
Closed 5-4 37-42 km/h (23-26 mph)
4-1 16-19 km/h (10-12 mph)
Minimum 1-2 19-21 km/h (12-13 mph)
Monitor PID: 2-3 27-31 km/h (17-19 mph)
TP Volt 1.25 3-4 34-35 km/h (21-22 mph)
4-5 39-43 km/h (24-27 mph)
Wide 1-2 64-68 km/h (40-42 mph)
Open 2-3 93-101 km/h (58-63 mph)
3-4 140-145 km/h (87-90 mph)
4-5 171-174 km/h (106-108 mph)
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Closed 5-4 39 km/h (24 mph)
4-1 16 km/h (10 mph)
Minimum 1-2 18 km/h (11 mph)
Monitor PID: 2-3 27 km/h (17 mph)
TP Volt 1.25 3-4 35 km/h (22 mph)
4-5 39 km/h (24 mph)
Wide 1-2 68 km/h (42 mph)
Open 2-3 106 km/h (66 mph)
3-4 148 km/h (92 mph)
4-5 217 km/h (135 mph)
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IN-VEHICLE REPAIR
Solenoid Body Assembly
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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plug assembly
plug gasket
3 Heated oxygen sensor
(part of 9F472)
4 HO2S electrical connector
retainer
5 7E395 Solenoid body harness
6 W500213 Transmission fluid pan screws
9 W70559 Transmission fluid pan filter
screws
10 7A098 Transmission fluid pan filter
11 W703189 Solenoid body screws
12 W702921 Solenoid body screw
13 7G391 Solenoid body
14 W705928 Solenoid body O-ring seals
Removal
Section 100-02.
transmission fluid.
Remove the transmission fluid pan screws,
Discard the drain plug gasket.
gasket and fluid pan.
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6. NOTE: Clean the area around the solenoid
body connector to prevent contamination.
Disconnect the solenoid body harness electrical
connector.
Installation
1. Install new O-ring seals on the solenoid body
connector. Lubricate the O-ring seals with clean
7. Remove the screws and the transmission fluid
filter.
material and not damaged. If it is damaged,
transmission leaks may occur.
solenoid body connector pins.
Remove the solenoid body screws and remove
the sequence shown.
the solenoid body by lifting on the body and
pushing the connector from the other side of the
case.
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5. Tighten the screws in a crisscross sequence.
NOTE: Make sure the fluid filter seals are
fluid filter.
assembly.
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tightened above specification.
connector.
connector.
10. Fill the transmission. For additional
information, refer to Transmission Fluid Drain
and Refill Automated Equipment or
Transmission Fluid Level Check in this
section.
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NOTE: The line pressure tap is used to verify
Special Testing Procedures
output pressure from PC A or PC B by turning
Special Tool(s)
either one off, while verifying the output from the
other solenoid. The second pressure tap is used to
Air Test Plate, Transmission
verify the output from the PC C solenoid.
307-405
This test verifies that the line pressure is within
specification.
1. Connect the pressure gauge to the line pressure
tap.
2. Start the engine and check line pressures. Refer
to the following Line Pressure Chart to
Gauge
determine if line pressure is within
307-004 (T57L-77820-A)
specifications.
The special tests are designed to aid the technician
in diagnosing the hydraulic and mechanical portion
of the transmission.
Engine Idle Speed Check
(PC/ED) manual for diagnosis and testing of the
engine idle speed.
Line Pressure Test
CAUTION: Carry out Line Pressure Test
1 Line pressure tap
prior to carrying out Stall Speed Test. If line
pressure is low at stall, do not carry out the Stall
Speed Test or further transmission damage will
occur. Do not maintain wide open throttle
(WOT) in any gear range for more than 5
seconds.
NOTE: Certain sensor failures may cause high PC,
FMEM (failure mode effect management) actions.
Be sure that self-test and electrical repairs have
been carried out or test results may be incorrect.
Line Pressure Chart 4.0L and 4.6L Engines
Idle Pressure WOT Stall Pressure
PC C Line PC C Line Range
N 0-103 kPa (0-15 psi) 758-1034 kPa
(110-150 psi)
R 758-862 kPa 965-1551 kPa 758-862 kPa 2,000-2,482 kPa
(110-125 psi) (140-225 psi) (110-125 psi) (290-360 psi)
(D), 2, 1 0-103 kPa (0-15 psi) 758-1045 kPa 0-103 kPa (0-15 psi) 1,448-1,793 kPa
(110-150 psi) (210-260 psi)
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3. If the line pressure is not within specification, 5. Start the engine and check the PC C pressure.
check the PC C pressure. Refer to Line Pressure Diagnosis Chart in this
section for specification.
4. Connect the pressure gauge to the PC C
pressure tap. 6. If the PC C pressure is not within specification,
GO to Pinpoint Test D to diagnose PC C
operation. If PC C operation is OK, refer to
Line Pressure Diagnosis Chart in this section
for line pressure concern causes.
1 Pressure control (PC C) tap
Line Pressure Diagnosis Chart
Test Results Possible Source
High at Idle All Ranges Wiring harnesses
PC C boost valve
PC C solenoid
Main regulator valve
Low at Idle All Ranges Low fluid level
Fluid inlet filter/seal
Main control body
Cross leaks
Gaskets
Pump
Separator plate
Low All Forward Ranges Forward clutch
Main control
Overdrive servo
Intermediate servo
Low in Park Only Valve body
Low in Reverse Only Separator plate
Rear servo piston, cover seal
Reverse clutch
Overdrive servo
Intermediate servo
Valve body
Forward clutch
Low in Neutral Only Valve body
Overdrive servo
Intermediate servo
Low in D Only Forward clutch
Overdrive servo
Intermediate servo
Valve body
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Line Pressure Diagnosis Chart (Continued)
Test Results Possible Source
Low in D Only (O/D Cancelled) Forward clutch
Overdrive servo
Intermediate servo
Valve body
Low in 1st Position Forward clutch
Valve body
Low in 2nd Position Intermediate servo
Overdrive servo
Intermediate servo
Forward clutch
Low in 3rd Position Intermediate servo
Overdrive servo
Forward clutch
Stall Speed Test
2. CAUTION: After testing each of the
This test checks operation of the following items: following ranges D, 3, 2, 1 and R, move the
transmission range selector lever to N and
Torque converter clutch
run the engine at 1,000 rpm for about 15
Forward clutch
seconds to allow the torque converter to cool
before testing the next range.
Low-one way clutch (OWC) assembly
Engine operation
CAUTION: Do not maintain wide open
throttle (WOT) in any range for more than 5
Overdrive one-way clutch assembly
seconds.
WARNING: Apply the parking brake
CAUTION: If the engine rpm recorded
firmly while carrying out each stall test.
by the tachometer exceeds maximum
CAUTION: Always carry out the Line
specified rpm, release the accelerator pedal
Pressure Test procedures prior to carrying out
immediately. Clutch or band slippage is
the Stall Speed Test. If line pressure is low at
indicated.
stall, do not carry out the Stall Speed Test or
NOTE: Prolonged use of this procedure may
further transmission damage will occur.
set Diagnostic Trouble Code (DTC) P0712,
NOTE: The Stall Speed Test should be carried out
P1783. After carrying out Stall Speed Test, run
with the engine and transmission at normal
OBD Test and clear DTCs from memory.
operating temperatures.
Press the accelerator pedal to the floor WOT in
1. Connect a tachometer to the engine.
each range. Record rpm reached in each range.
Stall speeds should be as follows:
Stall Speed Chart
Vehicle Engine RPM
Mustang 4.0L 2,290-2,705
Mustang 4.6L 2,556-3,014
If the stall speeds were too high, refer to the
following Stall Speed Diagnosis Chart. If the stall
speeds were too low, first check the engine idle
speed. If the engine idle is OK, remove the torque
converter and check the torque converter one-way
clutch for slippage.
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Stall Speed Diagnosis Chart
Transmission Range Selector
Lever Position Stall Speeds High Stall Speeds Low
D, D ((D) cancelled) and 1 Overdrive one-way clutch, rear
one-way clutch
D ((D) cancelled), 2 and 1 Forward clutch, overdrive one-way
clutch
D Forward clutch, overdrive one-way
clutch
D, D ((D) cancelled), 3, 2, 1 and R General pressure concerns, forward Converter one-way clutch or engine
clutch, overdrive one-way clutch driveability concerns
R Only High/reverse, high clutch, low and
reverse band/servo
2 Only Intermediate band/servo
1 Only Low/reverse band/servo
Air Pressure Tests
Follow the procedure to determine the location of
the inoperative clutch or band by substituting air
pressure into the various test plate passages.
NOTE: Use only dry, regulated 276 kPa (40 psi)
maximum air pressure.
1. Remove the main control valve body. Refer to
Main Control Valve Body in this section.
2. Install the transmission test plate and gasket.
3. NOTE: Do not apply air to the test plate vent
hole.
Apply air to the appropriate clutch or servo port
(refer to plate layout diagram). Refer to the Air
Pressure Test Diagnostic Chart for conditions,
1 Reverse servo
possible causes and actions.
2 Intermediate servo
4. After the testing is completed, remove the air
3 Overdrive servo
test plate and gasket and proceed with any
4 Coast clutch
repairs that are needed.
5 Forward clutch
5. After the repairs are completed, install the main
6 Direct clutch
control valve body. Refer to Main Control
7 Reverse servo modulator Valve Body in this section.
A no-drive or erratic shift condition may be due to
inoperative bands and clutches. To diagnose these
conditions a series of checks can be made by
substituting air pressure for fluid to determine the
location of the damaged or obstructed component.
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Air Pressure Test Diagnostic Chart
Condition Possible Causes Actions
Dull thud heard or movement felt Clutches, bands and fluid passages Concerns may not be in the
when air is applied and released are OK. transmission. Check the Powertrain
Control module (PCM), wiring
harness and non-transmission related
components.
No drive Clutches and bands inoperative. Disassemble the transmission, clean
and inspect to locate area of concern.
Erratic shifts Clutches and bands inoperative due to Disassemble the transmission, clean
incorrect pressures. and inspect to locate area of concern.
No dull thud heard Clutches, bands and fluid passages Disassemble the transmission, clean
may be damaged or obstructed. and inspect to locate area of concern.
No movement felt Clutches, bands and fluid passages Disassemble the transmission, clean
may be damaged or obstructed. and inspect to locate area of concern.
Hissing sound heard Clutch seals or check ball may be Disassemble the transmission, clean
damaged or leaking. and inspect to locate area of concern.
Servos do not operate Seals and pistons may be damaged. Disassemble the transmission, clean
Supply and release ports may be and inspect to locate area of concern.
obstructed. Spring may be broken.
Multiple clutches are applied Fluid passages in the center support Disassemble the transmission, clean
or the clutch cylinders may be and inspect to locate area of concern.
obstructed. Check fluid passages in the center
support for obstructions.
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SPECIFICATIONS
Item Specification
All engines 11.2L (11.9 qts)
Item Specification
Fluid Filter
Fluid
In-Line Transmission
CAUTION: Use only MERCON V transmission Fluid Filter Kit 7B155
fluid. Use of any other fluids may result in
In-Line Transmission
transmission failure.
Fluid Filter 7B155
Normal maintenance
Fluid change not necessary, filled for life. Lubricant
Severe duty maintenance
Change the fluid at 48,000 km (30,000 miles)
XG-4 and/or XL-5
intervals.
Grease XG-1-C or
Transmission Fluid
XT-5-QM (or
(Canada)
XT-5-QMC) (US);
Automatic CXT-5-LM12 (Canada)
Transmission/Power
Fluid Capacity
Steering Dye 164-R3701
NOTE: Approximate dry capacity includes cooler and or equivalent
tubes. Fluid level procedures in this section should be
used to determine actual fluid requirements and fluid
specification. DO NOT OVERFILL. If it is necessary to
add or change fluid, use only fluid which has been
certified by the supplier as meeting the Ford Motor
Company specification shown.
End Play Specifications
Select Thrust Washer (No. 1 Nylon)
Transmission Overdrive End
Part Number Thickness Play Dimension D ID: Color
38.05-38.13 mm (1.498-1.501 in) F7TZ-TA 1.55-1.60 mm (0.061-0.063 in) White
38.14-38.23 mm (1.50-1.51 in) F7TZ-MA 1.75-1.80 mm (0.069-0.071 in) Green
38.29-38.42 mm (1.507-1.513 in) F7TZ-NA 1.85-1.90 mm (0.073-0.075 in) Red
38.43-38.61 mm (1.51-1.52 in) F7TZ-RA 2.05-2.10 mm (0.081-0.083 in) Black
38.62-38.74 mm (1.52-1.53 in) F7TZ-SA 2.15-2.20 mm (0.095-0.097 in) Yellow
End Play Specifications
Selective Needle Bearings (No. 4)
ID:
Part Number Thickness Rear (No. 4) Dimension E Notches
1.67-1.85 mm (0.066-0.073 in) XW4Z-7D014-CA 2.65-2.80 mm (0.104-0.110 in) 0
1.86-2.04 mm (0.073-0.080 in) XW4Z-7D014-DA 2.80-2.95 mm (0.110-0.116 in) 1
2.05-2.23 mm (0.081-0.088 in) XW4Z-7D014-EA 3.00-3.15 mm (0.118-0.124 in) 2
2.25-2.43 mm (0.089-0.096 in) XW4Z-7D014-FA 3.20-3.35 mm (0.126-0.132 in) 3
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Closed 5-4 37-42 km/h (23-26 mph)
4-1 16-19 km/h (10-12 mph)
Minimum 1-2 19-21 km/h (12-13 mph)
Monitor PID: 2-3 27-31 km/h (17-19 mph)
TP Volt 1.25 3-4 34-35 km/h (21-22 mph)
4-5 39-43 km/h (24-27 mph)
Wide 1-2 64-68 km/h (40-42 mph)
Open 2-3 93-101 km/h (58-63 mph)
3-4 140-145 km/h (87-90 mph)
4-5 171-174 km/h (106-108 mph)
Closed 5-4 39 km/h (24 mph)
4-1 16 km/h (10 mph)
Minimum 1-2 18 km/h (11 mph)
Monitor PID: 2-3 27 km/h (17 mph)
TP Volt 1.25 3-4 35 km/h (22 mph)
4-5 39 km/h (24 mph)
Wide 1-2 68 km/h (42 mph)
Open 2-3 106 km/h (66 mph)
3-4 148 km/h (92 mph)
4-5 217 km/h (135 mph)
Band Adjustment and Torque Chart
Locknut Adjusting Screw
Number of Turns to Back
Nm Lb-Ft Nm Lb-Ft Description Off
Intermediate 1.5 54 40 14 10
Band
Overdrive 1.5 54 40 14 10
Band
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Selective Snap Rings
Coast and Direct Clutch Drum
Thickness Diameter
mm Inch mm Inch Part Number
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122
E860128-S 2.08 0.0819 130.1 5.122
E860129-S 2.44 0.0961 130.1 5.122
Selective Snap Rings
Forward Clutch Cylinder
Thickness Diameter
mm Inch mm Inch Part Number
XW4Z-7D483-AB 1.73 0.0681 141.45 5.56
XW4Z-7D483-AC 2.08 0.0819 141.45 5.56
XW4Z-7D483-AD 2.44 0.0961 141.45 5.56
Service Identification Model Chart
Vehicle Application
7000 Prefix and Suffix C=Column F=Floor Engine Displacement Vehicle Application
7R3P-BA F 4.0L Mustang
6R3P-AC F 4.6L Mustang
Solenoid Operation Chart
Gearshift PCM Comm-
P P ON OFF OFF ON L H/L L
N N ON OFF OFF ON L H/L L
R R ON OFF OFF ON L/H L H
4 OFF OFF OFF ON H H/L H
5 OFF OFF ON ON H H H
(D) 2 ON OFF ON ON L/H H L
Cancelled 3 ON ON OFF ON H L/H L
4 OFF OFF OFF OFF L/H H H
Manual 3 3 ON ON OFF OFF H L H/L
Manual 2 2 ON OFF ON OFF H L H/L
Manual 1 1 ON OFF OFF OFF H L H/L
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H = HIGH
L = LOW
H/L = PCM controlled
Manual = if equipped
Band/Clutch Application Chart A
Overdrive Interme- Reverse Forward Direct Coast
Band diate Band Band Clutch Clutch Clutch
Reverse A
a
A
a
1st A
a
2nd A A
a
3rd A
a
A
a
4th A
a
A
a
5th A
a
A
a
A
a
1st
b
A
a
2nd
b
A
a
A
a
3rd
b
A
a
A
a
4th
b
A
a
A
a
Ac
c
Manual 3rd Ac
c
A
a
Ac
c
Manual 2nd A
a
Ac
c
A
a
Manual 1st Ac
c
A
a
Ac
c
a A = Applied
b D Position (overdrive cancelled)
c Ac = Applied to carry coast torque
Band/Clutch Application Chart B
Direct One-Way Clutch Low One-Way Clutch
Engine
Drive Coast Drive Coast Braking
Reverse H
a
NE
b
NE
b
NE
b
NO
1st H
a
NE
b
H
a
NE
b
NO
2nd OR
c
OR
c
H
a
NE
b
NO
3rd H
a
NE
b
OR
c
OR
c
NO
4th H
a
NE
b
OR
c
OR
c
NO
5th OR
c
OR
c
OR
c
OR
c
YES
1st
d
H
a
NE
b
H
a
NE
b
YES
2nd
d
OR
c
OR
c
H
a
NE
b
YES
3rd
d
H
a
NE
b
OR
c
OR
c
YES
4th
d
H
a
NE
b
OR
c
OR
c
YES
Manual 3rd H
a
NE
b
OR
c
OR
c
YES
Manual 2nd OR
c
OR
c
H
a
NE
b
YES
Manual 1st H
a
NE
b
H
a
NE
b
YES
a H = Hold
b NE = No effect
c OR = Overrunning
d D Position (overdrive cancelled)
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Line Pressure Chart 4.0L and 4.6L Engines
Idle Pressure WOT Stall Pressure
PC C Line PC C Line Range
N 0-103 kPa (0-15 psi) 758-1034 kPa
(110-150 psi)
R 758-862 kPa 965-1551 kPa 758-862 kPa 2,000-2,482 kPa
(110-125 psi) (140-225 psi) (110-125 psi) (290-360 psi)
(D), 2, 1 0-103 kPa (0-15 psi) 758-1045 kPa 0-103 kPa (0-15 psi) 1,448-1,793 kPa
(110-150 psi) (210-260 psi)
Stall Speed Chart Torque Specifications (Continued)
Vehicle Engine RPM Description Nm lb-ft lb-in
Mustang 4.0L 2,290-2,705 Pressure tap plug to 13 10
case
Mustang 4.6L 2,556-3,014
Pump assembly-to-case 25 18
screws
Reverse servo
assembly-to-case
screws (Stage 1)
a
Case-to-center support 11 8
Reverse servo
screw
assembly-to-case
Digital transmission 8 71
screws (Stage 2)
a
range (TR)
Separator-to-main 7 62
sensor-to-case screws
control screws
Transmission output 103 73
Shift cable bracket 28 21
shaft flange bolts
screws
Extension housing 30 22
Solenoid body-to-case
screws and studs
screws
a
Fluid level indicator 10 89
Speed sensor-to-case 14 10
plug-to-drain pipe
screws
assembly
Torque converter 44 32
Fluid pan drain plug 26 19
adapter plate nuts to
Fluid pump housing 22 16
converter
screws
Torque converter 44 32
Heat shield screws 10 89
adapter
plate-to-flexplate nut
Locknut for band 54 40
adjustment
tube fitting to case
Main control valve
body-to-case screws
a
tube nut-to-case fitting
Manual control valve 10 89
detent spring-to-case
Transmission fluid 10 89
screw
filter-to-case screws
Manual control lever 48 35
Transmission fluid 11 8
shaft nut
pan-to-case screws
Output shaft-to-flange 130 96
Transmission 63 46
nut
crossmember-to-floor
pan screws
Band adjustment screw 14 10
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Transmission 70 52
insulator-to-extension
housing center screw
Vehicle 5 44
harness-to-solenoid
body screw
a Refer to the procedure in this section
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GENERAL PROCEDURES
3. Observe the color and odor of the fluid. The
Torque Converter Contamination
fluid should be red, not brown or black. Odor
Inspection
may indicate an overheating condition such as
clutch disc or band failure.
CAUTION: Do not use water-based
cleaners or mineral spirits to clean or flush the
4. Examine the stain on the tissue for evidence of
torque converter or transmission damage will
particles (spec of any kind). Examine the fluid
occur. Use only clean automatic transmission
level indicator for signs of antifreeze (gum or
fluid designated for the transmission and
varnish). If particles are present in the fluid or
converter being serviced.
there is evidence of engine coolant or water, a
new torque converter must be installed.
CAUTION: The torque converter drain
plug and seal are not reusable. If equipped,
5. If there are no particles or contamination
discard the drain plug and seal, then install a
present, drain the remainder of the transmission
new drain plug assembly.
fluid from the torque converter.
1. If a new or remanufactured torque converter is
6. Add 1.9 liter (2 qt) of clean automatic
not being installed, the following steps must be
transmission fluid into the converter and agitate
completed.
by hand.
2. With the torque converter on a bench, pour a
7. Thoroughly drain the fluid.
small amount of transmission fluid from the
torque converter onto an absorbent white tissue
or through a paper filter and examine the fluid.
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Torque Converter Operation Test
Torque Converter Diagnosis
This test verifies that the torque converter clutch
Prior to installing a new torque converter, all
control system and the torque converter are
diagnostic procedures must be followed. This is to
prevent the unnecessary installation of good torque
converters. Only after a complete diagnostic
1. Carry out the Quick Test. See On-Board
evaluation can the decision be made to install a
Diagnostics with scan tool. Refer to Diagnostics
new or remanufactured torque converter.
in this section. Check for DTCs. Refer to the
Diagnostic Trouble Code (DTC) Charts in this
Begin with the normal diagnostic procedures as
section.
follows:
2. Connect a tachometer to the engine.
1. Preliminary Inspection.
3. Bring the engine to normal operating
2. Know and Understand the Customer Concern.
temperature by driving the vehicle at highway
3. Verify the Concern Carry out the Torque
speeds for approximately 15 minutes in (D)
Converter Clutch Operation Test; refer to
position.
Torque Converter Operation Test in this section.
4. After normal operating temperature is reached,
4. Carry out Diagnostic Procedures.
maintain a constant vehicle speed of about 80
km/h (50 mph) and tap the brake pedal with the
Run on-board diagnostics. See On-Board
left foot.
Diagnostics with scan tool. Refer to
Diagnostics in this section.
5. The engine rpm should increase when the brake
pedal is tapped, and decrease about 5 seconds
Repair all non-transmission related DTCs
after the pedal is released. If this does not
first.
occur, refer to Torque Converter Operation
Repair all transmission DTCs.
Concerns in Diagnosis By Symptom.
Rerun on-board diagnostics to verify
6. If the vehicle stalls in (D) or manual 2 at idle
repair.
with vehicle at a stop, move the transmission
Carry out the Line Pressure Test. Refer to
range selector lever to manual 1 position. If the
Special Testing Procedures in this section.
vehicle stalls, refer to Diagnosis By Symptom,
Carry out the Stall Speed Test. Refer to Torque Converter Operation Concerns in this
Special Testing Procedures in this section. section. Repair as necessary. If the vehicle does
not stall in (D), refer to Diagnosis By Symptom
Carry out the Diagnosis by Symptom Index.
in this section.
Refer to Diagnosis By Symptom in this
section.
Use the index to locate the appropriate
routine that best describes the symptom(s).
The routine will list all possible
components that may cause or contribute
to the symptom. Check each component
listed, diagnose and service as necessary
before servicing the torque converter.
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GENERAL PROCEDURES
Torque Converter
1. A new or remanufactured torque converter must
be installed if one or more of the following
statements is true:
A torque converter malfunction has been
determined based on complete diagnostic
procedures.
Converter stud or studs, impeller hub or
bushing are damaged.
Discoloration (due to overheating).
Evidence of transmission assembly or fluid
contamination due to the following
transmission or converter failure Modes:
X Major metallic failure.
X Multiple clutches or clutch plate failures.
X Sufficient component wear which results
in metallic contamination.
X Internal torque converter contamination
present. For additional information, refer
to Torque Converter Contamination
Inspection in this section.
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The turbine reacts to the fluid motion from the
Torque Converter
impeller, transferring rotation to the geartrain
The torque converter transmits and multiplies
through the input shaft.
torque. The torque converter is a 4-element device:
The reactor redirects fluid going back into the
Impeller assembly
impeller, allowing for torque multiplication.
Turbine and damper assembly
The clutch and damper assembly dampens
Reactor assembly powertrain torsional vibration and provides a
direct mechanical connection for improved
Clutch
efficiency.
The standard torque converter components operate
Power is transmitted from the torque converter to
as follows:
the planetary gearsets and other components
Rotation of the converter housing and impeller
through the input shaft.
sets the fluid in motion.
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Transmission Connector Layouts
Connector Reference and Terminal
Readings
Powertrain Control module (PCM)
Pin Number Circuit Description
3 Output shaft speed (OSS) sensor signal input
4 Intermediate shaft speed sensor signal input
11 Pressure control solenoid A (PC A)
15 Turbine shaft speed (TSS) sensor signal input
16 Digital transmission range sensor TR1 to PCM
23 Pressure control solenoid B (PC B)
27 Digital transmission range sensor TR3A to PCM
29 Transmission fluid temperature (TFT) sensor
34 Pressure control solenoid C (PC C)
41 Signal return
42 Shift solenoid A (SSA)
43 Shift solenoid B (SSB)
44 Shift solenoid C (SSC)
45 Shift solenoid D (SSD)
46 Torque converter clutch (TCC) solenoid
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Transmission Vehicle Harness
1 Pressure control solenoid B (PC B)
2 Transmission fluid temperature (TFT) sensor input
3 Solenoid power
4 Pressure control solenoid C (PC C)
5 Shift solenoid D (SSD)
6 Shift solenoid C (SSC)
11 Pressure control solenoid A (PC A)
12 Signal return
14 Torque converter clutch (TCC) solenoid
15 Shift solenoid B (SSB)
16 Shift solenoid A (SSA)
Digital Transmission Range (TR) Sensor
2 Signal return
3 Digital transmission range (TR) sensor TR3A
4 Digital transmission range (TR) sensor TR1
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7 Ground
8 Neutral switch sense input
9 Fused power feed
10 Starter solenoid central power
11 Reverse lamps
12 Starter relay (overload protected)
Turbine Shaft Speed (TSS) Sensor
1 Turbine shaft speed (TSS) sensor signal
2 Signal return
Output Shaft Speed (OSS) Sensor
1 Output shaft speed (OSS) sensor signal
2 Signal return
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Intermediate Shaft Speed Sensor Harness Connector
1 Intermediate shaft speed sensor signal
2 Signal return
Digital Transmission Range (TR) Sensor Diagnosis Chart
PID: TR V
PID: TR D (volts)
TR3A (PCM
pin 27 to
signal Selector Shift Lever
TR4 TR3A TR2 TR1 return) Position Indicator
Park P 0 0 0 0 0.0 volts
Reverse R 1 1 0 0 1.3 - 1.8 volts
Neutral N 0 1 1 0 1.3 - 1.8 volts
Overdrive D 1 1 1 1 1.3 - 1.8 volts
Manual 3 3 1 0 1 0 0.0 volts
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Digital Transmission Range (TR) Sensor Diagnosis Chart (Continued)
PID: TR V
PID: TR D (volts)
TR3A (PCM
pin 27 to
signal Selector Shift Lever
TR4 TR3A TR2 TR1 return) Position Indicator
Manual 2 2 1 0 0 1 0.0 volts
Manual 1 Man 1 0 0 1 1 0.0 volts
A. TR V is the voltage at the PCM pin 27 (TR3A Circuit) to signal return.
B. TR D: 1= Open digital TR switch, 0= Closed digital TR switch.
C. EEC-V Control System Breakout Box Readings: Taken from PCM signal pins for TR1, TR2, TR3A and TR4 to
signal return.
Voltages for TR1, TR2 and TR4:
0 = 0.0 volts.
1 = 9.0-14.0 volts.
Voltage for TR3A:
0 = 0.0 volts.
1 = 1.3-1.8 volts.
Wiggle Test Information for Open/Shorts
A. TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits
(with scan tool monitoring TR D).
B. TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to
ground. To determine the shorted components while observing TR D, unplug the TR and see if the short goes
away. If the short is still present, unplug the transmission harness and see if the short goes away. If the short is
still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the
PCM connector. If the short is still present, then the PCM has an internal failure; otherwise the failure is in the
vehicle harness.
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moded torque converter clutch (TCC) applications.
Transmission Description
engine braking utilizing the coast clutch and band.
This transmission has:
manual first and second timing.
five forward speeds.
reverse inhibit timing.
electronic shift, pressure and torque converter
clutch controls.
Transmission View
three compound planetary gearsets.
three bands.
three multi-plate clutches.
two one-way clutches.
All hydraulic functions are directed by electronic
solenoids. The solenoids control:
static engagement feel.
shift feel.
shift scheduling.
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After On-Board Diagnostics
Transmission Drive Cycle Test
NOTE: The vehicle wiring harness, powertrain
NOTE: Always drive the vehicle in a safe manner
control module (PCM) and non-transmission sensors
according to driving conditions and obey all traffic
may affect transmission operations. Repair these
laws.
concerns first.
NOTE: The Transmission Drive Cycle Test must be
After the on-board diagnostic procedures are
followed exactly. Transmission failure must occur
completed, repair all DTCs.
four times consecutively for shift error DTC code to
be set, and 5 times consecutively for continuous
Begin with non-transmission related DTCs, then
torque converter clutch code to set.
repair any transmission related DTCs. Refer to the
Diagnostic Trouble Code (DTC) Charts in this
NOTE: When carrying out the Transmission Drive
section for information on condition and symptoms.
Cycle Test, use the Solenoid Operation Chart for
This chart will be helpful in referring to the correct
proper solenoid operation. Refer to Pinpoint Tests
manual(s) and aids in diagnosing internal
OSC Equipped Vehicle in this section.
transmission concerns and external non-transmission
After carrying out the Quick Test, use the
inputs. The pinpoint tests are used in diagnosing
Transmission Drive Cycle Test for checking
transmission electrical concerns. Make sure that the
continuous codes.
vehicle wiring harness and the PCM are diagnosed
1. Record and then erase Quick Test codes.
as well. The Powertrain Control/Emissions
Diagnosis (PC/ED) manual will aid in diagnosing
2. Warm engine to normal operating temperature.
non-transmission electronic components.
3. Make sure transmission fluid level is correct.
Before Pinpoint Tests 4. With transmission in (D) position, Moderately
accelerate from stop to 80 km/h (50 mph). This
NOTE: Prior to entering pinpoint tests, check the
allows the transmission to shift into 5th gear.
PCM wiring harness for correct connections, bent or
Hold speed and throttle open steady for a
broken pins, corrosion, loose wires, correct routing,
minimum of 15 seconds.
correct seals and their condition. Check the PCM,
sensors and actuators for damage. Refer to the
5. With transmission in 5th gear and maintaining
steady speed and throttle opening, lightly apply
manual.
and release brake to operate stop lamps. Then
hold speed and throttle steady for a minimum
NOTE: If a concern still exists after electrical
of 5 seconds.
diagnosis, refer to Diagnosis By Symptom in this
section.
6. Brake to a stop and remain stopped for a
minimum of 20 seconds.
If DTCs appear while carrying out the on-board
diagnostics, refer to the Diagnostic Trouble Code
7. Repeat steps 4 through 6 at least 5 times.
(DTC) Charts in this section for the appropriate
8. Carry out the Quick Test and record continuous
repair procedure. Prior to entering pinpoint tests,
DTCs.
refer to any TSBs and OASIS messages for
transmission concerns.
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Air Conditioning (A/C) Clutch
Transmission Electronic Control
An electromagnetic clutch is energized when the System
clutch cycling pressure switch closes. The switch is
Electronic System Description
located on the suction accumulator/drier. The
closing of the switch completes the circuit to the
The powertrain control module (PCM) and its
clutch and draws it into engagement with the
input/output network control the following
compressor driveshaft. When the A/C is engaged,
transmission operations:
operating pressures are adjusted to compensate for
Shift timing
additional load on the engine.
Line pressure (shift feel)
Brake Pedal Position (BPP) Switch
Torque converter clutch
The brake pedal position (BPP) switch tells the
The transmission control strategy combined with the
PCM when the brakes are applied. The torque
engine control provides optimum powertrain
converter clutch disengages when the brakes are
operation under all conditions. When determining
applied. The BPP switch closes when the brakes are
the best operating strategy for transmission
applied and opens when they are released. The BPP
operation, the PCM uses input information from
is also used to disengage the brake shift interlock.
certain engine-related and driver-demand-related
sensors and switches.
Sensor
In addition, the PCM receives input signals from
certain transmission-related sensors and switches.
The engine coolant temperature (ECT) sensor
The PCM also uses these signals when determining
detects engine coolant temperature and supplies the
transmission operating strategy.
information to the PCM. The ECT sensor is used to
control torque converter clutch (TCC) operation.
Using all of these input signals, the PCM can
determine when the time and conditions are right
Electronic Ignition (EI) System
for a shift, or when to apply or release the torque
The electronic ignition (EI) consists of a crankshaft
converter clutch. It will also determine the pressure
position sensor, a pair of 4-tower ignition coils and
needed to optimize shift feel. To accomplish this,
the PCM. The ignition control module operates by
the PCM uses 3 pressure controls, 1 torque
sending crankshaft position information from the
converter clutch and 4 shift solenoids to control
crankshaft position sensor to the ignition control
transmission operation.
module. The ignition control module generates a
The following provides a brief description of each
profile ignition pickup (PIP) signal (engine rpm)
of the sensors and actuators used to control
and sends it to the PCM. The PCM uses PIP signal
transmission operation.
in the transmission strategy, wide-open throttle
(WOT) shift control, TCC control and operating
pressures.
The operation of the transmission is controlled by
the powertrain control module (PCM). Many input
Intake Air Temperature (IAT) Sensor
sensors provide information to the powertrain
The intake air temperature (IAT) sensor provides
control module. The powertrain control module then
the sequential fuel injection (SFI) system mixture
controls the actuators which determine transmission
temperature information. The IAT sensor is used
operation.
both as a density corrector for air flow calculation
and to proportion cold enrichment fuel flow. The
IAT sensor is installed in the air cleaner outlet tube.
The IAT sensor is also used in determining control
pressures.
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Mass Air Flow (MAF) Sensor Digital Transmission Range (TR) Sensor
The mass air flow (MAF) sensor measures the mass The digital transmission range (TR) sensor is
of air flowing into the engine. The MAF sensor located on the outside of the transmission at the
output signal is used by the PCM to calculate manual lever. The digital TR sensor completes the
injector pulse width. For transmission strategies, the start circuit in PARK, NEUTRAL and the back-up
MAF sensor is used to regulate electronic pressure lamp circuit in REVERSE. The digital TR sensor
control, shift and torque converter clutch scheduling. also opens and closes a set of 4 switches that are
monitored by the powertrain control module to
Transmission Control (TC) Switch
determine the position of the manual lever (P, R, N,
The transmission control (TC) switch is a D, 3, 2, 1).
momentary contact switch that allows the driver to
Turbine Shaft Speed (TSS) Sensor
cancel operation of 5th (D) gear.
The turbine shaft speed (TSS) sensor is a magnetic
The TC switch is located on the end of the selector
pickup that sends the PCM the torque converter
lever.
turbine speed information.
When the driver initially presses the TC switch, a
The TSS sensor is mounted externally on the case.
signal is sent to the PCM.
The PCM uses TSS information to help determine
The PCM uses the shift solenoids to
appropriate operating pressures and TCC operation.
disengage/disable 5th gear operation and activate the
coast clutch.
At the same time, the PCM illuminates the
The output shaft speed (OSS) sensor is a magnetic
transmission control indicator lamp (TCIL) to notify
pickup, located at the park gear, that sends a signal
the driver that 5th gear is canceled.
to the powertrain control module to indicate
When the TC switch is pressed again, 5th (D) gear
transmission output shaft speed. The OSS sensor is
operation is enabled, the coast clutch is released and
mounted externally on the case. The OSS is used
the TCIL is turned OFF.
for torque converter clutch control, speed scheduling
and to determine electronic pressure control.
Whenever the ignition is cycled (vehicle shut OFF,
then started again), the TC switch is turned OFF
Intermediate Shaft Speed Sensor
and 5th gear will be enabled, even if the TCS had
The intermediate shaft speed sensor is a magnetic
been on when the ignition was shut off.
pickup that sends planetary sun gear speed
Transmission Control Indicator Lamp information to the PCM. The sensor is mounted
(TCIL)
externally on the center of the case.
The transmission control indicator lamp (TCIL) is
The PCM uses the sensor information to aid in
located in the instrument panel and is labeled
determining pressure requirements.
Overdrive OFF. It is illuminated in conjunction with
Pressure Control Solenoids (PCA, PCB,
the TC switch.
PCC)
The TCIL will flash if a fault has been detected in a
The pressure control (PC) solenoids are a
monitored sensor or solenoid used for transmission
variable-force style (VFS) solenoid. The VFS-type
operation.
solenoid is an electrohydraulic actuator combining a
Throttle Position (TP) Sensor solenoid and a regulating valve.
The throttle position (TP) sensor is a potentiometer
The line pressure tap is used to verify output
mounted on the throttle body. The TP sensor detects
pressure from PC A or PC B by turning either one
the position of the throttle plate and sends this
off while verifying the output from the other
information to the powertrain control module. The
solenoid. The second pressure tap is used to verify
TP sensor is used for shift scheduling, electronic
the output from the PC C solenoid.
pressure control and TCC control.
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Transmission Fluid Temperature (TFT) There are 3 PC solenoids located in the solenoid
Sensor
body assembly used to control line pressure, band
and clutch application pressure within the
The transmission fluid temperature (TFT) sensor
transmission.
is a thermistor-type sensor that varies a reference
The PCM varies the current to the PC solenoid.
voltage signal. The resistance in the TFT varies
with temperature. The PCM monitors the voltage
The PCM has an adaptive learn strategy to
signal across the TFT, and uses this information
electronically control the transmission which will
to determine the transmission fluid temperature.
automatically adjust the shift feel. When the battery
is disconnected or a new battery installed, certain
The TFT is located on the solenoid body.
transmission operating parameters can be lost. The
The PCM uses the TFT signal to help determine
PCM must relearn these parameters. During this
shift scheduling, torque converter clutch operation
learning process, you may experience slightly firm
and pressure control requirements.
shifts, delayed or early shifts. This operation is
It sends a voltage signal to the PCM. The voltage
considered normal and will not affect the function
signal varies with transmission fluid temperature.
of the transmission. Normal operation will return
The PCM uses this signal to determine whether a
once these parameters are stored by the PCM.
cold start shift schedule is necessary. The shift
Torque Converter Clutch (TCC) Solenoid schedule is compensated when the transmission
fluid temperature is cold. The PCM also inhibits
The torque converter clutch (TCC) solenoid is a
torque converter clutch operation at low
pulse width modulating-type solenoid that is used to
transmission fluid temperatures and determines PC
control the apply and release of the TCC.
solenoid operations.
Shift Solenoids (SSA, SSB, SSC, SSD)
Accelerator Pedal Position (APP) Sensor
Four ON/OFF shift solenoids allow the powertrain
The accelerator pedal position (APP) sensor is
control module to control shift scheduling.
mounted on the accelerator pedal. The APP detects
The solenoids are 3-way, normally open style.
the position of the accelerator pedal and inputs this
information as a voltage to the PCM. The PCM
The shift solenoids SSA, SSB, SSC and SSD
uses the APP sensor information to aid in
provide gear selection of 1st through 5th and
determining shift scheduling, electronic pressure
reverse gears by directing PC pressures to the
control (EPC) and torque converter control.
appropriate elements.
Coast braking and manual gears are also controlled
by the shift solenoids.
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IN-VEHICLE REPAIR
Transmission Filter In Line 3. CAUTION: The filter has a bypass
valve in it. The red arrow on the filter
indicates the direction of the fluid flow Material
through the filter. The filter must be
Item Specification
installed in the fluid cooler return line with
the red arrow on the filter pointing away
Transmission Fluid
from the transmission fluid cooler and
toward the transmission (the return line has
(US); CXT-5-LM12
fluid coming out of the cooler going to the (Canada)
transmission). If the fluid filter is not
NOTE: Use the following guidelines for installing
installed correctly, it will cause internal
the transmission fluid in-line filter:
transmission damage.
If the transmission was overhauled and the vehicle
CAUTION: Do not install any rubber
was equipped with an in-line fluid filter, install a
hoses or steel tubing with a bend entering
new in-line fluid filter.
the filter greater than 60 degrees.
If the transmission was overhauled and the vehicle
Install the one end of the filter into the rubber
was not equipped with an in-line fluid filter,
hose with a clamp, then install the other end of
install a new in-line fluid filter kit.
the filter into the rubber hose.
If the transmission is being installed for a
Install and tighten the 2 hose clamps.
non-internal repair, do not install an in-line filter
or filter kit.
If installing a new or a Ford-authorized
remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
Section 100-02.
2. Cut a section of the upper transmission fluid
cooler hose to allow installation of the
transmission fluid in-line filter.
4. Clean a visible section of the transmission fluid
pan and install the sticker indicating that the
vehicle is equipped with an in-line filter.
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5. Fill the transmission with clean automatic
transmission fluid.
Verify for correct operation.
Check the filter for leaks.
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GENERAL PROCEDURES
Transmission Fluid Cooler
Backflushing and Cleaning
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
CAUTION: Whenever a transmission has
been disassembled to install new parts or a new
3. To aid in attaching the cleaner to the
or remanufactured transmission has been
transmission steel cooler lines, connect 2
installed, a new transmission fluid cooler, either
additional rubber hoses to the transmission end
in-tank, auxiliary or oil to air (OTA), if equipped
of the steel transmission cooler lines as
will need to be installed. Using a suitable torque
described.
converter/fluid cooler cleaner, clean and
Connect the cleaner tank pressure line to the
backflush the transmission fluid cooler tubes.
steel transmission cooler return line
(transmission case upper fitting).
CAUTION: Use only clean automatic
transmission fluid specified for this transmission.
Connect a tank return hose to the steel
Do not use supplemental fluid additives,
transmission cooler pressure line
treatments or cleaning agent. The use of these
(transmission case lower fitting). Place the
materials may affect transmission operation and
outlet end of this hose in the solvent tank
result in internal damage to the transmission.
reservoir.
When internal wear or damage has occurred in
the transmission, metal particles, clutch plate
material or band material may have been carried
into the transmission fluid cooler. These
contaminants are a major cause of recurring
transmission concerns and must be removed
from the system before the transmission is put
back in use.
NOTE: Do not use any solvents while carrying out
this procedure. Only use clean automatic
transmission fluid.
1. Conduct backflushing with a suitable torque
4. Turn on the pump and allow the transmission
converter/transmission fluid cooler cleaner. Test
fluid to circulate a minimum of 5 minutes
the equipment to make sure that a vigorous
(cycling switch on and off will help dislodge
fluid flow is present before proceeding. Install a
contaminants in the cooler system).
new system filter if flow is weak or
contaminated.
5. Switch off the pump and disconnect the
pressure hose from the transmission cooler
2. Remove and discard the in-line transmission
return line.
fluid filter, if equipped.
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6. Use compressed air to blow out the cooler(s) 7. Remove the rubber return hose from the
and lines (blow air into the transmission cooler remaining steel cooler line.
return line) until all the fluid is removed.
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Transmission Fluid Cooler CAUTION: When internal wear or damage
has occurred in the transmission, metal particles,
Special Tool(s)
clutch plate material or band material may have
been carried into the transmission fluid cooler. Transmission Fluid Fill Tool
307-437 These contaminants are a major cause of
recurring transmission concerns and must be
removed from the system before the transmission
is put back into use.
When evidence of transmission fluid
contamination (such as metal particles, clutch
plate material or band material) is found in the
Material
cooling system, the transmission fluid cooler flow
Item Specification
test should be carried out.
If the transmission cooling system fails the
Transmission Fluid
transmission fluid cooler flow test, install a new
transmission fluid cooler and flush out the fluid
(US); CXT-5-LM12
cooler lines. If installing a new transmission fluid (Canada)
cooler, use only factory approved components.
Transmission Fluid Cooler Flow Test
CAUTION: The transmission fluid must be
at normal operating temperature 85C - 93C
been disassembled to install new parts or a new
(185F - 200F) to make sure that the cooler
or remanufactured transmission has been
bypass is open. The cooler bypass is located in
installed, a new transmission fluid cooler (either
the main control valve body. The transmission
in-tank, auxiliary or OTA) if equipped, will need
fluid at normal operating temperature will be
to be installed. Using a suitable torque
hot.
converter/fluid cooler cleaner, clean and
NOTE: The engine idle, transmission linkage/cable
backflush the transmission fluid cooler tubes.
adjustment, fluid level and line pressure must be
CAUTION: Use only clean automatic within specification before carrying out this test.
transmission fluid specified for this transmission. Refer to Section 307-05 for adjustments. For
Do not use supplemental fluid additives, information on engine idle diagnosis, refer to the
treatments or cleaning agents. The use of these Powertrain Control/Emissions Diagnosis (PC/ED)
materials may affect transmission operation and manual. For information on fluid level check, refer
result in internal damage to the transmission. to Transmission Fluid Level Check in this section.
For information on line pressure, refer to Special
Testing Procedures in this section.
1. Place the transmission range selector lever into
PARK.
2. Raise the vehicle on a hoist and place suitable
safety stands under the vehicle. Refer to Section
100-02.
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3. Hold the large drain plug with a wrench, and
remove the small (center) fluid level indicating
plug using a 3/16-inch Allen key.
7. Remove the safety stands and lower the vehicle.
8. Start the engine and run at idle.
9. With the engine running, raise the vehicle on a
hoist and place suitable safety stands under the
4. Install the special tool into the pan.
vehicle. Refer to Section 100-02.
10. Monitor the transmission fluid temperature to
make sure that the transmission fluid is at
normal operating temperature 85C - 93C
(185F - 200F).
11. Once a steady flow of fluid (without air
bubbles) is observed, remove the hose from the
special tool and place the hose in a measuring
container for 15 seconds. After 15 seconds,
place the hose back onto the special tool.
Lower the vehicle and turn the engine OFF.
Measure the amount of fluid in the container. If
adequate flow was observed, approximately 208
5. Remove the cooler return line (upper line) from
ml (7 oz) will be in the measuring container.
the fitting on the transmission case.
The test is complete. Reconnect the cooler line
and install the fluid fill plug.
12. If the flow is not liberal, disconnect the hose
from the cooler return line and connect the hose
to the cooler inlet (lower fitting) on the
transmission case. Reconnect the cooler return
line to the case (upper fitting).
6. Connect one end of a clear hose to the cooler
return line and route the other end of the hose
to the special tool in the pan.
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13. Repeat Steps 8 through 11. If flow is now
approximately 208 ml (7 oz) in 15 seconds, the
cooler lines and auxiliary cooler must be
cleaned. Refer to Transmission Fluid Cooler
Backflushing and Cleaning in this section.
Carry out this entire test after the backflushing
and cleaning procedure. If, after carrying out
the backflushing and cleaning procedure, the
flow is still not adequate, new cooler lines
and/or an auxiliary cooler must be installed. If
the flow from the case is still not adequate after
the installation of new cooler lines and/or an
auxiliary cooler (208 ml [7 oz] in 15 seconds),
the pump and/or torque converter may be at
fault. Carry out the appropriate procedures for
diagnosis and repair in this section.
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GENERAL PROCEDURES
2. Use a suitable flush and fill machine to change
Transmission Fluid Drain and Refill
the fluid.
Automated Equipment
3. When connecting the flush and fill machine,
Special Tool(s)
connect the machine to the fluid cooler tube
Automatic Transmission Flush after the fluid cooler on the cooler return line.
and Fill Machine
This will help remove any foreign material
211-00018
trapped in the fluid coolers.
Automatic Transmission Flush
and Fill Machine Refill
1. Use only clean automatic transmission fluid.
Material 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine.
Item Specification
Reconnect any disconnected fluid cooler tubes.
Transmission Fluid
3. With the engine running, check and adjust the
transmission fluid level, and check for any
(US); CXT-5-LM12
leaks. If fluid is needed, add fluid in increments (Canada)
of 0.24 liter (0.5 pint) until the correct level is
Draining
achieved. For additional information, refer to
CAUTION: Use only clean automatic
transmission fluid specified for this transmission.
Do not use supplemental transmission fluid
additives, treatments or clean agents. The use of
these materials can affect transmission operation
and result in damage to internal transmission
components.
CAUTION: Always refer to the
instructions supplied with the flush and fill
machine.
1. With the vehicle in PARK, position it on a
Section 100-02.
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GENERAL PROCEDURES
Fluid Fill Reference
Transmission Fluid Level Check
NOTE: Left side of case shown.
Special Tool(s)
Rubber Tip Air Nozzle
100-D009 (D93L-7000-A)
Vacuum Pump Kit
416-D002 (D95L-7559-A)
1 Fluid level
2 7A010 Fluid level tube
Fluid
3 W704999-S309 Fluid level and fill plug
Transporter/Evacuator/Injector
(small) (in-vehicle)
307-D465
4 7A010 Fluid drain plug (large)
1. Using the scan tool, monitor the transmission
fluid temperature (TFT) using PID: TFT.
2. Start the vehicle.
software with appropriate 3. NOTE: Engine idle speed is approximately 650
rpm.
tool
While proceeding with this procedure, run the
engine until the transmission fluid temperature
is between 27-49C (80-120F).
Transmission Fluid Fill Tool
307-437
4. Move the range selector lever slowly through
each gear, stopping in each position and
allowing the transmission to engage.
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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5. Place the range selector lever in the PARK
position.
6. With the engine running, position the vehicle
on a hoist and set it as close to level as
possible. For additional information, refer to
Section 100-02.
7. Hold the larger drain plug with a wrench and
remove the small (center) fluid level indicating
plug.
10. Hang the special tool under the vehicle.
Position it upright and close to the transmission.
8. Install the special tool into the pan.
11. Connect the special tools.
Connect the open end of the fluid hose from
the Fluid Transporter/Evacuator/Injector to
the Fluid Level and Fill Plug Adapter at the
bottom of the transmission fluid pan.
9. NOTE: Prior to filling the special tool with
clean transmission fluid, make sure that the
canister is clean.
Fill the special tool with clean automatic
transmission fluid.
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12. Apply a maximum of 206.85 kPa (30 psi) to 16. Allow the fluid to drain. Make sure that the
the open end of the vacuum/pressure hose from fluid temperature is between 27-49C
the special tool. Fluid will immediately start (80-120F). When the fluid comes out as a
flowing out of the special tool into the thin stream or drip, the fluid is at the correct
transmission fluid pan. level.
13. Add one pint of transmission fluid into the fluid 17. Reinstall the small (center) fluid level indicating
pan. Stop the process by releasing the air plug and tighten to 10 Nm (89 lb-in).
pressure and removing the air nozzle from the
end of the hose.
14. Inspect the fluid level in the special tool. If the
fluid drains back into the canister, the
transmission is full. If no fluid drains back,
more fluid will need to be added. Repeat Steps
12 and 13.
15. Once the transmission is full, place a hand
vacuum pump on the open end of the
vacuum/pressure hose of the special tool and
apply vacuum to the system. This will pull out
any extra fluid trapped in the system and direct
it into the container. 18. Check the operation of the transmission by
moving the range selector lever slowly through
each gear, stopping in each position and
allowing the transmission to engage.
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GENERAL PROCEDURES
Transmission Range (TR) Sensor 4. CAUTION: Tightening one screw
before tightening the other may cause the Adjustment
Special Tool(s) NOTE: The manual lever must be in the
NEUTRAL position.
307-351 (T97L-70010-A) Using the special tool, align the digital TR
sequence.
Adjust
Section 100-02.
2. Disconnect the shift cable from the manual
control lever.
5. Install the shift cable to the manual control
lever.
3. Loosen the screws.
6. Verify that the shift cable is adjusted correctly.
307-05.
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307-02-1 307-02-1 Transaxle/Transmission Cooling
SPECIFICATIONS
Cooler line bracket to 48 35
Item Specification engine nut
Fluid Fluid cooler tube nut at 40 30
transmission
Transmission Fluid Fluid cooler mounting 10 89
XT-5-QM (or screws
XT-5-QMC) (US);
CXT-5-LM12 (Canada)
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IN-VEHICLE REPAIR
Transmission Support Crossmember
4. Remove the transmission crossmember-to-floor
pan screws.
1 Transmission
screws
2 Transmission
insulator-to-extension housing
center screw
Removal
Section 100-02.
2. Remove the catalytic converter. For additional
3. Support the transmission with a transmission
jack.
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5. Remove the transmission insulator-to-extension 3. NOTE: The transmission support insulator must
housing center screw. be neutralized.
rearward and side-to-side until the gaps between
6. Remove the transmission crossmember.
Installation
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ASSEMBLY
Special Tool(s)
Transmission
Alignment Set, Fluid Pump
307-S039 (T74P-77103-X)
Special Tool(s)
Adjustment Set, Transmission
Band
307-S022 (T71P-77370-A)
Aligner, Fluid Pump Handle
307-431
Holding Fixture, Transmission
307-003 (T57L-500-B)
Aligner, Fluid Pump Pilot
307-432
Depth Micrometer
303-D026 (D80P-4201-A) or
equivalent
Gauge Bar
307-400
307-351 (T97L-70010-A)
Compressor, Servo Cover
307-402
Installer, Transmission
Extension Housing Oil Seal
307-038 (T74P-77052-A)
Installer, Shift Shaft Fluid Seal
307-050 (T74P-77498-A)
Sizer, Piston Seal
307-338 (T95L-70010-G)
Handle, Torque Converter
307-091 (T81P-7902-C)
(Continued)
(Continued)
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Special Tool(s) Special Tool(s)
Compressor, Cushion Spring Installer, Drive Pinion flange
307-401 205-479
Aligner, Valve Body Installer, Output Shaft Flange
307-334 (T95L-70010-C) 307-404
Alignment Pins, Transmission
Material
Pump
307-399
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
Aligner, Flex Plate
307-403
XG-4 and/or XL-5
Air Test Plate and Gaskets,
Transmission
307-433-01, 307-433-2,
307-433-3
(Continued)
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26 7C492 Overdrive/intermediate band 1 7045 Converter-to-flexplate nut
adjusting screw (attaches the converter
assembly to the flexplate)
27 71000 Overdrive/intermediate
(4.0L only)
locking nut
2 7902 Converter assembly
28 7L669 Overdrive brake band drum
assembly 3 N800750 Converter-to-adapter plate nut
(attaches the converter
29 7A548 Direct and overdrive piston
assembly to the adapter plate)
outer seal
(8 required) (4.6L only)
30 7D404 Direct and overdrive piston
4 N800750 Adapter plate-to-flexplate nut
inner seal
(attaches adapter plate to the
31 7A262 Direct and overdrive clutch
flexplate) (4 required) (4.6L
piston
only)
32 7A480 Direct and overdrive clutch
5 6K374 Adapter plate assembly (4.6L
piston spring
only)
33 7A527 Clutch piston spring retainer
6 7902 Converter assembly
(2 required)
7 7017 Input shaft
34 E860125 Retaining ring (retains 7D041
8 7A248 Front fluid pump seal
to drum) (2 required)
assembly
35 7B442 Coast clutch external splined
9 7A248 Front fluid pump seal
plate (steel) (2 required)
10 W704892 Screw and washer assembly
36 7B164 Coast clutch internal splined
M8 x 35 internal lobe
friction plate (2 required)
(attaches pump to case) (8
37 7B066 Coast and direct clutch
required)
pressure plate (2 required)
11 7G178 Fluid pump cover assembly
38 E860126 Coast and direct clutch plates
12 7B472 Fluid pump adapter plate
E860129 retaining ring (select fit) (2
required) 13 7A136 Front fluid pump gasket
39 7660 Coast clutch to overdrive 14 W701431 Fluid pump shaft-to-inner
carrier adapter gear O-ring seal (also in
pump assembly)
40 7D063 Overdrive sun gear
15 7L323 Stator support seal
41 7B446 Overdrive planetary gear
carrier (with trigger wheel) 16 7A108 Front pump support assembly
42 7L495 Overdrive planet thrust 17 7H416 O-ring
bearing No. 2
18 7H411 Fluid pump control valve
43 7A153 Overdrive ring gear
19 7A103 Fluid pump assembly
44 7A089 Center shaft one-way clutch
20 W701429 M8 x 1 x 35 internal lobe
assembly
screw (attaches pump support
45 7A658 Overdrive center shaft to pump assembly) (6
required)
46 W702037 Retaining ring (retains 7686
to 7653)
21 7D025 Overdrive brake drum seal
47 7L678 Hub and ring gear assembly
22 7D014 Fluid pump input thrust
(includes 7C109, 7A153, washer No. 1
7A658, W702037)
23 7D029 Intermediate and overdrive
48 7M153 Center shaft and forward brake band anchor strut (2
clutch cylinder bearing required)
assembly No. 3, No. 5, No. 8
and No. 9 (4 required)
brake band (2 required)
49 W702465 Retaining ring
50 7A130 Center support assembly brake band apply strut (2
(Continued)
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51 E826160 Nut and cage assembly 80 7C122 Output shaft ring gear
(attaches center support to retaining ring
case)
81 7D019 Output shaft hub seal
52 W705407 Bolt
82 7H027 Low/intermediate sun gear
53 7D014 Intermediate clutch drum bearing assembly
bearing No. 4
83 7C498 Reverse brake drum and
54 7D044 Intermediate brake drum clutch assembly (includes
assembly OWC)
55 7B442 Direct clutch external splined 84 7D095 Low/reverse band assembly
steel plates (5 required)
85 7R205 Output shaft bearing
56 7B164 Direct clutch internal splined
86 7B368 Output shaft thrust washer
friction plates (5 required)
No.11
57 7A360 Forward clutch cylinder
87 7A233 Transmission parking gear
58 7A262 Forward clutch piston assembly
assembly
88 7060 Output shaft
59 7G299 Forward clutch support and
89 7A441 Parking pawl
spring assembly
90 7D070 Parking pawl return spring
60 E860109 Forward clutch piston and
91 7D071 Parking pawl shaft
spring retaining ring in
forward clutch cylinder 92 7086 Extension housing gasket
61 7B442 Forward clutch external spline 93 7A039 Extension housing
steel plate (5 required)
94 W500311 M8 x 1.25 extension
62 7B164 Forward clutch internally housing-to-case screw (5
spline friction plate (5 required)
required)
63 7B066 Forward clutch pressure plate
96 7089 Output shaft flange
64 7D483 Retaining ring 141.45 x 1.37
97 W701357 Output shaft flange nut
internal (select fit)
98 7D273 Fluid tube connector
65 7D234 Forward ring gear hub thrust
assembly (2 required)
bearing No. 6A
99 7H074 Ring overdrive servo retainer
66 7D090 Forward clutch thrust washer
100 W703119 Overdrive servo cover seal (2
No. 6B
required)
67 7G375 Forward clutch hub retainer
101 7D027 Overdrive servo cover
ring
102 7D021 Overdrive servo piston and
68 7B067 Forward ring gear hub
rod
69 7D392 Forward ring gear
103 7D028 Intermediate/overdrive servo
70 7F374 Forward planet thrust bearing
piston spring (2 required)
No. 7
104 W702777 Ring intermediate servo
71 7A398 Forward planetary
retainer
72 7A019 Shell and sun gear assembly
105 W702969 Intermediate servo cover seal
73 7C167 Low and reverse spacer gear
106 7D027 Intermediate servo cover
74 W702775 Reverse carrier drum snap
107 7D021 Intermediate servo piston and
ring
rod
75 7D006 Reverse planet assembly
108 7005 Case assembly
76 7B176 Output shaft sleeve
109 7034 Case vent assembly
77 E860527 External retainer ring
110 W708389 Speed sensor-to-case screw
78 7A153 Output shaft ring gear (M6 x 19)
(Continued) 79 7D164 Output shaft hub
(Continued)
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111 7H103 Output shaft speed, turbine 138 W500102 Main control valve body
shaft speed and intermediate screws (18 required)
shaft speed sensors
112 W702981 Speed sensor-to-case O-ring screw
seal
140 7E332 Manual valve detent spring
113 7A179 Reverse brake drum lever
141 W500100 Screw detent spring
114 7D433 Reverse band actuating lever
shaft
screw
115 7A232 Parking pawl actuating rod
143 7A100 Main control valve body
116 390318 Pipe plug
144 W705928 Solenoid body connector
117 W703001 Manual lever shaft outer and O-ring seal
inner nut
145 7G391 Transmission control solenoid
118 7A115 Manual valve inner lever body
119 7B498 Manual control lever seal 146 W702921 Transmission control solenoid
body screw
120 7A256 Manual control lever
147 W703189 Transmission control solenoid
121 7F293 Digital transmission range
body screws (7 required)
(TR) sensor
148 7A098 Transmission fluid pan filter
122 W500015 Digital TR sensor screw and
washer (2 required) 149 W705559 Transmission fluid pan filter
screws
123 6026 Fluid fill plug
150 7L027 Transmission fluid pan
124 7B210 Manual lever shaft pin
magnet
retainer
125 7B193 Reverse servo assembly
126 7D372 Reverse servo plate
127 7D466 Reverse servo accumulator
plug gasket
spring
128 7D189 Reverse servo piston and seal
plug
129 7423 Reverse servo piston O-ring
155 W500213 Transmission fluid pan screw
seal
156 W707919 Transmission fluid pan drain
130 7D036 Reverse servo cover
tube plug (short hex)
131 W702359 Reverse servo piston-to-case
157 Overdrive/coast clutch
screw (4 required)
assembly
132 7D321 Control valve spring retainer
158 Direct clutch assembly
133 7A270 Main fluid pressure spring
159 Forward clutch assembly
regulator valve
160 Overdrive servo
134 7D488 Reverse servo check valve
161 Intermediate servo
separating plate screw
1. Thoroughly clean the transmission case and 136 7Z490 Main control valve body
separating plate (bonded) extension housing in solvent and blow dry with
compressed air. 137 7A101 Lower main control valve
body
(Continued)
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2. Inspect the transmission case for the following:
5. WARNING: Make sure the lockpin on
bench-mounted holding fixture is secure.
Stripped bolt hole threads.
Failure to follow these instructions may
Gasket and mating surfaces for burrs or
nicks.
Using the special tool, install the transmission
Obstructions to vent and fluid passages.
into the bench with the converter housing
Cracks or warpage.
facing up.
3. Inspect the extension housing for cracks, burrs
6. Using the special tool, install the manual
or warpage.
control lever shaft seal and lubricate it with
petroleum jelly.
4. Inspect the case bearing for damage. If damage
to the case bearing is indicated, install a new
7. Install the parking lever rod.
case.
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8. Install the manual control lever. 11. Install the manual valve inner lever onto the
manual shaft and loosely install the nut.
9. Assemble the manual valve inner lever and
parking lever actuating rod as shown.
12. CAUTION: Use care not to damage
the fluid pan rail surface when installing the
retaining pin.
NOTE: Align the manual control lever shaft
alignment groove with the manual control lever
shaft spring pin bore in the transmission case.
Install the manual control lever shaft spring pin.
Tap the manual control lever shaft spring
pin into the transmission case.
10. CAUTION: Align the flats on the
manual valve inner lever with the flats on
the manual control lever shaft.
Install the manual control lever shaft.
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13. CAUTION: To avoid damage, do not
allow the wrench to strike the manual valve
inner lever pin.
Tighten the nut.
16. Install the output shaft and park gear.
14. CAUTION: The tabs on the output
shaft thrust washer (No. 11) point into the
case. Make sure the thrust washer is
correctly seated.
Install the output shaft thrust washer (No. 11).
Coat the output shaft thrust washer with
petroleum jelly.
17. Install the low/reverse brake drum.
Rotate the low/reverse brake drum clockwise
to install.
15. Install the park gear on the output shaft.
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21. Install the No. 10 needle bearing into the case.
18. CAUTION: Make sure band is resting
on the 2 anchor pins in the case.
Install the low/reverse band over the reverse
drum.
22. CAUTION: Do not damage the seal
against the case during assembly.
Install the output shaft ring gear, hub and seal.
19. NOTE: The reverse band actuating lever must
fit into the notches in the band.
Install the reverse band actuating lever into the
reverse band.
23. CAUTION: Always install a new
output shaft retaining ring.
Install a new output shaft retaining ring.
20. Install the reverse band actuating lever shaft
into the case and into the reverse band actuating
lever.
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24. NOTE: Install the output shaft sleeve with the
27. CAUTION: The low/reverse brake
cone facing up. This sleeve will snap into place
drum must be pulled forward to install the
when correctly installed.
low/reverse planet retaining ring.
Install the output shaft sleeve.
Install the retaining ring.
25. Install low/reverse planetary carrier needle
28. Install the No. 8 thrust bearing.
bearing (No. 9) onto the output shaft ring gear
and hub assembly.
29. Install the spacer on the input shell, using
petroleum jelly to hold it in place.
26. CAUTION: Make sure the needle
bearings stay in place.
Install the low/reverse planetary assembly.
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30. Install the input shell and sun gear assembly. 33. Install the No. 6B forward clutch thrust washer
onto the forward ring gear hub.
31. NOTE: The No. 13 bearing must be correctly
seated in the forward planet assembly so the 34. Install the forward ring gear and hub as an
sun gear can be installed correctly. assembly.
Install the forward planetary assembly.
35. Install the No. 6A forward ring gear hub thrust
bearing into the forward ring gear and hub.
32. Install the No. 7 forward planet thrust bearing
into the forward ring gear and hub assembly.
Use petroleum jelly to hold the bearing in
place.
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36. Install the forward clutch cylinder.
40. Install the direct clutch drum.
37. Install the No. 5 thrust bearing.
41. Using a depth micrometer with an 8-inch
extension, measure from the top of the gauge
38. Install the intermediate servo piston and spring.
bar to center support ledge in the case at 4
places 90 degrees apart.
Lubricate the servo bore with clean
Add the 4 measurements, divide by 4, and
record as dimension A.
39. Using the special tool, install the retaining ring.
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43. NOTE: Align the disc holes on special tool
42. CAUTION: The torque specifications
with the slot in gauge bar for correct
are critical for this procedure. Failure to use
measurement.
the correct torque specifications may cause
Measure the distance from the top of the gauge
bar to the drum bearing surface through the
hole in the disc and record as dimension B.
1 Install the special tool and the bolts using
Repeat the measurement 180 degrees on the
the 2 pump screw locations at
opposite side of the special tool and record as
approximately 6 and 12 oclock positions.
dimension C.
2 Tighten the center screw.
X Tighten to 1.13 Nm (10 lb-in).
44. Add dimension B to C, divide by 2, and record
as dimension D.
45. Subtract A from D and record as dimension E.
46. Select bearing from the following chart, using
dimension E.
Service Part Number
Dimension E (7D014) Bearing Thickness Identification (Notches)
1.69-1.87 mm XW4Z-CA 2.65-2.80 mm None
(0.066-0.074 in) (0.104-0.110 in)
1.88-2.04 mm XW4X-DA 2.83-2.98 mm One
(0.073-0.080 in) (0.111-0.116 in)
2.05-2.22 mm XW4Z-EA 3.01-3.16 mm Two
(0.081- 0.088 in) (0.118-0.124 in)
2.23-2.43 mm XW4Z-FA 3.21-3.36 mm Three
(0.088-0.096 in) (0.126-0.132 in)
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47. NOTE: Make sure that the intermediate band
apply strut is aligned with the band notch.
NOTE: If the intermediate band is reused, it
must be installed in the same position as when
removed.
NOTE: The new intermediate band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also considered
normal. Do not install a new band based solely
on the color.
Install the intermediate band.
48. CAUTION: To avoid a fall-out
49. CAUTION: If the strut is installed
condition of the strut from the screw during
incorrectly, transmission damage will occur.
assembly and function, the small U
Check to make sure that the intermediate band
shaped notch should be toward the band/case
anchor strut is installed in the correct
side and the large U shaped notch toward
orientation to the case and adjustment screw.
the main control side.
Install the intermediate band anchor strut.
1 Band/case side of the anchor (small U
notch).
2 Main control side of the anchor (large U
notch).
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50. Loosely install the screw.
54. NOTE: Align the center support screw hole
with correct case hole.
51. Install the intermediate band apply strut.
Install the center support.
55. Install the center support locknut and cage.
apply strut is installed in the correct orientation
to the case and piston rod.
53. Install the selected No. 4 thrust washer on the
direct clutch drum.
Coat the thrust washer with petroleum jelly.
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57. CAUTION: Install the center support
retaining ring with the tapered side facing
up.
CAUTION: Make sure the notch
opening is not obstructed by the center
support retaining ring.
Install the center support retaining ring.
1 Make sure the center support retaining ring
is installed with the tapered side facing up.
2 Make sure the opening of the center support
58. Install the center shaft thrust bearing (No. 3).
retaining ring is positioned correctly.
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59. Install the overdrive ring gear, overdrive 62. Install the overdrive band servo piston and
one-way clutch and center shaft assembly. spring.
Lubricate the servo bore with clean
60. CAUTION: Do not bend the trigger
wheel. Make sure that the No. 2 thrust
bearing is in this assembly.
63. Using the special tools, install the retaining
ring.
Install the planetary gear overdrive carrier.
61. Install the overdrive brake drum and coast
clutch drum assembly.
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64. NOTE: If the overdrive band is reused, it must
be installed in the same position as when
removed.
NOTE: Make sure that the overdrive band
apply strut is aligned with the band notch.
NOTE: The new overdrive band is dark in
on the color.
Install the overdrive band.
65. CAUTION: To avoid a fall-out
condition of the strut from the screw during
assembly and function, the small U
shaped notch should be toward the band/case
anchor strut is installed in the correct
side and the large U shaped notch toward
orientation to the case and adjustment screw.
the main control side.
Install the overdrive band anchor strut.
1 Band/case side of the anchor (small U
notch).
2 Main control side of the anchor (large U
notch).
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70. CAUTION: The torque specifications
are critical for this procedure. Failure to use
the correct torque specifications may cause
1 Install the special tool and the bolts using
the 2 pump screw locations at
approximately 6 and 12 oclock positions.
2 Tighten the center screw.
68. Install the overdrive apply strut.
71. NOTE: Align the disc holes on special tool
with the slot in gauge bar for correct
measurement.
69. CAUTION: If the strut is installed Measure the distance from the top of the gauge
incorrectly, transmission damage will occur. bar to the drum bearing surface through the
hole in the disc and record as dimension A.
Check to make sure that the overdrive band
Repeat the measurement 180 degrees on the
apply strut is installed in the correct orientation
opposite side of the special tool and record as
to the case and piston rod.
dimension B.
72. Add dimension A to B, divide by 2, and record
as dimension C.
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73. Subtract the thickness of the gauge bar 17.78 74. Select the No. 1 thrust bearing from the
mm (0.70 in) from dimension C and record as following chart using dimension D.
dimension D.
Service Part Number
Dimension D (7D014) Bearing Thickness Identification (Color/ID)
38.05-38.13 mm F7TZ-TA 1.55-1.60 mm (0.061-0.063 White
(1.498-1.501 in) in)
38.14-38.28 mm F7TZ-MA 1.75-1.80 mm (0.069-0.071 Green
(1.50-1.51 in) in)
38.29-38.42 mm F7TZ-NA 1.85-1.90 mm (0.073-0.075 Red
(1.507-1.513 in) in)
38.43-38.61 mm F7TZ-RA 2.05-2.10 mm (0.081-0.083 Black
(1.51-1.52 in) in)
38.62-38.74 mm (1.52-1.53 F7TZ-SA 2.15-2.20 mm (0.095-0.097 Yellow
in) in)
75. Install the selected No. 1 fluid pump input
thrust washer.
Coat the fluid pump input thrust washer
with petroleum jelly.
78. CAUTION: Make sure that the fluid
pump inlet thrust washer (No. 1), selective
thrust washer, fluid pump gasket and the
fluid pump-to-case O-ring seal remain in the
correct position throughout this step.
76. Install the special tools into the transmission
Install the fluid pump.
case.
77. Install the pump gasket.
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79. CAUTION: The special tools must be
used to correctly align the pump with the
adapter plate to reduce gear noise, bushing
failure and leakage.
Using the special tool, align the fluid pump to
the adapter plate.
82. CAUTION: Do not allow overdrive
band adjustment screw to back out. Band
strut could fall out of position.
CAUTION: Install, but do not tighten,
a new locknut on the band adjustment screw.
Apply petroleum jelly to the locknut seal.
Install a new locknut on the band adjustment
80. Install screws. Tighten the screws in a star
screw.
pattern.
81. Remove the special tools and install the 2
remaining screws.
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83. CAUTION: The overdrive servo must
be installed prior to band adjustment.
Using the special tool, tighten the overdrive
band adjustment screw.
Then back off the screw exactly 1.5 turns
and hold that position.
86. CAUTION: The intermediate servo
must be installed prior to band adjustment.
Using the special tool, tighten the intermediate
band adjustment screw.
Then back off the screw exactly 1.5 turns
and hold that position.
84. Tighten the overdrive band locknut.
1 Hold the overdrive band adjustment screw
stationary.
2 Tighten the overdrive band locknut.
intermediate band adjusting screw to back
out. Band strut could fall out of position.
CAUTION: Install, but do not tighten,
a new locknut on the band adjustment screw.
Apply petroleum jelly to the locknut seal.
Install new nut on the band adjustment screw.
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87. Tighten the intermediate band locknut. 90. Install the special tools into the transmission
case.
1 Hold the intermediate band adjustment
screw stationary.
2 Tighten the intermediate band locknut.
91. Using the special tools, install the main control
valve body and loosely install the screws.
1 Install the short screw.
2 Install the screw with the larger head.
88. Tighten the center support screw.
3 Install the remaining screws.
92. Remove the special tools, and loosely install the
89. Using the special tools, carry out the air
screw.
pressure test procedure. For additional
information, refer to Special Testing Procedures
in this section.
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93. Tighten the screws in the sequence shown.
94. With the manual lever in the NEUTRAL 95. Install new O-ring seals on the solenoid body
position, install the manual valve detent spring. connector. Lubricate the O-ring seals with clean
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material and not damaged. If damaged,
transmission leak may occur.
the sequence shown.
97. Install the reverse servo. Tighten the bolts in
the sequence shown in 2 stages.
100. Tighten the 16 screws in a crisscross
sequence.
fluid filter.
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assembly.
104. Using the special tool, install the extension
housing seal.
102. Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl return spring.
3 Install the parking pawl.
4 Install a new gasket.
105. Using the special tools, install the output shaft
flange.
103. Install the extension housing.
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109. CAUTION: The splines of the input
shaft are not the same length on both ends.
The shaft end with the shorter splines goes
into the fluid pump.
107. CAUTION: The digital TR sensor
must fit flush against the boss on the case
Install the input shaft.
to prevent damage to the sensor.
Install the digital TR sensor and loosely install
the screws.
110. Using the special tool, make sure that the fluid
pump gear seal ring is fully seated.
108. CAUTION: Tightening one screw
before tightening the other may cause the
NOTE: The manual lever must be in the
NEUTRAL position.
Using the special tool, align the digital TR
sequence.
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113. WARNING: The torque converter can
fall out if the transmission is tipped. Failure
to follow these instructions may cause
personal injury.
Using the special tools, install the torque
converter by pushing and rotating.
112. CAUTION: Do not damage the fluid
pump gear O-ring seal when installing
torque converter.
CAUTION: Make sure the converter
hub is fully engaged in the pump support
114. Lubricate the torque converter pilot hub with
and gear and rotates freely. Do not damage
multi-purpose grease.
the hub seal.
CAUTION: If the torque converter
slides out, the hub seal may be damaged.
Lubricate the converter hub with clean
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117. Using one of the speed sensor holes, fill the
115. CAUTION: The special tool must be
transmission with 8.5L (9 qts) of automatic
used to correctly align the adapter plate to
transmission fluid.
the converter or transmission damage could
occur.
In order to correctly install the special
service tool, it must be installed using 1
round and 1 oblong hole. Using 2 oblong
holes will cause damage to the transmission.
NOTE: Position the adapter plate on the
torque converter and identify the position of
the orange or green paint daub on the
converter face.
If the vehicle is equipped, use the special tool
to install the torque converter flexplate adapter
assembly and 8 nuts.
118. NOTE: Inspect O-ring seals for damage.
Install new O-ring seals if damaged. Lubricate
the O-ring seals with petroleum jelly to
prevent damage to the O-ring seals.
Install the sensors.
116. Remove the special tool and install the
remaining torque converter flexplate adapter
nuts.
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DISASSEMBLY
Special Tool(s)
Transmission
Handle, Torque Converter
307-091 (T81P-7902-C)
Special Tool(s)
Remover, Input Shaft Oil Seal
308-375
307-523
Remover, Transmission Fluid
Pump
307-397
1. NOTE: Tag and identify all parts for
reassembly.
Place the transmission on a bench.
307-003 (T57L-500-B)
Slide Hammer
100-001 (T50T-100-A)
Remover, Torque Converter
Fluid Seal
307-309 (T94P-77001-BH)
Compressor, Servo Cover
307-402
(Continued)
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2. WARNING: The torque converter is
heavy, especially when full of fluid.
NOTE: If not installing a new torque converter,
leave the adapter plate screwed to the torque
converter.
Using the special tools, remove the torque
converter and adapter plate as an assembly.
5. Remove the input shaft.
3. If the vehicle is equipped, and installation of a
new or remanufactured torque converter is
necessary, remove the torque converter adapter
plate.
6. Using the special tool, install the transmission
into the bench with the torque converter
housing facing up.
4. If the adapter plate has been removed, use the
special tools to remove the torque converter.
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7. Remove the transmission sensors.
11. Using the special tools, remove the extension
housing seal.
8. Remove the transmission range (TR) senor.
12. CAUTION: The parking pawl, parking
pawl return spring and parking pawl shaft
could fall out during removal of the
extension housing.
Remove the extension housing.
flange.
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13. Remove the parking pawl assembly and discard
the gasket.
1 Remove the parking pawl shaft.
2 Remove the parking pawl.
3 Remove the parking pawl return spring.
4 Remove and discard the gasket.
16. Remove the transmission fluid filter and
discard.
14. Remove the drain plug and discard the gasket
17. Remove the manual control valve detent spring.
reusable. Clean and inspect the gasket for
damage. If the gasket is not damaged, the
gasket should be reused.
Remove the 16 transmission fluid pan screws,
transmission fluid pan and gasket.
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care when removing the piston and cover
assembly. Failure to follow these instructions
Remove the reverse servo assembly.
21. Using the special tools, remove the converter
hub seal.
19. CAUTION: Do not damage solenoid
body connector pins.
Remove the solenoid body assembly by lifting
on the body and pushing the connector from the
other side of the case.
22. CAUTION: Failure to loosen the
overdrive band adjusting screw prior to
pump removal may cause damage to the
pump and overdrive band.
CAUTION: Throw the locknuts away.
The locknuts are not reusable for assembly.
Remove and discard the locknuts, and loosen
the overdrive/intermediate band adjusting screw.
20. Remove the main control valve body, separator
plate and gasket.
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23. Remove and tag part for assembly. 26. Using the special tools, remove the pump.
24. CAUTION: The screws are not 27. CAUTION: Servo cover is under
reusable for assembly. Discard the screws. If spring tension.
the screws are reused, the housing may
Using the special tool, remove the intermediate
become separated from the transmission.
servo cover retaining ring.
Remove and discard the screws.
28. Remove the intermediate band servo piston and
25. Install the special tool. spring.
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32. NOTE: Tag and identify parts for reassembly.
29. CAUTION: Servo cover is under
spring tension.
Compress the overdrive band and remove the
apply strut.
Using the special tool, remove the overdrive
servo cover retaining ring and cover.
33. CAUTION: Identify the anchor and
30. Remove the front band servo piston and spring. apply ends of the overdrive band.
NOTE: The new overdrive band is dark in
on the color.
Remove and inspect the overdrive band. Check
the following conditions for installing a new
band:
Inspect for glazing.
Inspect for missing friction material.
Inspect for material flaking.
Inspect for damage to the anchor pins.
31. Remove the screw.
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34. Remove the overdrive brake and coast clutch 37. Remove the overdrive ring gear, overdrive
drum. one-way clutch assembly and center shaft as an
assembly.
35. CAUTION: Do not bend the trigger
38. NOTE: Tag and identify the center shaft thrust
wheel.
bearing No. 3 for reassembly.
NOTE: The No. 12 thrust bearing is in this
Remove the No. 3 center shaft thrust bearing.
assembly.
Remove the planetary gear overdrive carrier.
39. CAUTION: The center support locknut
could fall into the remaining assembly if not
36. Remove the No. 2 overdrive planet thrust
removed.
bearing.
Remove the bolt.
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40. Remove the locknut and cage. 43. Inspect the center support assembly for wear or
damage.
1 Inspect the thrust surfaces for wear or
damage.
2 Inspect the center support sealing surface.
3 Inspect the fluid passage for blockage or
damage.
41. Remove the center support retaining ring.
44. Inspect the seal rings for damage.
42. NOTE: The center support is repaired as an
assembly. Any damage requires installing a new
component.
NOTE: When removing the center support, pull
evenly around the center support web.
Remove the center support.
45. Inspect the bearing for missing rollers or
damage.
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46. Inspect the direct clutch feed hole for blockage
or damage.
1 Rotate the center support bearing to locate
the direct clutch feed hole.
2 Inspect the direct clutch feed hole for
blockage or damage.
49. CAUTION: Identify the anchor and
apply ends of the intermediate band.
NOTE: The new intermediate band is dark in
on the color.
47. NOTE: Tag and identify the No. 4 intermediate
Remove and inspect the intermediate band.
clutch drum thrust bearing.
Check the following conditions when installing
Remove the intermediate brake drum thrust a new band:
bearing (No. 4).
Inspect for glazing.
Inspect for missing friction material.
Inspect for material flaking.
Inspect for damage to the anchor pins.
48. Remove, tag and identify the band anchor strut
for assembly.
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50. Remove, tag and identify the band apply strut.
54. NOTE: The No. 6A thrust bearing may come
out with the cylinder. Tag and identify for
51. Remove the screw.
reassembly.
Remove the forward clutch cylinder.
52. NOTE: The No. 5 forward clutch cylinder
thrust bearing may come out with the
55. NOTE: The No. 6A forward ring gear hub
intermediate brake and direct clutch drum.
thrust bearing may have come out with the
Remove the direct clutch drum.
forward clutch cylinder.
Remove the No. 6A forward ring gear hub
thrust bearing.
53. Remove the No. 5 forward clutch cylinder
thrust bearing, tag and identify.
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56. NOTE: The No. 7 forward planet thrust
bearing may come out with the forward ring
gear and hub assembly.
Remove the forward ring gear and hub as an
assembly.
59. Remove the forward planetary assembly.
57. Remove the No. 6B forward clutch thrust
washer from the forward ring gear hub.
60. Remove the input shell and sun gear assembly.
58. NOTE: The No. 7 forward planet thrust
bearing may come out with the forward ring
gear and hub assembly.
Remove the No. 7 forward planet thrust
bearing.
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61. Remove the spacer.
65. NOTE: Tag and identify the No. 9 low/reverse
planetary carrier thrust bearing.
62. NOTE: Tag and identify the No. 8 low/reverse
Remove the thrust bearing.
planetary carrier thrust bearing.
Remove the thrust bearing.
66. NOTE: Use slots located around the outside of
the sleeve.
63. Remove the retaining ring.
Using a small pick, remove the output shaft
sleeve.
64. Remove the low/reverse planetary assembly.
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67. WARNING: The output shaft may fall
out after removing the snap ring. Failure to
personal injury.
CAUTION: Discard the output shaft
retaining ring. A new retaining ring must be
used for assembly.
While holding the output shaft, remove and
discard the output shaft retaining ring.
70. CAUTION: Do not pry on the outer
edge of the case. Damage to the gasket
sealing surface could occur.
NOTE: It may be necessary to grind flat spots
on the edges of the reverse band actuating lever
shaft in order to remove it.
Using a pair of vise grips, hold the flat spots on
the reverse band actuating lever shaft, wiggle it
back and forth and remove the reverse band
actuating lever shaft.
68. Remove the output shaft ring gear and hub.
71. Remove the reverse band actuating lever
assembly.
69. Remove the No. 10 low/intermediate sun gear
bearing.
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72. NOTE: The inner race of the rear one-way
clutch is not removable. It is repaired in the
case.
Remove the low/reverse brake drum and
one-way clutch assembly by rotating it
clockwise.
75. Remove the output shaft and park gear.
73. NOTE: The reverse one-way clutch is part of
the reverse brake drum assembly. Install a new
reverse brake drum as an assembly only.
Inspect the reverse brake drum assembly and
install a new reverse brake drum assembly if
damaged.
1 Inspect the reverse brake drum sprags.
76. NOTE: Tag and identify the No. 11 output
2 Inspect the reverse brake drum rollers.
shaft thrust washer.
3 Inspect the reverse brake drum.
Remove the output shaft thrust washer.
74. Remove the reverse band.
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80. Disconnect the manual valve inner lever from
77. CAUTION: To avoid damage, make
the parking lever actuating rod.
sure the wrench does not strike the manual
valve inner lever pin.
Remove the nut.
81. Remove the manual valve inner lever.
78. Remove the manual shaft retaining pin.
82. Remove the parking lever actuating rod.
79. Remove the manual control lever shaft.
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83. CAUTION: Do not damage the bore.
Remove the manual control lever seal.
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INSTALLATION
Transmission
All vehicles
1. WARNING: Secure the transmission to
in personal injury.
Secure the transmission to the transmission jack
with a safety chain.
2. Rotate the torque converter and adapter plate so
6. Install the access cover.
the orange or green paint daub on the torque
converter is in the 12 oclock location.
3. Raise and position the transmission to the back
of the engine.
4.6L engine
4. Install the 7 engine-to-transmission retaining
bolts.
7. Install the flexplate cover.
5. Install the 4 new torque converter nuts.
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4.0L engine
8. Install the starter.
11. Position the fuel line bracket in place and
install the 6 retaining bolts.
9. Install the starter motor electrical connectors.
Tighten the cable to 13 Nm (10 lb-ft).
Tighten the wire to 6 Nm (53 lb-in).
12. Install the 4 new torque converter nuts.
10. Install the starter motor electrical connector
cover.
13. Install the starter motor.
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14. Install the lower transmission retaining bolts.
17. Connect the digital transmission range (TR)
sensor connector.
All vehicles
15. CAUTION: Use care not to bend or
force the cooler tubes otherwise damage to
the cooler tubes and the transmission can
result.
Install the transmission fluid cooler tubes.
18. Position the wire harness and install the
retainers.
nut.
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tightened above the specification.
connector.
connector.
20. Connect the turbine shaft speed (TSS) sensor,
output shaft speed (OSS) sensor and
intermediate shaft speed sensor electrical
connectors.
24. NOTE: The transmission support insulator must
be neutralized.
21. Install the shift cable and bracket.
rearward and side-to-side until the gaps between
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25. With the transmission support insulator 28. Install the driveshaft. For additional
neutralized, tighten the transmission information, refer to Section 205-01.
30. Use the following guidelines for installing the
in-line transmission fluid filter:
If the transmission was overhauled and the
vehicle was equipped with an in-line fluid
filter, install a new in-line fluid filter.
If the transmission was overhauled and the
vehicle was not equipped with an in-line
fluid filter, install a new in-line fluid filter
kit.
If the transmission is being installed for a
non-internal repair, do not install an in-line
filter or filter kit.
If installing a new or a Ford-authorized
remanufactured transmission, install the
in-line transmission fluid filter that is
supplied.
X Prior to lowering the vehicle, install a
new in-line transmission filter or a filter
kit. For additional information, refer to
Transmission Filter In Line in this
section.
31. NOTE: When the battery has been
disconnected and reconnected, some abnormal
drive symptoms can occur while the vehicle
relearns its adaptive strategy. The customer
needs to be notified that they can experience
slightly different upshifts (either soft or firm)
and that this is a temporary condition and will
27. Install the heated oxygen sensor (HO2S) eventually return to normal operating condition.
connector to the front of the transmission pan
Connect the battery ground cable. For additional
rail.
32. Carry out the fluid level check. For additional
information, refer to Transmission Fluid Level
33. Verify that the shift cable is correctly adjusted.
307-05.
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34. Check the operation of the transmission and
inspect for leaks.
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REMOVAL
Transmission 5. WARNING: Secure the transmission to
Failure to follow these instructions may Special Tool(s)
Retainer, Torque Converter
Using a suitable transmission jack, support the 307-346 (T97T-7902-A)
transmission.
All vehicles
WARNING: Secure the transmission to the
transmission jack with a safety chain. Failure to
follow these instructions can result in personal
injury.
NOTE: When the battery has been disconnected
and reconnected, some abnormal drive symptoms
can occur while the vehicle relearns its adaptive
strategy. The customer needs to be notified that they
can experience slightly different upshifts (either soft
7. Remove the rear transmission
or firm) and that this is a temporary condition and
will eventually return to normal operating condition.
NOTE: If transmission disassembly or installation
of a new transmission is necessary, drain the
transmission fluid. Install the drain plug when
finished.
NOTE: If the transmission is to be removed for an
extended period of time, support the engine with a
safety stand and a word block.
Section 100-02.
3. Remove the catalytic converter. For additional
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REMOVAL (Continued)
8. Remove the rear transmission
insulator-to-extension housing center screw and
remove the transmission crossmember.
11. Remove the starter wire and positive battery
cable.
9. Remove the shift cable and bracket and position
out of PARK.
1 Disconnect the cable from the lever.
2 Position the manual lever out of PARK.
3 Remove the bolts and the shift cable and
bracket, and position aside.
12. Remove the starter motor bolts and starter.
4.6L engine
10. Remove the electrical connector cover.
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REMOVAL (Continued)
13. Remove the flexplate cover.
17. Remove and discard the 4 torque converter
nuts.
14. Remove the access cover.
18. Remove the lower transmission retaining bolts.
15. Remove the 4 torque converter nuts.
All vehicles
4.0L engine
19. Lower the transmission to gain access to the
16. Remove the starter and position aside.
sensor connectors and the transmission bolts.
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REMOVAL (Continued)
20. Disconnect the digital transmission range (TR) 23. Disconnect the harness retainers.
sensor connector.
24. CAUTION: Do not damage the cooler
21. Disconnect the turbine shaft speed (TSS)
tubes.
sensor, output shaft speed (OSS) sensor and
Disconnect the transmission cooler tubes.
intermediate shaft speed sensor electrical
connectors.
22. NOTE: Clean the area around the connector to
connector.
Remove the screw from the solenoid body
connector and disconnect the connector.
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REMOVAL (Continued)
4.6L engine All vehicles
26. Remove the 7 engine-to-transmission retaining 28. Lower the transmission assembly from the
bolts. vehicle.
4.0L engine
30. Carry out the transmission fluid cooler
27. Remove the 6 engine-to-transmission retaining
backflushing and cleaning if the transmission is
bolts and position the fuel line bracket aside.
being overhauled or installing a new or
remanufactured transmission. For additional
information, refer to Transmission Fluid Cooler
Backflushing and Cleaning in this section.
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Shift Linkage Check
Visual Inspection
Check for a misadjustment in shift linkage by
This inspection will identify modifications or
matching the detents in the transmission range
additions to the vehicle operating system that may
selector lever with those in the transmission. If they
affect diagnosis. Inspect the vehicle for non-Ford
match, the misadjustment is in the indicator. Do not
factory add-on devices such as:
adjust the shift linkage.
Electronic add-on items:
Hydraulic leakage at the manual control valve can
air conditioning.
cause delay in engagements and/or slipping while
operating if the linkage is not correctly adjusted.
generator (alternator).
engine turbo.
cellular telephone. Check TSBs and OASIS
cruise control. Refer to all Technical Service Bulletins (TSBs) and
OASIS messages which pertain to the transmission
CB radio.
concern and follow the procedure as outlined.
linear booster.
Carry Out On-Board Diagnostics (KOEO,
backup alarm signal.
KOER)
computer.
After a road test, with the vehicle warm and before
Vehicle modification:
disconnecting any connectors, carry out the Quick
These items, if not installed correctly, will affect the
Test using a suitable diagnostic scan tool. Refer to
powertrain control module (PCM) or transmission
function. Pay particular attention to add-on wiring
(PC/ED) manual for diagnosis and testing of the
splices in the PCM harness or transmission wiring
powertrain control system.
harness, abnormal tire size, or axle ratio changes.
Leaks; refer to Leakage Inspection in this section.
Correct linkage adjustments; refer to Section
307-05.
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For transmission fluid cooler flow test, refer to
Transmission Cooling
Section 307-01.
This vehicle with an automatic transmission is
For transmission fluid cooler backflushing and
equipped with an auxiliary transmission fluid cooler.
cleaning, refer to Section 307-01.
The cooler transfers heat from the transmission fluid
to the ambient air.
Transmission Fluid Cooler Tubes (4.6L engine)
6 Fluid cooler tube assembly 1 7A095 Auxiliary oil cooler
nuts (part of 7H420)
2 7W064 Fluid cooler outlet hose
7 7005 Transmission case
3 7W063 Fluid cooler inlet hose
8 7J081 Transmission fluid cooler
4 7H420 Fluid cooler tube assembly
tube quick connect secondary
5 Fluid cooler tube assembly
latch
bracket (part of 7H420)
(Continued)
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Transmission Fluid Cooler Tubes (4.0L engine)
6 Fluid cooler tube assembly 1 7A095 Auxiliary oil cooler
nuts (part of 7H420)
2 7W064 Fluid cooler outlet hose
7 7005 Transmission case
3 7W063 Fluid cooler inlet hose
4 7H420 Fluid cooler tube assembly
tube quick connect secondary
5 Fluid cooler tube assembly
latch
bracket (part of 7H420)
(Continued)
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Transmission Cooling
been disassembled to installed new parts, a new
transmission fluid cooler must be installed and
the transmission fluid cooler tubes must be
cleaned and backflushed.
NOTE: Cleaning and backflushing the transmission
fluid cooling system, along with normal cleaning
and inspection procedures as outlined in this section
during disassembly and reassembly, will keep
contamination from re-entering the transmission and
causing a repeat repair.
When internal wear or damage has occurred in the
transmission, metal particles, clutch plate material or
band material may have been carried into the torque
converter and transmission fluid cooler. These
contaminants are a major cause of recurring
transmission troubles and must be removed from the
system before the transmission is put back in use.
When fluid leakage is found in the fluid cooler,
install a new fluid cooler.
When there is evidence of transmission assembly or
fluid contamination due to the following
transmission failure modes, install a new fluid
cooler.
Major metallic failure
Multiple clutches or clutch plate failure
Sufficient component wear which result in
metallic contamination
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Symptom Chart
SYMPTOM CHART
Transmission overheating System leaks INSPECT for leaks. REPAIR
as necessary.
Incorrect fluid level ADJUST to proper level.
Fluid condition INSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307-01.
Damaged, blocked, reversed, INSPECT cooler lines and
leaking or restricted cooler tubes. REPAIR or flush as
lines or cooler tubes necessary.
Engine concerns causing INSPECT engine cooling
transmission to overheat system. For additional
information, REFER to
Section 303-03A.
Excessive towing loads CHECK gross vehicle weight.
Incorrect idle or performance REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
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GENERAL PROCEDURES
Backflushing and Cleaning
1. Refer to Section 307-01.
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GENERAL PROCEDURES
Transmission Fluid Cooler Flow Test
1. Refer to Section 307-01.
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Transmission Fluid Cooler Hoses
Special Tool(s)
Disconnect Tool, Transmission
Cooler Line
307-569
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
3 7J081 Transmission fluid cooler 1 Lower air deflector screws (7
tube quick connect secondary required)
latches
2 Lower air deflector
(Continued)
(Continued)
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5. Remove and discard the transmission fluid
cooler hose-to-cooler clamps.
4 7W063 Transmission fluid cooler
inlet hose
6. Disconnect the transmission fluid cooler hoses
from the cooler.
outlet hose
6 Transmission fluid cooler
7. Remove the transmission fluid cooler hoses
hose retainer
from the retainer.
7 376240 Transmission fluid cooler
hose-to-cooler clamps
Installation
Removal
1. Install the transmission fluid cooler hoses into
the retainer.
2. Connect the transmission fluid cooler hoses to
Section 100-02.
the cooler.
2. Remove the lower air deflector.
3. Install 2 new transmission fluid cooler
hose-to-cooler clamps.
3. Remove the transmission fluid cooler tube
quick connect secondary latches.
4. NOTE: When connecting the cooler hoses to
the cooler lines the white mark on the cooler
4. Using the special tool, disconnect the
tube must be aligned with the H mark on the
transmission fluid cooler hoses from the tubes.
hose.
Connect the transmission fluid cooler hoses to
the cooler tubes.
5. Install the transmission fluid cooler tube quick
connect secondary latches.
transmission fluid and verify correct operation.
7. Install the lower air deflector.
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Transmission Fluid Cooler Tubes
Special Tool(s)
Disconnect Tool, Transmission
Cooler Line
307-569
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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6 Transmission fluid cooler 1 Transmission fluid cooler
tube bracket (part of 7H420) tube bracket nut
Removal tube nuts (part of 7H420)
tube quick connect secondary All vehicles
latch
4 7H420 Transmission fluid cooler
tubes
Section 100-02.
tube retainer (part of 7H420)
(Continued)
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4.6L engines
2. Remove the fluid cooler tube bracket at the
engine.
5. Remove both transmission cooler tubes quick
connect secondary latches.
4.0L engines
3. Remove the fluid cooler tube bracket at the
engine.
6. Using the special tool, disconnect both
transmission cooler tubes from the transmission
cooler hoses.
All vehicles
4. NOTE: Use a backup wrench to hold the case
fitting secure.
Remove the fluid cooler tubes at the
transmission.
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4.6L engines
Installation
All vehicles
3. Install the fluid cooler tube bracket at the
engine.
1. NOTE: When connecting the cooler hoses to
the cooler lines the white mark on the cooler
tube must be aligned with the H mark on the
hose.
Install the fluid cooler hoses on the fluid cooler
tubes and install the secondary latches.
4.0L engines
4. Install the fluid cooler tube bracket at the
engine.
2. NOTE: Use a backup wrench to hold the case
fitting secure.
Install the fluid cooler tubes at the transmission.
All vehicles
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Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)
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5. Remove the transmission fluid cooler outlet
hose from the cooler.
1 Lower air deflector screws (7
required)
6. Remove the 2 transmission fluid cooler
2 Lower air deflector
retaining screws.
3 376240 Transmission fluid
cooler-to-hose clamps
7. Lift and remove the transmission fluid cooler
from the retaining pockets.
inlet hose
5 7W064 Transmission fluid cooler Installation
outlet hose
6 HS1 Transmission fluid cooler
1. Position the transmission fluid cooler in the
screws
retaining pockets.
7 7A095 Transmission fluid cooler
2. Install the transmission fluid cooler screws.
Removal
3. Connect the transmission fluid cooler hoses to
the cooler.
Section 100-02.
4. Install new transmission cooler-to-hose clamps.
2. Remove the lower air deflector.
3. Remove and discard the 2 transmission fluid
cooler-to-hose clamps.
6. Install the lower air deflector.
4. Remove the transmission fluid cooler inlet hose
from the cooler.
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307-05-1 307-05-1 Automatic Transaxle/Transmission External Controls
Brake Shift Interlock Actuator
NOTE: The brake shift interlock actuator is not
serviced separately. If a new brake shift interlock
actuator is required, install a new transmission
selector lever assembly.
For additional information, refer to Selector Lever
in this section.
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GENERAL PROCEDURES
3. Using an suitable tool, depress the brake shift
Brake Shift Interlock Override
interlock override mechanism on the selector
lever, apply the brake, depress the button on the
NOTE: If it is necessary to use the override
selector lever and move the selector lever into
procedure to move the gearshift lever out of the
NEUTRAL.
PARK position, it is possible that a fuse has blown
and the brake lights are not operational. Before
driving the vehicle, verify that the brake lights are
working.
This vehicle is equipped with a brake shift interlock
feature that prevents the gearshift lever from being
moved out of PARK when the ignition is in the ON
position unless the brake pedal is depressed.
If the gearshift lever cannot be moved out of the
PARK position when the ignition is in the ON
position and the brake pedal is depressed:
1. Apply the parking brake and remove the
ignition key.
4. Start the vehicle.
2. Remove the access panel.
5. To install, reverse the procedure.
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External Controls
The transmission control (TC) switch is a
The indicated position of the transmission floor
momentary contact switch that is located on the
mounted selector lever is transferred to the
floor mounted transmission range selector lever.
transmission through the cable and down to the
Pushing the TC switch will either disengage or
manual control lever on the transmission.
engage the overdrive function of the automatic
Shift Interlock System transmission. If OVERDRIVE is disengaged, the
word O/D OFF will illuminate on the instrument
The brake/shift interlock mechanism is used on
cluster.
vehicles equipped with an automatic transmission.
This system is used to prevent shifting from PARK
unless the brake pedal is depressed. The brake/shift
interlock system consists of an actuator attached to
the key interlock assembly and necessary wiring.
The shift interlock actuator is energized when the
ignition switch is turned to the RUN position,
locking the floor mounted transmission range
selector lever in the PARK position. When the
brake pedal is depressed, the shift interlock actuator
is deactivated and the floor mounted transmission
range selector lever can be moved out of the PARK
position.
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External Controls
Special Tool(s)
Shift control linkage Circuitry
73 Digital Multimeter binding Central junction box
105-R0051 or equivalent Shift interlock actuator (CJB) fuses:
Selector lever cable 17 (15A)
Interlock cable 28 (15A)
35 (15A)
Brake pedal position
(BPP) switch
Wiring harness
Loose or corroded
Inspection and Verification connections
LED
transmission external control.
3. If the concern is not visually evident, determine
the symptom. GO to Symptom Chart.
mechanical and electrical damage; refer to the
following chart:
Symptom Chart
Symptom Chart
The shift interlock system Circuitry GO to Pinpoint Test A.
does not release/lock correctly CJB fuse 17 (15A) or fuse 35
(15A)
Shift interlock actuator
Brake pedal position (BPP)
switch
The shift control is out of Transmission selector lever GO to Pinpoint Test B.
correct gear relationship cable and bracket
Retainer bracket
Shift control linkage out of
adjustment
Transmission range indicator Transmission selector lever TIGHTEN the bolts holding
does not correspond to the cable bracket the transmission selector lever
gear cable bracket.
Shift linkage VERIFY digital transmission
range (TR) sensor range for
correct adjustment. REFER to
Section 307-01.
The transmission control (TC) CJB fuse 28 (15A) GO to Pinpoint Test C.
switch is inoperative TC switch
TC switch not cycled during
self-test
Powertrain control module
(PCM)
Circuitry
The transmission control LED REFER to Section 413-01.
indicator lamp (TCIL) is not Instrument cluster
operating correctly PCM
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Excessive shift effort Transmission selector lever INSTALL a new transmission
cable selector lever cable.
Cable bracket ADJUST the cable.
TIGHTEN the screws.
Transmission selector lever Transmission selector lever INSTALL a new transmission
will not shift cable selector lever cable.
Broken transmission selector INSTALL a new transmission
level cable selector lever cable.
Pinpoint Tests Refer to Wiring Diagrams Cell 29, Transmission
Control for schematic and connector information.
Refer to Wiring Diagrams Cell 37, Shift Lock for
schematic and connector information.
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
A1 TEST THE BRAKE LIGHTS
Apply the brake pedal and observe the stoplamps. GO to A2.
Do the stoplamps illuminate?
No
A2 CHECK CIRCUIT 511 (LG) FOR AN OPEN
Disconnect: Selector Lever C307.
Measure the voltage between selector lever C307-3, circuit 511
(LG), harness side, and ground while depressing and releasing
the brake pedal.
Yes
GO to A3.
No
Is the voltage greater than 10 volts with the brake pedal REPAIR the circuit. TEST the system for
depressed and 0 volts with the brake pedal released? normal operation.
A3 CHECK CIRCUIT 294 (WH/LB) FOR AN OPEN
Key in ON position.
(Continued)
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PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
(Continued)
A3 CHECK CIRCUIT 294 (WH/LB) FOR AN OPEN (Continued)
(WH/LB), harness side, and ground.
Yes
GO to A4.
No
A4 TEST CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between selector lever C307-1, circuit
1205 (BK), harness side, and ground.
Yes
INSTALL a new selector lever assembly.
REFER to Selector Lever. TEST the
No
Is the resistance less than 5 ohms? normal operation.
PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP
B1 CHECK THE SHIFT CONTROL LINKAGE
Apply the brake pedal. GO to B2.
Actuate the transmission selector lever in all ranges.
No
Observe the shift control linkage during operation.
Is the shift control linkage OK?
B2 CHECK THE TRANSMISSION SHIFT CABLE
Check the transmission selector lever cable and bracket Yes
installation and tightness. GO to B3.
Is the transmission selector lever cable correctly installed
No
and adjusted?
(Continued)
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PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP (Continued)
B3 CHECK THE LINKAGE/CABLE FOR CORRECT GEAR
RELATIONSHIP
Apply the brake pedal. Yes
Actuate the transmission selector lever in all ranges. VERIFY the correct adjustment of the
Does the indicator match the gear selection? digital transmission range (TR) sensor.
REFER to Section 307-01. ADJUST the
digital TR sensor if necessary. TEST the
No
ADJUST the transmission selector lever
cable. REFER to Selector Lever Cable
Adjustment. TEST the system for normal
operation.
PINPOINT TEST C: THE TRANSMISSION CONTROL (TC) SWITCH IS INOPERATIVE
C1 CHECK THE VOLTAGE TO THE TRANSMISSION CONTROL
(TC) SWITCH
Disconnect: Selector Lever C307.
Key in ON position.
(WH/LG), harness side, and ground.
Yes
GO to C2.
No
C2 CHECK THE TC SWITCH
Measure the resistance between selector lever C307-5 and
C307-6, component side, while depressing and releasing the TC
switch.
Yes
GO to C3.
Is the resistance less than 5 ohms with the TC switch No
depressed and greater than 10,000 ohms with the TC switch INSTALL a new TC switch. Test the
released? system for normal operation.
(Continued)
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PINPOINT TEST C: THE TRANSMISSION CONTROL (TC) SWITCH IS INOPERATIVE (Continued)
C3 CHECK CIRCUIT 224 (TN/WH) FOR AN OPEN
Disconnect: Powertrain Control Module (PCM) C175T.
Measure the resistance between selector lever C307-4, circuit
224 (TN/WH), harness side and PCM C175T-18, circuit 224
(TN/WH), harness side.
Yes
REFER to Powertrain Control/Emissions
No
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GENERAL PROCEDURES
5. Install the transmission selector lever cable on
Selector Lever Cable Adjustment
the selector lever and push the lock downward
to lock the selector lever cable adjustment lock.
Section 100-02.
2. Place the transmission range selector lever in
the D position.
3. Lift the lock upward on the transmission
selector cable lock and remove the cable from
the selector lever.
4. Place the transmission manual control lever in
the D position by rotating the manual lever
clockwise to the extent of travel, then rotate
counterclockwise 3 detents.
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Selector Lever Cable and Bracket
Removal
2. Remove the selector lever cable from the
selector lever.
1 Transmission selector lever
cable
cable retaining clip
cable
cable bracket bolts
cable bracket
Section 100-02.
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Installation
bracket and discard the clip.
1. Install the selector lever cable bracket and
transmission manual lever.
2. Install the selector lever cable eyelet onto the
transmission manual lever.
5. Remove the 2 transmission selector lever cable
bracket bolts from the transmission and remove
the bracket.
3. NOTE: It is necessary to install a new plastic
clip prior to installation.
Install the selector lever cable into the selector
lever cable bracket.
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4. Install the selector lever cable onto the selector 5. Verify the selector lever cable is adjusted
lever and lock the selector lever cable correctly. For additional information, refer to
adjustment lock. Selector Lever Cable Adjustment in this section.
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Selector Lever Knob
Removal
knob screw
knob
1. Remove the transmission selector lever
Selector Lever in this section.
2. With the selector lever knob pulled to the rear,
remove the screw from the knob base.
3. Slide the knob up and off the selector shaft.
Disconnect the transmission control switch
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Installation
1. Connect the transmission control switch
2. Fold the transmission control switch wire into
the selector shaft channel to keep the harness
from contacting the sliding mechanisms.
3. CAUTION: Tightening the screw over
3 Nm (27 lb-in) may damage the selector
lever assembly.
Align the selector lever knob base screw hole
4. Install the transmission selector lever assembly
with the selector shaft and install the screw.
in the vehicle. For additional information, refer
Tighten to 3 Nm (27 lb-in). to Selector Lever in this section.
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Selector Lever
Removal
3 Selector lever trim 1 Transmission selector lever
cable
4 Center console finish panel
screws 2 Transmission selector lever
cable retaining clip
5 Center console finish panel
(Continued)
(Continued)
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6 Center stack kick panels
7 Center console nuts
8 Center console screws
9 Center console
housing nuts
housing screws
5. Remove the 2 screws and the center console top
finish panel.
Section 100-02.
selector lever.
6. NOTE: Passenger side center console kick
panel shown, driver side similar.
Remove the driver and passenger center console
kick panels.
bracket and discard the clip.
4. Remove the center console selector lever trim.
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7. Remove the 2 screws in the bottom of the
console bin.
11. Remove the 2 nuts and the 2 screws and
carefully lift the transmission selector lever
assembly from the vehicle.
8. Remove the 2 screws from the front of the
console.
Installation
9. Lift up the console, disconnect the power point
1. Position the transmission selector lever
electrical connector and remove the console.
assembly in the vehicle and install the 2 nuts
and the 2 screws.
10. Disconnect the selector lever electrical
connector.
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2. Connect the selector lever electrical connector.
6. Install the driver and passenger side center
console kick panels.
3. Connect the power point electrical connector
and install the console.
7. Install the center console top finish panel and
the 2 screws.
4. Install the 2 screws into the front of the
console.
5. Install the 2 screws into the bottom of the
console bin.
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8. Install the center console selector lever trim. 10. Install the selector lever cable onto the selector
lever and lock the selector lever cable
adjustment lock.
9. NOTE: It is necessary to install a new plastic
clip prior to installation.
11. Verify the selector lever cable is adjusted
Install the selector lever cable into the bracket.
correctly. For additional information, refer to
Selector Lever Cable Adjustment in this section.
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NOTE: The transmission control (TC) switch is not
serviced separately. If a new TC switch is required,
install a new transmission selector knob assembly.
For additional information, refer to Selector Lever
Knob in this section.
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SPECIFICATIONS
Selector lever assembly 9 80
to floor
Selector lever cable 28 20
bracket bolts
Selector lever knob 3 27
screw
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308-01-1 308-01-1 Clutch
The clamping force is obtained from a diaphragm
Clutch
spring contained within the clutch pressure plate
The primary function of the clutch is to couple and
assembly. This force is developed during the
uncouple engine power to the transmission upon
attachment of the clutch pressure plate to the
driver command.
flywheel.
The clutch is a single plate, dry friction clutch
The clutch system is disengaged when the clutch
disc. The clutch disc has a splined hub (with
pedal is depressed and engaged when the clutch
integral torsional dampening springs) which
pedal is released. This displacement removes the
attaches the clutch disc to the input shaft.
spring load from the clutch pressure plate and
Engine output is coupled to the input shaft by the eliminates the coupling friction between the
friction existing between the clutch disc facings engine and the transmission.
and the flywheel/clutch pressure plate assembly.
The extent of this friction is directly related to the
composition of the facing material and the
magnitude of the clamping force exerted by the
clutch pressure plate. These factors limit the
amount of torque that can be transmitted without
slippage.
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308-01-1 308-01-1 Clutch
Clutch
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308-02-1 308-02-1 Clutch Controls
Clutch Controls
Vehicles with 4.0L Engine and T50D Transmission
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6 7A543 Clutch master cylinder 1 7A508 Clutch slave cylinder
7 7K502 Hydraulic line-to-clutch slave 2 Brake and clutch reservoir
cylinder connector
3 Reservoir-to-clutch master
8 7K590 Clutch hose cylinder hose
4 7C534 Cruise control switch
switch
(Continued)
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Vehicles with 4.6L Engine and T3650 Transmission
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6 7A543 Clutch master cylinder 1 7A508 Clutch slave cylinder
7 7K502 Hydraulic line-to-clutch slave 2 Brake and clutch reservoir
cylinder connector
8 7K590 Clutch hose cylinder hose
switch
(Continued)
Vehicles with 5.4L Engine and T6060 Transmission
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The clutch control system actuates the clutch
system. The clutch control system disengages the
1 7A508 Clutch slave cylinder
clutch when the clutch pedal is depressed and
2 Brake and clutch reservoir
engages the clutch when the clutch pedal is
released. When the clutch pedal is depressed it
cylinder hose
pushes the clutch master cylinder plunger, which
transmits hydraulic pressure to the clutch slave
cylinder. The clutch slave cylinder engages and
switch
compresses the clutch pressure plate diaphragm
6 7A543 Clutch master cylinder
spring, releasing the pressure on the clutch disc,
7 7K502 Hydraulic line-to-clutch slave which in turn disengages the transmission from the
cylinder connector
engine.
8 7K590 Clutch hose
The hydraulic clutch system adjusts automatically
to compensate for clutch disc wear.
The clutch pedal position (CPP) switch prevents
the starter motor from engaging unless the clutch
pedal is depressed all the way to the floor. The
switch plunger is contacted by the clutch pedal
and extends as the clutch pedal is pressed. The
clutch pedal position switch is electrically
connected in line with the ignition switch and the
starter motor relay coil.
The cruise control switch deactivates the speed
control system and signals the electronic engine
control (EEC) module when the clutch pedal is
depressed.
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Clutch Controls
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308-01-1 308-01-1 Clutch
Clutch Disc and Pressure Plate
4.0L
Special Tool(s)
Clutch Aligner
308-020 (T74P-7137-K)
Removal
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Pressure plate
5 7A508 Clutch release bearing/slave
cylinder
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308-01-2 308-01-2 Clutch
Installation
2. CAUTION: Loosen the bolts evenly to
prevent clutch pressure plate damage.
NOTE: If installing the original pressure plate,
NOTE: If the parts are to be reused,
align it using the index marks made during removal.
index-mark the pressure plate to the flywheel.
NOTE: Clean the clutch pressure plate and
Remove the 6 pressure plate bolts, the pressure
flywheel with a commercial alcohol-based solvent
plate and the clutch disc. Discard the pressure
so surfaces are free from oil film. Do not use
plate bolts.
cleaners with a petroleum base. Do not immerse the
clutch pressure plate in the solvent.
NOTE: Always install new pressure plate bolts.
1. Using the special tool, position the clutch disc
on the flywheel, then install the pressure plate
and new pressure plate bolts.
Tighten the bolts in a star pattern.
Remove the special tool.
2. NOTE: Before securing the transmission to the
engine, connect the clutch hydraulic line to the
slave cylinder.
Install the transmission. For additional
3. Bleed the clutch hydraulic system. For
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308-01-1 308-01-1 Clutch
4.6L
Special Tool(s)
Puller with Slide Hammer
308-001 (T58L-101-B)
Removal
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Pressure plate
cylinder
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308-01-2 308-01-2 Clutch
Installation
2. CAUTION: Loosen the bolts evenly to
prevent damage to the pressure plate.
1. NOTE: Clean the clutch pressure plate and
NOTE: If the pressure plate is to be reused,
flywheel with a commercial alcohol-based
solvent so surfaces are free from oil film. Do
not use cleaners with a petroleum base.
NOTE: If installing the original pressure plate,
plate bolts.
align it using the index marks made during
removal.
Using a suitable clutch aligner, position the
clutch disc on the flywheel, then install the
pressure plate and new pressure plate bolts.
Tighten the pressure plate bolts in 2 stages
in a star pattern.
X Stage 2: Tighten an additional 60 degrees.
Remove the clutch aligner.
slave cylinder.
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308-01-3 308-01-3 Clutch
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308-01-1 308-01-1 Clutch
5.4L
Item Part Number Description 2. CAUTION: Loosen the bolts evenly to
prevent damage to the pressure plate.
1 6375 Flywheel
2 7600 Pilot bearing NOTE: If the pressure plate is to be reused,
3 7B546 Clutch disc and plate
assembly
cylinder
plate bolts.
5 W712838 Disc and plate assembly bolts
Removal
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308-01-2 308-01-2 Clutch
Installation
slave cylinder.
1. NOTE: If installing the original plate and disc
assembly, align it using the index marks made
during removal.
Using a suitable clutch aligner, position the
clutch disc on the flywheel, then install the
pressure plate and new pressure plate bolts.
Tighten the pressure plate bolts in a star
pattern.
Remove the clutch aligner.
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308-00-1 308-00-1 Manual Transaxle/Transmission and Clutch General Information
GENERAL PROCEDURES
Clutch Disc Check WARNING: OSHA requires areas where
asbestos dust generation is possible to be isolated
and posted with warning signs. Only technicians Special Tool(s)
concerned with carrying out brake or clutch
Brake/Automobile Brake Drum
service should be present in the area. Failure to
System with Vacuum
injury.
NOTE: The 5.4L application is an assembly of
discs and plates. It is serviced as an assembly only.
Dial Indicator/Magnetic Base 1. Check the clutch disc lining surface for
100-D002 (D78P-4201-B) or
hardening or the presence of oil.
equivalent
2. Check for a worn clutch disc lining. Measure
the minimum allowable depth to the rivet heads
with a slide caliper.
WARNING: Dust and dirt present on
wheel brake and clutch assemblies may contain
asbestos fibers that are hazardous to health when
made airborne by cleaning with compressed air
or by dry brushing. Failure to follow these
WARNING: Wheel brake assemblies and
clutch facings should be cleaned using a vacuum
cleaner recommended for use with asbestos fibers
such as the brake automobile brake drum system
with vacuum. Dust and dirt from the vacuum
should be disposed of in a manner that prevents
dust exposure such as sealed bags. The bag must
be labeled according to OSHA instructions and
the trash hauler notified as to the bags contents.
Failure to follow these instructions may result in
personal injury.
WARNING: If a vacuum suitable for
asbestos is not available, cleaning should be done
wet. If dust generation is still possible,
technicians should wear government-approved
toxic dust purifying respirators. Failure to follow
3. Check for loose clutch disc lining rivets.
WARNING: Grinding or sanding on the
brake linings, pads, rotors, drums or clutch
facings should be done only while using correct
exhaust-ventilated equipment. Failure to follow
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4. Use the special tool to check the maximum
allowable runout of the clutch disc.
6. Check for wear or rust on the splines. If
necessary, clean them with an emery cloth.
5. Use an emery cloth to remove minor 7. Check the clutch disc for cracking, scoring,
imperfections in the clutch disc lining surface. discoloration or other surface marks. Install a
new clutch disc as necessary.
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Clutch Housing Locating Dowels
Removal
1. NOTE: Take care not to damage the flywheel
housing to block dowel holes or the surface
areas around the flywheel housing to block
dowel hole during removal.
Remove the 2 flywheel housing to block dowels
using a drift pin where the flywheel housing to
block dowel is installed in a through hole and a
pair of locking pliers where the flywheel
Installation
housing to block dowel is installed in a blind
hole.
1. NOTE: Care should be taken to drive the
flywheel housing to block dowel squarely into
place until it is fully seated without damaging
the surrounding surface areas.
Install all flywheel housing to block dowels by
driving them into place using a brass or plastic
mallet.
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Clutch Master Cylinder
Material
Item Specification
Motorcraft High ESA-M6C25-A or
Performance DOT 3 WSS-M6C62-A
Motor Vehicle Brake Fluid
CPM-1 or CPM-1-C
(Canada)
3 7A543 Clutch master cylinder 1 Clutch master cylinder bolts
4 Hose clamp 2 Retaining clip
(Continued)
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3. Remove the 2 clutch master cylinder bolts, then
disconnect the clutch master cylinder from the
clutch pedal.
Sheet (MSDS). For 24-hour MEDICAL 4. Remove the reservoir hose from the clutch
EMERGENCY INFORMATION on master cylinder.
Install new hose clamps on the reservoir
hose.
Pump the clutch pedal until all the air is
painted or plastic surfaces. If the brake fluid is
forced back into the brake master cylinder
spilled onto a painted or plastic surface, wash
reservoir.
immediately with water.
Refill the brake and clutch reservoir with
the specified fluid.
1. Remove the brake pedal and bracket assembly.
Check the clutch for normal operation.
206-06.
2. Remove the retaining clip from the clutch pedal
pin.
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GENERAL PROCEDURES
4. Measure the wear of the diaphragm spring
Clutch Pressure Plate Check
fingers.
NOTE: The 5.4L application is an assembly of
discs and plates. It is serviced as an assembly only.
1. Check the clutch pressure plate surface for
scoring, cracks or discoloration. Minor scratches
or discoloration should be removed with a fine
emery cloth.
2. Measure the flatness of the clutch pressure plate
surface with a straightedge and a feeler gauge.
3. Check the diaphragm spring fingers for
discoloration, scoring, bent or broken segments
and spring ends that are higher or lower than
the rest.
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Clutch Pressure Plate Locating
Dowels
Removal
1. NOTE: Take care not to damage the flywheel
dowel holes or the surface areas around the
flywheel dowel during removal.
Remove the flywheel dowels by using a drift
pin where the flywheel dowel is installed in a
through hole and a pair of locking pliers where
the flywheel dowel is installed in a blind hole.
Installation
1. NOTE: Care should be taken to drive the
flywheel dowel squarely into place until it is
fully seated and to not damage the surrounding
surface areas.
Install all flywheel dowels by driving them into
place using a brass or plastic mallet.
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5. Inspect the clutch slave cylinder for the
Clutch Slave Cylinder
following:
Material Damaged boot.
Leaking brake fluid.
Item Specification
Motorcraft High ESA-M6C25-A or Worn or damaged release bearing.
X Rotate the release bearing while applying
Motor Vehicle Brake Fluid
pressure. If the bearing rotation is rough,
install a new clutch slave cylinder. CPM-1 or CPM-1-C
(Canada)
6. Install a new retaining clip.
Section 308-03B.
2. Place the transmission on a work bench.
3. Separate the connector from the clutch slave
cylinder.
4. Remove the 2 clutch slave cylinder bolts. Pull
the clutch slave cylinder outward and release
the line from the retaining clip.
7. Install the clutch slave cylinder and the 2 bolts.
engine, connect the hydraulic line to the clutch
slave cylinder. When connecting the hydraulic
line, a click will be heard when the line is
correctly connected. Tug on the line to make
sure it is locked in the fitting.
Section 308-03B.
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GENERAL PROCEDURES
4. Using a suitable bleeder kit and a vacuum
Clutch System Bleeding
pump, install the rubber stopper in the reservoir
opening. Make sure the rubber stopper has a
Special Tool(s)
tight fit.
Vacuum Pump Kit
Alternate method: use a 50 mm (1.96 in)
416-D002 (D95L-7559-A) or
rubber stopper with an 8 mm (0.31 in) pipe
equivalent
inserted through the rubber stopper.
5. Holding the rubber stopper in place, operate the
vacuum pump to 15-20 inches of vacuum. Hold
the vacuum for one minute, then quickly relieve
the vacuum. Remove the special tools.
Material
Item Specification
6. Check the fluid level of the reservoir. Fill the
reservoir with the specified fluid to the MAX
mark. Install the reservoir cap.
CPM-1 or CPM-1-C
7. Depress and release the clutch pedal 10 to 12
(Canada)
times or until clutch pedal effort is consistent
and positive at top of clutch pedal travel.
1. Make sure all hydraulic lines are correctly
seated. Make sure all bleed screws are tightened
8. Repeat Steps 4 through 6 two additional times
to specification.
or until clutch pedal effort is consistent and
positive at top of clutch pedal travel.
2. Make sure the clutch pedal is in the most
9. Install the reservoir cap.
upward position.
10. Check the clutch pedal reserve. Test the clutch
3. Check the fluid level of the brake/clutch
reservoir. Fill the reservoir with the specified
fluid to the MAX mark.
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308-03B-1 308-03B-1 Manual Transaxle/Transmission TR3650
OF SUBASSEMBLIES
2. Using the special tool and a press, remove the
Countershaft Bearing
inner bearing.
Special Tool(s)
Remover, Drive Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent
1. Cut the outer cage, then remove the outer cage
and rollers.
3. Using the special tools, install the new
countershaft bearing.
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308-03A-1 308-03A-1 Manual Transaxle/Transmission T5OD
OF SUBASSEMBLIES
Special Tool(s)
Countershaft Bearing
Remover/Installer, Bearing Tube
308-024 (T75L-7025-B)
Special Tool(s)
Installer, Bearing
308-061 (T77J-7025-L)
Remover/Installer Bearing Tube
308-052 (T77J-7025-B)
Installer, Input Shaft Bearing
308-062 (T77J-7025-M)
Material
Item Specification
Installer, Mainshaft Front
Bearing
TA-25
308-081 (T82T-7003-DH)
Disassembly
1. Using the special tool, press and remove the
countershaft bearing from the countershaft.
Remover, Drive Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent
Cone
205-011 (T57L-4621-B)
(Continued)
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2. Coat the outside diameter of the bearing cup
2. CAUTION: Failure to correctly
with threadlock.
support the case during bearing race
removal will result in permanent distortion
of the case.
support the case during bearing race
NOTE: Remove the front countershaft bearing
installation will result in permanent
cup if damaged, worn or a new countershaft
distortion of the case.
bearing is being installed.
Using the special tools and a press, install the
Using the special tools, press and remove the
bearing cup.
bearing cup and the countershaft front bearing
seal from the case.
4. Using the special tool and a press, install the
front countershaft bearing.
Assembly
NOTE: Position the countershaft in the transmission
case before installing the rear countershaft bearing.
1. Install the countershaft front bearing seal on the
bearing cup.
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308-03C-1 308-03C-1 Manual Transaxle/Transmission TR6060
OF SUBASSEMBLIES
Countershaft
Special Tool(s)
205-090 (T75L-1165-B)
Puller, Bearing
205-D064 (D84L-1123-A)
Cone
205-004 (T53T-4621-B)
308-025 (T75L-7025-C)
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8 7107 Synchronizer blocking ring 1 7025 Countershaft front bearing
assembly
2 7113 Countershaft
9 Synchronizer blocking ring
3 7025 Countershaft rear bearing
(part of 7107)
4 Thrust washer
10 Synchronizer inner cone (part
5 7117 Spacer
of 7107)
6 7025 6th gear needle bearing
11 Synchronizer outer cone (part
of 7107)
7 7146 6th gear
(Continued)
(Continued)
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3. Inspect the countershaft.
12 7124 5th/6th synchronizer assembly Check the shaft surface for wear or damage.
Install a new shaft as necessary.
13 7A082 Snap ring
14 7117 Spacer Check the gear teeth for wear, pitting,
scoring, spalling or fractures. Install new
15 7025 5th gear needle bearing
16 7144 5th gear
17 7117 Spacer
4. Using the special tools, install the countershaft
18 7A082 Snap ring
rear bearing.
19 Reverse driver gear
20 7A082 Snap ring
countershaft rear bearing.
countershaft front bearing.
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5. Using the special tools, install the countershaft
front bearing.
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OF SUBASSEMBLIES
Extension Housing
11 7314 Shift linkage retainers 1 7A039 Extension housing
12 7H103 Output shaft speed (OSS) 2 7140 Reverse idler gear shaft
sensor
3 7025 Reverse idler gear needle
13 7A443 OSS sensor bolt bearing
14 7K187 Reverse lockout solenoid 4 7141 Reverse idler gear
15 Reverse lockout solenoid bolt 5 7723 Reverse idler shaft bracket
16 7025 Output shaft bearing 6 Reverse idler shroud bracket
bolt
17 7A082 Output shaft bearing snap
ring 7 Countershaft bearing cup and
fluid funnel
8 Output shaft bearing cup
19 7089 Output flange
9 Snap ring
20 7K440 Output flange nut
10 7A010 Case plug
(Continued)
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1. Remove the bolt and the output shaft speed
(OSS) sensor.
5. Remove the reverse idler gear needle bearing.
Inspect the needle bearing for wear or
damage. Install a new bearing as necessary.
2. Remove the bolt and the reverse lockout
solenoid.
6. Remove the reverse idler gear shaft.
3. Remove the bolts and the reverse idler shaft
bracket.
7. Remove the countershaft bearing cup and the
fluid funnel assembly.
8. Remove the output shaft bearing cup snap ring
and the bearing cup.
4. Remove the reverse idler gear.
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9. Remove and discard the extension housing seal. 11. To assemble, reverse the disassembly procedure.
12. Remove the snap ring. Position the extension
housing with the seal facing downward. Using a
brass drift, remove the output shaft bearing.
10. WARNING: Make sure protective eye
wear is in place.
Clean the housing with solvent and dry with
compressed air. Clean and check the sealing
surface for nicks or scratches. Inspect the
housing for cracks.
If the housing is cracked, install a new
housing. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to
remove.
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GENERAL PROCEDURES
Flywheel Housing Check
1. Check the flywheel surface for scoring, cracks
or discoloration. Minor scratches or
discoloration should be removed with a fine
emery cloth.
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GENERAL PROCEDURES
3. Inspect the ring gear for:
Flywheel Runout Check
worn, chopped or broken teeth.
Special Tool(s)
4. Mount the special tool so that the indicator
Dial Indicator/Magnetic Base
contact point rides on the clutch disc contact
100-D002 (D78P-4201-B) or
surface.
equivalent
5. Rotate the flywheel and measure the runout.
If the runout exceeds the maximum
allowance, install a new flywheel.
NOTE: Do not reface the flywheel surface. Install a
new flywheel as necessary.
1. CAUTION: Do not use
petroleum-based cleaning solutions.
NOTE: Always inspect the flywheel whenever
the clutch is removed or installed new.
Using a suitable cleaning solution, clean the
flywheel clutch surface.
2. Inspect the flywheel for:
surface cracks.
heat check.
glazing.
scoring.
scratches or grooves.
X For minor damage, finish the flywheel
surface with coarse emery cloth or with a
fine grade (400 grit) sandpaper.
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IN-VEHICLE REPAIR
Gearshift Lever and Boot
Gearshift Lever Exploded View
4 Transmission shift arm bolt 1 7K327 Gearshift lever knob
5 W702751-S441 Gearshift lever nuts (2 2 7C372 Gearshift lever boot
required)
3 Transmission shift linkage
6 7400 Gearshift lever assembly bolt
(Continued)
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Section 100-02.
1. Remove the gearshift lever knob and boot.
Pull the gearshift lever boot rearward, then
3. Remove the 2 rear gearshift underbody nuts.
lift up the corner of the boot.
Do not pry on the shift boot bezel. This will
separate the bezel from the boot.
4. Remove the transmission shift linkage bolt, the
transmission shift arm bolt and the gearshift
lever assembly.
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IN-VEHICLE REPAIR
Gearshift Lever
Gearshift Lever Exploded View
1 7C392 Gearshift lever knob and boot
2 Gearshift lever bolts (part of
7C392)
3 7Z206 Gearshift lever shield
4 W702751-S441 Gearshift lever shield nuts
5 W505424-S438 Gearshift lever shield bolts
6 7314 Gearshift lever retainers
7 W711489-S439 Gearshift lever bolt
8 7400 Gearshift lever assembly
1. Remove the gearshift lever knob and boot.
2. Remove the upper gearshift lever bolts and the
upper gearshift lever.
Section 100-02.
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4. Remove the driveshaft. For additional 10. Remove the gearshift lever assembly.
1 Insert a pick into the lower hole to unlock
the clip.
5. Remove the 4 subframe cross brace bolts and
2 Rotate the gearshift lever retainers, then
the subframe cross brace.
remove the retainers.
3 Remove the gearshift lever bolt.
4 Remove the gearshift lever assembly from
the vehicle.
transmission.
7. Remove the 4 rear transmission mount outer
bolts.
8. Lower the transmission.
9. Remove the 2 rear gearshift lever nuts.
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Make sure to snap the gearshift lever
retainers into the locked position.
Carefully position the gearshift lever into the
lower shift boot. Make sure the lever is
through the boot.
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OF SUBASSEMBLIES
Gearshift Rail and Fork 3. CAUTION: Support the shift rail to
prevent damage to the parts.
Position the gearshift fork on the shift rail.
Align the split pin hole and install a new split
1. Using a 5/32-inch drift and a hammer, remove pin.
and discard the split pin. Slide the shift fork
from the shift rail.
4. Install the gearshift fork inserts.
2. Remove the gearshift fork inserts.
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OF SUBASSEMBLIES
Gearshift Rail and Fork
1st/2nd and 3rd/4th Shift Rail Assembly
6 7K201 Interlock plate 1 1st/2nd and 3rd/4th shift rail
assembly
7 7230 3rd/4th shift fork and link
2 7230 1st/2nd shift fork and link
8 7L082 3rd/4th shift fork pad
3 7L082 1st/2nd shift fork pads
9 7L267 1st/2nd, 3rd/4th shift rail
4 7814 Selector pin
5 7A082 Roll pin
(Continued)
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5th/6th and Reverse Shift Rail Assembly
1. Disassemble the 1st/2nd and 3rd/4th shift rail as
follows:
1 5th/6th and reverse shift rail
assembly Rotate the interlock plate until it is opposite
of the shift links. 2 7A082 Snap ring
3 7L082 Reverse shift fork pads Slide off the 3rd/4th shift fork and shift link.
4 7230 Reverse shift fork
Slide off the 1st/2nd shift fork and shift
5 7241 5th/6th shift rail assembly link.
6 Shift rail collar (part of 7241)
Using a 5/32-inch drift and a hammer,
7 Roll pin (part of 7241) remove and discard the roll pin. Remove the
interlock plate. 8 Snap ring (part of 7241)
9 5th/6th inner shift rail lever
2. Disassemble the 5th/6th and reverse shift rail as
(part of 7241)
follows:
10 5th/6th outer shift rail lever
(part of 7241)
Using a 5/32-inch drift and a hammer,
11 5th/6th outer shift lever pad remove and discard the roll pins. Slide the
(part of 7241)
collar and the reverse shift lever from the
12 Reverse shift rail lever (part shift rail.
of 7241)
Remove the snap ring.
13 Roll pin (part of 7241)
Slide off the 5th/6th shift lever and shift
14 5th/6th shift rail (part of
link.
7241)
Using a press, separate the 5th/6th outer
shift rail lever from the inner shift rail lever.
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3. Inspect the shift rail components.
Check the rails, shift forks, shift levers and
shift links for wear or damage. Install new
Check the shift fork pads for wear. Install
new pads as necessary.
Install new roll pins.
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OF SUBASSEMBLIES
Gearshift Rail Bushing
Special Tool(s)
Universal Puller Set
303-DS005 (D80L-100-A) or
equivalent
Installer, Shift Rail Bushing
308-244 (T96P-7025-F)
2. Using the special tool, install the main shift rail
bearing.
Slide Hammer
100-001 (T50T-100-A)
1. Using the special tools, remove the gearshift
rail bearing from the transmission case. Discard
the bearing.
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OF SUBASSEMBLIES
Input Shaft and Bearing
Special Tool(s)
Input Shaft Seal Replacer
308-220 (T94P-7025-AH)
205-D002 (D79L-4621-A) or
equivalent
3. Remove and discard the input shaft seal.
Assembly
1. Using the special tool, install a new input shaft
seal.
Disassembly
input shaft bearing.
2. NOTE: Do not install the end play selective
shims at this time.
Install the input shaft bearing cup.
2. Remove the input shaft bearing cup and the end
play selective shims.
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3. Using a press and a capped length of pipe,
install the input shaft bearing.
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OF SUBASSEMBLIES
Special Tool(s)
Remover, Driver Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent
Cone
205-011 (T57L-4621-B)
308-024 (T75L-7025-B)
input shaft front bearing assembly. Discard the
1. Disassemble the input shaft.
bearing.
1 Remove the 3rd/4th synchronizer blocking
ring.
2 Remove the input shaft thrust washer.
3 Remove the input shaft thrust bearing.
4 Remove the input shaft pocket bearing.
Inspect all components for wear or damage.
3. Inspect the input shaft and bearings for wear or
damage. Install new components as necessary.
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4. Using the special tools and a press, install the 5. Install the input shaft pocket bearing, the
new input shaft front bearing. washer, input shaft bearing and the 3rd/4th
synchronizer blocking ring.
Lubricate the bearing and bearing race with
petroleum jelly.
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OF SUBASSEMBLIES
Special Tool(s)
Puller, Bearing
205-D064 (D84L-1123-A)
input shaft front bearing.
1 7025 Input shaft bearing
3. Using the special tools and a press, install a
2 7017 Input shaft
new input shaft bearing.
1. NOTE: Any wear or damage on the input shaft
can prevent the clutch from operating correctly.
Inspect the splines on the input shaft for wear
or damage. If worn or damaged, install a new
input shaft.
Use an emery cloth to remove small
scratches.
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The clutch master cylinder transmits fluid pressure
Manual Transmission and Clutch
to the clutch slave cylinder, which in turn moves
This vehicle uses 3 manual transmissions:
the clutch release bearing. The clutch hydraulic
T5OD is used with the 4.0L engine. system uses brake fluid and shares a reservoir with
the brake system. The clutch with the 4.0L or 4.6L
TR3650 is used with the 4.6L engine.
engine is a single-plate, dry-friction disc with a
T6060 is used with the 5.4L engine.
diaphragm-style spring pressure plate. The clutch
The manual transmission has a tag to identify
disc has frictional material where it contacts the
assemblies for repair purposes. Refer to Section
flywheel and the clutch pressure plate. The clutch
308-03A, Section 308-03B or Section 308-03C for
pressure plate applies pressure to the clutch disc,
the transmission tag information.
holding it tightly against the surface of the flywheel.
The 5.4L clutch is a dual disc clutch and pressure The purpose of the clutch is to connect and
plate that is serviced as an assembly. disconnect a manually operated transmission and the
remainder of the driveline system from the engine.
In the ENGAGED position, the clutch pressure plate
This allows starting and stopping the vehicle,
diaphragm spring holds the clutch pressure plate
shifting and changing speeds that correspond to the
against the clutch disc, so that the engine torque is
engine speed through gear reductions.
transmitted to the input shaft. When the clutch is
The clutch operating mechanism consists of the depressed, movement is transmitted through the
following components: clutch hydraulic system, which actuates the clutch
release bearing. The clutch release bearing pushes
Flywheel
on the spring center toward the flywheel. The
Clutch disc
diaphragm spring pivots at the fulcrum, relieving the
load on the clutch pressure plate. Steel spring
Clutch pressure plate
straps riveted in the clutch pressure plate cover pull
Clutch release bearing
the clutch pressure plate from the clutch disc,
Clutch master cylinder
disengaging the engine torque from the
Clutch slave cylinder transmission.
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X Driving at a particular speed.
Manual Transmission and Clutch
coasting.
hard acceleration.
CAUTION: If transmission noise is
X Shifting.
reported, first check the fluid level. The vehicle
upshifts.
should not be driven if the fluid level is low.
downshifts.
NOTE: If any evaluation or inspection reveals an
obvious concern, repair the vehicle.
in a particular gear.
NOTE: Before attempting to rectify any concerns,
in all gears.
road test the vehicle to ascertain in which system
X Hot or cold ambient temperatures.
the concern falls.
5 Has the transmission/clutch been repaired
before or components installed?
of transmission/clutch operation and accepted
X Check the vehicle service record. Note
general transmission/clutch guidelines to detect any
any repairs.
problems.
6 Check TSBs, SSMs and OASIS messages.
Check Fluid Level and Condition
Certain conditions, such as, road and weather, will CAUTION: The vehicle should not be
amplify normal vehicle noise. driven if the fluid level is low.
The following overview is a guide to diagnose a
CAUTION: Excessive temperatures may
transmission/clutch concern:
break down the transmission lubricant. If there
is reason to believe that the transmission has
been subjected to temperatures exceeding 275F,
During the customer interview, if a leak was
change the lubricant immediately.
noticed or if a leak is the concern, check the
An incorrect level may affect the transmission
transmission fluid. The vehicle should not be
operation and can result in transmission damage. To
driven if the fluid level is low.
correctly check and add fluid to the transmission,
Check fluid level and condition.
refer to Specifications in this section.
Evaluation of the clutch hydraulic system.
A low fluid level can result in poor transmission
Evaluation of the clutch.
shifting, engagement or damage. It can also indicate
a leak in one of the transmission seals or gaskets. Inspect gearshift mechanism.
1. Check the fluid condition. Road test.
Observe the color and the odor of the fluid. Find the cause of the problem and correct it.
Allow the fluid to drip onto a white cloth
Verify Customer Concern
and examine the stain. Check the fluid for
contamination or metal particles. 1. Verify and document the customer concern.
X Fluid should appear reddish in color. 1 When was it first noticed?
Evaluation of Clutch Hydraulic System
3 Did anything unusual occur that would
1. Verify that the clutch hydraulic fluid reservoir
is filled to the correct level.
4 Identify when the condition occurs:
If the fluid level is correct, proceed to clutch
X Hot or cold vehicle operating conditions. check.
X Type of terrain. If the fluid level is low, add fluid as
necessary. Check the clutch hydraulic
X City/highway driving.
system for leaks and repair as necessary.
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Symptom Chart
Evaluation Of The Clutch
1. Depress and release the clutch pedal slowly to Conditions/Sources Action
check if the pedal is binding. Make sure the
Clutch Slippage GO to Pinpoint Test A.
clutch pedal can be fully depressed and is not Clutch pedal reserve
Diaphragm springs restricted by the floor mat.
2. Measure the clutch reserve. GO to Pinpoint
Clutch disc facing
Test A.
Hardened or oiled
clutch disc facing
3. With the engine idling, the parking brake on
surface
and the clutch pedal up, gently move the
Flywheel
gearshift lever forward into and out of
Clutch Chatter, Rattle GO to Pinpoint Test B.
REVERSE gear, until gear clash can be heard.
or Shudder
Depress the clutch pedal slowly.
Engine mounts
Oil on clutch disc
If the gears cease to clash (full disengage at
facing
1 to 1.5 inch from the floor), then hold the
Diaphragm springs
pedal at the point of disengagement and
increase engine to 4,000 rpm. The clutch
Clutch disc facing
should remain disengaged, clutch OK. Flywheel
Clutch disc
Any concerns indicate a worn or damaged
Clutch Drag GO to Pinpoint Test C.
clutch. Repair as necessary.
Insufficient clutch
4. With the engine idling, move the gearshift lever
fluid
into 4th gear. Increase the rpm to 2,000 and Air in hydraulic
system slowly release the clutch pedal.
Clutch pedal reserve
If the engine stalls, clutch is OK.
Diaphragm springs
Clutch disc
If the engine does not stall, clutch slipping.
Clutch disc splines
Repair as necessary.
Oil on facing
5. Compare the clutch evaluation results with the
Clutch Pedal Pulsation GO to Pinpoint Test D.
following table. The following list of conditions
Clutch and brake
are typical faults into which clutch concerns
pedal pivot shaft not
will fall. correctly lubricated
Flywheel
Worn springs in
pressure plate
Clutch Related GO to Pinpoint Test E.
Vibrations
Engine component
grounding against
frame
Accessory drive belt
Flywheel bolts
Flywheel
Imbalanced clutch
pressure plate
Hard Shifting GO to Pinpoint Test F.
Insufficient clutch
fluid
Transmission
concern
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X Check whether the noise is present with
the gearshift in the NEUTRAL position
Conditions/Sources Action
and the clutch fully engaged (foot off
Excessive Noise GO to Pinpoint Test G.
pedal). With the parking brake engaged,
move the gearshift towards the 1st gear
Clutch slave cylinder
Pilot bearing position. Apply very slight pressure and
Excessive crankshaft
note if the gear noise level is reduced.
end play
(for gear rollover noise).
Clutch System GO to Pinpoint Test C.
X With the clutch fully engaged (foot off
Leakage
pedal) check whether the noise is present
Clutch master
as the engine speed is raised. If the noise
cylinder
Clutch slave cylinder reduces, note the engine speed at which
Clutch hydraulic
this occurs.
tubes
For single mass flywheel: function.
If the clutch was the concern, REPAIR the clutch
Listen for any change in noise while
system. TEST the system for normal operation.
depressing and releasing the clutch pedal.
Listen for any change in noise while
Inspect The Gearshift Mechanism
changing the engine rpm.
1. Inspect the gearshift mechanism for:
Drive the vehicle and shift through all of the
signs of damage. gear ranges, including reverse. Listen for
any change in noise in a particular gear.
missing or loose fasteners.
Drive the vehicle in the gear in which the
binding.
noise is most noticeable. Depress the clutch
2. Repair any concerns as necessary.
pedal and leave the gear engaged. Listen for
any change in noise.
Road Test the Vehicle
Drive the vehicle in the gear in which is
1. During the road test, use the following driving
most noticeable. Depress the clutch pedal
methods to diagnose the problem.
and shift the transmission into NEUTRAL.
Start the engine.
Release the clutch pedal and allow the
Evaluate the noise in NEUTRAL while the
vehicle to coast.
vehicle is parked.
2. Compare the road test results with the following
X Check whether the noise is present with
symptom chart. It is a list of conditions that are
the clutch fully disengaged (pedal fully
typical faults into which the transmission will
depressed). Check to see if the pedal
fall:
pulsates abnormally (for clutch diaphragm
GO to Symptom Chart in this section.
finger run out).
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Symptom Chart
Symptom Chart
Transmission difficult to shift Lubricant ADD or DRAIN AND FILL
with specified lubricant.
Internal shift mechanism CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new mechanism
as necessary.
Sliding gears, synchronizers CHECK for free movement
of gears and synchronizers.
Housings, shaft CHECK for binding condition
between the input shaft and
the engine crankshaft pilot
bearing or bushing. REPAIR
or INSTALL new
REFER to Section 308-03A,
Section 308-03B or Section
308-03C.
Loose pressure plate to CHECK for loose bolts at the
flywheel bolts pressure plate. INSTALL new
Transmission will not shift Gearshift lever damaged INSTALL a new gearshift
gearshift lever moves lever.
Damaged or worn offset CHECK the internal shift
lever, shift plate or selector components. INSTALL new
arm. Loose shift rail bushings component as necessary.
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NOTE: While verifying the Lubricant ADD or DRAIN and FILL
condition, determine whether with specified lubricant.
the noise is gear rollover
noise, release bearing rub or
some other
transmission-related noise.
Gear rollover noise, inherent
in manual transmissions, is
caused by the constant mesh
gears turning at the engine
idle speed while the clutch is
engaged and the transmission
is in NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear rollover
noise will disappear when the
clutch is disengaged or when
the transmission is engaged
in gear. Release bearing rub
will disappear when the
clutch is engaged. In the
event that a bearing is
damaged, the noise is more
pronounced while engaged in
gear under load or coast than
in NEUTRAL.
Noisy in forward gears
Components grounding out on CHECK for screws, bolts,
the transmission etc., of body or other
components grounding out.
CORRECT as necessary.
Components housing bolts CHECK the torque on the
transmission-to-flywheel
housing bolts and the
flywheel housing-to-engine
block bolts. TIGHTEN the
bolts to specification. REFER
to Section 308-01.
Bearings or gears INSPECT the bearings.
INSPECT the gears and gear
teeth for wear or damage.
Section 308-03A, Section
308-03B or Section 308-03C.
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Gears clash when shifting Pilot bearing CHECK for a binding
from one forward gear to condition between the input
another shaft and the engine
crankshaft pilot bearing.
Section 308-01.
Gear teeth and/or REPAIR or INSTALL new
synchronizer components as necessary.
308-03C.
Damaged shift forks or worn INSPECT for wear or
shift fork inserts damage. INSTALL new
308-03C.
Transmission jumps out of Transmission range selector INSTALL a new boot if
gear lever boot exceptionally stiff. REFER to
Transmission-to-engine TIGHTEN the bolts to
mounting bolts specification.
Crankshaft pilot bearing INSTALL a new bearing.
Internal damage INSPECT the synchronizer
sleeves for free movement on
their hubs. INSPECT the
synchronizer blocking rings
for widened index slots,
rounded clutch teeth and
smooth internal surface.
CHECK countershaft cluster
gear for excessive end play.
CHECK shift forks for worn
or loose mounting on shift
rails. INSPECT the
synchronizer sliding sleeve
and the gear clutch teeth for
wear or damage. REPAIR or
INSTALL a new component
as necessary.
Gear teeth If worn or damaged,
INSTALL new gears. REFER
to Section 308-03A, Section
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Transmission will not shift Manual shift linkage REPAIR or INSTALL new
into one gear all others components as necessary.
OK
Backup switch ball If REVERSE is the problem,
CHECK backup switch for
ball frozen in extended
position.
Internal components INSPECT the shift rail and
fork system, synchronizer
system and the gear clutch
teeth for restricted travel.
Transmission is locked in one Internal components INSPECT the problem gears,
gear and cannot be shifted out shift rails, forks and the
of that gear synchronizer for wear or
damage. REPAIR as
308-03A, Section 308-03B
or Section 308-03C.
Fork on rail, offset lever or CHECK the shift rail
shift rail interlock system. REFER to
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Transmission leaks Lubricant CHECK the level and type.
Other component leaking IDENTIFY leaking fluid as
engine, power steering, or
transmission fluid. REPAIR
as necessary.
False report REMOVE all traces of lube
on the exposed transmission
surfaces. CHECK the vent for
free breathing. OPERATE the
transmission and INSPECT
for new leakage. REPAIR as
308-03A, Section 308-03B or
Section 308-03C.
Internal components INSPECT for leaks at the
input shaft bearing retainer
seal and the shift rail
expansion plug. REFER to
INSPECT for leaks at the top
cover gasket. INSPECT the
case for sand holes or
cracks. REPAIR or INSTALL
a new case as necessary.
308-03C.
Fill and drain plugs CHECK fill and drain plugs
and bore threads. REPAIR as
necessary. TIGHTEN plugs to
specified torque value.
308-03C.
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Bearing failure Other part failure REMOVE, DISASSEMBLE
Raceways or rollers and CLEAN the transmission.
Lubricant Inspect for damaged parts and
Towing vehicle further than install new components as
80 km (50 miles) with necessary. (Note: RESET the
driveshaft installed. Mainshaft bearing preload if any new
tapered bearing and needle tapered bearings are
caged bearings are especially installed.) REFER to Section
susceptible to damage 308-03A, Section 308-03B or
Section 308-03C.
Vibration break-up of retainer DETERMINE the cause of
and brinelling of races vibration and CORRECT.
Bearing(s) Otherwise PROCEED as
Shafts or bore above.
Overloading of vehicle
Incorrect preload
Input shaft oil dam INSTALL new components
as necessary and VERIFY the
oil dam installation is correct.
308-03C. CHECK for correct
installation of the snap ring
on the mainshaft next to the
oil dam.
Oil baffle in the input bearing INSTALL a new oil baffle,
shim pack making sure it is not damaged
during assembly. REFER to
Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
A1 INSPECT THE CLUTCH PEDAL
Block the wheels and apply the parking brake. GO to A2.
Depress and slowly release the clutch pedal.
No
Does the clutch pedal release without binding?
INSPECT the clutch pedal. REFER to
Section 308-02.
A2 CHECK THE HYDRAULIC SYSTEM
Depress and release the clutch pedal. INSTALL a new clutch master cylinder.
Is there residual hydraulic pressure at the bleed screw? REFER to Section 308-02.
No
GO to A3.
A3 CARRY OUT A STALL TEST
Block the wheels and apply the parking brake. The clutch is not slipping. VERIFY the
Place the transmission in 4th gear. customer concern.
Increase the engine speed to 2000 rpm and slowly release the
No
clutch pedal.
INSPECT the clutch components for
Does the engine stall within 5 seconds?
damage.
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PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER
B1 CHECK THE ENGINE OR TRANSMISSION MOUNTS
Inspect all the engine and transmission mounts for loose Yes
fasteners or damage. TIGHTEN or INSTALL new engine mounts
Are any of the engine or transmission mounts loose or or transmission mounts as necessary.
damaged? TEST the system for normal operation.
No
GO to B2.
B2 INSPECT THE PRESSURE PLATE BOLTS
Inspect the pressure plate-to-flywheel bolts. Yes
Are any of the pressure plate-to-flywheel bolts loose? TIGHTEN or INSTALL new bolts as
No
GO to B3.
B3 INSPECT THE PRESSURE PLATE
Remove the clutch pressure plate. Refer to Section 308-01. Yes
Inspect the clutch pressure plate. Refer to Clutch Pressure Plate INSTALL a new clutch pressure plate.
Check in this section. REFER to Section 308-01. TEST the
Are any signs of damage present on the clutch pressure system for normal operation.
plate?
No
GO to B4.
B4 CHECK THE CLUTCH DISC
Carry out the clutch disc inspection procedure. Refer to Clutch Yes
Disc Check in this section. GO to B5.
Is the clutch disc OK?
No
INSTALL a new clutch disc. REFER to
normal operation.
B5 INSPECT THE FLYWHEEL
Inspect the flywheel for damage and runout. Refer to Flywheel Yes
Runout Check in this section. GO to B6.
Is the flywheel OK?
No
REPAIR or INSTALL a new flywheel as
operation.
B6 INSPECT THE PILOT BEARING
Inspect the pilot bearing for wear or damage. Yes
Are there signs of wear or damage? INSTALL a new pilot bearing. REFER to
Section 308-01.
No
GO to B7.
B7 INSPECT THE INPUT SHAFT
Inspect the input shaft for signs of wear or damage. Yes
Are any signs of wear or damage present on the input INSTALL a new input shaft. REFER to
shaft? Section 308-03A, Section 308-03B or
Section 308-03C.
No
VERIFY the customer concerns. GO to
Symptom Chart if necessary.
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PINPOINT TEST C: CLUTCH HYDRAULIC SYSTEM CHECK
C1 CHECK THE FLUID LEVEL
NOTE: Do not check the hydraulic system after the road test.
Allow the vehicle to cool down before carrying out the clutch
hydraulic system check.
Remove the brake and clutch reservoir cap.
Yes
INSTALL the reservoir cap. GO to C2.
No
Check the fluid level of the brake and clutch reservoir. ADD brake fluid to the specified level. GO
Is the fluid level at or above the step mark? to C2.
C2 INSPECT THE HYDRAULIC SYSTEM FOR LEAKAGE
Check the reservoir and reservoir lines for leakage. Yes
Check the master cylinder and hydraulic line for leakage. INSTALL new components as necessary.
Check the clutch slave cylinder and the hydraulic line connection TEST the system for normal operation.
for leakage.
No
Are there any signs of leakage?
GO to C3.
C3 CHECK INTERNAL OPERATION
Remove the reservoir cap. Yes
Have an assistant slowly depress and release the clutch pedal. INSTALL a new cylinder master cylinder
On the down stroke, the fluid level should not increase by more assembly.
than 1 mm (0.039 in).
No
Does the fluid level increase more than 1 mm (0.039 in)?
GO to C4.
C4 CHECK THE CLUTCH PEDAL RESERVE
NOTE: The clutch reserve is the distance between the clutch pedal
when fully depressed and the position when the vehicle starts to
move forward.
Park the vehicle on a level surface.
Check for obstructions behind clutch pedal.
Attach a cable tie to the lower clutch pedal.
Attach a tape measure to the cable tie.
Depress the clutch fully and start the vehicle.
(Continued)
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PINPOINT TEST C: CLUTCH HYDRAULIC SYSTEM CHECK (Continued)
C4 CHECK THE CLUTCH PEDAL RESERVE (Continued)
Shift the transmission into 1st gear.
Use the seam on the steering wheel as a reference point.
While observing the tape measure, slowly engage the clutch,
noting when the vehicle starts to move forward.
Yes
The clutch hydraulic system is OK. TEST
Is the clutch pedal reserve greater than or equal to 25 mm No
(1 in)? GO to C5.
C5 CHECK THE CLUTCH PRESSURE PLATE
Inspect the clutch pressure plate for wear or runout. Refer to INSTALL a new clutch pressure plate.
Clutch Pressure Plate Check in this section. REFER to Section 308-01.
Are there any signs of excessive wear or runout to the
No
clutch pressure plate?
GO to C6.
(Continued)
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PINPOINT TEST C: CLUTCH HYDRAULIC SYSTEM CHECK (Continued)
C6 INSPECT THE CLUTCH DISC
NOTE: Vehicles equipped with a 4.0L engine use an inner floating Yes
damper design disc. When inspecting the disc, a rattle type noise GO to C7.
can be heard. This is a normal condition.
No
Carry out the clutch disc inspection procedure in this section.
normal operation.
C7 CHECK CLUTCH PEDAL FREE PLAY
NOTE: The clutch pedal free play is the distance between the
clutch pedal when fully released and the position when slight
resistance is felt on downward motion.
Engine OFF.
While observing the tape measure, slowly push downward on
the clutch pedal until a slight resistance is felt.
Yes
No
BLEED the clutch hydraulic system.
REFER to Clutch System Bleeding in this
Is the clutch pedal free play less than 13 mm (0.5 in)? operation.
PINPOINT TEST D: CLUTCH DRAG/HARD SHIFTING
D1 CHECK FLUID LEVEL
Remove the reservoir cap. INSTALL the reservoir cap. GO to D2.
Inspect the fluid level in the brake and clutch reservoir.
No
Is the fluid level at or above the step mark?
ADD brake fluid. GO to D2 and CHECK
for leaks. TEST the system for normal
operation.
D2 INSPECT THE CLUTCH HYDRAULIC SYSTEM FOR LEAKAGE
Inspect the clutch master cylinder and the hydraulic lines for
Yes
leakage.
INSTALL new components as necessary.
Inspect the reservoir and reservoir line for leakage.
Test the system for normal operation.
Inspect the clutch slave cylinder and the hydraulic line
connection for leakage. No
Are there any signs of leakage? GO to D3.
D3 CHECK INTERNAL OPERATION
Remove the reservoir cap. Yes
Have an assistant slowly depress and release the clutch pedal. INSTALL a new cylinder master cylinder
On the down stroke, the fluid level should not increase by more assembly.
than 1 mm (0.039 in).
No
Does the fluid level increase more than 1 mm (0.039 in)?
GO to D4.
D4 CHECK THE CLUTCH PEDAL RESERVE
NOTE: The clutch reserve is the distance between the clutch pedal
when fully depressed and the position when the vehicle starts to
move forward.
Park the vehicle on a level surface.
Check for obstructions behind the clutch pedal. Check the carpet
for correct installation. Remove the floor mat.
(Continued)
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PINPOINT TEST D: CLUTCH DRAG/HARD SHIFTING (Continued)
D4 CHECK THE CLUTCH PEDAL RESERVE (Continued)
Attach a cable tie to the lower clutch pedal.
Depress the clutch fully and start the vehicle.
Shift the transmission into 1st gear.
Use the seam on the steering wheel as a reference point.
(Continued)
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D4 CHECK THE CLUTCH PEDAL RESERVE (Continued)
While observing the tape measure, slowly engage the clutch,
noting when the vehicle starts to move forward.
Yes
Is the clutch pedal reserve greater than or equal to 25 mm No
(1 in)? GO to D5.
D5 CHECK THE CLUTCH PEDAL FREE PLAY
NOTE: The clutch pedal free play is the distance between the
clutch pedal when fully released and the position when slight
resistance is felt on downward motion.
Engine OFF.
While observing the tape measure, slowly push downward on
the clutch pedal until a slight resistance is felt.
Yes
No
Is the clutch pedal free play less than 13 mm (0.5 in)? GO to D6.
D6 CHECK THE CLUTCH PRESSURE PLATE
Inspect the clutch pressure plate for wear or runout. Refer to INSTALL a new clutch pressure plate.
Clutch Pressure Plate Check in this section. REFER to Section 308-01.
Are there any signs of excessive wear or runout to the
No
clutch pressure plate?
GO to D7.
D7 INSPECT THE CLUTCH DISC
NOTE: Vehicles equipped with a 4.0L engine use an inner floating Yes
damper design disc. When inspecting the disc, a rattle type noise GO to D8.
can be heard. This is a normal operation.
No
Carry out the clutch disc inspection procedure in this section.
normal operation.
D8 INSPECT THE TRANSMISSION
Remove the transmission.
Disassemble the transmission. Refer to Section 308-03A,
Section 308-03B or Section 308-03C.
(Continued)
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D8 INSPECT THE TRANSMISSION (Continued)
Carry out the following:
Inspect all the shift rails for excessive scuffing or wear.
Check the interlock pins on the shift rail.
Make sure the interlock bolts are tightened to 31 Nm (23
lb-ft).
Yes
Inspect the shift pads for wear or cracking.
INSTALL new components or REPAIR as
Inspect the shift forks for wear or damage.
Check the synchronizer rings of the affected gear for wear
operation.
or damage.
Check the synchronizer hubs of the affected gear for wear No
or damage. ASSEMBLE and INSTALL the
Inspect the clutching teeth of the affected gear. transmission. TEST the system for normal
Are there any internal components worn or damaged? operation.
PINPOINT TEST E: CLUTCH PEDAL PULSATION
E1 CHECK THE CLUTCH PEDAL PULSATION
With the transmission in NEUTRAL, slowly press the clutch GO to E2.
pedal.
No
Does the clutch pedal pulsate while being pressed?
VERIFY customer concern. GO to
Symptom Chart if necessary.
E2 INSPECT THE PRESSURE PLATE BOLTS
Inspect the pressure plate-to-flywheel bolts. Yes
Are any of the pressure plate-to-flywheel bolts loose? TIGHTEN or INSTALL new bolts. REFER
to Section 308-01. TEST the system for
normal operation.
No
GO to E3.
E3 INSPECT THE CLUTCH PRESSURE PLATE
Inspect the clutch pressure plate for damage. Refer to Clutch INSTALL a new clutch pressure plate.
Pressure Plate Check in this section. REFER to Section 308-01. TEST the
Are there any signs of damage present on the clutch system for normal operation.
pressure plate?
No
GO to E4.
E4 INSPECT THE CLUTCH DISC
Carry out the clutch disc inspection procedure. Refer to Clutch Yes
Disc Check in this section. GO to E5.
No
normal operation.
E5 INSPECT THE FLYWHEEL
Inspect the flywheel for damage and runout. Refer to Flywheel Yes
Runout Check in this section. VERIFY customer concern. GO to
Is flywheel OK? Symptom Chart if necessary.
No
TIGHTEN, RESURFACE or INSTALL a
new flywheel as necessary. REFER to
normal operation.
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PINPOINT TEST F: CLUTCH-RELATED VIBRATIONS
F1 CHECK FOR ENGINE COMPONENT GROUNDING
With the vehicle in NEUTRAL, position it on a hoist. Refer to
Yes
Section 100-02.
REPAIR the components as necessary.
Check the engine and transmission mounts for grounding.
Check for exhaust manifolds or other engine component
grounding on the body or frame. No
Is there evidence of grounding on the body or frame? GO to F2.
F2 CHECK FOR ACCESSORY DRIVE VIBRATIONS
Remove the accessory drive belt. REFER to Section 303-05 to diagnose the
Does the vibration stop when the accessory drive belt is accessory drive belt components.
removed from the engine?
No
STOP the engine and INSTALL the drive
belt. GO to F3.
F3 CHECK FOR CLUTCH RELEASE BEARING NOISE
NOTE: With the transmission in NEUTRAL, transmission rollover
noise can be heard. Make sure to distinguish between rollover
Yes
noise and clutch release bearing noise.
INSTALL a new clutch release bearing.
Depress and hold the clutch pedal.
Is a whirring, grating or grinding noise present only when No
pedal is pushed? GO to F4.
F4 INSPECT THE FLYWHEEL
Remove the transmission. Refer to Section 308-03A, Section VERIFY customer concern. GO to
308-03B or Section 308-03C. Symptom Chart if necessary.
Carry out a flywheel check. Refer to Flywheel Runout Check in
No
this section.
TIGHTEN or INSTALL a new flywheel.
Is the flywheel OK?
PINPOINT TEST G: EXCESSIVE NOISE
G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST
Start the engine and let it idle with the transmission in Yes
NEUTRAL and the clutch engaged (pedal up). If noise is INSPECT the clutch component for
excessive, depress the clutch pedal to stop the transmission damage.
input shaft from rotating.
No
Does the noise stop when the clutch pedal is depressed?
GO to G2.
G2 CHECK THE PILOT BEARING
Inspect the pilot bearing for damage. Refer to Pilot Bearing Yes
Check in this section. GO to G3.
Is the pilot bearing OK?
No
INSTALL a new pilot bearing. REFER to
Section 308-01.
G3 CHECK THE TORSION SPRINGS
Inspect the torsion springs for fatigue or breakage. Yes
Are there any signs of fatigue or breakage? INSTALL a new clutch disc. REFER to
normal operation.
No
INSPECT the crankshaft end play. REFER
to Section 303-00.
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Manual Transmission
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removable wear pads on the shift forks.
Manual Transmission
an aluminum main case, extension housing and
clutch housing.
Transmission Identification
The transmission identification tag is located under
the lower bolt that retains the extension housing to
the main case.
The 6 speed (TR-6060) transmission is available for
the Mustang Shelby GT500 5.4L (4V).
The TR-6060 6-speed manual transmission features
the following:
six forward speeds and one reverse speed.
forward gears are synchronized and helical cut.
a reverse gear operates through a constant-mesh,
fully synchronized system.
a shift interlock system prevents the engagement
of more than one gear.
the countershaft is a one-piece design for added
torque capacity. Item Part Number Description
1 7003 Transmission assembly two tapered roller bearings on the output shaft.
number
two tapered roller bearings on the countershaft
2 Build date code month
cluster.
3 Build date code day
a tapered roller bearing on the input shaft.
4 Build date code year
a tapered roller bearing on the countershaft
5 Shift number
extension.
6 Serial number
countershaft cluster endplay controlled by shims
7 Service repair code
located in the transmission clutch housing.
8 Identification number located
input/output shaft endplay is controlled by shims
on left lower side of
located in the transmission clutch housing. transmission case
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Manual Transmission
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Manual Transmission
The TR3650 5-speed manual transmission features
the following:
The 5th speed gear functions as an overdrive gear
The forward gears are synchronized and helical
cut
The reverse gear operates through a
constant-mesh, fully synchronized system
The shift interlock system prevents the
engagement of more than one gear
The countershaft is serviced as an assembly
An aluminum main case, extension housing and
bellhousing
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Transmission Internal Components Main Shaft Disassembled View
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22 7107 1st/2nd gear synchronizer 1 7L172 Shim kit
cones assembly (3 piece)
2 7025 Input shaft front bearing and
23 7025 1st gear needle bearing cup assembly
24 7100 1st gear 3 7017 Input shaft
25 7124 Reverse clutch cone 4 7107 3rd/4th gear synchronizer
blocking ring
26 7107 Reverse gear synchronizer
blocking ring 5 7025 Input shaft pocket bearing kit
27 7124 Reverse gear synchronizer 6 7025 Input shaft thrust bearing kit
assembly
7 7L271 Input shaft thrust washer (part
28 7109 Retaining ring (part of spring of spring kit)
kit)
8 7L271 Retaining ring (part of spring
29 7025 Reverse needle bearing kit)
30 7C238 Reverse driven gear 9 7124 3rd/4th gear synchronizer
assembly
31 7N193 Reverse gear bushing
10 7107 3rd/4th gear synchronizer
32 7109 Check ball (part of spring kit)
blocking ring
33 7109 Selector gate (part of spring
11 7B340 3rd gear
kit)
12 7025 3rd gear needle bearing kit
34 7025 Main shaft rear bearing and
cup 13 7N193 3rd gear bushing
35 7K316 Main shaft 5th gear 14 7L271 Check ball (part of spring kit)
36 7109 Retaining ring (part of spring 15 7L271 Thrust washer (part of spring
kit) kit)
37 7109 Check ball (part of spring kit) 16 7025 2nd gear needle bearing kit
38 7H150 Output shaft speed (OSS) 17 7102 2nd gear
sensor ring
18 7107 1st/2nd gear synchronizer
39 7109 Retaining ring cones assembly (3 piece)
40 7L271 Spacer 19 7061 Output shaft
41 7025 Extension housing bearing 20 7124 1st/2nd gear synchronizer
bushing assembly
21 7L271 Retaining ring (part of spring
kit)
(Continued)
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Transmission Internal Components Countershaft and Reverse Idler Gear Disassembled View
10 7124 Countershaft 5th gear and 1 7L172 Shim
synchronizer assembly
2 7025 Countershaft front bearing
11 7107 5th gear synchronizer and cup
blocking ring
3 7113 Countershaft
12 7124 5th gear clutch cone
4 7025 Countershaft rear bearing and
13 7L271 Retaining ring (part of spring cup
kit)
5 7L271 Thrust bearing (part of spring
14 7141 Reverse idler gear kit)
15 7025 Reverse idler gear needle 6 7L271 Check ball (part of spring kit)
bearing
7 7124 Countershaft 5th gear (part of
16 7141 Reverse idler gear support 5th gear and synchronizer
bolt assembly)
17 7723 Reverse idler gear support 8 7025 Countershaft 5th gear needle
bearing
18 7140 Reverse idler gear shaft
9 Retaining ring (part of 5th
gear synchronizer assembly)
(Continued)
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Transmission Case and Shift Components Disassembled View
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33 7L271 Extension housing bearing 1 7A508 Slave cylinder and release
snap ring (part of kit) bearing
34 7052 Output shaft seal 2 6392 Clutch housing
35 7089 Transmission flange 3 7052 Input shaft seal
36 7E397 Flange O-ring 4 7A082 Detent plug (part of detent
kit)
37 7114 Flange washer
5 7A082 Detent spring (part of detent
38 7K440 Flange nut
kit)
6 7A082 Detent (part of detent kit)
7 7K584 Slave cylinder line retainer
8 7L082 Shift fork inserts
the lower bolt that retains the extension housing to
9 7358 3rd/4th shift rail and fork the main case.
10 7K131 3rd/4th shift gate
The 5-speed overdrive (TR3650) transmission is
11 7241 1st/2nd shift rail and fork available for the Mustang 4.6L (3V).
12 7K130 1st/2nd shift gate
13 7242 5th/reverse shift rail and
reverse shift fork
14 7230 5th gear shift fork
15 4L042 5th shift gate
16 7005 Transmission main case
17 15520 Reverse lamp switch
18 7A010 Drain plug
19 Interlock pins
20 7K201 Shift interlock plate
21 7L027 Magnet
22 7A082 5th/reverse gear lockout (part
of kit)
23 7A082 5th/reverse gear lockout
spring (part of kit)
1 Transmission assembly
24 7A082 Spacers
number
25 7337 Selector finger
2 Build date code month
26 7240 Selector rail
3 Build date code day
4 Build date code year
28 7A010 Fill plug
5 Shift number
29 7234 Detent/bias spring plunger
6 Serial number
30 7127 Selector shift rail bearing
7 Service repair code
31 7052 Selector shift rail seal
8 Identification number located
on left lower side of 32 7025 Extension housing
transmission case bearing/race assembly
(Continued)
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Manual Transmission
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Manual Transmission
The T5OD 5-speed transmission:
fifth speed gear functions as an overdrive gear.
forward gears are synchronized and helical cut.
shift interlock system prevents the engagement of
more than one gear.
has an aluminum main case, extension housing
and bellhousing.
has an input shaft, output shaft and countershaft.
reverse idler gear is used to produce a reverse
rotation of the output shaft.
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Transmission Internal Components Input and Output Shaft Disassembled View
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22 7107 1st/2nd gear synchronizer 1 7052 Input shaft seal
intermediate cones
2 7L172 Shim
3 7025 Input shaft cup and bearing
blocking rings
4 7017 Input shaft
24 7061 Main shaft and synchronizer
5 7118 Roller bearing (15 required)
assembly
6 7L357 Input shaft bearing spacer
25 7K218 1st/2nd gear synchronizer
check ball
7 7D234 Input shaft thrust bearing
8 7D235 Input shaft thrust washer
assembly (serviced with
7061)
blocking ring
27 1st gear bearing spacer check
ball
assembly
28 7173 1st gear bearing spacer
11 7B340 3rd gear
29 7127 1st gear needle bearing
12 7B369 3rd gear needle bearing
30 7100 1st gear
13 7B320 3rd gear bearing spacer
31 7065 Main shaft rear bearing and
14 7064 Snap ring
cup
15 7119 Thrust washer
32 7K316 Main shaft 5th gear
16 7102 2nd gear
33 7H373 Main shaft speed (OSS)
17 7B369 2nd gear needle bearing sensor ring
18 7B320 2nd gear bearing spacer 34 7A021 Main shaft inner spacer
19 7160 Main shaft bearing snap ring 35 Main shaft outer spacer check
ball
20 7117 2nd gear synchronizer thrust
washer 36 7065 Main shaft outer bearing and
race assembly
inner cones
(Continued)
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Transmission Internal Components Countershaft and Reverse Idler Gear Disassembled View
6 7107 5th gear synchronizer 1 7F431 Countershaft front bearing
blocking rings and cup
7 7124 5th gear synchronizer 2 7113 Countershaft
assembly
3 7F431 Countershaft rear bearing and
8 7M000 Reverse brake ring cup
9 7G042 Thrust washer 4 7L172 Countershaft rear bearing
adjustment shim
10 7059 5th gear synchronizer
retaining ring 5 7144 Countershaft 5th gear
(Continued) 11 7L276 Oil pick up funnel
(Continued)
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12 7E397 Reverse gear overtravel stop 14 357479-S15 Pin
13 7141 Reverse idler gear and 15 7140 Reverse idler gear shaft
bushing
(Continued)
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Transmission Case and Shift Components Disassembled View
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36 7K201 Gear selector interlock sleeve 1 7A508 Slave cylinder and release
bearing
37 7N232 Gear shift plate
2 7500 Clutch housing
38 7230 1st/2nd gear shift fork
3 7N584 Slave cylinder line retainer
39 7240 Reverse gear shift rail
4 7050 Input shaft bearing retainer
40 7230 Reverse shift fork
5 7052 Input shaft seal
41 7E485 Reverse shift fork spring
6 7005 Main case
42 7K002 Reverse gearshift lever
7 7A443 Main case-to-clutch housing
43 7230 5th gear shift fork
bolt
8 87675-S Drain and fill plugs
9 7K024 Reverse lever pivot bolt
the lower left bolt that retains the extension housing
11 7K024 Shift lever reverse pin to the case.
12 7H103 Output shaft speed (OSS)
The T50D transmission is available for the Mustang
sensor
4.0L SOHC.
Transmission Identification Tag
14 7065 Extension housing bearing
15 7109 Extension housing bearing
snap ring
16 7052 Output shaft seal
17 7K359 Transmission flange
18 7E347 Flange O-ring
19 7119 Flange washer
20 Flange nut
21 7A443 Gear shift cover bolt
22 7222 Gear shift cover
23 7240 Main shift rail
24 7052 Selector rail seal
25 7N094 Selector finger
26 7F018 Gearshift offset lever
1 Transmission assembly
number 27 7234 Detent spring
2 Build date code month 28 372720-S Detent ball
3 Build date code day 29 7358 Main shift control shaft
4 Build date code year 30 Main shift rail seal
5 Shift number 31 7222 Transmission case cover
6 Serial number 32 7231 3rd/4th gear shift fork
7 Identification number 33 7L082 Shift fork inserts
(Located on the extension
34 7N232 Gear shift plate
housing bolt on the LH side
35 7302 Selector body
of the transmission)
(Continued)
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IN-VEHICLE REPAIR
Section 100-02.
2. Disconnect the electrical connector.
3. Remove the output shaft speed (OSS) sensor.
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OF SUBASSEMBLIES
Output Shaft
Special Tool(s)
Pinion Bearing Cone Remove
205-D002 (D79L-4621-A) or
equivalent
Remover, Bearing
205-055 (T71P-4621-B)
3. Remove 1st gear needle bearing.
Disassembly
1. CAUTION: Support the output shaft
while using the press to prevent damage to
the shaft or gears.
Using the special tool, press the output shaft
speed (OSS) sensor ring from the output shaft.
4. NOTE: The 1st gear bearing spacer fits snugly
on the output shaft.
Remove the 1st gear bearing spacer.
2. Using the special tool, press 1st gear, the output
shaft rear bearing and the 5th speed driven gear
from the output shaft as an assembly.
Discard the output shaft rear bearing.
Inspect the gears for wear or damage. Install
new gears as necessary.
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5. Remove the 1st and 2nd speed synchronizer 9. Remove 3rd gear needle bearing.
hub ball.
6. Remove the 1st gear synchronizer inner cone,
1st gear synchronizer outer cone and the 1st
10. Remove the snap ring.
gear synchronizer blocking ring.
11. Remove the 2nd gear bearing spacer.
7. NOTE: Reposition the output shaft on the press
with the input shaft end facing upward.
Using the special tool, press the 3rd and 4th
gear synchronizer assembly, the 3rd gear
blocking ring and 3rd gear from the output
shaft as an assembly.
Inspect the gear for wear or damage. Install
a new gear as necessary.
8. Disassemble and inspect the 3rd and 4th gear
synchronizer assembly. For additional
information, refer to Synchronizers in this
section.
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12. Remove 2nd gear.
13. Remove 2nd gear needle bearing.
15. Remove the 2nd gear synchronizer thrust
washer.
14. Remove the output shaft bearing snap ring.
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16. Remove the 2nd gear synchronizer inner cone,
the 2nd gear synchronizer outer cone and the
2nd gear synchronizer blocking ring as an
assembly.
4. Install the 2nd gear synchronizer thrust washer.
17. NOTE: The 1st and 2nd gear synchronizer
sliding sleeve, the hub and the output shaft are
an assembly. Do not attempt to separate the hub
from the output shaft. Only the synchronizer
hub insert springs and the synchronizer hub
inserts are available separately.
Remove the 1st and 2nd gear synchronizer
sliding sleeve. Disassemble and inspect the 1st
and 2nd gear synchronizer assembly. For
additional information, refer to Synchronizers in
5. Install the new output shaft bearing snap ring.
this section.
Assembly
1. Lubricate all components with transmission
fluid during assemble. Soak the blocking rings
in transmission fluid for 10 minutes.
2. Assemble the 1st and 2nd gear synchronizer.
Install the synchronizer hub insert springs
and the synchronizer inserts into the
synchronizer hub. Install the sliding sleeve
onto the hub.
3. Install the 2nd gear synchronizer blocking ring,
the 2nd gear synchronizer outer cone and the
2nd gear synchronizer inner cone.
Align the slots in the synchronizer blocking
ring with the tabs in the 1st and 2nd gear
synchronizer.
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6. Install the 2nd gear needle bearing. 8. Install the 2nd gear bearing spacer.
7. Install 2nd gear. 9. Install a new snap ring.
Align the slots on 2nd gear with the tabs on
the synchronizer blocking ring.
10. Install 3rd gear needle bearing.
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11. Position 3rd gear, the 3rd gear synchronizer
blocking ring and the 3rd and 4th gear
synchronizer assembly on the output shaft.
Align the slots on 3rd gear with the tabs on
the synchronizer blocking ring.
14. Install the 1st and 2nd gear synchronizer hub
ball.
12. CAUTION: Before pressing the
components together, verify that the
synchronizer hub faces the short end of the
output shaft. Hold 3rd gear against the
synchronizer to maintain the synchronizer
blocking ring alignment.
Using a 1-1/2-inch deep well socket, press the
3rd gear, the 3rd gear synchronizer blocking
ring and the 3rd and 4th gear synchronizer
assembly onto the output shaft.
15. NOTE: The 1st gear bearing spacer fits snugly
Install the 1st gear bearing spacer.
Align the notch in the 1st gear bearing
spacer and the 1st and 2nd gear
synchronizer hub ball.
with the output end facing upward.
Install the 1st gear synchronizer blocking ring,
the 1st gear synchronizer outer cone and the 1st
gear synchronizer inner cone.
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16. Install the 1st gear needle bearing.
19. CAUTION: Align the output shaft
splines and the splines of the 5th speed
driven gear or damage will occur.
Lubricate the splines of the 5th speed driven
gear with petroleum jelly. Position the 5th
speed driven gear on the output shaft. Using a
capped length of pipe 31.7 mm (1.24 in) inside
diameter by 356 mm (14.01 in) long, press on
the 5th speed driven gear.
17. Install 1st gear.
Align the slots on the synchronizer blocking
ring and the slots on the 1st gear.
18. Install the output shaft rear bearing.
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20. Using the capped length of pipe 31.7 mm (1.24
in) inside diameter by 356 mm (14.01 in) long,
press the output shaft speed (OSS) sensor ring
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OF SUBASSEMBLIES
Output Shaft
Special Tool(s)
Puller, Bearing
205-D064 (D84L-1123-A)
Adapter for 303-224 (Handle)
205-153 (T80T-4000-W)
Installer, Output Shaft Rear
Bearing
308-401
308-025 (T75L-7025-C)
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
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Disassembly
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24 Split washer 1 7025 Output shaft front bearing
25 7100 1st gear 2 7A082 Snap ring
26 7025 1st gear needle bearing 3 7124 3rd/4th synchronizer assembly
27 7025 Output shaft rear bearing 4 7107 3rd/4th synchronizer blocking
ring assembly
28 7L047 6th driven gear
29 7K316 5th driven gear
(part of 7107)
30 7117 Spacer
31 7050 Retainer
of 7107)
32 7A082 Thrust washer
of 7107) 33 7124 Reverse synchronizer
assembly
8 7117 Spacer
34 7A082 Snap ring
9 7B340 3rd gear
35 7107 Reverse gear synchronizer
10 7025 3rd gear needle bearing
blocking ring assembly
11 7061 Output shaft
12 7102 2nd gear
(part of 7107)
13 7025 2nd gear needle bearing
of 7107) 14 7117 Spacer
15 7107 2nd gear synchronizer
of 7107) blocking ring assembly
39 7N168 Reverse gear needle bearing 16 Synchronizer inner cone (part
of 7107)
40 7C238 Reverse gear
41 7A385 Thrust washer
of 7107)
42 7A082 Snap ring
43 Spacer
(part of 7107)
44 7025 Rear output shaft bearing
19 7124 1st/2nd synchronizer
assembly 45 Spacer
20 7107 1st gear synchronizer 46 7A082 Snap ring
blocking ring assembly
47 7E172 Check ball
48 7H150 Speedometer rotor
(part of 7107)
49 7A082 Snap ring
50 Spacer
of 7107)
51 Output shaft bearing race
of 7107)
(Continued)
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5. Remove the synchronizer sleeve and the 3
1. CAUTION: Hand tighten the special
synchronizer keys.
tool to prevent gear damage.
CAUTION: Support the output shaft
6. NOTE: Install the special tool behind 2nd gear
while using the press to prevent damage to
with the flat side of the tool facing 2nd gear.
the shaft or gears.
Using the special tool, remove the 2nd gear, the
Using the special tool and a press, remove 1st
inner cone, the outer cone, the 2nd gear
gear, the output shaft rear bearing, the 5th
synchronizer blocking ring and the synchronizer
driven gear and the 6th driven gear.
hub.
Discard the output shaft bearing.
Inspect the all synchronizer components for
wear or damage. Install a new components
as necessary.
7. Remove the 2nd gear needle bearing and the
spacer.
damage. Install a new needle bearing as
necessary.
Remove and discard the snap ring, then using
the special tool, remove the 3rd/4th gear
synchronizer assembly, the 3rd gear
synchronizer double cone and the 3rd gear.
Inspect the gear for broken or cracked teeth.
Install a new gear as necessary.
9. Remove the 3rd gear needle bearing and the
spacer.
necessary.
2. Remove the 1st gear needle bearing.
necessary.
3. Remove the split washer.
the outer cone and the blocking ring.
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10. NOTE: Install the special tool with the flat side
facing the bearing.
Using the special tool, press the output shaft
front bearing from the output shaft. Discard the
bearing.
13. Inspect the output shaft for scoring or worn or
damaged splines. Install a new output shaft as
necessary.
Assembly
1. Lubricate all components with the
11. Inspect the synchronizers.
recommended transmission fluid when
Check for worn, nicked or broken teeth.
reassembling.
Install a new synchronizer as necessary.
Check keys for wear or distortion. Install a 2. Using the special tools, press the new output
new synchronizer as necessary. shaft front bearing on the output shaft.
Check springs for distortion. Install a new
synchronizer as necessary.
12. Inspect the synchronizer blocking rings.
Check for wear or damage. Install new
synchronizer blocking rings as necessary.
Check the clearance between the
synchronizer blocking ring and the gear.
X Position the blocking ring onto the gear.
Make sure the correct blocking ring is
measured with the correct gear and that
the blocking ring is fully seated on the
gear.
X Insert a feeler gauge and measure the
clearance, while applying pressure and
rotating the blocking ring. The
measurement should be the same around
the entire circumference. If the clearance
is less than 0.38 mm (0.015 in), install
new blocking rings.
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3. Install the 3rd gear bearing and the spacer.
Apply petroleum jelly to the bearing.
4. Install 3rd gear, the 3rd gear synchronizer
double cones and the 3rd/4th gear synchronizer
assembly. Position the output shaft with the
output end facing upward. Using the special
tool, press the 3rd/4th gear synchronizer
assembly into place.
Install the synchronizer body with the
groove facing 3rd gear.
Stop press operation before keys engage the
blocking ring slots. Lift and rotate the 3rd
5. Install a new snap ring.
gear and the blocking ring until the keys are
seated in the blocking ring.
6. Install the 2nd gear needle bearing.
7. Install 2nd gear and the bearing spacer.
8. Install the 2nd gear, the inner cone, the
intermediate cone and the 2nd gear
Align the blocking ring tabs with the 2nd
gear slots.
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9. Install the 1st/2nd gear synchronizer assembly. 11. Install the 1st gear needle bearing.
Position the output shaft with the output end
facing downward. Using the special tools, press
the 1st/2nd gear synchronizer assembly into
place.
Install the synchronizer with the groove on
the sleeve facing 1st gear.
Stop press operation before keys engage the
blocking ring slots. Lift and rotate the 2nd
gear and the blocking ring until the keys are
seated in the blocking ring.
Rotate the gear to align the gear slots with
the intermediate cone tabs.
13. Install a new rear output shaft bearing.
14. Using the special tools, install the 5th driven
gear.
10. Install the 1st gear synchronizer split washer,
the inner cone, the intermediate cone and the
1st gear synchronizer blocking ring.
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OF SUBASSEMBLIES
Output Shaft 2. CAUTION: Hand tighten the special
tool to prevent gear damage.
Special Tool(s)
CAUTION: Support the output shaft
Remover, Drive Pinion Bearing while using the press to prevent damage to
Cone
the shaft or gears.
205-D002 (D79L-4621-A) or
Using the special tool, press 5th gear, the
equivalent
spacer, the output shaft bearing and reverse
gear from the output shaft.
Discard the output shaft bearing.
Cone
205-011 (T57L-4621-B)
308-025
3. Remove reverse gear needle bearing.
Material Inspect the needle bearing for wear or
Item Specification
necessary.
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
Disassembly
1. Remove the retaining ring above 5th gear.
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4. Remove the check ball and the blocking ring. 6. Remove the 1st gear needle bearing.
Inspect the blocking ring for wear or Inspect the needle bearing for wear or
damage. Install new blocking rings as damage. Install a new needle bearing as
necessary. necessary.
the 1st gear synchronizer outer cone and the 1st
5. NOTE: Install the special tool with the flat side
facing 1st gear.
Using the special tools, press the bearing
spacer, the reverse gear synchronizer cone and
1st gear from the output shaft.
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Remove and discard the retaining ring.
12. Remove the 3rd gear needle bearing.
necessary.
9. Remove the 3rd/4th synchronizer hub.
13. NOTE: Install the special tool behind 2nd gear
10. Remove the 3rd/4th blocking ring.
with the flat side of the tool facing 2nd gear.
Using the special tool, remove the spacer, 2nd
gear thrust washer and 2nd gear.
11. Remove the 3rd gear.
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14. Remove the check ball and 2nd gear needle 16. Remove the snap ring, then using the special
bearing. tool, press off the 1st/2nd gear synchronizer.
necessary.
Assembly
1. Carry out the following before reassembling:
15. Remove the 2nd gear synchronizer inner cone, Inspect the gears for broken or cracked
2nd gear synchronizer outer cone and the 2nd teeth. Check for unusual wear patterns.
Inspect the thrust washers for face wear,
Inspect all components for wear or damage. cracks, scoring and for signs of heat
Install new components as necessary. damage.
Inspect the bearings, bearing cups and the
synchronizers for wear or damage.
Inspect the output shaft for scoring or worn
or damaged splines. Install new components
as necessary.
Always install new retaining rings.
2. Lubricate all components with the
recommended transmission fluid when
reassembling.
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3. NOTE: Position the output shaft with the
output end facing upward.
NOTE: Install the synchronizer assembly with
the deeper center flange of the synchronizer hub
facing toward the rear of the output shaft.
Install the 1st/2nd synchronizer assembly on the
output shaft, then install a new retaining ring.
If installing the original synchronizer
assembly, make sure the index marks made
during disassembly are aligned.
It may be necessary to press the hub into
position on the shaft.
5. Install the outer 1st gear synchronizer cone.
Do not overextend the retaining ring. A
damaged or overextended retaining ring will
not allow 1st gear to fully seat.
6. Install the inner 1st gear synchronizer cone.
Rotate the inner cone till it is seated.
4. Install the 1st gear synchronizer blocking ring.
Align the blocking ring tabs with the
synchronizer assembly.
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7. Install the 1st gear needle bearing. 9. Install the reverse synchronizer cone.
10. Install the reverse gear blocking ring.
First gear is 127 mm (5 in) in diameter.
the inner cone tabs.
Make sure that the gear fits over the
retaining ring.
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11. Using the special tools, install the reverse gear
bearing spacer.
14. Install reverse gear.
Make sure the clutching teeth on the gear
snap inside the sliding sleeve and the sliding
sleeve is against the gear.
Function the synchronizer sleeve through the
2 positions to make sure of normal function.
12. Install the reverse gear needle bearing.
15. Install the check ball.
Use petroleum jelly to hold the check ball in
place.
13. Install the reverse gear synchronizer assembly.
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16. Install the thrust washer. Be sure to align the 19. Reposition the output shaft with the input end
slot in the washer with the check ball. facing upward.
20. Install the 2nd gear synchronizer blocking ring.
Rotate the blocking ring until seated.
17. Install the rear output shaft bearing, then 5th
gear. Using the special tool, press both the
bearing and gear into place.
21. Install the 2nd gear synchronizer outer cone and
The flatside of 5th gear faces the output
the second gear synchronizer inner cone.
shaft end.
18. Install a new retaining ring.
Do not overextend the retaining ring.
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22. Install the 2nd gear bearing.
23. Install 2nd gear.
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24. Install the check ball. 25. Install the thrust washer. Be sure to align the
slot in the washer with the check ball.
place.
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26. Press the bearing spacer onto the output shaft.
27. Install the 3rd gear bearing.
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28. Install 3rd gear. 29. Install the 3rd gear synchronizer blocking ring.
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30. Install the 3rd/4th gear synchronizer body. 31. Install a new retaining ring.
Install the synchronizer body with the raised
center facing downward.
Rotate the blocking ring until seated.
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GENERAL PROCEDURES
Pilot Bearing Check
1. CAUTION: The pilot bearing is a
sealed bearing and must not be immersed in
any type of cleaning fluid.
Inspect the pilot bearing for:
needle rollers for scoring, worn or broken
rollers, cracked roller cage inadequate grease
or discoloration.
seal leakage.
misalignment and looseness in the
crankshaft.
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308-01-1 308-01-1 Clutch
Pilot Bearing
Special Tool(s)
Puller with Slide Hammer
308-001 (T58L-101-B)
Removal
2. Install the clutch disc and the clutch pressure
1. Remove the clutch disc and the clutch pressure
plate. For additional information, refer to Clutch
plate. For additional information, refer to Clutch
Disc and Pressure Plate 4.0L, Clutch Disc
Disc and Pressure Plate 4.0L, Clutch Disc
and Pressure Plate 4.6L or Clutch Disc and
and Pressure Plate 4.6L or Clutch Disc and
Pressure Plate 5.4L in this section.
Pressure Plate 5.4L in this section.
2. Using the special tool, remove the pilot bearing.
Installation
1. Position the pilot bearing to the crankshaft,
using a suitable driver, install the pilot bearing.
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OF SUBASSEMBLIES
Selector Plate
Disassembly
1. NOTE: Mark the position of each gear shifter
fork.
Place the gear shift plates and the gear selector
interlock sleeve in the NEUTRAL position to
center the gear shift plates and the selector
body.
4. Remove the gear shifter forks, the gear shift
plates, the pin, the gear selector interlock sleeve
and the selector body.
2. Rotate the main shift control shaft
counterclockwise and pull it rearward to access
the pin. Remove the pin.
5. Remove and discard the O-ring.
3. Using a twisting motion, remove the main shift
control shaft.
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3. NOTE: Position the narrow side of the
6. CAUTION: Note the orientation of the
C-shaped gear selector interlock sleeve in the
gear shift plate for assembly reference.
case cover slot. Position the roll pin hole in the
Remove the gear shift plate and the gear shift
selector body toward the rear of the cover.
fork inserts from the shifter forks.
Install the gear selector interlock sleeve and the
selector body as an assembly.
Assembly
4. Lubricate the main shift control shaft with
1. Install a new O-ring.
petroleum jelly.
5. NOTE: The 1-2 gear shifter fork is the larger
shifter fork. The gear shifter fork offset lever
must face the cover. Position the gear shift
plate attached to the 3-4 gear shifter fork under
the gear shift plate attached to the 1-2 gear
shifter fork.
Position the gear shifter forks and the main
shift control shaft in the cover.
Slide the shaft through the cover and shift
the components until the shaft stops against
the cover.
2. Assemble the gear shifter forks.
1 Install the gear shift plate into the gear
shifter fork.
2 Install the gear shift fork inserts.
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6. CAUTION: Install the pin slightly
below the selector body surface. Failure to
countersink the pin may result in
interference between the pin and the gear
selector interlock sleeve during shifts.
NOTE: The flat on the main shift control shaft
must face upward.
Install the pin.
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SPECIFICATIONS
Clutch master cylinder 10 89
Item Specification bolts
Clutch System Clutch slave cylinder 20 15
Hydraulic Self adjusting
Fluid and Lubricant
Motorcraft High ESA-M6C25-A or
Motor Vehicle Brake
(Canada)
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SPECIFICATIONS
Clutch 32 24
Item Specification housing-to-transmission
main case bolt
Crossmember-to-frame 62 46
bolts
Grease XG-1-C or
XG-1-K (US); CXG-1-C Crossmember-to- 70 52
(Canada) transmission bolt
Threadlock and Sealer WSK-M2G351-A5 Detent plugs 28 21
TA-25
Drain plug 27 20
Clear Silicone Rubber ESB-M4G92-A
Extension 32 24
TA-32
housing-to-transmission
MERCON MERCON main case bolt
Fifth/reverse lockout 20 15
Transmission Fluid
side bolt
XT-2-QDX (US);
XT-2-LM12 (Canada) Fifth/reverse lockout 20 15
top bolt
Synchronizer
Fill plug 25 18
Capacity 3.0L (6.3 pt)
Gearshift underbody 11 8
Synchronizer blocking 0.5 mm (0.02 in)
nuts
ring to conical face runout
Lock plate bolts 31 23
End Play
Output flange nut 142 105
Input shaft end play 0.027-0.127 mm
(0.001-0.005 in) Output shaft speed 10 89
(OSS) sensor bolt
Countershaft cluster gear 0.026-0.126 mm
end play (0.001-0.004 in) Reverse idler gear bolt 27 20
Reversing lamp switch 27 20
Transmission-to-engine 45 33
bolt
Transmission shift arm 40 30
bolt
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SPECIFICATIONS
Clutch housing cover 31 23
Item Specification bolt
Lubricants and Sealants Clutch slave cylinder 9 80
bolts
XG-4 and/or XL-5 Countershaft rear 21 15
bearing retainer bolt
Grease XG-1-C or Crossmember bolts 62 46
Crossmember 70 52
(Canada)
transmission bolt
Drain plug 18 13
TA-25
Driveshaft bolts 103 76
TA-32 Exhaust manifold nuts 40 30
Thread Sealant with PTFE WSK-M2G350-A2 Extension cover bolt 19 14
TA-24
Extension housing bolt 54 40
MERCON MERCON
Fill plug 18 13
Gearshift underbody 11 8 Transmission Fluid
nuts
XT-2-QDX (US);
XT-2-LM12 (Canada)
Input shaft bearing 21 15
retainer bolt Synchronizer
Output flange nut 142 105 Synchronizer blocking 0.5 mm (0.02 in)
ring to conical face runout
Output shaft speed 10 89
(OSS) sensor bolt
End Play
Overcenter spring bolt 35 26 Countershaft cluster gear 0.013 mm (0.0005 in) -
end play 0.102 mm (0.0040 in)
Output shaft end play 0.03 mm (0.0010 in) -
Shift lever reverse pin 40 30
0.230 mm (0.0090 in)
Starter bolts 25 18
Transmission bolts 45 33
Transmission mount 115 85
Description Nm lb-ft lb-in nut
Case cover bolt 12 9 Transmission shift 40 30
linkage bolt
Clutch housing bolts 63 46
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SPECIFICATIONS
Item Specification
High Performance DOT3 ESA-M6C25-A or
Pressure plate
Pressure spring Belleville
(Canada)
Sensor spring Belleville
MERCON MERCON
Clutch Disc (4.0L)
Transmission Fluid
Clutch diameter 254 mm (10.0 in)
XT-2-QDX (US);
XT-2-LM12 (Canada)
Number of springs 5
a
Capacity
Color identification none
4.0L 2.6L (2.8 qt)
Clutch Disc (4.6L)
4.6L 3.6L (7.5 pt)
5.4L 3.6L (7.5 pt)
Number of springs 4
Color identification none
a Inner floating damper design.
b Serviced as assembly only.
Clutch Disc (5.4L)
Number of springs 6
Number of discs 2
b
Clutch bleed screw 8 71
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308-01-1 308-01-1 Clutch
SPECIFICATIONS
Item Specification
5.4L No. of springs: 6 springs
Item Specification
Fluid and Lubricants
Pressure Plate
Pressure plate diameter 254 mm (10.0 in) Grease XG-1-C or
(4.0L) XG-1-K (US); CXG-1-C
(Canada)
Pressure plate diameter 280 mm (11.0 in)
(4.6L)
Pressure plate diameter 215 mm (8.5 in)
(5.4L)
Clutch Disc
Pressure plate bolt (4.0L) 35 26
4.0L No. of springs: 5 springs
Pressure plate bolts (4.6L)
a
Inner floating damper
design
Pressure plate bolts (5.4L) 15 11
4.6L No. of springs: 4 plain
a Refer to procedures in this section.
Color identification: no
paint daub
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SPECIFICATIONS
Filler plug 27 20
Item Specification
Gearshaft lever bolt 40 30
Gearshift lever upper 35 26
Premium Long-Life ESA-M1C75-B bolts
Grease
Guide plate bolts 22 16
XG-1-C or XG-1K (US);
CXG-1-C (Canada) Lower gearshift lever 20 15
bolts
TA-25 OSS sensor bolt 10 89
Silicone Gasket and WSE-M4G323-A4 Reverse idler shaft 30 22
Sealant TA-30 bracket bolts
Preload Reverse lockout 18 13
solenoid bolt
Input/output shaft preload 0.0127 mm (0.0005 in) -
0.0889 mm (0.0035 in) Reversing lamp switch 27 20
Countershaft cluster gear 0.0127 mm (0.0005 in) - Shift detent 40 30
preload 0.0889 mm (0.0035 in)
Shift detent cover bolts 20 15
Fluid
Shift lever guide bolts 27 20
MERCON V MERCON V
Subframe cross brace 48 35
bolts
Transmission Fluid
Transmission insulator 70 52 XT-2-QDX (US);
center bolt XT-2-LM12 (Canada)
Transmission mount 63 46 Capacity 3.46L (3.65 qt)
outer bolts
Transmission-to-clutch 48 35
adapter housing bolts
Description Nm lb-ft lb-in Transmission-to-engine 45 33
bolts
Clutch slave cylinder 12 9
bolts Upper gearshift lever 37 27
bolts
Drain plug 27 20
Extension housing bolts 48 35
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OF SUBASSEMBLIES
4. Inspect the synchronizer blocking rings.
Synchronizers
Check for wear or damage. Install new
Disassembly synchronizer blocking rings as necessary.
NOTE: This procedure applies to all synchronizer
assemblies.
1. NOTE: Synchronizer components are not
interchangeable. During disassembly, mark each
individual synchronizer for assembly.
gear.
Synchronizer hubs and sleeves are a selected
assembly and should be kept together as
originally assembled. Blocking rings are not
rotating the blocking ring. The
interchangeable, do not mix.
Scribe an alignment mark on the sliding sleeve
and the hub for assembly reference.
new blocking rings.
2. Using a screwdriver, remove the spring. Turn
the synchronizer over and remove the 2nd
spring. Remove the sliding sleeve and the
synchronizer struts from the hub.
3. Inspect the synchronizer components.
Check keys for wear or distortion. Install a
new synchronizer as necessary.
Check springs for distortion. Install a new
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Assembly
1. CAUTION: Match the alignment
marks make during disassembly. The sleeve
and the hub have an extremely close fit.
Hold the sleeve and hub square to prevent
jamming. Do not force the sleeve onto the
hub.
Assemble the synchronizer as follows:
Position the synchronizer sleeve on the hub.
Make sure to align key openings in the hub
with the synchronizer sleeve.
Install the keys with the slots facing the
hub.
Install the spring. Locate the tang to one of
the key slots and position into place. Install
the second spring. Locate the spring tank on
the same key but position in the opposite
direction.
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OF SUBASSEMBLIES
Synchronizers
NOTE: This procedure applies to all synchronizer
assemblies.
1. Scribe an alignment mark on the sliding sleeve
and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the
synchronizer struts and the springs.
3. Install the synchronizer struts and the springs.
4. CAUTION: Match the alignment
marks made during disassembly. The sleeve
and the hub have an extremely close fit.
Hold the sleeve and hub square to prevent
jamming. Do not force the sleeve onto the
hub.
Install the sliding sleeve.
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OF SUBASSEMBLIES
Transmission Case
Special Tool(s)
Handle
205-D055 (D81L-4000-A)
Installer, Bearing Cup
204-039 (T77F-1217-B)
204-080 (T83P-1104-AH1)
205-155 (T80T-4000-Y)
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9 Shift rail (part of 7C453) 1 7A508 Clutch slave cylinder
10 Retaining ring (part of 2 6392 Clutch housing
7C453)
3 7005 Transmission main case
11 Shift finger bolt (part of
4 Shift cover bolt (4 required)
7C453)
5 7C453 Shift cover assembly
12 Shift finger (part of 7C453)
6 Shift cover plug (part of
13 7A082 Roll pin (part of 7C453)
7C453)
14 7F476 Shift guide plate
7 Shift cover seal (part of
15 Shift guide plate bolts (2 7C453)
required)
8 Offset lever (part of 7C453)
(Continued)
(Continued)
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16 Output shaft bearing cup
17 Countershaft bearing cup
18 Shift detent plug
19 7234 Shift detent spring
20 Shift detent
21 7052 Input shaft seal
22 7127 Top shift rail bearing
23 Magnets
5. Remove the reverse lamp switch.
1. Remove the shift detent from the transmission
main case.
6. Inspect the countershaft and mainshaft bearing
cups for wear or damage. Install new
7. Using the special tools, remove the countershaft
bearing cup.
2. Remove the shift detent plug and the spring and
shift detent from the clutch housing.
3. Remove the bolts and the guide plate.
Inspect the plate for wear or damage. Install
a new plate as necessary.
8. Using the special tools, remove mainshaft
bearing cup.
4. NOTE: Do not remove the magnets.
Clean the case magnets.
wear is in place.
Clean the case with solvent and dry with
compressed air. Clean and check the sealing
surface for nicks or scratches. Inspect the case
for cracks.
If the case is cracked, install a new case. If
the sealing surface has nicks or scratches,
use a soft stone or crocus cloth to remove.
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10. NOTE: If a new countershaft bearing is being 11. NOTE: If a new mainshaft bearing is being
installed, install a new bearing cup. Always installed, install a new bearing cup. Always
install new bearings and cups in a set. install new bearings and cups in a set.
Using the special tools, install the countershaft Using the special tools, install the mainshaft
bearing cup. bearing cup.
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GENERAL PROCEDURES
4. NOTE: Prior to removal, clean the area around
Transmission Draining and Filling
the fill plug.
Material Remove the fill plug.
Item Specification
TA-25
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
Section 100-02.
2. NOTE: Drain the transmission while the
transmission fluid is warm. 5. NOTE: Do not overfill the transmission. This
will cause transmission fluid to be forced out of
Remove the drain plug.
the case.
Position a drain pan under the transmission.
Fill the transmission with the recommended
fluid.
Make sure the fluid is 12.7 mm (0.5 in)
below the filler opening for the correct fluid
level. Using a tie strap, measure an inch
from the end and bend it at a 90-degree
angle, place it in the filler opening and
check the fluid. Adjust the fluid level as
necessary.
6. Apply threadlock and sealer and install the fill
plug.
3. Apply threadlock and sealer and install the
drain plug.
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GENERAL PROCEDURES
Material
Item Specification
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
transmission.
Position a suitable drain pan under the
4. Using a suitable oil suction gun, fill the
transmission.
transmission to the correct level with the
specified fluid.
Transmission capacity is 3.46L (3.65 qt).
2. Clean and install the drain plug.
5. Install the filler plug.
3. NOTE: Before removing, clean the area around
the filler plug.
Remove the filler plug.
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GENERAL PROCEDURES
3. NOTE: Prior to removal, clean the area around
the fill plug.
Special Tool(s) Remove the fill plug.
Oil Suction Gun
303-D104 (D94T-9000-A) or
equivalent
Material
Item Specification
TA-24
4. NOTE: Do not overfill the transmission. This
Fluid
will cause transmission fluid to be forced out of
XT-2-QDX (US);
the case.
XT-2-LM12 (Canada)
Using a suitable oil suction gun, fill the
1. NOTE: Drain the transmission while the
transmission with the recommended fluid.
transmission fluid is warm.
Transmission capacity is 2.6 liters (2.8
Remove the drain plug.
quarts).
Position a drain pan under the transmission.
5. Clean the fill plug. Apply thread sealant and
install the fill plug.
2. Clean the drain plug. Apply thread sealant and
install the drain plug.
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IN-VEHICLE REPAIR
Transmission Rear Support Insulator
Transmission Rear Support Insulator Exploded View
1 6068 Transmission rear support
insulator
2 6068 Transmission mount
3 W505466-S439 Transmission mount outer
bolts (4 required)
4 N804518-S439 Transmission rear support
insulator center bolt
Section 100-02.
4. Remove the 4 transmission mount outer bolts.
transmission.
5. Remove the transmission rear insulator center
3. Loosen the 2 transmission rear support insulator
bolt. Carefully pry the exhaust brackets from
nuts.
the exhaust insulators on the rear transmission
mount. Remove the transmission mount.
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6. Remove the 2 transmission rear support 7. To install, reverse the removal procedure.
insulator nuts. Separate the transmission rear
support insulator from the transmission mount.
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INSTALLATION
Installation
Transmission
1. NOTE: Insert the clutch hydraulic line into the
Material
clutch slave cylinder and install the clip before
Item Specification
tightening the transmission-to-engine bolts.
NOTE: Before installing the transmission, the
input shaft must be cleaned and lubricated with
Fluid
XT-2-QDX (US); grease.
XT-2-LM12 (Canada)
To install, reverse the removal procedure. For
additional information, refer to Transmission in
Grease
this section.
CXG-1-C (Canada) Check, and as necessary, fill the
transmission with transmission fluid. The Threadlock and Sealer WSK-M2G351-A5
TA-25 total fill capacity is 3.0 liters (6.3 pints).
Fill the brake and clutch reservoir. Bleed the
clutch hydraulic system. For additional
2. Apply threadlock and sealer to the fill plug
threads and install the fill plug.
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REMOVAL
Transmission
Removal
Section 100-02.
3. Remove the catalytic converter H-pipe. For
8. If transmission disassembly is necessary, drain
the transmission fluid.
6. Disconnect the reversing lamp switch electrical
connector. Disconnect the wiring harness from
the transmission.
9. Position a transmission jack and support the
transmission.
7. Disconnect the OSS sensor electrical connector.
Disconnect the wiring harness from the
transmission.
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REMOVAL (Continued)
10. Remove the transmission crossmember. 12. Release the clutch hydraulic line clip and
separate the connector from the clutch slave
1 Remove the crossmember-to-transmission
cylinder.
bolt.
2 Remove the 4 crossmember-to-frame bolts.
13. Remove the 8 transmission-to-engine bolts.
To install, tighten 45 Nm (33 lb-ft).
14. Pull the transmission rearward until the input
11. Lower the transmission 25.4 mm (1 in). shaft is clear of the pressure plate, then lower
Disconnect the shift linkage from the the transmission from the vehicle.
transmission.
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ASSEMBLY
Special Tool(s)
Transmission
308-024 (T75L-7025-B)
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
Replacer/Adapter
308-239 (T96P-7025-A)
307-003 (T57L-500-B)
Material
Item Specification
204-039 (T77F-1217-B)
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
Grease
Adapter for 303-224 (Handle)
CXG-1-C (Canada)
205-153 (T80T-4000-W)
TA-25
Sealant
TA-30
Installer, Axle Shaft Oil Seal
205-123 (T78P-1177-A)
fluid during assembly.
2. Attach the transmission clutch housing to the
special tool.
3. NOTE: If a new front input shaft bearing or
(Continued)
front countershaft bearing was installed, install
the new bearing cups.
Install the input shaft bearing cup and the
countershaft bearing cup. Do not install the
shims at this time.
4. Install the input shaft.
5. Install the output shaft onto the input shaft.
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6. Install the countershaft. 10. NOTE: Rotate the countershaft to seat the
bearings.
Lift the output shaft upward, tilt the
countershaft and install. Using the special tools, measure the
countershaft gear end play by pulling upward
7. Install the transmission case and tighten the
on the countershaft. Record the measurement.
bolts.
Unscrew the installer from the handle. Insert
the handle into the adapter plate plug hole.
Countershaft preload specification is
0.0127-0.0889 mm (0.0005-0.0035 in).
8. NOTE: Rotate the transmission so that the
input shaft is pointing downward.
11. Assemble the bolts and the transmission case.
NOTE: Rotate the input shaft/output shaft to
seat the bearings.
12. Remove the countershaft.
Using the special tools, measure the input
13. Remove the output shaft.
shaft/output shaft end play by applying an
upward load on the input shaft. Record the
measurement.
Input/output shaft preload specification is
15. Remove the input shaft bearing cup and the
0.0127-0.0889 mm (0.0005-0.0035 in).
countershaft bearing cup.
16. Using special tools 205-153 and 204-039, install
the new input shaft seal.
17. Using the recorded end play measurements,
select and install the appropriate shims to
achieve the correct end play. Install the front
input shaft bearing cup and the front
countershaft bearing cup.
Lubricate the bearing cups with petroleum
jelly.
18. Install the input shaft and 4th gear synchronizer
blocking ring.
9. Reposition the special tool on the countershaft.
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19. Assemble the shift rail assembly to the output
shaft, then install the output shaft and shift rail
as an assembly.
Rotate the output shaft to engage the 4th
gear synchronizer blocking ring with the
synchronizer keys.
22. Clean the mating surfaces of the transmission
main case and the transmission clutch housing.
Apply a bead of silicone rubber to the sealing
surface on the transmission clutch housing.
Install the shift lever detent, spring and bolt.
Make sure the transmission is in NEUTRAL
to keep the 3rd/4th gear shift rail from
20. Lift up the output shaft, then install the
engaging. Check for correct alignment of
countershaft.
roller with top shift rail.
Install the shaft lever guide plate bolts.
21. Install the 5th/6th and reverse shift rail
assembly and align the slots of the shift levers
with the shift interlock plate.
Compress the front offset lever against the
guide plate when installing.
Tighten the bolts in a star pattern to 35 Nm
(26 lb-ft).
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23. Apply threadlock and sealer to the threads of 29. Install the 5th/6th gear shift fork and the 5th/6th
the shift lever guide bolts, then install the bolts. gear synchronizer as an assembly.
Pull up on the 5th/6th shift rail to align the
30. Install the new 5th/6th shift fork snap ring.
slot of the interlock plate with the guide bolt
hole.
31. Install the snap ring on the countershaft.
24. Install a new front offset lever roll pin.
32. Install the 5th/6th gear synchronizer double
Install the pin until it is flush with the lever.
cone as an assembly.
25. Apply threadlock and sealer to the threads of
the shift detent, then install the shift detent
assembly.
33. Install the spacer and the 5th drive gear needle
bearing.
26. Install the thrust washers, the spacer and the
5th/6th gear needle bearing.
27. Install 5th/6th gear.
28. Install the 5th/6th gear synchronizer double
cone as an assembly.
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34. Install the following components:
The 5th drive gear.
The 5th drive gear thrust washer.
A new 5th drive gear snap ring.
35. Using a suitable driver, install the reverse drive
gear.
39. Install the reverse shift fork, the reverse
synchronizer and the strut retainer as an
assembly.
36. Install a new reverse drive gear snap ring.
40. Install the reverse shift fork snap ring.
37. Using the special tool, press the 5th driven
gear.
Align the splines of the 5th driven gear with
the drive gear on the countershaft extension.
38. Install the split ring.
41. Install a new reverse gear synchronizer snap
ring.
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42. Install the reverse gear synchronizer blocking 45. Install the reverse gear thrust washer.
rings.
46. Install a new reverse gear snap ring.
43. Install the reverse gear needle bearing.
47. Install the lower spacer, the rear output shaft
44. Install reverse gear. roller bearing and the upper spacer.
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48. Install the rear output shaft roller bearing snap
ring.
52. Install the vent hose.
53. Install the shift detent cover and the 4 shift
49. Position the check ball on the shaft. Install the detent cover bolts.
OSS sensor tone wheel. Install a new OSS
sensor tone wheel retaining ring.
54. Install the output shaft flange.
50. Install the bearing spacer and the race.
55. Install the output shaft flange nut as follows:
Using the old flange nut, tighten to 135 Nm
(100 lb-ft).
Remove the nut and discard.
Install a new flange nut and tighten to 142
Nm (105 lb-ft).
main case and the extension housing. Apply a
bead of silicone rubber to the sealing surface on
the transmission case. Install the extension
housing and tighten the bolts.
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56. Apply thread sealer to the plug threads. Install 57. Install the clutch slave cylinder and the 2 clutch
the drain plug. slave cylinder bolts.
58. Install the clip and the line connector.
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ASSEMBLY
Material
Transmission
Item Specification
Special Tool(s) MERCON Multi-Purpose MERCON
Fluid
Holding Fixture
XT-2-QDX (US);
100-002 (TOOL-4201-C) or
XT-2-LM12 (Canada)
equivalent
TA-24
XG-4 and/or XL-5
Gauge, Clutch Housing Clear Silicone Rubber ESB-M4G92-A
308-021 (T75L-4201-A) TA-32
Grease
CXG-1-C (Canada)
1. NOTE: Soak the blocking rings in transmission
Installer, Transmission
fluid for 10 minutes.
Extension Housing Oil Seal
308-227 (T94P-7657-A) Lubricate all components with transmission
2. Position the countershaft cluster gear in the
case.
307-003 (T57L-500-B)
308-052 (T77J-7025-B)
Installer, Torrington Bearing
308-083 (T83P-7025-AH)
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support the case during bearing installation
will result in permanent distortion of the
case.
Using the special tools and a press, install the
rear countershaft bearing assembly.
1 Position two 6.35 mm (0.25 in) pieces of
bar stock between the countershaft and the
case.
2 Press the rear countershaft bearing assembly
in the case.
5. Install the rear countershaft bearing cup.
6. NOTE: Do not install the shims at this time.
Install the countershaft rear bearing retainer.
4. Position the reverse idler gear and bushing in
the case with the shift lever groove facing the
rear of the case. Install the reverse idler gear
shaft and the reverse gear overtravel stop.
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7. Using the special tool, measure the countershaft
cluster gear end play.
If the end play is not within specification,
remove the countershaft rear bearing retainer
and install the necessary thickness shim(s).
Reinstall the countershaft rear bearing
retainer and recheck the end play.
Bend the tabs of the countershaft rear
bearing retainer over the bolts when the end
play adjustment is complete.
10. NOTE: Observe the reverse positioning spring
rotation. The spring must rotate
counterclockwise into its installed position.
Install the reverse shift fork.
Place the reverse idler gear and bushing into
the NEUTRAL position. Align the reverse
shift fork and the reverse idler gear and
bushing. Push downward on the reverse shift
fork until fully engaged into the reverse
idler gear and bushing.
8. Install a new pin.
11. Install the output shaft assembly.
9. Align the reverse gearshift lever, the reverse
shift fork and the reverse positioning spring.
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12. Apply pipe sealant to the shift lever reverse pin
threads. Position the looped end of the reverse
positioning spring around the shift lever reverse
pin. Install the pin.
15. NOTE: Verify that the 4th speed synchronizer
blocking ring is still in position.
Align the flat on the 4th gear clutching teeth
with the countershaft cluster gear, then install
the input shaft.
13. Install the roller bearings, the input shaft
bearing spacer, the thrust bearing and the thrust
washer.
Coat the 15 bearings, the spacer, the thrust
bearing and the thrust washer with grease.
16. NOTE: Do not install the end play shims at
this time.
NOTE: Do not apply sealant to the input shaft
bearing retainer at this time.
Install the bearing race in the bearing retainer.
14. Install the 4th gear synchronizer blocking ring.
Align the notches in the synchronizer
blocking ring and the synchronizer hub
inserts.
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17. Install the input shaft bearing retainer with the 20. Install the reverse gear shift rail.
notch facing upward.
Align the ball stud with the slot in the case
and align the reverse gear shift rail with the
reverse shift fork. Once the ball stud enters
the case, rotate the reverse gear shift rail
until the ball aligns with the reverse
gearshift lever. Rotate the reverse gear shift
rail counterclockwise until the ball stud fully
engages the reverse gearshift lever.
18. Install the 4 input shaft bearing retainer bolts.
21. Install the 5th gear shifter fork, the
synchronizer blocking ring, the synchronizer
assembly and the 5th gear shifter fork pin as an
assembly.
19. Install 5th gear and the output shaft rear bearing
cup.
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22. CAUTION: To prevent component 25. CAUTION: Do not under any
damage when installing the extension circumstance apply silicone sealant to the top
housing, the alignment tab on the reverse of the transmission case. The sealant could
brake ring must engage the alignment slot in fall into the transmission and affect
the extension housing. transmission operation.
Install the synchronizer blocking ring, the Apply a 3.2 mm (1/8 in) bead of silicone
reverse brake ring, the thrust washer and the rubber to the sealing surface on the case cover.
5th speed synchronizer retaining snap ring.
26. NOTE: Verify that all of the synchronizers are
in the NEUTRAL position and the gear shifter
forks in the cover are in the NEUTRAL
position.
Install the case cover.
Position the cover toward the filler plug side
of the transmission and lower it until the
gear shifter forks engage the synchronizers.
Continue to lower the cover and move it
into position to engage the reverse gearshift
lever.
23. Apply pipe sealant to the reversing lamp switch
threads and install the switch.
27. Install the 10 case cover bolts.
28. Install a new output shaft bearing and a new
snap ring.
24. Install the reverse gearshift lever retaining clip.
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29. Using the special tool, install a new output 32. Install the small output shaft spacer.
shaft seal.
33. Apply a 3.2 mm (1/8 in) bead of silicone
30. Install the large output shaft spacer. rubber to the sealing surface on the extension
housing.
31. Install a new check ball.
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34. Install the detent ball, the shifter detent spring
and the gearshift offset lever.
1 Coat the shifter detent spring with
petroleum jelly and install it in the gearshift
offset lever.
2 Lubricate the detent plate and install the
detent ball in the NEUTRAL position on
the plate.
3 Position the gearshift offset lever in the
extension housing with the gear shift
interlock spring over the detent ball.
36. Install the identification tag and the 7 extension
housing bolts.
35. CAUTION: To prevent component
damage, the alignment tab on the reverse
brake ring must align with the alignment slot
in the extension housing.
37. Install a new roll pin and the gearshift shaft
NOTE: Verify that the oil pick-up funnel
bushing.
engages the 5th gear synchronizer.
Slide the gearshift offset lever and the extension
housing into place as an assembly. Press
downward on the gearshift offset lever to
compress the shifter interlock spring and push
the gearshift offset lever and extension housing
into place.
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38. Install the spring, the shift lever and the
41. CAUTION: Install the thickest shim
gearshift shaft.
closest to the front bearing cup to provide
support for the cup.
CAUTION: Although zero end play is
the ideal, end play up to 0.05 mm (0.002 in)
is an acceptable tolerance. Do not overload
the bearings with a shim that is too thick as
damage may occur.
NOTE: Select a shim with a thickness equal to
the dial indicator reading. This will provide
zero end play.
Rotate the transmission to the horizontal
position and remove the input shaft bearing
retainer. Remove the bearing race and install
the necessary shim(s).
39. Install a new gearshift lever offset lever roll
pin.
42. CAUTION: Do not cover the notch in
the input shaft bearing retainer with sealer.
40. Using the special tools, measure the output
shaft end play.
Apply a 3.2 mm (1/8 inch) bead of silicone
rubber to the sealing surface on the input shaft
1 Place the transmission in a vertical position.
bearing retainer.
3 Push upward on the input shaft and record
43. Install the input shaft bearing retainer and the 4
the dial indicator reading.
bolts.
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44. Apply a 3.2 mm (1/8 inch) bead of silicone 47. Install the output shaft speed (OSS) sensor.
rubber to the sealing surface on the gearshift
lever.
45. Install the shift cover plate and the 4 shift cover
plate bolts.
48. Install the output shaft oil seal.
49. Install the output shaft flange, washer and nut.
50. Install the clutch housing to the transmission.
46. NOTE: Apply thread sealant to the drain plug
threads.
Install the drain plug.
51. Install a new clutch slave cylinder retaining
clip.
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52. Install the clutch release slave cylinder.
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REMOVAL
4. Separate the wiring harness from the
Transmission
transmission.
Disconnect the catalyst monitor sensor
NOTE: Do not separate the transmission from the
(CMS) electrical connector.
clutch housing. Remove the transmission and clutch
housing as an assembly.
Disconnect the reverse lamp switch
Disconnect the wiring harness clips.
Disconnect the output shaft speed (OSS)
Section 100-02.
2. NOTE: Index-mark the driveshaft to the output
shaft flange.
Remove the 4 driveshaft bolts and separate the
driveshaft from the output flange. Position the
driveshaft aside.
Using mechanics wire, support the
driveshaft.
3. Disconnect the shift linkage from the
transmission.
5. Remove the 2 starter motor bolts and the starter
motor. Position the starter motor aside.
Using mechanics wire, support the starter
motor.
transmission.
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REMOVAL (Continued)
7. Remove the 4 crossmember bolts and the 8. Release the clutch hydraulic line clip and
transmission mount nut. Move the crossmember separate the connector from the clutch slave
downward to slide the exhaust isolators from cylinder.
the brackets. Remove the crossmember.
9. Loosen the 4 exhaust manifold nuts.
shaft is clear of the pressure plate, then lower
the transmission from the vehicle.
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DISASSEMBLY
Special Tool(s)
Transmission
Removal Screw, Bearing Tube
308-092 (T84T-7025-B)
Special Tool(s)
307-003 (T57L-500-B)
307-523
Puller, Bearing
205-D064 (D84L-1123-A)
Disassembly
2 or 3 Jaw Puller NOTE: During disassembly, if any roll pins,
205-D027 (D80L-1013-A)
retaining rings or bearings are removed, install new
components. Install bearings and bearing cups as a
set only.
wear is in place.
Remover, Mainshaft Bearing
Clean the transmission exterior with solvent and
308-058 (T77J-7025-H)
dry with compressed air. During disassembly,
clean all components with solvent and dry with
compressed air.
2. Remove the 2 clutch slave cylinder bolts and
the clutch slave cylinder.
308-025 (T75L-7025-C)
(Continued)
3. Remove the clip and the line connector.
4. Using special tool 307-003, attach the
transmission to the special tool.
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5. Rotate the transmission to a vertical position. 10. Remove the 8 bolts and carefully separate the
extension housing from the transmission.
6. NOTE: Position a drain pan under the
transmission.
If the transmission was not drained during
removal, drain the transmission.
11. Remove the 4 shift detent cover bolts and the
shift detent cover.
7. Rotate the transmission to a horizontal position. 12. Rotate the transmission, with the output shaft
pointing upward.
8. Remove the output shaft flange nut.
13. Remove the bearing race and the spacer.
9. Using the special tools, remove the output shaft
flange.
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14. Remove the output shaft speed (OSS) sensor 16. NOTE: Position the gearshift lever in 3rd/4th
tone wheel retaining ring, the tone wheel and neutral position.
the ball.
Using a 5/32-inch drift and a hammer, drive the
roll pin downward, then remove the rear shift
lever and the reverse shift rail.
Discard the roll pin.
17. Remove the following:
1 The reverse gear snap ring.
2 The reverse gear thrust washer.
3 The reverse gear.
Discard the reverse gear snap ring.
Inspect reverse gear for wear or damage.
Install a new gear as necessary.
15. Remove the snap ring, the rear output shaft
roller bearing and the upper and lower spacers.
Inspect the rear output shaft roller bearing
for wear or damage. Install a new bearing as
necessary.
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18. Remove the reverse gear needle bearing.
22. Remove the reverse shift fork and the reverse
synchronizer.
19. Remove the 3 piece reverse gear synchronizer
blocking ring.
23. Inspect the synchronizer for the following:
Check keys for wear or distortion. Check
20. Remove the reverse gear synchronizer snap
the springs for distortion. Install a new
ring.
21. Remove the reverse shift fork snap ring.
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24. Inspect the synchronizer blocking ring for the
following:
Check for wear or damage. Install a new
synchronizer blocking ring as necessary.
gear.
27. Remove the 5th/6th shift fork snap ring.
rotating the blocking ring. The Discard the snap ring.
new blocking ring.
28. Remove the reverse drive gear snap ring.
Discard the snap ring.
25. Remove the 5th driven gear 3 piece retainer.
26. Using the special tools, remove the 5th driven
gear.
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29. Using a suitable puller, remove the reverse
drive gear.
Inspect reverse drive gear for wear or
damage. Install a new gear as necessary.
32. Remove the 5th/6th gear synchronizer
intermediate cone, the 5th/6th gear synchronizer
outer cone and the 5th/6th gear synchronizer
blocking ring.
1 The 5th drive gear snap ring.
2 The 5th drive gear thrust washer.
3 The 5th drive gear.
Discard the snap ring.
Inspect the 5th drive gear for wear or
damage. Install a new gear as necessary.
1 Snap ring and the 5th/6th gear shift fork.
2 The 5th/6th gear shift fork and 5th/6th gear
synchronizer.
31. Remove the 5th/6th drive gear needle bearing
and spacer.
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34. Remove the 5th/6th gear synchronizer
intermediate cone, the 5th/6th gear synchronizer
outer cone and the 5th/6th gear synchronizer
blocking ring.
38. Remove the vent hose.
39. NOTE: Rotate the transmission to a vertical
position.
Remove the shift lever guide bolts.
35. Remove 6th gear.
40. Remove the 5th/6th and reverse shift lever
36. Remove the 6th gear needle bearing, the spacer
detent bolt, spring and detent.
and the thrust washer.
37. Remove 9 of the adapter-to-transmission case
bolts.
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41. Remove the 2 remaining adapter-to-transmission 47. Remove the input shaft bearing cup and input
case bolts, then remove the transmission case shaft shim.
and the front offset lever.
Inspect the cup for wear or damage. Install a
Slide the transmission case upward, off the new cup and bearing as necessary.
output shaft and shift rails. Hold the offset
Inspect the cup bore for wear, scratches or
lever against the guide plate to prevent the
grooves. Install a new transmission adapter
release of the detent ball and spring.
plate as necessary.
42. Rotate the 5th/6th and reverse shift levers from
48. Remove and discard the input shaft seal.
the shift interlock plate, then remove the 5th/6th
and reverse shift rail assembly.
wear is in place.
43. Lift up the output shaft, then remove the
Clean the transmission clutch housing with
countershaft.
solvent and dry with compressed air. Inspect
the clutch housing for cracks. Clean and check
44. Remove the output shaft and shift rail as an
the sealing surface for nicks or scratches.
assembly. Separate the shift rail assembly from
the output shaft on the work bench.
If the clutch housing is cracked, install a
new housing. If the sealing surface has nicks
45. Remove the input shaft, the 4th gear
or scratches, use a soft stone or crocus cloth
synchronizer blocking ring and the double cone
to remove.
(3 rings).
46. Remove the countershaft bearing cup and the
countershaft shim.
Inspect the cup for wear or damage. Install a
new cup and bearing as necessary.
Inspect the cup bore for wear, scratches or
grooves. Install a new transmission adapter
plate as necessary.
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ASSEMBLY
Special Tool(s)
Transmission
Adapter for 308-220 (handle)
205-153 (T80T-4000-W)
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
Installer, Input Shaft Oil Seal
308-220 (T94P-7025-AH)
307-003 (T57L-500-B)
Material
Item Specification
308-024 (T75L-7025-B)
Fluid
XT-2-QDX (US);
XT-2-LM12 (Canada)
TA-25
Replacer/Adapter Clear Silicone Rubber ESB-M4G92-A
308-239 (T96P-7025-A) TA-32
Assembly
NOTE: Install new roll pins, retaining rings or
bearings that were removed during disassembly.
Install bearings and bearing cups as a set.
Installer, Output Shaft Oil Seal
308-246 (T96P-7127-A) or use
205-115
2. Attach the clutch housing to the special tool.
(Continued)
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3. NOTE: If a new rear output shaft bearing was 6. Install the reverse idler gear on the shaft.
installed or a new rear countershaft bearing is
being used, install new bearing cups.
Install the rear countershaft bearing cup and the
rear output shaft bearing cup.
Lubricate the bearing cups and the shift rail
bearing with petroleum jelly.
7. Install the reverse idler gear into the case.
4. Install the rear countershaft bearing.
8. Install a new seal on the reverse idler bolt, then
install the bolt in the transmission case.
5. Install the reverse idler gear bearing on the
reverse idler gear shaft.
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9. NOTE: If a new front input shaft bearing or 12. Install the mainshaft onto the clutch housing.
front countershaft bearing was installed, install
The notches on the shift rail should be
new bearing cups.
pointing upward.
Install the front input shaft bearing cup and the
Align the shift rails in the bores.
front countershaft bearing cup. Do not install
The 3rd/4th shift fork has an oil deflector
the shims at this time.
that will line up with an oil deflector on the
Install the transmission main case.
inside of the case.
Make sure the 3rd/4th synchronizer blocking
ring is aligned with the slots in the 3rd/4th
synchronizer hub.
10. Install the input shaft with the 3rd/4th
11. Install the shift rails and shift forks on the
mainshaft.
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13. Using a jack and a block of wood, lift the
mainshaft 13 mm (0.50 in) upward, then tilt the
countershaft inward and install the countershaft.
Make sure all synchronizer assemblies are in
the neutral position.
16. Rotate the transmission so that the input shaft is
pointing downward.
14. Install the case while holding the countershaft
bearing in place. Install 2 opposing bolts.
15. NOTE: Rotate the transmission so that the
input shaft is pointing upward.
NOTE: Rotate the input shaft to seat the
bearings.
Using the special tools, measure the input shaft
end play by applying an upward load on the
output shaft. Record the measurement.
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17. NOTE: Rotate the countershaft to seat the 19. Using a jack and a block of wood, lift the
bearings. mainshaft 13 mm (0.50 in) upward, then tilt the
countershaft outward and remove the
Using the special tools, measure the
countershaft.
countershaft gear end play by pulling upward
on the countershaft. Record the measurement.
18. Remove the 2 bolts and lift the transmission
main case off.
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20. While holding the mainshaft, release the jack
and remove the mainshaft and shift assembly.
23. Using the special tools, install the new input
shaft seal.
24. Using the recorded end play measurements,
select and install the appropriate shims to
achieve the correct end play.
22. Remove the front input shaft bearing cup and
the front countershaft bearing cup.
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25. Install the front input shaft bearing cup and the
front countershaft bearing cup.
26. Install the input shaft and the 3rd/4th
27. Install the mainshaft.
The notches on the shift rail should be
pointing upward.
Align the shift rails in the bores.
The 3rd/4th shift fork has an oil deflector
that will line up with an oil deflector on the
inside of the case.
Make sure the 3rd/4th synchronizer blocking
ring is aligned with the slots in the 3rd/4th
synchronizer hub.
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28. Using a jack and a block of wood, lift the
countershaft inward and install the countershaft.
30. Install the clutch housing-to-main case bolts.
Tighten the bolts in a star pattern to 32 Nm
(24 lb-ft).
main case and the clutch housing. Apply a bead
of silicone rubber to the sealing surface on the
clutch housing, then install the transmission
main case.
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31. Install the lock pins.
35. Install the check ball.
32. Install the lock plate and the lock plate bolts.
place.
36. NOTE: The thrust washer is positioned with
33. Install the 3 detents and the 3 detent springs.
the flat surface facing upward towards 5th gear.
Install the thrust washer and the 5th gear needle
bearings.
34. Install the 3 detent plugs.
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37. Place the 5th gear synchronizer blocking ring
and the synchronizer hub on the countershaft
5th gear. Install the synchronizer springs and
inserts.
40. Install the 5th gear synchronizer cone.
38. Install the sliding sleeve on the synchronizer
hub.
Align the pockets in the blocking ring with
the struts in the synchronizer.
The sliding sleeve is not reversible. Install
the sleeve with the pointed teeth on the
synchronizer sleeve away from 5th gear.
41. Install the 5th gear shift fork, the synchronizer
assembly, the synchronizer cone and 5th gear as
an assembly.
Lubricate the shift rail with transmission
fluid. Using a plastic hammer, alternately
tap the shift fork and the synchronizer cone
into position.
39. Install 5th gear synchronizer blocking ring.
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42. Install a new split pin. 45. Install new plastic spacers on the main shift
rail.
Install the pin until it is flush with the fork.
46. Install the main shift rail, then install the
1st/2nd shift finger. Install new split pins.
Install the split pins until it is flush with the
shift finger and the shift rail.
43. Install a new snap ring.
47. Install the OSS sensor tone wheel check ball.
place.
44. Install the 3rd/4th shift finger, then install a
new split pin.
Install the split pin until it is flush with the
shift finger.
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48. Place the OSS sensor tone wheel on the output 51. Install the 5th/reverse gear lockout side bolt.
shaft, aligning the slot in the OSS wheel with
the check ball. Using the special tool, install the
OSS sensor tone wheel.
The OSS sensor tone wheel is brittle. Gently
tap the tone wheel into position.
main case and the extension housing. Apply a
bead of silicone rubber to the sealing surface of
the transmission case.
49. Install a new OSS sensor tone wheel retaining
ring.
53. Install a new split pin in the gear shift offset
lever.
50. Install the 5th/reverse gear lockout spring, arm,
The split pin should be flush in the gear
seal and top bolt.
shift offset lever.
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54. Seat the extension housing and install the bolts. 56. Install the output shaft speed (OSS) sensor.
Tighten to 32 Nm (24 lb-ft). Tighten to 10 Nm (89 lb-in).
Fill the gear shift offset lever with
petroleum jelly.
57. Position the output flange onto the output shaft.
Install the output flange nut and tighten until
the output flange is fully seated onto the output
55. Position a new extension housing seal onto the
shaft.
extension housing. Using the special tool, install
the extension housing seal.
58. Remove the nut.
Lubricate the seal with transmission fluid.
59. Install the output flange oil seal, the output
flange washer and the output flange nut.
60. Install a new plastic retainer.
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61. Install the clutch slave cylinder. For additional 62. Install the clutch slave cylinder connector and
information, refer to Section 308-02. engage the clip.
63. Fill the transmission with transmission fluid to
the specified level.
Transmission capacity is 3.0 liters (6.3
pints).
64. Apply threadlock and sealer to the fill plug
threads and install the fill plug.
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INSTALLATION
Transmission
engine, connect the hydraulic line to the clutch
slave cylinder.
Material
Item Specification
the Removal portion of this section.
Fluid Check and as necessary, fill the transmission
XT-2-QDX (US);
with the specified fluid. The total fill
XT-2-LM12 (Canada)
capacity is 2.6L (2.8 qt).
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DISASSEMBLY
Transmission
Special Tool(s)
Puller, Bearing
205-D064 (D84L-1123-A) or
equivalent
Remover/Installer, Front Wheel
Hub
204-069 (T81P-1104-C)
2. Remove the 4 clutch housing bolts.
Separate the clutch housing from the
transmission.
Remover, Front Wheel Hub
205-D070 (D93P-1175-B) or
equivalent
307-003 (T57L-500-B)
3. WARNING: Make sure protective
eyewear is in place.
Staking Tool, Locknut
308-056 (T77J-7025-F)
compressed air.
1. Remove the clutch slave cylinder and the
retaining clip. Discard the clip.
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4. NOTE: Position the gearshift lever in
NEUTRAL.
Attach the transmission to the special tool.
8. Remove the 4 bolts and pry the shift cover
plate off.
transmission fluid.
9. CAUTION: Do not attempt to remove
the gearshift offset lever with the extension
housing bolted in place. A lug, located on the
bottom of the gearshift offset lever, meshes
6. Remove the output shaft flange nut. Using the with the detent plate preventing enough
special tool, remove the output shaft flange, the rearward movement of the gearshift offset
washer and the seal. Discard the seal. lever to allow removal.
Using a suitable punch, remove the roll pin.
7. Remove the output shaft speed (OSS) sensor.
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10. Remove the gearshift shaft, the shift lever and
13. CAUTION: The gearshift offset lever is
the spring.
under spring pressure.
While applying downward pressure on the
gearshift offset lever, remove the extension
housing and the gearshift offset lever as an
assembly.
11. Using a suitable punch, remove the gearshift
offset lever roll pin.
14. Remove the gearshift offset lever, the split pin,
the shifter detent spring and the detent ball.
12. Remove the 7 extension housing bolts and the
identification tag.
Carefully pry the extension housing to break
the gasket seal.
15. Using a hammer and a drift, remove the output
shaft seal from the inside. Discard the seal.
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16. Remove the snap ring, then using a hammer
and a drift, remove the output shaft bearing.
20. CAUTION: Support the reverse gear
shift rail with a block of wood.
Remove the roll pin.
17. Remove the small output shaft spacer.
21. Remove the 10 case cover bolts. Carefully pry
18. Remove the check ball.
the case cover to break the gasket seal. Lift the
case cover and slide it toward the filler plug
side of the case to clear the reverse gearshift
lever.
19. Remove the large output shaft spacer.
22. Rotate the transmission with the output shaft
facing upward.
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23. Remove the 5th speed synchronizer snap ring,
29. CAUTION: Do not drop the 15 roller
the thrust washer, the reverse brake ring and the
bearings, the input shaft bearing spacer, the
thrust bearing and the thrust washer from
the rear of the input shaft.
24. Remove the 5th speed cluster gear, the
Remove the input shaft.
synchronizer blocking ring, the synchronizer
Rotate the input shaft until the flat on the
assembly and the 5th gear shifter fork as an
4th gear clutching teeth aligns with the
assembly.
countershaft cluster gear.
30. Remove the 4th gear synchronizer ring, the
thrust washer, the thrust bearing, the input shaft
bearing spacer and the 15 roller bearings.
25. Remove the reverse gear shift rail.
Rotate the reverse gear shift rail clockwise
to disengage the ball stud from the reverse
gearshift lever. Pull the reverse gear shift
rail rearward slightly. Rotate the reverse
31. NOTE: If the output shaft rear bearing cup
gear shift rail counterclockwise to align the
sticks, it is misaligned in the case bore. To free
ball stud with the slot in the case and
the output shaft rear bearing cup, work the
remove the reverse gear shift rail.
output shaft assembly back and forth in the
case.
26. Loosen the rear bearing cup in the case. Pull
Remove the output shaft rear bearing cup.
upward on the mainshaft and remove the 5th
gear.
27. Rotate the transmission with the input shaft
facing upward.
28. Remove the 4 input shaft bearing retainer bolts
and the input shaft bearing retainer.
The input shaft bearing retainer is notched.
Carefully pry the retainer to break the
gasket seal.
32. Remove the output shaft assembly.
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33. Using the special tool, flatten the tabs on the 36. Using the special tools, remove the rear
countershaft rear bearing retainer. countershaft bearing assembly.
34. Remove the 4 bolts, the countershaft rear 37. Remove the reverse gearshift lever retaining
bearing retainer and the shim. clip.
35. NOTE: If the bearing race sticks in the case, it 38. Using a TORX bit driver, remove the shift
is misaligned in the case bore. To free the race, lever reverse pin.
work the countershaft cluster gear back and
39. Remove the reversing lamp switch.
forth.
Remove the bearing race.
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40. NOTE: Observe the location of the reverse 42. Remove the reverse idler gear shaft, the reverse
gearshift lever, the reverse shift fork and the idler gear and bushing and the reverse gear
reverse positioning spring. overtravel stop.
NOTE: Observe the rotation action of the
reverse positioning spring.
Remove the reverse gearshift lever, the reverse
shift fork and the reverse positioning spring as
an assembly.
Hold the reverse gearshift lever and lift it
upward as straight up as possible to remove
the assembly.
43. Move the countershaft cluster gear rearward
through the bearing bore. Tilt the assembly
upward and remove it from the case.
41. Using a suitable punch, remove the roll pin.
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INSTALLATION
Installation
Transmission
Material 1. CAUTION: Align the index marks on
the driveshaft flange and pinion flange, and
Item Specification
the driveshaft flange and transmission output
shaft flange.
Fluid NOTE: Insert the clutch hydraulic line into the
XT-2-QDX (US);
clutch slave cylinder and install the clip before
XT-2-LM12 (Canada)
tightening the transmission-to-engine bolts.
NOTE: Before installing the transmission, the
Grease
input shaft must be cleaned and lightly
CXG-1-C (Canada) lubricated with grease.
NOTE: When installing the transmission with
TA-25
the gearshift lever attached, position the gear
shifter into neutral position, so that the shifter
will not damage the shift boot.
this section.
Check, and as necessary, fill the
transmission with transmission fluid. The
total fill capacity is 3.46L (3.65 qt). Apply
threadlock and sealer to the fill plug threads
and install the fill plug.
Fill the brake and clutch reservoir. Bleed the
clutch hydraulic system. For additional
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REMOVAL
Transmission
Transmission Removal
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REMOVAL (Continued)
6. Remove the catalytic converter assembly
(H-pipe). For additional information, refer to
1 7K590 Clutch hydraulic line
Section 309-00.
2 Heated exhaust gas oxygen
sensor (HO2S) electrical
connector
3 Reverse lamp electrical
connector
8. Remove the 4 subframe cross brace bolts and
4 Catalyst monitor sensor
the subframe cross brace.
(CMS) electrical connector
5 7H103 Output shaft speed (OSS)
6 7K187 Reverse lockout electrical
connector
7 CMS electrical connector
8 HO2S electrical connector
9 N606067-S2 Transmission-to-engine bolts
(2 required)
10 N606065-S2 Transmission-to-engine bolts
(5 required)
12 7K502 Hydraulic connector
9. Disconnect the electrical connectors from the
LH side of the transmission. Detach the harness
2. Remove the gearshift lever knob and boot. from the transmission and position it aside.
10. Disconnect the electrical connectors from the
RH side of the transmission. Detach the harness
from the transmission and position it aside.
11. Release the clutch hydraulic line clip and
separate the clutch hydraulic line from the
connector.
3. Remove the upper gearshift lever bolts and the
upper gearshift lever.
Section 100-02.
12. If transmission disassembly is necessary, drain
the transmission fluid.
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REMOVAL (Continued)
13. Using a suitable transmission jack, support the 19. If necessary, remove the rear transmission
transmission. insulator center bolt and remove the
transmission mount.
Securely strap the jack to the transmission.
14. Remove the 4 rear transmission mount outer
bolts. 20. If necessary, remove the gearshift lever
assembly.
1 Insert a pick into the lower hole to unlock
the clip.
2 Rotate the gearshift lever retainers, then
remove the retainers.
3 Remove the gearshift lever bolt.
4 Remove the gearshift lever assembly.
15. Lower the transmission.
16. Remove the 2 rear gearshift lever nuts.
shaft is clear of the pressure plate, then lower
the transmission from the vehicle.
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DISASSEMBLY
Disassembly
Transmission
NOTE: If any roll pins, retaining rings or bearings
Special Tool(s)
are removed during disassembly, install new
Remover, Mainshaft Bearing
components. Install bearings and bearing cups as a
308-058 (T77J-7025-H)
set.
1. WARNING: Make sure protective
eyewear is in place.
307-003 (T57L-500-B)
compressed air.
2. Attach the transmission to the special tool.
Remover, Bushing
307-001 (TOOL-1175-AC)
Puller, 2 Jaw
205-D027 (D80L-1002-L) or
equivalent
Remover, Front Wheel Hub
205-D070 (D93P-1175-B) or
equivalent
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3. Remove the output flange nut, washer and oil 6. Using the special tool, remove the extension
seal. housing fluid seal.
4. Using the special tool, remove the output 7. Remove the output shaft speed (OSS) sensor.
flange.
8. Remove the 12 bolts.
5. NOTE: Position a drain pan under the
transmission.
Remove the case plug, then rotate the
transmission to a horizontal position.
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9. Using a flat-blade screwdriver, separate the 12. NOTE: Always install a new bearing race if
extension housing, then remove the gearshift installing a new bearing.
offset lever from the transmission case.
Remove the output shaft bearing.
Remove and discard the split pin from the
Inspect the bearing, install a new bearing if
gearshift offset lever during removal.
necessary.
10. Remove the 5th/reverse gear lockout bolt.
bearing race.
11. Remove the snap ring.
14. Remove the bearing race spacer.
15. Remove the OSS sensor tone wheel retaining
ring.
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16. Using the special tools, remove the OSS sensor
tone wheel.
20. NOTE: A flat-blade screwdriver may aid in
removal.
Using the special tool, remove the 5th gear shift
17. Remove the OSS sensor tone wheel check ball.
fork, synchronizer assembly, synchronizer cone
and the 5th gear as an assembly.
18. Remove and discard the 5th gear synchronizer
retaining ring.
21. Remove the 5th gear clutch cone.
19. Using a 5/32-inch drift and a hammer, remove
and discard the pin from the 5th gear shift fork.
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22. Remove the 5th gear synchronizer blocking 25. Remove the 5th gear needle bearings and the
ring. thrust washer.
Inspect the blocking ring for wear or Inspect the needle bearings for wear or
damage. Install new blocking rings as damage. Install new bearings as necessary.
necessary.
26. Remove the check ball.
23. Remove the 5th gear synchronizer sleeve from
the synchronizer hub.
27. Using a 5/32-inch drift and a hammer, drive out
the split pin, then remove the 5th/reverse lever
24. Remove the synchronizer inserts and the fork. Discard the split pin.
springs.
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28. Remove the main shift rail and the 2 plastic
spacers.
32. Remove the bolts and the shift interlock plate.
29. Remove and discard the 2 plastic spacers.
33. Using a magnet, remove the interlock pins.
One lock pin in the center rail, 2 between
the rails.
the split pin, then remove the 3rd/4th shift
finger. Discard the split pin.
the split pin, then remove the 1st/2nd shift
finger. Discard the split pin.
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34. Remove the 5th/reverse gear lockout side bolt. 37. Carefully pry the clutch housing from the
transmission main case.
35. Remove the 5th/reverse gear lockout top bolt,
then remove the seal, arm and spring. 38. Remove the transmission main case from the
clutch housing.
The countershaft bearing will remain in the
housing. Lightly tap the bearing to remove.
Inspect the bearing and install a new one if
necessary.
36. CAUTION: Do not remove all the bolts
while in the horizontal position.
Remove the bolts.
Rotate the transmission to a horizontal
position. Remove 12 bolts, leaving 2
opposing bolts in. Rotate the transmission to
a vertical position, then remove the
remaining 2 bolts.
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39. Remove the 3 detent plugs. 42. Using a jack and a block of wood, lift the
countershaft outward and remove the
countershaft.
40. Remove the 3 detent springs.
41. Remove the 3 detents.
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43. While holding the mainshaft, release the jack
and remove the mainshaft and shift assembly.
46. Remove the reverse idler shaft bolt. Remove
and discard the seal.
47. Remove the reverse idler gear assembly.
44. Remove the input shaft. For input shaft
disassembly, refer to Input Shaft and Bearing in
48. Remove the reverse idler gear from the shaft.
this section.
45. Carefully remove the shift rails and shift forks
from the main shaft. For gearshift rail and fork
disassembly, refer to Gearshift Rail and Fork in
this section.
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49. Remove the reverse idler gear bearing. 53. Disassemble the clutch housing.
Inspect the bearing for wear or damage. 1 Remove the countershaft bearing cup and
Install new bearings as necessary. shim.
2 Remove the input shaft bearing cup and
shim.
3 Remove the input shaft seal.
X Carefully pry out from the inside of the
case.
50. Release the clip and remove the clutch slave
cylinder connector.
51. Remove the clutch slave cylinder. For
52. Remove and discard the plastic retainer.
54. Remove the rear countershaft bearing.
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55. Remove the rear countershaft bearing cup and
the rear output shaft bearing cup.
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309-00-1 309-00-1 Exhaust System
SPECIFICATIONS
Exhaust isolator bracket bolts 25 18
Exhaust coupler nuts
a

Exhaust manifold
Intermediate pipe damper 25 18
stud-to-catalytic converter
nuts
a
Tailpipe damper 25 18
Exhaust clamp nuts 54 40
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6. NOTE: Hand-tighten all the catalytic converter
Catalytic Converter 4.0L
nuts.
Removal and Installation Remove and discard the 2 RH catalytic
converter-to-exhaust manifold nuts.
X Starting with the upper nut, alternately
Section 100-02.
tighten, in 10 Nm (89 lb-in) increments,
the RH catalytic converter-to-exhaust
2. Using a jackstand, support the muffler.
manifold nuts to specification.
3. Loosen the exhaust coupler and disconnect the
intermediate pipe from the catalytic converter
assembly. Discard the exhaust coupler.
4. CAUTION: When repairing the
exhaust system or removing exhaust
components, disconnect all heated oxygen
sensors (HO2S) and catalyst monitor sensors
at the wiring connectors to prevent damage
to the sensors and wiring harnesses.
Disconnect the RH and LH HO2S electrical
connectors.
7. Remove and discard the 2 LH catalytic
the LH catalytic converter-to-exhaust
5. Disconnect the RH and LH catalyst monitor
sensor electrical connectors.
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8. NOTE: Make sure not to damage the manifold 9. NOTE: Using a Scotch Brite pad, clean the
outlet flare, the converter inlet flare or the mating surfaces of the manifold outlet flare, the
studs. catalytic converter inlet flare, at the catalytic
converter outlet flare and the muffler inlet pipe.
Remove the catalytic converter assembly.
Keep foreign materials out of the catalytic
converters.
NOTE: Using a jackstand, support the catalytic
converter near the rear outlet while positioning
the converter into place. Align the manifold
studs into the pipe flange. Make sure not to
damage the studs or mating surfaces.
Make sure to correctly align the catalytic
converter to the exhaust manifold before
installing the fasteners. The catalytic
converter is correctly positioned when the
hanger rods are centered in the isolators.
Always install new converter-to-manifold
nuts and exhaust coupler.
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6. NOTE: Hand-tighten all the catalytic converter
Catalytic Converter 4.6L, 5.4L
nuts.
Removal and Installation Remove and discard the 2 RH catalytic
Section 100-02.
the RH catalytic converter-to-exhaust
2. CAUTION: When repairing the
exhaust system or removing exhaust
components, disconnect all heated oxygen
sensors (HO2S) and catalyst monitor sensors
at the wiring connectors to prevent damage
to the sensors and wiring harnesses.
Disconnect the RH HO2S electrical connector.
7. Remove and discard the 2 LH catalytic
the LH catalytic converter-to-exhaust
3. Using a jackstand, support the muffler.
4. Loosen the 2 exhaust couplers and disconnect
the intermediate pipes from the catalytic
converter assembly. Discard the exhaust
couplers.
5. Disconnect the RH and LH catalyst monitor
sensor electrical connectors.
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8. NOTE: Make sure not to damage the manifold 9. NOTE: Using a Scotch Brite pad, clean the
outlet flare, the converter inlet flare or the mating surfaces of the manifold outlet flare, the
studs. catalytic converter inlet flare, at the catalytic
converter outlet flare and the muffler inlet pipe.
Remove the catalytic converter assembly.
Keep foreign materials out of the catalytic
converters.
NOTE: Using a jackstand, support the catalytic
converter near the rear outlet while positioning
the converter into place. Align the manifold
studs into the pipe flange. Make sure not to
damage the studs or mating surfaces.
Make sure to correctly align the catalytic
converter to the exhaust manifold before
installing the fasteners. The catalytic
converter is correctly positioned when the
hanger rods are centered in the isolators.
Always install new converter-to-manifold
nuts and exhaust couplers.
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Exhaust Intermediate Pipe
NOTE: 4.0L has single intermediate pipe, 4.6L and
5.4L have dual. Repeat steps for both sides, if
necessary.
Section 100-02.
8. Push the muffler forward to fully seat the pipe
in the coupler.
Verify that the intermediate pipe is inserted
3. Loosen the muffler clamp and disconnect the
into the coupler correctly. Correct
muffler from the intermediate pipe.
installation is achieved when the coupler
terminates in the knurled region of the
intermediate pipe. The knurled section on
the intermediate pipe must be at the coupler
lip.
4. Remove the intermediate pipe from the vehicle.
5. Install the intermediate pipe.
6. NOTE: Install a new exhaust clamp.
9. Place the new exhaust coupler over the
intermediate pipe. Position the intermediate pipe
Connect the intermediate pipe into the muffler.
to the catalytic converter, slide the coupler into
7. Tighten the exhaust clamp. position until the converter button is seated into
the intermediate pipe notch.
The exhaust clamp should be installed so
that it is up to, but not over, the bottom of
10. Tighten the exhaust coupler nuts.
the notches.
Alternately tighten, in 10 Nm (89 lb-in)
increments.
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Exhaust System Exploded View
Exhaust System 4.0L
7 HO2S electrical connectors 1 Exhaust coupler nuts (2
required) (part of 5A281)
8 N811485-S Catalytic
converter-to-manifold nuts (4 2 5A281 Exhaust coupler
required)
3 Exhaust clamp nut (part of
9 5F250 Catalytic converter assembly 5230)
(Y-pipe)
4 5270 Exhaust clamp
10 W709209-S Exhaust manifold studs (4
5 5230 Muffler
required)
6 5A212 Intermediate pipe
(Continued)
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6 5A246 Front isolator 1 W707079-S RH rear isolator bolt (2
required)
7 W707079-S LH rear isolator bottom bolt
2 5A262 RH rear isolator
8 W707079-S LH rear isolator top bolt
3 5230 Muffler
9 5A246 LH rear isolator
4 W707079-S Front isolator top bolt
5 W707079-S Front isolator bottom bolt
(Continued)
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Exhaust System 4.6L
NOTE: 4.6L shown, 5.4L similar.
6 N811485-S Catalytic 1 5A281 Exhaust coupler
converter-to-manifold nuts (4
2 5270 Exhaust clamp
required)
3 5230/5232 Muffler (RH/LH)
7 5F250 Catalytic converter assembly
4 5A212/5A213 Intermediate pipe (RH/LH)
(H-pipe)
5 HO2S electrical connectors
8 W709209-S Exhaust manifold studs (4
(Continued) required)
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3 W500222-S Front isolator top bolt
4 5A246 Front isolator
5 W500222-S Rear isolator bottom bolt
6 W500222-S Rear isolator top bolt
7 5A246 Rear isolator
1 5230/5232 Muffler (RH/LH)
2 W500222-S Front isolator bottom bolt
(Continued)
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GENERAL PROCEDURES
6. Beginning at the front of the vehicle, align the
Exhaust System Alignment
exhaust system.
1 Hand-tighten all the catalytic converter nuts.
2 Alternately tighten, in 10 Nm (89 lb-in)
Section 100-02.
increments, the upper catalytic
converter-to-manifold nuts to 45 Nm (33
2. Loosen the muffler-to-intermediate pipe clamp.
lb-ft).
X LH upper.
3. Remove and discard the exhaust coupler and
X RH upper.
position a new coupler on the pipe. Do not
tighten the coupler at this time.
3 Alternately tighten, in 10 Nm (89 lb-in)
increments, the lower catalytic
4. Remove and discard the converter-to-manifold
converter-to-manifold nuts to 45 Nm (33
nuts and install new nuts. Do not tighten the
lb-ft).
nuts at this time.
X LH lower.
X RH lower. 5. NOTE: Make sure the exhaust system hanger
rods are correctly inserted into the center of all
4 Verify the intermediate pipe button is fully
the catalyst and muffler isolators.
seated to the bottom of the muffler inlet
pipe notch. Install a jackstand at the rear of the catalytic
converter. Adjust the coverter height by
X Tighten the muffler-to-intermediate pipe
adjusting the jackstand. The catalytic converter
clamp nuts to 54 Nm (40 lb-ft).
is correctly positioned when the catalytic
5 NOTE: Make sure that the intermediate
converter hanger rods are centered in the
pipe is inserted into the coupler correctly.
isolators.
Correct installation is achieved when the
rearmost end of the coupler terminates in
the knurled region of the intermediate pipe.
Slide coupler over catalyst pipe and engage
the coupler clip completely over the
converter button.
6 Push the muffler forward. The back of the
exhaust coupler should be in the
crosshatched area on the intermediate pipe.
X Alternately tighten, in 10 Nm (89 lb-in)
increments, the intermediate
pipe-to-converter assembly coupling(s) to
54 Nm (40 lb-ft).
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7. Start the engine and check the exhaust system
for leaks.
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NOTE: Exhaust fasteners are of a torque prevailing
Exhaust System
design. Use only new fasteners with the same part
WARNING: The normal operating
number as the original. Torque values must be used
temperature of the exhaust system is very high.
as specified during reassembly to make sure of
Never attempt to repair any part of the system
correct retention of exhaust components.
until it has cooled. Be especially careful when
The exhaust system:
working around the 3-way catalytic converter.
The temperature of the catalytic converter rises
contains a one-piece catalytic converter assembly.
to a high level after only a few minutes of engine
has one muffler assembly (4.0L).
operation.
has a LH muffler assembly and a RH muffler
CAUTION: When repairing exhaust system
assembly (4.6L and 5.4L).
or removing exhaust components, disconnect all
has muffler brackets with isolators at the front and
heated oxygen sensors (HO2S) at the wiring
rear of the muffler, bolted to the body.
connectors to prevent damage to the heated
has 2 upstream heated oxygen sensors (HO2S)
oxygen sensors and wiring harness. For
mounted to the catalytic converters (4.0L).
additional information, refer to Section 303-14
for location of the heated oxygen sensors.
has one upstream HO2S mounted to the LH
exhaust manifold and one mounted to the RH
CAUTION: Do not use oil or grease-based
catalytic converter (4.6L and 5.4L).
lubricants on the isolators. They may case
production muffler and tailpipe assembly is a
deterioration of the rubber.
one-piece design exhaust system.
CAUTION: Oil or grease-based lubricants
on the isolators may cause the exhaust hanger
isolator to separate from the exhaust hanger
bracket during vehicle operation.
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Exhaust System
Special Tool(s)
Exhaust Back Pressure Gauge
309-D002 (D95L-6000-A) or
equivalent
Socket, Exhaust Gas Oxygen
Sensor
303-476 (T94P-9472-A)
1. Verify the concern by running the engine (with
the vehicle on the ground) or road testing the
vehicle to duplicate the condition.
2. Visually inspect the components of the exhaust
system and related controls that may affect
exhaust gas quality or loss of power.
mechanical damage. Refer to the following
chart.
Mechanical
Exhaust pipe pinched or crushed
Damaged muffler
Broken or damaged exhaust hanger brackets
Damaged catalytic converter
Cracked exhaust manifold
Dirty engine air cleaner
Loose or damaged heat shields
4. Verify that the exhaust system is installed
correctly, with clamps correctly located and
tightened to specification.
5. If the fault is not visually evident, determine
the symptom. GO to Symptom Chart.
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Symptom Chart
Symptom Chart
Rattle, squeaks or buzz type Loose or damaged heat shield INSPECT the exhaust system
noise from the bottom of for loose or missing heat
vehicle shields or foreign material
trapped between the heat
shields and the exhaust
system components. If any
heat shields are loose,
INSTALL worm gear clamp
7L5Z-5A231-AA and tighten
to 7 Nm (62 lb-in). If the
heat shields are missing,
INSTALL new heat shields or
exhaust system components
as necessary. If a rattle, noise
or buzz condition persists,
INSTALL a new heat shield
or component as necessary.
Loose or damaged exhaust CHECK exhaust isolators are
isolators correctly installed. INSPECT
the exhaust isolators for wear
or damage. INSTALL new
isolators as necessary.
Damaged exhaust isolator INSPECT the exhaust system
hanger bracket components for damage or
broken hangers. INSTALL
CHECK for loose or damaged
exhaust hanger brackets or
fasteners. TIGHTEN bolts to
specification or INSTALL
Loose or damaged catalytic MOVE the exhaust system to
converter or muffler simulate the bouncing action
of the vehicle, checking for
exhaust-to-body contact while
moving the exhaust system.
Using a rubber mallet, TAP
on the exhaust components to
duplicate the noise concern.
Lightly tap on the muffler,
then the catalytic converter.
Determine if there are loose
or broken baffles in the
muffler or a loose or broken
element in the catalytic
converter. REPAIR or
as necessary.
Exhaust grounded to chassis INSPECT for signs of
exhaust components-to-body
contact. If necessary, CARRY
OUT the Exhaust System
Alignment in this section.
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Drone or clunk type noise Loose or damaged exhaust INSPECT exhaust isolators
from bottom of vehicle isolators for wear or damage.
INSTALL new isolators as
necessary.
Exhaust grounded to chassis INSPECT for signs of
exhaust components-to-body
contact. If necessary, CARRY
OUT the Exhaust System
Alignment in this section.
Whistles, boom, hum or Punctures in the muffler REPAIR as necessary.
ticking type noise noise Broken, loose or missing
tends to change as engine exhaust manifold fasteners or
warms. Noises are often gaskets
accompanied by exhaust Loose heated oxygen or
fumes catalyst monitor sensor
Exhaust system leak INSPECT the entire exhaust
system for leaks. CHECK for
punctures, loose or damaged
clamps/fasteners, or broken
welds. EXAMINE the chassis
for grayish-white or black
exhaust soot, which would
indicate exhaust leakage at
that point. To magnify a
small leak, have an assistant
hold a rag over the tailpipe
outlet, while listening for a
leak. REPAIR or INSTALL
Catalytic converter MOVE the exhaust system to
simulate the bouncing action
of the vehicle, checking for
exhaust-to-body contact while
moving the exhaust system.
Using a rubber mallet, TAP
on the exhaust components to
duplicate the noise concern.
Lightly tap on the muffler,
then the catalytic converter.
Determine if there are loose
or broken baffles in the
muffler or a loose or broken
element in the catalytic
converter. REPAIR or
as necessary.
Exhaust muffler/resonator NOTE: Check with vehicle
drain hole enlarged due to on the ground, not on a hoist.
corrosion
CONFIRM drain holes are
noise source. INSTALL new
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Hissing or rushing noise Exhaust system. Exhaust flow CHECK the exhaust system
high frequency sound. through pipes for leaks. Using a rubber
Vehicle performance is mallet, TAP on the exhaust
unaffected components to duplicate the
noise concern. Lightly tap on
the muffler, then the catalytic
converter. Determine if there
are loose or broken baffles in
the muffler or a loose or
broken element in the
catalytic converter. REPAIR
or INSTALL new
Pinging noise occurs when Catalytic converter/exhaust Cool down pinging is the
exhaust system is hot, engine system exhaust system expanding and
turned off contracting during heating
and cooling. Condition is
normal.
Vibration occurs at idle Loose or damage exhaust INSPECT the exhaust
and at low speeds. Also isolator isolators for wear or damage.
accompanied by clunk or INSTALL new isolators as
buzz type noise necessary.
Loose or damaged exhaust INSPECT the exhaust isolator
isolator hanger brackets hanger brackets for wear or
damage. INSTALL or
Damper broken or out of CHECK for the correct
position if equipped damper orientation in this
section. RELOCATE to
correct position and tighten
nuts to specification.
INSPECT for missing or
damaged damper. INSTALL
Exhaust system grounded to CARRY OUT the Exhaust
chassis System Alignment in this
section.
Vehicle has low or no power Exhaust pipe pinched or INSTALL new components
vehicle performance crushed as necessary.
complaint Damaged catalytic converter REFER to the Powertrain
Loose obstruction in exhaust Control/Emissions Diagnosis
(PC/ED) manual.
Restricted exhaust (possible CHECK drain holes for
frozen condensate in muffler) foreign material. PARK the
vehicle inside to thaw. TEST
vehicle for normal operation.
If concern is still present,
REFER to the Powertrain
(PC/ED) manual.
Burning smell usually Foreign material caught in INSPECT the exhaust system
occurs at idle, with possible exhaust system for foreign material. REPAIR
traces of smoke or INSTALL new
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Odor described as a sulfur Catalytic converter At times, a slight sulfur smell
or rotten egg smell is normal for catalytic
converters. The cause is the
sulfur content in the gasoline
being used. ADVISE
customer, no repair required.
Rich fuel conditions REFER to the Powertrain
Miss-fire conditions Control/Emissions Diagnosis
Excessive sulfur content in (PC/ED) manual.
fuel
Visible rust on surface of Catalytic converter/exhaust Surface rust is a characteristic
exhaust pipes system of materials used on exhaust
system. Exposure to heat or
road salt may result in surface
rust. INSPECT for
perforations. If there are no
perforations, condition is
normal.
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10. Tighten the exhaust clamp.
Muffler
The exhaust clamp should be installed so
Removal and Installation that it is up to, but not over, the bottom of
the notches.
NOTE: 4.0L has single muffler, 4.6L and 5.4L
have dual mufflers. Repeat steps for both sides, if
necessary.
Section 100-02.
3. Loosen the muffler clamp and disconnect the
muffler from the intermediate pipe.
11. Place the new exhaust coupler over the
intermediate pipe. Position the intermediate pipe
to the catalytic converter, slide the coupler into
position until the converter button is seated into
the intermediate pipe notch.
12. Push the muffler forward to fully seat the pipe
in the coupler.
Verify that the intermediate pipe is inserted
into the coupler correctly. Correct
installation is achieved when the coupler
terminates in the knurled region of the
intermediate pipe. The knurled section on
4. Remove the intermediate pipe from the vehicle.
the intermediate pipe must be at the coupler
lip.
5. Slide the muffler out of the muffler isolators
and remove from the vehicle.
To install isolators, tighten to 25 Nm (18
lb-ft).
6. If the tailpipe damper is removed or a new one
is installed, install 2 new bolts.
7. Slide the muffler into the isolators.
8. Install the intermediate pipe.
9. NOTE: Install a new exhaust clamp.
Connect the intermediate pipe into the muffler.
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13. Tighten the exhaust coupler nuts.
Alternately tighten, in 10 Nm (89 lb-in)
increments.
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Introduction
Note: The descriptions and specifications contained in this manual were in effect at the time this manual
was approved for publication. Ford Motor Company reserves the right to discontinue models at any time, or
change specifications or design without notice and without incurring obligation.

Important Safety Notice
Appropriate repair methods and procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the personal safety of the individual doing the work. This manual provides general
directions for repairing vehicles with tested, effective techniques. Following them helps to establish reliability.
There are numerous variations in procedures, techniques, tools, and parts for repairing vehicles, as well as
in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and
provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in
this manual must first establish that they compromise neither their personal safety nor the vehicle integrity
by their choice of methods, tools, or parts.
Notes, Cautions, and Warnings
As you read through the procedures, NOTES, CAUTIONS, and WARNINGS are found throughout the
publication. Each one is there for a specific purpose. NOTES give added information that help to complete a
particular procedure. CAUTIONS are given to prevent making errors that could damage the vehicle.
WARNINGS are to remind the technician to be especially careful in those areas where carelessness may
cause personal injury. The following list contains some general WARNINGS that should be followed when
working on a vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires working under the vehicle.
Make sure that the key is always in the OFF position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If the vehicle is equipped with an automatic
transmission, place the gear selector in PARK unless otherwise instructed for a specific operation. If
the vehicle is equipped with a manual transmission, the gear selector should be in REVERSE (engine
OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood
blocks (4 inch x 4 inch or larger) against the front and rear surfaces of the tires to help prevent the
vehicle from moving.
Operate the engine in a well-ventilated area to avoid the danger of carbon monoxide poisoning.
Keep yourself and your clothing away from moving parts when the engine is running, especially the
drive belts.
2007 PCED On Board Diagnostics Introduction
Procedure revision date: 03/29/2006
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To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold
(s), tail pipe(s), three-way catalytic converter(s), and muffler(s).
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan
blades.

Preface
This manual provides a step-by-step approach for diagnosing driveability, emission, and powertrain control
system symptoms. Before beginning diagnosis, it may be helpful to reference any Technical Service
Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is
available. TSB/OASIS information is available on either the Professional Technician Society (PTS) or
Motorcraft website.
Note: For the diesel engines, refer to the appropriate Diesel Powertrain Control/Emissions Diagnosis
Manual. For the Escape Hybrid or Mariner Hybrid, refer to the Escape Hybrid, Mariner Hybrid Powertrain
Control/Emissions Diagnosis Manual.
This manual is used in conjunction with the Workshop and Wiring Diagrams Manuals. The Workshop
Manuals are used to provide additional diagnostic or component removal and installation information. Refer
to the Wiring Diagrams Manuals for vehicle specific wiring information and component, connector, and splice
locations.
The following is a description of the information contained in each section of this manual.
Section 1: Description and Operation
This section contains description and operation information on powertrain control systems and components
and provides the technician with a general knowledge of the powertrain control system. Use this section
when general information about the powertrain control system is desired.
Section 2: Diagnostic Methods
This section contains information on specific diagnostic tasks that are used during diagnosis. Descriptions of
specific diagnostic methods are included, as well as detailed instructions on how to access or carry out the
task.
Section 3: Symptom Charts
All diagnosis begins in Section 3 with QT Step 1: Powertrain Control Module (PCM) Quick Test. If the PCM
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Quick Test is completed and no diagnostic trouble codes (DTCs) are retrieved, the technician is directed to
Step 2: No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index. The No Diagnostic Trouble
Codes (DTCs) Present Symptom Chart Index contains the list of symptoms addressed in this manual, and
directs the technician to the appropriate Step 3: No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart. If no PCM DTCs are present and the vehicle symptom is not listed in Step 2: No Diagnostic Trouble
Codes (DTCs) Present Symptom Chart Index, the technician should go to the appropriate Workshop Manual
section to continue diagnosis.
Section 4: Powertrain Diagnostic Trouble Code (DTC) Charts and
Descriptions
This section contains the Diagnostic Trouble Code (DTC) Charts and Descriptions. These charts and
descriptions are referenced if a DTC is retrieved in Section 3 . Also included in this section are the list of
possible causes and diagnostic aids.
Section 5: Pinpoint Tests
All pinpoint tests are included in this section. Never enter a pinpoint test unless directed there. When
directed to a pinpoint test, always read the information included at the beginning of the pinpoint test.
Section 6: Reference Values
This section contains the Typical Diagnostic Reference Values charts. The technician is directed to these
charts from Pinpoint Test Z in Section 5 .

How to Use the Diagnostic Procedures
Use the information about the vehicle driveability or emission concerns to attempt to verify/recreate
the symptom. Look for any vehicle modifications or aftermarket items that may contribute to the
symptom. A check of any applicable TSBs or OASIS messages may be useful if this information is
available.
Go to Section 3 , QT Step 1: Powertrain Control Module (PCM) Quick Test. Carry out the PCM quick
test steps. Follow any notes as directed.
If the PCM quick test is completed, no DTCs were retrieved, and no special notes applied, go to Step
2: No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index.
Select the symptom that best describes the vehicle symptom (for multiple symptoms select the one
that is most evident). Go to Step 3: No Diagnostic Trouble Codes (DTCs) Present Symptom Chart
that is indicated. If no PCM DTCs are present and the vehicle symptom is not listed in the No
Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index, go to the appropriate Workshop
Manual section to continue diagnosis.
The No Diagnostic Trouble Codes (DTCs) Present Symptom Charts contain areas to be tested for
diagnosis of the vehicle symptom. The chart is arranged to place the higher probability or easiest to
test items toward the top of the chart. However, the technician is not required to follow this order due
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to reasons such as variations in vehicle type, vehicle repair history, or technician experience.
The System/Component column indicates the areas that are tested. This column may also
contain a quick system/component test.
The Reference column indicates where to go for the System/Component testing. All references
are to the beginning of a pinpoint test in Section 5 of this manual unless noted otherwise. If
referred to a pinpoint test in this manual or a Workshop Manual section, go to the procedures.
Follow the directions given in those procedures, including directions to other tests or sections.
If a damaged part is found, repair as directed. If no concern is found, and diagnosis in that
area is complete, return to the No Diagnostic Trouble Codes (DTCs) Present Symptom Chart
and continue to the next item.
If a quick system/component test is in the System/Component column, the Reference column
indicates where to go if the test failed.
During diagnosis, if directed to test a system/component that is not contained on that vehicle, go to
the next step.
If the No Diagnostic Trouble Codes (DTCs) Present Symptom Chart for the vehicle symptom is
completed and no concern is found, return to Step 2: No Diagnostic Trouble Codes (DTCs) Present
Symptom Chart Index to address the next most prominent symptom. If all diagnosis is complete and
no concern is found, it may be helpful to GO to Pinpoint Test Z in Section 5 to continue diagnosis.
The installation of any new component that affects the PCM adaptive learning strategies (idle speed,
refueling event, or fuel trim) requires the reset of keep alive memory (KAM). Refer to Section 2,
Resetting The Keep Alive Memory (KAM) .
After any repair, reconnect any components and remove any test equipment. Verify that the vehicle is
operating correctly and the original complaint is no longer present. If a DTC was present, clear the
DTCs and repeat the self-test to verify the repair.
If a symptom is determined to be intermittent, a careful visual and physical underhood inspection of
connectors, wiring harnesses, vacuum lines, and components is required. The Customer Information
Worksheet may contain more detailed symptom information. Before an in-depth diagnosis begins,
start the engine and wiggle wires, tap on components while listening for an indication of a concern
(such as an RPM change or a relay clicking).
Information about engine conditions is stored when a DTC that illuminates the malfunction indicator lamp
(MIL) is set. This information is called freeze frame data and may be helpful in diagnosing intermittent
concerns. Refer to Section 2, Freeze Frame Data for more information.

What's New in this Manual
The following is a list of changes to this manual for 2007:
New Vehicles:
Explorer Sport Trac
Deleted Vehicles:
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Ford GT
Lincoln LS
Other Changes:
Computer-controlled shutdown feature for equipped vehicles
Crown Victoria, Grand Marquis, Town Car and Ranger equipped with new 170-pin PCM
Mustang with new 5.4L supercharged engine

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Acronyms and Definitions
Note: This acronyms and definitions listing contains technical terms applicable to Ford Motor Company
products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed
description of a particular system or component is desired, refer to the applicable section within this PC/ED
Manual or refer to the Workshop Manual for the specific vehicle being repaired.
2V: Two valves per engine cylinder
3V: Three valves per engine cylinder
4V: Four valves per engine cylinder
A/C: Air Conditioning
A/CC: Air Conditioning Clutch
A/CCR: Air Conditioning Clutch Control Relay
ACCS: Air Conditioning Cycling Switch
ACDS: Air Conditioning Diagnostic Switch (refrigerant containment switch)
ACET: Air Conditioning Evaporator Temperature
ACP: Air Conditioning Head Pressure or A/C cycling switch input state
ACPSW: Air Conditioning Pressure Switch
ACPT: Air Conditioning Pressure Transducer (Switch)
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
AFCM: Alternative Fuel Control Module
AIR: Secondary Air Injection
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the AIR System
has been evaluated for On Board Diagnostic (OBD) purposes.
AIRM: Secondary Air Pump Monitor
APP: Accelerator Pedal Position
ARB: Air Resource Board
ASCII: American Standard Code Information Interchange
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
BARO: Barometric Pressure
BJB: Battery Junction Box
BPA: Brake Pedal Applied
BPP: Brake Pedal Position
BPS: Brake Pedal Switch/Speed Control Deactivation
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
CAC: Charge Air Cooler. A device which lowers the temperature of pressurized intake air.
2007 PCED On Board Diagnostics Introduction
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CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CAN: Controller Area Network
CCM: Comprehensive Component Monitor
CD A through J: Coil Driver 1 through 10
CGND: Case Ground. Provides a ground source for the PCM case.
CHT: Cylinder Head Temperature
CHTIL: Cylinder Head Temperature Indicator Lamp
CKP: Crankshaft Position
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP, CMP1, CMP2: Camshaft Position. CMP1 and CMP2 on V engines where applicable.
CMS: Catalyst Monitor Sensor. The downstream HO2S.
CMVSS: Canadian Motor Vehicle Safety Standards
CO: Carbon Monoxide. A colorless, odorless, and toxic gas that is a component of auto exhaust
emissions.
CO
2
: Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
CONT: Continuous Memory. The portion of keep alive memory (KAM) used to store DTCs generated
during the continuous memory self-test.
COP: Coil On Plug. Ignition coil on plug assembly.
CPP: Clutch Pedal Position
CT: Closed Throttle. A mode in which the PCM varies the pulse width of the fuel injectors to obtain
the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
CV: Canister Vent Solenoid. A solenoid which seals the evaporative emission (EVAP) system from
the atmosphere during the EVAP monitor test.
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link. A communication path between various in-vehicle electronic
modules.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
DIS: Distributorless Ignition System. A system in which the ignition coil secondary circuit is
sequenced without a distributor.
DLC: Data Link Connector. SAE standard J1962 connector providing access to vehicle diagnostic
information.
DMM: Digital Multimeter
DOHC: Dual Overhead Cam. An engine configuration that uses 2 camshafts positioned above the
valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFE: Differential Pressure Feedback EGR. A system that uses a pressure transducer to control the
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operation of the exhaust gas recirculation (EGR) vacuum regulator solenoid.
DTM: Diagnostic Test Mode. A level of capability in an OBD system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a concern identified by the OBD
system.
E-85: Fuel containing 85% ethanol alcohol
ECT: Engine Coolant Temperature
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs
or outputs.
EEC: Electronic Engine Control
EEGR: Electric Exhaust Gas Recirculation System
EEPROM: Electrically Erasable Programmable Read-Only Memory. An electronic component in the
PCM that allows the electronic storage of information.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the
combustion chamber.
EGRMC (1-4): Electric Exhaust Gas Recirculation Motor Control
EGRT: Exhaust Gas Recirculation Valve Temperature. A temperature sensor that is threaded into the
bottom of the intake plenum.
EI: Integrated Electronic Ignition. An electronic ignition system that has the ignition control module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition-High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation, or noisy generator contacts.
EOL: End of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles conform to design specifications.
EONV: Engine Off Natural Vacuum
EOT: Engine Oil Temperature
EPA: Environmental Protection Agency
E-Quizzer: Enhanced Quizzer
ESM: EGR System Module
ESOF: Electronic Shift-on-the-Fly
ETB: Electronic Throttle Body
ETC: Electronic Throttle Control
ETCREF: Voltage Reference (5V) for ETC (APP VREF, TP VREF).
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. A solenoid which controls the venting of fuel vapor
from the evaporative emissions canister into the intake manifold for combustion.
EVO: Electronic Variable Orifice
FCIL: Fuel Cap Indicator Lamp. Indicates that the fuel filler cap is not correctly installed.
FEAD: Front End Accessory Drive
FEPS: Flash EEPROM Programming Signal. An 18-volt DC signal input from the scan tool used by
the PCM to initiate programming.
FFV: Flexible Fuel Vehicle
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FLI: Fuel Level Input. Provides information on the amount of liquid fuel in the fuel tank. Used by the
EVAP monitor to calculate the fuel tank vapor volume. Displayed as a percentage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function
in the event of a PCM or EEC component failure.
FP: 1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FRP: Fuel Rail Pressure
FRPT: Fuel Rail Pressure Temperature
FSS: Fan Speed Sensor
FTP: Fuel Tank Pressure
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered by the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at the time of the last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by HO2S11.
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by HO2S21.
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
FWD: Front Wheel Drive
GND: Ground
GPM: 1. Grams per Mile. 2. Gallons per Minute.
GVW: Gross Vehicle Weight
GVWR: Gross Vehicle Weight Rating
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM uses fixed values
in response to internal PCM concerns in place of output commands.
HO: High Output
HO2S: Heated Oxygen Sensor. Provides information on rich or lean exhaust conditions to the PCM.
HTR11, HTR12, HTR13, HTR21, HTR22: HO2S Heater. Heater element for the HO2S sensor.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature
IAT2: Intake Air Temperature 2. Used on supercharged vehicles.
IC: Integrated Circuit. A small semi-conductor device capable of many separate circuit functions.
IFS: Inertia Fuel Switch
IMRC: Intake Manifold Runner Control. Controls or modifies airflow in the intake air system.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC circuits for concerns.
IMTV, IMTV1, IMTV2: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake
manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ10: Injector number or its signal output from
the PCM.
IPC: Independent Plausibility Checker
ISO: International Standards Organization
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KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when
the vehicle is not operating.
KAPWR: Keep Alive Power. A dedicated and unswitched power circuit that maintains KAM.
KOEO Self-Test: Key On Engine Off self-test. A test of the EEC system conducted by the PCM with
power applied and the engine at rest.
KOER Self-Test: Key On Engine Running self-test. A test of the EEC system conducted by the PCM
with the engine running and the vehicle at rest.
Km/h: Kilometers per Hour
kPa: Kilopascal. Unit of pressure. 3.386 kPa equals 1 (in-Hg).
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle
LONGFT: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
M-85: Fuel containing 85% methanol alcohol
MAF: Mass Air Flow
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related concern.
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
MON: Motor Octane Number
MSOF: Manual Shift-on-the-Fly
MY: Model Year
NA: Naturally Aspirated. An engine that is not supercharged or turbocharged.
NC: Normally Closed
NGS: New Generation Self-Test Automatic Readout (STAR) tester
NO: Normally Open
NO
X
: Oxides of Nitrogen. Gasses formed at high combustion temperatures.
OASIS: On-line Automotive Service Information System
OBD, OBD-II: On Board Diagnostics, On Board Diagnostics Second Generation. A system that
monitors the PCM input and output control signals.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer
OHC: Overhead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
ORVR: On-Board Refueling Vapor Recovery
OSC: Output State Control
OSS: Output Shaft Speed
OTM: Output Test Mode
PATS: Passive Anti-Theft System
PCM: Powertrain Control Module. Formerly known as the electronic engine control (EEC) processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors
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into the combustion chamber.
PID: Parameter Identifier. Identifies an address in the PCM memory which contains operating
information.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
PPM: Parts per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM, except without program instructions.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSPT: Power Steering Pressure Transducer
PTO: Power Take-Off
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
RAM: Random Access Memory. Memory into which information can be written as well as read.
RF: Radio Frequency
RFI: Radio Frequency Interference
RFS: Returnless Fuel System
ROM: Read-Only Memory. Computer memory that can be accessed and used, but not altered.
RPM: Revolutions Per Minute
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive
SAE: Society of Automotive Engineers
SCB: Supercharger Bypass
SCBC: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SFI: Sequential Multiport Fuel Injection. A multiport fuel delivery system in which each injector is
individually energized and timed relative to its cylinder intake event.
SHRTFT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during
closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to 2 or more sensors.
SOHC: Single Overhead Cam
TA: Traction Assist
TAC: Throttle Actuator Control
TACM, TACMP, TACMN, TACP (+/-): Throttle Actuator Control Motor +/- used in the ETC system.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve and has an
air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center
TP: Throttle Position sensor. A potentiometer that provides throttle angle and rate information for the
PCM.
TP1: Throttle Position 1
TP2: Throttle Position 2
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TSB: Technical Service Bulletin. Notifies technician of any known vehicle concerns, procedures, or
general repair information.
VCT, VCT1, VCT2: Variable Camshaft Timing. VCT1 and VCT2 on V engines where applicable.
VECI: Vehicle Emission Control Information
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Also known as EVAPCP. Refer to EVAPCP.
VBPWR: Vehicle Buffered Power. A PCM-supplied power source that supplies regulated voltage.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare to battery
voltage (B+).
VREF: Reference Voltage. A dedicated circuit that provides an approximately 5.0 volt signal used as
a reference by certain sensors.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Transmissions:
Note: The automatic transmission naming convention is as follows:
The first character, a number, is the number of forward gears.
The second character, either the letter F or R, represents front (transaxle) or rear
(transmission) wheel drive.
The next set of characters, a grouping of numbers, represents the design torque capacity of
the transmission/transaxle.
The last character, if used, is one of the following:
E for electronic shift
N for non-synchronous shift
S for synchronous shift
W for wide ratio
As an example, for the 4F27E transaxle, the number of forward gears is 4, the character F indicates
front transaxle, 27 represents 270 ft-lbs of torque capacity and the character E represents an
electronic shift.
A/T: Automatic Transmission
CCS: Coast Clutch Solenoid
EPC, EPC1, EPC2: Electronic Pressure Control
ESS: Electronic Shift Scheduling
ISS: Intermediate/Input Shaft Speed Sensor
M/T: Manual Transmission/Transaxle
OCS: Overdrive Cancel Switch
OSS: Output Shaft Speed. Indicates the rotational speed of the transmission output shaft.
PNP: Park/Neutral Position switch.
REVERSE or REV: Transmission Reverse Switch Input
SSA/SSB/SSC/SSD/SSE: Shift solenoids. Devices in an automatic transmission that control the
shifting by varying fluid flow when commanded by the PCM.
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SS1/SS2/SS3: Shift solenoids. Devices in an automatic transmission that control the shifting by
varying fluid flow when commanded by the PCM.
TCC/TCCH: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the torque converter clutch.
TCIL: Transmission Control Indicator Lamp. Indicates that the TCS has been activated.
TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions.
TFT: Transmission Fluid Temperature. Indicates the temperature of transmission fluid.
TR, TR1, TR2, TR3, TR4: Transmission Range. The range in which the transmission is operating.
TSS: Turbine Shaft Speed. Indicates the rotational speed of the transmission turbine shaft.
VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to the vehicle speed.
VSOUT: Vehicle Speed Output. A pulse width modulated vehicle speed signal.

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Catalyst and Exhaust Systems
Overview
The catalytic converter and exhaust systems work together to control the release of harmful engine exhaust
emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO
2
) and water vapor (H
2
O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NO
x
),
hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants of CO, NO
x
, and HCs,
and their emission into the atmosphere must be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen
sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter
is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one
catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the
on board diagnostic (OBD) system strategy in the PCM. For information on the OBD catalyst monitor, refer
to the description for the Catalyst Efficiency Monitor in this section.
The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the vehicle
emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are used in an
exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control
while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some
partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors
(HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors
(HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23)
located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft
oxygen sensor control). Current PZEV vehicles use only a 4-cylinder engine, so only the bank 1 HO2Ss are
used.

2007 PCED On Board Diagnostics SECTION 1: Description and Operation
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V-Engines

In-Line Engines
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical
reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of
exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this
task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with
catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are
changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical
reactions of the exhaust gas components so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds
50% is called catalyst light off. For most catalysts this point occurs at 246C to 302C (475F to 575F). A
fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible.
Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduces
emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst
quickly reaches the maximum conversion efficiency for that catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion
efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a
narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion
efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture
decreases the NO
x
conversion efficiency.
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TWC Conversion Efficiency Chart
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic
converter through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst.
The catalytic converter reduces the concentration of CO, unburned HCs, and NO
x
in the exhaust emissions
to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past
another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions
are directed to the atmosphere through an exhaust tailpipe.
On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1),
one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off
catalyst.

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Typical Bank 1 Catalyst 2 HO2S Configuration

Typical Bank 1 Catalyst 3 HO2S Configuration
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the
light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe
configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to
the Workshop Manual Section 309-00, Exhaust System.
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Three-Way Catalytic (TWC) Converter
The TWC converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The
TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NO
x
. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close
to stoichiometry.
Exhaust Manifold Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the
life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold
through the catalytic converter and the muffler.
The HO2Ss provide the powertrain control module (PCM) with voltage and frequency information related to
the oxygen content of the exhaust gas. For additional information on the HO2S, refer to Engine Control
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of
the product. The muffler reduces the level of noise produced by the engine, and also reduces the noise
produced by exhaust gases as they travel from the catalytic converter to the atmosphere.

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Catalyst Efficiency Monitor
The catalyst efficiency monitor uses an oxygen sensor before and after the catalyst to infer the hydrocarbon
(HC) efficiency based on the oxygen storage capacity of the catalyst. Under normal closed-loop fuel
conditions, high efficiency catalysts have significant oxygen storage. This makes the switching frequency of
the rear heated oxygen sensor (HO2S) very slow and reduces the amplitude of those switches as compared
to the switching frequency and amplitude of the front HO2S. As the catalyst efficiency deteriorates due to
thermal and chemical deterioration, its ability to store oxygen declines. The post-catalyst or downstream
HO2S signal begins to switch more rapidly with increasing amplitude, approaching the switching frequency
and amplitude of the pre-catalyst or upstream HO2S. The predominant failure mode for high mileage
catalysts is chemical deterioration (phosphorus deposits on the front brick of the catalyst), not thermal
deterioration.
In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches during part-
throttle, closed-loop fuel conditions after the engine is warmed-up and the inferred catalyst temperature is
within limits. Front switches are accumulated in up to 3 different air mass regions or cells. While catalyst
monitoring entry conditions are being met, the front and rear HO2S signal lengths are continually being
calculated. When the required number of front switches has accumulated in each cell, the total signal length
of the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index ratio. An
index ratio near 0.0 indicates high oxygen storage capacity, hence high HC efficiency. An index ratio near
1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual index ratio exceeds the
threshold index ratio, the catalyst is considered failed.
Inputs from engine coolant temperature (ECT) or cylinder head temperature (CHT), intake air temperature
(IAT), mass air flow (MAF), crankshaft position (CKP), throttle position (TP), and vehicle speed sensors are
required to enable the Catalyst Efficiency Monitor.
Typical Monitor Entry Conditions:
Minimum 330 seconds since start-up at 21C (70F)
Engine coolant temperature is between 76.6C - 110C (170F - 230F)
Intake air temperature is between -7C - 82C (20F - 180F)
Time since entering closed-loop is 30 seconds
Inferred rear HO2S sensor temperature of 482C (900F)
EGR is between 1% and 12%
Part throttle, maximum rate of change is 0.2 volts/0.050 sec
Vehicle speed is between 8 and 112 km/h (5 and 70 mph)
Fuel level is greater than 15%
First Air Flow Cell
Engine RPM 1,000 to 1,300 RPM
Engine load 15 to 35%
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Inferred catalyst temperature 454C - 649C (850F - 1,200F)
Number of front HO2S switches is 50
Second Air Flow Cell
Inferred catalyst temperature 482C - 677C (900F - 1,250F )
Number of front HO2S switches: 70
Third Air Flow Cell
Inferred catalyst temperature 510C - 704C (950F - 1,300F)
Number of front HO2S switches is 30
The DTCs associated with this test are DTC P0420 (Bank 1 or Y-pipe system) and P0430 (Bank 2).
Because an exponentially weighted moving average algorithm is used to determine a concern, up to 6
driving cycles may be required to illuminate the MIL during normal customer driving. If the KAM is reset or
the battery is disconnected, a concern illuminates the MIL in 2 drive cycles.
General Catalyst Monitor Operation
Monitor execution is once per drive cycle. The typical monitor duration is 700 seconds. In order for the
catalyst monitor to run, the HO2S monitor must be complete and the secondary AIR and EVAP system
functional with no stored DTCs. If the catalyst monitor does not complete during a particular driving cycle,
the already accumulated switch/signal data is retained in the KAM and is used during the next driving cycle
to allow the catalyst monitor a better opportunity to complete.
Rear HO2S can be located in various configurations to monitor different kinds of exhaust systems. In-line
engines and many V-engines are monitored by their individual bank. A rear HO2S is used along with the
front, fuel control HO2S for each bank. Two sensors are used on an in-line engine and 4 sensors are used
on a V-engine. Some V-engines have exhaust banks that combine into a single underbody catalyst. These
systems are referred to as Y-pipe systems. They use only 1 rear HO2S along with the 2 front, fuel-control
HO2S. The Y-pipe system uses 3 sensors in all. For Y-piped systems, the 2 front HO2S signals are
combined by the PCM software to infer what the HO2S signal would have been in front of the monitored
catalyst. The inferred front HO2S signal and the actual single, rear HO2S signal is then used to calculate the
index ratio.
Exhaust systems that use an underbody catalyst without a downstream/rear HO2S are not monitored by the
catalyst efficiency monitor.
Most vehicles that are part of the low emission vehicle (LEV) catalyst monitor phase-in, monitor less than
100% of the catalyst volume. Often this is the first catalyst brick of the catalyst system. Partial volume
monitoring is done on LEV and ultra low emission vehicle (ULEV) vehicles in order to meet the 1.75
emission standard. The rationale for this strategy is that the catalyst nearest the engine deteriorate first,
allowing the catalyst monitor to be more sensitive and illuminate the MIL correctly at lower emission
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standards.
Many applications that use partial-volume monitoring place the rear HO2S after the first light-off catalyst can
or after the second catalyst can in a 3-can per bank system. (A few applications placed the HO2S in the
middle of the catalyst can, between the first and second bricks).
Some partial zero emission vehicles (PZEV) use 3 sets of HO2S per engine bank. The front sensors or
stream 1 (HO2S11/HO2S21) are the primary fuel control sensors. The next sensors downstream or stream
2 in the exhaust are used to monitor the light-off catalyst (HO2S12/HO2S22). The last sensors downstream
or stream 3 in the exhaust (HO2S13/HO2S23) are used for very long term fuel trim in order to optimize
catalyst efficiency (fore aft oxygen sensor control). For additional heated oxygen sensor information, refer to
the Heated Oxygen Sensor (HO2S) Monitor in this section.
Index ratios for ethanol (flex fuel) vehicles vary based on the changing concentration of alcohol in the fuel.
The threshold to determine a concern typically increases as the percent of alcohol increases. For example, a
threshold of 0.5 may be used at E10 (10% ethanol) and 0.9 may be used at E85 (85% ethanol). The
thresholds are adjusted based on the percentage of alcohol in the fuel. Standard fuel may contain up to 10%
ethanol.

Catalyst Efficiency Monitor

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Cold Start Emission Reduction Monitor
Overview
The cold start emission reduction monitor is an on-board strategy designed for vehicles that meet the low
emissions vehicle-II (LEV-II) emissions standards. The monitor works by validating the operation of the
components of the system required to achieve the cold start emission reduction strategy. There are 2 types
of monitors:
cold start emission reduction component monitor
cold start emission reduction system monitor
Cold Start Emission Reduction Component Monitor
Two different tests are carried out during the cold start emission reduction component monitor. The low idle
airflow test which checks the performance of the idle air control strategy and the spark timing monitor test
which checks the spark timing strategy.
Low Idle Air Flow Test
When the cold start emission reduction monitor is enabled, the powertrain control module (PCM) commands
the idle air control system to increase the RPM, which elevates engine air flow. While this cold start emission
reduction elevated air flow is requested, the low idle air flow test compares the measured idle air flow from
the mass air flow (MAF) sensor to the commanded idle air control strategy. For the purpose of detecting low
air flow failures, the low air flow test uses the measured air flow and the commanded air flow to create a low
air flow index.
Low idle air flow test operation:
DTC: P050A cold start idle air control system performance
Monitor execution: Once per driving cycle, from start up with the cold start emissions reduction active
Monitor sequence: none
Monitoring duration: 7 seconds
Low idle air flow test entry conditions:
Engine coolant temperature is between 4.4C (40F) and 82.2C (180F)
Barometric pressure is between 76.2 kPa (22.5 in-Hg) and 105 kPa (31 in-Hg)
Engine off soak time is at least 50 minutes
Throttle is at closed position
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Spark Timing Monitor Test
The PCM is equipped with a spark conduction capture circuit which measures the timing and duration of the
spark delivered by processing the flyback voltage signal from the primary side of the ignition coil. When the
cold start emission reduction monitor is enabled, the spark control strategy in the PCM commands the spark
timing strategy to retard the spark timing. While retarded spark timing is requested, the spark timing monitor
compares the measured spark timing from the spark conduction capture circuit to the commanded spark
timing from the spark control strategy. For the purpose of detecting spark timing failures, the spark timing
monitor increments a fault filter if the measured spark timing is advanced by more than 5 degrees from the
commanded spark timing. A failure is indicated if the fault filter exceeds a value of 200, equivalent to a
failure duration of approximately 4 seconds.
Spark timing monitor test operation:
DTC: P050B cold start ignition timing performance
Monitor execution: once per driving cycle, from start up with the cold start emission reduction monitor
active
Monitor sequence: none
Monitoring duration: 7 seconds
Spark timing monitor test entry conditions:
Engine speed is between 400 RPM and 2,000 RPM
Engine position and cylinder identification are synchronized
There is no concerns with the ignition coils primary circuits
Cold Start Emission Reduction System Monitor
The powertrain control module (PCM) uses the cold start emission reduction system monitor to calculate the
actual catalyst warm up temperature during a cold start. The actual catalyst warm up temperature
calculation uses measured engine speed, measured air mass and commanded spark timing inputs to the
PCM. The PCM then compares the actual temperature to the expected catalyst temperature model. The
expected catalyst temperature model calculation uses desired engine speed, desired air mass and desired
spark timing inputs to the PCM. The difference between the actual and expected temperatures is reflected in
a ratio. This ratio is a measure of how much loss of catalyst heating occurred over the period of time and
when compared with a calibrated threshold it helps the PCM to determine if the cold start emission reduction
system is working properly. This ratio correlates to tailpipe emissions, and a malfunction indicator lamp (MIL)
illuminates when the calibrated threshold is exceeded. The monitor is disabled if a concern is present in any
of the sensors or systems used for expected catalyst temperature model calculation.
Cold start emission reduction system monitor test operation:
DTC: P050E cold start engine exhaust temperature out of range
Monitor execution: once per driving cycle, from start up with the cold start emission reduction monitor
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active
Monitor sequence: the monitor collects data during first 15 seconds of the cold start
Monitoring duration: the monitor completes 300 seconds after initial engine start
Cold start emission reduction system monitor entry conditions:
Engine coolant temperature at the start of the monitor is between 1.67C (35F) and 37.78C (100F)
Barometric pressure is above 74.5 kPa (22 in-Hg)
Catalyst temperature at the start of the monitor is between 1.67C (35F) and 51.67C (125F)
Fuel level is above 15%
Power take-off operation is disabled

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Comprehensive Component Monitor (CCM)
The CCM monitors for concerns in any powertrain electronic component or circuit that provides input or
output signals to the PCM that can affect emissions and is not monitored by another on board diagnostics
(OBD) monitor. Inputs and outputs are, at a minimum, monitored for circuit continuity or correct range of
values. Where feasible, inputs are also checked for rationality, and outputs are also checked for correct
functionality.
The CCM covers many components and circuits and tests them in various ways depending on the hardware,
function, and type of signal. For example, analog inputs such as throttle position or engine coolant
temperature are typically checked for opens, shorts, and out-of-range values. This type of monitoring is
carried out continuously. Some digital inputs like brake switch or crankshaft position rely on rationality
checks - checking to see if the input value makes sense at the current engine operating conditions. These
types of tests may require monitoring several components and can only be carried out under the appropriate
test conditions.
Outputs such as coil drivers are checked for opens and shorts by monitoring a feedback circuit or smart
driver associated with the output. Other outputs, such as relays, require additional feedback circuits to
monitor the secondary side of the relay. Some outputs are also monitored for correct function by observing
the reaction of the control system to a given change in the output command. An idle air control solenoid can
be functionally tested by monitoring the idle RPM relative to the target idle RPM. Some tests can only be
carried out under the appropriate test conditions. For example, the transmission shift solenoids can only be
tested when the PCM commands a shift.
The following is an example of some of the input and output components monitored by the CCM. The
component monitor may belong to the engine, ignition, transmission, air conditioning, or any other PCM
supported subsystem.
1. Inputs:

Air conditioning pressure (ACP) sensor, camshaft position (CMP) sensor, crankshaft position (CKP)
sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, fuel rail
pressure (FRP) sensor, fuel rail pressure temperature (FRPT) sensor, fuel tank pressure (FTP)
sensor, intake air temperature (IAT) sensor, mass air flow (MAF) sensor, throttle position (TP) sensor.
2. Outputs:

EVAP canister purge valve, EVAP canister vent (CV) solenoid, fuel injector, fuel pump (FP), idle air
control (IAC), intake manifold runner control (IMRC), shift solenoid, torque converter clutch (TCC)
solenoid, variable camshaft timing (VCT) actuator, wide open throttle A/C cutout (WAC).
3. CCM is enabled after the engine starts and is running. A DTC is stored in KAM and the MIL is
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illuminated after 2 driving cycles when a concern is detected. Many of the CCM tests are also carried
out during an on-demand self-test.

Comprehensive Component Monitor (CCM)

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Electric Exhaust Gas Recirculation (EEGR) System Monitor
The EEGR system monitor is an on-board strategy designed to test the integrity and flow characteristics of
the EGR system. The monitor is activated during EGR system operation and after certain base engine
conditions are satisfied. Input from the engine coolant temperature (ECT) or cylinder head temperature
(CHT), intake air temperature (IAT), throttle position (TP), crankshaft position (CKP), mass air flow (MAF),
and manifold absolute pressure (MAP) sensors is required to activate the EGR system monitor. Once
activated, the EGR system monitor carries out each of the tests described below during the engine modes
and conditions indicated. Some of the EGR system monitor tests are also carried out during a key on engine
off (KOEO) or key on engine running (KOER) self-test.
The EEGR monitor consists of an electrical and functional test that checks the stepper motor and the EEGR
system for correct flow. The powertrain control module (PCM) controls the EEGR valve by commanding
from 0 to 52 discreet increments or steps to get the valve from fully closed to fully open. The stepper motor
electrical test is a continuous check of the 4 electric stepper motor coils and circuits to the PCM. A concern
is indicated if an open circuit, short to power, or short to ground has occurred in one or more of the stepper
motor coils or circuits for a calibrated period of time. If a concern has been detected, the EEGR system is
disabled, setting diagnostic trouble code (DTC) P0403. Additional monitoring is suspended for the remainder
of the drive cycle, or until the next engine startup.
After the vehicle has warmed up and normal EEGR flow rates are being commanded by the PCM, the
EEGR flow check is carried out. The flow test is carried out once per drive cycle when a minimum amount of
exhaust gas is requested and the remaining entry conditions required to initiate the test are satisfied. If a
concern is detected, the EEGR system, as well as the EEGR monitor, is disabled until the next engine
startup.
The EEGR flow test is done by observing the behavior of 2 different values: MAP - the analog MAP sensor
reading, and inferred MAP - calculated from the MAF sensor, throttle position and RPM. An EGR flow
concern is indicated by either a no flow condition or a low flow condition prior to exceeding 1.5 times the
applicable emission standard. The criteria used to determine which flow concern threshold applies is based
upon whether or not the applicable emission standards are exceeded on the federal test procedure test
cycle without EGR delivery.
When the flow test entry conditions have been satisfied, EEGR is commanded to flow at a calibrated test
rate (about 10%). At this time, the value of MAP is recorded (EGR-ON MAP). The value of inferred MAP
EGR-ON inferred MAP is also recorded. Next the EEGR is commanded off (0%). Again, the value of MAP is
recorded (EGR-OFF MAP). The value of EGR-OFF inferred MAP is also recorded. Typically, 7 such
ON/OFF samples are taken. After all the samples have been taken, the average EGR-ON MAP, EGR-ON
inferred MAP, EGR-OFF MAP and EGR-OFF inferred MAP values are stored.
The difference between the EGR-ON and EGR-OFF value is calculated as follows:
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MAP-delta equals EGR-ON MAP EGR-OFF MAP
Inferred MAP-delta equals EGR-ON inferred MAP EGR-OFF inferred MAP
If the sum of MAP-delta and inferred MAP-delta exceeds a maximum threshold or falls to less than a
minimum threshold, DTC P0400 (high or low flow concern) is registered.
As an additional check, if the EGR-ON MAP exceeds a maximum threshold (BARO, a calibrated value),
DTC P0400 (low flow) is set. This check is carried out to detect reduced EGR flow on systems where the
MAP sensor is located in the intake manifold plenum.
Note: BARO is inferred at engine startup using the KOEO MAP sensor reading. It is updated during high,
part-throttle or high RPM engine operation.
If the inferred ambient temperature is less than -7C (20F), greater than 54C (130F), or the altitude is
greater than 8,000 feet (BARO less than 22.5 in-Hg), the EEGR flow test cannot be reliably done. In these
conditions, the EEGR flow test is suspended and a timer starts to accumulate the time in these conditions.
When the vehicle leaves these extreme conditions, the timer starts to decrement, and if conditions permit,
attempts to complete the EGR flow monitor. If the timer reaches 800 seconds, the EEGR flow test is
disabled for the remainder of the current driving cycle and the EGR monitor is set to a ready condition.
A DTC P1408, like the P0400, indicates a EGR flow concern (outside the minimum or maximum limits) but is
only set during the KOER self-test. The P0400 and P0403 are MIL codes. P1408 is a non-MIL code.

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EEGR System Monitor

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Electronic Engine Control (EEC) System
Overview
The EEC system provides optimum control of the engine and transmission through the enhanced capability
of the powertrain control module (PCM). The EEC system also has an on board diagnostics (OBD)
monitoring system with features and functions to meet federal regulations on exhaust emissions.
Some vehicle applications use a stand-alone transmission control module (TCM). Even though it is still part
of the EEC system, the TCM communicates with the PCM, the anti-lock brake system (ABS) module, the
instrument cluster, and the four-wheel drive (4WD) control modules using the high speed controller area
network (CAN) communications network. The TCM incorporates a stand alone OBD-II system. The TCM
independently processes and stores diagnostic trouble codes (DTCs), freeze frame, support PIDs as well as
J1979 Mode 09 CALID and calibration verification number. The TCM does not directly illuminate the
malfunction indicator lamp (MIL), but requests the PCM to do so. The TCM is located inside the transmission
assembly. It is not repairable, with the exception of reprogramming.
Below is a list of transmissions that use a TCM:
AWF21 (FWD) 6-speed automatic transmission
FNR5 (FWD) transmission
F21 (FWD) transmission
ZF CFT30 (FWD) continuously variable transmission (CVT)
ZF 6HP26 (RWD) transmission
ZF 6R (RWD)
6R60 (RWD)
For additional information on these transmissions and TCM diagnostics, refer to the Workshop Manual
Section 307-01, Automatic Transmission/Transaxle.
The EEC system has 2 major divisions: hardware and software. The hardware includes the PCM, sensors,
switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the
strategy control for outputs (engine hardware) based on the values of the inputs to the PCM. The EEC
hardware and software are discussed in this section.
This section contains detailed descriptions of the operation of the EEC system input sensors and switches,
output actuators, solenoids, relays and connector pins (including other power-ground signals). For additional
information on the input sensors and output actuators, refer to Engine Control Components in this section.
The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and
calibration stored within the memory chip, the PCM generates the appropriate output. The system is
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designed to minimize emissions and optimize fuel economy and driveability. The software strategy controls
the basic operation of the engine and transmission, provides the OBD strategy, controls the MIL,
communicates to the scan tool via the data link connector (DLC), allows for flash electrically erasable
programmable read only memory (EEPROM), provides idle air and fuel trim, and controls failure mode
effects management (FMEM).
Modifications to OBD Vehicles
Modifications or additions to the vehicle may cause incorrect operation of the OBD system. Install anti-theft
systems, remote starters, cellular telephones and aftermarket radios carefully. Do not install these devices
by tapping into or running wires close to the powertrain control system wires or components.

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Engine Control Components
Note: Transmission inputs, which are not described in this section are discussed in the applicable Workshop
Manual transmission section.

Accelerator Pedal Position (APP) Sensor
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque
demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope
(increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope
(increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal
position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1
signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. For
additional information, refer to Torque Based Electronic Throttle Control (ETC) in this section.

Air Conditioning (A/C) Clutch Relay (A/CCR)
Note: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor
the A/CCR output.
The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or
electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal
indicating that A/C is requested. For some applications, this message is sent through the communications
network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C
pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine
conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output,
closing the relay contacts and sending voltage to the A/CCR.

Air Conditioning (A/C) Cycling Switch
The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling
switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling
switch, refer to the Workshop Manual Section 412-00, Climate Control System. Also, refer to the applicable
Wiring Diagrams Manual for vehicle specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For
additional information, refer to wide open throttle air conditioning cutoff (WAC) in this section.
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Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested.
This information is received by the PCM through the communication link.

Air Conditioning Evaporator Temperature (ACET) Sensor
The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor
device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as
the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a
low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying
resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature
changes, the varying resistance of the ACET sensor changes the voltage the PCM detects.
The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist
performance, and reduce A/C clutch cycling.
Note: These values can vary 15 % due to sensor and VREF variations. Voltage values were calculated for
VREF equals 5.0 volts.

A/C EVAPORATOR TEMPERATURE
(ACET) SENSOR VOLTAGE AND
RESISTANCE
C F Volts Resistance (K ohms)
100 212 0.47 2.08
90 194 0.61 2.80
80 176 0.80 3.84
70 158 1.05 5.34
60 140 1.37 7.55
50 122 1.77 10.93
40 104 2.23 16.11
30 86 2.74 24.25
20 68 3.26 37.34
10 50 3.73 58.99
0 32 4.14 95.85
-10 14 4.45 160.31
-20 -4 4.66 276.96
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Air Conditioning (A/C) High Pressure Switch
The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure
switch is either dual function for multiple speed, relay controlled electric fan applications, or single function
for all others.
For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C
pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would
open the A/C high pressure relief valve.
For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This
grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the
pressure.
For additional information, refer to the Workshop Manual Section 412-00, Climate Control System or the
Wiring Diagrams Manual.

Air Conditioning Pressure (ACP) Sensor
The ACP sensor is located in the high pressure (discharge) side of the A/C system. The ACP sensor
provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information
for A/C clutch control, fan control and idle speed control.

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Typical A/C Pressure Sensor

Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake
pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows:
to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then
broadcast over the network to be received by the PCM.
to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input
along with other ABS inputs and generates an output called the driver brake application (DBA) signal.
The DBA signal is then sent to the PCM and to other BPP signal users.

Typical BPP Switch

Brake Pedal Switch (BPS)/Brake Deactivator Switch
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally
closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When
the brake pedal is applied, the normally closed switch opens and power is removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used for a
brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a
brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they
were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy.

The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is
on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing
of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition
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coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second
sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector
variable reluctance type sensor.

Typical Synchronizer Hall-Effect CMP Sensor

Typical Variable Reluctance CMP Sensor

Canister Vent (CV) Solenoid
During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from
the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel
tank during the EVAP leak check monitor.
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Typical Canister Vent (CV) Solenoid

Check Fuel Cap Indicator
The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the
message to illuminate the lamp when the strategy determines that there is a failure in the vapor
management system due to the fuel filler cap not being sealed correctly. This would be detected by the
inability to pull vacuum in the fuel tank, after a fueling event.

Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current
voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN
circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load
information for mass air flow and fuel calculations.

Typical Clutch Pedal Position (CPP) Switch

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Coil On Plug (COP)
The COP ignition operates similar to a standard coil pack ignition except each plug has one coil per plug.
The COP has 3 different modes of operation: engine crank, engine running, and CMP failure mode effects
management (FMEM). For additional information, refer to Ignition Systems in this section.

Coil On Plug (COP)

Coil Pack
The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is
applied to the coil primary circuit. This creates a magnetic field around the primary coil. The PCM opens the
switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and
firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke,
the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The
next pair of spark plugs fire according to the engine firing order.
Coil packs come in 4-tower, 6-tower horizontal and series 5 6-tower models. Two adjacent coil towers share
a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder) applications, the matched
pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder) applications, the matched pairs
are 1 and 4, and 2 and 3.
When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective
spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the
compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired, the
situation is reversed. The next pair of spark plugs fire according to the engine firing order.

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Four-Tower Coil Pack

Typical Six-Tower Coil Pack

Cooling Fan Clutch
The cooling fan clutch is an electrically actuated viscous clutch that consists of 3 main elements:
a working chamber
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a reservoir chamber
a cooling fan clutch actuator valve and a fan speed sensor (FSS)
The cooling fan clutch actuator valve controls the fluid flow from the reservoir into the working chamber.
Once viscous fluid is in the working chamber, shearing of the fluid results in fan rotation. The cooling fan
clutch actuator valve is activated with a pulse width modulated (PWM) output signal from the PCM. By
opening and closing the fluid port valve, the PCM can control the cooling fan clutch speed. The cooling fan
clutch speed is measured by a Hall-effect sensor and is monitored by the PCM during closed loop operation.
The PCM optimizes fan speed based on engine coolant temperature (ECT), engine oil temperature (EOT),
transmission fluid temperature (TFT), intake air temperature (IAT), or air conditioning requirements. When
an increased demand for fan speed is requested for vehicle cooling, the PCM monitors the fan speed
through the Hall-effect sensor. If a fan speed increase is required, the PCM outputs the PWM signal to the
fluid port, providing the required fan speed increase.

Cooling Fan Clutch with Fan Speed Sensor (FSS)

The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located
on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for
ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one
empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and
one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal
indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP
sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration.
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The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations
between teeth.

Typical Crankshaft Position (CKP) Sensor

Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical
resistance of a thermistor decreases as temperature increases, and the resistance increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and
provides electrical signals to the PCM corresponding to temperature.
The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can
provide complete engine temperature information and can be used to infer coolant temperature. If the CHT
sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause
an overheating condition. As a result, damage to major engine components could occur. Using both the CHT
sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and
limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy in this section.

Typical CHT Sensor

Differential Pressure Feedback EGR (DPFE) Sensor
The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure
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across a metering orifice located in the orifice tube assembly. The DPFE sensor receives this signal through
2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification
(note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.

DPFE Sensor
DPFE Sensor Tube Mounted
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0
volt offset. The HI and REF hose connections are marked on the side of the sensor.

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DPFE Sensor Tube Mounted

Electric Exhaust Gas Recirculation (EEGR) Valve
Depending on the application, the EEGR valve is a water cooled or an air cooled motor/valve assembly. The
motor is commanded to move in 52 discrete steps as it acts directly on the EEGR valve. The position of the
valve determines the rate of EGR. The built-in spring works to close the valve (against the motor opening
force).

EEGR Motor/Valve Assembly

Electronic Throttle Actuator Control (TAC)
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The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). The gear ratio from the motor to
the throttle plate shaft is 17:1. There are 2 designs for the TAC, parallel and in-series. The parallel design
has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main
housing. The in-series design has a separate motor housing. Two springs are used; one is used to close the
throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is
applied. The force of the plunger spring is 2 times stronger than the main spring. The default angle is usually
set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from
the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the
bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the
minimum engine airflow required at idle. For additional information, refer to Torque Based Electronic Throttle
Control (ETC) in this section.

Electronic Throttle Body (ETB) Position Sensor
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position
signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative
slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing
angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is
used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make
sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit
and 1 signal return circuit for the sensor. For additional information, refer to Torque Based Electronic
Throttle Control (ETC) in this section.

Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases as the
temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider
network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage
that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at
the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed
resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and
for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor
is located in an engine coolant passage.

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Typical Thread Type ECT Sensor

Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases and the resistance increases as the
temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and
resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the
engine oil lubrication system. The PCM can use the EOT sensor input to determine the following:
On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage
from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine
shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM
begins reducing power by disabling engine cylinders.

Typical EOT Sensor
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Evaporative Emission (EVAP) Canister Purge Valve
Note: The EVAP canister purge valve may also be referred to as a vapor management valve (VMV).
The EVAP canister purge valve is part of the enhanced EVAP system that is controlled by the PCM. This
valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various
engine operating modes. The EVAP canister purge valve is a normally closed valve. The EVAP canister
purge valve controls the flow of vapors by way of a solenoid, eliminating the need for an electronic vacuum
regulator and vacuum diaphragm. The PCM outputs a signal between 0 mA and 1,000 mA to control the
EVAP canister purge valve.
Typical EVAP Canister Purge Valve

Exhaust Gas Recirculation (EGR) Orifice Tube Assembly
The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The
assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice
and 2 pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as
the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential
pressure feedback EGR (DPFE) sensor which provides feedback to the PCM.

1 Fuel Vapor to Intake Manifold
2 Fuel Vapor to EVAP Canister
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EGR Orifice Tube Assembly

Exhaust Gas Recirculation (EGR) System Module (ESM)
The ESM is an integrated differential pressure feedback EGR (DPFE) system that functions in the same
manner as a conventional DPFE system. The various system components have been integrated into a
single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake
manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability,
response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the
EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). This MAP signal
is used for EGR correction and inferred barometric pressure (BARO) at key on. The system provides the
powertrain control module (PCM) with a differential DPFE signal, identical to a traditional DPFE system.
ESM

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Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid
The EGR vacuum regulator solenoid is an electromagnetic device used to regulate the vacuum supply to the
EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the
vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR
valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to
atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid
allows some vacuum to pass, but not enough to open the EGR valve.

EGR Vacuum Regulator Solenoid

1 EGR Vacuum Regulator Integrated into Upper Body
2 DPFE and MAP Sensor
3 Upstream DPFE Port
4 Exhaust Flow
5 Valve Seat
6 Pin/Pintle
7 To Intake Manifold Plenum
8 Diaphragm
9 EGR Spring
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Exhaust Gas Recirculation (EGR) Valve
The EGR valve in the differential pressure feedback EGR (DPFE) system is a conventional, vacuum-
actuated. The valve increases or decreases the flow of EGR. As vacuum applied to the EGR valve
diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa
(1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-
Hg).
Since EGR flow requirement varies greatly, providing repair specifications on flow rate is impractical. The on
board diagnostic (OBD) system monitors the EGR valve function and triggers a diagnostic trouble code
(DTC) if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the
diagnostic procedures.
Typical EGR Valve
EGR VACUUM REGULATOR SOLENOID DATA
Duty Cycle (%)
Vacuum Output
Minimum Nominal Maximum
In-Hg kPa In-Hg kPa In-Hg kPa
0 0 0 0.38 1.28 0.75 2.53
33 0.55 1.86 1.3 4.39 2.05 6.9
90 5.69 19.2 6.32 21.3 6.95 23.47
EGR vacuum regulator resistance: 26-40 Ohms
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Fan Control
The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off
status, A/C pressure) to determine engine cooling fan needs.
For variable speed electric fan(s):
1 Vacuum Connection from EGR Vacuum Regulator
Solenoid
2 Intake Manifold Connector
3 Orifice Tube Connection
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The PCM controls the fan speed and operation using a duty cycle output on the fan control variable (FCV)
circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives the FCV
command and operates the cooling fan at the speed requested (by varying the power applied to the fan
motor).

For relay controlled fans:
The PCM controls the fan operation through the fan control (FC) (single speed fan applications), low fan
control (LFC), medium fan control (MFC), and/or high fan control (HFC) outputs. Some applications will have
the xFC circuit wired to 2 separate relays.
For 3-speed fans, although the PCM output circuits are called low, medium, and high fan control (FC),
cooling fan speed is controlled by a combination of these outputs. Refer to the following table.

FIVE HUNDRED/FREESTYLE/MONTEGO, FUSION/MILAN/ZEPHYR, CROWN VICTORIA/GRAND
MARQUIS, TOWN CAR: FCV DUTY CYCLE OUTPUT FROM PCM (negative duty cycle)
FCV Duty Cycle Command (NEGATIVE (-) duty
cycle) Cooling Fan Response/Speed
Greater than 0 but less than 5% Fan off, controller inactive
Greater than 5% but less than 10% Fan off, controller is in active/ready state
Crown Victoria/Grand Marquis, Town Car:
10% - 90%
Crown Victoria/Grand Marquis, Town Car:
Linear speed increase from 20% to 100%
Five Hundred/Freestyle/Montego,
Fusion/Milan/Zephyr:
30% - 90%
Five Hundred/Freestyle/Montego,
Fusion/Milan/Zephyr:
Linear speed increase from 50% to 100%
Greater than 90% but less than 95% 100%
Greater than 95% but less than 100% Fan off
2.0L FOCUS (with A/C) and TAURUS: PCM FC OUTPUT STATE FOR
COOLING FAN SPEEDS
PCM OUTPUT LOW SPEED MEDIUM SPEED HIGH SPEED FAN OFF
LFC (FC1) ON ON ON OFF
MFC (FC2) ON OFF ON OFF
HFC (FC3) ON OFF OFF OFF
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Fan Speed Sensor (FSS)
The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a
frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the
sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor
generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal
generated by the FSS as a feedback for closed loop control of the cooling fan clutch. For additional
information on the cooling fan clutch, refer to the Cooling Fan Clutch in this section.

2.3L ESCAPE: PCM FC OUTPUT STATE FOR COOLING FAN SPEEDS
LFC (FC1) ON ON ON OFF
MFC (FC2) OFF ON OFF (or ON) OFF
HFC (FC3) OFF OFF ON OFF
FREESTAR, MONTEREY: PCM FC OUTPUT STATE FOR COOLING
FAN SPEEDS
LFC (FC1) OFF ON ON OFF
MFC (FC2) ON OFF ON OFF
HFC (FC3) ON ON ON OFF
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Cooling Fan Clutch with FSS

Fuel Injectors
CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical
connector terminals. The solenoids may be damaged internally in a matter of seconds.
The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is opened
and closed a constant number of times per crankshaft revolution. The amount of fuel is controlled by the
length of time the fuel injector is held open.
The fuel injector is normally closed, and is operated by a 12-volt source from either the electronic engine
control (EEC) power relay or fuel pump relay. The ground signal is controlled by the PCM.
The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. However, it can be
flow checked and, if found outside of specification, a new fuel injector should be installed.
Typical Fuel Injector

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Fuel Level Input (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI
sensor connected to a float in the FP module to determine fuel level.

Fuel Pump (FP) Module
The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located
inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP
module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the
manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in
the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill.

1 Fuel Filter Screen
2 Connector
3 Solenoid Coil
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Mechanical Returnless Fuel Pump Module (FPM)

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Electronic Returnless Fuel Pump Module (FPM)

Fuel Pump Module and Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve
that maintains the system pressure after the key has been turned off to minimize starting concerns. The
reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels.

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Fuel Pump Module and Reservoir

Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The
electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the
pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and
provides electrical signals to the PCM corresponding to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage
divider network so that varying the resistance of the passive sensor causes a variation in total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage
signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the
fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to
adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.

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Fuel Rail Pressure (FRP) Sensor

Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals
to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure
difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel
temperature is used to determine the possible presence of fuel vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with
temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the
resistance increases as the temperature decreases. The varying resistance changes the voltage drop
across the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease.

Typical Fuel Rail Pressure Temperature (FRPT) Sensor

Fuel Rail Pulse Damper
The fuel rail pulse damper is located on the fuel rail and reduces the fuel system noise caused by the
pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to
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avoid fuel spillage if the pulse damper diaphragm ruptures. The fuel rail pulse damper should not be
confused with a fuel pressure regulator; it does not regulate the fuel rail pressure.

Typical Fuel Rail Pulse Damper

Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.

Fuel Tank Pressure (FTP) Sensor

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In-Line Fuel Tank Pressure (FTP) Sensor

The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the
amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a
voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal
greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a
near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a
temperature of 800C (1,472F). At approximately 300C (572F) the engine can enter closed loop
operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the
ground when the correct conditions occur. The heater allows the engine to enter closed loop operation
sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the
heater.

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Idle Air Control (IAC) Valve
Note: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally
open and others are normally closed. Some IAC valves require engine vacuum to operate.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve
assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and
throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly
through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of
bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to
achieve the desired RPM.
The PCM uses the IAC valve assembly to control:
no touch start
cold engine fast idle for rapid warm-up
idle (corrects for engine load)
stumble or stalling on deceleration (provides a dashpot function)
over-temperature idle boost

Inertia Fuel Shutoff (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff
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the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact
occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens
the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be
manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS.

Typical Inertia Fuel Shutoff (IFS) Switch

Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and
resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as
a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor.
Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated
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type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF)
sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as
described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather
input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor
located after the supercharger provides air temperature information to the PCM to control spark and to help
determine charge air cooler (CAC) efficiency.

Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors

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Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type MAF
sensor

Intake Manifold Tuning Valve (IMTV)
WARNING: SUBSTANTIAL OPENING AND CLOSING TORQUE IS APPLIED BY THIS SYSTEM.
TO PREVENT INJURY, BE CAREFUL TO KEEP FINGERS AWAY FROM LEVER MECHANISMS WHEN
ACTUATED.
The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a
shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to
indicate shutter position.
The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the closed
position not allowing airflow blend to occur in the intake manifold. The motorized unit is energized above
approximately 2,600 RPM. The motorized unit is commanded on by the PCM initially at a 100 percent duty
cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to
hold the shutter open.

Knock Sensor (KS)
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The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The
PCM uses this signal to determine the presence of engine knock and to retard spark timing.

Two Types of Knock Sensor (KS)

Manifold Absolute Pressure (MAP) Sensor
The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP
sensor to measure how much exhaust gas is introduced into the intake manifold.

Typical Manifold Absolute Pressure (MAP) Sensor

Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air
passing over the hot wire causes it to cool. This hot wire is maintained at 200C (392F) above the ambient
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temperature as measured by a constant cold wire. The current required to maintain the temperature of the
hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the
PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order
to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure
control (EPC), shift and torque converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly.
Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT)
sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the
element may change the air flow calibration.

Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor
Wire Where Applicable) Terminals.

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Typical Mass Air Flow (MAF) Sensor

Typical Drop-in Mass Air Flow (MAF) Sensor

The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM
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uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also
used as the source of vehicle speed. The sensor may be physically located in different places on the
vehicle, depending upon the specific application. The design of each speed sensor is unique and depends
on which powertrain control feature uses the information that is generated.

Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage
input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP
sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine
stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers.

Typical Power Steering Pressure (PSP) Sensor

Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a
normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current
voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN
circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine
by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch
signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.

Typical Power Steering Pressure (PSP) Switch
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Power Take-Off (PTO) Switch and Circuits
The PTO circuit is used by the PCM to disable some of the on board diagnostics (OBD) monitors during
PTO operation. The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed
and battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional load is
being applied to the engine. The PTO indicator lamp illuminates when the PTO system is functioning
correctly and flashes when the PTO system is damaged.
When the PTO unit is activated, the PCM disables some OBD monitors, which may not function reliably
during PTO operation. Without the PTO circuit information to the PCM, false DTCs may be set during PTO
operation. Prior to an Inspection/Maintenance test, operate the vehicle with the PTO disengaged long
enough to successfully complete the OBD Monitors.
PTO Circuits Description
The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM.
The PTO engage circuit is used when the operator is requesting the PCM to check the needed inputs
required to initiate the PTO engagement.
The PTO RPM circuit is used for the operator to request additional engine RPM for PTO operation.

Powertrain Control Module - Vehicle Speed Output (PCM-VSO)
The PCM-VSO speed signal subsystem generates vehicle speed information for distribution to the vehicle's
electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the
transmission output shaft speed with a sensor. The data is processed by the PCM and distributed as a
hardwired signal or as a message on the vehicle communication network.
The key features of the PCM-VSO system are to:
infer vehicle movement from the output shaft speed (OSS) sensor signal.
convert transmission output shaft rotational information to vehicle speed information.
compensate for tire size and axle ratio with a programmed calibration variable.
use a transfer case speed sensor (TCSS) for four wheel drive (4WD) applications.
distribute vehicle speed information as a multiplexed message and/or an analog signal.
The signal from a non-contact shaft sensor OSS or TCSS mounted on the transmission (automatic, manual,
or 4WD transfer case) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to
8,000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is
programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for
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servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be
transmitted by a hardwired interface between the vehicle speed signal user and the PCM, or by a speed and
odometer data message through the vehicle communication network data link.
The PCM-VSO hardwired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical
output operating range is 1.3808 Hz per 1 km/h (2.22 Hz per mph).

Secondary Air Injection (AIR) Bypass Solenoid
The secondary AIR bypass solenoid is used by the PCM to control vacuum to the secondary air injection
diverter (AIR diverter) valve. The secondary AIR bypass solenoid is a normally closed solenoid. The
secondary AIR bypass solenoid also has a filtered vent feature to permit vacuum release.

Secondary AIR Bypass Solenoid

Secondary AIR Diverter Valve
The secondary AIR diverter valve is used with the secondary AIR pump to provide on/off control of air to the
exhaust manifold and catalytic converter. When the secondary AIR pump is on and vacuum is supplied to
the AIR diverter valve, air passes the integral check valve disk. When the secondary AIR pump is off, and
vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops
air from being drawn into the exhaust system and prevents the back flow of the exhaust into the secondary
AIR system.

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Secondary AIR Diverter Valve

Secondary AIR Pump
The secondary AIR pump provides pressurized air to the secondary AIR system. The secondary AIR pump
functions independently of RPM and is controlled by the PCM. The secondary AIR pump is only used for
short periods of time. Delivery of air is dependent on the amount of system backpressure and system
voltage. The secondary AIR pump draws dry filtered air from the intake air system downstream of the
MAF/IAT sensor. For additional information on the secondary AIR injection system, refer to Secondary Air
Injection (AIR) System in this section.

Secondary Air Pump

Starter Motor Request (SMR) Circuit
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The SMR circuit provides the PCM with a signal from the ignition switch to the PCM. The input is pulled high
when the key is in the START position and the transmission range sensor ignition lockout circuit allows the
starter to engage.

Throttle Position (TP) Sensor
The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional
to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold
plated. The gold plating increases the corrosion resistance on the terminals and increases the connector
durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4
operating conditions are determined by the PCM from the TP. The operating conditions are:
closed throttle (includes idle or deceleration)
part throttle (includes cruise or moderate acceleration)
wide open throttle (includes maximum acceleration or de-choke on crank)
throttle angle rate

Typical TP Sensor

Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.

Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the
transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive.
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Typical Transmission Control Switch (TCS)

Typical Transmission Control Switch (TCS)

Vapor Management Valve (VMV)
See the description of the EVAP canister purge valve in this section.

Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency that is
proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor
produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with
a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control
such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque
converter clutch scheduling.

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Typical Vehicle Speed Sensor (VSS)

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Evaporative Emission (EVAP) Leak Check Monitor
The EVAP leak check monitor is an on-board strategy designed to detect a leak from a hole (opening) equal
to or greater than 0.508 mm (0.020 inch) in the enhanced EVAP system. The correct function of the
individual components of the enhanced EVAP system, as well as its ability to flow fuel vapor to the engine, is
also examined. The EVAP leak check monitor relies on the individual components of the enhanced EVAP
system to either allow a natural vacuum to occur in the fuel tank or apply engine vacuum to the fuel tank and
then seal the entire enhanced EVAP system from the atmosphere. The fuel tank pressure is then monitored
to determine the total vacuum lost (bleed-up) for a calibrated period of time. Inputs from the engine coolant
temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor,
mass air flow (MAF) sensor, vehicle speed, fuel level input (FLI) and fuel tank pressure (FTP) sensor are
required to enable the EVAP leak check monitor.
During the EVAP leak check monitor repair verification drive cycle, clearing the continuous diagnostic
trouble codes (DTCs) and resetting the emission monitors information in the powertrain control module
(PCM) bypasses the minimum soak time required to complete the monitor. The EVAP leak check monitor
does not run if the key is turned off after clearing the continuous DTCs and resetting the emission monitors
information in the PCM. The EVAP leak check monitor does not run if a MAF sensor concern is present. The
EVAP leak check monitor does not initiate until the heated oxygen sensor (HO2S) monitor is complete.
If the vapor generation is high on some vehicle enhanced EVAP systems, where the monitor does not pass,
the result is treated as a no test. Therefore, the test is complete for the day.
Some vehicle applications have an engine off natural vacuum (EONV) check as part of the EVAP leak check
monitor.
Engine On EVAP Leak Check Monitor
The engine on EVAP leak check monitor is executed by the individual components of the enhanced EVAP
system as follows:
1. The EVAP canister purge valve, also known as the vapor management valve (VMV), is used to
control the flow of vacuum from the engine and create a target vacuum on the fuel tank.
2. The canister vent (CV) solenoid is used to seal the EVAP system from the atmosphere. It is closed by
the PCM (100% duty cycle) to allow the EVAP canister purge valve to obtain the target vacuum on
the fuel tank.
3. The FTP sensor is used by the engine on EVAP leak check monitor to determine if the target vacuum
necessary to carry out the leak check on the fuel tank is reached. Some vehicle applications with the
engine on EVAP leak check monitor use a remote in-line FTP sensor. Once the target vacuum on the
fuel tank is achieved, the change in fuel tank vacuum over a calibrated period of time determines if a
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leak exists.
4. If the initial target vacuum cannot be reached, DTC P0455 (gross leak detected) is set. The engine on
EVAP leak check monitor aborts and does not continue with the leak check portion of the test.

For some vehicle applications, if the initial target vacuum cannot be reached after a refueling event
and the purge vapor flow is excessive, DTC P0457 (fuel cap off) is set. If the initial target vacuum
cannot be reached and the purge flow is too small, DTC P1443 (no purge flow condition) is set.

If the initial target vacuum is exceeded, a system flow concern exists and DTC P1450 (unable to
bleed-up fuel tank vacuum) is set. The engine on EVAP leak check monitor aborts and does not
continue with the leak check portion of the test.

If the target vacuum is obtained on the fuel tank, the change in the fuel tank vacuum (bleed-up) is
calculated for a calibrated period of time. The calculated change in fuel tank vacuum is compared to a
calibrated threshold for a leak from a hole (opening) of 1.016 mm (0.040 inch) in the enhanced EVAP
system. If the calculated bleed-up is less than the calibrated threshold, the enhanced EVAP system
passes. If the calibrated bleed-up exceeds the calibrated threshold, the test aborts. The test can be
repeated up to 3 times.

If the bleed-up threshold is still being exceeded after 3 tests, a vapor generation test must be carried
out before DTC P0442 (small leak detected) is set. This is accomplished by returning the enhanced
EVAP system to atmospheric pressure by closing the EVAP canister purge valve and opening the CV
solenoid. Once the FTP sensor observes the fuel tank is at atmospheric pressure, the CV solenoid
closes and seals the enhanced EVAP system.

The fuel tank pressure build-up, over a calibrated period of time is compared to a calibrated threshold
for pressure build-up due to vapor generation.

If the fuel tank pressure build-up exceeds the threshold, the leak test results are invalid due to vapor
generation. The engine on EVAP leak check monitor attempts to repeat the test again.

If the fuel tank pressure build-up does not exceed the threshold, the leak test results are valid and
DTC P0442 is set.
5. If the 1.016 mm (0.40 inch) test passes, the test time is extended to allow the 0.508 mm (0.020 inch)
test to run.

The calculated change in fuel vacuum over the extended time is compared to a calibrated threshold
for a leak from a 0.508 mm (0.020 inch) hole (opening).

If the calculated bleed-up exceeds the calibrated threshold, the vapor generation test is run. If the
vapor generation test passes (no vapor generation), an internal flag is set in the PCM to run a 0.508
mm (0.020 inch) test at idle (vehicle stopped).

On the next start following a long engine off period, the enhanced EVAP system is sealed and
evacuated for the first 10 minutes of operation.

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If the appropriate conditions are met, a 0.508 mm (0.020 inch) leak check is conducted at idle.

If the test at idle fails, a DTC P0456 is set. There is no vapor generation test with the idle test.
6. The MIL is activated for DTCs P0442, P0455, P0456, P0457, P1443, and P1450 (or P0446) after 2
occurrences of the same concern. The MIL can also be activated for any enhanced EVAP system
component DTCs in the same manner. The enhanced EVAP system component DTCs P0443,
P0452, P0453, and P1451 are tested as part of the CCM.

Evaporative Emission (EVAP) Leak Check Monitor
Engine Off Natural Vacuum (EONV) EVAP Leak Check Monitor
The EONV EVAP leak check monitor is executed during key off, after the engine on EVAP leak check
monitor is completed. The EONV EVAP leak check monitor determines a leak is present when the naturally
occurring change in fuel tank pressure or vacuum does not exceed a calibrated limit during a calibrated
amount of time. A separate, low power consuming, microprocessor in the PCM manages the EONV leak
check. The engine off EVAP leak check monitor is executed by the individual components of the enhanced
EVAP system as follows:
1. The EVAP canister purge valve, also known as the vapor management valve (VMV), is normally
closed at key off.
2. The normally open canister vent (CV) remains open for a calibrated amount of time to allow the fuel
tank pressure to stabilize with the atmosphere. During this time period the FTP sensor is monitored
for an increase in pressure. If pressure remains below a calibrated limit the CV is closed by the PCM
(100% duty cycle) and seals the EVAP system from the atmosphere.
3. The FTP sensor is used by the EONV EVAP leak check monitor to determine if the target pressure or
vacuum necessary to complete the EONV EVAP leak check monitor on the fuel tank is reached.
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Some vehicle applications with the EONV EVAP leak check monitor use a remote in-line FTP sensor.
If the target pressure or vacuum on the fuel tank is achieved within the calibrated amount of time, the
test is complete.
4. The EONV EVAP leak check monitor uses the naturally occurring change in fuel tank pressure as a
means to detect a leak in the EVAP system. At key off, a target pressure and vacuum is determined
by the PCM. These target values are based on the fuel level and the ambient temperature at key off.
As the fuel tank temperature increases, the pressure in the tank increases and as the temperature
decreases a vacuum develops. If a leak is present in the EVAP system the fuel tank pressure or
vacuum does not exceed the target value during the testing time period. The EONV EVAP leak check
monitor begins at key off.

After key off the normally open canister vent (CV) remains open for a calibrated amount of time to
allow the fuel tank pressure to stabilize with the atmosphere. During this time period the FTP sensor
is monitored for an increase in pressure. If pressure remains below a calibrated limit the CV is closed
by the PCM (100% duty cycle) and seals the EVAP system from the atmosphere.

If the pressure on the fuel tank decreases after the EVAP system is sealed, the EONV EVAP leak
check monitor begins to monitor the fuel tank pressure. When the target vacuum is exceeded within
the calibrated amount of time the test completes and the fuel tank pressure and time since key off
information is stored. If the target vacuum is not reached in the calibrated amount of time, a leak is
suspected and the fuel tank pressure and time since key off information is stored.

If the pressure on the fuel tank increases after the EVAP system is sealed, but does not exceed the
target pressure within a calibrated amount of time the CV is opened to allow the fuel tank pressure to
again stabilize with the atmosphere. After a calibrated amount of time the CV is closed by the PCM
and seals the EVAP system. When the fuel tank pressure exceeds either the target pressure or
vacuum within the calibrated amount of time the test completes and the fuel tank pressure and time
since key off information is stored. If the target pressure or vacuum is not reached in the calibrated
amount of time, a leak is suspected and the fuel tank pressure and time since key off information is
stored.

When a leak is suspected, the PCM uses the stored fuel tank pressure and time since key off
information from an average run of 4 tests to suspect a leak. Some vehicles use an alternative
method of a single run of 5 tests to determine the presence of a leak. If a leak is still suspected after 2
consecutive runs of 4 tests, (8 total tests) or 1 run of 5 tests, DTC P0456 is set and the MIL is
illuminated.
5. The EONV EVAP leak check monitor is controlled by a separate low power consuming
microprocessor inside the PCM. The fuel level indicator, fuel tank pressure, and battery voltage are
inputs to the microprocessor. The microprocessor outputs are the CV solenoid and the stored test
information. If the separate microprocessor is unable to control the CV solenoid or communicate with
other processors DTC P260F is set.
6. The MIL is activated for DTCs P0456 and P260F. The MIL can also be activated for any enhanced
EVAP system component DTCs in the same manner. The enhanced EVAP system component DTCs
P0443, P0446, P0452, P0453, and P1451 are tested as part of the CCM.
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EONV EVAP Leak Check Monitor

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Evaporative Emission (EVAP) Systems
Overview
The EVAP system prevents fuel vapor build-up in the sealed fuel tank. Fuel vapors trapped in the sealed
tank are vented through the vapor valve assembly on top of the tank. The vapors leave the valve assembly
through a single vapor line and continue to the EVAP canister for storage until the vapors are purged to the
engine for burning.
All applications required to meet on board diagnostics (OBD) regulations use the enhanced EVAP system.
Some applications also incorporate an on-board refueling vapor recovery (ORVR) system. Refer to the
Workshop Manual Section 303-13, Evaporative Emissions for vehicle specific information.
Enhanced Evaporative Emission (EVAP) System
The enhanced EVAP system consists of a fuel tank, fuel filler cap, fuel tank mounted or in-line fuel vapor
control valve, fuel vapor vent valve, EVAP canister, fuel tank mounted or fuel pump mounted or in-line fuel
tank pressure (FTP) sensor, EVAP canister purge valve or vapor management valve (VMV), intake manifold
hose assembly, EVAP canister vent (CV) solenoid, powertrain control module (PCM) and connecting wires,
and fuel vapor hoses. For additional information on the EVAP system components, refer to Engine Control
1. The enhanced EVAP system uses inputs from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, the intake air temperature (IAT) sensor, the mass air flow
(MAF) sensor, the vehicle speed and the FTP sensor to provide information about engine operating
conditions to the PCM. The fuel level input (FLI) and FTP sensor signals to the PCM are used by the
PCM to determine activation of the EVAP leak check monitor based on the presence of vapor
generation or fuel sloshing.
2. The PCM determines the desired amount of purge vapor flow to the intake manifold for a given
engine condition. The PCM can then output the required signal to the EVAP canister purge valve or
VMV. The PCM uses the enhanced EVAP system inputs to evacuate the system using the EVAP
canister purge valve or VMV, seals the enhanced EVAP system from the atmosphere using the CV
solenoid, and uses the FTP sensor to observe total vacuum lost for a period of time.
3. The CV solenoid seals the enhanced EVAP system to atmosphere during the EVAP leak check
monitor.
4. The PCM outputs a variable current (between 0 mA and 1,000 mA) to the solenoid on the EVAP
canister purge valve or VMV.
5. The FTP sensor monitors the fuel tank pressure during engine operation and continuously transmits
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an input signal to the PCM. During the EVAP monitor testing, the FTP sensor monitors the fuel tank
pressure or vacuum bleed-up.
6. The fuel tank mounted fuel vapor vent valve assembly and the fuel tank mounted fuel vapor control
valve (or remote fuel vapor control valve) are used in the enhanced EVAP system to control the flow
of fuel vapor entering the engine. All of these valves also prevent fuel tank overfilling during refueling
operation and prevent liquid fuel from entering the EVAP canister and the EVAP canister purge valve
or VMV under any vehicle altitude, handling, or rollover condition.
7. The enhanced EVAP system, including all the fuel vapor hoses, can be checked when a leak is
detected by the PCM. Refer to the Workshop Manual Section 303-13, Evaporative Emissions for
information on leak detection tools and procedures.

Enhanced Evaporative Emission System

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Exhaust Gas Recirculation (EGR) System Monitor Differential
Pressure Feedback EGR (DPFE) and EGR System Module (ESM)
The EGR system monitor is an on-board strategy designed to test the integrity and flow characteristics of the
EGR system. The monitor is activated during EGR system operation and after certain base engine
conditions are satisfied. Input from the engine coolant temperature (ECT) or cylinder head temperature
(CHT), intake air temperature (IAT), throttle position (TP), and crankshaft position (CKP) sensors is required
to activate the monitor. Once activated, the EGR system monitor carries out each of the tests described
below during the engine modes and conditions indicated. Some of the EGR system monitor tests are also
carried out during an on-demand self-test.
1. The DPFE sensor and circuit are continuously tested for opens and shorts. The monitor checks for
the DPFE circuit voltage to exceed the maximum or minimum allowable limits.

The diagnostic trouble codes (DTCs) associated with this test are P0405 and P0406.
2. The EGR vacuum regulator solenoid is continuously tested for opens and shorts. The monitor looks
for an EVR circuit voltage that is inconsistent with the EVR circuit commanded output state.

The DTC associated with this test is P0403.
3. The test for a stuck open EGR valve or EGR flow at idle is continuously carried out at idle (TP sensor
indicating closed throttle). The monitor compares the DPFE circuit voltage at idle to the DPFE circuit
voltage stored during key on engine off (KOEO) to determine if EGR flow is present at idle.

4. The DPFE sensor hoses are tested once per drive cycle for disconnect and plugging. The test is
carried out with the EGR valve closed and during a period of acceleration. The powertrain control
module (PCM) momentarily commands the EGR valve closed. The monitor looks for the DPFE
sensor voltage to be inconsistent for a no flow voltage. A voltage increase or decrease during
acceleration while the EGR valve is closed may indicate a concern with a signal hose during this test.

The DTCs associated with this test are P1405 and P1406 (DPFE systems only).
5. The EGR flow rate test is carried out during a steady state when the engine speed and load are
moderate and the EGR vacuum regulator duty cycle is high. The monitor compares the actual DPFE
circuit voltage to a desired EGR flow voltage for that state to determine if the EGR flow rate is
acceptable or insufficient. This is a system test and may trigger a DTC for any concern causing the
EGR system to fail.

The DTC associated with this test is P0401. DTC P1408 is similar to P0401 but is carried out during
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key on engine running (KOER) self-test conditions.
6. The MIL is activated after one of the above tests fails on 2 consecutive drive cycles.

EGR System Monitor - DPFE

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Exhaust Gas Recirculation (EGR) Systems
Overview
The EGR system controls the oxides of nitrogen (NO
x
) emissions. Small amounts of exhaust gases are
recirculated back into the combustion chamber to mix with the air/fuel charge. The combustion chamber
temperature is reduced, lowering NO
x
emissions.

Differential Pressure Feedback EGR (DPFE) System
The DPFE system consists of a DPFE sensor, EGR vacuum regulator solenoid, EGR valve, orifice tube
assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. For additional
information on the DPFE system, refer to Engine Control Components in this section. Operation of the
system is as follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder
head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor,
mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine
operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load
and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide
open throttle, or whenever a concern is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines
the desired pressure drop across the metering orifice required to achieve that flow and outputs the
corresponding signal to the EGR vacuum regulator solenoid.
3. The EGR vacuum regulator solenoid receives a variable duty cycle signal (0 to 100%). The higher the
duty cycle the more vacuum the solenoid diverts to the EGR valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins
to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With
one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a
pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes,
there is no longer flow across the metering orifice and pressure on both sides of the orifice is the
same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the
desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
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proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for
any errors in achieving the desired EGR flow.

DPFE System Operation

Electric Exhaust Gas Recirculation (EEGR) System
Highlights of the EEGR System
The EEGR valve is activated by an electric stepper motor and does not use vacuum to control the
physical movement of the valve.
No vacuum diaphragm is used.
No differential pressure feedback EGR (DPFE) sensor is used.
No orifice tube/assembly is used.
No EGR vacuum regulator solenoid is used.
Engine coolant is routed through the assembly on some vehicle applications. Some vehicle
applications are air cooled.
Overview
The EEGR system uses exhaust gas recirculation to control the oxides of nitrogen (NO
x
) emissions just like
vacuum operated systems. The only difference is the way in which the exhaust gas is controlled.
The EEGR system consists of an electric motor/EGR valve integrated assembly, a PCM, and connecting
wiring. Additionally a manifold absolute pressure (MAP) sensor is also required. For additional information
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on the EGR system components, refer to Engine Control Components in this section. Operation of the
system is as follows:
1. The EEGR system receives signals from the ECT or CHT sensor, TP sensor, MAF sensor, CKP
sensor, and the MAP sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EEGR system is
activated. The PCM deactivates the EEGR during idle, extended wide open throttle (WOT), or
whenever a concern is detected in an EEGR component or EGR required input.
2. The PCM calculates the desired amount of EGR for a given set of engine operating conditions.
3. The PCM in turn outputs signals the EEGR motor to move (advance or retract) a calibrated number of
discrete steps. The electric stepper motor directly actuates the EEGR valve, independent of engine
vacuum. The EEGR valve is commanded from 0 to 52 discrete steps to get the EGR valve from a
fully closed to fully open position. The position of the EGR valve determines the EGR flow.
4. A MAP sensor is used to measure variations in manifold pressure as exhaust gas recirculation is
introduced into the intake manifold. Variations in EGR being used correlate to the MAP signal
(increasing EGR increases manifold pressure values).

EEGR System
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Exhaust Gas Recirculation (EGR) System Module (ESM)
Overview
The ESM is an updated differential pressure feedback EGR (DPFE) system. It functions in the same manner
as the conventional DPFE system, however the various system components have been integrated into a
single component called the ESM. For additional information on the ESM system components, refer to
Engine Control Components in this section. The flange of the valve portion of the ESM bolts directly to the
intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system
reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake
side of the EGR valve, the downstream pressure signal measures MAP. This MAP signal is used for EGR
correction and inferred barometric pressure (BARO) at key on. The system provides the PCM with a
differential DPFE signal, identical to a traditional DPFE system.
First, the DPFE sensor input circuit is checked for out of range values (DTCs P0405 or P0406). The EGR
vacuum regulator output circuit is checked for opens and shorts (DTC P0403).
The EGR system normally has large amounts of water vapor that are the result of the engine combustion
process. During cold ambient temperatures, under some circumstances, water vapor can freeze in the
DPFE sensor, hoses, as well as other components in the EGR system. In order to prevent malfunction
indicator lamp (MIL) illumination for temporary freezing, the following logic is used.
If an EGR system concern is detected below 0C (32F), only the EGR system is disabled for the current
driving cycle. A diagnostic trouble code (DTC) is not stored and the I/M readiness status for the EGR
monitor does not change. The EGR monitor, however, continues to operate. If the EGR monitor determines
that the concern is no longer present, the EGR system is enabled and normal system operation is restored.
If an EGR system concern is detected above 0C (32F), the EGR system and the EGR monitor is disabled
for the current driving cycle. A DTC is stored and the MIL is illuminated if the concern has been detected on
2 consecutive driving cycles.
After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the low flow
check is carried out. Since the EGR system is a closed loop system, the EGR system delivers the requested
EGR flow as long as it has the capability to do so. If the EGR vacuum regulator duty cycle is very high
(greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is evaluated to
determine the amount of EGR system restriction. If the differential pressure is below a calibrated threshold,
a low flow concern is indicated (DTCs P0401/P0406).
Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero requested
EGR flow to carry out the high flow check. If the differential pressure exceeds a calibrated limit, it indicates a
stuck open EGR valve or debris temporarily lodged under the EGR valve seat (DTC P0402).
If the inferred ambient temperature is less than 0C (32F), or greater than 60C (140F), or the altitude is
greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run reliably. In these
conditions, a timer starts to accumulate the time in these conditions. If the vehicle leaves these extreme
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conditions, the timer starts to decrement, and, if conditions permit, attempts to complete the EGR flow
monitor. If the timer reaches 800 seconds, the EGR monitor is disabled for the remainder of the current
driving cycle and the EGR monitor I/M readiness bit is set to a ready condition after one such driving cycle.
Vehicles require 2 such driving cycles for the EGR monitor to be set to a ready condition.

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Fuel System Monitor
The fuel system monitor is an on-board strategy designed to monitor the fuel control system. The fuel control
system uses fuel trim tables stored in the powertrain control module (PCM) keep alive memory (KAM) to
compensate for the variability that occurs in fuel system components due to normal wear and aging. Fuel
trim tables are based on engine RPM and engine load. During closed-loop fuel control, the fuel trim strategy
learns the corrections needed to correct a biased rich or lean fuel system. The correction is stored in the fuel
trim tables. The fuel trim has 2 means of adapting: long term fuel trim and a short term fuel trim. Refer to
Powertrain Control Software , Fuel Trim in this section. Long term fuel trim relies on the fuel trim tables and
short term fuel trim refers to the desired air/fuel ratio parameter called LAMBSE. LAMBSE is calculated by
the PCM from the heated oxygen sensor (HO2S) inputs and helps maintain a 14.7:1 air/fuel ratio during
closed-loop operation. Short term fuel trim and long term fuel trim work together. If the HO2S indicates the
engine is running rich, the PCM corrects the rich condition by moving the short term fuel trim into the
negative range, less fuel to correct for a rich combustion. If after a certain amount of time the short term fuel
trim is still compensating for a rich condition, the PCM learns this and moves the long term fuel trim into the
negative range to compensate and allow the short term fuel trim to return to a value near 0%. Inputs from
the engine coolant temperature (ECT) or cylinder head temperature (CHT), intake air temperature (IAT),
mass air flow (MAF) sensors are required to activate the fuel trim system, which in turn activates the fuel
system monitor. Once activated, the fuel system monitor looks for the fuel trim tables to reach the adaptive
clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The fuel system monitor stores the appropriate
DTC when a concern is detected as described below.
1. The HO2S detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating air/fuel ratio.
2. A correction factor is added to the fuel injector pulse width calculation and the mass air flow
calculation, according to the long and short term fuel trims as needed to compensate for variations in
the fuel system.
3. When deviation in the LAMBSE parameter increases, air/fuel control suffers and emissions increase.
When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped, the fuel system monitor
sets a DTC as follows:

The DTCs associated with the monitor detecting a lean shift in fuel system operation are P0171
(Bank 1) and P0174 (Bank 2).

The DTCs associated with the monitor detecting a rich shift in fuel system operation are P0172 (Bank
1) and P0175 (Bank 2).
4. The MIL is activated after a concern is detected on 2 consecutive drive cycles.
Typical fuel system monitor entry conditions:
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RPM range greater than idle
Air mass range greater than 5.67 g/sec (0.75 lb/min)
Purge duty cycle of 0%
Typical fuel monitor thresholds:
Lean Condition Concern: LONGFT greater than 25%, SHRTFT greater than 5%
Rich Condition Concern: LONGFT less than 25%, SHRTFT less than 10%

Fuel System Monitor

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Fuel Systems
Overview
The fuel system supplies the sequential multiport fuel injection (SFI) fuel injectors with clean fuel at a
controlled pressure. The powertrain control module (PCM) controls the fuel pump and monitors the fuel
pump circuit. The PCM controls the fuel injector on/off cycle duration and determines the correct timing and
amount of fuel delivered. When a new fuel injector is installed it is necessary to reset the learned values
contained in the keep alive memory (KAM) in the PCM. Refer to Section 2, Resetting The Keep Alive
Memory (KAM) .
The 2 types of fuel systems used are:
electronic returnless fuel
mechanical returnless fuel

Electronic Returnless Fuel System (ERFS)
The electronic returnless fuel system consists of a fuel tank with reservoir, the fuel pump, the fuel rail
pressure (FRP) or fuel rail pressure temperature (FRPT) sensor, the fuel filter, the fuel supply line, the fuel
rail, and the fuel injectors. For additional information on the fuel system components, refer to Engine Control
Components in this section. Operation of the system is as follows:
1. The fuel delivery system is enabled during crank or running mode once the PCM receives a
crankshaft position (CKP) sensor signal.
2. The fuel pump logic is defined in the fuel system control strategy and is executed by the PCM.
3. The PCM commands a duty cycle to the fuel pump driver module (FPDM).
4. The FPDM modulates the voltage to the fuel pump (FP) required to achieve the correct fuel pressure.
Voltage for the fuel pump is supplied by the power relay or FPDM power supply relay. For additional
information refer to Fuel Pump Control and Fuel Pump Monitor.
5. The FRP or FRPT sensor provides the PCM with the current fuel rail pressure. The PCM uses this
information to vary the duty cycle output to the FPDM to compensate for varying loads.
6. The FRPT sensor measures the current fuel temperatures in the fuel rail. This information is used to
vary the fuel pressure and avoid fuel system vaporization.
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7. The fuel injector is a solenoid-operated valve that meters the fuel flow to each combustion cylinder.
The fuel injector is opened and closed a constant number of times per crankshaft revolution. The
amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injector is
normally closed, and is operated by a 12-volt source from either the electronic engine control (EEC)
power relay or the fuel pump relay. The ground signal is controlled by the PCM.
8. There are 3 filtering or screening devices in the fuel delivery system. The intake sock is a fine, nylon
mesh screen mounted on the intake side of the fuel pump. There is a fuel filter screen located at the
fuel rail side of the fuel injector. The fuel filter assembly is located between the fuel pump and the fuel
rail.
9. The fuel pump (FP) module is a device that contains the fuel pump and the fuel sender assembly.
The fuel pump is located inside the reservoir and supplies fuel through the fuel pump module
manifold to the engine and the fuel pump module jet pump.
10. The inertia fuel shut-off (IFS) switch is used to de-energize the fuel delivery secondary circuit in the
event of a collision. The IFS switch is a safety device that should only be reset after a thorough
inspection of the vehicle following a collision.

Electronic Returnless Fuel System

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Typical Electronic Returnless Fuel System Schematic

Fuel Pump Control ERFS
Note: The Mustang 5.4L uses 2 FPDMs to control fuel for the fuel delivery system. The PCM sends one FP
duty cycle on the fuel pump control (FPC) circuit. This circuit is used by both FPDMs.
The FP signal is a duty cycle command sent from the PCM to the FPDM. The FPDM uses the FP command
to operate the fuel pump at the speed requested by the PCM or to turn the pump off.

FUEL PUMP DUTY CYCLE OUTPUT FROM PCM
FP Duty
Cycle
Command PCM Status FPDM Actions
0-5% PCM does not output
this duty cycle.
Invalid FP duty cycle. FPDM sends 25% duty cycle signal on the
fuel pump monitor (FPM) circuit. The fuel pump is off.
5-51% Normal operation. FPDM operates the fuel pump at the speed requested. "FP duty
cycle" x 2 equals pump speed % of full on. (for example, FP duty
cycle equals 42%. 42x2 equals 84. Pump is run at 84% of full on).
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For additional information, refer to Powertrain Control Hardware , Fuel Pump Driver Module (FPDM).

Fuel Pump Monitor (FPM) ERFS
Note: The Mustang 5.4L uses 2 FPDMs to control fuel for the fuel delivery system. The PCM individually
monitors both FPDMs through the FPM and FPM2 circuits.
The FPDM communicates diagnostic information to the PCM through the FPM circuit. This information is
sent by the FPDM as a duty cycle signal. The 3 duty cycle signals that may be sent are listed in the following
table.

a
If a duty cycle meter and breakout box is used, be aware that these values may be reversed depending on
the trigger setting of the specific meter (for example, 25% from FPDM may read as 75% on duty cycle meter
depending on trigger setting).
b
Some scan tools display the FP_M PID as the duty cycle in column 1. Other scan tools display the FP_M
PID as a value shown in the FP_M PID column. This value fluctuates randomly. It is OK for the value to
briefly go outside this range, then return.
For additional information, refer to Powertrain Control Hardware , Fuel Pump Driver Module (FPDM).
FPDM sends 50% duty cycle signal on FPM circuit.
this duty cycle.
fuel pump monitor (FPM) circuit. The fuel pump is off.
70-81% To request the fuel
pump off, the PCM
outputs a 75% duty
cycle.
Valid fuel pump off command from the PCM. FPDM does not
operate the fuel pump. FPDM sends a 50% duty cycle signal on
the FPM circuit.
this duty cycle.
FPM circuit. The fuel pump is off.
FUEL PUMP DRIVER MODULE DUTY CYCLE SIGNALS
Duty
Cycle
a
On Time
(msec) Comments
FP_M
PID
b
50% 500 All OK output from FPDM. With this input, the PCM can verify that the
FPDM is powered and able to communicate on the FPM circuit.
80-
125%
25% 250 FPDM did not receive a fuel pump (FP) duty cycle command from the
PCM, or the duty cycle that was received was invalid.
15-60%
75% 750 The FPDM has detected a concern in the circuits between the fuel
pump and FPDM.
250-
400%
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Mechanical Returnless Fuel System (MRFS)
The MRFS consists of a fuel tank with reservoir, the fuel pump, the fuel pressure regulator, the fuel filter, the
fuel supply line, the fuel rail, the fuel rail pulse damper (if equipped), fuel injectors, and a Schrader
valve/pressure test point. For additional information on the fuel system components, refer to Engine Control
Components in this section. Operation of the system is as follows:
1. The fuel delivery system is enabled during crank or running mode once the PCM receives a CKP
sensor signal.
2. The fuel pump logic is defined in the fuel system control strategy and is executed by the PCM.
3. The PCM grounds the fuel pump relay, which provides power to the fuel pump.
4. The IFS switch is used to de-energize the fuel delivery secondary circuit in the event of collision. The
IFS switch is a safety device that should only be reset after a thorough inspection of the vehicle
following a collision.
5. A pressure test point valve, Schrader valve, is located on the fuel rail and is used to measure the fuel
injector supply pressure for diagnostic procedures and repairs. On vehicles not equipped with a
Schrader valve, use the Rotunda Fuel Pressure Test Kit 134-R0087 or equivalent.
6. A pulse damper is located on the fuel rail (if equipped). The pulse damper reduces the fuel system
noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is
connected to manifold vacuum to avoid fuel spillage if the pulse damper diaphragm ruptures. The
pulse damper should not be confused with a fuel pressure regulator.
7. The fuel injector is a solenoid-operated valve that meters the fuel flow to each combustion cylinder.
The fuel injector is opened and closed a constant number of times per crankshaft revolution. The
amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injector is
normally closed, and is operated by a 12-volt source from either the EEC power relay or the fuel
pump relay. The ground signal is controlled by the PCM.
8. There are 3 filtering or screening devices in the fuel delivery system. The intake sock is a fine, nylon
mesh screen mounted on the intake side of the fuel pump. There is a fuel filter screen located at the
fuel rail side of the fuel injector. The fuel filter assembly is located between the fuel pump and the
pressure test point/Schrader valve.
9. The FP module contains the fuel pump, the fuel pressure regulator and the fuel sender assembly.
The fuel pressure regulator is attached to the fuel pump in the fuel pump module located in the fuel
tank. It regulates the fuel pressure supplied to the fuel injectors. The fuel pressure regulator is a
diaphragm-operated relief valve. Fuel pressure is established by a spring preload applied to the
diaphragm. Excess fuel is bypassed through the regulator and returned to the fuel tank.
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Mechanical Returnless Fuel System

Fuel Pump Control MRFS
The output signal from the PCM, FP, is used to control the electric fuel pump. With the EEC power relay
contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump
operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This
energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric
fuel pump. When the key is turned on, the electric fuel pump runs for about 1 second and is turned off by the
PCM if engine rotation is not detected.

Fuel Pump Monitor (FPM) MRFS
The FPM circuit is spliced into the fuel pump power (FP PWR) circuit and is used by the PCM for diagnostic
purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage
is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low,
the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through
the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not short to power. With
the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits.
With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel
pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and
there is a B+ supply to the fuel pump relay.
Fuel Filters
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The system contains 4 filtering or screening devices. Refer to the individual component illustrations for
locations.
1. The fuel intake sock or screen is a fine nylon mesh sock mounted on the intake side of the fuel pump.
It is part of the assembly and cannot be repaired separately.
2. The filter/screen at the fuel rail port of the injectors is part of the fuel injector assembly and cannot be
repaired separately.
3. The filter/screen at fuel inlet side of the fuel pressure regulator is part of the regulator assembly and
cannot be repaired separately.
4. The fuel filter assembly is located between the fuel pump (tank) and the pressure test point (Schrader
valve) or injectors. A new filter may be installed.
Pressure Test Point
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel
pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before
repairing or diagnosing the fuel system, read any WARNING, CAUTION, and HANDLING information. On
vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit 134-R0087 or
equivalent.

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Heated Oxygen Sensor (HO2S) Monitor
The HO2S monitor is an on-board strategy designed to monitor the HO2S sensors for concerns or
deterioration which can affect emissions. The fuel control or stream 1 HO2S are checked for correct output
voltage and response rate. Response rate is the time it takes to switch from lean to rich or rich to lean.
Stream 2 HO2S sensors are used for catalyst monitoring, and stream 3 HO2S sensors used for fore-aft
oxygen sensor (FAOS) control are also monitored for correct output voltage. Input is required from the
camshaft position (CMP), crankshaft position (CKP), engine coolant temperature (ECT) or cylinder head
temperature (CHT), fuel rail pressure (FRP), fuel tank pressure (FTP), intake air temperature (IAT), mass air
flow (MAF), manifold absolute pressure (MAP), and throttle position (TP) sensors and the vehicle speed
sensor (VSS) to activate the HO2S monitor. The fuel system monitor and misfire detection monitor must also
have completed successfully before the HO2S monitor is enabled.
1. The HO2S senses the oxygen content in the exhaust flow and outputs a voltage between 0 and 1.0
volt. Lean of stoichiometric, air/fuel ratio of approximately 14.7:1, the HO2S generates a voltage
between 0 and 0.45 volt. Rich of stoichiometric, the HO2S generates a voltage between 0.45 and 1.0
volt. The HO2S monitor evaluates the stream 1 (fuel control), stream 2 (catalyst monitor), and stream
3 (FAOS control) HO2S for correct function.
2. The time between HO2S switches is monitored after vehicle startup and during closed loop fuel
conditions. Excessive time between switches or no switches since startup indicates a concern. Since
lack of switching concerns can be caused by HO2S sensor concerns or by shifts in the fuel system,
DTCs are stored that provide additional information for the lack of switching concern. Different DTCs
indicate whether the sensor always indicates lean/disconnected (P2195 or P2197), or always
indicates rich (P2196 or P2198). The HO2S signal is also monitored for high voltage, in excess of 1.1
volts and stores a unique DTC (P0132 or P0152). An over-voltage condition is caused by a HO2S
heater or battery power short to the HO2S signal line.

A functional test of the rear HO2S sensors is done during normal vehicle operation. The peak rich
and lean voltages are continuously monitored. Voltages that exceed the calibrated rich and lean
thresholds indicate a functional sensor. If the voltages have not exceeded the thresholds after a long
period of vehicle operation, the air/fuel ratio may be forced rich or lean in an attempt to get the rear
sensor to switch. This situation normally occurs only with a green, less than 804.7 km (500 mi),
catalyst. If the sensor does not exceed the rich and lean peak thresholds, a concern is indicated. The
HO2S signal is also monitored for high voltage, in excess of 1.1 volts and stores a unique DTC
(P0138 or P0158). An over-voltage condition is caused by a HO2S heater or battery power short to
the HO2S signal line.
3. The MIL is activated after a concern is detected on 2 consecutive drive cycles.
4. Some partial zero emission vehicles (PZEV) use 3 sets of HO2Ss. The front sensors
(HO2S11/HO2S21) are the primary fuel control sensors. The next sensors downstream in the
exhaust are used to monitor the light-off catalyst (HO2S12/HO2S22). The last sensors downstream in
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the exhaust (HO2S13/HO2S23) are used for very long term fuel trim in order to optimize catalyst
efficiency (FAOS control). The current PZEV vehicle uses a 4-cylinder engine, so only the Bank 1
DTCs are used.
The HO2S monitor DTCs can be categorized as follows:
HO2S slow response rate - P0133, P0139, P0153, P0159
HO2S circuit high voltage - P0132, P0138, P0144, P0152, P0158, P0164
HO2S heater circuit - P0135, P0141, P0155, P0161, P0147, P0167
HO2S heater resistance - P0053, P0054, P0055, P0059, P0060
Downstream HO2S not running in on-demand self-test - P1127
Swapped HO2S connectors - P0040, P0041
HO2S lack of switching - P2195, P2196, P2197, P2198
HO2S lack of switching (sensor indicates lean) - P2270, P2272, P2274, P2276
HO2S lack of switching (sensor indicates rich) - P2271, P2273, P2275, P2277

Heated Oxygen Sensor (HO2S) Monitor

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Heated Oxygen Sensor (HO2S) Monitor - PZEV

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Ignition Systems
Overview
The ignition system is designed to ignite the compressed air/fuel mixture in an internal combustion engine by
a high voltage spark delivered from an ignition coil controlled by the powertrain control module (PCM).
Integrated Electronic Ignition System
Note: Electronic ignition engine timing is entirely controlled by the PCM. Electronic ignition engine timing is
not adjustable. Do not attempt to check base timing. You will receive false readings.
The integrated electronic ignition system consists of a crankshaft position (CKP) sensor, coil pack(s),
connecting wiring, and a PCM. For additional information on the ignition system components, refer to Engine
Control Components in this section. The coil-on-plug (COP) integrated electronic ignition system uses a
separate coil per spark plug, and each coil is mounted directly onto the plug. The COP integrated electronic
ignition system eliminates the need for spark plug wires, but does require input from the camshaft position
(CMP) sensor. Operation of the components are as follows:
1. The CKP sensor is used to indicate the crankshaft position and speed by sensing a missing tooth on
a pulse wheel mounted to the crankshaft. The CMP sensor is used by the COP integrated electronic
ignition system to identify the compression stroke of cylinder 1 and to synchronize the firing of the
individual coils.
2. The PCM uses the CKP signal to calculate a spark target and then fires the coil pack(s) to that target
shown. The PCM uses the CMP sensor to identify the compression stroke of cylinder 1, and to
synchronize the firing of the individual coils.
3. The PCM controls the ignition coils after it calculates the spark target. The COP system fires only one
spark plug per coil upon synchronization during the compression stroke. For the coil pack ignition
system, each coil within a pack fires 2 spark plugs at the same time. The plugs are paired so that as
one fires during the compression stroke the other fires during the exhaust stroke. The next time the
coil is fired the situation is reversed.

The current flow, or dwell, through the primary ignition coil is controlled by the PCM by providing a
switched ground path through the ignition coil driver to ground. When the ignition coil driver is
switched on, current rapidly builds up to a maximum value, determined by the coil inductance and
resistance. When the current is switched off, the magnetic field collapses which induces a secondary
high voltage surge and the spark plug is fired. This high voltage surge creates a flyback voltage which
the PCM uses as a feedback during the ignition diagnostics. The PCM uses the charge current dwell
time characteristics to carry out the ignition diagnostics.
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4. The PCM processes the CKP signal and uses it to drive the tachometer as the clean tach out (CTO)
signal.


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Six Cylinder Integrated Electronic Ignition Waveforms. 4, 8, and 10-Cylinder are Similar.
Engine Crank/Engine Running
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During engine crank the PCM fires 2 spark plugs simultaneously. Of the 2 plugs simultaneously fired one will
be under compression the other will be on the exhaust stroke. Both plugs fire until camshaft position is
identified by a successful camshaft position (CMP) sensor signal. Once camshaft position is identified only
the cylinder under compression is fired.
CMP FMEM
During CMP FMEM the COP ignition works the same as during engine crank. This allows the engine to
operate without the PCM knowing if cylinder one is under compression or exhaust.

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Intake Air Systems
Overview
The intake air system provides clean air to the engine, optimizes air flow, and reduces unwanted induction
noise. The intake air system consists of an air cleaner assembly, resonator assemblies, and hoses. Some
vehicles use a hydrocarbon filter trap to help reduce emissions by preventing fuel vapor from escaping into
the atmosphere from the intake when the engine is off. It is typically located inside the air intake system. The
mass air flow (MAF) sensor is attached to the air cleaner assembly and measures the volume of air
delivered to the engine. The hydrocarbon trap is part of the EVAP system. For more information on the
EVAP system, refer to Evaporative Emission (EVAP) Systems in this section. The MAF sensor can be
replaced as an individual component. The intake air system also contains a sensor that measures the intake
air temperature (IAT), which is also integrated with the MAF sensor. For additional information on the intake
air system components, refer to Engine Control Components in this section. Intake air components can be
separate components or part of the intake air housing. The function of a resonator is to reduce induction
noise. The intake air components are connected to each other and to the throttle body assembly with hoses.

Typical Intake Air System

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Throttle Body System Overview
Note: This overview is for applications without electronic throttle control (ETC). For ETC applications, refer
to Torque Based Electronic Throttle Control (ETC) in this section.
Note: The traditional idle air adjust procedure and the throttle return screw are no longer used on OBD
applications.
The throttle body system meters air to the engine during idle, part throttle, and wide open throttle (WOT)
conditions. The throttle body system consists of an idle air control (IAC) valve assembly, an idle air orifice,
single or dual bores with butterfly valve throttle plates, and a throttle position (TP) sensor. One other source
of idle air flow is the positive crankcase ventilation (PCV) system. The combined idle air flow (from idle air
orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications.
During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air
passage and the PCV valve. The IAC valve assembly provides additional air when commanded by the PCM
to maintain the correct engine idle speed under varying conditions. The IAC valve assembly mounts directly
to the intake manifold assembly in most applications. Idle speed is controlled by the PCM and cannot be
adjusted.
Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The
TP sensor monitors the throttle position and provides a signal to the PCM. Some throttle body applications
Intake Air System Component
1 Air Cleaner Intake Pipe
2 Intake Air Resonator
3 Air Cleaner Element
4 Mass Air Flow/Intake Air Temperature
5 Air Cleaner Outlet
6 Secondary AIR Pump (if equipped)
7 Throttle Body
8 Idle Air Control
9 Upper Intake Manifold
10 Exhaust Gas Recirculation (EGR)
11 Positive Crankcase Ventilation (PCV)
12 Evaporative Emission Canister Purge Valve
13 Evaporative Emission Canister
14 Evaporative Emission Canister Vent (CV) Solenoid
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provide an air supply channel upstream of the throttle plate to provide fresh air to the PCV or IAC systems.
Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV
return, exhaust gas recirculation (EGR), evaporative emission (EVAP), and miscellaneous control signals.
Throttle Body System Hardware
The major components of the throttle body assembly include the TP sensor, the IAC valve assembly, and
the throttle body housing assembly. For additional information on the intake air system components, refer to
Engine Control Components in this section.
Throttle Body Housing
The throttle body housing assembly is a single piece aluminum or plastic casting with an air passage and a
butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the
throttle lever arm should be in contact with the throttle return stop. The throttle return stop prevents the
throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air
flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to
the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant
to engine intake sludge accumulation.
Features of the Throttle Body Assembly include:
1. IAC valve assembly mounted directly to the throttle body assembly (some vehicles).
2. A pre-set stop to locate the WOT position.
3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some
vehicles only).
4. Individual vacuum taps for PCV, EGR, EVAP and miscellaneous control signals (some vehicles only).
5. PCV air return (if applicable).
6. A throttle body-mounted TP sensor.
7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to
engine intake sludge accumulation. These throttle body assemblies must not be cleaned and have a
white/black attention decal advising not to clean.
8. A non-adjustable stop screw for close plate idle air flow.
Overview of the Intake Manifold Runner Control (IMRC) and Intake Manifold
Tuning Valve (IMTV) Systems
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There are 3 basic types of intake air sub-systems:
IMRC electric actuated system
IMRC vacuum actuated system
IMTV
There are several different styles of hardware used to control airflow within the engine air intake system. In
general, the devices are defined based on whether they control in-cylinder motion (charge motion) or
manifold dynamics (tuning).
The IMRC is a charge motion device that modifies the air charge motion in the manifold. The IMRC control
valve is located close to the intake valve/cylinder head. The IMRC actuator can be either electric or vacuum
controlled. The IMRC system must have a monitor feedback system in order to meet OBDII regulations.
The IMTV is a manifold tuning device that effects the air flow volume of the manifold by connecting multiple
plenums or inlets within the manifold system. The IMTV control valve is located in the center of the intake
manifold away from the intake valve or cylinder head. The IMTV actuator can be either electric or vacuum
controlled. The IMTV system does not have to be monitored for OBDII regulations.
Some vehicles may use both systems.
These subsystems are used to provide increased intake airflow to improve torque, emissions and
performance. The overall volume of air metered to the engine is controlled by the throttle body. Vehicles
equipped with electronic throttle control (ETC) do not use idle air control (IAC).
Intake Manifold Runner Control (IMRC) Electric Actuated System
ACTUATED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
The IMRC electric actuated system consists of a remote mounted motorized actuator with an attaching
linkage for each housing on each bank. For additional information on IMRC components, refer to Engine
Control Components in this section. The linkage attaches to the housing butterfly plate levers. Some
variations can have either 2 intake air passages for each cylinder with one passageway that is always open
and the other is opened and closed with a butterfly valve plate. The other type has a butterfly valve with a
small passageway that opens up into a larger size orifice when the butterfly plates are opened. The butterfly
valve plates are opened and closed by an electric motor and the motorized actuator houses an internal
switch or switches, depending on the application, to provide feedback to PCM indicating the butterfly valve
plate position. If the IMRC system is not working correctly then a DTC is set.
Below approximately 3,000 RPM, the motorized actuator is not energized. This allows the linkage to fully
extend and the butterfly valve plates to remain closed. Above approximately 3,000 RPM the motorized
actuator is energized. The attaching linkage pulls the butterfly valve plates into the open position. Some
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vehicles activate the IMRC near 1,500 RPM.
1. The PCM uses the TP sensor and CKP signals to determine activation of the IMRC system. There
must be a positive change in voltage from the TP sensor along with the increase in RPM to open the
valve plates.
2. The PCM uses the information from the input signals to control the IMRC motorized actuator based
upon RPM and changes in the throttle position.
3. The PCM energizes the actuator to open the butterfly plates.
4. The IMRC housing contains butterfly plates to allow increased air flow.

Intake Manifold Runner Control (IMRC) Electric Actuated System.
Intake Manifold Runner Control (IMRC) Vacuum Actuated System
The IMRC vacuum actuated system consists of a manifold mounted vacuum actuator and a PCM controlled
electric solenoid. For additional information on IMRC vacuum actuated components, refer to Engine Control
Components in this section. The linkage from the actuator attaches to the manifold butterfly plate lever. The
IMRC actuator and manifold are composite/plastic with a single intake air passage for each cylinder. The
passage has a butterfly valve plate that blocks a large percentage of the opening when actuated, leaving the
top of the passage open to generate turbulence. The housing uses a return spring to hold the butterfly valve
plates open. The vacuum actuator houses an internal monitor circuit to provide feedback to the PCM
indicating the butterfly valve plate position.
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Below approximately 3,000 RPM, the vacuum solenoid is energized. This allows manifold vacuum to be
applied and the butterfly valve plates to remain closed. Above approximately 3,000 RPM, the vacuum
solenoid is de-energized. This allows vacuum to vent from the actuator and the butterfly valve plates to
open.
1. The PCM monitors the TP sensor, CHT, and CKP signals to determine activation of the IMRC
system. There must be a positive change in voltage from the TP sensor along with the increase in
RPM at the correct engine temperature to open the valve plates.
2. The PCM uses the information from the input signals to control the IMRC electric solenoid based
upon changes in the throttle position, the engine temperature, and the RPM.
3. The PCM energizes the solenoid with the key on and the engine running. Vacuum is then applied to
the actuator to pull the butterfly plates closed.

Intake Manifold Runner Control (IMRC) Vacuum Actuated System
Intake Manifold Tuning Valve (IMTV) System
The IMTV is a motorized actuated unit mounted directly to the intake manifold. For additional information on
IMTV components, refer to Engine Control Components in this section.
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The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the closed
position not allowing airflow blend to occur in the intake manifold. Above approximately 2,600 RPM the
motorized unit is energized. The motorized unit is commanded on by the PCM initially at a 100 percent duty
cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to
hold the shutter open.
1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There
must be a positive change in voltage from the TP sensor along with the increase in RPM to open the
shutter.
2. The PCM uses the information from the input signals to control the IMTV.
3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical
separating wall at high engine speeds to allow both sides of the manifold to blend together.

Intake Manifold Tuning Valve (IMTV)

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Malfunction Indicator Lamp (MIL)
The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic
(OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code
(DTC) sets.
The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or the international standards organization (ISO) standard engine symbol.
The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
The MIL remains illuminated after instrument cluster prove out if:
an emission-related concern and DTC exists.
the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
the PCM is operating in the hardware limited operation strategy (HLOS).
The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster
concern is present.
To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive
drive cycles must be completed without a concern.
For all MIL concerns, go to Section 3 , Symptom Charts.
If the MIL flashes at a steady rate, a severe misfire condition may exist.
If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low.
The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC
P1000 is set.

CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol

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Misfire Detection Monitor
The misfire detection monitor is an on-board strategy designed to monitor engine misfire and identify the
specific cylinder in which the misfire has occurred. Misfire is defined as lack of combustion in a cylinder due
to absence of spark, poor fuel metering, poor compression, or any other cause. The misfire detection
monitor is enabled only when certain base engine conditions are first satisfied. Input from the engine coolant
temperature (ECT) or cylinder head temperature (CHT), intake air temperature (IAT), mass air flow (MAF)
sensors is required to enable the monitor. The misfire detection monitor is also carried out during an on-
demand self-test.
1. The PCM synchronized ignition spark is based on information received from the CKP sensor. The
CKP signal generated is also the main input used in determining cylinder misfire.
2. The input signal generated by the CKP sensor is derived by sensing the passage of teeth from the
crankshaft position wheel mounted on the end of the crankshaft.
3. The input signal to the PCM is then used to calculate the time between CKP edges and the
crankshaft rotational velocity and acceleration. By comparing the accelerations of each cylinder
event, the power loss of each cylinder is determined. When the power loss of a particular cylinder is
sufficiently less than a calibrated value and other criteria are met, then the suspect cylinder is
determined to have misfired.
4. The MIL is activated after one of the above tests fail on 2 consecutive drive cycles.

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Misfire Detection Monitor
Misfire Monitor Operation
There are 3 different misfire monitoring technologies used. They are low data rate (LDR) and high data rate
(HDR), and neural network misfire. The LDR system is capable of meeting the federal test procedure
monitoring requirements on most engines and is capable of meeting the full-range of misfire monitoring
requirements on 4-cylinder engines. The HDR system is capable of meeting the full-range of misfire
monitoring requirements on 6 and 8 cylinder engines. The neural network misfire detection system improves
detection ranges and cylinder identification for a wider range of misfire patterns on some 8, 10, and 12
cylinder vehicles. The HDR on these engines meets the full-range of misfire phase-in requirements specified
in the OBD regulations. All engines except the 6.8L V-10 are full-range capable. All software allows for
detection of any misfires that occur 6 engine revolutions after initially cranking the engine. This meets the
OBD requirement to identify misfires within 2 engine revolutions after exceeding the warm drive, idle RPM.
Low Data Rate System (LDR)
The LDR misfire monitor uses a low data rate crankshaft position signal, one position reference signal at 10
degrees before top dead center (BTDC) for each cylinder event. The PCM calculates the crankshaft
rotational velocity for each cylinder from this crankshaft position signal. The acceleration for each cylinder
can then be calculated using successive velocity values. The changes in overall engine RPM are removed
by subtracting the median engine acceleration over a complete engine cycle. The resulting deviant cylinder
acceleration values are used in evaluating misfire in the General Misfire Processing section below.
High Data Rate System (HDR)
The HDR misfire monitor uses a high data rate crankshaft position signal, 18 position references per
crankshaft revolution. This high resolution signal is processed using 2 different algorithms. The first
algorithm is optimized to detect hard misfires on one or more continuously misfiring cylinders. The low pass
filter filters the high-resolution crankshaft velocity signal to remove some of the crankshaft torsional
vibrations that degrade signal to noise. Two low pass filters are used to enhance detection capability a
base filter and a more aggressive filter to enhance single-cylinder capability at higher RPM. This significantly
improves detection capability for continuous misfires on single cylinders at redline. The second algorithm,
called pattern cancellation, is optimized to detect low rates of misfire. The algorithm learns the normal
pattern of cylinder accelerations from the mostly good firing events and is then able to accurately detect
deviations from that pattern. Both the hard misfire algorithm and the pattern cancellation algorithm produce a
deviant cylinder acceleration value, which is used in evaluating misfire in the General Misfire Algorithm
Processing section below. Due to the high data processing requirements, the HDR algorithms could not be
implemented in the PCM microprocessor. They are implemented in a separate chip in the PCM called an
AICE chip. The PCM microprocessor communicates with the AICE chip using a dedicated serial
communication link. The AICE chip sends the cylinder acceleration values back to the PCM microprocessor
for additional processing as described below. Lack of serial communication between the AICE chip and the
PCM microprocessor, or an inability to synchronize the crankshaft or camshaft sensors inputs sets a DTC.
DTC P0606 is set if there is a lack of serial communication between the AICE chip and the PCM
microprocessor. DTC P1336 is set if there is an inability to synchronize the crank or camshaft sensor inputs.
This change was made to improve diagnosis. DTC P0606 generally results in PCM replacement while DTC
P1336 points to a camshaft sensor that is out of synchronization with the crank. Profile correction software is
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used to learn and correct for mechanical inaccuracies in crankshaft tooth spacing under de-fueled engine
conditions (requires 3 decelerations from 97 to 64 km/h (60 to 40 mph) with no-braking after the keep alive
memory (KAM) has been reset). If the KAM has been reset, the PCM microprocessor initiates a special
routine which computes correction factors for each of the 18 (or 20) position references and sends these
correction factors back to the AICE chip to be used for subsequent misfire signal processing. These learned
corrections improve the high RPM capability of the monitor. The misfire monitor is not active until a profile
has been learned.
Neural Network System
The neural network misfire monitor uses a dedicated microprocessor in the PCM along with crankshaft
position, (36-tooth wheel or 40-tooth wheel on a V-10), camshaft position, and engine load to determine
engine misfire. A neural network is a different way of computing that uses a large number of simple
processing elements with a high degree of interconnection to process complex information. The processing
elements have adaptive characteristics (coefficients) that must be learned through a process called training.
During training, the network is fed a sample set of data that consists of the inputs along with the desired
output (misfire/no misfire). The network coefficients are recursively optimized so that the correct output is
generated from the set of inputs and error is minimized. Once the coefficients have been learned, the
network can process real data. The neural network size is 23 nodes and 469 coefficients. The engine off
natural vacuum evaporative system monitor also uses the same microprocessor. Profile correction software
is also used on neural network system to learn and correct for mechanical inaccuracies in crankshaft tooth
spacing under de-fueled engine conditions (requires up to three 60 to 40 mph no-braking decelerations after
Keep Alive Memory has been reset). These learned corrections improve the high RPM capability of the
monitor. The misfire monitor is not active until a profile has been learned.
Generic Misfire Processing
The acceleration that a piston undergoes during a normal firing event is directly related to the amount of
torque that cylinder produces. The calculated piston/cylinder acceleration value(s) are compared to a misfire
threshold that is continuously adjusted based on inferred engine torque. Deviant accelerations exceeding
the threshold are conditionally labeled as misfires. The calculated deviant acceleration value(s) are also
evaluated for noise. Normally, misfire results in a nonsymmetrical loss of cylinder acceleration. Mechanical
noise, such as rough roads or high RPM/light load conditions, will produce symmetrical acceleration
variations. Cylinder events that indicate excessive deviant accelerations of this type are considered noise.
Noise-free deviant acceleration exceeding a given threshold is labeled a misfire. The number of misfires are
counted over a continuous 200 revolution and 1,000 revolution period. The revolution counters are not reset
if the misfire monitor is temporarily disabled such as for negative torque mode. At the end of the evaluation
period, the total misfire rate and the misfire rate for each individual cylinder is computed. The misfire rate is
evaluated every 200 revolution period (Type A) and compared to a threshold value obtained from an engine
speed/load table. This misfire threshold is designed to prevent damage to the catalyst due to sustained
excessive temperature 871C (1,600F) for Pt/Pd/Rh conventional washcoat, 899C (1,650F) for Pt/Pd/Rh
advanced washcoat and 982C (1,800F) for Pd-only high tech washcoat. If the misfire threshold is
exceeded and the catalyst temperature model calculates a catalyst mid-bed temperature that exceeds the
catalyst damage threshold, the MIL blinks at a 1 Hz rate while the misfire is present. If the threshold is again
exceeded on a subsequent driving cycle, the MIL is illuminated. If a single cylinder is indicated to be
consistently misfiring in excess of the catalyst damage criteria, the fuel injector to that cylinder may be shut
off for a period of time to prevent catalyst damage. Up to 2 cylinders may be disabled at the same time. This
fuel shut-off feature is used on many 8-cylinder engines and some 6-cylinder engines. It is never used on a
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4-cylinder engine. Next, the misfire rate is evaluated every 1,000 revolution period and compared to a single
(type B) threshold value to indicate if the emission-threshold exceeded, which can be either a single 1,000
over-rev event from startup or 4 subsequent 1,000 over-rev events on a drive cycle after start-up. Many
vehicles will set DTC P0316 if the type B threshold is exceeded during the first 1,000 revolutions after
engine startup. This DTC is stored in addition to the normal P03xx DTC that indicates the misfiring cylinder.
Profile Correction
Profile correction software is used to learn and correct for mechanical inaccuracies in the crankshaft position
wheel tooth spacing. Since the sum of all the angles between the crankshaft teeth must equal 360 degrees,
a correction factor can be calculated for each misfire sample interval that makes all the angles between
individual teeth equal. To prevent any fueling or combustion differences from affecting the correction factors,
learning is done during deceleration-fuel cutout. The correction factors are learned during closed-throttle,
non-braking, de-fueled decelerations in the 97 to 64 km/h (60 to 40 mph) range after exceeding 97 km/h (60
mph) (likely to correspond to a freeway exit condition). In order to minimize the learning time for the
correction factors, a more aggressive deceleration-fuel cutout strategy may be employed when the
conditions for learning are present. The corrections are typically learned in a single deceleration, but can be
learned during up to 3 such decelerations. The mature correction factors are the average of a selected
number of samples. A low data rate misfire system will typically learn 4 such corrections in this interval,
while a high data rate system will learn 36 or 40 in the same interval (data is actually processed in the AICE
chip). In order to assure the accuracy of these corrections, a tolerance is placed on the incoming values
such that an individual correction factor must be repeatable within the tolerance during learning. This is to
reduce the possibility of learning corrections on rough road conditions which could limit misfire detection
capability. Since inaccuracies in the wheel tooth spacing can produce a false indication of misfire, the misfire
monitor is not active until the corrections are learned. In the event of battery disconnection or loss of keep
alive memory (KAM), the correction factors are lost and must be relearned. If the software is unable to learn
a profile after three, 97 to 64 km/h (60 to 40 mph) deceleration cycles, DTC P0315 is set.
Misfire Monitor Specifications
Misfire monitor operation: DTCs P0300 to P0310 (random and specific cylinder misfire), P1336
(crankshaft/camshaft sensor range/performance), P0606 (control module processor), P0315 (crankshaft
position system variation not learned), P0316 (misfire detected on startup [first 1000 revolutions]). The
monitor execution is continuous, misfire rate calculated every 200 or 1,000 revolutions. The monitor does
not have a specific sequence. The CKP and CMP sensors have to be operating correctly to run the monitor.
The monitoring duration is the entire driving cycle (see disablement conditions below).
Typical misfire monitor entry conditions: Entry condition minimum/maximum time since engine start-up is 0
seconds, engine coolant temperature is -7C to 121C (20F to 250F), RPM range is (full-range misfire
certified, with 2 revolution delay) 2 revolutions after exceeding 150 RPM below drive idle RPM to redline on
tach or fuel cutoff, profile correction factors learned in KAM are Yes, and the fuel tank level is greater than
15%.
Typical misfire temporary disablement conditions: Closed throttle deceleration (negative torque, engine
being driven), Fuel shut-off due to vehicle-speed limiting or engine-RPM limiting mode, and a high rate of
change of torque (heavy throttle tip-in or tip out)
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The profile learning operation includes DTC P0315 - unable to learn profile in three, 97 to 64 km/h (60 to 40
mph) decelerations; monitor execution is once per KAM reset; The monitor sequence: profile must be
learned before the misfire monitor is active; The CKP and CMP sensors are required to be OK; AICE
communication errors, CKP/CMP in synch. The monitoring duration is 10 cumulative seconds in conditions
(a maximum of three, 97 to 64 km/h (60 to 40 mph) de-fueled decelerations).
Typical profile learning entry conditions: Entry conditions from minimum to maximum: Engine in
deceleration-fuel cutout mode for 4 engine cycles the brakes are not applied, the engine RPM is 1,300 to
3,700 RPM, the change is less than 600 RPM, the vehicle speed is 48 to 112 km/h (30 to 70 mph), and the
learning tolerance is 1%.

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On Board Diagnostics (OBD) Monitors

OBD-I, OBD-II and Engine Manufacturer Diagnostics (EMD) Overview
The California Air Resources Board (CARB) began regulating OBD systems for vehicles sold in California
beginning with the 1988 model year. The initial requirements, known as OBD-I, required identifying the likely
area of concern with regard to the fuel metering system, exhaust gas recirculation (EGR) system, emission-
related components and the powertrain control module (PCM). A malfunction indicator lamp (MIL) was
required to illuminate and alert the driver of the concern and the need to repair the emission control system.
A diagnostic trouble code (DTC) was required to assist in identifying the system or component associated
with the concern.
Starting with the 1994 model year, both CARB and the Environmental Protection Agency (EPA) mandated
enhanced OBD systems, commonly known as OBD-II. The objectives of the OBD-II system are to improve
air quality by reducing high in-use emissions caused by emission-related concerns, reducing the time
between the occurrence of a concern and its detection and repair, and assisting in the diagnosis and repair
of emission-related problems.
North American OBD-II/Federal OBD requirements apply to:
Gasoline engine passenger cars and trucks: All California and Federal passenger cars, medium
duty passenger vehicles, and trucks up to 6,350 kg (14,000 lb) gross vehicle weight rating (GVWR).
California and Federal heavy-duty trucks over 6,350 kg (14,000 lb) GVWR must comply with EMD.
Passenger cars and trucks sold in Canada and Mexico have Federal calibrations, unless unique
calibrations are certified for Mexico at high altitude. Mexico requires OBD-II for vehicles under 3,856
kg (8,500 lb) GVWR. Trucks over 3,856 kg (8,500 lb) GVWR must comply with EMD in order to meet
the minimum Ford requirements.
Diesel engine passenger cars and trucks: All California and Federal passenger cars, medium duty
passenger vehicles, and trucks up to 6,350 kg (14,000 lb) GVWR. California and Federal heavy-duty
trucks over 6,350 kg (14,000 lb) GVWR must comply with EMD.
The OBD-II system monitors virtually all emission control systems and components that can affect tailpipe or
evaporative emissions. In most cases, concerns must be detected before emissions exceed 1.5 times the
applicable 100,000, 120,000, or 150,000 (passenger cars), or 120,000 (trucks) mile emission standards.
Partial zero emission vehicle (PZEV) and super ultra low emission vehicle (SULEV-II) vehicles can use the
concern criteria of 2.5 in lieu of the 1.5 standard whenever required. Federal Tier 2 (Bins 3 and 4) must use
a 1.5 concern criteria for non-methane organic gases (NMOG) and carbon monoxide (CO), a 1.75 criteria for
NMOG catalyst monitor, and a 2.5 criteria for oxides of nitrogen (NO
x
). If a system or component exceeds
emission thresholds or does not operate within a manufacturer's specifications, a DTC is stored and the MIL
is illuminated within 2 driving cycles.
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The OBD-II system monitors for concerns either continuously, regardless of driving mode, or non-
continuously, once per drive cycle during specific drive modes. A pending DTC is stored in the PCM keep
alive memory (KAM) when a concern is initially detected. Pending DTCs are displayed as long as the
concern is present. Note that OBD regulations required a complete concern-free monitoring cycle to occur
before erasing a pending DTC. This means that a pending DTC is erased on the next power-up after a
concern-free monitoring cycle. However, if the concern is still present after 2 consecutive drive cycles, the
MIL is illuminated. Once the MIL is illuminated, 3 consecutive drive cycles without a concern detected are
required to extinguish the MIL. The DTC is erased after 40 engine warm-up cycles once the MIL is
extinguished.
In addition to specifying and standardizing much of the diagnostics and MIL operation, OBD requires the use
of a standard data link connector (DLC), standard communication links and messages, standardized DTCs
and terminology. Examples of standard diagnostic information are freeze frame data and inspection
maintenance (IM) readiness indicators.
Freeze frame data describes data stored in the KAM at the point the concern is initially detected. Freeze
frame data consists of parameters such as engine RPM and load, state of fuel control, spark, and warm-up
status. Freeze frame data is stored at the time the first concern is detected; however, previously stored
conditions are superseded if a fuel or misfire concern is detected. This data is accessible with the scan tool
to assist in repairing the vehicle.
OBD IM readiness indicators show whether all of the OBD monitors have been completed since the last time
the KAM or the PCM DTC(s) have been cleared. Ford stores a DTC P1000 to indicate that some monitors
have not completed. In some states, it may be necessary to carry out an OBD check in order to renew a
vehicle registration. The IM readiness indicators must show that all monitors have been completed prior to
the OBD check.
Starting with the 2007 model year, vehicles not required to comply with OBD-II requirements use an EMD
system. EMD systems are used on all California and Federal gas and diesel on-road heavy duty engines
used in vehicles over 6,350 kg (14,000 lb) GVWR. EMD systems are required to functionally monitor the fuel
delivery system, EGR system, particulate matter trap, as well as emission related PCM inputs for circuit
continuity and rationality, and emission related outputs for circuit continuity and functionality. For gasoline
engines, which have no particulate matter trap, EMD requirements are very similar to previous OBD-I
system requirements. As such, OBD-I system principles are employed, with the addition of some
comprehensive component monitor (CCM) rationality and functionality checks. EMD vehicles use the same
PCM, controller area network (CAN), data link connector (DLC) and PCM software as the corresponding
OBD-II vehicles. Differences between EMD and OBD-II vehicles may be removal of the rear oxygen sensor
(s), fuel tank pressure sensor, canister vent solenoid, and PCM calibration. The table below lists what
monitors and functions have been altered for the EMD calibration.

Monitor/Feature Calibration
Catalyst Monitor Not required, monitor calibrated out, rear O2 sensors may be deleted.
Misfire Monitor Calibrated in for repair, all DTC are non-MIL. Catalyst damage misfire criteria
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The following monitor descriptions provide a general description of each OBD monitor. In these descriptions,
the monitor strategy, hardware, testing requirements, and methods are presented to provide an overall
understanding of monitor operation. An illustration of each monitor may also be provided. These illustrations
should be used as typical examples and are not intended to represent all possible vehicle configurations.
Each illustration depicts the PCM as the main focus with primary inputs and outputs for each monitor. The
icons to the left of the PCM represent the inputs used by each of the monitor strategies to enable or activate
the monitor. The components and subsystems to the right of the PCM represent the hardware and signals
used while carrying out the tests and the systems being tested. The CCM illustration has numerous
components and signals involved which are shown generically. When referring to the illustrations, match the
numbers to the corresponding numbers in the monitor descriptions for a better comprehension of the
monitor and associated DTCs.
These icons are used in the illustrations of the OBD monitors and throughout this section.

calibrated out, emission threshold criteria set to 4%, enabled between 66C
(150F) and 104C (220F), 254 second start-up delay.
Oxygen Sensor Monitor Rear heated oxygen sensor (HO2S) test calibrated out, rear HO2S may be
deleted, front HO2S response test calibrated out.
EGR Monitor Same as OBD-II calibration except that DTC P0402 test uses a higher
threshold.
Fuel System Monitor Same as OBD-II calibration.
Secondary Air Monitor Functional (low flow) test calibrated out, circuit codes are same as OBD-II
calibration.
Evaporative Emission
(EVAP) System Monitor
EVAP system leak check calibrated out, fuel level input circuit checks retained
as non-MIL. Fuel tank pressure sensor and canister vent solenoid may be
deleted.
PCV Monitor Same hardware and function as OBD-II
Thermostat Monitor Thermostat monitor calibrated out.
Comprehensive
Component Monitor
(CCM)
All circuit checks, rationality and functional tests are the same as OBD-II.
Communication Protocol
and DLC
Same as OBD-II, all generic and enhanced scan tool modes work the same as
OBD-II, but reflect the EMD calibration that contains fewer supported
monitors.
MIL Control Same as OBD-II, it takes 2 driving cycles to illuminate the MIL.
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Positive Crankcase Ventilation (PCV) System Monitor
The PCV monitor consists of a modified PCV system design. The PCV valve is installed into the rocker
cover using a quarter-turn cam-lock design to prevent accidental disconnection. High retention force molded
plastic lines are used from the PCV valve to the intake manifold. The diameter of the lines and the intake
manifold entry fitting are increased so that inadvertent disconnection of the lines after a vehicle is repaired
causes either an immediate engine stall or does not allow the engine to be restarted. In the event that the
vehicle does not stall if the line between the intake manifold and PCV valve is inadvertently disconnected,
the vehicle has a large vacuum leak that causes the vehicle to run lean at idle. This illuminates the MIL after
2 consecutive driving cycles and stores one or more of the following DTCs: Lack of HO2S sensor switches,
bank 1 (P2195), Lack of HO2S sensor switches bank 2 (P2197), fuel system lean, bank 1 (P0171) or fuel
system lean, bank 2 (P0174).
For additional PCV information, refer to Positive Crankcase Ventilation (PCV) System in this section.

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Positive Crankcase Ventilation (PCV) System
Overview
The PCV system cycles crankcase gases back through the intake air system into the engine where they are
burned. The PCV valve regulates the amount of ventilated air and blow-by gases to the intake manifold.
Currently, both heated and non-heated PCV systems are used. The heated systems use either a water
heated valve, an electrically heated valve, or an electrically heated tube. Engine coolant flows around the
water heated valve to prevent it from freezing. Electrically heated systems use a heating element enclosed
in the PCV valve or the PCV tube to prevent the valve or tube from freezing. The valve or the tube heater
can be controlled by either the PCM or the thermal harness.
Thermal harness controlled heater On vehicle applications that are equipped with a thermal
harness to the PCV valve or tube. The thermal harness only provides electrical continuity to the
heating element when temperatures are less than 5C +/- 4C (40F +/- 7F). Typically this harness is
located close to the PCV valve or tube.
PCM controlled heater On these applications the PCV heater is turned on by the PCM. When the
intake air temperature is less than 0C (32F) the PCM grounds the positive crankcase ventilation
valve heater control (PCVHC) circuit and turns the heater ON. When the intake air temperature
exceeds 9C (48F) the heater is turned OFF. The PCV heater is also OFF when the engine is not
running to prevent unnecessary battery drain. The heater is also OFF if the vehicle charging system
is greater than 16 volts. This minimizes heater element overload.
PCV systems that comply with OBD PCV monitoring requirements use a quarter-turn cam-lock thread
design at one end to prevent accidental disconnection from the valve cover. For more information about the
PCV monitor refer to Positive Crankcase Ventilation (PCV) System Monitor in this section.
PCV Types
Heated Tubes
PCM-controlled (no thermistor in harness)
non-PCM controlled (thermistor in harness)
PCV Valves
water heated
non-heated
PCM-controlled
non-PCM controlled electrically heated thermistor in harness
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Refer to the following figures for examples of these types of PCV valves.

Typical PCV System for V-Engine
Hardware

Typical PCV Internal Drawing

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Water Heated PCV

Quarter-Turn Cam-Lock Design PCV

Electrically Heated PCV (with Thermal Harness)

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Electrically Heated PCV Tube (with Thermal Harness)

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Powertrain Control Hardware

The center of the electronic engine control (EEC) system is a microprocessor called the PCM. The PCM
receives input from sensors and other electronic components (switches, relays). Based on the information
received and programmed into its memory, the PCM generates output signals to control various relays,
solenoids and actuators. There are several different types of PCMs in use for this model year. Refer to the
Vehicle PCM Application Table below for PCM types and their applications.

PCM Locations
For PCM removal and installation procedures, refer to the Workshop Manual Section 303-14 Electronic
Engine Controls.
Focus - passenger side behind the kickpanel.
Five Hundred, Freestyle, Montego - engine compartment, passenger side, mounted to the cowl.
Fusion, Milan, Zephyr - engine compartment, driver side, under battery, mounted to the cowl.
Taurus, Freestar, Monterey - (access from the engine compartment) on the passenger side.
Mustang - front of engine compartment, passenger side, near fender, under the battery junction box
(BJB).
Crown Victoria, Grand Marquis, Town Car - engine compartment, driver side, fender mounted.
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Explorer, Explorer Sport Trac, Mountaineer - passenger side, near side cowl, behind the glove
compartment.
Escape, Mariner, Ranger - behind the instrument panel (cowl), center to both driver and passenger
sides (access from the engine compartment).
Expedition, Mark LT, Navigator, F-Series, F-Super Duty - passenger side of the engine compartment,
mounted to the cowl.
E-Series - engine compartment, driver side, near the cowl (access from the engine compartment).
104-Pin PCM

104-Pin PCM

140-Pin PCM

TABLE 1 104-PIN PCM POWER AND GROUNDS
Function Description Connector/Pin
VPWR Voltage input to module 71,97
PWRGND Power ground 24,25,51,76,77,103
CSEGND Case ground 25
SIGRTN Signal return 91
VREF 5.0-volt reference 90
KAPWR Keep alive power 55
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140-Pin PCM

VPWR Voltage input to module B51
PWRGND Power ground B67
CSEGND Case ground B66
SIGRTN Connector B signal return B58
SIGRTN Connector E signal return E58
VREF Connector B buffered 5.0-volt reference B33
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150-Pin PCM

150-Pin PCM

VREF Connector E buffered 5.0-volt reference E57
KAPWR Keep alive power B54
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170-Pin PCM

170-Pin PCM

SIGRTN Connector T signal return T41
VREF Connector buffered 5.0-volt reference B40
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190-Pin PCM

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190-Pin PCM

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Note: The Mustang 5.4L uses 2 FPDMs to control fuel for the fuel delivery system. The PCM outputs only
one fuel pump duty cycle on the fuel pump control (FPC) circuit. This circuit is used by both FPDMs. The
PCM individually monitors the FPDMs through the fuel pump monitor (FPM) and FPM2 circuits. The FPDM
located on the driver side of the luggage compartment is referred to as FPDM and the FPDM located on the
passenger side of the luggage compartment, is referred to as FPDM2.
The FPDM receives a duty cycle signal from the PCM and controls the fuel pump operation in relation to this
duty cycle. This results in variable speed fuel pump operation. The FPDM sends diagnostic information to
the PCM on the fuel pump monitor circuit. For additional information on the fuel pump control and the fuel
pump monitor, refer to Fuel Systems in this section.

Keep Alive Memory (KAM)
The PCM stores information in KAM (a memory integrated circuit chip) about vehicle operating conditions
and then uses this information to compensate for component variability. The KAM remains powered when
the key is in the OFF position so that this information is not lost.

Hardware Limited Operation Strategy (HLOS)
This system of special circuitry provides minimal engine operation should the PCM (mainly the central
processing unit [CPU] or EEPROM) stop functioning correctly. All modes of self-test are not functional at this
time. Electronic hardware is in control of the system while in HLOS.
HLOS Allowable Output Functions:
spark output controlled directly by the crankshaft position (CKP) signal
fixed fuel pulse width synchronized with the CKP signal
fuel pump relay energized
idle speed control output signal functional
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HLOS Disabled Outputs To Default State:
exhaust gas recirculation (EGR) solenoids
no torque converter clutch lock-up

The integrated electronic ignition system consists of a CKP sensor, coil pack(s), connecting wiring, and
PCM. The coil on plug (COP) integrated electronic ignition system uses a separate coil for each spark plug
and each coil is mounted directly onto the plug. The COP integrated electronic ignition system eliminates the
need for spark plug wires but does require input from the camshaft position (CMP) sensor.

Power and Ground Signals
Electronic Throttle Control Reference Voltage (ETCREF)
ETCREF is a consistent positive voltage (5.0 volts 0.5) supplied by the PCM. ETCREF is internally bussed
within the PCM and is specifically dedicated to the accelerator pedal position (APP) sensor and the
electronic throttle body (ETB) throttle position (TP) sensor.
Electronic Throttle Control Return (ETCRTN)
ETCRTN is a return path for ETCREF and is internally bussed within the PCM. ETCRTN is specifically
dedicated to the APP sensor and the ETB TP sensor.
Gold Plated Pins
Note: Gold plated terminals should only be replaced with new gold plated terminals.
Some engine control hardware has gold plated pins within the connectors and mating harness connectors to
improve electrical stability for low current draw circuits and to enhance corrosion resistance. The electronic
engine control (EEC) components equipped with gold terminals vary by vehicle application.
Keep Alive Power (KAPWR)
KAPWR provides a constant voltage input independent of ignition switch state to the PCM. This voltage is
used by the PCM to maintain the keep alive memory (KAM).
Mass Air Flow (MAF) Return
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The mass air flow return (MAF RTN) is a dedicated analog signal return from the MAF sensor. It serves as a
ground offset for the analog voltage differential input by the MAF sensor to the PCM.
Power Ground (PWR GND)
The PWR GND circuit(s) is directly connected to the battery negative terminal. PWR GND provides a return
path for the PCM vehicle power (VPWR) circuits.
Signal Return (SIG RTN)
SIG RTN is a dedicated return path for VREF applied components.
Vehicle Buffered Power (VBPWR)
VBPWR is a regulated voltage supplied by the PCM to vehicle sensors. These sensors require a constant
12 volts for operation and cannot withstand VPWR voltage variations. VBPWR is regulated to VPWR minus
1.5 volts and is also current limited to protect the sensors.
Vehicle Power (VPWR)
VPWR is the primary source of PCM power. VPWR is switched through the EEC power relay and is
controlled by the ignition switch.
Vehicle Reference Voltage (VREF)
VREF is a consistent positive voltage (5.0 volts 0.5) provided by the PCM. VREF is typically used by 3-
wire sensors and some digital input signals.

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Powertrain Control Module (PCM) Controlled Charging System
Overview
Note: When the battery (or PCM) is disconnected and connected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The charging system set point may also vary. The
vehicle may need to be driven to relearn its strategy.
The PCM-controlled charging system provides many additional benefits over the current integral generator
regulator system. The first benefit is improved battery life. In an integral generator regulator system, the
regulator set point is established by a temperature sensor in the regulator which estimates battery
temperature. In a PCM-controlled charging system, the regulator voltage set point is determined by the PCM
and communicated to the regulator through the generator regulator control (GENRC) circuit. The PCM uses
an algorithm to estimate battery temperature. Improving battery temperature estimates reduces battery
damage caused by over- and undercharging.
The second benefit is improved engine performance. Whenever the PCM senses a wide open throttle
(WOT) condition, the PCM momentarily lowers the regulator voltage set point. This reduces the torque load
of the generator on the engine and improves acceleration. The PCM has a calibratable time limit on this
reduced voltage feature. This is to prevent the generator output from being cut back for an extended WOT
period, which could cause battery discharge.
The third benefit is improved idle stability. In response to the PCMs GENRC signal, the regulator uses a
generator load input (GENLI) signal to provide feedback to the PCM. The GENLI signal provides the PCM
with charging system information. Specifically, it lets the PCM know when the charging system receives a
transient electrical load which would normally affect idle stability. Because the PCM can anticipate additional
loads, actions can be taken to minimize idle sag. The PCM can choose to either reduce the regulator set
point or increase engine idle speed, both of which are calibratable features. In order to establish whether the
regulator is accurately maintaining the desired voltage set point, the regulator uses a charging system
voltage line to sense battery voltage.
The fourth benefit is reduced cranking efforts. The PCM can reduce the mechanical load on the starter by
initially commanding a low voltage set point. This may improve start times.
If the PCM detects a charging system error, it broadcasts a low voltage telltale (ON) network communication
message which tells the cluster to illuminate the charge indicator. The charge indicator is illuminated if the
PCM does not see a signal on the GENLI circuit for a time period greater than 500 milliseconds. This telltale
command is also used to indicate over-voltage conditions detected by the PCM-controlled generator.
Each time the ignition switch is cycled to the run position, the instrument cluster initiates a bulb check by
illuminating the charge indicator. It is the PCMs responsibility to issue a low voltage telltale (OFF) command
if the charging system is functioning correctly. This message should be sent during the network initialization
in the voluntary phase (250 milliseconds to 450 milliseconds after the ignition switch is cycled to the run
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position). If a low voltage telltale (OFF) communications network message is not received, the instrument
cluster continues to illuminate the charge indicator indefinitely.

PCM-Controlled Charging System

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Powertrain Control Software

Computer Controlled Shutdown
The powertrain control module (PCM) controls the electronic engine control (EEC) power relay when the key
is turned to the ON or START position, by grounding the PCM relay control (PCMRC) circuit. After the key is
turned to the OFF, ACC or LOCK position, the PCM stays powered up until the correct engine shutdown
occurs.
The ignition switch position run (ISP-R) and the injector power monitor (INJPWRM) circuits provide the key
state input to the PCM. Based on the ISP-R and INJPWRM signals the PCM determines when to power
down the EEC power relay.

Engine RPM/Vehicle Speed Limiter
The PCM disables some or all of the fuel injectors whenever an engine RPM or vehicle over speed condition
is detected. The purpose of the engine RPM or vehicle speed limiter is to prevent damage to the powertrain.
The vehicle exhibits a rough running engine condition, and the PCM stores one of the following continuous
memory diagnostic trouble codes (DTCs): P0219, P0297, or P1270. Once the driver reduces the excessive
speed, the engine returns to the normal operating mode. No repair is required. However, the technician
should clear the DTCs and inform the customer of the reason for the DTC.
Excessive wheel slippage may be caused by sand, gravel, rain, mud, snow, ice, or excessive and sudden
increase in RPM while in NEUTRAL or while driving.

Fail-Safe Cooling Strategy
Note: Not all vehicles with a cylinder head temperature (CHT) sensor have the fail-safe cooling strategy.
The fail-safe cooling strategy is activated by the PCM only in the event that an overheating condition has
been identified. This strategy provides engine temperature control when the cylinder head temperature
exceeds certain limits. The cylinder head temperature is measured by the CHT sensor. For additional
information about the CHT sensor, refer to Engine Control Components in this section.
A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a
result, damage to major engine components could occur. Along with a CHT sensor, the fail-safe cooling
strategy is used to prevent damage by allowing air cooling of the engine. This strategy allows the vehicle to
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be driven safely for a short time with some loss of performance when a overheat condition exist.
Engine temperature is controlled by varying and alternating the number of disabled fuel injectors. This allows
all cylinders to cool. When the fuel injectors are disabled, the respective cylinders work as air pumps, and
this air is used to cool the cylinders. The more fuel injectors that are disabled, the cooler the engine runs, but
the engine has less power.
A wide open throttle (WOT) delay is incorporated if the CHT temperature is exceeded during WOT
operation. At WOT, the injectors function for a limited amount of time allowing the customer to complete a
passing maneuver.
Before injectors are disabled, the fail-safe cooling strategy alerts the customer to a cooling system problem
by moving the instrument cluster temperature gauge to the hot zone and DTC P1285 is set. Depending on
the vehicle, other indicators, such as an audible chime or warning lamp, can be used to alert the customer of
fail-safe cooling. If overheating continues, the strategy begins to disable the fuel injectors, DTC P1299 is
stored in the PCM memory, and a malfunction indicator lamp (MIL) illuminates. If the overheating condition
continues and a critical temperature is reached, all fuel injectors are turned off and the engine is disabled.

Failure Mode Effects Management
Failure mode effects management (FMEM) is an alternate system strategy in the PCM designed to maintain
engine operation if one or more sensor inputs fail.
When a sensor input is determined to be out-of-limits by the PCM, an alternative strategy is initiated. The
PCM substitutes a fixed value for the incorrect input and continues to monitor the suspect sensor input. If the
suspect sensor begins to operate within limits, the PCM returns to the normal engine operational strategy.
All FMEM sensors display a sequence error message on the scan tool. The message may or may not be
followed by key on engine off (KOEO) or continuous memory DTCs when attempting key on engine running
(KOER) self-test mode.

Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
The flash EEPROM is an integrated circuit (IC) within the PCM. This IC contains the software code required
by the PCM to control the powertrain. One feature of the EEPROM is that it can be electrically erased and
then reprogrammed without removing the PCM from the vehicle. If a software change is required to the
PCM, a new module is no longer necessary as the current one can be reprogrammed through the data link
connector (DLC).

Fuel Trim
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Short Term Fuel Trim
If the oxygen sensors are warmed up and the PCM determines that the engine can operate near
stoichiometric air/fuel ratio (14.7:1 for gasoline), the PCM enters closed loop fuel control mode. Since an
oxygen sensor can only indicate rich or lean, the fuel control strategy continuously adjusts the desired
air/fuel ratio between rich and lean causing the oxygen sensor to switch around the stoichiometric point. If
the time between rich and lean switches are the same, then the system is actually operating at
stoichiometric. The desired air/fuel control parameter is called short term fuel trim (SHRTFT1 and 2) where
stoichiometric is represented by 0%. Richer (more fuel) is represented by a positive number and leaner (less
fuel) is represented by a negative number. Normal operating range for short term fuel trim is +/- 25%. Some
calibrations have time between switches and short term fuel trim excursions that are not equal. These
unequal excursions are used to run the system slightly lean or rich of stoichiometric. This practice is referred
to as using bias. For example, the fuel system can be biased slightly rich during closed loop fuel to help
reduce oxides of nitrogen (NO
x
).
Values for SHRTFT1 and 2 may change significantly on a scan tool as the engine is operated at different
RPM and load points. This is because SHRTFT1 and 2 react to fuel delivery variability that changes as a
function of engine RPM and load. Short term fuel trim values are not retained after the engine is turned off.
Long Term Fuel Trim
While the engine is operating in closed loop fuel control, the short term fuel trim corrections are learned by
the PCM as long term fuel trim (LONGFT1 and 2) corrections. These corrections are stored in the keep alive
memory (KAM) fuel trim tables. Fuel trim tables are based on engine speed and load and by bank for
engines with 2 heated oxygen sensor (HO2S) forward of the catalyst. Learning the corrections in KAM
improves both open loop and closed loop air/fuel ratio control. Advantages include:
Short term fuel trim does not have to generate new corrections each time the engine goes into closed
loop.
Long term fuel trim corrections can be used both while in open loop and closed loop modes.
Long term fuel trim is represented as a percentage, similar to the short term fuel trim, however it is not a
single parameter. A separate long term fuel trim value is used for each RPM/load point of engine operation.
Long term fuel trim corrections may change depending on the operating conditions of the engine (RPM and
load), ambient air temperature, and fuel quality (% alcohol, oxygenates). When viewing the LONGFT1/2 PID
(s), the values may change a great deal as the engine is operated at different RPM and load points. The
LONGFT1/2 PID(s) display the long term fuel trim correction that is currently being used at that RPM/load
point.

High Speed Controller Area Network (CAN)
High speed CAN is a serial communication language protocol used to transfer messages (signals) between
electronic modules or nodes. Two or more signals can be sent over one CAN communications network
circuit allowing 2 or more electronic modules or nodes to communicate with each other. This communication
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or multiplexing network operates at 500kB/sec (kilobytes per second) and allows the electronic modules to
share their information messages.
Included in these messages is diagnostic data that is outputted over the CAN + and CAN - lines to the DLC.
PCM connection to the DLC is typically done with a 2-wire, twisted pair cable used for the network
interconnection. The diagnostic data such as self-test or PIDs can be accessed with a scan tool. For
additional information on scan tool equipment, refer to Section 2, Diagnostic Methods .

Idle Air Trim
Idle air trim is designed to adjust the idle air control (IAC) calibration to correct for wear and aging of
components. When the engine conditions meet the learning requirement, the strategy monitors the engine
and determines the values required for ideal idle calibration. The idle air trim values are stored in a table for
reference. This table is used by the PCM as a correction factor when controlling the idle speed. The table is
stored in the KAM and retains the learned values even after the engine is shut off. A DTC is set if the idle air
trim has reached its learning limits.
Whenever an IAC component is replaced, or a repair affecting idle is carried out, it is recommended that the
KAM be reset. This is necessary so the idle strategy does not use the previously learned idle air trim values.
To reset the KAM, refer to Section 2, Resetting The Keep Alive Memory (KAM) . It is important to note that
erasing DTCs with a scan tool does not reset the idle air trim table.
Once the KAM has been reset, the engine must idle for 15 minutes (actual time varies between strategies)
to learn new idle air trim values. Idle quality improves as the strategy adapts. Adaptation occurs in 4
separate modes as shown in the following table.

Idle Speed Control Closed Throttle Determination Applications Without
Electronic Throttle Control
IDLE AIR TRIM LEARNING MODES
Transmission Range Air Conditioning Mode
NEUTRAL A/C ON
NEUTRAL A/C OFF
DRIVE A/C ON
DRIVE A/C OFF
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One of the fundamental criteria for entering RPM control is an indication of closed throttle. Throttle mode is
always calculated to the lowest learned throttle position (TP) voltage seen since engine start. This lowest
learned value is called ratch, since the software acts like a one-way ratch. The ratch value (voltage) is
displayed as the TPREL PID. The ratch value is relearned after every engine start. Ratch learns the lowest,
steady TP voltage seen after the engine starts. In some cases, ratch can learn higher values of TP. The time
to learn the higher values is significantly longer than the time to learn the lower values. The brakes must
also be applied to learn the higher values.
All PCM functions are done using this ratch voltage, including idle speed control. The PCM goes into closed
throttle mode when the TP voltage is at the ratch (TPREL PID) value. An increase in TP voltage, normally
less than 0.05 volts, puts the PCM in part throttle mode. Throttle mode can be viewed by looking at the TP
MODE PID. With the throttle closed, the PID must read C/T (closed throttle). Slightly corrupt values of ratch
can prevent the PCM from entering closed throttle mode. An incorrect part throttle indication at idle prevents
entry into closed throttle RPM control, and could result in a high idle. Ratch can be corrupted by a throttle
position sensor or a circuit that drops out or is noisy, or by loose/worn throttle plates that close tight during a
deceleration and spring back at a normal engine vacuum.

Multiplexing
The increased number of modules on the vehicle necessitates a more efficient method of communication.
Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit. In an automotive
application, multiplexing is used to allow 2 or more electronic modules to communicate simultaneously over
a single media. Typically this media is a twisted pair of wires. The information or messages that can be
communicated on these wires consists of commands, status or data. The advantage of using multiplexing is
to reduce the weight of the vehicle by reducing the number of redundant components and electrical wiring.

Multiplexing Implementation
Currently Ford Motor Company uses CAN communication language protocol to communicate with the PCM.
For additional information about the module communications network, refer to the Workshop Manual Section
418-00, Module Communications Network.

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Secondary Air Injection (AIR) System Monitor
The secondary air injection (AIR) system monitor is an on-board strategy designed to monitor the correct
function of the secondary air injection system. The AIR monitor for the secondary air injection pump system
consists of 2 monitor circuits: an AIR circuit to diagnose concerns with the primary circuit side of the AIR
relay, and an AIR monitor circuit to diagnose concerns with the secondary circuit side of the AIR relay. A
functional check is also carried out that tests the ability of the AIR system to inject air into the exhaust. The
functional flow test relies on the mass air flow (MAF) sensor to determine the presence of air flow. The
monitor check for specific changes in MAF input with the secondary AIR pump ON compared to secondary
AIR pump OFF for failure detection. The integrity of the secondary AIR pump, inlet house, outlet house and
related secondary AIR mechanical components are all checked during the functional flow test. The monitor
is enabled during AIR system operation and only after certain base engine conditions are first satisfied. Input
is required from the engine coolant temperature (ECT) or cylinder head temperature (CHT), mass air flow /
intake air temperature (MAF/IAT), crankshaft position (CKP) sensors and the HO2S monitor test must also
have passed without a fault detection to enable the AIR monitor. The AIR monitor is also activated during
on-demand self-test.
1. On the primary side of the AIR relay, open and short circuit concerns are detected during normal
operation by the PCM output driver. This circuit energizes the relay and the vacuum-operated check
and solenoid control valves.

2. On the secondary side of the AIR relay, the AIR monitor circuit is held low by the resistance path
through the secondary AIR pump when the secondary AIR pump is off. If the AIR monitor circuit is
high there is either an open circuit to the PCM from the pump or there is power supplied to the
secondary AIR pump. If the AIR monitor is low when the secondary AIR pump is commanded on,
there is either an open circuit from the AIR relay or the AIR relay has failed to supply power to the
secondary AIR pump.

The DTCs associated with this test are P2257 and P2258.
3. The functional flow test is done when the secondary AIR pump is normally commanded on. The flow
test relies on the MAF sensor for air meter flow changes during secondary AIR pump transitions and
the heated oxygen sensor for exhaust rich/lean information. The flow test consist of three diagnostic
tests:
Secondary AIR pump flow test - Compares the change in the air meter flow during secondary
AIR pump transitions (ON/OFF) to a calibrated (expected) air flow table within the PCM.
Associated DTC P0491 (Bank 1) and P0492 (Bank 2).
Inlet hose test - When the inlet hose is off, the secondary AIR pump still flows the same
amount of air into the exhaust, but it is drawing air from the atmosphere instead of through the
MAF sensor. This lack of expected air flow through the MAF fails the secondary AIR pump flow
test. The engine fuel control system is still fueling for the air meter, therefore the excess air
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that is going into the exhaust causes the exhaust air fuel ratio to be lean. To set an inlet hose
concern DTC P0410, the pump flow test must fail and the exhaust air fuel ratio must indicate
too lean.
Outlet hose test - When the outlet hose is off, the secondary AIR pump flows more air than
anticipated, since the exhaust back pressure is no longer impacting the secondary AIR pump
air flow. The MAF sensor indicates excess air is drawn through the system. During this failure
mode, engine air fuel ratio is reduced to protect the engine from running too rich. But since the
outlet hose is disconnected, secondary air is not delivered to the exhaust system, causing the
exhaust air fuel ratio to be rich at idle. To set the outlet hose concern DTC P2448 (Bank 1) and
P2449 (Bank 2), the secondary AIR pump on flow test must indicate excess air flow and
exhaust air fuel ratio too rich.
4. The MIL is activated after one of the above tests fail on 2 consecutive drive cycles.

Secondary AIR System Monitor

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Secondary Air Injection (AIR) System
Overview
The secondary AIR system controls emissions during the first few seconds of engine operation by forcing air
downstream into the exhaust manifolds to oxidize the hydrocarbons and carbon monoxide created by
running rich at start up.
Secondary AIR System
The secondary AIR system consists of an secondary AIR pump, check air injection diverter (AIR diverter)
valve, an secondary AIR bypass solenoid, an AIR relay, a powertrain control module (PCM) and connecting
wires, and vacuum hoses. For additional information on the secondary AIR system components, refer to
Engine Control Components in this section.
1. The PCM requires engine coolant temperature (ECT) or cylinder head temperature (CHT), mass air
flow/intake air temperature (MAF/IAT), and crankshaft position (CKP) sensor inputs to initiate the
secondary air injection function.
2. When the engine is started, the strategy determines when to enable the secondary AIR pump. The
PCM signals the AIR relay and the AIR bypass solenoid, after a 5 to 15 second delay, to begin
system operation. Once the catalyst is lit-off, the PCM then signals the AIR relay to stop secondary
AIR pump operation and to close the AIR bypass solenoid from supplying vacuum to the AIR diverter
valve.
3. The AIR relay provides the start-up signal and switches the high current required to operate the
secondary AIR pump.
4. The AIR bypass solenoid applies a vacuum to the AIR diverter valve(s) causing it to open and to
allow air to flow into the exhaust manifolds.
5. The secondary AIR pump draws dry filtered air from the intake air system downstream of the
MAF/IAT sensor.
6. The secondary AIR pump delivers the required amount of air to control emissions during engine
operation. Air is forced into the exhaust manifolds to oxidize the hydrocarbons and carbon monoxide
created by running rich at start up.

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Single AIR Valve Secondary Air Injection (AIR)

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Supercharger and Charge Air Cooler (CAC) Systems
Supercharger Bypass (SCB) System
The SCB system allows the high pressure air at the outlet of the supercharger to vent back into the inlet of
the supercharger, equalizing the pressure. This eliminates the boost (increased pressure that the
supercharger produces) for times when supercharger function is undesirable. The system uses a vacuum
bypass actuator, which controls the bypass valve inside the supercharger. The system normally operates
with engine vacuum applied to the upper port of the vacuum bypass actuator, while the lower port
references the air pressure in the clean air tube to cancel out any pressure difference in the intake air
system. The actuator is set to open (bypassing the supercharger) during high vacuum engine conditions. As
the throttle is opened and engine vacuum decreases, the actuator closes to allow the supercharger to
pressurize the air in the manifold.
Supercharger Assembly
The supercharger assembly is a positive displacement pump. The supercharger will supply an excess
volume of intake air to the engine by increasing air pressure and density in the intake manifold. The
supercharger assembly incorporates the bypass system to reduce air handling losses when boost is not
required, resulting in better fuel economy. When integrated on the engine the supercharger increases torque
across the entire engine operating range from 25 to 50 percent without compromising driveability or
emissions. The supercharger is matched to the engine by it's displacement, and belt ratio and can provide
excess airflow at any engine speed. It contains 2 screw-type 3-lobed rotors. The helical shape of the rotors
and specialized porting provide a smooth discharge flow and a low level of noise during operation. The
rotors are supported by ball bearings in front and needle bearings at the rear.

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5.4L Supercharger Assembly
Charge Air Cooler (CAC) System
The CAC system is designed to cool the intake air which has been heated by the supercharger. The removal
of heat from the pressurized air going into the CAC increases the air density which improves combustion
efficiency, engine horsepower, and torque. The system consists of an additional CAC radiator in the grille, a
reservoir (independent from the engine cooling system), an electric water pump, the CAC located in the
lower intake manifold, and tubing to interconnect these components. The CAC is positioned after the
supercharger directly in the flow of the intake air. As the heated air flows through the CAC, heat is
transferred to the coolant which is circulated back to the CAC radiator to be cooled by the airflow through the
grille. The CAC pump is controlled by the powertrain control module (PCM). The PCM maintains a desirable
intake air temperature by monitoring a second intake air temperature (IAT2) sensor in the lower intake
manifold.

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Charge Air Cooler (CAC) System

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Charge Air Cooler (CAC)

Charge Air Cooler (CAC) Pump

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Thermostat Monitor
The thermostat monitor is designed to verify correct thermostat operation. This monitor is executed once per
drive cycle and has a monitor run duration of 300-800 seconds. If a concern is present, DTC P0125 or
P0128 is set and the malfunction indicator lamp (MIL) is illuminated.
The monitor checks the engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor to
warm up in a predictable manner when the engine is generating sufficient heat. A timer is initialized while the
engine is at moderate load and the vehicle speed is above a calibrated limit. The target timer value is based
on ambient air temperature at start-up. If the timer exceeds the target time and ECT or CHT has not warmed
up to the target temperature, a concern is indicated. The test runs if the start-up intake air temperature from
the intake air temperature (IAT) sensor is at, or below the target temperature. A 2-hour engine off soak time
is also required to enable the monitor and to prevent erasing of any pending DTCs during a hot soak. This
soak time feature also prevents false-passes of the monitor when the engine coolant temperature rises after
the engine is turned off during a short engine off soak period.
The target temperature is calibrated to -11C (20F) the thermostat regulating temperature. For a typical 90
C (195F) thermostat, the target temperature would be calibrated to 79C (175F). Some vehicle calibrations
may lower the target temperature to less than 27C (50F) for vehicles that do not warm-up to thermostat
regulating temperatures in the 11C (20F) to 27C (50F) ambient temperature range.
1. Inputs: ECT or CHT, IAT, engine LOAD (from MAF sensor) and vehicle speed input.
Typical monitor entry conditions:
vehicle speed greater than 24 km/h (15 mph)
intake air temperature at start-up is between -7C (20F) and target thermostat temperature
engine load greater than 30%
engine off (soak) time greater than 2 hours
2. Output: MIL.

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Thermostat Monitor

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Torque Based Electronic Throttle Control (ETC)
Overview
The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle
angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control
module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The
ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire
throttle position (TP) sensor, and mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later
downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts,
and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold
vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel
economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque
during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother
traction control.
Other benefits of ETC are:
eliminate cruise control actuators
eliminate idle air control (IAC) valve
better airflow range
packaging (no cable)
more responsive powertrain at altitude and improved shift quality
It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the
instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes
(DTCs) and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics:
1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The
gear ratio from the motor to the throttle plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel
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to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a
separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no power is applied. This is for limp home reasons (the
force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set
to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees
from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75
degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum
engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate
or to use plate sealant. The hole is not required in the ETB because the required idle airflow is
provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality,
and eliminates the need for an IAC valve.
6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position
signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope
(increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing
angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the
control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits.
5-volt reference voltage
Signal return (ground)
TP1 voltage with negative voltage slope (5-0 volts)
TP2 voltage with positive voltage slope (0-5 volts)
Accelerator Pedal Position (APP) Sensors
The ETC strategy uses pedal position sensors as an input to determine the driver demand.
1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing
angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position
by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins)
between the PCM and the APP sensor assembly.
2 reference voltage circuits (5 volts)
2 signal return (ground) circuits
APP1 voltage with negative voltage slope (5-0 volts)
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APP2 voltage with positive voltage slope (0-5 volts)
APP3 voltage with positive voltage slope (0-5 volts)
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts, which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from
the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect.

Electronic Throttle Body (ETB) and Accelerator Pedal Assembly
Electronic Throttle Control (ETC) System Strategy
The torque based ETC strategy was developed to improve fuel economy and to accommodate variable
camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position.
Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the
powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the
requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control
processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The
primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides
on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an
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estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified
amount, the IPC takes appropriate corrective action.

ETC System
Since the IPC and the main controller share the same processor, they are subject to a number of potential
common failure modes. The E-Quizzer processor was added to redundantly monitor selected PCM inputs
and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it
determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects
management (FMEM) actions.

ETC System Failure Mode and Effects Management:
Effect Failure Mode
a
No Effect on
Driveability
A loss of redundancy or loss of a non-critical input could result in a concern that does not
affect driveability. The powertrain malfunction indicator (wrench) illuminates, but the throttle
control and torque control systems function normally.
Disable
Speed
Control
If certain concerns are detected, speed control is disabled. Throttle control and torque
control continue to function normally.
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a
ETC illuminates or displays a message on the message center immediately; MIL illuminates after 2 driving
cycles

RPM Guard
with Pedal
Follower
In this mode, torque control is disabled due to the loss of a critical sensor or PCM concern.
The throttle is controlled in pedal-follower mode as a function of the pedal position sensor
input only. A maximum allowed RPM is determined based on pedal position (RPM Guard).
If the actual RPM exceeds this limit, spark and fuel are used to bring the RPM below the
limit. The powertrain malfunction indicator (wrench) and the MIL illuminate in this mode and
a DTC P2106 is set. EGR, VCT, and IMRC outputs are set to default values.
RPM Guard
with Default
Throttle
In this mode, the throttle plate control is disabled due to the loss of throttle position, the
throttle plate position controller, or other major electronic throttle body concern. A default
command is sent to the TPPC, or the H-bridge is disabled. Depending on the concern
detected, the throttle plate is controlled or springs to the default (limp home) position. A
maximum allowed RPM is determined based on pedal position (RPM Guard). If the actual
RPM exceeds this limit, spark and fuel are used to bring the RPM below the limit. The
powertrain malfunction indicator (wrench) and the MIL illuminate in this mode and a DTC
P2110 is set. EGR, VCT, and IMRC outputs are set to default values.
RPM Guard
with High
Forced Idle
This mode is caused by the loss of 2 or 3 pedal position sensor inputs due to sensor,
wiring, or PCM concerns. The system is unable to determine driver demand, and the
throttle is controlled to a fixed high idle airflow. There is no response to the driver input. The
maximum allowed RPM is a fixed value (RPM Guard). If the actual RPM exceeds this limit,
spark and fuel are used to bring the RPM below the limit. The powertrain malfunction
indicator (wrench) and the MIL illuminate in this mode and a DTC P2104 is set. EGR, VCT,
and IMRC outputs are set to default values.
Shutdown If a significant processor concern is detected, the monitor forces vehicle shutdown by
disabling all fuel injectors. The powertrain malfunction indicator (wrench) and the MIL
illuminate in this mode and a DTC P2105 is set.
Electronic Throttle Monitor Operation:
DTCs
a

P0606,
P060X,
P061X
PCM processor concern (MIL, powertrain malfunction indicator [wrench])
P2104 ETC FMEM forced idle, 2 or 3 pedal sensor concerns (MIL, powertrain malfunction
indicator [wrench])
P2105 ETC FMEM forced engine shutdown; E-Quizzer detected concern (MIL, powertrain
malfunction indicator [wrench])
P2106 ETC FMEM forced limited power; sensor concern: MAF, one TP, CKP, TSS, OSS, stuck
throttle, throttle actuator circuit concern (MIL, powertrain malfunction indicator [wrench])
P2110 ETC FMEM forced limited RPM; Concern with 2 TPs; TPPC detected concern (MIL,
powertrain malfunction indicator [wrench])
U0300 ETC software version mismatch, IPC, E-Quizzer or TPPC (non-MIL, powertrain
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a
Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a
concern.
Accelerator and Throttle Position (TP) Sensor Inputs
a
Correlation and range/performance - sensor disagreement between processors (PCM and E-Quizzer).
Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern.
Refer to Section 4, Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information.

a
Correlation and range/performance - sensor disagreement between processors (PCM and E-Quizzer), TP
inconsistent with TPPC throttle plate position. Monitor execution is continuous. Monitor false detection
duration is less than 1 second to register a concern. Refer to Section 4, Diagnostic Trouble Code (DTC)
Charts and Descriptions for additional DTC information.
Throttle Plate Position Controller (TPPC) Outputs
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip
embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle
(DC) signal. The TPPC interprets the duty cycle signal as follows:
Less than 5% - Out of range, limp home default position.
Greater than or equal to 5% but less than 6% - Commanded default position, closed.
Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON,
engine OFF.
Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle
malfunction indicator [wrench])
Accelerator Pedal Position (APP) Sensor Check:
DTCs
a

P2122, P2123, P2127, P2128,
P2132, P2133
APP sensor circuit continuity test (powertrain malfunction indicator
[wrench], non-MIL)
P2121, P2126, P2131 APP range/performance (powertrain malfunction indicator [wrench],
non-MIL)
P2138, P2140, P2139 APP to APP sensor correlation (powertrain malfunction indicator
[wrench], non-MIL)
Throttle Position (TP) Sensor Check:
DTCs
a

P0122, P0123, P0222,
P0223
TP circuit continuity test (MIL, powertrain malfunction indicator [wrench])
P0121, P0221 TP range/performance (non-MIL)
P2135 TP to TP sensor correlation test (powertrain malfunction indicator [wrench],
non-MIL)
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angle position (hard stop) after key-up.
Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees
(hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals
82 degrees throttle angle.
Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle angle.
Greater than 96% but less than or equal to 100% - Out of range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each key-up
process before the main CPU requests the throttle plate be closed against the hard stop. The output of the
TPPC is a voltage request to the H driver (also in PCM). The H driver is capable of positive or negative
voltage to the electronic throttle body motor.

a
Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the
concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is
less than 5 second to register a concern.

Throttle Plate Controller Check Operation:
DTCs
a

P2072 Throttle body ice blockage (non-MIL)
P2100 Throttle actuator circuit open, short to power, short to ground (MIL)
P2101 Throttle actuator range/performance test (MIL)
P2107 Processor test (MIL)
P2111 Throttle actuator system stuck open (MIL)
P2112 Throttle actuator system stuck closed (MIL)
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Variable Camshaft Timing (VCT) Monitor
The VCT output driver in the powertrain control module (PCM) is checked electrically for opens and shorts.
The VCT system is checked functionally by monitoring the closed loop camshaft position error correction. If
the correct camshaft position cannot be maintained and the system has an advance or retard error greater
than the calibrated threshold, a VCT control concern is indicated.
For additional VCT information, refer to Variable Camshaft Timing (VCT) System in this section.

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Variable Camshaft Timing (VCT) System
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine
operating conditions. There are 4 types of VCT systems.
Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted
independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle
and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase
angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open
throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT
systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS
systems also have the added benefit of improved torque. In addition, some VCT system applications can
eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR
system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve
closing. Currently, both the IPS and DEPS systems are used
Variable Camshaft Timing (VCT) System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP)
sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the
number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1
tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the
equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides
the PCM with crankshaft positioning information in 10 degree increments.
1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant
temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor,
mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and
low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT,
IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine
RPM, load and throttle position. The VCT system does not operate until the engine is at normal
operating temperature.
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2. The VCT system is enabled by the PCM when the correct conditions are met.
3. The CKP signal is used as a reference for CMP positioning.
4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of
engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil
pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid
movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering
(oscillating) the solenoid valve duty cycle.

The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and actual
camshaft position represents a position error in the PCM VCT control loop. The PCM disables the
VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set
when the concern is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the
camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves
couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber
to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance
or retard position depending on the oil flow.

VCT System

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Vehicle Certification Label

Base Engine Calibration Information
Base engine calibration information, also sometimes referred to as the powertrain calibration, is located in
the lower right corner of the vehicle certification label. Engine calibration information is limited to a maximum
of 5 characters per line (2 lines maximum). Calibration information more than 5 characters long wrap to the
second line of this field. Only the base calibration appears on this label. The revision level is no longer
printed on the label, however, it can be found in the On-Line Automotive Service Information System
(OASIS). For more information on the vehicle certification label or engine calibration, refer to the Workshop
Manual Section 100-01, Identification Codes.
Engine Calibration Information (Car)

Typical Car Vehicle Certification Label
Engine Calibration Information (Truck)
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Typical Truck Vehicle Certification Label
Vehicle Certification Label Location
Typical location of the vehicle certification label is on the LH door or door post pillar.
Engine Calibration Code
2007 Model Year Example
Engine Calibration Code: 7B7 1 4D 0 A 00
7 MODEL YEAR Model year in which the calibration was first introduced. 7 equals 2007
B7 VEHICLE CODE Vehicle line description. B7 equals Expedition
1 TRANSMISSION CODE Transmission description. 1 equals automatic, 2 equals manual
4D UNIQUE CALIBRATION Identifications are assigned to cover similar vehicles to differentiate
between tires, drive configurations, final drive ratios and other calibration-significant factors.
0 FLEET CODE Describes which fleet the vehicle belongs to. 0 equals Certification (U.S. 4K)
A CERTIFICATION REGION Lead region code where multiple regions are included in one calibration.
A equals U.S. Federal
00 REVISION LEVEL Revision level of the calibration. 00 equals Job 1 production or initial calibration.
(Not printed on vehicle certification label)
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Vehicle Emission Control Information (VECI) Acronym Definitions
CARB: California Air Resource Board
CARB LEV: Low Emission Vehicle
CARB SULEV: Super Ultra Low Emission Vehicle
CARB TLEV: Transitional Low Emission Vehicle
CARB ULEV: Ultra Low Emission Vehicle
CARB ZEV: Zero Emission Vehicle
CI: Cylinder Injection
EPA: Environmental Protection Agency
EVAP: Evaporative Emissions
GVW: Gross Vehicle Weight
GVWR: Gross Vehicle Weight Rating, curb weight plus payload.
HHDDE: Heavy Heavy Duty Diesel Engine
HHDE: Heavy Heavy Duty Engine
ILEV: Inherently Low Emission Vehicle
LDDT: Light Duty Diesel Truck categories
LDT: Light Duty Truck (gasoline) categories based on weight as defined in the table.
LDV: Light Duty Vehicle, generally passenger cars and light trucks under 2,721.55 Kg (6,000 lb)
GVWR.
LEV: Low Emission Vehicle
LEV-II: California regulations beginning in the 2004 model year.
LHDE: Light Heavy Duty Engine (several weight categories).
LVW: Loaded Vehicle Weight, curb weight plus 136.08 Kg (300 lb).
MDPV: Medium Duty Passenger Vehicle
MDT: Medium Duty Truck categories based on weight as defined in the table.
MDV: Medium Duty Vehicle
MHDDE: Medium Heavy Duty Diesel Engine
MHDE: Medium Heavy Duty Engine
MPI: Multi-Port Injection
MY: Model Year
NCP: Non-Compliance Penalty
OBD: On Board Diagnostic
ORVR: On-Board Refueling Vapor Recovery
PC: Passenger Car
PZEV: Partially Zero Emission Vehicle
SI: Sequential Injection
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SULEV: Super Ultra Low Emission Vehicle
Tier 0: California and Federal regulations effective prior to Tier 1 phase in dates.
Tier 1: California regulations beginning in 1993 model year and Federal regulations beginning in 1994
model year.
Tier 2: Federal regulations beginning in the 2004 model year.
ULEV: Ultra Low Emission Vehicle
ZEV: Zero Emission Vehicle

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Vehicle Emission Control Information (VECI)
VECI Decal
Each vehicle has a VECI decal containing emission control information that applies specifically to the vehicle
and engine. The specifications on the decal are critical to repairing the emissions systems.

Typical VECI Decal
VECI Decal Location
Typical location of the decal is on the underside of the hood or on the radiator support sight shield.
Engine/Evaporative Emission (EVAP) System Information
Manufacturers must use a standardized system for identifying their individual engine families. The system
described below was developed by the Environmental Protection Agency (EPA) in 1991 to meet new
regulatory requirements for 1994 and later model years.
The engine family group and evaporative family name consists of 12 characters each.
Both the engine family group and the evaporative family name are listed in the box on the emission decal as
indicated in the area marked as engine evaporative family information. The first line contains engine size
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and the 12-character engine family group. The second line contains the 12-character evaporative family
name information. Both the engine family group and the evaporative family name are specific to the vehicle.
Please refer to the Engine Family Group and the Evaporative Family Name worksheet for decoding
information.

Typical VECI Decal Used As An Example

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Adaptive Fuel DTC Diagnostic Techniques
The Adaptive Fuel Diagnostic Trouble Codes (DTC) Diagnostic Techniques help isolate the root cause of
the adaptive fuel concern. Before proceeding, attempt to verify if any driveability concerns are present.
These diagnostic aids are meant as a supplement to the pinpoint test steps in Section 5. For a description of
fuel trim, refer to Section 1, Powertrain Control Software , Fuel Trim.
Obtain Freeze Frame Data
Freeze frame data is helpful in duplicating and diagnosing adaptive fuel concerns. The data (a snapshot of
certain parameter identification (PID) values recorded at the time the DTC is stored in Continuous Memory)
is helpful to determine how the vehicle was being driven when the concern occurred, and is especially useful
on intermittent concerns. Freeze frame data, in many cases, helps to isolate possible areas of concern as
well as rule out others. Refer to Freeze Frame Data in this section for a more detailed description of this
data.
Using the LONGFT1 and LONGFT2 (Dual Bank Engines) PIDs
The LONGFT1/2 PIDs are useful for diagnosing fuel trim concerns. A negative PID value indicates that fuel
is being reduced to compensate for a rich condition. A positive PID value indicates that fuel is being
increased to compensate for a lean condition. It is important to know that there is a separate LONGFT value
that is used for each RPM/load point of engine operation. When viewing the LONGFT1/2 PIDs, the values
may change a great deal as the engine is operating at different RPM and load points. This is because the
fuel system may have learned corrections for fuel delivery concerns that can change as a function of engine
RPM and load. The LONGFT1/2 PIDs display the fuel trim currently being used at that RPM and load point.
Observing the changes in LONGFT1/2 can help when diagnosing fuel system concerns. For example:
A contaminated mass air flow (MAF) sensor results in matching LONGFT1/2 correction values that
are negative at idle (reducing fuel), but positive (adding fuel) at higher RPM and loads.
LONGFT1 values that differ greatly from LONGFT2 values rule out concerns that are common for
both banks (for example, fuel pressure concerns, MAF sensor, etc. can be ruled out).
Vacuum leaks result in large rich corrections (positive LONGFT1/2 value) at idle, but little or no
correction at higher RPM and loads.
A plugged fuel filter results in no correction at idle, but large rich corrections (positive LONGFT1/2
value) at high RPM and load.
Resetting Long Term Fuel Trims
Long term fuel trim corrections are reset by resetting the keep alive memory (KAM). Refer to Resetting The
Keep Alive Memory (KAM) in this section. After making a fuel system repair, the KAM must be reset. For
example, if dirty/plugged injectors cause the engine to run lean and generate rich long term corrections,
2007 PCED On Board Diagnostics SECTION 2: Diagnostic Methods
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installing new injectors and not resetting the KAM causes the engine to run very rich. The rich correction
eventually leans out during closed loop operation, but the vehicle may have poor driveability and high CO
emissions while it is learning.
DTCs P0171/P0174 System Too Lean Diagnostic Aids
Note: If the system is lean at certain conditions, then the LONGFT PID would be a positive value at those
conditions, indicating that increased fuel is needed.
The ability to identify the type of lean condition causing the concern is crucial to a correct diagnosis.
Air Measurement System
With this condition, the engine runs rich or lean of stoichiometry (14.7:1 air/fuel ratio) if the powertrain control
module (PCM) is not able to compensate enough to correct for the condition. One possibility is that the mass
of air entering the engine is actually greater than what the MAF sensor is indicating to the PCM. For
example, with a contaminated MAF sensor, the engine runs lean at higher RPM because the PCM delivers
fuel for less air than is actually entering the engine. Examples:
The MAF sensor measurement is inaccurate due to a corroded connector, contaminated or dirty
connector. A contaminated MAF sensor typically results in a rich system at low airflows (PCM
reduces fuel) and a lean system at high airflows (PCM increases fuel).
Vacuum Leaks/Unmetered Air
With this condition, the engine runs lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to
compensate enough to correct for the condition. This condition is caused by unmetered air entering the
engine, or due to a MAF concern. In this situation, the volume of air entering the engine is actually greater
than what the MAF sensor is indicating to the PCM. Vacuum leaks are normally most apparent when high
manifold vacuum is present (for example, during idle or light throttle). If freeze frame data indicates that the
concern occurred at idle, a check for vacuum leaks/unmetered air is the best starting point. Examples:
loose, leaking, or disconnected vacuum lines
intake manifold gaskets, or O-rings
throttle body gaskets
brake booster
air inlet tube
stuck/frozen/aftermarket positive crankcase valve (PCV)
unseated engine oil dipstick.
Insufficient Fueling
With this condition, the engine runs lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to
compensate enough to correct for the condition. This condition is caused by a fuel delivery system concern
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that restricts or limits the amount of fuel being delivered to the engine. This condition is normally apparent as
the engine is under a heavy load and at high RPM, when a higher volume of fuel is required. If the freeze
frame data indicates that the concern occurs under a heavy load and at higher RPM, a check of the fuel
delivery system (checking fuel pressure with engine under a load) is the best starting point. Examples:
low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines)
fuel injector concerns
Exhaust System Leaks
In this type of condition, the engine runs rich of stoichiometry (14.7:1 air/fuel ratio) because the fuel control
system is adding fuel to compensate for a perceived (not actual) lean condition. This condition is caused by
oxygen (air) entering the exhaust system from an external source. The HO2S react to this exhaust leak by
increasing fuel delivery. This condition causes the exhaust gas mixture from the cylinder to be rich.
Examples:
exhaust system leaks upstream or near the HO2S
cracked/leaking HO2S boss
inoperative secondary air injection system
DTCs P0172/P0175 System Too Rich Diagnostic Aids
Note: If the system is rich at certain conditions, then the LONGFT PID would be a negative value at that
airflow, indicating that decreased fuel is needed.
System rich concerns are caused by fuel system concerns, although the MAF sensor and base engine (for
example, engine oil contaminated with fuel) should also be checked.
Air Measurement System
With this condition, the engine runs rich or lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able
to compensate enough to correct for the condition. One possibility is that the mass of air entering the engine
is actually less than what the MAF sensor is indicating to the PCM. For example, with a contaminated MAF
sensor, the engine runs rich at idle because the PCM delivers fuel for more air than is actually entering the
engine. Examples:
MAF sensor measurement inaccurate due to a corroded connector, contamination/dirt. A
contaminated MAF sensor typically results in a rich system at low airflows (PCM reduces fuel) and a
lean system at high airflows (PCM increases fuel).
Fuel System
With this condition, the engine runs rich of stoichiometry (14.7:1 air/fuel ratio), if the PCM is not able to
compensate enough to correct for the condition. This situation causes a fuel delivery system that is
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delivering excessive fuel to the engine.
Examples:
fuel pressure regulator causes excessive fuel pressure (system rich at all airflows), fuel pressure is
intermittent, going to pump deadhead pressure, then returning to normal after the engine is turned off
and restarted.
fuel pulse dampener diaphragm ruptured (fuel leaking into the intake manifold, system rich at lower
airflows).
fuel injector leaks (injector delivers extra fuel).
EVAP canister purge valve leak (if the canister is full of vapors, introduces extra fuel).
fuel rail pressure (FRP) sensor (electronic returnless fuel systems) concern causes the sensor to
indicate a lower pressure than actual. The PCM commands a higher duty cycle to the fuel pump
driver module (FPDM), causing high fuel pressure (system rich at all airflows).
Air Inlet System
A restriction within any of the following components may be significant enough to affect the ability of the
PCM adaptive fuel control.
air inlet tube
air cleaner element
air cleaner assembly
resonators
clean air tube
Base Engine
Engine oil contaminated with fuel can contribute to a rich-running engine.

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Diagnostic Methods

Overview
The Diagnostic Method Section provides information on routine diagnostic tasks.
When following powertrain diagnostics on on board diagnostics (OBD) vehicles, the system may be checked
by an off-board tester referred to as a scan tool. This section contains information for carrying out
diagnostics with a scan tool. A scan tool has certain generic capabilities that are standard across the
automotive industry in the United States and Canada. All functions are selected from a menu. Refer to the
instruction manual provided by the tool manufacturer.

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Diagnostic Monitoring Test Results Mode 6
Mode 6 allows access to the results of on board diagnostic (OBD) monitor diagnostic test results. The test
values are stored at the time of the particular monitor completion. Refer to mode 6 on the scan tool for test
information.

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Diagnostic Tools
Below is an equipment list with corresponding part numbers:
REQUIRED EQUIPMENT:
Vehicle Communication Module (VCM) with appropriate adapters (078-00496) or equivalent scan tool
with functionality described under Scan Tool Setup and Functionality.
Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent.
RECOMMENDED EQUIPMENT:
Rotunda Vacuum/Pressure Tester 164-R0253 or equivalent. Range 0-101.3 kPa (0-30 in-Hg.)
Resolution 3.4 kPa (1 in-Hg.)
Rotunda Vacuum Tester 014-R1054 or equivalent. Range 0-101.3 kPa (0-30 in-Hg.)
Rotunda 73III Automotive Meter 105-R0057 or equivalent. Input impedance 10 Megaohm minimum.
Spark Tester D81P-6666-A (303-D037) or equivalent.
Non-powered test lamp.
OPTIONAL EQUIPMENT:
Rotunda Fuel (Gasoline) pressure test kit 134-R0087 or equivalent. (Use tool manufacturer's
instructions.)

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Flash Electrically Erasable Programmable Read Only Memory
(EEPROM)
Description
The EEPROM is contained in an integrated circuit (IC) internal to the powertrain control module (PCM). The
EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is
capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block
is programmed when installing a new PCM as described under Programming the VID Block for a
Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block
in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to
the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635,
Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC
P1639. This is described under Making Changes to the VID Block and also under Making Changes to the
PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of
these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle
speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly
(ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported
by the VID block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as tire and
axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the
scan tool displays a message indicating the need to flash the PCM again to reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool
manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block
is blank and needs programming. There are 2 procedures available. The first is an automatic data transfer
from the old PCM to the new PCM, and the second is manual data entry into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of
a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then
be downloaded to the new PCM after it has been installed.
Manual data entry must be carried out if the old module is damaged or incapable of communicating.
Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
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programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters
are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by
the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and
P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually
update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is
corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional
Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford
technicians use the Motorcraft website at www.motorcraft.com. From the Motorcraft homepage, use the
search function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS
website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to accommodate
the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made
to the strategy or calibration after production, or the need to reset the VID block because it has reached its
limit. Refer to Module Reprogramming on the scan tool.

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Freeze Frame Data
Description
Freeze frame data allows access to emission-related values from specific generic parameter identification
(PIDs). These values are stored when an emission-related diagnostic trouble code (DTC) is stored in
continuous memory. This provides a snapshot of the conditions that were present when the DTC was
stored. Once one set of freeze frame data is stored, this data remains in memory even if another emission-
related DTC is stored, with the exception of misfire or fuel system DTCs. Once freeze frame data for a
misfire or fuel system DTC is stored, it overwrites any previous data, and freeze frame data is no longer
overwritten. When a DTC associated with the freeze frame data is erased or the DTCs are cleared, new
freeze frame data can be stored again. In the event of multiple emission-related DTCs in memory, always
note the DTC for the freeze frame data.

FREEZE FRAME DATA TABLE
Acronym Description Measurement Units
AAT Ambient Air Temperature Degrees
AIR Secondary Air Status
APP_D Accelerator Pedal Position D %
APP_E Accelerator Pedal Position E %
APP_F Accelerator Pedal Position F %
ECT Engine Coolant Temperature Degrees
FRP Fuel Rail Pressure kPa
FUELSYS1 Open/Closed Loop1 OL/CL/OL DRIVE/OL FAULT/CL FAULT
FUELSYS2 Open/Closed Loop2 OL/CL/OL DRIVE/OL FAULT/CL FAULT
LONGFT1 Long Term Fuel Bank1 %
LONGFT2 Long Term Fuel Bank2 %
LOAD Calculated Load Value %
MAP Manifold Absolute Pressure kPa
RPM Engine RPM RPM
RUNTM Run Time Seconds
SHRTFT1 Short Term Fuel Bank1 %
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Some unique PIDs are stored in the keep alive memory (KAM) of the powertrain control module (PCM) to
help in diagnosing the root cause of misfires. These PIDs are collectively called misfire freeze frame (MFF)
data. These parameters are separate from the generic freeze frame data that is stored for every MIL code.
They are used for misfire diagnosis only. The MFF data could be more useful for misfire diagnosis than the
generic freeze frame data. It is captured at the time of the highest misfire rate, and not when the DTC is
stored at the end of a 1,000 or 200 revolution block. (Generic freeze frame data for misfire can be stored
minutes after the misfire actually occurred.)
Note: MFF PIDs are supported on all vehicles, but may not be available on all scan tools because enhanced
PID access may vary by scan tool manufacturer.

SHRTFT2 Short Term Fuel Bank2 %
SPARKADV Spark Advance Degrees
TP Absolute Throttle Position %
VSS Vehicle Speed km/h-mph
MISFIRE FREEZE-FRAME PIDs
PID Name Description PID Number Measurement Units
MFF RPM Engine RPM at the time of misfire 16D3 RPM
MFF LOAD Engine load at the time of misfire 16D4 %
MFF VS Vehicle speed at the time of misfire 16D5 km/h-mph
MFF IAT Intake air temperature at the time of misfire 16D6 Degrees
MFF SOAK Engine-off soak time at the time of misfire 16D7 Minutes
MFF RNTM Engine running time at the time of misfire 16D8 Seconds
MFF EGR EGR DPFE sensor at the time of misfire 16D9 Volts
MFF TP Throttle Position at time of misfire 16DA Volts
MFF T CNT Number of driving cycles at the time of
misfire (at least one 1,000 rev block)
16DC No. Trips
MFF PNP 1= in DRIVE during the time of misfire 16DD b1 Mode
MP LRN 1= Misfire wheel profile learned in KAM 16DD b0 None
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Intermittent Diagnostic Techniques
Intermittent diagnostic techniques help find and isolate the root cause of intermittent concerns associated
with the electronic engine control (EEC) system. The information is organized to help find the concern and
carry out the repair. The process of finding and isolating an intermittent concern starts with recreating a fault
symptom, accumulating powertrain control module (PCM) data, and comparing that data to typical values,
then analyzing the results. Refer to the scan tool manufacturer's instruction manual for the functions
described below.
Before proceeding, be sure that:
Customary mechanical system tests and inspections do not reveal a concern. NOTE: Mechanical
component conditions can make a PCM system react abnormally.
Technical Service Bulletins (TSBs) and On-line Automotive Service Information System (OASIS)
messages, if available, are reviewed.
Quick Test and associated diagnostic subroutines have been completed without finding a concern,
and the symptom is still present.

Recreating the Fault
Recreating the concern is the first step in isolating the cause of the intermittent symptom. A thorough
investigation should start with the customer information worksheet located in the back of this manual. If
freeze frame data is available, it may help in recreating the conditions at the time of a malfunction indicator
lamp diagnostic trouble code (MIL DTC). Listed below are some of the conditions for recreating the concern:

Accumulating PCM Data
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PCM data can be accumulated in a number of ways. This includes circuit measurements with a digital
multimeter (DMM) or scan tool parameter identification (PID) data. Acquisition of PCM PID data using a
scan tool is one of the easiest ways to gather information. Gather as much data as possible when the
concern is occurring to prevent improper diagnosis. Data should be accumulated during different operating
conditions and based on the customer description of the intermittent concern. Compare this data with the
known good data values located in Section 6 Typical Diagnostic Reference Values . This requires recording
data in 4 conditions for comparison: 1) KOEO, 2) Hot Idle, 3) 48 km/h (30 mph), and 4) 89 km/h (55 mph).

Comparing PCM Data
After the PCM values are acquired, it is necessary to determine the concern area. This typically requires the
comparison of the actual values from the vehicle to the typical values from the Section 6 Typical Diagnostic
Reference Values . The charts apply to different vehicle applications (engine, model, transmission).
Analyzing PCM Data
Look for abnormal events or values that are clearly incorrect. Inspect the signals for abrupt or unexpected
changes. For example, during a steady cruise most of the sensor values should be relatively stable. Sensors
such as throttle position (TP), mass air flow (MAF), and RPM that change abruptly when the vehicle is
traveling at a constant speed are clues to a possible concern area.
Look for an agreement in related signals. For example, if the APP1, APP2, or APP3, is changed during
acceleration, a corresponding change should occur in idle air control (IAC), RPM, and SPARK ADV PID.
Make sure the signals act in proper sequence. An increase in RPM after the TP1 and TP2 is increased is
expected. However, if the RPM increases without a TP1 and TP2 change, a concern may exist.
(Figure 1): Scroll through the PID data while analyzing the information. Look for sudden drops or spikes in
the values. (Refer to the following TP1 example). Notice the major jump in the TP1 voltage while scrolling
through the information. This example would require a smooth and progressive accelerator pedal travel
during a key on and engine off mode.

Figure 1.
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On Board Diagnostic (OBD) Drive Cycle
Description of On Board Diagnostic (OBD) Drive Cycle
The following procedure is designed to execute and complete the OBD monitors and to clear the Ford
P1000, I/M readiness code. To complete a specific monitor for repair verification, follow steps 1 through 4,
then continue with the step described by the appropriate monitor found under the OBD Monitor Exercised
column. For the EVAP/secondary AIR monitor to run, the ambient air temperature must be between 4.4 to
37.8C (40 to 100F), and the altitude below 2,438 meters (8,000 feet). If the P1000 code must be cleared in
these conditions, the powertrain control module (PCM) must detect them once (twice on some applications)
before the EVAP/secondary AIR monitor can be bypassed and diagnostic trouble code (DTC) P1000 is
cleared. The EVAP/secondary AIR bypassing procedure is described in the following drive cycle.
The OBD drive cycle is carried out using a scan tool. Refer to the manufacturer's instruction manual for each
described function.
A detailed description for clearing the DTCs is found in this section. Refer to Clear The Continuous
Diagnostic Trouble Codes (DTCs) And Reset The Emission Monitors Information in The Powertrain Control
Module (PCM) .
Drive Cycle Recommendations
WARNING: STRICT OBSERVANCE OF POSTED SPEED LIMITS AND ATTENTION TO DRIVING
CONDITIONS ARE MANDATORY WHEN PROCEEDING THROUGH THE FOLLOWING DRIVE CYCLES.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Most OBD monitors complete more readily using a steady foot driving style during cruise or
acceleration modes. Operating the throttle in a smooth fashion minimizes the time required for
monitor completion.
2. The fuel tank level should be between 1/2 and 3/4 full with 3/4 full being the most desirable.
3. The evaporative monitor can operate only during the first 30 minutes of engine operation. When
executing the procedure for this monitor, stay in part throttle mode and drive in a smooth fashion to
minimize fuel slosh.
4. When bypassing the EVAP/secondary AIR engine soak times, the PCM must remain powered (key
ON) after clearing the continuous DTCs and relearning emission diagnostic information.
For best results, follow each of the following steps as accurately as possible:
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OBD Monitor
Exercised Drive Cycle Procedure
Purpose of Drive
Cycle Procedure
Drive Cycle
Preparation
NOTE: To bypass the EVAP/secondary AIR soak timer
(normally 6 hours), the PCM must remain powered after
clearing the continuous DTCs and resetting the emission
monitors information in the PCM.
1. Install the scan tool. Turn the key on with the engine off.
Cycle the key off, then on. If needed, select the appropriate
vehicle and engine qualifier. Clear the continuous DTCs
and reset the emission monitors information in the PCM.
Bypasses the engine
soak timer. Resets
the OBD monitor
status.
2. Begin to monitor the following PIDs (if available): ECT,
EVAPDC, FLI and TP MODE. Start the vehicle without
returning the key to the OFF position.

3. Idle the vehicle for 15 seconds. Drive at 64 km/h (40
mph) until the engine coolant temperature (ECT) is at least
76.7C (170F).

Prep for Monitor Entry 4. Is the intake air temperature (IAT) between 4.4 to 37.8C
(40 to 100F)? If not, complete the following steps, but note
that step 14 is required to bypass the EVAP/secondary AIR
monitor and clear DTC P1000.
Engine warm-up and
provides IAT input to
the PCM.
HEGO 5. Cruise at 64 km/h (40 mph) for at least 5 minutes. Executes the HO2S
monitor.
EVAP 6. Cruise at 64 to 89 km/h (40 to 55 mph) for 10 minutes
(avoid sharp turns and hills). NOTE: To initiate the monitor,
the throttle should be at part throttle, EVAPDC must be
greater than 75%, and FLI must be between 15 and 85%,
and for fuel tanks over 25 gallons FLI must be between 30
and 85%.
Executes the EVAP
monitor if the IAT is
between 4.4 to 37.8C
(40 to 100F).
Catalyst 7. Drive in stop and go traffic conditions. Include 5 different
constant cruise speeds, ranging from 32 to 89 km/h (20 to
55 mph) over a 10 minute period.
Executes the catalyst
monitor.
EGR 8. From a stop, accelerate to 72 km/h (45 mph) at 1/2 to
3/4 throttle. Repeat 3 times.
Executes the EGR
monitor.
SEC AIR/CCM
(Engine)
9. Bring the vehicle to a stop. Idle with the transmission in
drive (neutral for M/T) for 2 minutes.
Executes the idle air
control (IAC) portion
of the comprehensive
component monitor
(CCM).
CCM (Trans) 10. For M/T, accelerate from 0 to 81 km/h (0 to 50 mph), Executes the
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and continue to step 11. For A/T, from a stop and in
overdrive, moderately accelerate to 81 km/h (50 mph) and
cruise for at least 15 seconds. Stop the vehicle and repeat
without overdrive to 64 km/h (40 mph) cruising for at least
30 seconds. While at 64 km/h (40 mph), activate the
overdrive, accelerate to 81 km/h (50 mph) and cruise for at
least 15 seconds. Stop for at least 20 seconds and repeat
step 10 five times.
transmission portion
of the CCM.
Misfire and Fuel
Monitors
11. From a stop, accelerate to 97 km/h (60 mph).
Decelerate at closed throttle to 64 km/h (40 mph) (no
brakes). Repeat this 3 times.
Allows learning for the
misfire monitor.
Readiness Check 12. Access the On-Board System Readiness (OBD monitor
status) function on the scan tool. Determine whether all
non-continuous monitors have completed. If not, go to step
13.
Determines if any
monitor has not
completed.
Pending Code Check
and EVAP/secondary
AIR Monitor Bypass
Check
13. With the scan tool, check for pending codes. Conduct
the normal repair procedures for any pending code
concern. Otherwise, repeat any incomplete monitor. If the
EVAP/secondary AIR monitor is not complete and the IAT
was out of the 4.4 to 37.8C (40 to 100F) temperature
range in step 4, or the altitude is over 2438 m (8000 ft.), the
EVAP/secondary AIR bypass procedure must be followed.
Go to Step 14.
Determines if a
pending code is
preventing the
clearing of DTC
P1000.
EVAP/secondary AIR
Monitor Bypass
14. Park the vehicle for a minimum of 8 hours. Repeat
steps 2 through 12. Do not repeat step 1.
Allows the bypass
counter to increment
to 2.
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On-Board System Readiness (OSR) Test
Description
All on board diagnostic (OBD) scan tools display the on-board system readiness (OSR) test. The OSR
displays the supported monitors on the vehicle and the status of all monitors (complete or not complete) at
that time. Fuel, misfire, and comprehensive component monitors run continuously and always display YES
status. Clearing the continuous diagnostic trouble codes (DTCs) and resetting the emission monitors
information in the powertrain control module (PCM), or resetting the keep alive memory (KAM) causes the
non-continuous monitors to change to a NO status.
A detailed description of completing the OBD monitors is found in this section. Refer to On Board Diagnostic
(OBD) Drive Cycle .

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Output State Control (OSC)
Description
WARNING: SAFETY MUST BE OBSERVED WHEN USING OSC. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
The OSC aids in diagnosing output actuators associated with the powertrain control module (PCM) for the
engine. This mode allows the technician to command the individual actuator state. For example: the output
can be enabled or disabled, the duty cycle or the angle of the output can be increased or decreased. The
OSC is used to help test the electrical, hydraulic or mechanical components of the vehicle. This function is
supported by the vehicle strategy but may not be present on all vehicles or available on all scan tools.
Retrieve the continuous codes and carry out a key on, engine off (KOEO) and key on, engine running
(KOER) on-demand self-test before using any OSC. Any diagnostic trouble codes (DTCs) related to the
transmission range (TR) sensor, output shaft sensor (OSS) or the vehicle speed sensor (VSS) must be fixed
or the PCM does not allow the OSC to operate.
The OSC has 2 options for operation, the Bench Mode and the Drive Mode. The Bench Mode is functional
only when the vehicle gear selector is in the PARK or NEUTRAL position. The Bench Mode may be used
when the engine is on (running) or off (not running).
Each OSC function has a unique set of vehicle operating requirements that the technician is required to
meet before operating the OSC. If the vehicle requirements are not met while commanding the OSC value,
an error message appears. When the error message is received, OSC is canceled.
To confirm that the scan tool sent the OSC value and the PCM has accepted the OSC substitution, a
corresponding parameter identification (PID) for each OSC parameter must be monitored.

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Output Test Mode (OTM)
Description
WARNING: SAFETY MUST BE OBSERVED WHEN USING OTM.
WHEN ALL OUTPUTS ARE ON, THE ELECTRIC FUEL PUMP IS BRIEFLY ENERGIZED. MAKE
SURE THE FUEL SYSTEM IS INTACT AND IS NOT BEING REPAIRED AT THIS TIME.
WHEN LOW SPEED OR HIGH SPEED FAN CONTROL(S) ARE TURNED ON, MAKE SURE THE
FAN BLADES ARE CLEAR OF ANY OBSTRUCTION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
The OTM aids in diagnosing output actuators associated with the powertrain control module (PCM). This
mode allows the technician to energize and de-energize most of the system output actuators on command.
When entering OTM, the outputs can be turned off and on without activating the fan control. The low and
high speed fan controls may be turned on separately without energizing the other outputs. This function is
supported by each vehicle strategy and may not be available on all scan tools.
As a safety precaution, OTM defaults to the off state after 10 minutes, and the fuel pump off state after
approximately 7-10 seconds. OTM also turns off after the vehicle is started or after cycling the key off then
on.

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Parameter Identification (PID)
Description
The parameter identification (PID) mode allows access to powertrain control module (PCM) information. This
includes analog and digital signal inputs and outputs along with calculated values and the system status.
There are 2 types of PID lists available and both are used throughout this manual. The first is the generic
(J1979) OBD PID list. This is a standard set of PIDs that all scan tools must be able to access. The second
is a Ford-specific (J2190) list which can be accessed by an appropriate scan tool. When accessing any of
these PIDs, the values are continuously updated. The generic or Ford PID list provides definitions and
values in appropriate units. For more information, refer to the Society of Automotive Engineers (SAE)
document J2205.
Generic OBD PID List
An X in the Freeze Frame column denotes both a mode 1 and mode 2 PID (real time and freeze frame).

Freeze
Frame Acronym Description Measurement Units
X AAT Ambient Air Temperature Degrees
X AIR Secondary Air Status On/Off
X APP_D Accelerator Pedal Position D %
X APP_E Accelerator Pedal Position E %
X APP_F Accelerator Pedal Position F %
X CATEMP11 Catalyst Temperature Bank 1, Sensor 1 Degrees
CLR_DST Distance since codes cleared Km
CCNT Continuous DTC Counter Unitless
X ECT Engine Coolant Temperature Degrees
X EGR_PCT Commanded EGR %
X EGR_ERR EGR Error %
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X EVAP_PCT Commanded Evaporative Purge %
X EVAP_VP Evaporative System Vapor Pressure Pa
X EQ_RAT Commanded Equivalence Ratio Unit
X FUEL SYS1 Fuel System Feedback Control Status-Bank 1
OL/CL/OL DRIVE
a
/OL
FAULT/ CL FAULT
X FUEL SYS2 Fuel System Feedback Control Status-Bank 2
OL/CL/OL DRIVE
a
/OL
FAULT/ CL FAULT
IAT Intake Air Temperature Degrees
X
LOAD
b
Calculated Engine Load %
X LOAD_ABS Absolute Load Value %
X LONGFT1 Current Bank 1 Fuel Trim Adjustment (kamref1)
From Stoichiometry Which Is Considered Long
Term
%
X LONGFT2 Current Bank 2 Fuel Trim Adjustment (kamref2)
From Stoichiometry Which Is Considered Long
Term
%
X MAF Mass Air Flow Rate gm/s-lb/min
MIL_DIST Distance traveled with MIL on Kilometer
X O2S11 Bank 1 Upstream Oxygen Sensor (11) Volts
X O2S12 Bank 1 Downstream Oxygen Sensor (12) Volts
X O2S21 Bank 2 Upstream Oxygen Sensor (21) Volts
OBDSUP On Board Diagnostic System OBD II
OBD I
OBD
Combination of
or None
X PTO Power Take-Off Status On/Off
X RPM Revolutions per Minute RPM
X RUNTM Run time Seconds
X SHRTFT1 Current Bank Fuel Trim Adjustment (lambse1)
From Stoichiometry Which Is Considered Short
Term
%
X SHRTFT2 Current Bank 2 Fuel Trim Adjustment (lambse1)
From Stoichiometry Which Is Considered Short
%
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a
OL = Open loop, have not satisfied conditions for closed loop.

b
Percent engine load adjusted for atmospheric pressure.
CL = Closed loop using HO2S(s) as feedback for fuel control.
OL DRIVE = Open loop due to driving conditions (heavy acceleration).
OL FAULT = Open loop due to fault with all upstream HO2S sensors.
CL FAULT = Closed loop fuel control, but fault with one upstream HO2S sensor on dual bank
vehicles.

Ford PID List
Note: This is not a complete list of Ford PIDs available. This is a list of Ford PIDs in this manual.

Term
X SPARKADV Spark Advance Requested Degrees
X SPARK_ACT Spark Advance Actual Degrees
% TAC_PCT Commanded Throttle Actuator %
X TP Throttle Position %
X TP_R Relative Throttle Position %
WARM_UPS Number of warm ups since codes cleared Units
X VSS Vehicle Speed Sensor km/h-mph
Acronym Description Ford Units
4X4L Requested 4-Wheel Drive Input On/Off
ACCS Air Conditioning Cycling Switch Input On/Off
ACP A/C Head Pressure Switch Input Open/Closed
ACP A/C Head Pressure Switch Input Volts
ACP A/C Head Pressure Transducer Sensor kPa/psi
AIR Secondary AIR Pump Control On/Off
AIRF Secondary AIR Fault Indicator Yes/No
AIRM Secondary AIR Pump Monitor On/Off
ALTLAMP Generator Indicator Fault Yes/No
ALT SEN Alternator Sensor Line On/Off
ALT V Generator Output Voltage Volts
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APP Accelerator Pedal Position Volts
APP1 Accelerator Pedal Position 1 Volts
BARO Barometric Pressure (may be software determined) Hz
BARO V Barometric Pressure Signal Voltage Volts
BPA Brake Pressure Applied On/Off
BPP/BOO Brake Pedal Position/Brake On-Off Switch Input On/Off
CAMDCR Commanded Duty Cycle for VCT Solenoid %
CAMERRR VCT Error in Crankshaft Degrees Degrees
CAS GND PCM Case Ground Volts
CCS Coast Clutch Solenoid Control On/Off
CHT Cylinder Head Temperature Input Degrees
CHT Cylinder Head Temperature Input Volts
CMPFM Camshaft Position Sensor Fault Mode Yes/No
CMPFM2 Camshaft Position Sensor 2 Fault Mode Yes/No
CPP Clutch Pedal Position Switch Input On/Off
CPP/PNP Clutch Pedal Position/Park Neutral Position Switch Input On/Off
DPFEGR Differential Pressure Feedback EGR Input Volts
ECT Engine Coolant Temperature Input Degrees
ECT V Engine Coolant Temperature Input Volts
EGRBARO Enable BARO Read (instead of EGR pressure) Yes/No
EGRMC1 EGR Motor Control Output Command On/Off
EGRMDSD Electric EGR Motor Commanded in Steps Steps
EGRVR EGR Valve Vacuum Control %
EOT Engine Oil Temperature Sensor Input Degrees
EOT Engine Oil Temperature Sensor Input Volts Volts
EOT _F Engine Oil Temperature Fault Detection Yes/No
EPC Electronic Pressure Control kPa/PSI
EPC V Electronic Pressure Control Volts
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EVAPCPF Evaporative Emissions Canister Purge Fault Yes/No
EVAPCV Evaporative Emissions Canister Purge Vent Control %
EVAPCV_F Evaporative Emissions Canister Purge Vent Fault Yes/No
EVAPPDC Evaporative Emissions Canister Purge Control %
EVAPPF Evaporative Purge Flow Input Volts
EVAPSOAK Evaporative Emissions Monitor Soak Conditions are Met Yes/No
EVAPVMA Evaporative Vapor Management Valve Internal Circuit Monitor Volts
EVMV Electronic Vapor Management Valve Commanded Current Current (mA)
FANDC Variable Speed Fan Duty Cycle %
FANSS Fan Speed Sensor Signal RPM
FANVARF Variable Speed Fan Output Fault Yes/No
FLI Fuel Level Indicator Input %
FLI Fuel Level Indicator Input Volts
FP Fuel Pump Duty Cycle %
FP M Fuel Pump Secondary Monitor %
FP_F Fuel Pump Output Fault Yes/No
FPM Fuel Pump Secondary Monitor On/Off
FRP Fuel Rail Pressure Input kPa/PSI
FRP_DSD Fuel Rail Pressure Desired kPa/PSI
FRP Fuel Rail Pressure Input Volts
FRT Fuel Rail Temperature Degrees
FRT Fuel Rail Temperature Voltage Volts
FTP Fuel Tank Pressure Input kPa/in-H2O
FTP Fuel Tank Pressure Input Volts
FUELPW1 Injector Pulse Width Bank 1 Milliseconds
FUELPW2 Injector Pulse Width Bank 2 Milliseconds
GEAR Transmission Gear Status Gear
GENF Generator Output Fault Detection Yes/No
GENFDC Generator Field Control Output %
GENVDSD Generator Desired Voltage Volts
GENMN (GFS) Generator Field Signal Monitor %
GEN F Generator 2 Fault Yes/No
HFC High Speed Fan Control On/Off
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HFC_F High Speed Fan Control Fault Yes/No
HTRCM11 Bank 1 Sensor 1 HO2S Heater Control On/Off
HTRCM11F Bank 1 Sensor 1 HO2S Heater Circuit Fault Yes/No
HTR2CM2 Bank 2 Sensor 2 HO2S Heater Circuit Fault Yes/No
HTRX1 HO2S Sensor 1 (Upstream) Heater Control On/Off
HTRX2 HO2S Sensor 2 (Downstream) Heater Control On/Off
IAC Idle Air Control %
IAT Intake Air Temperature Input Degrees
IAT V Intake Air Temperature Input Volts Volts
IAT2 Intake Air Temperature Sensor 2 Input Degrees
IAT2 V Intake Air Temperature Sensor 2 Input Volts
IGN 1-8_F Ignition Timing Fault Detected (cylinders 1-8) Fault/No Fault
IGNPCM_F Spark Conduction Capture Circuit Fault Detected Fault/No Fault
IMRC Intake Manifold Runner Control On/Off
IMRC F Intake Manifold Runner Control Fault Yes/No
IMRCM Intake Manifold Runner Control Monitor Input Bank 1 Volts
IMRCM2 Intake Manifold Runner Control Monitor Input Bank 2 Volts
IMTV Intake Manifold Tuning Valve Control %
IMTVF Intake Manifold Tuning Valve Control Fault Yes/No
INJ1_F-8_F Fuel Injector Primary Fault (cylinders 1- 8) Yes/No
INJ9_F-10_F Fuel Injector Primary Fault (cylinders 9 and 10) Yes/No
ISS Intermediate/Input Speed Shaft Hz/RPM
KNOCK 1 Knock Sensor Input Bank 1 Volts
KNOCK 2 Knock Sensor Input Bank 2 Volts
LFC Low Speed Fan Control On/Off
LFC_F Low Speed Fan Control Fault Yes/No
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LOAD Calculated Engine Load %
LONGFT1 Long Term Fuel Trim Bank 1 %
LONGFT2 Long Term Fuel Trim Bank 2 %
MAF Mass Airflow Rate Input gm/s
MAF V Mass Airflow Rate Input Volts
MAF V Mass Airflow Rate Input (before FMEM substitutions) Volts
MAP Intake Manifold Absolute Pressure Hz
MAP V Intake Manifold Absolute Pressure (analog) Volts
MFC Medium Speed Fan Control On/Off
MFC_F Medium Speed Fan Control Fault Yes/No
MIL Malfunction Indicator Lamp Control On/Off
MFF RPM Engine RPM at the Time of Misfire RPM
MFF LOAD Engine Load at the Time of Misfire %
MFF VSS Vehicle Speed at the Time of Misfire km/h-mph
MFF IAT Intake Air Temperature at the Time of Misfire Degrees
MFF SOAK Engine-Off Soak Time at the Time of Misfire Minutes
MFF RNTM Engine Running Time at the Time of Misfire Minutes
MFF EGR EGR DPFE Sensor at the Time of Misfire Volts
MFF TP Throttle Position at Time of Misfire Volts
MFF T CNT Number of Driving Cycles at the Time of Misfire (at Least One 1,000
Rev Block)
No. Trips
MFF PNP 1= in Drive During the Time of Misfire Mode
MP LRN 1= Misfire Wheel Profile Learned in KAM Mode
OCTADJ Octane Adjust Status Open/Closed
OCTADJS Octane Adjust Software Status Retard/No
Retard
O2S11 Bank 1 Sensor 1 HO2S Input Volts
O2HTR13 Bank 1 Sensor 3 HO2S Heater Control On/Off
OSS Output Shaft Speed RPM
PIP Profile Ignition Pickup Input On/Off
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PSP Power Steering Pressure Switch Input High/Low
PSP V Power Steering Pressure Input Volts
PSP V Power Steering Pressure Input Volts
PTO Power Take Off Status Input On/Off
PTO LOAD Power Take Off Engage Input Yes/No
PTOIR_V Power Take Off RPM Select Input Volts
PTOIL Power Take Off Indicator Lamp Output On/Off
PTOIL_F Power Take Off Indicator Lamp Fault Output Yes/No
RCAM VCT Solenoid Commanded in Crank Shaft Degrees Degrees
REM-
PWM_DC1
Rear Electronic Module - Pulse Width Modulated Duty Cycle %
REV Transmission Reverse Switch Input On/Off
RPM Engine Speed Based Upon CKP Input RPM
SCCS Speed Control Input Switch Volts
SCICP Supercharger Intercooler Pump Control On/Off
SCICPF Supercharger Intercooler Pump Control Fault Yes/No
SHRTFT1 Short Term Fuel Trim %
SHRTFT2 Short Term Fuel Trim %
SIL Shift Indicator Light On/Off
SPARKADV Spark Advance Desired Degrees
SPKDUR 1-4 Spark Duration (cylinders 1-4) Milliseconds
SPKDUR 5-8 Spark Duration (cylinders 5-8) Milliseconds
SS1 Shift Solenoid 1 Control On/Off
TANKPR Fuel Tank Pressure Transducer Pressure
TCC Torque Converter Clutch Control %
TCCA Torque Converter Clutch Control Internal Circuit Monitor On/Off
TCIL Transmission Control Indicator Lamp Clutch Control Status On/Off
TCS Transmission Control Switch (TCS) On/Off
TFT Transmission Fluid Temperature Input Degrees
TFT Transmission Fluid Temperature Input Volts
TIREREV Active Tire Size Revs/Mile
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THTRC Thermostat Heater Control %
TP Throttle Position %
TP MODE Throttle Position Mode C/T, P/T, WOT
TP Throttle Position Input Volts
TP1 Throttle Position 1 Voltage Volts
TP2 Throttle Position 2 Voltage Volts
TPB Secondary Throttle Position Input Volts
TPREL Lowest Steady TP Voltage Since Engine Start (RATCH) Volts
TR Transmission Selector Position Input Status Position
TR V Transmission Selector Position Input Status Volts
TR D Transmission Selector Position Input Status (digital) Binary
TSS Turbine Shaft Speed/Input Shaft Speed RPM
VCTA VCT Control Circuit Monitor On/Off
VCTENA Conditions Correct to Enable VCT Yes/No
VOLTDSD Desired Voltage Volts
VFCDC Variable Speed Fan Duty Cycle %
VFCF Variable Speed Fan Output Fault Yes/No
VPWR Vehicle Power Voltage Volts
VREF Vehicle Reference Voltage Volts
VSS Vehicle Speed km/h-mph
WAC/ACCR A/C Clutch Command On/Off
WAC_F WOT A/C Primary Circuit Fault Yes/No
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Quick Test Description
Quick Test
The quick test is divided into 3 specialized tests:
1. Key On Engine Off (KOEO) On-Demand Self-Test
2. Key On Engine Running (KOER) On-Demand Self-Test
3. Continuous Memory Self-Test
The quick test checks the integrity and function of the electronic engine control (EEC) system and outputs
the test results when requested by the scan tool. The quick test also provides a quick check of the
powertrain control system, and is usually carried out at the start of each diagnostic procedure with all
accessories off. The quick test is also carried out at the end of most pinpoint tests for verification of the
repair and to make sure no other concerns are incurred while repairing a previous concern. A system pass is
displayed when no diagnostic trouble codes (DTCs) are output and a scan tool communication error does
not exist. System pass means that hardware monitored by the powertrain control module (PCM) is
functioning within the normal operating limits. Only a system pass, a DTC, or an incomplete on board
diagnostic (OBD) drive cycle (P1000) is displayed.
For applications that use a stand-alone transmission control module (TCM) the PCM does not output TCM
DTCs. For TCM self-test and diagnostics, refer to the Workshop Manual Section 307-01 Automatic
Transmission.
Key On Engine Off (KOEO) On-Demand Self-Test
The KOEO on-demand self-test is a functional test of the PCM carried out on-demand with the key on and
the engine off. This test carries out checks on certain sensor and actuator circuits. A concern must be
present at the time of testing for the KOEO self-test to detect the concern. When a concern is detected, a
DTC is output on the data link at the end of the test as requested by the scan tool.
Key On Engine Running (KOER) On-Demand Self-Test
The KOER on-demand self-test is a functional test of the PCM carried out on-demand with the key on, the
engine running and the vehicle stopped. A check of certain inputs and outputs is made during operating
conditions and at a normal operating temperature. The brake pedal position, transmission control, and the
power steering tests are part of the KOER on-demand self-test and must be carried out during this operation
if applicable. These are described below. A concern must be present at the time of testing for the KOER on-
demand self-test to detect the concern. When a concern is detected, a DTC is output on the data link at the
end of the test as requested by the scan tool.
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Brake Pedal Position (BPP) Test
The BPP test checks the ability of the EEC system to detect a change of state in the BPP switch. The brake
pedal is briefly applied and released on all vehicles equipped with a BPP input. This is done during a KOER
on-demand self-test.
Power Steering Pressure (PSP) Test
The PSP test checks the ability of the EEC system to detect a change in the power steering system fluid
pressure. The steering wheel is briefly turned at least 1/4 of a revolution on vehicles equipped with a PSP
switch or sensor. This is done during a KOER on-demand self-test.
Transmission Control Switch (TCS) Test
The TCS test checks the ability of the EEC system to detect a change of state in the TCS. The switch is
briefly cycled on all vehicles equipped with a TCS input. This is done during a KOER on-demand self-test.
Continuous Memory Self-Test
The continuous memory self-test is a functional test of the PCM carried out under any condition (engine
running or off) with the key on. Unlike the KOEO and KOER self-tests, which can only be activated on-
demand, the continuous self-test is always active. A concern does not need to be present when accessing
continuous memory self-test DTCs, making the test valuable when diagnosing intermittent concerns. The
vehicle may need to be driven or the on board diagnostic (OBD) drive cycle completed to allow the PCM to
detect a concern. Refer to On Board Diagnostic (OBD) Drive Cycle for more information. When a concern is
stored in memory, a DTC is output on the data link when requested by the scan tool.
There are two types of continuous DTCs. The first type is an emission-related code which illuminates the
malfunction indicator lamp (MIL) in the instrument cluster. The second is a non-emission related, non-MIL
code which does not illuminate the cluster indicator.
For emission-related MIL codes, the PCM stores the DTC in continuous memory when a concern is detected
for the first time. At this point the DTC does not illuminate the MIL and is now considered a pending code.
The purpose of pending codes is to assist in repair verification by reporting a pending DTC after one drive
cycle. If the same concern is detected after the next ignition start-run cycle, the emission-related MIL code
illuminates the MIL. The MIL remains on even if the concern is intermittent. The MIL is extinguished if the
concern is not present through 3 consecutive drive cycles or if the concern is fixed and the DTCs are
cleared. Also, an emission-related pending MIL and any non-emission related, non-MIL DTCs are erased
after approximately 40 vehicle warm-up cycles or if the DTCs are cleared.
Any scan tool that meets OBD requirements can access the continuous memory to retrieve emission-related
MIL DTCs. However, not all scan tools access pending and non-emission related, non-MIL DTCs in the
same way.
During most diagnostic procedures in this manual, it is required that all DTCs be retrieved and cleared.
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Consult the instruction manual from the tool manufacturer for specific instructions.

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Resetting The Keep Alive Memory (KAM)
Description
Resetting the KAM returns the powertrain control module (PCM) memory to its default setting. Adaptive
learning contents such as idle speed, refueling event, and fuel trim are included. Clear the continuous
diagnostic trouble codes (DTCs) in the PCM and reset the emission monitors information, is part of a KAM
reset. Refer to Clear the Continuous Diagnostic Trouble Codes (DTCs) and Reset the Emission Monitors
Information in the Powertrain Control Module (PCM) in this section. Both can be useful in post-repair testing.
After the KAM has been reset, the vehicle may exhibit certain driveability concerns. It is necessary to drive
the vehicle to allow the PCM to learn the values for optimum driveability and performance.
This function may not be supported by all scan tools. Refer to the scan tool manufacturer's instruction
manual.
If an error message is received or the scan tool does not support this function, disconnecting the battery
ground cable for a minimum of 5 minutes may be used as an alternative procedure.

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Scan Tool Setup and Functionality
Connect the scan tool to the data link connector (DLC) for communication with the vehicle.
The DLC is located in the driver side compartment under the steering column. It is attached to the
instrument panel and accessible from the driver seat.
The DLC is rectangular in design and capable of accommodating up to 16 terminals. The connector has
keying features to allow easy connection.
The required scan tool functions are described below:
monitor, record, and playback of parameter identification (PIDs)
freeze frame PID data
diagnostic test modes; self-test, clear diagnostic trouble codes (DTCs)
output test mode
resetting keep alive memory (KAM)
diagnostic monitoring test results (mode 6) for on board diagnostic (OBD) on board monitors
on-board system readiness (OBD monitor completion status)
Some of these functions are described in this section. Refer to the scan tool manufacturer's instruction
manual for specific information on scan tool setup and operation.

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Vehicle Check/Preparation
Before using the scan tool to carry out any test, refer to the important Safety Notice located at the beginning
of this manual and the necessary visual checks listed below.

Visual Checks
Inspect the air cleaner and inlet duct.
Check all engine vacuum hoses for damage, leaks, cracks, kinks, and proper routing.
Check the electronic engine control (EEC) system wiring harness for proper connections, bent or
broken pins, corrosion, loose wires, and proper routing.
Check the powertrain control module (PCM), sensors, and actuators for physical damage.
Check the engine coolant for proper level and mixture.
Check the transmission fluid level and quality.
Make all necessary repairs before continuing with the quick test. Refer to Section 3, Quick Test .

Vehicle Preparation
Carry out all safety steps required to start and run vehicle tests. Apply the parking brake, place the
gear selector lever firmly into the PARK position on automatic transmission vehicles or NEUTRAL on
manual transmission vehicles, and block the drive wheels.
Turn off all electrical loads such as radios, lamps, A/C, blower, and fans.
Start the engine (if the engine runs) and bring it up to the normal operating temperature before
running the quick test.

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QT: Step 1: Powertrain Control Module (PCM) Quick Test

QT1 CARRY OUT THE PCM QUICK TEST
Note: If the vehicle was brought in with an emission compliance concern, GO to Pinpoint Test EM .
Note: For applications that use a stand-alone transmission control module (TCM), the PCM does not
output TCM related diagnostic trouble codes (DTCs). Refer to the Workshop Manual Section 307-01,
Automatic Transaxle/Transmission for diagnosis and testing.
Note: If unable to access the PCM DTCs, or a scan tool communication concern exists, GO to
Pinpoint Test QA in Section 5. For additional information on retrieving malfunction indicator lamp
(MIL) and non-MIL DTCs, refer to Section 2, Diagnostic Methods Continuous Memory Self-Test.
Complete the preliminary checks looking for obvious concerns that may relate to the symptom. Check
for the following items:
related electrical connectors or fuses
vacuum lines (leaks, routing)
air intake system (leaks, restrictions)
fuel quality (octane, contamination, winter/summer blend)
cooling system (engine operating at proper temperature)
Access any related On-line Automotive Service Information System (OASIS) or Technical Service
Bulletin (TSB) information (if available).
Carry out the PCM self-test to access any DTCs. Record any key on engine off (KOEO), key on
engine running (KOER) (if the engine runs) and continuous memory (MIL and non-MIL) DTCs.
Are any DTCs present?
2007 PCED On Board Diagnostics SECTION 3: Symptom Charts
Yes No
GO to Section 4, Diagnostic Trouble Code
(DTC) Charts and Descriptions for direction to
repair DTCs after noting the following:

Diagnose the DTCs in the following order (begin
diagnosis with the first DTC output in that mode
and diagnose any circuit related DTCs first). For
multiple circuit DTCs that are set as a result of a
GO to Step 2: No Diagnostic Trouble Codes
(DTCs) Present Symptom Chart Index for
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concern with more than one component,
REFER to the Wiring Diagrams Manual and
identify the common cause such as SIG RTN,
VREF, or VPWR. Continue DTC diagnosis by
referring to the appropriately identified pinpoint
test.
1. Any KOEO self-test DTCs
2. Any KOER self-test DTCs
3. Any continuous memory self-test DTCs.
Retrieve any available freeze frame data
and disregard any identical/related
continuous DTCs already repaired.
direction to the proper symptom chart in Step 3:
No Diagnostic Trouble Codes (DTCs) Present
Symptom Charts .

If the symptom is not listed, REFER to the
applicable Workshop Manual Section to
continue diagnosis.
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Step 2: No Diagnostic Trouble Codes (DTCs) Present Symptom
Chart Index

Driveability
System/Symptom
Oasis
Number
Chart
Number
Starting Concerns
Hard Start/Long Crank/Erratic Start/Erratic
Crank
602300
Chart
Number: 2
No crank 601300
Chart
Number: 23
No start (engine cranks) 603300
Chart
Number: 3
Unique Idle
Concerns
Slow return to idle 617400
Chart
Number: 4
Rolling idle 618400
Chart
Number: 1
Fast idle 619400
Chart
Number: 5
Low/Slow idle 607400
Chart
Number: 6
Driveability - Performance While Driving Concerns
System/Symptom
Oasis
Number
Chart
Number
Stalls/Quits
Idle/Acceleration/Cruise 607x00
Chart
Number: 1
Deceleration 607700
Chart
Number: 6
Stall after start 607000
Chart
Number: 1
Runs Rough 608x00
Chart
Number: 1
Misses 609x00
Chart
Number: 1
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Note: OASIS identifiers (the x means any number (1-9) can be used) xxx4xx equals during idle,
xxx5xx equals during acceleration, xxx6xx equals during cruise, xxx7xx equals during deceleration.

Buck/Jerk 610x00
Chart
Number: 1
Hesitation/Stumble 611x00
Chart
Number: 1
Surge 612x00
Chart
Number: 1
Backfires 613x00
Chart
Number: 7
Lack/Loss of Power 614x00
Chart
Number: 8
Spark Knock 615x00
Chart
Number: 9
Additional Driveability Concerns
System/Symptom
Oasis
Number
Chart
Number
Diesels/Runs On 621000
Chart
Number: 5
Poor Fuel Economy 622000
Chart
Number: 10
Emissions Compliance 623000
Chart
Number: 11
Electrical
System/Symptom
Oasis
Number
Chart
Number
Warning
Indicators
Malfunction indicator lamp (MIL) 698298
Chart
Number: 12
Transmission control indicator lamp (TCIL) 698298
Chart
Number: 12
Power take off (PTO) 507000
Chart
Number: 12
Temperature warning indicator or gauge (for vehicles
equipped with a cylinder head temperature (CHT)
sensor only)
206000
Chart
Number: 12
Check fuel cap indicator 206000
Chart
Number: 12
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Powertrain malfunction indicator (wrench) 698298
Chart
Number: 12
Climate Control
Lack of A/C cooling, A/C not functioning 208200
Chart
Number: 21
A/C always on or A/C compressor runs continuously 208999
Chart
Number: 21
Instrumentation
Tachometer inoperative 204000
Chart
Number: 14
Speedometer/odometer inoperative 204000
Chart
Number: 14
Boost gauge indicates higher than normal boost 204000
Chart
Number: 14
Fuel gauge inoperative 204000
Chart
Number: 14
Engine
System/Symptom
Oasis
Number
Chart
Number
Oil System
Concerns
High oil consumption 401000
Chart
Number: 15
Leaks 401000
Chart
Number: 15
Cooling System
Concerns
Electric cooling fan(s) does not operate (low,
medium, high or variable speed)
402000
Chart
Number: 16
Cooling fan clutch does not operate 402000
Chart
Number: 16
Electric cooling fan(s) always runs 402000
Chart
Number: 17
Exhaust System
Concerns
Visible smoke 403000
Chart
Number: 18
Odor (sulfur or rotten egg smell) 403000
Chart
Number: 22
Fuel System
Concerns
Odor, engine compartment 404000
Chart
Number: 19
Engine Noise (under hood) 497000
Chart
Number: 20
Driveline
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System/Symptom
Oasis
Number
Chart
Number
Automatic Transmission (A/T) Shift Concerns
Upshift 501000
Chart
Number: 13
Downshift 502000
Chart
Number: 13
Engagement 503000
Chart
Number: 13
Power Take Off (PTO)
System/Symptom
Oasis
Number
Chart
Number
PTO Concerns Not working correctly 507000
Chart
Number: 12
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Step 3: No Diagnostic Trouble Codes (DTCs) Present Symptom
Charts

Chart 1
Stalls/Quits: Idle, Acceleration, Cruise, Stall After Start
Runs Rough
Misses
Buck/Jerk
Hesitation/Stumble
Surge
Unique Idle Concerns: Rolling Idle
Intermittent Rough Idle
Note: For some vehicle applications, the engine may stall if left running while refueling. Advise the customer
to turn the engine off while refueling to avoid contamination or damage to the evaporative emission (EVAP)
system.

SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test
unless noted)
Check the following parameter identifiers (PIDs):
DPFEGR (if equipped) (hot idle value within 0.15
volt of the key ON, engine OFF value)
LONGFT1/LONGFT2 (value between -20 and
+20%)
VPWR (value between 10.5 and 17.0 volts, and
within 0.5 volt of battery voltage)
DPFEGR PID value not within
0.15 volt of key ON, engine OFF
value:
For vehicles equipped with
an exhaust gas recirculation
system module (ESM), GO
to Pinpoint Test HH .
For all others, GO to Pinpoint
Test HE .
LONGFT1/LONGFT2 value low (-):
Continue diagnosis. Concentrate
checks in areas that would cause
the engine to run rich.
LONGFT1/LONGFT2 value high
(+):
Continue diagnosis. Concentrate
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checks in areas that would cause
the engine to run lean.
VPWR not between 10.5 and 17.0
volts:
REFER to the Workshop Manual
Section 414-00, Charging System.
VPWR between 10.5 and 17.0
volts, but not within 0.5 volt of
battery voltage:
CHECK the B+ voltage to the
powertrain control module (PCM)
power relay. CHECK the VPWR
circuit between the PCM and the
PCM power relay. CHECK the PWR
GND circuits.
For vehicles that run rough at idle:
Check the INJx_F PIDs (the "x" indicates the injector
number) with the key ON, engine OFF. There is 1
INJx_F PID for each engine cylinder. All INJx_F PIDs
must indicate no fault (or NO).
The INJx_F PID(s) indicate a fault
(an injector circuit concern is
indicated), GO to Pinpoint Test KG .
Mass Air Flow (MAF) Sensor GO to Pinpoint Test DC .
Secondary Ignition System For vehicles equipped with a coil
pack ignition system, GO to
Pinpoint Test JC .
For all others, GO to Pinpoint Test
JB .
Fuel Delivery System GO to Pinpoint Test HC .
Exhaust System GO to Pinpoint Test HF .
Positive Crankcase Ventilation (PCV) System GO to Pinpoint Test HG .
EVAP System GO to Pinpoint Test HX .
Charging System GO to Pinpoint Test HY .
Automatic Transmission REFER to the Workshop Manual
Section 307-01, Automatic
Transmission/Transaxle.
Base Engine REFER to the Workshop Manual
Section 303-01, Engine.
Intake Air System (for vehicles equipped with an idle air
control [IAC] valve)
GO to Pinpoint Test HU .
A/C Pressure (ACP) Sensor GO to Pinpoint Test DS .
Additional Testing GO to Pinpoint Test Z .
Additional Checks: REFER to the applicable Workshop
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Chart 2
Starting Concerns: Hard Start/Long Crank/Erratic Start/Erratic Crank

Some vehicles have a TQ_CNTRL PID
available. Check this PID to determine if the
PCM is reducing torque, and if so, why the
torque is being reduced. As a PID display
example; 0 equals no torque reduction
requested, 1 equals torque truncation, which
cuts fuel to protect when line pressure falls to
minimum limit and 2 equals traction control
event, which cuts fuel/spark for traction control.
Correct PCM vehicle identification (VID) block
information. Refer to Section 2, Flash Electrically
Erasable Programmable Read Only Memory
(EEPROM) .
Be aware of engine RPM/speed limiting
functions of the PCM (look for incorrect high
vehicle speed signal from ABS, VSS, or OSS).
Verify the fuel filler cap is properly tightened and
not physically damaged.
Drivelines
Manual transmission/clutch
Charging system
Traction control system (if equipped)
A/C system (for surge with A/C on)
Speed control system (for surge with speed
control on)
A/C compressor diode, if equipped (for rolling
idle)
Manual section.
SYSTEM/COMPONENT
unless noted)
Battery Condition and Current Draw Visual. REFER to the Workshop
Manual Section 414-00, Charging
System.
Secondary Ignition System For vehicles equipped with a coil
pack ignition system, GO to
Pinpoint Test JC .
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Chart 3
Starting Concerns: No Start (Engine Cranks)
Note: An extended crank because of a no start may load the exhaust system with raw fuel, damaging the
catalytic converter after the engine starts. For vehicles equipped with a secondary air injection (AIR) system,
carry out the following after the no start concern is repaired: Disconnect the electric AIR pump relay, run the
engine until the surplus fuel is used up, and connect the relay. Disconnecting the relay may set a continuous
memory PCM DTC that needs to be cleared.

For all others, GO to Pinpoint Test
JB .
PCV System GO to Pinpoint Test HG .
EVAP System GO to Pinpoint Test HX .
Intake Air System (for vehicles equipped with an IAC
valve)
Starting System REFER to the Workshop Manual
Section 303-06, Starting System.
MAF Sensor GO to Pinpoint Test DC .
Additional Checks:
For vehicles equipped with 2 camshaft position
(CMP) sensors, verify the CMP1 and CMP2
circuits are not shorted together.
Visual
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint
Test unless noted)
Add-on Anti-Theft Devices Visual. CHECK with the
customer.
Fuel/Ignition GO to Pinpoint Test A .
Intake Air System (for vehicles equipped with an IAC
valve).
If the engine will not start at closed throttle, but will start and
GO to Pinpoint Test KE .
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Chart 4
Unique Idle Concerns: Slow Return To Idle

Chart 5
Unique Idle Concerns: Fast Idle
Diesels/Runs On
Note: If the vehicle runs normally with the key in the OFF position, check for a damaged ignition switch, an
IGN RUN circuit short to voltage, or a VPWR circuit short to voltage. Refer to the applicable Wiring
Diagrams Manual or Workshop Manual.

run normally at part throttle, check the IAC valve.
Exhaust System Restrictions GO to Pinpoint Test HF .
Base Engine REFER to the Workshop
Manual Section 303-01,
Engine.
SYSTEM/COMPONENT
unless noted)
Vacuum Leaks, Throttle Body Visual
Intake Air System Leaks (for vehicles equipped with
an IAC valve)
SYSTEM/COMPONENT REFERENCE (Section 5 Pinpoint Test unless noted)
Base Engine
Check for air leaks, including proper
sealing of intake manifold and
Visual. REFER to the Workshop Manual Section
303-01, Engine.
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Chart 6
Unique Idle Concerns: Low/Slow Idle
Stalls/Quits: Deceleration

components/vacuum lines attached to
intake air (such as the PCV, EGR or IAC
valve/vacuum lines).
Verify the engine operates at normal
temperature.
Visual. REFER to the Workshop Manual Section
303-03, Engine Cooling or Step 2: No Diagnostic
Trouble Codes (DTCs) Present Symptom Chart
Index , to diagnose any cooling system concerns
that are present.
Fast idle concerns (for vehicles equipped
with an IAC valve)
With the key ON, engine OFF monitor the
TP MODE PID while wiggling the TP
sensor circuits. The TP MODE PID can
also be monitored during vehicle drive.
With the throttle closed, the TP MODE
PID must be C/T (closed throttle).
TP MODE PID is not C/T with the throttle closed:
At vehicle start, the TPREL begins at about 1.25
volts and counts down to the lowest TP voltage
value seen since engine start. If the TP voltage
value goes below the normal range, then
increases again, TPREL sets to the lower voltage.
If the TP voltage is about 0.04 volt greater than
the TPREL value at closed throttle, the PCM goes
into part throttle mode.
MONITOR the TP voltage and TPREL PIDs for
sudden changes while checking for intermittent
TP circuit/connector concerns. CHECK for loose
or worn throttle plates. If no concern is found, GO
to Pinpoint Test Z .
Intake Air System Leaks (for vehicles
equipped with an IAC valve)
Verify the fuel filler cap is
properly tightened.
Visual
(stalls/quits on deceleration)
REFER to the Workshop Manual Section 307-01, Automatic
Transmission/Transaxle to diagnose the torque convertor
operation concerns.
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Chart 7
Backfires

Chart 8
Lack/Loss of Power
Note: Verify the symptom is reported under normal driving conditions without excessive engine or vehicle
load. Also, be aware of the engine RPM/speed limiting functions of the PCM.
Note: For vehicles equipped with a knock sensor, a lack of power may result when the vehicle is operated
with a breakout box installed at the PCM. The knock sensor circuits are not shielded in the breakout box,
and knock sensor signal noise may be noticed by the PCM. If this happens, spark timing is retarded and a
lack of power may result.
Intake Air System (for vehicles
equipped with an IAC valve)
Charging System GO to Pinpoint Test HY .
Base Engine REFER to the Workshop Manual Section 303-01, Engine.
Secondary Ignition For vehicles equipped with a coil pack ignition system, GO to Pinpoint
Test JC .
For all others, GO to Pinpoint Test JB .
Fuel Delivery
System
GO to Pinpoint Test HC .
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SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint
Test unless noted)
Automatic Transmission Fluid Visual
Throttle Linkage Visual
Air Cleaner Element Visual
Check the following PIDS:
LONGFT1/LONGFT2 (value between -20 and +20%)
IMTVF (if equipped): For both key ON, engine OFF
and key ON, engine running with the transmission in
PARK/NEUTRAL and the engine RPM greater than
3,000 RPM, the PID should indicate no fault (or NO) in
both situations.
LONGFT1/LONGFT2 value
low (-):
Continue diagnosis.
Concentrate checks in areas
that would cause the engine
to run rich.
LONGFT1/LONGFT2 value
high (+):
Continue diagnosis.
Concentrate checks in areas
that would cause the engine
to run lean.
IMTVF PID indicates a fault:
Secondary Ignition For vehicles equipped with a
coil pack ignition system, GO
to Pinpoint Test JC .
For all others, GO to Pinpoint
Test JB .
Variable Camshaft Timing (VCT) System GO to Pinpoint Test HK .
Accelerator Pedal Position Sensor GO to Pinpoint Test DK .
Base Engine REFER to the Workshop
Engine.
Automatic Transmission REFER to the Workshop
Automatic
Brake System Drag or Binding REFER to the Workshop
Manual Section 206-00, Brake
System.
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Chart 9
Spark Knock

Supercharger Bypass System GO to Pinpoint Test KJ .
Additional Checks:
Some vehicles have a TQ_CNTRL PID available.
Check this PID to determine if the PCM is reducing
torque, and if so, why the torque is being reduced. As
a PID display example; 0 equals no torque reduction
requested, 1 equals torque truncation, which cuts fuel
to protect when line pressure falls to minimum limit,
and 2 equals traction control event, which cuts
fuel/spark for traction control.
Customer driving habits
Correct PCM vehicle identification (VID) block
information. REFER to Section 2, Flash Electrically
Erasable Programmable Read Only Memory
(EEPROM) .
Intake manifold runner control (IMRC) linkage (if
equipped)
Clutch (M/T)
Charging system
Engine RPM/speed limiting functions of the PCM (look
for incorrect high vehicle speed signal from ABS, VSS,
or OSS)
Visual. REFER to the
applicable Workshop Manual
section.
Verify the engine operates
at normal temperature
Visual. REFER to the Workshop Manual Section 303-03, Engine
Cooling or Step 2: No Diagnostic Trouble Codes (DTCs) Present
Symptom Chart Index to diagnose any cooling system concerns
that are present.
Verify correct coolant level
and coolant concentration
REFER to the Workshop Manual Section 303-03, Engine
Cooling for proper coolant concentrations and fill procedures.
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Chart 10
Poor Fuel Economy
Note: Driving styles may have a significant influence on fuel economy. Verify the concern before starting an
in-depth diagnosis. The following external factors may contribute to poor fuel economy:
stop and go driving
improper tire pressure and size
vehicle loads (such as trailer towing)
extended winter warm-up conditions
high speed driving
incorrect axle ratio
road/weather conditions
aftermarket add-ons
short run operations
customer expectations

Secondary Ignition
System
For vehicles equipped with a coil pack ignition system, GO to
Pinpoint Test JC .
Engine Oil Quality Visual
SYSTEM/COMPONENT
REFERENCE (Section 5 Pinpoint Test unless
noted)
Check the following PIDs:
LONGFT1/LONGFT2 (value between -
20 and +20%)
VPWR (value between 10.5 and 17.0
volts, and within 0.5 volt of battery
voltage)
LONGFT1/LONGFT2 value low (-):
Continue diagnosis. Concentrate checks in
areas that would cause the engine to run
rich.
LONGFT1/LONGFT2 value high (+):
Continue diagnosis. Concentrate checks in
areas that would cause the engine to run
lean.
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Chart 11
Emissions Compliance
VPWR not between 10.5 and 17.0 volts:
REFER to the Workshop Manual Section
414-00, Battery and Charging System.
VPWR between 10.5 and 17.0 volts, but
not within 0.5 volt of battery voltage:
CHECK the B+ voltage to the PCM power
relay. CHECK the VPWR circuit between the
PCM and the PCM power relay. CHECK the
PWR GND circuits.
Verify the engine operates at normal
temperature.
Visual. REFER to the Workshop Manual
Section 303-03, Engine Cooling to diagnose
any cooling system concerns that are
present.
Secondary Ignition System For vehicles equipped with a coil pack
ignition system, GO to Pinpoint Test JC .
Fuel System GO to Pinpoint Test HC .
Variable Camshaft Timing (VCT) System GO to Pinpoint Test HK .
Transmission Fluid Level Visual
Automatic Transmission REFER to the Workshop Manual Section
307-01, Automatic Transmission/Transaxle.
Additional Checks:
Correct PCM VID block information.
Refer to Section 2, Flash Electrically
Erasable Programmable Read Only
Memory (EEPROM) .
Brake drag
Base engine concerns
Incorrect PCV valve
Contaminated MAF sensor
Intake air system
REFER to the applicable Workshop Manual
section.
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Chart 12
Warning Indicators: Check Fuel Cap Indicator, Malfunction Indicator Lamp (MIL), Power Take Off
(PTO), Temperature Warning Indicator or Gauge (applications with CHT sensor only), Transmission
Control Indicator Lamp (TCIL), Powertrain Malfunction Indicator (Wrench)
PTO Concerns: Not Working Correctly
Note:
If the symptom is both a MIL on and exhaust emission test failure, GO directly to Chart 11.
If the engine is a no start, GO directly to Chart 3.
If the engine runs rough at idle, GO directly to Chart 1.

Emissions Related Systems GO to Pinpoint Test EM .
Verify the fuel filler cap is properly
tightened.
Visual
Check Fuel Cap Indicator
Never/always on
REFER to the Workshop Manual Section 413-01,
Instrument Cluster or Section 413-08 Information and
Message Center.
MIL
Always on when the
engine is running (no
DTCs present)
Never on (including during
indicator prove out)
Instrument Cluster.
PTO
PTO indicator
never/always on
PTO not working correctly
GO to Pinpoint Test FB .
Temperature Warning Indicator or
Gauge (applications with CHT
For an engine that is overheating, REFER to the
Workshop Manual Section 303-03, Engine Cooling. Be
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Chart 13
Automatic Transmission (A/T) Shift Concerns: Upshift, Downshift, Engagement

Chart 14
Instrumentation: Tachometer Inoperative, Speedometer/Odometer Inoperative, Boost Gauge
Indicates Higher Than Normal Boost, Fuel Gauge Inoperative

sensor only)
Engine cooling system
Indicator circuits
aware that since a PCM DTC is not present, the PCM is
not attempting to activate the indicator.
For an engine operating at normal temperature, GO to
Pinpoint Test DL .
TCIL
Always on when the
engine is running (no
DTCs present)
Never on
For E-Series, GO to Pinpoint Test TB .
For all others, REFER to the Workshop Manual Section
413-01, Instrument Cluster.
Powertrain Malfunction Indicator
(Wrench)
Never/always on
Instrument Cluster.
Transmission REFER to the Workshop Manual Section 307-01, Automatic
Additional Tests GO to Pinpoint Test Z .
SYSTEM/COMPONENT
unless noted)
Tachometer Inoperative (for vehicles equipped
with a CTO circuit from the PCM)
GO to Pinpoint Test JH .
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Chart 15
Oil System Concerns: High Oil Consumption, Leaks

Chart 16
Cooling System Concerns: Electric Cooling Fan(s) Does Not Operate (Low, Medium, High or Variable
Speed), Cooling Fan Clutch Does Not Operate

Speedometer/Odometer Inoperative GO to Pinpoint Test DP .
Boost Gauge (for vehicles equipped with a
supercharger)
Indicates higher than normal boost
For supercharger bypass control
concerns, GO to Pinpoint Test KJ .
For charge air cooler (CAC) system
concerns, GO to Pinpoint Test KP .
Fuel Gauge Inoperative
Fuel gauge always indicates full or empty
REFER to the Workshop Manual
Section 413-01, Instrument Cluster.
Instrumentation REFER to the Workshop Manual
Section 413-01, Instrument Cluster.
Additional Checks
External leaks
Proper dipstick
Proper oil viscosity
Visual
Electric Cooling
Fan
For Crown Victoria/Grand Marquis, Five Hundred/Freestyle/Montego,
Fusion/Milan/Zephyr, and Town Car, GO to Pinpoint Test KN .
For all others, GO to Pinpoint Test KF .
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Chart 17
Cooling System Concerns: Electric Cooling Fan(s) Always Runs
Note: This chart is only intended to diagnose an electric cooling fan that always runs with a cool engine and
the A/C and defroster off.

Chart 18
Exhaust System Concerns: Visible Smoke
Note: Black smoke indicates a rich fuel mixture, blue smoke indicates burning oil, and white smoke indicates
water in the combustion chamber.

Cooling Fan
Clutch
GO to Pinpoint Test HV .
Cooling System REFER to the Workshop Manual Section 303-03, Engine Cooling.
Cooling Fan
A/C pressure switch
(ACPSW) or ACP sensor
circuits
For Crown Victoria/Grand Marquis, Five
Hundred/Freestyle/Montego, Fusion/Milan/Zephyr, and Town Car,
VERIFY the results of the PCM self-test. Visually INSPECT the
cooling fan for concerns.
For all others, GO to Pinpoint Test KF .
Cooling System REFER to the Workshop Manual Section 303-03, Engine Cooling.
Fuel Delivery
System
Black smoke
GO to Pinpoint Test HC .
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Chart 19
Fuel System Concerns: Odor, Engine Compartment

Chart 20
Engine Noise (under hood)
Note: Attempt to identify the source of the noise. If the noise is from a source other than those listed below,
refer to Step 2: No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index (for noise such as
spark knock) or the applicable Workshop Manual section.

Chart 21
Ignition System
Black smoke
For vehicles equipped with a coil pack ignition system, GO to Pinpoint
Test JC .
PCV System
Blue smoke
REFER to the Workshop Manual Section 303-00, Engine System for a
description of the Oil Consumption Test.
EVAP System Visual
Fuel System Visual. GO to Pinpoint Test HC .
Secondary Ignition System
Snap noise that may be due to
secondary ignition arcing.
For vehicles equipped with a coil pack ignition
system, GO to Pinpoint Test JC .
For all others, CHECK the condition of the spark
plug boots.
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Climate Control: Lack of A/C Cooling, A/C Not Functioning, A/C Always On, or A/C Compressor Runs
Continuously

Chart 22
Exhaust System Concerns: Odor (Sulfur or Rotten Egg Smell)
Note: A slight sulfur smell may be normal. Catalysts with less than 8,000-16,000 kilometers (5,000-10,000
miles), either from a new vehicle or new catalyst, are likely to have a sulfur smell due to the highly active
state of new catalysts. Installing a new catalyst may actually make the symptom worse.

Chart 23
Starting Concerns: No Crank

A/C System If sent here from the Workshop Manual with WAC_F PID indicating a fault
(or YES), GO to Section 4, Diagnostic Trouble Code (DTC) Charts and
Descriptions and follow the directions for KOEO DTC P0645.
For all others, REFER to the Workshop Manual Section 412-00, Climate
Control System.
Check for any driveability or
exhaust smoke symptoms.
REFER to Step 2: No DTC(s) Present Symptom Chart
Index for direction to repair other symptoms.
Fuel Source Talk with the customer. Sulfur content can vary in
different fuels. Suggest trying a different fuel source.
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Add-on Anti-Theft
Devices
Visual. CHECK with the customer.
Anti-Theft REFER to the Workshop Manual Section 419-01, Anti-Theft.
Base Engine
Starting system
REFER to the Workshop Manual Section 303-06, Starting
System.
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Diagnostic Trouble Code (DTC) Charts and Descriptions
Note: Refer to the applicable Workshop Manual section to diagnose the body and chassis DTCs.

2007 PCED On Board Diagnostics SECTION 4: Powertrain DTC Charts and Descriptions
P0010 - Intake Camshaft Position Actuator Circuit/Open (Bank 1)
Description: The powertrain control module (PCM) monitors the variable camshaft timing (VCT) circuit
to the PCM for high and low voltage. The test fails if the voltage exceeds or falls below a
calibrated limit for a calibrated amount of time.
Possible
Causes:
Open or short in the VCT circuit
Open VPWR circuit
Open or short in the VCT solenoid valve
Diagnostic
Aids:
This DTC is a circuit check. Testing should include the harness and solenoid coil.
Application Key On Engine Off Key On Engine Running Continuous Memory
All GO to Pinpoint Test HK .
P0011 - Intake Camshaft Position Timing - Over-Advanced (Bank 1)
Description: The powertrain control module (PCM) monitors the variable camshaft timing (VCT) position
for an over-advanced camshaft timing. The test fails when the camshaft timing exceeds a
maximum calibrated value or remains in an advanced position.
Possible
Causes:
Camshaft timing improperly set
Continuous oil flow to the VCT piston chamber
VCT solenoid valve stuck open
Camshaft advance mechanism binding (VCT unit)
Diagnostic
Aids:
This DTC is a functional check of the VCT unit. Diagnose any base engine concerns
related to the engine oil pressure or engine timing. Refer to the Workshop Manual Section
303-00, Engine System.
All GO to Pinpoint Test HK . GO to Pinpoint Test HK .
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P0012 - Intake Camshaft Position Timing - Over-Retarded (Bank 1)
Description: The powertrain control module (PCM) monitors the variable camshaft timing (VCT) position
for over-retarded camshaft timing. The test fails when the camshaft timing exceeds a
maximum calibrated value or remains in a retarded position.
Possible
Causes:
Camshaft timing improperly set
Continuous oil flow to the VCT piston chamber
VCT solenoid valve stuck open
Camshaft advance mechanism binding (VCT unit)
Diagnostic
Aids:
This DTC is a functional check of the VCT unit. Diagnose any base engine concerns
related to the engine oil pressure or engine timing. Refer to the Workshop Manual Section
303-00, Engine System.
P0016 - Crankshaft Position - Camshaft Position Correlation - Bank 1 Sensor A
Description: The powertrain control module (PCM) monitors the variable camshaft timing (VCT)
position for a misalignment between the camshaft and crankshaft. The test fails when the
misalignment is greater than 1 tooth.
Possible
Causes:
Worn timing chain tensioner
Worn timing chain tensioner arm
Loose timing chain
Diagnostic
Aids:
Check or adjust the timing.
All Refer to the Workshop Manual Section 303-01, Engine, to verify the timing.
P0018 - Crankshaft Position - Camshaft Position Correlation - Bank 2 Sensor A
Description: See the description for DTC P0016.
Possible Causes: See the possible causes for DTC P0016.
Diagnostic Aids: See the diagnostic aids for DTC P0016.
All Refer to the Workshop Manual Section 303-01, Engine, to verify the timing.
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P0020 - Intake Camshaft Position Actuator Circuit/Open (Bank 2)
All GO to Pinpoint Test HK .
P0021 - Intake Camshaft Position Timing - Over-Advanced (Bank 2)
P0022 - Intake Camshaft Position Timing - Over-Retarded (Bank 2)
P0040 - Oxygen Sensor Signals Swapped Bank 1 Sensor 1/Bank 2 Sensor 1
Description: The heated oxygen sensor (HO2S) monitor determines if the HO2S signal response for a
fuel shift corresponds to the correct engine bank. The test fails when there is no response
from the HO2S being tested.
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Possible
Causes:
Crossed HO2S harness connectors
Crossed HO2S wiring at the harness connectors
Crossed HO2S wiring at the PCM connectors
Diagnostic
Aids:
Connect the HO2S connector to the correct bank.
All GO to Pinpoint Test DW .
P0041 - Oxygen Sensor Signals Swapped Bank 1 Sensor 2/Bank 2 Sensor 2
Description: The heated oxygen sensor (HO2S) monitor determines if the HO2S signal response for a
fuel shift corresponds to the correct engine bank. The test fails when there is no response
from the HO2S being tested.
Possible
Causes:
Crossed HO2S harness connectors
Crossed HO2S wiring at the harness connectors
Crossed HO2S wiring at the PCM connectors
Diagnostic
Aids:
Connect the HO2S connector to the correct bank.
P005x - HO2S Heater Resistance (Bank 1, Sensor 1), (Bank 1, Sensor 2), (Bank 1, Sensor 3), and
(Bank 2, Sensor 1)
Description: Heater current requirements too low or high in the heated oxygen sensor (HO2S) heater
control circuit (HO2S11, HO2S12, HO2S13, HO2S21).
Possible
Causes:
VPWR circuit open
HO2S heater circuit open
HO2S heater circuit short in the harness
Damaged HO2S heater
Diagnostic
Aids:
Inspect the connectors for signs of damage, water ingress, or corrosion.
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P0060 - HO2S Heater Resistance (Bank 2, Sensor 2)
Description: Heater current requirements too low or high in the heated oxygen sensor (HO2S) heater
control circuit (HO2S22).
Possible
Causes:
See the possible causes for DTC P005x.
Diagnostic
Aids:
See the diagnostic aids for DTC P005x.
P0068 - Manifold Absolute Pressure (MAP)/Mass Air Flow (MAF) - Throttle Position Correlation
Description: The powertrain control module (PCM) monitors a vehicle operation rationality check by
comparing sensed throttle position to mass air flow readings. If during a key on engine
running (KOER) self-test, the comparison of the throttle position (TP) sensor and MAF
sensor readings are not consistent with the calibrated load values, the test fails and a
DTC is stored in continuous memory.
Possible
Causes:
Air leak between MAF sensor and throttle body
TP sensor not seated properly
Damaged TP sensor
Damaged MAF sensor
Diagnostic Aids: Diagnose any MAP, MAF, or TP circuit DTCs first. Drive the vehicle and exercise the
throttle and the TP sensor in all gears. A TP PID less than 4.82% (0.24 volt) with a
LOAD PID greater than 55%, or a TP PID greater than 49.05% (2.44 volts) with a
LOAD PID less than 30% indicates a concern is present.
Vehicles With
Electronic Throttle
Control (ETC)
GO to Pinpoint Test DV . GO to Pinpoint Test DV .
All others GO to Pinpoint Test DH . GO to Pinpoint Test DH .
P0097 - Intake Air Temperature Sensor 2 Circuit Low
Description: Indicates the sensor signal is less than the self-test minimum. The intake air temperature
2 (IAT2) sensor minimum is 0.2 volt.
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Possible
Causes:
Grounded circuit in the harness
Incorrect harness connection
Damaged sensor
Diagnostic
Aids:
Monitor the IAT2 PID value. A typical IAT2 temperature should be greater than the IAT1
temperature. Refer to Section 6 , Reference Values.
All GO to Pinpoint Test DU .
P0098 - Intake Air Temperature Sensor 2 Circuit High
Description: Indicates the sensor signal is greater than the self-test maximum. The intake air
temperature 2 (IAT2) sensor maximum is 4.6 volts.
Possible
Causes:
Open circuit in the harness
Sensor signal short to voltage
Damaged sensor
Diagnostic
Aids:
P0102 - Mass or Volume Air Flow A Circuit Low
Description: The mass air flow (MAF) sensor circuit is monitored by the powertrain control module
(PCM) for low air flow (or voltage) input through the comprehensive component monitor
(CCM). If during key on, engine running (KOER) the air flow (or voltage) changes below a
minimum calibrated limit, the test fails.
Possible
Causes:
MAF sensor disconnected
MAF circuit open to PCM
VPWR open to MAF sensor
PWR GND open to the MAF sensor
MAF RTN circuit open to PCM
MAF circuit shorted to GND
Intake air leak (near the MAF sensor)
A closed throttle indication (throttle position [TP] sensor system)
Damaged MAF sensor
Diagnostic
Aids:
A MAF V PID reading less than 0.23 volt in continuous memory or KOER indicates a hard
fault.
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All GO to Pinpoint Test DC . GO to Pinpoint Test DC .
P0103 - Mass or Volume Air Flow A Circuit High
Description: The mass air flow (MAF) sensor circuit is monitored by the powertrain control module
(PCM) for high air flow (or voltage) input through the comprehensive component monitor
(CCM). If during key on, engine off (KOEO), or key on, engine running (KOER), the air flow
(or voltage) changes above a maximum calibrated limit, the test fails.
Possible
Causes:
MAF sensor screen is blocked
MAF circuit shorted to voltage
Damaged MAF sensor
Diagnostic
Aids:
A MAF V PID (MAF PID) reading greater than 4.6 volts during KOER indicates a hard fault.
All GO to Pinpoint Test DC .
P0104 - Mass or Volume Air Flow A Circuit Intermittent/Erratic
Description: A concern exists in the mass air flow (MAF) sensor A circuit, or the air tube containing the
sensor, causing an incorrect air flow reading.
Possible
Causes:
Intermittent circuit A open or short
Air leaks in the tube from the MAF to the throttle body
Diagnostic
Aids:
Verify the integrity of the MAF sensor circuit A for an intermittent concern. Check the
MAF sensor tube for air leaks.
P0106 - Manifold Absolute Pressure (MAP/BARO) Sensor Range/Performance
Description: MAP sensor input to the powertrain control module (PCM) is monitored and is not within
the calibrated value.
Possible
Causes:
Slow responding MAP sensor
Electrical circuit failure
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Damaged MAP sensor
Diagnostic
Aids:
VREF voltage should be between 4.0 and 6.0 volts. The PID reading is in frequency.
All GO to Pinpoint Test DM .
P0107 - Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Sensor Low
Description: MAP sensor operating voltage is below the minimum calibrated parameter of 0.25
volts.
Possible
Causes:
Open in the circuit, or short to ground
VREF circuit open, or short to ground
Damaged MAP sensor
Diagnostic Aids: VREF should be greater than 4.0 volts. The PID reading is in frequency/volts.
P0108 - Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Sensor High
Description: Sensor operating voltage is greater than 5 volts (VREF). As a result it failed above the
maximum allowable calibrated parameter.
Possible
Causes:
VREF shorted to VPWR
MAP signal shorted to VPWR
VREF should be less than 6.0 volts. The PID reading is in frequency/volts
Open circuit
Diagnostic
Aids:
VREF should be greater than 4.0 volts. The PID reading is in frequency/volts.
P0109 - Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Sensor Intermittent
Description: The sensor signal to the powertrain control module (PCM) is failing intermittently.
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Possible Causes: Loose electrical connection
Damaged MAP sensor
Diagnostic Aids: Check the harness and connection.
P0111 - Intake Air Temperature (IAT) Sensor 1 Circuit Range/Performance
Description: Indicates the IAT rationality test has failed. This DTC indicates that the IAT value is higher
than a calibrated value and could prevent 1 or more on-board diagnostic (OBD) monitors
from completing.
The PCM runs this logic after an engine off and a calibrated soak period (typically 6 hours).
This soak period allows IAT and engine coolant temperature (CHT or ECT) to stabilize and
not differ by more than a calibrated value. DTC P0111 is set when:
the IAT at engine start exceeds the ECT or CHT by more than a calibrated value, typically
17C (30F).
Possible
Causes:
IAT Sensor
Diagnostic
Aids:
Make sure the IAT and the CHT or ECT are similar when the engine is cold.
All GO to Pinpoint Test DA .
P0112 - Intake Air Temperature (IAT) Sensor 1 Circuit Low
Description: Indicates the sensor signal is less than the self-test minimum. The IAT sensor minimum
is 0.2 volt or 121C (250F).
Possible
Causes:
Damaged sensor
Improper harness connection
Diagnostic
Aids:
An IAT V PID reading less than 0.2 volt with key ON engine OFF or during any engine
operating mode indicates a concern is present.
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P0113 - Intake Air Temperature (IAT) Sensor 1 Circuit High
Description: Indicates the sensor signal is greater than the self-test maximum. The IAT sensor
maximum is 4.6 volts or -50C (-58F).
Possible
Causes:
Damaged sensor
Diagnostic
Aids:
An IAT V PID reading greater than 4.6 volts with the key ON engine OFF or during any
engine operating mode indicates a concern is present.
P0114 - Intake Air Temperature (IAT) Sensor 1 Intermittent/Erratic
Description: Indicates the sensor signal was intermittent during the comprehensive component
monitor (CCM).
Possible
Causes:
Damaged harness
Damaged sensor
Damaged harness connector
Diagnostic
Aids:
Monitor the IAT on a scan tool. Look for sudden changes in the reading when the
harness is wiggled or the sensor is tapped.
P0116 - Engine Coolant Temperature (ECT) Sensor 1 Circuit Range/Performance
Description: Indicates the engine coolant temperature rationality test has failed. This DTC indicates
that the ECT or cylinder head temperature (CHT) value is higher than the calibrated
value and could prevent 1 or more on-board diagnostic (OBD) monitors from
completing.
The PCM runs this logic after an engine off and a calibrated soak period (typically 6
hours). This soak period allows the intake air temperature (IAT) and the CHT or ECT to
stabilize and not differ by more than a calibrated value. DTC P0116 is set when all of the
following conditions are met:
The ECT at engine start exceeds the IAT at engine start by more than a calibrated
value, typically 17C (30F).
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The ECT exceeds a calibrated value, typically 107C (225F).
The fuel system, heated oxygen and misfire monitors have not completed.
The calibrated time to set DTC P0116 has expired.
Possible
Causes:
ECT or CHT sensor
Coolant system concern
Diagnostic
Aids:
Make sure the IAT and the ECT are similar when the engine is cold. Also make sure the
ECT or CHT sensor and the actual engine operating temperatures are the same.
Vehicles with
only a CHT
sensor
GO to Pinpoint Test DL .
All others GO to Pinpoint Test DX .
P0117 - Engine Coolant Temperature (ECT) Sensor 1 Circuit Low
Description: Indicates the sensor signal is less than the self-test minimum. The ECT sensor minimum
is 0.2 volt or 121C (250F).
Possible
Causes:
Damaged sensor
Diagnostic
Aids:
A concern is present if an ECT V PID reading less than 0.2 volt with the key ON engine
OFF or during any engine operating mode.
All GO to Pinpoint Test DX .
P0118 - Engine Coolant Temperature (ECT) Sensor 1 Circuit High
Description: Indicates the sensor signal is greater than the self-test maximum. The ECT sensor
maximum is 4.6 volts or -50C (-58F).
Possible
Causes:
Damaged sensor
Diagnostic
Aids:
An ECT V PID reading greater than 4.6 volts with the key ON engine OFF or during any
engine operating mode indicates a concern is present.
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P0119 - Engine Coolant Temperature (ECT) Sensor 1 Circuit Intermittent/Erratic
Description: Indicates the ECT circuit became intermittently open or shorted while the engine was
running. On vehicles that are not equipped with an ECT sensor, the cylinder head
temperature (CHT) sensor can be used and can set this DTC.
Possible
Causes:
Damaged harness
Damaged sensor
Low engine coolant
Diagnostic Aids: Monitor the ECT or the CHT on a scan tool, look for sudden changes in the reading
when the harness is wiggled or the sensor is tapped.
Vehicles with only
a CHT sensor
P0121 - Throttle/Pedal Position Sensor A Circuit Range/Performance
For Vehicles With Electronic Throttle Control (ETC)
Description: The electronic throttle control (ETC) throttle position (TP) sensor 1 circuit was flagged
as a concern by the powertrain control module (PCM) indicating an out of range in
either the closed or wide open throttle (WOT) modes.
Possible
Causes:
Obstruction in the throttle plate movement
Damaged throttle body
TP circuit open to PCM
Damaged TP sensor
SIG RTN circuit open to the TP sensor
Diagnostic Aids: This concern exhibits a symptom of limited power. A TP1 PID reading less than 13%
(0.65 volt), or greater than 93% (4.65 volts) in key ON, engine OFF or key ON, engine
running indicates a concern is present.
For All Others
Description: The throttle position (TP) sensor circuit is monitored by the powertrain control module
(PCM) for a non-closed throttle position at idle. The test fails if the key on engine
running (KOER) self-test terminates upon placing the transmission gear selector in
DRIVE or REVERSE or the TP closed throttle position is not achieved when closing the
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throttle (idle) after opening it (in PARK or NEUTRAL).
Possible
Causes:
Binding throttle linkage
Damaged TP sensor
Diagnostic Aids: Drive the vehicle, bring it to a stop, and turn the key to the OFF position. Start the
vehicle, and run the KOER self-test at idle.
Vehicles With
Electronic Throttle
Control (ETC)
GO to Pinpoint Test DV .
All others GO to Pinpoint Test DH .
P0122 - Throttle/Pedal Position Sensor A Circuit Low
Description: The ETC throttle position (TP) sensor 1 circuit was flagged as a concern by the
powertrain control module (PCM) indicating a low voltage or open circuit.
Possible Causes: Open ETC TP sensor harness
Short to ground in the ETC TP sensor harness
Damaged TP sensor
Diagnostic Aids: This concern exhibits a symptom of limited power. A TP1 PID reading less than
3.42% (0.17 volt) in key ON, engine OFF or key ON, engine running indicates a
concern is present.
For All Others
Description: The TP sensor circuit is monitored by the PCM for a high TP rotation angle (or
voltage) input through the comprehensive component monitor (CCM). The test fails
if the TP rotation angle (or voltage) changes above the maximum calibrated limit.
Possible Causes: TP sensor not seated properly
VREF open to TP sensor
TP circuit short to GND
Damaged TP sensor
Diagnostic Aids: This concern exhibits a symptom of limited power. A TP PID reading less than
3.42% (0.17 volt) in key ON, engine OFF or key ON, engine running indicates a
concern is present.
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Vehicles With
Electronic Throttle
Control (ETC)
P0123 - Throttle/Pedal Position Sensor A Circuit High
Description: The ETC throttle position (TP) sensor 1 circuit was flagged as a concern by the
powertrain control module (PCM) indicating a high voltage.
Possible Causes: TP sensor harness short to VREF
TP sensor harness is short to voltage
Damaged TP sensor
VREF circuit short to TP sensor
Diagnostic Aids: Drive the vehicle, bring it to a stop, and turn the key to the OFF position. Start the
vehicle and carry out the key on engine running (KOER) self-test at idle. Access the
KOER DTCs on the scan tool. The TP1 signal is normally at a high voltage at closed
throttle, and a lower voltage at wide open throttle (WOT) (opposite of TP2).
For All Others
Description: The TP sensor circuit is monitored by the PCM for a high TP rotation angle (or
voltage) input through the comprehensive component monitor (CCM). The test fails if
the TP rotation angle (or voltage) changes above the maximum calibrated limit.
Possible Causes: TP sensor not seated properly
TP sensor harness short to VREF
Damaged TP sensor
Diagnostic Aids: A TP PID reading greater than 93% (4.65 volts) in key ON, engine OFF or key ON,
engine running indicates a concern is present.
Vehicles With
Electronic Throttle
Control (ETC)
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P0125 - Insufficient Coolant Temperature For Closed Loop Fuel Control
Description: Indicates the engine coolant temperature (ECT) or the cylinder heat temperature (CHT)
sensor has not achieved the required temperature level to enter closed loop operating
conditions within a specified amount of time after starting the engine.
Possible
Causes:
Insufficient warm up time
Low engine coolant level
Leaking or stuck open thermostat
Malfunctioning ECT sensor
Malfunctioning CHT sensor
Diagnostic Aids: Compare the thermostat specification to the actual ECT using the engine temperature
PID (ECT or CHT). The temperature reading should be similar when the engine is at a
normal operating temperature.
Vehicles with only
a CHT sensor
P0127 - Intake Air Temperature (IAT) Too High
Description: Indicates that the IAT2 sensor has detected a concern in the charge air cooler CAC
system.
Possible
Causes:
Blockage of heat exchangers
Low fluid level
Fluid leakage
CAC pump or relay failure
Crossed CAC coolant lines
Diagnostic
Aids:
Monitor the IAT2 PID. A typical IAT2 temperature should be greater than the IAT1
temperature. Refer to Section 6 , Reference Values for IAT values.
P0128 - Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
Description: Indicates that the thermostat monitor has not achieved the required engine
operating temperature within a specified amount of time after starting the engine.
Possible Causes: Insufficient warm up time
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Leaking or stuck open thermostat
Inoperative engine coolant temperature (ECT) sensor
Inoperative cylinder head temperature (CHT) sensor
Diagnostic Aids: Refer to Section 1, Thermostat Monitor for system information.
Vehicles with only a
CHT sensor
P012B - Turbocharger/Supercharger Inlet Pressure Sensor Circuit Range/Performance
Description: Manifold absolute pressure (MAP) sensor input to the powertrain control module (PCM) is
monitored and is not within the calibrated value.
Possible
Causes:
Slow responding MAP sensor
Electrical circuit failure
Damaged MAP sensor
Diagnostic
Aids:
VREF voltage should be between 4.0 and 6.0 volts. The PID reading is in frequency.
P012C - Turbocharger/Supercharger Inlet Pressure Sensor Circuit Low
Description: MAP sensor operating voltage is below the minimum calibrated parameter of 0.25
volts.
Possible
Causes:
Open in the circuit, or short to ground
VREF circuit open, or short to ground
Damaged MAP sensor
Diagnostic Aids: VREF should be greater than 4.0 volts. The PID reading is in frequency/volts.
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P012D - Turbocharger/Supercharger Inlet Pressure Sensor Circuit High
Description: Manifold absolute pressure (MAP) sensor operating voltage is above the maximum
calibrated parameter of 5 volts.
Possible
Causes:
VREF shorted to VPWR
MAP signal shorted to VPWR
VREF short to voltage
Open circuit
Diagnostic
Aids:
VREF should be greater than 4.0 volts.
P012E - Turbocharger/Supercharger Inlet Pressure Sensor Circuit Intermittent/Erratic
Description: The sensor signal to the powertrain control module (PCM) is intermittent.
Possible Causes: Loose electrical connection
Damaged manifold absolute pressure (MAP) sensor
Diagnostic Aids: Check the harness and connection.
P0132 - O2 Circuit High Voltage (Bank 1, Sensor 1)
Description: The heated oxygen sensor (HO2S) signals are monitored for an over voltage condition.
The code is set when the HO2S signal voltage is 1.5 volts or greater.
Possible
Causes:
Short to VPWR in the harness or HO2S
Diagnostic
Aids:
An HO2S PID switching across 0.45 volt from 0.2 to 0.9 volt indicates a normal switching
HO2S. An HO2S PID voltage of 1.5 volts or greater indicates a short to voltage.
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P0133 - O2 Circuit Slow Response (Bank 1, Sensor 1)
Description: The heated oxygen sensor (HO2S) monitor checks the HO2S frequency and amplitude.
The test fails if the frequency and amplitude fall below a calibrated limit during testing.
Possible
Causes:
Contaminated HO2S
Exhaust leaks
Short/open wiring
Incorrect fueling
MAF sensor
Deteriorating HO2S
Inlet air leaks
Diagnostic
Aids:
Access the HO2S test results from the generic OBD menu to verify the DTC.
P0135 - O2 Heater Circuit (Bank 1, Sensor 1)
Description: During testing the heated oxygen sensor (HO2S) heaters are checked for open and short
circuits and excessive current draw. The test fails when the current draw exceeds a
calibrated limit or an open or short circuit is detected.
Possible
Causes:
Vacuum hose disconnected on exhaust gas recirculation (EGR) system module
(ESM) applications
Water in the harness connector
Open VPWR circuit
Open GND circuit
Low battery voltage
Corrosion or incorrect harness connections
Damaged HO2S heater
Diagnostic
Aids:
Check the HO2S electrical connector for damage, corrosion, and water intrusion.
Damaged HO2S heater.
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Description: The heated oxygen sensor (HO2S) monitor tracks the rate of voltage change during the rise
and fall of the HO2S signal. When the rate of voltage change is less than a calibrated value,
the powertrain control module (PCM) begins to modify the fuel trim attempting to increase
the HO2S voltage switch rate. The DTC is set when the PCM is at the allowable limit or has
exceeded an allowable length of time for fuel trim modification, without detecting an
acceptable rate of voltage change.
Possible
Causes:
Contaminated or damaged HO2S
Deteriorating HO2S
Exhaust leaks
Aftermarket accessories
Performance modifications
Diagnostic
Aids:
Access the HO2S test results from the generic OBD menu to verify the DTC.
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P0148 - Fuel Delivery Error
Description: At least 1 bank is lean at wide open throttle (WOT).
Possible Causes: Severely restricted fuel filter
Severely restricted fuel supply line
Damaged or worn fuel pump
Damaged or contaminated mass air flow (MAF) sensor
Diagnostic Aids:
All GO to Pinpoint Test HC .
All GO to Pinpoint Test DW . GO to Pinpoint Test DW .
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All GO to Pinpoint Test DW . GO to Pinpoint Test DW .
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P0171 - System Too Lean (Bank 1)
Description: The adaptive fuel strategy continuously monitors the fuel delivery hardware. The test fails
when the adaptive fuel tables reach a rich calibrated limit. Refer to Section 1, Powertrain
Control Software Fuel Trim for more information.
Possible
Causes:
Fuel System:
Damaged or leaking fuel pulse damper
Fuel filter plugged or dirty
Damaged or worn fuel pump
Leaking fuel pump check valve
Leaking/contaminated fuel injectors
Low fuel pressure or running out of fuel
Evaporative emission (EVAP) canister purge valve is leaking when the canister is
clean
Fuel supply line restricted
Fuel rail pressure sensor bias
Exhaust System:
Exhaust leaks in the exhaust manifold gasket or mating gaskets before or near the
heated oxygen sensor (HO2S)
EGR System:
Vacuum hose disconnected on exhaust gas recirculation (EGR) system module
(ESM) applications
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EGR valve tube/gasket leak
EGR vacuum regulator solenoid leak
Intake Air System:
Air leaks after the mass air flow (MAF) sensor
Vacuum leaks
Positive crankcase ventilation (PCV) system is leaking or the valve is stuck open
Improperly seated engine oil dipstick
Damaged or contaminated MAF sensor
Secondary Air Injection:
Damaged secondary air injection system or a mechanically stuck valve
Diagnostic
Aids:
View freeze frame data to determine the operating conditions when the DTC was set.
Observe the LONGFT1 and LONGFT2 PIDs. Refer to Section 2, Adaptive Fuel DTC
Diagnostic Techniques for more information.
All GO to Pinpoint Test H .
P0172 - System Too Rich (Bank 1)
Description: The adaptive fuel strategy continuously monitors the fuel delivery hardware. The test fails
when the adaptive fuel tables reach a rich calibrated limit. Refer to Section 1, Powertrain
Control Software Fuel Trim for more information.
Possible
Causes:
Fuel System:
Damaged or leaking fuel pulse damper
Leaking fuel injectors
Fuel return line restricted
Fuel rail pressure sensor bias
EVAP canister purge valve is leaking when the canister is full
Base engine.
Engine oil contamination
Intake Air System:
Damaged or contaminated mass air flow (MAF) sensor
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Diagnostic
Aids:
View freeze frame data to determine the operating conditions when the DTC was set.
Observe the LONGFT1 and LONGFT2 PIDs. Refer to Section 2, Adaptive Fuel DTC
Diagnostic Techniques for more information.
P0174 - System Too Lean (Bank 2)
P0175 - System Too Rich (Bank 2)
P0180 - Fuel Temperature Sensor A Circuit
Description: The comprehensive component monitor (CCM) monitors the fuel temperature sensor
circuit to the powertrain control module (PCM) for low and high voltage. The test fails if the
voltage falls below or exceeds a calibrated limit and amount of time during testing.
Possible
Causes:
Open or short in the harness
Low ambient temperature operation
Damaged fuel temperature sensor
Diagnostic
Aids:
Verify the FRT PID value to determine an open or short.
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All GO to Pinpoint Test DD .
P0181 - Fuel Temperature Sensor A Circuit Range/Performance
Description: The comprehensive component monitor (CCM) monitors the fuel temperature sensor for
acceptable operating temperature. The test fails if the voltage falls below or exceeds a
calibrated limit, for a calibrated amount of time during testing.
Possible
Causes:
Open or short in the harness
Damaged powertrain control module (PCM)
Diagnostic
Aids:
All GO to Pinpoint Test DD . GO to Pinpoint Test DD .
P0182 - Fuel Temperature Sensor A Circuit Low
circuit to the powertrain control module (PCM) for low voltage. The test fails if the voltage
falls below a calibrated limit for a calibrated amount of time during testing.
Possible
Causes:
Short in the harness
VREF open or short
Diagnostic
Aids:
Verify the FRT PID and VREF values to determine an open or short.
P0183 - Fuel Temperature Sensor A Circuit High
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circuit to the powertrain control module (PCM) for high voltage. The test fails if the voltage
exceeds a calibrated limit for a calibrated amount of time during testing.
Possible
Causes:
Open circuit
Open or short to voltage in the harness
Diagnostic
Aids:
P0190 - Fuel Rail Pressure Sensor A Circuit
Description: The comprehensive component monitor (CCM) monitors the fuel rail pressure (FRP)
sensor to the powertrain control module (PCM) for VREF voltage. The test fails when the
VREF voltage from the PCM drops to a voltage less than a minimum calibrated value.
Possible
Causes:
VREF open in harness
VREF open in sensor
Vacuum leaks
Diagnostic
Aids:
Verify a VREF voltage between 4 and 6 volts.
P0191 - Fuel Rail Pressure Sensor A Circuit Range/Performance
Description: The comprehensive component monitor (CCM) checks the fuel rail pressure (FRP) sensor
for an acceptable fuel pressure. The test fails when the fuel pressure falls below or
exceeds a minimum/maximum calibrated value for a calibrated period of time.
Possible
Causes:
High fuel pressure
Low fuel pressure
Damaged FRP sensor
Excessive resistance in the circuit
Vacuum leaks
Low or no fuel
Diagnostic A FRP PID value during key ON, engine running of 138 kPa (20 psi) to 413 kPa (60 psi) is
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Aids: acceptable.
P0192 - Fuel Rail Pressure Sensor A Circuit Low
sensor circuit to the powertrain control module (PCM) for low voltage. The test fails if the
voltage falls below a calibrated limit for a calibrated amount of time during testing.
Possible
Causes:
FRP signal short to SIG RTN or PWR GND
Damaged FRP sensor
Diagnostic
Aids:
A FRP PID value during key ON, engine OFF or key ON, engine running less than 0.3 volt
indicates a concern is present.
P0193 - Fuel Rail Pressure Sensor A Circuit High
sensor circuit to the powertrain control module (PCM) for high voltage. The test fails if the
voltage exceeds a calibrated limit for a calibrated amount of time during testing.
Possible
Causes:
FRP signal short to VREF or VPWR
FRP signal open
Damaged FRP sensor
Diagnostic
Aids:
An FRP signal high condition can be caused by any number of conditions, including a short
on FRP signal to VREF, a more positive voltage level, an open FRP signal or signal return.
The FRP signal line is pulled up by the PCM and VREF at the sensor, and down by the
sensor through SIGRTN.
P0196 - Engine Oil Temperature (EOT) Sensor Circuit Range/Performance
Description: Indicates the value from the EOT sensor is not within the powertrain control module (PCM)
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predicted engine oil temperature range, based on other PCM inputs.
Possible
Causes:
Engine not at operating temperature
Cooling system problem or stuck thermostat
EOT circuit failure
Diagnostic
Aids:
The EOT rationality test looks for the EOT sensor value to be within a calibrated delta of
the PCM predicted engine oil temperature. Make sure the EOT sensor reading is similar to
the engine temperature. If the EOT reading greatly differs from engine temperature, check
the EOT circuitry for correct operation.
All GO to Pinpoint Test DY .
P0197 - Engine Oil Temperature (EOT) Sensor Circuit Low
Description: Indicates EOT signal voltage is low (high temperature).
Possible
Causes:
Damaged harness
Damaged sensor
Diagnostic
Aids:
An EOT V PID reading less than 0.2 volt with the key on engine off (KOEO) or during any
engine operating mode indicates a short to ground.
P0198 - Engine Oil Temperature (EOT) Sensor Circuit High
Description: Indicates EOT signal voltage is high (low temperature).
Possible
Causes:
Damaged harness
Damaged sensor
Diagnostic
Aids:
An EOT V PID reading greater than 4.5 volts with the key ON engine OFF or during any
engine operating mode indicates an open circuit.
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P020x - Injector Circuit/Open - Cylinder X
Description: Note: x represents injector numbers 1 through 9.
The comprehensive component monitor (CCM) monitors the operation of the fuel injector
drivers in the powertrain control module (PCM). The test fails when the fuel injector
circuitry is inoperative.
Possible
Causes:
Open circuit
Damaged fuel injector
Damaged PCM
Diagnostic
Aids:
PID Data Monitor INJx_F fault flags equals YES.
This DTC is set when a concern is detected between the PCM and the fuel injector.
All GO to Pinpoint Test KG .
P0210 - Injector Circuit/Open - Cylinder 10
Description: See the description for DTC P020x.
Possible Causes: See the possible causes for DTC P020x.
Diagnostic Aids: See the diagnostic aids for DTC P020x.
All GO to Pinpoint Test KG .
P0217 - Engine Coolant Over-Temperature Condition
Description: Indicates an engine overheat condition was detected by the engine temperature sensor
(CHT or ECT depending how the vehicle is equipped).
Possible
Causes:
Engine cooling system concerns
Diagnostic
Aids:
Monitor the engine temperature PID (CHT or ECT) for an overheat condition. Typical
engine temperature should be close to cooling system thermostat specification.
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P0218 - Transmission Fluid Temperature Over-Temperature Condition
Description: Indicates a transmission overheat condition was sensed by the transmission fluid
temperature (TFT) sensor.
Possible
Causes:
Low transmission fluid level
Transmission cooling system concerns
Diagnostic
Aids:
Monitor the transmission temperature PID TFT for an overheat condition.
All Refer to the Workshop Manual Section 307-01, Automatic Transmission.
P0219 - Engine Over Speed Condition
Description: Indicates the vehicle has been operated in a manner which caused the engine speed to
exceed a calibrated limit. The engine RPM is continuously monitored and evaluated by the
powertrain control module (PCM). The DTC is set when the RPM exceeds the calibrated
limit set within the PCM. For additional information on the engine RPM limiter, refer to
Section 1, Powertrain Control Software .
Possible
Causes:
Wheel slippage (water, ice, mud, and snow)
Excessive engine RPM in NEUTRAL or operated in the wrong transmission gear
Diagnostic
Aids:
The DTC indicates the vehicle has been operated in a manner which caused the engine
speed to exceed a calibrated limit.
All GO to Pinpoint Test ND .
P0221 - Throttle/Pedal Position Sensor/Switch B Circuit Range/Performance
Description: The electronic throttle control (ETC) throttle position (TP) sensor 2 circuit was flagged as a
concern by the powertrain control module (PCM) indicating an out of range in either the
closed or wide open throttle (WOT) modes.
Possible
Causes:
Binding throttle linkage
Damaged TP sensor
Self-test operator error (foot resting on the accelerator pedal during test)
Diagnostic This concern exhibits a symptom of limited power. A TP2 PID reading greater than 96.42%
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Aids: (4.65 volts) during key ON, engine OFF or key ON, engine running indicates a concern is
present.
All GO to Pinpoint Test DV .
P0222 - Throttle/Pedal Position Sensor/Switch B Circuit Low
concern by the powertrain control module (PCM) indicating a low voltage, or open circuit.
Possible
Causes:
Open ETC TP sensor harness
Short to ground in the ETC TP sensor harness
Damaged TP sensor
Diagnostic
Aids:
This concern exhibits a symptom of limited power. A TP2 PID reading less than 3.42%
(0.17 volt) during key ON, engine OFF or key ON, engine running indicates a concern is
present.
P0223 - Throttle/Pedal Position Sensor/Switch B Circuit High
concern by the powertrain control module (PCM) indicating a high voltage.
Possible
Causes:
ETC TP sensor harness shorted to VREF
Damaged TP sensor
ETC TP2 circuit open
VREF circuit short to TP sensor
Diagnostic
Aids:
This concern exhibits a symptom of limited power. A TP2 PID reading greater than 93%
(4.65 volts) in key ON, engine OFF or key ON, engine running indicates a concern is
present.
P0230 - Fuel Pump Primary Circuit
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Description: The powertrain control module (PCM) monitors the fuel pump (FP) circuit output from the
PCM. The test fails when the FP output is commanded ON (grounded) and excessive
current draw is detected on the FP circuit. The test also fails when the FP output is
commanded OFF and voltage is not detected on the FP circuit. The PCM expects to detect
VPWR voltage coming through the fuel pump relay coil to the FP circuit.
Possible
Causes:
Open or shorted (FP) circuit
Open VPWR circuit to the fuel pump relay
Damaged fuel pump relay
Damaged PCM
Diagnostic
Aids:
A concern is present when the FP_F PID reads YES. An open circuit or short to ground can
only be detected with the fuel pump commanded OFF. A short to voltage can only be
detected with the fuel pump commanded ON. During the key on engine off (KOEO) and key
on engine running (KOER) self-test, the fuel pump output command is cycled on and off.
All GO to Pinpoint Test KA .
P0231 - Fuel Pump Secondary Circuit Low
Description: The powertrain control module (PCM) monitors the fuel pump monitor (FPM) circuit. The
test fails if the PCM commands the fuel pump ON and B+ voltage is not detected on the
FPM circuit.
Possible
Causes:
Open B+ circuit to the fuel pump relay
Open FP PWR circuit between the fuel pump relay and its connection to the FPM
circuit
Damaged fuel pump relay
Diagnostic
Aids:
During the key on engine off (KOEO) self-test, the PCM commands the fuel pump ON so
this test can be carried out.
P0232 - Fuel Pump Secondary Circuit High
Description: The powertrain control module (PCM) monitors the fuel pump monitor (FPM) circuit. This
test fails when the PCM detects voltage on the FPM circuit while the fuel pump is
commanded OFF. The FPM circuit is wired to a pull-up voltage inside the PCM. The FPM
circuit goes high if, with the key ON, engine OFF and the fuel pump commanded OFF, the
FPM/FP PWR circuit loses its path to ground through the fuel pump. The FPM circuit also
goes high if the FPM/FP PWR circuit is short to voltage.
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Possible
Causes:
Inertia fuel shutoff (IFS) switch not reset or electrically open
Open circuit between the fuel pump and the FPM connection to the FP PWR circuit
Poor fuel pump ground
Fuel pump electrically open
Fuel pump secondary circuits short to voltage
Fuel pump relay contacts always closed
Open FPM circuit between the PCM and the connection to the FP PWR circuit
Diagnostic
Aids:
Continuous memory P0232 can be set if the IFS switch is tripped then reset, or if the fuel
pump circuit is activated when the PCM expected the circuit to be off. This DTC may set
during a fuel system test or prime procedure.
P0297 - Vehicle Over Speed Condition
Description: Indicates the vehicle has been operated in a manner which caused the vehicle speed to
exceed a calibration limit. The vehicle speed is continuously monitored and evaluated by
the powertrain control module (PCM). The DTC is set when the vehicle speed exceeds the
calibrated limit set within the PCM. For additional information on the vehicle speed limiter,
refer to Section 1, Powertrain Control Software .
Possible
Causes:
Vehicle driven at a high rate of speed
Diagnostic
Aids:
The DTC indicates the vehicle has been operated in a manner which caused the engine
speed to exceed a calibrated limit.
P0298 - Engine Oil Over Temperature Condition
Description: Indicates the engine oil temperature protection strategy in the powertrain control module
(PCM) has been activated. This temporarily prohibits high engine speed operation by
disabling injectors, to reduce the risk of engine damage from high engine oil temperature.
On engines equipped with an oil temperature sensor, the PCM reads oil temperature to
determine if it is excessive. When an oil temperature sensor is not present, the PCM uses
an oil algorithm to determine actual temperature. Engine shutdown strategy function is the
same on vehicles with and without oil temperature sensors.
Possible
Causes:
Very high engine RPM for an extended period of time
Overheating condition
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Damaged engine oil temperature (EOT) sensor or circuit (vehicles with an EOT
sensor)
Diagnostic
Aids:
The engine is operating in high RPM range due to improper gear selection. This may cause
a lack/loss of power or surge.
P0300 - Random Misfire Detected
Description: The random misfire DTC indicates multiple cylinders are misfiring or the powertrain control
module (PCM) cannot identify which cylinder is misfiring.
Possible
Causes:
Camshaft position sensor (CMP)
Low fuel (less than 1/8 tank)
Stuck open EGR valve
Blocked EGR passages
Diagnostic
Aids:
One or more EGR passages may be blocked or partially blocked. If this is the case the
misfire detection monitor indicates the EGR port to check for possible blockage.
All GO to Pinpoint Test HD .
P030x - Cylinder x Misfire Detected
Description: NOTE: x represents cylinder numbers 1 through 9.
The misfire detection monitor is designed to monitor engine misfire and identify the specific
cylinder in which the misfire has occurred. Misfire is defined as lack of combustion in a
cylinder due to absence of spark, poor fuel metering, poor compression, or any other
cause.
Possible
Causes:
Ignition system
Fuel injectors
Running out of fuel
EVAP canister purge valve
Fuel pressure
Evaporative emission system
EGR system
Base engine
Diagnostic
Aids:
The malfunction indicator lamp (MIL) blinks once per second when a misfire severe enough
to cause catalyst damage is detected. If the MIL is on steady state due to a misfire, this
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indicates the threshold for emissions was exceeded and caused the vehicle to fail an
inspection and maintenance tailpipe test.
P0310 - Cylinder 10 Misfire Detected
Description: See the description for DTC P030x.
Possible Causes: See the possible causes for DTC P030x.
Diagnostic Aids: See the diagnostic aids for DTC P030x.
P0315 - Crankshaft Position System Variation Not Learned.
Description: The powertrain control module (PCM) is unable to learn and correct for mechanical
inaccuracies in crankshaft pulse wheel tooth spacing. This DTC disables the misfire
monitor.
Possible
Causes:
Damaged crankshaft pulse wheel teeth
Damaged crankshaft position (CKP) sensor
Diagnostic
Aids:
Requires visual inspection of the CKP sensor and the crankshaft pulse wheel teeth for
damage.
P0316 - Misfire Detected On Startup (First 1000 Revolutions)
Description: DTC P0316 is set in addition to any type B misfire DTC which occurs in the first 1,000
revolution test interval following engine start.
Possible
Causes:
Damaged crankshaft position (CKP) sensor
Ignition system
Fuel injectors
Running out of fuel
Fuel quality
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Base engine
Diagnostic
Aids:
Freeze frame data and the DTC P03xx are also stored, indicating which cylinder the
misfire occurred.
P0320 - Ignition/Distributor Engine Speed Input Circuit
Description: The ignition engine speed sensor input signal to powertrain control module (PCM) is
continuously monitored. The test fails when the signal indicates that 2 successive erratic
profile ignition pickup (PIP) pulses occurred.
Possible
Causes:
Loose wires/connectors
Arcing secondary ignition components (coil, wires and plugs)
On-board transmitter (2-way radio)
Diagnostic
Aids:
The DTC indicates that 2 successive erratic PIP pulses occurred.
All GO to Pinpoint Test NC .
P0325 - Knock Sensor 1 Circuit (Bank 1)
Description: The KS detects vibrations upon increase and decrease in engine RPM. The knock sensor
generates a voltage based on this vibration. A DTC is set if the voltage goes outside a
calibrated level.
Possible
Causes:
KS circuit short to GND
KS sensor circuit short to voltage
KS circuit open
Damaged KS
Diagnostic
Aids:
A knock sensor voltage greater than 0.5 volt with the key ON engine OFF indicates a
concern is present.
All GO to Pinpoint Test DG . GO to Pinpoint Test DG .
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P0326 - Knock Sensor 1 Circuit Range/Performance (Bank 1)
P0330 - Knock Sensor 2 Circuit (Bank 2)
P0331 - Knock Sensor 2 Circuit Range/Performance (Bank 2)
P0340 - Camshaft Position Sensor A Circuit (Bank 1 or single sensor)
Description: The test fails when the powertrain control module (PCM) can no longer detect the signal
from the camshaft position (CMP) sensor on bank 1.
Possible
Causes:
CMP circuit open
CMP circuit short to GND
CMP circuit short to voltage
SIG RTN open (VR sensor)
CMP GND open (Hall-effect sensor)
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CMP circuit short to CMP2 circuit (if equipped)
CMP incorrectly installed (Hall-effect sensor)
Damaged CMP sensor shielding
Damaged CMP sensor
Damaged PCM
Diagnostic
Aids:
Harness routing, harness alterations, improper shielding, or electrical interference from
other improperly functioning systems may have an intermittent impact on the CMP signal.
All GO to Pinpoint Test DR .
P0344 - Camshaft Position Sensor A Circuit Intermittent (Bank 1 or single sensor)
Description: The test fails when the powertrain control module (PCM) detects an intermittent signal
from the camshaft position (CMP) sensor.
Possible
Causes:
Intermittent open circuit
Intermittent short circuit
Damaged sensor shielding
Damaged sensor
Diagnostic
Aids:
Harness routing, harness alterations, improper shielding, or electrical interference from
other improperly functioning systems may have an intermittent impact on the CMP signal.
P0345 - Camshaft Position Sensor A Circuit (Bank 2)
Description: The test fails when the powertrain control module (PCM) can no longer detect the signal
from the camshaft position (CMP) sensor on bank 2.
Possible
Causes:
See the possible causes for DTC P0340.
Diagnostic
Aids:
See the diagnostic aids for DTC P0340.
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P0349 - Camshaft Position Sensor A Circuit Intermittent (Bank 2)
P0350 - Ignition Coil Primary/Secondary Circuit
Description: Each ignition primary circuit is continuously monitored. The test fails when the powertrain
control module (PCM) does not receive a valid ignition diagnostic monitor (IDM) pulse
signal from the ignition module (integrated in the PCM).
Possible
Causes:
Open or short in the ignition START/RUN circuit
Open coil driver circuit
Coil driver circuit short to ground
Damaged coil
Coil driver circuit short to VPWR
Diagnostic
Aids:
Use the 12-volt non-powered test lamp to verify START/RUN voltage at the ignition coil
harness connector.
Check the coil driver circuit for open, short to VPWR, or short to ground.
All GO to Pinpoint Test JE .
P0351 - Ignition Coil A Primary/Secondary Circuit
Application Key On Engine
Off
Key On Engine
Running
Continuous Memory
Coil-on-plug (COP) ignition
testing
GO to Pinpoint Test JF . GO to Pinpoint Test
JF .
Coil pack ignition testing GO to Pinpoint Test JE . GO to Pinpoint Test
JE .
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P0352 - Ignition Coil B Primary/Secondary Circuit
Off
Key On Engine
Running
Continuous Memory
testing
JF .
JE .
P0353 - Ignition Coil C Primary/Secondary Circuit
Off
Key On Engine
Running
Continuous Memory
testing
JF .
JE .
P0354 - Ignition Coil D Primary/Secondary Circuit
Off
Key On Engine
Running
Continuous Memory
testing
JF .
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JE .
P0355 - Ignition Coil E Primary/Secondary Circuit
All GO to Pinpoint Test JF . GO to Pinpoint Test JF .
P0356 - Ignition Coil F Primary/Secondary Circuit
P0357 - Ignition Coil G Primary/Secondary Circuit
P0358 - Ignition Coil H Primary/Secondary Circuit
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P0359 - Ignition Coil I Primary/Secondary Circuit
P0360 - Ignition Coil J Primary/Secondary Circuit
P0400 - Exhaust Gas Recirculation (EGR) Flow
Description: The electric EGR (EEGR) system is monitored once per drive cycle at high and low load
conditions. The test fails when a concern is detected by powertrain control module (PCM)
calculations indicating the EGR flow is less or greater than expected.
Possible
Causes:
EEGR valve stuck open or closed
Connector to EEGR not seated
EEGR motor winding circuits short or open
No voltage to the EEGR
Harness open or short to voltage or ground
Vacuum signal to manifold absolute pressure (MAP) restricted or leaking
Mass air flow (MAF) sensor signal erroneous
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Carbon build up in the EEGR valve seat area
One or more sensors is not responding or is out of range
Diagnostic
Aids:
All of the following sensors input data to the PCM for correct operation of the EEGR
system: engine coolant temperature (ECT), crankshaft position (CKP), intake air
temperature (IAT), MAF, throttle position (TP), MAP. Any DTC relating to these sensors
must be resolved prior to addressing DTC P0400.
All GO to Pinpoint Test KD .
P0401 - Exhaust Gas Recirculation (EGR) Flow Insufficient Detected
Description: The EGR system is monitored during steady state driving conditions while the EGR
is commanded on. The test fails when the signal from the differential pressure
feedback EGR (DPFE) sensor indicates that EGR flow is less than the desired
minimum.
Possible Causes: Vacuum supply
EGR valve stuck closed
EGR valve leaks vacuum
EGR flow path restricted
EVR circuit short to voltage
VREF open to DPFE sensor
DPFE sensor downstream hose is off or plugged
EVR circuit open
VPWR open to EGR vacuum regulator solenoid
DPFE sensor hoses are both off
DPFE sensor hoses are reversed
Damaged EGR orifice tube
Damaged EGR vacuum regulator solenoid
Diagnostic Aids: Carry out the key on engine running (KOER) self-test and look for DTC P1408 as an
indication of a hard fault. If DTC P1408 is not present, look for contamination,
restrictions, leaks, and intermittent concerns.
Vehicles with an
EGR system
module (ESM)
GO to Pinpoint Test HH .
All others GO to Pinpoint Test HE .
P0402 - Exhaust Gas Recirculation (EGR) Flow Excessive Detected
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Description: The EGR system is monitored for undesired EGR flow during idle. The EGR monitor
looks at the differential pressure feedback EGR (DPFE) signal at idle and compares it
to the stored signal measured during key on engine off (KOEO). The test fails when
the signal at idle is greater than at KOEO by a calibrated amount.
Possible Causes: EGR valve stuck open
Plugged EGR vacuum regulator solenoid vent
Plugged EGR tube
Slow responding DPFE sensor
Damaged DPFE sensor
Incorrect vacuum hose connection
Plugged vacuum hoses
EVR circuit short to ground
Diagnostic Aids: A DPFEGR PID reading that is greater at idle than during KOEO by 0.5 volt or a rough
engine idle may indicate a hard fault.
Vehicles with an
EGR system
module (ESM)
GO to Pinpoint Test HH . GO to Pinpoint Test HH .
All others GO to Pinpoint Test HE . GO to Pinpoint Test HE .
P0403 - Exhaust Gas Recirculation (EGR) Control Circuit
For Vehicles With an Electric EGR (EEGR)
Description: The EEGR system is continuously monitored to check the 4 EEGR motor coils,
circuits, and the powertrain control module (PCM) for opens, shorts to voltage and
ground. If a concern is detected, the EEGR system is disabled and additional
monitoring is suspended for the remainder of the drive until the next drive cycle.
Possible Causes: EEGR motor windings open
Connector to EEGR not seated
Open circuit in the harness from the PCM to the EEGR
Short circuit in the EEGR motor
Short circuit in the harness from the PCM to the EEGR
PCM
Diagnostic Aids:
For All Others
Description: This test checks the electrical function of the EGR vacuum regulator solenoid. The test
fails when the EVR circuit voltage is either too high or too low when compared to the
expected voltage range. The EGR system must be enabled for the test to be
completed.
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Possible Causes: EVR circuit open
EVR circuit short to voltage or ground
EGR vacuum regulator solenoid
PCM
Diagnostic Aids: The EGR vacuum regulator solenoid resistance is between 26 and 40 ohms.
Vehicles with an
EGR system
module (ESM)
Vehicles With an
Electric EGR
(EEGR)
GO to Pinpoint Test KD .
P0405 - Exhaust Gas Recirculation (EGR) Sensor A Circuit Low
Description: The EGR monitor checks the differential pressure feedback EGR (DPFE) sensor
signal to the powertrain control module (PCM) for low voltage. The test fails when the
average voltage to the PCM drops to a voltage less than the minimum calibrated
value.
Possible Causes: DPFE circuit short to ground
Damaged DPFE sensor
VREF short to ground
Diagnostic Aids: A DPFEGR PID reading less than 0.05 volt with the key ON, engine OFF or running
indicates a hard fault.
Vehicles with an
EGR system
module (ESM)
P0406 - Exhaust Gas Recirculation (EGR) Sensor A Circuit High
Description: The EGR monitor checks the EGR sensor signal to the powertrain control module
(PCM) for high voltage. The test fails when the average voltage to the PCM
exceeds the maximum calibrated value.
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Possible Causes: Differential pressure feedback EGR (DPFE) circuit open
VREF short to voltage
Damaged DPFE sensor
DPFE circuit short to voltage
SIG RTN circuit open
Diagnostic Aids: A DPFEGR PID reading greater than 4.5 volts with the key ON, engine OFF or
running indicates a hard fault.
Vehicles with an EGR
system module (ESM)
P0410 - Secondary Air Injection (AIR) System
Description: The AIR system detected a lack of air flow with the secondary AIR pump ON.
Possible Causes: AIR inlet hose leak.
AIR inlet hose disconnected.
Diagnostic Aids: Measured air flow is less than expected. Visually inspect the secondary AIR inlet hose.
All GO to Pinpoint Test HM .
P0412 - Secondary Air Injection (AIR) System - Switching Valve A Circuit
Description: On the primary side of the AIR relay, open and short faults on the AIR command circuit are
detected during normal operation by the powertrain control module (PCM) output driver.
Possible
Causes:
Short to voltage or ground in the AIR command circuit
Open in the AIR command circuit
AIR bypass solenoid fault
AIR relay fault
Diagnostic
Aids:
For intermittent faults use the AIR PCM output driver fault PID (AIRF) during a harness
wiggle test with the AIR PCM output driver in OFF and ON states. The AIR PCM output
driver fault PID AIRF instantly detects open circuits and shorts to ground with the PCM
output driver off. The AIR PCM output driver fault PID AIRF instantly detects open circuits
and shorts to ground with the PCM output driver off. The AIR PCM output driver fault PID
AIRF instantly detects a short to voltage or low resistance load with the PCM output driver
on. Use the output test mode to toggle the PCM output driver from OFF to ON.
Refer to Section 2, Output Test Mode (OTM) .
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P0420 - Catalyst System Efficiency Below Threshold (Bank 1)
Description: Indicates the bank 1 catalyst system efficiency is below the acceptable threshold.
Possible
Causes:
Use of leaded fuel
Damaged heated oxygen sensor (HO2S)
Out of range engine coolant temperature (ECT) sensor
High fuel pressure
Damaged exhaust manifold
Damaged catalytic converter
Oil contamination
Cylinder misfiring
Downstream HO2S wires improperly connected
Damaged exhaust system pipe
Damaged muffler/tailpipe assembly
Retarded spark timing
Leaking fuel injector
Diagnostic
Aids:
Compare HO2S upstream HO2S11 and downstream HO2S12 switch rate and amplitude.
Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage
which makes the switching frequency of the downstream HO2S very slow and reduces the
amplitude of those switches as compared to the upstream HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines and the downstream HO2S signal begins to
switch more rapidly with increased amplitude, approaching the switching rate and amplitude
of the upstream HO2S. Once beyond an acceptable limit the DTC is set.
All GO to Pinpoint Test HF .
P0430 - Catalyst System Efficiency Below Threshold (Bank 2)
Description: Indicates the bank 2 catalyst system efficiency is below the acceptable threshold.
All GO to Pinpoint Test HF .
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P0442 - Evaporative Emission System Leak Detected (Small Leak)
Description: The powertrain control module (PCM) monitors the complete evaporative emission (EVAP)
control system for the presence of a small fuel vapor leak. System failure occurs when a
fuel vapor leak from an opening as small as 1.016 mm (0.040 in) is detected by the EVAP
running loss monitor test.
Possible
Causes:
Aftermarket EVAP hardware that does not conform to the required specifications
Small holes or cuts in the fuel vapor hoses/tubes
Canister vent solenoid stays partially open on closed command
Damaged, missing or loosely installed fuel filler cap
Loose fuel vapor hose/tube connections to the EVAP system components
EVAP system component seals leaking at or near the EVAP canister purge valve,
fuel tank pressure sensor, canister vent (CV) solenoid, fuel vapor control valve tube
assembly or fuel vapor vent valve assembly
Diagnostic
Aids:
Check for a missing fuel filler cap or the integrity of the cap.
Check for loose or damaged vapor hoses. Visually inspect the EVAP canister inlet port, CV
solenoid filter, and canister vent hose assembly for contamination or debris.
All GO to Pinpoint Test HX .
P0443 - Evaporative Emission System Purge Control Valve Circuit
Description: The powertrain control module (PCM) monitors the state of the evaporative emission
(EVAP) canister purge valve circuit output driver. The test fails when the signal moves
outside the minimum or maximum limit for the commanded state.
Possible
Causes:
VPWR circuit open
EVAP canister purge valve circuit short to GND
Damaged EVAP canister purge valve
EVAP canister purge valve circuit open
EVAP canister purge valve circuit short to VPWR
Damaged PCM
Diagnostic
Aids:
To verify normal function, monitor the EVAP canister purge valve signal PID EVAPPDC (or
EVMV for electronic valve) and the signal voltage (PCM control side). With the valve closed,
the EVAPPDC indicates a 0% duty cycle (0 mA for EVMV) and voltage approximately equal
to battery voltage. When the valve is commanded fully open, EVAPPDC indicates 100%
duty cycle (1000 mA for EVMV) and a voltage drop of 3 volts minimum is normal. Output
test mode may be used to switch output on/off to verify function.
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P0446 - Evaporative Emission System Vent Control Circuit
Description: Monitors the canister vent (CV) solenoid circuit for an electrical failure. The test fails when
the signal moves outside the minimum or maximum allowable calibrated parameters for a
specified canister vent duty cycle by powertrain control module (PCM) command.
Possible
Causes:
VPWR circuit open
KAPWR circuit open (vehicles equipped with engine off natural vacuum (EONV)
EVAP leak check monitor)
CV solenoid circuit short to PWR GND or CHASSIS GND
Damaged CV solenoid
CV solenoid circuit open
CV solenoid circuit short to VPWR
CV solenoid circuit short to KAPWR (vehicles equipped with engine off natural
vacuum (EONV) EVAP leak check monitor)
Damaged PCM
Diagnostic
Aids:
To verify normal functioning, monitor the EVAP canister vent solenoid signal PID EVAPCV
and the signal voltage (PCM control side). With the valve open, EVAPCV indicates 0% duty
cycle and a voltage approximately equal to battery voltage. When the valve is commanded
fully closed, EVAPCV indicates 100% duty cycle, and a minimum voltage drop of 4 volts is
normal. Output test mode may be used to switch output on/off to verify function.
P0451 - Evaporative Emission System Pressure Sensor/Switch Range/Performance
Description: Note: For some vehicle applications, DTC P0451 is set for a fuel tank pressure (FTP)
sensor range (offset) concern. The DTC P0454 replaces the original P0451 for intermittent
(noisy) sensor concerns. Until the phase in process is complete, noisy or offset FTP sensor
concerns may set DTC P0451.
The fuel tank pressure changes greater than 14 inches of water in 0.10 seconds.
FTP sensor output is offset by + /- 1.7 inches of water.
Possible
Causes:
Intermittent open or short in the FTP sensor or the FTP sensor signal
Contaminated or damaged sensor
Diagnostic
Aids:
Monitor the FTP PID and note if it changes from above 15 inches of water to below minus
(-) 15 inches of water often in 1 minute.
With the FTP sensor at atmospheric pressure, the FTP PID normally indicates 0 inches of
water. Look for a minimum reading of +/- 1.7 inches of water as an indication of an offset
condition.
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P0452 - Evaporative Emission System Pressure Sensor/Switch Low
Description: The powertrain control module (PCM) monitors the evaporative emission (EVAP) control
system fuel tank pressure (FTP) sensor input signal to the PCM. The test fails when the
signal average drops below a minimum allowable calibrated parameter.
Possible
Causes:
Contamination internal to the FTP sensor connector
FTP circuit short to GND or SIG RTN
Damaged FTP sensor
Diagnostic
Aids:
An FTP voltage PID reading less than 0.22 volt in key ON, engine OFF or key ON, engine
P0453 - Evaporative Emission System Pressure Sensor/Switch High
Description: The powertrain control module (PCM) monitors the evaporative emission (EVAP) control
system fuel tank pressure (FTP) sensor input signal to the PCM. The test fails when the
signal average jumps above a minimum allowable calibrated parameter.
Possible
Causes:
FTP circuit open
VREF short to VPWR
FTP circuit short to VREF or VPWR
Damaged FTP sensor
Diagnostic
Aids:
An FTP voltage PID reading greater than 4.50 volts in key ON, engine OFF or key ON,
engine running indicates a concern is present.
P0454 - Evaporative Emission System Pressure Sensor/Switch Intermittent
Description: The fuel tank pressure changes greater than 14 inches of water in 0.10 seconds.
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Possible
Causes:
Intermittent open or short in the fuel tank pressure (FTP) sensor or the FTP sensor
signal
Contaminated or damaged sensor
Diagnostic
Aids:
Monitor the FTP PID and note if it changes from above 15 inches of water to below minus
(-) 15 inches of water often in 1 minute.
All GO to Pinpoint Test Z .
P0455 - Evaporative Emission System Leak Detected (Gross Leak/No Flow)
control system for no purge flow, the presence of a large fuel vapor leak, or multiple small
fuel vapor leaks. System failure occurs when no purge flow, which is attributed to fuel vapor
blockages or restrictions, a large fuel vapor leak, or multiple fuel vapor leaks are detected
by the EVAP running loss monitor test with the engine running, but not at idle.
Possible
Causes:
Aftermarket EVAP hardware that does not conform to the required specifications
Disconnected or cracked fuel EVAP canister tube, EVAP canister purge outlet tube,
or EVAP return tube
EVAP canister purge valve stuck closed
Damaged EVAP canister
Damaged or missing fuel filler cap
Insufficient fuel filler cap installation
Blockages or restrictions in the fuel vapor hoses/tubes
Fuel vapor control valve tube assembly or fuel vapor vent valve assembly blocked
Canister vent (CV) solenoid stuck open
Mechanically inoperative fuel tank pressure (FTP) sensor
Diagnostic
Aids:
Check for audible vacuum noise or significant fuel odor in the engine compartment or near
the EVAP canister and fuel tank.
P0456 - Evaporative Emission System Leak Detected (Very Small Leak)
control system for the presence of a very small fuel vapor leak. The system failure occurs
when a fuel vapor leak from an opening as small as 0.508 mm (0.020 inch) is detected by
the EVAP running loss monitor test.
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Possible
Causes:
Very small holes or cuts in the fuel vapor hoses/tubes
EVAP system component seals leaking. See the Possible Causes for DTC P0442
Diagnostic
Aids:
Check for a missing fuel filler cap or the integrity of the cap.
Check for loose or damaged vapor hoses. Visually inspect the EVAP canister inlet port, CV
solenoid filter, and canister vent hose assembly for contamination or debris.
P0457 - Evaporative Emission System Leak Detected (Fuel Cap Loose/Off)
Description: A fuel tank pressure change less than a minus (-) 7 inches of water in 30 seconds has
occurred after refueling; or there is excessive purge, fuel vapor, flow greater than 0.06
lb/min (0.45 gm/s).
Possible
Causes:
Fuel filler cap not installed on refueling (storing continuous memory DTC) and the
fuel cap indicator lamp (FCIL) may also be illuminated
Damaged, missing, or loosely installed fuel filler cap
Diagnostic
Aids:
Check for a missing fuel filler cap or the integrity of the cap. If OK, clear continuous
memory DTCs and reinitiate the EVAP emission running loss monitor drive cycle.
P0460 - Fuel Level Sensor A Circuit
Description: The powertrain control module (PCM) monitors the fuel level input (FLI) communications
network message for a concern. The test fails when the PCM determines that the value of
the FLI signal is stuck. The PCM calculates the amount of fuel used during operation. If the
FLI signal does not change or does not correspond with the calculated fuel usage, the DTC
is set.
Possible
Causes:
Empty fuel tank
Fuel pump (FP) module concern
Incorrectly installed fuel gauge
Damaged instrument cluster
FLI short to VPWR
Overfilled fuel tank
Damaged fuel gauge
FLI circuit open
FLI circuit short to CASE GND or PWR GND
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Stuck float arm
Diagnostic
Aids:
Monitor the FLI PIDs in key ON, engine running. A concern is present if the FLI percentage
PID is at 25% fill and the FLI voltage PID is less than 0.90 volt with a non-matching fuel
gauge or the FLI percentage PID is at 75% fill and the FLI voltage PID is greater than 2.45
volts with a non-matching fuel gauge.
All Refer to the Workshop Manual Section 413-01, Instrument Cluster for fuel level indicator
diagnosis.
P0461 - Fuel Level Sensor A Circuit Range/Performance
network message for a concern. The test fails when the FLI signal repeatedly moves in and
out of range, exceeding the minimum or maximum allowable calibrated parameters for a
specified fuel fill percentage in the fuel tank.
Possible
Causes:
Excessive electrical noise
Intermittent open circuit
Diagnostic
Aids:
Verify aftermarket equipment does not generate the radio frequency interference /
electromagnetic interference (RFI/EMI) which may cause noisy FLI input signal.
All Refer to the Workshop Manual Section 413-01, Instrument Cluster for fuel level indicator
diagnosis.
P0462 - Fuel Level Sensor A Circuit Low
network message for a concern. The test fails when the FLI signal is less than the
minimum allowable calibrated parameter for a specified fuel fill percentage in the fuel tank.
Possible
Causes:
Empty fuel tank
Damaged fuel gauge
FLI circuit open
FLI circuit short to ground
Diagnostic
Aids:
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All Refer to the Workshop Manual Section 413-01, Instrument Cluster for fuel level
indicator diagnosis.
P0463 - Fuel Level Sensor A Circuit High
network message for a concern. The test fails when the FLI signal is greater than the
maximum allowable calibrated parameter for a specified fuel fill percentage in the fuel tank.
Possible
Causes:
FLI short to VPWR
Overfilled fuel tank
Damaged fuel gauge
Diagnostic
Aids:
P0480 - Fan 1 Control Circuit
For Relay Controlled Electric Cooling Fan
Description: Monitors the low fan control (LFC) primary circuit output from the powertrain control (PCM).
The test fails when the PCM grounds the LFC circuit and excessive current draw is
detected on the LFC circuit; or with the LFC circuit not grounded by the PCM the voltage is
not detected on the LFC circuit (the PCM expects to detect VPWR voltage coming through
the low speed fan control relay coil to the LFC circuit).
Possible
Causes:
Open or short LFC circuit
Open VPWR circuit to the low speed FC relay
Damaged low speed FC relay
Diagnostic
Aids:
When the LFCF PID reads YES, a concern is currently present. During the key on engine
off (KOEO) self-test, the cooling fan is cycled on and off. A short to voltage can only be
detected when the PCM is grounding the LFC circuit. During the KOEO and key on engine
running (KOER) self-test, the LFC circuit is cycled on and off.
For Variable Speed Electric Cooling Fan
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Description: This test checks the fan control-variable (FCV) output circuit. The DTC sets if the
powertrain control module (PCM) detects the voltage on the FCV circuit is not within the
expected range.
Possible
Causes:
FCV circuit open or short
B+ or ground circuit concern to cooling fan
VPWR open to cooling fan (if applicable)
Damaged cooling fan module
Diagnostic
Aids:
During the key on engine off (KOEO) self-test, the cooling fan is cycled on and off.
For Cooling Fan Clutch
Description: This test checks the fan control-variable (FCV) output circuit for the cooling fan clutch. The
DTC sets if the powertrain control module (PCM) detects the voltage on the FCV circuit is
not within the expected range.
Possible
Causes:
FCV circuit open in the harness
FCV circuit short to voltage or ground in the harness
Damaged cooling fan clutch solenoid.
Diagnostic
Aids:
During the key on engine off (KOEO) self-test, the cooling fan is cycled on and off.
Crown
Victoria,
Five
Hundred,
Freestyle,
Fusion,
Grand
Marquis,
Milan,
Montego,
Town Car,
Zephyr
GO to Pinpoint Test KN .
Cooling Fan
Clutch
GO to Pinpoint Test HV .
All others GO to Pinpoint Test KF .
Description: Monitors the HFC primary circuit output from the powertrain control module (PCM). The test
fails, when the HFC output is commanded on (grounded) and excessive current draw is
detected on the HFC circuit; or when the HFC circuit is commanded off and voltage is not
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detected on the HFC circuit (the PCM expects to detect VPWR voltage through the high
speed FC relay coil to the HFC circuit).
Possible
Causes:
Open or short HFC circuit
Open VPWR circuit to the high speed FC relay
Damaged high speed FC relay
Diagnostic
Aids:
When the HFCF PID reads YES, a concern is currently present. An open circuit or short to
ground can only be detected when the PCM is not grounding the HFC circuit. A short to
voltage can only be detected when the PCM is grounding the HFC circuit. During the key
on engine off (KOEO) and key on engine running (KOER) self-test, the HFC circuit is cycled
on and off.
All GO to Pinpoint Test KF .
Description: Monitors the MFC primary circuit output from the powertrain control module (PCM). The test
fails, when the MFC output is commanded on (grounded) and excessive current draw is
detected on the MFC circuit; or when the MFC circuit is commanded off and voltage is not
detected on the MFC circuit (the PCM expects to detect IGN START/RUN voltage through
the medium speed FC relay coil to the MFC circuit).
Possible
Causes:
Open or short MFC circuit
Open IGN START/RUN circuit to the medium speed FC relay
Damaged medium speed FC relay
Diagnostic
Aids:
When the MFCF PID reads YES, a concern is currently present. An open circuit or short to
ground can only be detected when the PCM is not grounding the MFC circuit. A short to
voltage can only be detected when the PCM is grounding the MFC circuit. During the key
on engine off (KOEO) and key on engine running (KOER) self-test, the MFC circuit is cycled
on and off. Use output test mode to command the low speed/high speed fan on. The PCM
also activates the medium speed fan output.
P0483 - Fan Performance
Description: The fan control module, referred to as the cooling fan motor, indicates a cooling fan
motor stall or cooling fan motor overheat condition.
Possible
Causes:
Cooling fan motor mechanical concerns
Obstructions
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Diagnostic
Aids:
Check for a mechanical concern with the cooling fan motor or for obstructions limiting the
cooling fan motor operation.
All GO to Pinpoint Test KN .
P0491 - Secondary Air Injection (AIR) System Insufficient Flow (Bank 1)
Description: The secondary AIR system detected that there was insufficient mass air flow change
during pump switching (ON/OFF).
Possible
Causes:
Secondary AIR pump with no or low air flow
Secondary AIR bypass solenoid leaking/blocked or stuck open/closed
Secondary AIR diverter valve leaking/blocked or stuck open/closed
Secondary AIR air hose restricted
Secondary AIR vacuum hoes restricted or leaking
Diagnostic
Aids:
Measured air flow is less than expected. Visually inspect the secondary AIR inlet hose.
All GO to Pinpoint Test HM . GO to Pinpoint Test HM .
P0500 - Vehicle Speed Sensor (VSS) A
Description: Indicates the powertrain control module (PCM) detected an error in the vehicle speed
information. Vehicle speed data is received from either the VSS, the transfer case
speed sensor (TCSS) or the anti-lock brake system (ABS) control module. If the engine
RPM is above the torque converter stall speed (automatic transmission) and the engine
load is high, it can be inferred that the vehicle must be moving. If there is insufficient
vehicle speed data input, a concern is indicated and a DTC is set. On most vehicle
applications the malfunction indicator lamp (MIL) is illuminated when this DTC is set.
Possible
Causes:
Open in the VSS+/VSS- harness circuit
Open in the TCSS signal or the TCSS signal return harness circuit
Short to GND in the VSS harness circuit
Short to GND in the TCSS harness circuit
Short to PWR in the VSS harness circuit
Short to PWR in the TCSS harness circuit
Damaged drive mechanism for VSS or TCSS
Damaged VSS or TCSS
Damaged wheel speed sensors
Damaged wheel speed sensor harness circuits
Damage in the module(s) connected to the VSC/VSS circuit
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Open or short in the vehicle speed circuit VSS signal between the ABS VSS
signal output and the VSS signal inputs to the PCM and other modules (F-Super
Duty)
Diagnostic Aids: Monitor the VSS PID while driving the vehicle. This DTC is set when the PCM detects a
sudden loss of vehicle speed signal over a period of time. If vehicle speed data is lost,
check the source of the vehicle speed input: VSS, TCSS or ABS. Note: On some
manual shift-on-the-fly (MSOF) applications, VSS and TCSS PID can be monitored.
However if no TCSS PID is available and VSS PID is zero, TCSS circuitry frequency
must be checked for loss of sensor signal. If another vehicle electronic module has
generated the P0500 and the vehicle does not receive its vehicle speed input from the
VSS, TCSS or ABS, check the PCM for output shaft speed (OSS) sensor DTCs. On
OSS applications the PCM uses the OSS to calculate the vehicle speed. If no OSS
DTCs are found check for correct PCM configuration, tire size and axle ratio.
F-Super Duty GO to Pinpoint Test DF .
Vehicles with an
automatic
transmission and
output shaft
speed (OSS)
sensor DTCs
Refer to the Workshop Manual Section 307-01, Automatic Transmission.
All others GO to Pinpoint Test DP .
P0503 - Vehicle Speed Sensor (VSS) A Intermittent/Erratic/High
Description: Indicates poor or noisy VSS performance. Vehicle speed data is received
from either the VSS, the transfer case speed sensor (TCSS), or the anti-
lock brake system (ABS) control module.
Possible Causes: Noisy VSS/TCSS input signal from the radio frequency interference /
electromagnetic interference (RFI/EMI) external sources, such as
ignition components or the charging circuit
Damaged VSS or driven gears
Damaged TCSS
Damaged wiring harness or connectors
Malfunction in the module(s) or circuit connected to the VSS/TCSS
circuit
Aftermarket add-on
Diagnostic Aids: Monitor the VSS PID while driving the vehicle, and check for intermittent
vehicle speed indication. Verify the ignition and charging systems are
functioning correctly.
Application Key On Engine Off Key On Engine Continuous Memory
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Running
Five Hundred,
Freestyle,
Montego,
Navigator
The powertrain control module (PCM) uses information from the anti-lock
brake system (ABS) module and the transmission control module (TCM)
to calculate vehicle speed. Check these modules for DTCs.
Vehicles with an automatic
transmission and output shaft
speed (OSS) sensor DTCs
P0505 - Idle Air Control (IAC) System
Description: The powertrain control module (PCM) attempts to control engine speed during the
key on, engine running (KOER) self-test. The test fails when the desired RPM could
not be reached or controlled during the self-test.
Possible Causes: Failure mode effects management (FMEM) condition is present
Intake air restriction
Exhaust restriction
Sludged throttle body
Vacuum leaks
Damaged electronic throttle body (ETB)
Damaged PCM
Diagnostic Aids: This DTC is informational only and it may be accompanied by other DTCs. Diagnose
other DTCs first. If other DTCs are not present inspect the intake air system for air
restrictions, vacuum leaks, and damage. If no concerns are present, clear the DTC
and carry out the KOER self-test.
For All Others
Description: The powertrain control module (PCM) attempts to control engine speed during the
key on, engine running (KOER) self-test. The test fails when the desired RPM could
not be reached or controlled during the self-test.
Possible Causes: IAC circuit open
VPWR to IAC solenoid open
B+ or VPWR to IAC solenoid open
Air inlet is plugged
IAC circuit shorted to PWR
Damaged IAC valve
Diagnostic Aids:
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Vehicles With
Electronic Throttle
Control (ETC)
Refer to the Description, Possible Causes and Diagnostic Aids for the DTC.
All others GO to Pinpoint Test KE .
P0506 - Idle Air Control (IAC) System RPM Lower Than Expected
Description: This DTC is set when the powertrain control module (PCM) detects an engine idle
speed that is less than the desired RPM.
Possible Causes: Intake air restriction
Vacuum leaks
Exhaust restriction
Engine mechanical concern
Sludged throttle body
Damaged PCM
restrictions and damage. If no concerns are present, clear the DTC and carry out the
KOER self-test.
For All Others
speed that is less than the desired RPM.
Possible Causes: IAC circuit open
Damaged or incorrect IAC valve
IAC valve stuck closed
Diagnostic Aids: Disconnect the IAC valve and look for little or no change in engine RPM as an
indication of a stuck or damaged valve.
Vehicles With
Electronic Throttle
Control (ETC)
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P0507 - Idle Air Control (IAC) System RPM Higher Than Expected
speed that is greater than the desired RPM.
Possible Causes: Intake air leak after throttle body
Vacuum leaks
Damaged EVAP system
Damaged PCM
other DTCs first. If other DTCs are not present inspect the intake air system for air or
vacuum leaks and damage. If no concerns are present, clear the DTC and repeat the
self-test.
For All Others
speed that is greater than the desired RPM.
Possible Causes: IAC circuit shorted to ground
IAC valve stuck open
Intake air leak after throttle body
Vacuum leaks
Damaged EVAP system
Diagnostic Aids: Disconnect the IAC valve and look for little or no change in engine RPM as an
indication of a stuck or damaged valve.
Vehicles With
Electronic Throttle
Control (ETC)
P050A - Cold Start Idle Air Control Performance
Description: The cold start emission reduction monitor has detected an airflow performance deficiency.
The cold start emission reduction monitor validates the operation of the components of the
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system required to achieve the cold start emission reduction strategy, retarded spark timing
(P050B) and elevated idle airflow (P050A). When the idle airflow test portion of the cold
start emission reduction strategy is enabled, the idle air control system requests a higher
idle RPM to increase the engine airflow. The cold start emission reduction monitor
compares the actual airflow measured by the MAF sensor to the requested PCM airflow.
The DTC is set when the airflow is less than the calibrated limit.
Possible
Causes:
Damaged intake air system tubes
Restricted air filter
Restricted or blocked idle air control or intake passages
Air or vacuum leaks
Base engine problem
Diagnostic
Aids:
This DTC is an informational DTC and may be accompanied by other DTCs. Diagnose other
DTCs first. If other DTCs are not present inspect the intake air system for air restrictions and
damage. If no concerns are present, clear the DTCs and repeat the self-test.
The cold start emission reduction monitor runs during a cold start. Before repeating the self-
test, a 2 to 3 hour soak period is required for the cold start emission reduction monitor to run
at start up.
All Refer to the Description, Possible Causes and Diagnostic Aids for the DTC.
P050B - Cold Start Ignition Timing Performance
Description: The cold start ignition timing performance has a functional response test of actual
spark timing angle actual versus commanded spark timing in the powertrain control
module (PCM).
Possible Causes: Spark timing
Spark capture circuit
Spark timing monitor
Spark capture circuit monitor
Diagnostic Aids: Diagnose all other powertrain related DTCs first.
Vehicles with coil
pack ignition system
GO to Pinpoint Test JC .
All others GO to Pinpoint Test JB .
P050E - Cold Start Engine Exhaust Temperature Out of Range
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Description: The powertrain control module (PCM) calculates the actual catalyst warm up
temperature during a cold start. The PCM then compares the actual temperature to the
expected catalyst temperature model. The difference between the actual and expected
temperatures is a ratio. When this ratio exceeds the calibrated value this DTC is set
and the malfunction indicator lamp (MIL) illuminates.
Possible
Causes:
Exhaust restriction
Engine mechanical concern
Damaged or sludged electronic throttle body (ETB)
Vacuum leaks
Damaged PCM
restrictions, vacuum leaks, and damage. If no concerns are present, clear the DTC and
carry out the key ON, engine running (KOER) self-test.
For All Others
Description: The powertrain control module (PCM) attempts to control engine speed during the key
on, engine running (KOER) self-test. The test fails when the desired RPM could not be
reached or controlled during the self-test.
Possible
Causes:
IAC circuit open
Damaged IAC valve
Diagnostic Aids:
Vehicles With
Electronic Throttle
Control (ETC)
All others Refer to the Description, Possible Causes and Diagnostic Aids for the DTC.
P0511 - Idle Air Control (IAC) Circuit
Description: This DTC is set when the powertrain control module (PCM) detects an electrical load
failure on the IAC output circuit.
Possible
Causes:
IAC circuit open
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Damaged IAC valve
IAC circuit short to GND
Diagnostic
Aids:

All GO to Pinpoint Test KE .
P0528 - Fan Speed Sensor Circuit No Signal
Description: The powertrain control module (PCM) uses the fan speed sensor (FSS) input to monitor
the cooling fan clutch speed. If the indicated fan speed is lower than the calibrated value
during the key on engine running (KOER) self-test, the DTC is set.
Possible
Causes:
FSS VPWR circuit open in the harness
FSS PWRGND circuit open in the harness
FSS circuit open in the harness
FSS circuit short to voltage or ground in the harness
Damaged FSS sensor
Damaged PCM
Diagnostic
Aids:
Visually inspect the cooling fan clutch for damage or obstruction.
All GO to Pinpoint Test HV .
P0532 - A/C Refrigerant Pressure Sensor A Circuit Low
Description: The ACP sensor inputs a voltage to the powertrain control module (PCM). If the voltage
is below the calibrated level the DTC sets.
Possible
Causes:
ACP circuit short to GND or SIGRTN
VREF circuit open
Open ACP circuit
Damaged ACP sensor
Diagnostic
Aids:
Verify the VREF voltage is between 4 and 6 volts.
All GO to Pinpoint Test DS .
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P0533 - A/C Refrigerant Pressure Sensor A Circuit High
Description: The ACP sensor inputs a voltage to the powertrain control module (PCM). If the voltage
is above a calibrated level the DTC sets.
Possible
Causes:
ACP sensor circuit short to PWR
ACP circuit open
ACP circuit short to VREF
Damaged ACP sensor
Diagnostic
Aids:
Verify the VREF voltage is between 4 and 6 volts.
P0534 - A/C Refrigerant Charge Loss
Description: Indicates frequent A/C compressor clutch cycling.
Possible
Causes:
Mechanical A/C system concern (such as low refrigerant charge, damaged A/C
cycling switch)
Intermittent open between the cycling pressure switch and the powertrain control
module (PCM)
Intermittent open in the IGN RUN circuit to cycling pressure switch (if applicable)
Diagnostic
Aids:
This test is designed to protect the transmission. In some strategies, the PCM unlocks the
torque converter during A/C clutch engagement. If a concern is present that results in
frequent A/C clutch cycling, damage could occur if the torque converter is cycled at these
intervals. This test detects this condition, sets the DTC and prevents the torque converter
from excessive cycling.
All GO to Pinpoint Test KM .
P0537 - A/C Evaporator Temperature Sensor Circuit Low
Description: Indicates the ACET signal input was less than the self-test minimum. The self-test minimum
is 0.13 volts.
Possible
Causes:
ACET circuit short to ground or SIG RTN
Damaged ACET sensor
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Diagnostic
Aids:
The powertrain control module (PCM) sources a low current 5 volts on the ACET circuit
(this voltage can be measured with the sensor disconnected). As the A/C evaporator air
temperature changes, the ACET circuit resistance to SIG RTN (ground) changes (which
changes the voltage the PCM detects). When the ACET signal is detected below the self-
test minimum, check for shorts to the SIG RTN or ground, which would pull the voltage low.
All GO to Pinpoint Test DJ .
P0538 - A/C Evaporator Temperature Sensor Circuit High
Description: Indicates the ACET signal input was greater than the self-test maximum. The self-test
maximum is 4.5 volts.
Possible
Causes:
ACET circuit open
SIG RTN circuit open to the ACET sensor
ACET circuit short to voltage (VREF)
Damaged ACET sensor
Diagnostic
Aids:
The powertrain control module (PCM) sources a low current 5 volts on the ACET circuit
(this voltage can be measured with the sensor disconnected). As the A/C evaporator air
temperature changes, the ACET circuit resistance to SIG RTN (ground) changes (which
changes the voltage the PCM detects). When the ACET signal is detected above the self-
test maximum, check for open circuits (ACET or SIG RTN), which would cause the voltage
to remain high. Although not as probable, also check for a short to voltage (VREF).
P0552 - Power Steering Pressure (PSP) Sensor/Switch Circuit Low
Description: Indicates the PSP sensor input signal was less than the self-test minimum.
Possible Causes: PSP sensor damaged
VREF circuit open or shorted
PSP sensor signal circuit open or shorted
Diagnostic Aids: View the PSP PID to monitor the PSP input.
All GO to Pinpoint Test DT .
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P0553 - Power Steering Pressure (PSP) Sensor Circuit High Input
Description: Indicates the PSP sensor input signal was greater than the self-test maximum.
Possible Causes: PSP sensor damaged
VREF circuit shorted to voltage
PSP sensor signal circuit open
PSP sensor signal circuit shorted to voltage
Diagnostic Aids: View the PSP PID to monitor the PSP input.
All GO to Pinpoint Test DT .
P0579 - Cruise Control Multifunction Input A Circuit Range / Performance
Description:
Possible Causes:
Diagnostic Aids:
All Refer to the Workshop Manual Section 310-03, Speed Control.
P0581 - Cruise Control Multifunction Input A Circuit High
Description:
Possible Causes:
Diagnostic Aids:
P0600 - Serial Communication Link
Description: Indicates an error occurred in the powertrain control module (PCM). This DTC may be
set alone or in combination with P2105.
Possible Damaged PCM
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Causes:
Diagnostic
Aids:

All GO to Pinpoint Test QE .
P0602 - Powertrain Control Module (PCM) Programming Error
Description: This DTC indicates a programming error within the vehicle ID (VID) block.
Possible
Causes:
VID data corrupted by the scan tool during VID reprogramming
Diagnostic
Aids:
Using the scan tool, reprogram the VID block. If the PCM does not allow reprogramming
of the VID block, reflashing of the PCM is required.
All The VID block must programmed. Refer to Section 2, Flash Electrically Erasable
Programmable Read Only Memory (EEPROM) .
P0603 - Internal Control Module Keep Alive Memory (KAM) Error
Description: Indicates the powertrain control module (PCM) has experienced an internal memory
concern. However, there are external items that can cause this DTC.
Possible
Causes:
Reprogramming
Battery terminal corrosion
KAPWR to PCM interrupt/open
Loose battery connection
Diagnostic
Aids:
If KAPWR is interrupted to the PCM because of a battery or PCM disconnect, this DTC
can be generated on the first power-up.
All GO to Pinpoint Test QB . GO to Pinpoint Test QB .
P0604 - Internal Control Module Random Access Memory (RAM) Error
Description: Indicates the powertrain control module (PCM) RAM has been corrupted.
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Possible
Causes:
Module reprogramming
Aftermarket performance products.
Damaged PCM
Diagnostic
Aids:

All Reprogram or update the calibration. Check for other DTCs or drive symptoms for further
action. Make sure to check for aftermarket performance products before installing a new
PCM. If it is necessary to install a new PCM, refer to Section 2, Flash Electrically
Erasable Programmable Read Only Memory (EEPROM) .
P0605 - Internal Control Module Read Only Memory (ROM) Error
Description: The powertrain control module (PCM) ROM has been corrupted.
Possible
Causes:
An attempt was made to change the calibration
Module programming error
Damaged PCM
Diagnostic
Aids:

All Reprogram or update the calibration. Reprogram the vehicle identification VID block (use
as built data). Check for other DTCs or drive symptoms for further action. Make sure to
check for aftermarket performance products before installing a new powertrain control
module (PCM). If it is necessary to install a new PCM, refer to Section 2, Flash
Electrically Erasable Programmable Read Only Memory (EEPROM) .
P0606 - Control Module Processor
Description: This DTC indicates a register readback (powertrain control module [PCM] internal
communications) error.
Possible
Causes:
Damaged PCM
Diagnostic
Aids:
Internal PCM concern. Install a new PCM.
All Make sure to check for aftermarket performance products before installing a new PCM.
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Reprogram or update the calibration. Check for other DTCs and diagnose those first.
Make sure to check for aftermarket performance products before installing a new PCM.
Clear the DTCs, repeat the self-test. If the DTC is retrieved again, install a new PCM.
Refer to Section 2, Flash Electrically Erasable Programmable Read Only Memory
(EEPROM) .
P0607 - Control Module Performance
Description: Indicates that the powertrain control module (PCM) internal central processing unit (CPU)
has encountered an error. The PCM monitors itself and carries out internal checks of its
own CPU. If any of these checks returns an incorrect value, the DTC is set.
Possible
Causes:
Module programming error
Aftermarket performance products
Damaged PCM
Diagnostic
Aids:

All Reprogram or update the calibration. Check for other DTCs or drive symptoms for
further action. Make sure to check for aftermarket performance products before installing
a new PCM. If it is necessary to install a new PCM, refer to Section 2, Flash Electrically
Erasable Programmable Read Only Memory (EEPROM) .
P060A - Internal Control Module Monitoring Processor Performance
Description: Indicates an error occurred in the powertrain control module (PCM). This DTC is set in
combination with P2105.
Possible
Causes:
Software incompatibility issue
Damaged PCM
Diagnostic
Aids:
Verify the PCM is at the latest calibration level.
P060B - Internal Control Module A/D Processing Performance
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combination with P2104 or P2110.
Possible
Causes:
Damaged PCM
Diagnostic
Aids:
Inspect the harness for damage. Verify correct operation of the sensors using VREF and
related circuits.
P060C - Internal Control Module Main Processor Performance
Description: Indicates an error occurred in the powertrain control module (PCM).
Possible Causes: Software incompatibility issue
Damaged PCM
Diagnostic Aids: Verify the PCM is at the latest calibration level.
P0610 - Control Module Vehicle Options Error
Description: Indicates a powertrain control module (PCM) vehicle options error.
Possible Causes: Module reprogramming
Aftermarket performance products.
PCM
Diagnostic Aids:
All See Note 1
P061B - Internal Control Module Torque Calculation Performance
Description: Indicates a calculation error occurred in the powertrain control module (PCM).
Possible
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Causes:
Diagnostic
Aids:
Check for sensor and circuit related DTCs. Do not install a new electronic throttle body
(ETB) for this DTC.
P061C - Internal Control Module Engine RPM Performance
Description: Indicates a calculation error occurred in the powertrain control module (PCM).
Possible Causes: Crankshaft position (CKP) sensor circuit is open or short
CKP sensor circuit intermittent
Damaged CKP sensor
Camshaft position (CMP) sensor circuit is open or short
CMP sensor circuit intermittent
Damaged CMP sensor
Damaged PCM
Diagnostic Aids: Verify correct operation of the CKP and CMP sensors and related circuits.
P061D - Internal Control Module Engine Air Mass Performance
Possible Causes: Software incompatibility issue
Damaged PCM
Diagnostic Aids: Verify the PCM is at the latest calibration level.
P061F - Internal Control Module Throttle Actuator Controller Performance
Possible
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Causes:
Diagnostic Aids: Verify correct operation of the electronic throttle control (ETC) components and related
circuits.
P0620 - Generator Control Circuit
Description: The powertrain control module (PCM) reads the GENLI and sends a DTC through the
network when the GENLI indicates a concern.
Possible
Causes:
I-line control (ILC) circuit short to ground
ILC circuit short to voltage
ILC circuit open
GENLI circuit short to voltage or ground
GENLI circuit open
B+ circuit open
Generator drive mechanism
Damaged generator/regulator assembly
Damaged PCM
Diagnostic
Aids:
Verify the battery voltage is 14.5 volts. Verify the generator/regulator has the correct part
number.
All GO to Pinpoint Test HY .
P0622 - Generator Field Terminal Circuit
Description: The powertrain control module (PCM) monitors the generator load from the
generator/regulator in the form of frequency. The frequency range is determined by the
temperature of the voltage regulator, where 97% indicates a full load, and less than 6%
indicates no load.
Possible
Causes:
GENLI circuit short to voltage or ground
GENLI circuit open
GENRC circuit short to voltage or ground
GENRC circuit open
ILC circuit short to voltage or ground
ILC circuit open
Battery-sense circuit open
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Damaged PCM
Diagnostic
Aids:
number.
P0625 - Generator Field Terminal Circuit Low
Description: The powertrain control module (PCM) monitors generator load from the generator/regulator
in the form of frequency. The concern indicates the input is lower than the load should be
in normal operation. The load input could be low when no generator output exists.
Possible
Causes:
GENRC circuit short to ground
GENLI circuit short to ground
Open B+ wire during operation
Low system voltage
Broken generator belt
Diagnostic
Aids:
number.
P0626 - Generator Field Terminal Circuit High
in the form of frequency. The concern indicates the input is higher than the load should be
in normal operation. The load input could be high when a battery short to ground exists.
Possible
Causes:
GENLI circuit short to voltage
GENRC circuit short to voltage
B+ open prior to start-up
Open GENRC prior to start-up
Open ILC prior to start-up
Diagnostic
Aids:
number.
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P062C - Internal Control Module Vehicle Speed Performance
Possible
Causes:
Module communications network concerns
Output shaft speed (OSS) sensor concern
Turbine shaft speed (TSS) sensor concern
Anti-lock brake system (ABS) concern
Diagnostic Aids: Repair any ABS DTCs, ABS-related DTCs in other modules, or vehicle communication
concerns.
P0642 - Sensor Reference Voltage A Circuit Low
Description: Indicates the reference voltage (VREF) circuit is lower than VREF minimum.
Possible Causes: VREF short to ground
Damaged sensor
Diagnostic Aids: This DTC is set due to an under voltage condition on the VREF circuit.
All GO to Pinpoint Test C .
P0643 - Sensor Reference Voltage A Circuit High
Description: Indicates the reference voltage (VREF) circuit is higher than VREF maximum.
Possible Causes: VREF short to voltage
Damaged sensor
Diagnostic Aids: This DTC is set due to an over voltage condition on the VREF circuit.
All GO to Pinpoint Test C .
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P0645 - Air Conditioning Clutch Relay (A/CCR) Control Circuit
Description: Monitors the A/CCR circuit output from the powertrain control module (PCM). The test fails
when the PCM grounds the A/CCR circuit, excessive current draw is detected on the
A/CCR circuit; or, with the A/CCR circuit not grounded by the PCM, voltage is not detected
on the A/CCR circuit (the PCM expects to detect VPWR voltage coming through the A/CCR
relay coil to the A/CCR circuit).
Possible
Causes:
Open or short A/CCR circuit
Damaged A/CCR relay
Open VPWR circuit to the A/CCR relay
Diagnostic
Aids:
The A/CCR control circuit can be monitored using the WACF and WAC PID.
When the WACF PID reads YES, a concern is present.
An open circuit or short to ground can only be detected when the PCM is not grounding the
circuit.
A short to voltage can only be detected when the PCM is grounding the circuit.
During the key on engine off (KOEO) and key on engine running (KOER) self-test, the WAC
circuit is cycled on and off. Verify the A/C and the defrost were OFF during the KOEO and
KOER self-tests. Check ACCS the PID to verify. If the vehicle is not equipped with A/C,
ignore DTC P0645.
P0657 - Actuator Supply Voltage A Circuit/Open
Description: Voltage to all transmission solenoids has been interrupted.
Possible Causes:
Diagnostic Aids: Refer to the Workshop Manual Section 307-01, Automatic Transmission.
P0660 - Intake Manifold Tuning Valve (IMTV) Control Circuit Open - Bank 1
Description: The IMTV system is monitored for failure during continuous, key on engine off (KOEO), or
key on engine running (KOER) self-tests. The test fails when the signal is more or less
than an expected calibrated range.
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Possible
Causes:
IMTV signal circuit open, shorted to PWR GND or SIG RTN
Damaged IMTV actuator
Diagnostic
Aids:
An IMTVM PID reading may indicate a fault.
All GO to Pinpoint Test HU .
P0663 - Intake Manifold Tuning Valve (IMTV) Control Circuit Open - Bank 2
Possible
Causes:
IMTV signal circuit open, shorted to PWR GND or SIG RTN
Damaged IMTV actuator
Diagnostic
Aids:
P0685 - Electronic Control Module (ECM)/Powertrain Control Module (PCM) Power Relay Control
Circuit/Open
Description: This DTC sets when the ignition switch position run (ISP-R) circuit indicates the key is in
the OFF, ACC, or LOCK position, and the amount of time the PCM remains powered
through the PCM power relay exceeds a predetermined amount of time.
Possible
Causes:
PCM relay control (PCMRC) circuit short to ground in the harness
Damaged PCM power relay
Diagnostic
Aids:
Ability to communicate with the PCM when the key is in the OFF, ACC, or LOCK position
indicates a hard fault.
All GO to Pinpoint Test B .
P0689 - Electronic Control Module (ECM)/Powertrain Control Module (PCM) Power Relay Sense
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Circuit Low
Description: This DTC sets when the passive anti theft system (PATS) system indicates the key is in
ON or START position and the ignition switch position run (ISP-R) circuit indicates OFF,
ACC, or LOCK position.
Possible
Causes:
Ignition circuit fuse
ISP-R circuit open in the harness
ISP-R circuit short to ground in the harness
Damaged ignition switch
Damaged PATS system
Diagnostic
Aids:
Diagnose and repair all PATS DTCs first.
P0690 - Electronic Control Module (ECM)/Powertrain Control Module (PCM) Power Relay Sense
Circuit High
Description: This DTC sets when the passive anti theft system (PATS) system indicates the key is in
the OFF, ACC, or LOCK position and the ignition switch position run (ISP-R) circuit
indicates ON or START position.
Possible
Causes:
ISP-R circuit short to voltage in the harness
Damaged PATS system
Damaged ignition switch
Diagnostic
Aids:
Diagnose and repair all PATS DTCs first.
P0703 - Brake Switch B Input Circuit
Description: Indicates the powertrain control module (PCM) did not receive a brake pedal position
(BPP) input.
Possible Causes: Open or short in the BPP circuit
Open or short in the stoplamp circuits
Damage in module(s) connected to the BPP circuit.
Damaged brake switch
Misadjusted brake switch
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Diagnostic Aids: Check for proper function of the stoplamps. Using a scan tool, check the BPP PID.
The stoplamps and PID should toggle on and off with brake pedal activation.
Freestar/Monterey,

Town Car
Verify the brake pedal was applied and released during the key on engine running
(KOER) self-test. For additional concerns, refer to the Workshop Manual Section
417-01, Exterior Lighting.
Expedition,
Navigator
Verify the brake pedal was applied and released during the key on engine running
(KOER) self-test. For additional concerns, refer to the Workshop Manual Section
206-09, Anti-Lock Control.
All others GO to Pinpoint Test FD .
P0704 - Clutch Switch Input Circuit
Description: When the clutch pedal is applied the voltage goes to low. If the powertrain control module
(PCM) does not see this change from high to low the DTC is set.
Possible
Causes:
Clutch pedal position (CPP) circuit short to voltage
Damaged CPP switch
CPP circuit open in the SIGRTN
Diagnostic
Aids:
When the clutch pedal is applied and then released, the CPP switch voltage should cycle.
All GO to Pinpoint Test TA . GO to Pinpoint Test TA .
P0705 - Transmission Range Sensor A Circuit (PRNDL) Input
Description:
Possible Causes:
Diagnostic Aids:
P0707 - Transmission Range Sensor A Circuit Low
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Description:
Possible Causes:
Diagnostic Aids:
P0708 - Transmission Range Sensor A Circuit High
Description:
Possible Causes:
Diagnostic Aids:
P071x - Transmission Code
Description:
Possible Causes:
Diagnostic Aids:
P0720 - Output Shaft Speed (OSS) Sensor Circuit
Description: The OSS sensor inputs a signal to the powertrain control module (PCM) based on the
speed of the output shaft of the transmission.
Possible
Causes:
OSS sensor circuit short to GND
OSS sensor circuit short to PWR
OSS sensor circuit open
Damaged OSS sensor
Diagnostic
Aids:
Verify the sensor signal output varies with the vehicle speed.
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Manual
transmission
GO to Pinpoint Test DP .
All others Refer to the Workshop Manual Section 307-01, Automatic Transmission.
P0721 - Output Shaft Speed (OSS) Sensor Circuit Range/Performance
Description: The OSS sensor signal is very sensitive to noise. This noise distorts the input to the
Possible
Causes:
Wiring misrouted
Aftermarket add-on
Wiring damaged
Wiring insulation wear
Diagnostic Aids: Check the routing of the harness.
Check the wiring and the connector for damage.
Manual
transmission
P0722 - Output Shaft Speed (OSS) Sensor Circuit No Signal
Description: The OSS sensor failed to provide a signal to the PCM upon initial movement of
vehicle.
Possible Causes: Damaged OSS connector
Damaged OSS sensor, or not installed properly
Harness intermittently shorted or open
Diagnostic Aids: Check the wiring, connector, and sensor for damage.
Manual
transmission
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P0723 - Output Shaft Speed (OSS) Sensor Circuit Intermittent
Description: The OSS sensor signal to the PCM is irregular or interrupted.
Possible Causes: Harness connector not properly seated
Harness connector damaged
OSS sensor damaged, or not installed properly
Diagnostic Aids: Verify harness and connector integrity.
Verify proper installation of the OSS sensor.
Manual transmission GO to Pinpoint Test DP .
Description:
Possible Causes:
Diagnostic Aids:
Description:
Possible Causes:
Diagnostic Aids:
Description:
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Possible Causes:
Diagnostic Aids:
Description:
Possible Causes:
Diagnostic Aids:
Description:
Possible Causes:
Diagnostic Aids:
Description:
Possible Causes:
Diagnostic Aids:
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Description:
Possible Causes:
Diagnostic Aids:
P0815 - Upshift Switch Circuit
Description:
Possible Causes:
Diagnostic Aids:
P0830 - Clutch Pedal Switch A Circuit
Description: The powertrain control module (PCM) monitors the clutch pedal position bottom of travel
(CPP-BT) switch only during the calibrated engine speed range (cranking speed range).
This DTC is set when the CPP-BT switch does not indicate that the clutch is disengaged
(clutch pedal pressed) when the engine is cranked.
Possible
Causes:
Damaged CPP-BT switch
Damaged CPP-BT harness
Open PWRGND circuit to the CPP-BT switch
Vehicle push-started with the clutch engaged (clutch pedal released)
Aftermarket remote starting device
Diagnostic
Aids:
Verify that the vehicle was not push-started with the clutch engaged. Check for aftermarket
equipment such as remote starting devices which may bypass the clutch pedal position
switch when cranking the engine.
F-150 4.2L GO to Pinpoint Test TA .
All others Refer to the Workshop Manual Section 303-06, Starting System to diagnose the
symptom no start, no crank.
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P0833 - Clutch Pedal Switch B Circuit
Description: The powertrain control module (PCM) monitors the clutch pedal position top of travel (CPP-
TT) switch only during the calibrated engine speed range (cranking speed range). This
DTC is set when the CPP-TT does not indicate that the clutch is disengaged (clutch pedal
pressed) when the engine is cranked.
Possible
Causes:
Damaged CPP-TT switch
Damaged CPP-TT harness
Open PWRGND circuit to the CPP-TT switch
Vehicle push-started with the clutch engaged (clutch pedal released)
Aftermarket remote starting device
Diagnostic
Aids:
Verify that the vehicle was not push-started with the clutch engaged. Check for aftermarket
equipment such as remote starting devices which may bypass the clutch pedal position
switch when cranking the engine.
P0840 - Transmission Fluid Pressure Sensor/Switch A Circuit
Description:
Possible Causes:
Diagnostic Aids:
P09xx - Transmission Code
Description:
Possible Causes:
Diagnostic Aids:
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P1000 - On-Board Diagnostic (OBD) Systems Readiness Test Not Complete
Description: The OBD monitors are carried out during the OBD drive cycle. DTC P1000 is stored in
continuous memory if any of the OBD monitors do not carry out their full diagnostic check.
Possible
Causes:
The vehicle is new from the factory
Battery or powertrain control module (PCM) had recently been disconnected
An OBD monitor concern occurred before completion of an OBD drive cycle
PCM DTCs have recently been cleared with a scan tool
Power take off (PTO) circuit concern or PTO is on during testing.
Diagnostic
Aids:
This DTC, inspection/maintenance (I/M) readiness function is part of the PCM strategy. A
battery disconnection or clearing codes using a scan tool results in the various I/M
readiness bits being set to a not-ready condition. As each non-continuous OBD monitor
completes a full diagnostic check, the I/M readiness bit associated with that monitor is set to
a ready condition. This may take 1 or 2 drive cycles based on whether concerns are
detected or not. The readiness bits for comprehensive component monitoring (CCM),
misfire, and fuel system monitoring are considered complete once all the non-continuous
monitors have been evaluated. Because the EVAP and secondary air injection (AIR) system
monitors require certain ambient conditions to run, special logic can bypass the monitor for
the purpose of clearing the EVAP/secondary AIR system I/M readiness bit, due to continued
presence of these extreme conditions. DTC P1000 does not need to be cleared from the
PCM except to pass an I/M test. The malfunction indicator lamp (MIL) flashes after a period
of time with the key in the RUN position (engine not running) if DTC P1000 is set.
All See Note 2 See Note 2 GO to Pinpoint Test QC .
P1001 - Key On Engine Running (KOER) Not Able To Complete, KOER Aborted
Description: This non-malfunction indicator lamp (MIL) DTC is set when the KOER self-test does not
complete in the time allowed.
Possible
Causes:
Incorrect self-test procedure
Unexpected response from the self-test monitors
RPM out of specification
Diagnostic
Aids:
Carry out the KOEO self-test. Refer to Section 3 , Step 1: Powertrain Control Module
(PCM) Quick Test.
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P1100 - Mass Air Flow (MAF) Sensor Circuit Intermittent
Description: The MAF sensor circuit is monitored by the powertrain control module (PCM) for sudden
voltage (or air flow) input change through the comprehensive component monitor (CCM). If
during the last 40 warm-up cycles in key on, engine running (KOER) the PCM detects a
voltage (or air flow) change beyond the minimum or maximum calibrated limit, a continuous
memory DTC is stored.
Possible
Causes:
Poor continuity through the MAF sensor connectors
Poor continuity through the MAF sensor harness
Intermittent open or short inside the MAF sensor
Diagnostic
Aids:
While accessing the MAF V PID on the scan tool, lightly tap on the MAF sensor or wiggle
the MAF sensor connector and harness. If the MAF V PID suddenly changes below 0.23
volt or above 4.60 volts, an intermittent fault is indicated.
All GO to Pinpoint Test DC .
P1101 - Mass Air Flow (MAF) Sensor Out of Self-Test Range
Description: The MAF sensor circuit is monitored by the powertrain control module (PCM) for an out of
range air flow (or voltage) input. If, during key on engine off (KOEO), the air flow voltage
signal is greater than 0.27 volt the test fails. Likewise, if, during key on engine running
(KOER), the air flow voltage signal is not within 0.46 volt to 2.44 volts, the test fails.
Possible
Causes:
Low battery charge
MAF sensor partially connected
MAF sensor contamination
PWR GND open to the MAF sensor
MAF RTN circuit open to PCM
Damaged MAF sensor
Diagnostic
Aids:
A MAF V PID reading greater than 0.27 volt (KOEO) or a MAF V PID reading outside the
0.46 volt to 2.44 volts range (KOER) indicates a hard fault.
P1112 - Intake Air Temperature (IAT) Circuit Intermittent
Description: Indicates the IAT sensor signal was intermittent.
Possible Damaged harness
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Causes: Damaged sensor
Diagnostic
Aids:
Monitor the IAT on a scan tool. Look for sudden changes in the reading when the
P1114 - Intake Air Temperature 2 (IAT2) Circuit Low (Supercharged/Turbocharged engines)
Description: Indicates the sensor signal is less than the self-test minimum. The IAT2 sensor minimum
is 0.2 volt.
Possible
Causes:
Damaged sensor
Diagnostic
Aids:
P1115 - Intake Air Temperature 2 (IAT2) Circuit High (Supercharged/Turbocharged engines)
Description: Indicates the sensor signal is greater than the self-test maximum. The IAT2 sensor
Possible
Causes:
Damaged sensor
Diagnostic
Aids:
P1116 - Engine Coolant Temperature (ECT) Sensor Out of Self-Test Range
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Description: Indicates the ECT sensor is out of self-test range. The correct range is 0.3 to 3.7
volts.
Possible Causes: Overheating condition
Malfunctioning thermostat
Damaged ECT sensor
Low engine coolant
Diagnostic Aids: The ECT must be greater than 10C (50F) to pass the key on engine off (KOEO)
self-test and greater than 82C (180F) to pass the key on engine running (KOER)
self-test.
Vehicles with only a
(CHT) sensor
GO to Pinpoint Test DL . GO to Pinpoint Test DL .
All others GO to Pinpoint Test DX . GO to Pinpoint Test DX .
P1117 - Engine Coolant Temperature (ECT) Sensor Circuit Intermittent
Description: Indicates the ECT circuit became intermittently open or shorted while the engine was
running.
Possible
Causes:
Damaged harness
Damaged sensor
Low engine coolant
Diagnostic
Aids:
Monitor the ECT on a scan tool. Look for sudden changes in the reading when the
P1120 - Throttle Position Sensor A Out Of Range Low (Ratch Too Low)
(PCM) for a low TP rotation angle or voltage input below the closed throttle position through
the comprehensive component monitor (CCM). The test fails if the TP rotation angle or
voltage remains within the calibrated self-test range, but falls between 3.42-9.85% (0.17-
0.49 volt).
Possible
Causes:
TP circuit with frayed wires
Corrosion or loose connection on the TP circuit connectors and pins
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VREF open to TP sensor
VREF short to SIG RTN
Diagnostic
Aids:
A TP PID between 3.42-9.85% (0.17-0.49 volt) in key ON, engine OFF or key ON, engine
All GO to Pinpoint Test DH .
P1124 - Throttle Position Sensor A Out Of Self-Test Range
(PCM) for an out of range TP rotation angle or voltage input. The test fails if the TP rotation
angle or voltage reading is less than 13.27% (0.66 volt) or greater than 23.52% (1.17
volts).
Possible
Causes:
Binding or bent throttle linkage
TP sensor not seated properly
Throttle plate below closed throttle position
Throttle plate/screw misadjusted
Damaged TP sensor
Diagnostic
Aids:
The TP PID reading not between 13.27-23.52% (0.66-1.17 volts) in key ON, engine OFF or
key ON, engine running indicates a concern is present.
All GO to Pinpoint Test DH . GO to Pinpoint Test DH .
P1127 - Exhaust Temperature Out of Range, O2 Sensor Tests Not Completed
Description: The heated oxygen sensor (HO2S) monitor uses an exhaust temperature model to
determine when the HO2S heaters are cycled ON. The test fails when the inferred exhaust
temperature is below a minimum calibrated value.
Possible
Causes:
Engine not operating long enough prior to carrying out the key on engine running
(KOER) self-test
Exhaust system too cool
Diagnostic
Aids:
Monitor the HO2S heater PIDs to determine their ON/OFF state. DTC P1127 is present if
the exhaust is not hot.
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P115E - Throttle Actuator Control (TAC) Throttle Body Air Flow Trim at Max Limit
Description: During idle, the powertrain control module (PCM) monitors the throttle angle and air flow. If
the air flow is determined to be less than expected, the PCM adjusts the throttle angle to
compensate. The air flow reduction is typically the result of sludge buildup around the
throttle plate. This DTC indicates the PCM has reached the maximum allowed
compensation and is no longer able to compensate for the buildup.
Possible
Causes:
Sludge around the throttle plate
Diagnostic
Aids:

All Install a new ETB. Refer to the Workshop Manual Section 303-04, Fuel Charging and
Controls.
P117A - Engine Oil Over Temperature Forced Limited Power
Description: Indicates the engine oil protection strategy is enabled when the engine oil temperature
(EOT) reaches a predetermined level in the powertrain control module (PCM). The PCM
then limits the engine RPMs until the EOT returns to normal.
Possible
Causes:
Engine overheating
Low engine coolant
Loaded weight is greater than the maximum vehicle weight rating. Refer to Owner's
Literature for vehicle weight ratings.
Diagnostic
Aids:
This DTC is an informational DTC and may be set by an engine overheating concern. If the
engine overheats, check the cooling system. Refer to the Workshop Manual Section 303-
03, Engine Cooling for cooling system diagnosis.
P1184 - Engine Oil Temperature (EOT) Sensor Out of Self-Test Range
Description: Indicates the EOT signal was out of self-test range.
Possible Causes: Damaged harness
Damaged sensor
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Diagnostic Aids: The engine should be at operating temperature before carrying out the self-test.
P1227 - Wastegate Failed Closed (Over pressure)
Description: Indicates that boost pressure is continuously higher than desired.
Possible
Causes:
EGR valve
MAF sensor
SIP sensor
Supercharger bypass actuator stuck closed
Supercharger
Diagnostic
Aids:
This DTC is informational only and it may be accompanied by other DTCs. Diagnose
other DTCs first.
All GO to Pinpoint Test KJ .
P1228 - Wastegate Failed Open (Under pressure)
Description: Indicates that boost pressure is continuously lower than desired.
Possible
Causes:
EGR valve
MAF sensor
SIP sensor
Supercharger bypass actuator stuck open
Supercharger
Diagnostic
Aids:
This DTC is informational only and it may be accompanied by other DTCs. Diagnose
other DTCs first.
All GO to Pinpoint Test KJ .
P1229 - Charge Air Cooler (CAC) Pump Driver
Description: This DTC sets when the powertrain control module (PCM) commands the supercharger
CAC pump to operate but no current is detected.
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Possible
Causes:
CAC pump motor open circuit
CAC pump relay coil open
Open circuit between the relay and pump
CAC pump motor shorted
Open circuit between the PCM and the relay
Poor CAC pump ground connection
Diagnostic
Aids:
Check for voltage at the relay. Check the fuse in the voltage circuit. Check the ground
connection of the CAC pump motor.
All GO to Pinpoint Test KP .
P1233 - Fuel Pump Driver Module Disabled or Off Line
Description: The powertrain control module (PCM) monitors the fuel pump monitor (FPM) circuit from
the fuel pump driver module (FPDM). With the key ON, engine OFF or key ON, engine
running the FPDM continuously sends a duty cycle signal to the PCM through the FPM
circuit. The test fails if the PCM stops receiving the duty cycle signal.
Possible
Causes:
Inertia fuel shutoff (IFS) switch needs to be reset
Open FPDM ground circuit
Open circuit to FPDM PWR RLY
Open FPDM PWR circuit
Open or short FPM circuit (engine should start)
Damaged IFS switch
Damaged FPDM PWR RLY
Damaged FPDM
Diagnostic
Aids:
The PCM expects to see one of the following duty cycle signals from the FPDM on the FPM
circuit: 1) 50% (500 ms on, 500 ms off), all OK. 2) 25% (250 ms on, 750 ms off), FPDM did
not receive a fuel pump (FP) duty cycle command from the PCM, or the duty cycle that was
received was invalid. 3) 75% (750 ms on, 250 off), the FPDM detected a concern in the
circuits between the FPDM and the fuel pump.
All GO to Pinpoint Test KB .
P1234 - Fuel Pump Driver Module Disabled or Off Line
Description: The powertrain control module (PCM) monitors the fuel pump monitor 2 (FPM2) circuit from
the fuel pump driver module 2 (FPDM2). With the key ON, engine OFF or key ON, engine
running the FPDM2 continuously sends a duty cycle signal to the PCM through the FPM2
circuit. The test fails if the PCM stops receiving the duty cycle signal.
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Possible
Causes:
Inertia fuel shutoff (IFS) switch needs to be reset
Open FPDM2 ground circuit
Open circuit to FPDM2 PWR RLY
Open FPDM2 PWR circuit
Open or short FPM2 circuit (engine should start)
Damaged IFS switch
Damaged FPDM2 PWR RLY
Damaged FPDM2
Diagnostic
Aids:
The PCM expects to see one of the following duty cycle signals from the FPDM2 on the
FPM2 circuit: 1) 50% (500 ms on, 500 ms off), all OK. 2) 25% (250 ms on, 750 ms off), the
FPDM2 did not receive a fuel pump (FP) duty cycle command from the PCM, or the duty
cycle that was received was invalid. 3) 75% (750 ms on, 250 off), the FPDM2 detected a
concern in the circuits between the FPDM2 and the fuel pump.
P1235 - Fuel Pump Control Out Of Range
Description: This DTC indicates the fuel pump driver module (FPDM) detected an invalid or missing fuel
pump (FP) duty cycle signal on the fuel pump control (FPC) circuit from the powertrain
control module (PCM). The FPDM sends a message to the PCM through the fuel pump
monitor (FPM) circuit, indicating this concern was detected. The PCM sets the DTC when
the message is received.
Possible
Causes:
FPC circuit open or short
Electronic throttle control (ETC) system concern. Check for ETC DTCs
Damaged FPDM
Damaged PCM
Diagnostic
Aids:
The FPDM sends a 25% duty cycle (250 ms on, 750 ms off) through the FPM circuit to the
PCM while the concern is being detected by the FPDM. If the concern is no longer
detected, the FPDM returns to sending an all OK (50% duty cycle) message to the PCM.
For ETC applications, check if ETC DTC P2105 is present. An ETC system concern could
cause DTC P1235, and should be diagnosed first.
P1236 - Fuel Pump Control Out Of Range
Description: This DTC indicates the fuel pump driver module 2 (FPDM2) detected an invalid or missing
fuel pump (FP) duty cycle signal on the fuel pump control (FPC) circuit from the powertrain
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control module (PCM). The FPDM2 sends a message to the PCM through the fuel pump
monitor 2 (FPM2) circuit, indicating this concern was detected. The PCM sets the DTC
when the message is received.
Possible
Causes:
FPC circuit open or short
Damaged FPDM2
Damaged PCM
Diagnostic
Aids:
The FPDM2 sends a 25% duty cycle (250 ms on, 750 ms off) through the FPM2 circuit to
the PCM while the concern is being detected by the FPDM2. If the concern is no longer
detected, the FPDM2 returns to sending an all OK (50% duty cycle) message to the PCM.
P1237 - Fuel Pump Secondary Circuit
Description: This DTC indicates that the fuel pump driver module (FPDM) detected a fuel pump
secondary circuit concern. The FPDM sends a message to the powertrain control module
(PCM) through the fuel pump monitor (FPM) circuit indicating this concern was detected.
The PCM sets the DTC when the message is received.
Possible
Causes:
Open or short FP PWR circuit
Open FP RTN circuit to FPDM
Open or short circuit in the fuel pump
Locked fuel pump rotor
Damaged FPDM
Diagnostic
Aids:
The FPDM sends a 75% duty cycle (750 ms on, 250 ms off) through the FPM circuit to the
PCM while the concern is being detected by the FPDM. If the concern is no longer
detected, the PCM returns to sending an all OK (50% duty cycle) message to the PCM.
The FPDM controls pump speed by supplying a variable ground on the FP RTN circuit.
P1238 - Fuel Pump Secondary Circuit
Description: This DTC indicates the fuel pump driver module (FPDM2) detected a fuel pump secondary
circuit concern. The FPDM2 sends a message to the powertrain control module (PCM)
through the fuel pump monitor (FPM2) circuit, indicating this concern was detected. The
PCM sets the DTC when the message is received.
Possible
Causes:
Open or short FP2PWR circuit
Open FP2RTN circuit to FPDM2
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Open or short circuit in the fuel pump
Locked fuel pump rotor
Damaged FPDM2
Diagnostic
Aids:
The FPDM2 sends a 75% duty cycle (750 ms on, 250 ms off) through the FPM2 circuit to
the PCM while the concern is being detected by the FPDM2. If the concern is no longer
detected, the PCM returns to sending an all OK (50% duty cycle) message to the PCM.
The FPDM2 controls pump speed by supplying a variable ground on the FP2RTN circuit.
P1244 - Alternator Load High Input
in the form of frequency. The concern indicates the input is higher than the load should be
in normal operation. The load input could be high when a battery short to ground exists.
Possible
Causes:
GENLI circuit short to voltage
GENRC circuit short to voltage
B+ open prior to start-up
Open GENRC prior to start-up
Open ILC prior to start-up
Damaged PCM
Diagnostic
Aids:
Verify the battery voltage is 14.5 volts.
Verify the generator/regulator has the correct part number.
P1245 - Alternator Load Low Input
in the form of frequency. The concern indicates the input is lower than the load should be
in normal operation. The load input could be low when no generator output exists.
Possible
Causes:
GENRC circuit short to ground
GENLI circuit short to ground
Open B+ wire during operation
Low system voltage
Broken generator belt
Damaged PCM
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Diagnostic
Aids:
P1246 - Alternator Load Input
Description: The powertrain control module (PCM) monitors the generator load from the
generator/regulator in the form of frequency. The frequency range is determined by the
temperature of the voltage regulator, where 97% indicates a full load, and less than 6%
indicates no load.
Possible
Causes:
GENLI circuit shorted to voltage or ground
GENLI circuit open
GENRC circuit shorted to power or ground
GENRC circuit open
ILC circuit shorted to voltage or ground
ILC circuit open
Battery-sense circuit open
Damaged PCM
Diagnostic
Aids:
P1260 - Theft Detected, Vehicle Immobilized
Description: Indicates the passive anti-theft system (PATS) determined a theft condition existed and
the engine is disabled. This DTC is a good indicator to check the PATS for DTCs.
Possible
Causes:
Previous theft condition
Anti-theft system failure
Diagnostic
Aids:
Theft indicator flashing rapidly or on solid when ignition switch is in the ON position.
Check anti-theft system for DTCs.
All GO to Pinpoint Test QD .
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P1270 - Engine RPM or Vehicle Speed Limiter Reached
Description: Indicates the vehicle has been operated in a manner which caused the engine or vehicle to
exceed a calibration limit. The engine RPM and vehicle speed are continuously monitored
and evaluated by the powertrain control module (PCM). The DTC is set when the RPM or
vehicle speed falls out of a calibrated range. For additional information on the engine
RPM/vehicle speed limiter, refer to Section 1, Powertrain Control Software .
Possible
Causes:
Wheel slippage (water, ice, mud, and snow)
Excessive engine RPM in NEUTRAL or operated in the wrong transmission gear
Vehicle driven at a high rate of speed
Diagnostic
Aids:
The DTC indicates the vehicle was operated in a manner which caused the engine RPM or
vehicle speed to exceed a calibrated limit.
P1285 - Cylinder Head Over Temperature Condition
Description: Indicates an engine overheat condition was sensed by the cylinder head temperature
(CHT) sensor.
Possible
Causes:
CHT sensor concern
Diagnostic
Aids:
On some applications when this fault occurs the engine temperature warning indicator
illuminates or forces the temperature gauge to the full H (hot) zone. The warning indicator
can be triggered by either grounding the engine temperature warning circuit when wired to
the powertrain control module (PCM), or by sending a PCM network message to the
instrument cluster.
All GO to Pinpoint Test DL .
P1288 - Cylinder Head Temperature (CHT) Sensor Out of Self-Test Range
Description: Indicates the CHT sensor is out of self-test range. The engine is not at a normal operating
temperature.
Possible Cold engine
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Causes: Engine overheating
Damaged CHT sensor
Diagnostic
Aids:
Bring the engine to operating temperature. If cold, repeat the self-test. If the engine
overheats, check the cooling system. Refer to the Workshop Manual Section 303-03,
Engine Cooling for cooling system diagnosis.
P1289 - Cylinder Head Temperature (CHT) Sensor Circuit High
Description: Indicates a CHT sensor circuit open.
Possible
Causes:
Open CHT sensor circuit
CHT sensor circuit short to voltage
Damaged CHT sensor
Diagnostic
Aids:
A CHT V PID reading of greater than 4.6 volts with key ON engine OFF, or during any
engine operating mode, indicates a concern is present. Note: DTC P0118 may also be
reported when this DTC is set. Either of these DTCs activate the MIL.
P128A - Cylinder Head Temperature (CHT) Sensor Circuit Intermittent/Erratic
Description: Indicates the CHT circuit became intermittently open or shorted while the engine was
running.
Possible
Causes:
Damaged harness or connector
Damaged sensor
Diagnostic
Aids:
Monitor the CHT on a scan tool. Look for sudden changes in the reading when the
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P1290 - Cylinder Head Temperature (CHT) Sensor Circuit Low
Description: Indicates a CHT sensor circuit short to ground.
Possible
Causes:
Grounded circuit in CHT harness
Damaged CHT sensor
Diagnostic
Aids:
A CHT V PID value reading of less than 0.2 volt with key ON engine OFF, or during any
engine operating mode, indicates a concern is present. DTC P0117 may also be reported
when this DTC is set. Either of these DTCs activates the malfunction indicator lamp (MIL).
P1299 - Cylinder Head Over Temperature Protection Active
Description: Indicates an engine overheat condition was detected by the cylinder head temperature
(CHT) sensor. A failure mode effects management (FMEM) strategy called fail-safe
cooling was activated to cool the engine.
Possible
Causes:
Diagnostic
Aids:
Refer to Section 1, Powertrain Control Software , for more information on the fail-safe
cooling strategy and cylinder head temperature sensor.
P1336 - Crankshaft/Camshaft Sensor Range/Performance
Description: The input signal to the powertrain control module (PCM) from the crankshaft position
(CKP) sensor or the camshaft position (CMP) sensor is erratic.
Possible
Causes:
Damaged CKP sensor
Damaged CMP sensor
Harness concerns
Diagnostic
Aids:
Check the harness for routing, alterations, improper shielding, or electrical interference
from other improperly functioning systems.
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All GO to Pinpoint Test JD .
P1397 - System Voltage Out Of Self -Test Range
Description: This DTC indicates that the 12-volt system voltage is too high or too low during the key on
engine off (KOEO) or key on engine running (KOER) self-test. It sets if the system voltage
falls below or exceeds the calibrated threshold at any time during the KOEO or KOER self-
test.
Possible
Causes:
Battery or charging system concern.
Diagnostic
Aids:
Make sure the battery voltage is between 11 and 18 volts before running a KOEO or KOER
self-test.
All Refer to the Workshop Manual Section 414-00, Charging System to diagnose the
charging system concern.
P1405 - Differential Pressure Feedback Sensor Upstream Hose Off or Plugged
Description: While driving, the exhaust gas recirculation (EGR) monitor commands the EGR valve
closed and checks the differential pressure across the EGR orifice. The test fails when the
signal from the differential pressure feedback EGR (DPFE) sensor indicates EGR flow is in
the negative direction.
Possible
Causes:
The upstream hose is disconnected
The upstream hose is plugged (ice)
Plugged or damaged EGR tube
Diagnostic
Aids:
Look for signs of water or icing in the hose. Verify the hose connection and routing (no
excessive dips). Check the DPFE sensor for correct mounting and function. View the
DPFEGR PID while applying and releasing vacuum directly to the sensor with a hand
pump.
All GO to Pinpoint Test HE . GO to Pinpoint Test HE .
P1406 - Differential Pressure Feedback Sensor Downstream Hose Off or Plugged
Description: While driving, the exhaust gas recirculation (EGR) monitor commands the EGR valve
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closed and checks the differential pressure across the EGR orifice. The test fails when the
signal from the differential pressure feedback EGR (DPFE) sensor continues to indicate
EGR flow even after the EGR valve is commanded closed.
Possible
Causes:
Downstream hose is disconnected
Downstream hose is plugged (ice)
Plugged or damaged EGR tube
Diagnostic
Aids:
Look for signs of water or icing in the hose. Verify the hose connection and routing (no
excessive dips). Check the DPFE sensor for correct mounting and function. View the
DPFEGR PID while applying and releasing vacuum directly to the sensor with a hand
pump.
All GO to Pinpoint Test HE .
P1408 - Exhaust Gas Recirculation (EGR) Flow Out of Self-Test Range (Non-MIL)
Description: This test is carried out during the key on engine running (KOER) on-demand self-test
only. The EGR system is commanded on at a fixed engine speed. The test does not
pass and the DTC is set when the measured EGR flow falls above or below the
required calibration.
Possible Causes: For electric EGR (EEGR) system, see possible causes for DTC P0400.
For vacuum activated systems, see the possible causes for DTC P0401.
Diagnostic Aids: For EEGR, use the output state control function of the scan tool and monitor the
manifold absolute pressure (MAP) PID and the EEGR PID (EGRMDSD) while
commanding the EEGR on. If EGR is introduced into the engine at idle, the RPM
drops or stalls out. For vacuum systems see diagnostic aids for DTC P0401.
Vehicles With an
Electric EGR
(EEGR)
GO to Pinpoint Test KD .
Vehicles with an
EGR system
module (ESM)
P1409 - Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid Circuit
Description: This test checks the electrical function of the EGR vacuum regulator solenoid. The
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test fails when the EVR circuit voltage is either too high or too low when compared to
the expected voltage range. The EGR system must be enabled for the test to be
completed.
Possible Causes: EVR circuit open
EVR circuit short to voltage or ground
Diagnostic Aids: The EGR vacuum regulator solenoid resistance is between 26 and 40 ohms.
Vehicles with an
EGR system
module (ESM)
P1436 - A/C Evaporator Air Temperature Circuit Low
Description: Indicates the A/CET signal input was less than the self-test minimum. The self-test
minimum is 0.13 volts.
Possible
Causes:
A/CET circuit short to ground or SIG RTN
Damaged A/CET sensor
Diagnostic
Aids:
The powertrain control module (PCM) sources a low current 5 volt reference on the A/CET
circuit (this voltage can be measured with the sensor disconnected). As the A/C evaporator
air temperature changes, the A/CET circuit resistance to SIG RTN (ground) changes (which
changes the voltage the PCM detects). When the A/CET signal is detected below the self-
test minimum, check for shorts to SIG RTN or ground which would pull the voltage low.
P1437 - A/C Evaporator Air Temperature Circuit High
Description: Indicates the A/CET signal input was greater than the self-test minimum. The self-test
Possible
Causes:
A/CET circuit open
SIG RTN circuit open to A/CET sensor
A/CET circuit short to voltage (VREF)
Damaged A/CET sensor
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Diagnostic
Aids:
The powertrain control module (PCM) sources a low current 5 volt reference on the A/CET
circuit (this voltage can be measured with the sensor disconnected). As the A/C evaporator
air temperature changes, the A/CET circuit resistance to SIG RTN (ground) changes (which
changes the voltage the PCM detects). When the A/CET signal is detected above the self-
test maximum, check for open circuits (A/CET or SIG RTN), which would cause the voltage
to remain high. Although not as probable, also check for a short to voltage (VREF).
P1443 - Evaporative Emission System Control Valve (Low/No Flow)
Description: A fuel tank pressure change greater than minus (-) 7 inches of water in 30 seconds
occurred with a purge, fuel vapor, flow at less than 0.02 lb/min (0.15 gm/s).
Possible
Causes:
Blocked fuel vapor hose between the EVAP canister purge valve and the fuel tank
pressure (FTP) sensor
Blocked fuel vapor hose between the EVAP canister purge valve and the engine
intake manifold
Blocked vacuum hose between the EVAP canister purge valve solenoid and the
engine intake manifold
EVAP canister purge valve mechanically stuck closed
Diagnostic
Aids:
Check for blockages between the fuel tank, the EVAP canister purge valve, and the
engine intake manifold. Check for obstructions in the EVAP canister purge valve
diaphragm and ports.
P1450 - Unable to Bleed Up Fuel Tank Vacuum
Description: Monitors the fuel vapor vacuum and pressure in the fuel tank. System failure occurs when
the evaporative emission (EVAP) running loss monitor detects excessive fuel tank vacuum
with the engine running, but not at idle.
Possible
Causes:
Blockages or kinks in the EVAP canister tube or EVAP canister purge outlet tube
between the fuel tank, the EVAP canister purge valve and the EVAP canister
Fuel filler cap stuck closed, preventing vacuum relief
Contaminated fuel vapor elbow on the EVAP canister
Restricted EVAP canister
CV solenoid stuck partially or fully open
Plugged CV solenoid filter
EVAP canister purge valve stuck open
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VREF circuit open in the harness near the fuel tank pressure (FTP) sensor, the FTP
sensor or the powertrain control module (PCM)
Damaged FTP sensor
Diagnostic
Aids:
Visually inspect the EVAP canister inlet port, CV solenoid filter, and canister vent hose
assembly for contamination or debris.
Check EVAP canister purge valve for vacuum leak.
P1451 - Evaporative Emission System Vent Control Circuit
Description: Monitors the canister vent (CV) solenoid circuit for an electrical failure. The test fails when
the signal moves outside the minimum or maximum allowable calibrated parameters for a
specified canister vent duty cycle by powertrain control module (PCM) command.
Possible
Causes:
VPWR circuit open
CV solenoid circuit short to PWR GND or CHASSIS GND
Damaged CV solenoid
CV solenoid circuit open
CV solenoid circuit short to VPWR
Diagnostic
Aids:
To verify normal functioning, monitor the evaporative emission (EVAP) CV solenoid signal
PID EVAPCV and the signal voltage on the PCM control side. With the valve open, the
EVAPCV PID indicates 0% duty cycle and a voltage approximately equal to battery voltage.
When the valve is commanded fully closed, the EVAPCV PID indicates 100% duty cycle,
and a minimum voltage drop of 4 volts is normal. Output test mode may be used to switch
the output on and off to verify function.
P1460 - Wide Open Throttle A/C Cutout Circuit
Description: Monitors the A/CCR circuit output from the powertrain control module (PCM). The test fails
when the PCM grounds the A/CCR circuit, excessive current draw is detected on the
A/CCR circuit; or, with the A/CCR circuit not grounded by the PCM, voltage is not detected
on the A/CCR circuit (the PCM expects to detect VPWR voltage coming through the A/CCR
relay coil to the A/CCR circuit).
Possible
Causes:
Open or short A/CCR circuit
Damaged A/CCR relay
Open VPWR circuit to the A/CCR relay
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Diagnostic
Aids:
The A/CCR control circuit can be monitored using the WACF and WAC PID.
When the WACF PID reads YES, a concern is present.
circuit.
A short to voltage can only be detected when the PCM is grounding the circuit.
During the key ON engine OFF (KOEO) and the key OFF engine running (KOER) self-test,
the WAC circuit is cycled on and off.
Verify the A/C and the defrost were off during KOEO and KOER self-test (Check the A/CCS
PID to verify).
If the vehicle is not equipped with A/C, ignore DTC P1460.
P1461 - A/C Pressure Sensor Circuit High
Description: The A/CP sensor inputs a voltage to the PCM. If the voltage is above a calibrated level
the DTC sets.
Possible
Causes:
A/CP sensor circuit short to PWR
A/CP circuit open
A/CP circuit short to VREF
Damaged A/CP sensor
Diagnostic
Aids:
P1462 - Air Conditioning Pressure (A/CP) Sensor Low Voltage Detected
Description: The A/CP sensor inputs a voltage to the powertrain control module (PCM). If the voltage is
below the calibrated level the DTC sets. The A/CP sensor inputs a voltage to the PCM. If
the voltage is below the calibrated level the DTC sets.
Possible
Causes:
A/CP circuit short to GND or SIGRTN
VREF circuit open
Open A/CP circuit
Damaged A/CP sensor
Diagnostic
Aids:
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P1463 - Air Conditioning Pressure Sensor (A/CP) Insufficient Pressure Change
Description: Each time the A/C clutch engages, the powertrain control module (PCM) is looking for a
pressure change in the refrigerant. If the change in pressure is outside of the calibration
the DTC sets.
Possible
Causes:
A/C system mechanical failure
Open ACP or VREF circuit
A/C sensor damaged
A/C system electrical failure
A/C clutch always engaged
Diagnostic
Aids:
Verify the A/C system function, including refrigerant charge. Refer to the Workshop
Manual Section 412-00, Climate Control System.
P1464 - A/C Demand Out Of Self-Test Range
Description: The diagnostic trouble code (DTC) sets when the powertrain control module (PCM)
receives a request for A/C during the self-test.
Possible
Causes:
A/C or defrost on during self-test
A/CCS circuit short to voltage
Damaged A/C demand switch
Damaged WAC relay
Diagnostic
Aids:
If the A/C or defrost was on during self-test, turn the A/C or defrost off and repeat the self-
test. An A/C request to the PCM may come through the communication link or on a
dedicated hardwire circuit from the A/C switch.
All GO to Pinpoint Test KM . GO to Pinpoint Test KM .
P1469 - Rapid A/C Cycling
Description: Indicates frequent A/C compressor clutch cycling.
Possible Mechanical A/C system concern (such as low refrigerant charge, damaged A/C
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Causes: cycling switch)
Intermittent open between the cycling pressure switch and the powertrain control
module (PCM)
Intermittent open in the IGN RUN circuit to cycling pressure switch (if applicable)
Diagnostic
Aids:
This test is designed to protect the transmission. In some strategies, the PCM unlocks the
torque converter during A/C clutch engagement. If a concern is present that results in
frequent A/C clutch cycling, damage could occur if the torque converter is cycled at these
intervals. This test detects this condition, sets the DTC and prevents the torque converter
from excessive cycling.
P1474 - Fan Control Primary Circuit
Description: Monitors the LFC primary circuit output from the powertrain control module (PCM). The test
fails if the PCM grounds the LFC circuit, excessive current draw is detected on the LFC
circuit, or with the LFC circuit not grounded by the PCM, voltage is not detected on the LFC
circuit (the PCM expects to detect VPWR voltage coming through the.
Possible
Causes:
Open or short LFC circuit
Open VPWR circuit to the low speed FC relay
Damaged low speed FC relay
Diagnostic
Aids:
When the LFCF PID reads YES, a concern is currently present.
LFC circuit.
A short to voltage can only be detected when the PCM is grounding the LFC circuit.
During the key on engine off (KOEO) and key on engine running (KOER) self-test, the LFC
circuit is cycled on and off.
P1477 - Additional Fan Relay Circuit
Description: Monitors the MFC primary circuit output from the powertrain control module (PCM). The
test fails if the MFC output commanded on (grounded), excessive current draw is detected
on the MFC circuit or, with the MFC circuit commanded off, voltage is not detected on the
MFC circuit (the PCM expects to detect IGN START/RUN voltage through the medium
speed FC relay coil to the MFC circuit).
Possible Open or short MFC circuit
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Causes: Open IGN START/RUN circuit to the medium speed FC relay
Damaged medium speed FC relay
Diagnostic
Aids:
When the MFCF PID reads YES, a concern is currently present.
MFC circuit.
A short to voltage can only be detected when the PCM is grounding the MFC circuit.
During the key on engine off (KOEO) and key on engine running (KOER) self-test, the MFC
When using output test mode on a scan tool, and commanding the low speed fan on, the
PCM also activates the medium speed fan output.
P1479 - High Fan Control Primary Circuit
Description: Monitors the HFC primary circuit output from the powertrain control module (PCM). The test
fails if the HFC output commanded on (grounded), excessive current draw is detected on
the HFC circuit or, with the HFC circuit commanded off, voltage is not detected on the HFC
circuit (the PCM expects to detect VPWR voltage through the high speed FC relay coil to
the HFC circuit).
Possible
Causes:
Open or short HFC circuit
Open VPWR circuit to the high speed FC relay
Damaged high speed FC relay
Diagnostic
Aids:
When the HFCF PID reads YES, a concern is currently present.
HFC circuit.
A short to voltage can only be detected when the PCM is grounding the HFC circuit.
During the key on engine off (KOEO) and key on engine running (KOER) self-test, the HFC
P1489 - PCV Heater Control Circuit
Description: This DTC sets when the powertrain control module (PCM) detects a positive crankcase
ventilation (PCV) heater circuit failure.
Possible
Causes:
Open or shorted PCV circuit
Damaged PCV heater assembly
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Diagnostic
Aids:
Make sure the PCV valve is correct for the engine application and the PCV heater circuit
is properly connected.
All GO to Pinpoint Test HG .
P1500 - Vehicle Speed Sensor (VSS)
Description: Indicates the VSS input signal was intermittent. This DTC is set when a VSS
concern interferes with other on-board diagnostics (OBD) tests, such as the
catalyst efficiency monitor, the EVAP monitor or the HO2S monitor.
Possible Causes: Intermittent VSS connections
Intermittent open in the VSS harness circuit(s)
Intermittent short in VSS harness circuit(s)
Damaged VSS
Diagnostic Aids: Check the wiring, connector, and sensor for damage.
Application Key On Engine Off Key On Engine
Running
Continuous Memory
Five Hundred,
Freestyle,
Montego,
Navigator
transmission and output
shaft speed (OSS) sensor
DTCs
P1501 - Vehicle Speed Sensor (VSS) Out of Self-Test Range
Description: Indicates the VSS input signal is out of self-test range. If the powertrain
control module (PCM) detects a VSS input signal any time during the self-
test, DTC P1501 is set and the test aborts.
Possible Causes: Noise on the VSS input signal from the radio frequency
interference/electro magnetic interference (RFI/EMI)
External sources, such as ignition wires, the charging circuit or
aftermarket equipment
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Diagnostic Aids: Verify the VSS input is 0 km/h (0 mph) when the vehicle transmission is in
PARK.
Application Key On Engine Off Key On Engine
Running
Continuous Memory
F-Super Duty GO to Pinpoint Test
DF .
GO to Pinpoint Test
DF .

Five Hundred,
Freestyle,
Montego,
Navigator
transmission and output shaft
speed (OSS) sensor DTCs
All others GO to Pinpoint Test
DP .
GO to Pinpoint Test
DP .

P1502 - Vehicle Speed Sensor (VSS) Intermittent
Description: Indicates the powertrain control module (PCM) detected an error in the vehicle
speed information. Vehicle speed data is received from either the VSS, transfer
case speed sensor (TCSS) or anti-lock brake system (ABS) control module. This
DTC is set the same way as P0500. However, it is intended to flash the
transmission control indicator lamp (TCIL) for first time VSS circuit
error/malfunctions.
Vehicles with an
automatic
transmission and
output shaft speed
(OSS) sensor DTCs
P1504 - Idle Air Control (IAC) Circuit
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Description: This DTC is set when the powertrain control module (PCM) detects an electrical load
failure on the IAC output circuit.
Possible
Causes:
IAC circuit open
IAC circuit short to voltage
Damaged IAC valve
Diagnostic
Aids:

P1506 - Idle Air Control (IAC) Overspeed Error
Description: This DTC is set when the powertrain control module (PCM) detects an engine idle speed
that is greater than the desired RPM.
Possible
Causes:
Damaged IAC valve
IAC valve stuck open
Intake air leak after throttle body
Vacuum leaks
Failed EVAP system
Diagnostic
Aids:
Disconnect the IAC valve and look for little or no change in engine RPM as an indication
of a stuck or damaged valve.
P1507 - Idle Air Control (IAC) Underspeed Error
Description: This DTC is set when the powertrain control module (PCM) detects an engine idle speed
that is less than the desired RPM.
Possible
Causes:
IAC circuit open
IAC valve stuck closed
IAC circuit short to voltage
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Diagnostic
Aids:
Disconnect the IAC valve and look for little or no change in engine RPM as an indication
of a stuck or damaged valve.
P1512 - Intake Manifold Runner Control (IMRC) Stuck Closed (Bank 1)
Description: This DTC is set when the vacuum actuated IMRC is commanded open, but the IMRC
monitor indicates closed.
Possible
Causes:
IMRC monitor circuit open
Suspect IMRC solenoid
Mechanical concern - bind, seize, damage, or obstruction of IMRC hardware
Diagnostic
Aids:
Monitor the IMRC and IMRCM PIDs. The IMRCM state should change when the IMRC is
commanded open or closed.
Description: This DTC is set when the vacuum actuated IMRC is commanded open, but the IMRC
Possible
Causes:
Suspect IMRC solenoid
Diagnostic
Aids:
P1516 - Intake Manifold Runner Control (IMRC) Input Error (Bank 1)
Description: The IMRC system is monitored for failure during continuous or key on engine off (KOEO)
self-test. Each DTC distinguishes the corresponding failed bank for IMRC actuator
assemblies with dual monitor switches. The test fails when the signal is outside an
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expected calibrated range.
Possible
Causes:
Diagnostic
Aids:
All GO to Pinpoint Test HU . GO to Pinpoint Test HU .
P1517 - Intake Manifold Runner Control (IMRC) Input Error (Bank 2)
Description: The IMRC system is monitored for failure during continuous or key on engine off (KOEO)
self-test. Each DTC distinguishes the corresponding failed bank for IMRC actuator
assemblies with dual monitor switches. The test fails when the signal is outside an
expected calibrated range.
Possible
Causes:
Diagnostic
Aids:
P1518 - Intake Manifold Runner Control (IMRC) Stuck Open Bank 1
Description: This DTC is set when the electrically actuated IMRC is commanded closed, but the
IMRC monitor indicates open.
Possible
Causes:
IMRC monitor signal circuit shorted to PWR GND or SIG RTN
Damaged IMRC actuator
Diagnostic
Aids:
P1519 - Intake Manifold Runner Control (IMRC) Stuck Closed Bank 1
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Description: This DTC is set when the electrically actuated IMRC is commanded open, but the IMRC
Possible
Causes:
IMRC control circuit open
IMRC monitor circuit short to VREF
IMRC monitor return circuit open
IMRC VPWR circuit open
Diagnostic
Aids:
P151A - Intake Manifold Runner Controller Performance
Description: The intake manifold runner control (IMRC) system is monitored for failures. The test fails
when the system detects a loss of bi-directional communication or signal(s) between the
PCM and the IMRC solenoid.
Possible
Causes:
IMRC control circuit short to voltage
IMRC VPWR circuit open
IMRC GND circuit open
Diagnostic
Aids:
View the IMRCF PID to monitor for a fault.
P1520 - Intake Manifold Runner Control (IMRC) Circuit
Description: This DTC indicates a failure in the IMRC primary control circuit.
Possible
Causes:
Diagnostic
Aids:
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P1537 - Intake Manifold Runner Control (IMRC) Stuck Open (Bank 1)
Description: This DTC is set when the vacuum actuated IMRC is commanded closed, but the IMRC
monitor indicates open.
Possible
Causes:
Damaged IMRC solenoid
Blocked vacuum hoses
Diagnostic
Aids:
Description: This DTC is set when the vacuum actuated IMRC is commanded closed, but the IMRC
monitor indicates open.
Possible
Causes:
Damaged IMRC solenoid
Diagnostic
Aids:
P1548 - Engine Air Filter Restriction
Description: The powertrain control module (PCM) monitors the manifold absolute pressure (MAP) at
various engine speeds during wide open throttle (WOT) operation, and compares the
information to a calibrated value. If the air flow is out of range, the DTC is set.
Possible
Causes:
Clogged air filter
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Diagnostic
Aids:
If this DTC is set, inspect the intake air system and replace the air filter if no obstructions
are found.
All REFER to the Workshop Manual Section 303-12.
P1549 - Intake Manifold Communication Control (IMCC) Circuit (Bank 1)
Description: The IMCC or intake manifold tuning (IMTV) system is monitored for failure during
continuous or key on engine off (KOEO) self-test. The test fails when the powertrain
control module (PCM) detects a concern with the IMTV output circuit.
Possible
Causes:
Open IMTV circuit
Open VPWR circuit
Shorted IMTV circuit
Damaged IMTV
Diagnostic
Aids:
An IMTV fault PID (IMTVF) displaying YES may indicate a fault.
P1550 - Power Steering Pressure (PSP) Sensor Out of Self-Test Range
Description: The PSP sensor input signal to the powertrain control module (PCM) is continuously
monitored. The test fails when the signal falls out of a maximum or minimum calibrated
range.
Possible
Causes:
Steering wheel not turned during self-test.
PSP sensor or circuit damaged
Power steering concern
Diagnostic
Aids:
The DTC indicates the PSP sensor is out of self-test range.
All GO to Pinpoint Test DT . GO to Pinpoint Test DT .
P1565 - Speed Control Command Switch Out Of Range High
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Description:
Possible Causes:
Diagnostic Aids:
P1566 - Speed Control Command Switch Out Of Range Low
Description:
Possible Causes:
Diagnostic Aids:
P1567 - Speed Control Output Circuit
Description:
Possible Causes:
Diagnostic Aids:
P1568 - Speed Control Unable to Hold Speed
Description:
Possible Causes:
Diagnostic Aids:
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P1572 - Brake Pedal Switch Circuit
Description: Indicates the brake input rationality test for brake pedal position (BPP) and brake pressure
switch (BPS) has failed. One or both inputs to the powertrain control module (PCM) did not
change state when expected. On some vehicles with stability assist, the BPP switch is
connected to the anti-lock brake system (ABS) module and the ABS generates a driver
brake application (DBA) signal, which is then sent to the PCM.
Possible
Causes:
Misadjusted brake switches, BPP or BPS
Blown fuse
Damaged BPP switch
Damaged BPS switch
Open or short in the BPP circuit
Open or short in the DBA circuit
Open or short in the BPS circuit
Diagnostic
Aids:
DTC P1572 is set when the PCM does not sense the proper sequence of the brake pedal
input signal from both the BPP and BPS switches when the brake pedal is pressed and
released.
All GO to Pinpoint Test FD .
P1582 - Electronic Throttle Monitor Data Available
Description: Indicates the actuation of restraint deployment, and the availability of electronic throttle
monitor data.
Possible
Causes:

Diagnostic
Aids:
This DTC indicates the actuation of the restraint deployment system. Do not install a new
powertrain control module (PCM), because there is no concern indicated.
P1633 - Keep Alive Power (KAPWR) Voltage Too Low
Description: Indicates the KAPWR circuit has experienced a voltage interrupt.
Possible
Causes:
Open KAPWR circuit
Intermittent KAPWR
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Diagnostic
Aids:
Loss of KAPWR to the powertrain control module (PCM) results in immediate malfunction
indicator lamp (MIL) illumination and DTC P1633.
All GO to Pinpoint Test QB .
P1635 - Tire/Axle Ratio Out of Acceptable Range
Description: This DTC indicates the tire and axle information contained in the vehicle ID block (VID)
does not match the vehicle hardware.
Possible
Causes:
Incorrect tire size
Incorrect axle ratio
Incorrect VID configuration parameters
Diagnostic
Aids:
Using the scan tool, view the tire and axle parameters within the VID. They must match
the vehicle hardware.
P1636 - Inductive Signature Chip Communication Error
Description: Indicates the powertrain control module (PCM) has lost communication with the inductive
signature chip.
Possible
Causes:
Damaged PCM
Diagnostic
Aids:

All DTC P1636 indicates the PCM has lost communication with the inductive signature chip.
Install a new PCM. Refer to Section 2, Flash Electrically Erasable Programmable Read
Only Memory (EEPROM) .
P1639 - Vehicle ID (VID) Block Corrupted, Not Programmed
Description: This DTC indicates the VID block is not programmed or the information within is corrupt.
Possible New powertrain control module (PCM)
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Causes: Incorrect PCM
Incorrect VID configuration
Diagnostic
Aids:
Program the PCM to the most recent calibration available.
All The VID block must programmed. Refer to Section 2, Flash Electrically Erasable
P1640 - Powertrain DTCs Available in Another Module
Description: Vehicles using a secondary engine control module can request that the powertrain control
module (PCM) illuminates the malfunction indicator lamp (MIL) when a failure occurs
which affects emissions.
Possible
Causes:
DTCs stored in a secondary module, which requested the MIL to be turned on
Diagnostic
Aids:

P1641 - Fuel Pump Primary Circuit
For Vehicles Equipped With a FPDM
Description: See the description for DTC P1235/P1236.
Possible Causes: See the possible causes for DTC P1235/P1236.
Diagnostic Aids: See the diagnostic aids for DTC P1235/P1236.
For All Others
Vehicles Equipped With a FPDM GO to Pinpoint Test KB .
All others GO to Pinpoint Test KA .
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P1650 - Power Steering Pressure (PSP) Switch Out of Self-Test Range
Description: In the key on engine off (KOEO) self-test, this DTC indicates the PSP input to the
powertrain control module (PCM) is high. In the key on engine running (KOER) self-test,
this DTC indicates the PSP input did not change state.
Possible
Causes:
The steering wheel must be turned during KOER self-test
PSP switch/shorting bar damaged
PSP circuit open or shorted to SIGRTN
Diagnostic
Aids:
Check if the vehicle was towed or a power steering repair was carried out.
Observe the PSP V PID while checking the wires for intermittent concerns.
All GO to Pinpoint Test FF . GO to Pinpoint Test FF .
P1651 - Power Steering Pressure (PSP) Switch Input
Description: The powertrain control module (PCM) counts the number of vehicle speed transitions from
0 to a calibrated speed. After a calibrated number of speed transitions, the PCM expects
the PSP input to change. This DTC is set if the transition is not detected.
Possible
Causes:
Vehicle towed with the engine running
The power steering hydraulic concern was repaired but the DTC was not erased
PSP switch/shorting bar damaged
PSP circuit open or shorted to SIGRTN
Diagnostic
Aids:
Check if the vehicle was towed or a power steering repair was carried out.
Observe the PSP V PID while checking the wires for intermittent concerns.
All GO to Pinpoint Test FF .
P1674 - Control Module Software Corrupted
combination with P2105.
Possible Software incompatibility issue
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Causes: Damaged PCM
Diagnostic
Aids:
P1703 - Brake Switch Out of Self-Test Range
Description: Indicates that during the key on engine off (KOEO) self-test, the brake pedal position
(BPP) signal was high, or during the key on engine running (KOER) self-test, the BPP
signal did not cycle high and low.
Possible Causes: Open or short in the BPP circuit
Open or short in the stoplamp circuits
Concern in module(s) connected to the BPP circuit
Damaged brake switch
Misadjusted brake switch
Diagnostic Aids: Check for correct function of the stoplamps. Using the scan tool, check the BPP PID.
The stoplamps and PID should toggle on and off with brake pedal activation.
Freestar/Monterey,

Town Car
Verify the brake pedal was applied and released during the KOER self-test. For
additional concerns, refer to the Workshop Manual Section 417-01, Exterior
Lighting.
Expedition,
Navigator
Verify the brake pedal was applied and released during the KOER self-test. For
additional concerns, refer to the Workshop Manual Section 206-09, Anti-Lock
Control.
All others GO to Pinpoint Test FD .
P1705 - Transmission Range Sensor Out of Self-Test Range
Description: The transmission range circuit is not indicating PARK/NEUTRAL during self-test.
Possible Causes: Gear selector not in PARK/NEUTRAL
Diagnostic Aids: Verify the gear selector is in PARK/NEUTRAL.
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P1709 - Park/Neutral Position (PNP) Switch Out of Self-Test Range
Description: This DTC indicates that the voltage is high when it should be low.
Possible
Causes:
PNP/CPP circuit short to PWR
Damaged PNP or CPP switch
PNP/CPP circuit open in the SIGRTN
Diagnostic Aids: When activating either the PNP or CPP switch, the voltage should cycle from 5 volts to
low.
P1729 - 4x4L Switch
Description: The 4x4L switch is an on/off switch. If the powertrain control module (PCM) does not
sense appropriate voltage when the switch is cycled on and off, a DTC sets for mechanical
shift on the fly systems.
Possible
Causes:
The 4x4L harness between the PCM and the 4x4L switch is open or shorted
Damaged 4x4L switch
Diagnostic
Aids:
Verify the 4x4L switch cycles on/off.
All Refer to the Workshop Manual Section 308-07A, Four-Wheel Drive Systems.
P1780 - Transmission Control Switch (TCS) Out of Self-Test Range
Description: During key on engine running (KOER) self-test the TCS must be cycled, or a DTC is
set.
Possible
Causes:
TCS not cycled during the self-test.
TCS circuit short or open
Damaged TCS switch
Diagnostic Aids: Verify the TCS switch cycles on/off.
All GO to Pinpoint Test TB .
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P1781 - 4x4L Switch Out of Self-Test Range
Description: The 4x4L switch is an on/off switch. If the powertrain control module (PCM) does not
sense low voltage when the switch is on, the DTC sets.
Possible
Causes:
4x4L harness open or shorted
Damaged electronic shift module
Diagnostic
Aids:
Verify the 4x4L switch cycles on/off.
P17xx -
Description:
Possible Causes:
Diagnostic Aids:
P18xx -
Description:
Possible Causes:
Diagnostic Aids:
P1900 - Output Shaft Speed (OSS) Sensor Circuit Intermittent
Description: The OSS sensor signal to the powertrain control module (PCM) is irregular or
interrupted.
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Possible Causes: Harness connector not properly seated
OSS sensor damaged, or not installed properly
Verify proper installation of the OSS sensor.
Manual
transmission
P1901 - Turbine Shaft Speed (TSS) Sensor Circuit Intermittent
Description: The TSS sensor signal to the powertrain control module (PCM) is irregular or
interrupted.
Possible
Causes:
Harness connector not properly seated
TSS sensor damaged or not installed properly
Verify proper installation of the TSS sensor.
Description: This DTC is set when the IMRC is commanded closed, but the IMRC monitor indicates
open. This DTC replaces P1518 and P1537.
Possible
Causes:
Damaged IMRC actuator or solenoid
Diagnostic
Aids:
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Description: This DTC is set when the IMRC is commanded closed, but the IMRC monitor indicates
open. This DTC replaces P1538.
Possible
Causes:
Damaged PCM
Diagnostic
Aids:
An IMRCM PID reading near approximately 1 volt at closed throttle may indicate a fault.
Description: This DTC is set when the IMRC is commanded open, but the IMRC monitor indicates
closed. This DTC replaces P1512 and P1519.
Possible
Causes:
Diagnostic
Aids:
Description: This DTC is set when the IMRC is commanded open, but the IMRC monitor indicates
closed. This DTC replaces P1513.
Possible
Causes:
Diagnostic Monitor the IMRC and IMRCM PIDs. The IMRCM state should change when the IMRC is
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Aids: commanded open or closed.
P2008 - Intake Manifold Runner Control (IMRC) Circuit Open (Bank 1)
Description: This DTC indicates a failure in the IMRC primary control circuit. This DTC replaces
P1520.
Possible
Causes:
Diagnostic
Aids:
P2014 - Intake Manifold Runner Position Sensor/Switch Circuit (Bank 1)
Description: The intake manifold runner control (IMRC) system is monitored for failure during continuous
or key on engine off (KOEO) self-test. Each DTC distinguishes the corresponding failed
bank for IMRC actuator assemblies with dual monitor switches. The test fails when the
signal on the monitor pin is outside an expected calibrated range. This DTC replaces
P1516.
Possible
Causes:
Mechanical concern - bind, seize, damage or obstruction of IMRC hardware
Diagnostic
Aids:
P2015 - Intake Manifold Runner Position Sensor/Switch Circuit Range/Performance (Bank 1)
Description: The intake manifold runner control (IMRC) system is monitored for failures. Each DTC
distinguishes the corresponding failed bank. The test fails when the system detects the
presence of a broken or persistently out of range linkage.
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Possible
Causes:
Diagnostic
Aids:

P2019 - Intake Manifold Runner Position Sensor/Switch Circuit (Bank 2)
Description: The intake manifold runner control (IMRC) system is monitored for failure during continuous
or key on engine off (KOEO) self-test. Each DTC distinguishes the corresponding failed
bank for IMRC actuator assemblies with dual monitor switches. The test fails when the
signal on the monitor pin is outside an expected calibrated range. This DTC replaces
P1517.
Possible
Causes:
Mechanical concern - bind, seize, damage or obstruction of IMRC hardware
Diagnostic
Aids:
P2020 - Intake Manifold Runner Position Sensor/Switch Circuit Range/Performance
(Bank 2)
Diagnostic Aids:
P2065 - Fuel Level Sensor B Circuit
Description: Fuel level information is sent to the powertrain control module (PCM) on the
communication link.
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Possible
Causes:
Communication link concern
Damaged smart junction box (SJB)
Damaged PCM
Diagnostic
Aids:
Refer to the Workshop Manual Section 413-01, Instrument Cluster for fuel level
P2066 - Fuel Level Sensor B Circuit Range/Performance
Possible
Causes:
Diagnostic
Aids:
P2067 - Fuel Level Sensor B Circuit Low
Possible
Causes:
Diagnostic
Aids:
P2068 - Fuel Level Sensor B Circuit High
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Possible
Causes:
Diagnostic
Aids:
P2070 - Intake Manifold Tuning Valve (IMTV) Stuck Open Bank 1
Possible
Causes:
IMTV signal circuit shorted to PWR GND or SIG RTN
Diagnostic
Aids:
P2071 - Intake Manifold Tuning Valve (IMTV) Stuck Closed Bank 1
Possible
Causes:
IMTV signal circuit shorted to PWR GND or SIG RTN
IMTV circuit open
Diagnostic
Aids:
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P2072 - Throttle Actuator Control (TAC) System - Ice Breakage
Description: This DTC only identifies that the strategy has carried out several open and close cycles to
remove potential ice build up. This DTC does not imply any system concerns, only that the
mode has occurred, and that mode may be causing a long start time.
Possible
Causes:
Ice or oil in the intake air system could be the result of a positive crankcase
ventilation (PCV) system concern
Diagnostic
Aids:
Check the PCV system for evidence of water or ice. Disconnect the intake air fresh air
plenum from the throttle body. Check for water or oily residue at the PCV fresh air port.
Disconnect the tube at the valve cover and check the tube for ice obstruction/ice. Start the
engine and, to check the PCV system, place a piece of cardboard on the crankcase vent in
the rocker cover. If the cardboard is held on the crankcase vent and fumes are not exiting,
reconnect the tube to the valve cover and the intake air port. If the test passes, the PCV
system is OK. If the cardboard is not held in place, turn off the engine and check the PCV
valve side of the system for ice or obstruction and repair as necessary. If no obstruction is
found there, isolate and repair any obstruction in the intake manifold connection. If no
obstruction is found there, make sure the PCV coolant heater is functional and repair as
necessary. If no concern is present, make sure the PCV valve is allowing the proper
vacuum flow and repair as necessary.
P2100 - Throttle Actuator Control (TAC) Motor Circuit/Open
Description: A powertrain control module (PCM) fault flag is set indicating the motor circuit is open.
May require cycling the key.
Possible
Causes:
TAC motor has an open winding
TAC motor is damaged
TAC motor harness is open
TAC motor harness is short to PWR
TAC motor harness circuits are short together
TAC motor harness connector is unplugged
Diagnostic
Aids:
A TAC motor circuit PID reading may indicate a concern, if available.
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P2101 - Throttle Actuator Control (TAC) Motor Range/Performance
Description: A powertrain control module (PCM) fault flag is set indicating the motor circuit is open,
and may require cycling the key.
Possible
Causes:
TAC motor circuits are cross-wired
Diagnostic
Aids:
P2104 - Throttle Actuator Control (TAC) System - Forced Idle
Description: The TAC system is in the failure mode effects management (FMEM) mode of forced idle.
Possible
Causes:

Diagnostic
Aids:
This DTC is an informational DTC and may be set in combination with a number of other
DTCs which are causing the FMEM. Diagnose other DTCs first.
P2105 - Throttle Actuator Control (TAC) System - Forced Engine Shutdown
Description: The TAC system is in the failure mode effects management (FMEM) mode of forced
engine shutdown.
Possible
Causes:

Diagnostic
Aids:
P2106 - Throttle Actuator Control (TAC) System - Forced Limited Power
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limited power. This DTC indicates the FMEM action is in effect due to a concern in an
electronic throttle control (ETC) related component or module.
Possible
Causes:

Diagnostic
Aids:
DTCs which are causing the FMEM. Diagnose other DTCs first. Do not install a new
electronic throttle body (ETB) for this DTC.
P2107 - Throttle Actuator Control (TAC) Module Processor
Description: The electronic throttle control (ETC) area of the powertrain control module (PCM) failed the
self-test. The concern could be the result of an incorrect throttle position (TP) command, or
TAC motor wires shorted together.
Possible
Causes:
TAC motor wire shorted together
TAC motor circuit wires short to PWR
Damaged PCM
Diagnostic
Aids:
P2110 - Throttle Actuator Control (TAC) System - Forced Limited RPM
limited RPM.
Possible
Causes:

Diagnostic
Aids:
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P2111 - Throttle Actuator Control (TAC) System - Stuck Open
Description: This powertrain control module (PCM) fault status indicates the throttle plate is at a
greater angle than commanded.
Possible
Causes:
Binding throttle body, stuck open
TAC motor circuits are cross-wired
TAC motor harness circuits are shorted together
Damaged PCM
Diagnostic
Aids:

P2112 - Throttle Actuator Control (TAC) System - Stuck Closed
Description: This powertrain control module (PCM) fault status indicates the throttle plate is at a lower
angle than commanded.
Possible
Causes:
Binding throttle body, stuck closed
Damaged PCM
Diagnostic
Aids:

P2121 - Throttle/Pedal Position Sensor/Switch D Circuit Range/Performance
Description: The accelerator pedal position (APP) sensor fault flag is set for sensor 1 by the powertrain
control module (PCM), indicating the signal is out of the normal self-test operating range.
Possible
Causes:
APP sensor 1 is open, or short to ground or voltage
APP sensor signal circuits are short together
Damaged APP sensor
Damaged PCM
Diagnostic
Aids:
An APP1 sensor PID reading may indicate a concern.
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All GO to Pinpoint Test DK .
P2122 - Throttle/Pedal Position Sensor/Switch D Circuit Low
Description: The accelerator pedal position (APP) sensor 1 is out of self-test range low.
Possible Causes: APP sensor harness short to ground
Damaged APP sensor
Diagnostic Aids: An APP1 sensor PID reading may indicate a concern.
P2123 - Throttle/Pedal Position Sensor/Switch D Circuit High
Description: The accelerator pedal position (APP) sensor 1 is out of self-test range high.
Possible Causes: APP sensor harness open
APP sensor harness is short to VREF
Damaged APP sensor
P2126 - Throttle/Pedal Position Sensor/Switch E Circuit Range/Performance
Possible
Causes:
APP sensor assembly is binding
Damaged APP sensor
Damaged PCM
Diagnostic
Aids:
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P2127 - Throttle/Pedal Position Sensor/Switch E Circuit Low
Possible Causes: APP sensor circuit is short to ground
APP sensor circuit is open
Damaged APP sensor
P2128 - Throttle/Pedal Position Sensor/Switch E Circuit High
Possible Causes: APP sensor assembly is binding
APP sensor harness is short to voltage
Damaged APP sensor
P2131 - Throttle/Pedal Position Sensor/Switch F Circuit Range/Performance
Possible
Causes:
APP sensor assembly is binding
Damaged APP sensor
Damaged PCM
Diagnostic
Aids:
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P2132 - Throttle/Pedal Position Sensor/Switch F Circuit Low
APP sensor harness short to ground
Damaged APP sensor
P2133 - Throttle/Pedal Position Sensor/Switch F Circuit High
APP sensor harness is short to voltage
Damaged APP sensor
P2135 - Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation
Description: The powertrain control module (PCM) flagged a concern indicating that throttle position
(TP) 1 and TP2 disagree by more than a calibrated limit.
Possible
Causes:
TP sensor shorted internally to VREF
TP sensor signal wires are short together
Damaged TP sensor
Diagnostic
Aids:
Compare the TP1 and TP2 PID values for a full sweep and correlation. Refer to the chart
in pinpoint test DV. GO to Pinpoint Test DV .
Check the wiring harness for an open or a short circuit. Check the TP sensor for an
internal open or short circuit. If no circuit concerns are present, install a new TP sensor.
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P2195 - O2 Sensor Signal Biased/Stuck Lean - Bank 1, Sensor 1
Description: A heated oxygen sensor (HO2S) indicating lean at the end of a test is trying to correct for
an over-rich condition. The test fails when the fuel control system no longer detects
switching for a calibrated amount of time.
Possible
Causes:
Electrical:
Water in the harness connector
Open/shorted HO2S circuit
Corrosion or incorrect harness connections
Damaged HO2S
Fuel System:
Excessive fuel pressure
Leaking/contaminated fuel injectors
Leaking fuel pressure regulator
Low fuel pressure or running out of fuel
Vapor recovery system
Intake Air System:
Air leaks after the mass air flow (MAF) sensor
Vacuum leaks
Positive crankcase ventilation (PCV) system
Improperly seated engine oil dipstick
EGR System:
Leaking gasket
Stuck EGR valve
Leaking diaphragm or EGR vacuum regulator
Base Engine:
Oil overfill
Camshaft timing
Cylinder compression
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Exhaust leaks before or near the HO2S(s)
Diagnostic
Aids:

All GO to Pinpoint Test H . GO to Pinpoint Test H .
P2196 - O2 Sensor Signal Biased/Stuck Rich - Bank 1, Sensor 1
Description: A heated oxygen sensor (HO2S) indicating rich at the end of a test is trying to correct for
an over-lean condition. The test fails when the fuel control system no longer detects
switching for a calibrated amount of time.
Possible
Causes:
Diagnostic
Aids:

P2197 - O2 Sensor Signal Biased/Stuck Lean - Bank 2, Sensor 1
Diagnostic Aids:
P2198 - O2 Sensor Signal Biased/Stuck Rich - Bank 2, Sensor 1
Diagnostic Aids:
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P2257 - Secondary Air Injection (AIR) System Control A Circuit Low
Description: The AIR system monitor circuit is low, indicating the secondary AIR pump is off although
the secondary AIR pump was commanded on by the powertrain control module (PCM).
Possible
Causes:
Open B+ circuit
Open VPWR circuit
Open voltage circuit between the AIR relay and the secondary AIR pump
Damaged AIR relay
Diagnostic
Aids:
The AIR monitor circuit PCM input contains a pull up voltage through a resistance internal
to the PCM. This voltage is normally held low by the resistance path through the
secondary AIR pump when the secondary AIR pump is off.
A single electrical open circuit component such as an AIR relay coil in this multi-
component circuit is not detected by the PCM output driver, yet it sets DTC P2257.
P2258 - Secondary Air Injection (AIR) System Control A Circuit High
Description: The AIR system monitor circuit is high, indicating the secondary AIR pump is on although
the secondary AIR pump was commanded off by the powertrain control module (PCM).
Possible
Causes:
AIR relay fault - stuck closed
Secondary AIR pump fault - circuit open in motor
Open ground to secondary AIR pump
Open AIR monitor circuit between the secondary AIR pump and the PCM
Short to voltage in the AIR relay to secondary AIR pump voltage circuit
Diagnostic
Aids:
The AIR monitor circuit PCM input contains a pull up voltage through a resistance internal
to the PCM. This voltage is normally held low by the resistance path through the
secondary AIR pump when the secondary AIR pump is off.
P2270 - O2 Sensor Signal Stuck Lean - Bank 1, Sensor 2
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Description: The downstream heated oxygen sensor (HO2S) is forced rich and lean and monitored by
the powertrain control module (PCM). The test fails if the PCM does not detect the output
of the HO2S in a calibrated amount of time.
Possible
Causes:
Pinched, shorted, and corroded wiring and pins
Crossed HO2S wires
Exhaust leaks
Contaminated or damaged HO2S
Diagnostic
Aids:

P2271 - O2 Sensor Signal Stuck Rich - Bank 1, Sensor 2
Diagnostic Aids:
Diagnostic Aids:
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Diagnostic Aids:
Diagnostic Aids:
Diagnostic Aids:
P2448 - Secondary Air Injection System High Airflow (Bank 1)
Description: The secondary AIR system detects excessive mass air flow change with the pump ON
and a rich exhaust system air fuel ratio.
Possible
Causes:
Secondary AIR outlet hose leak.
Secondary AIR outlet hose is disconnected.
Diagnostic
Aids:
Measured air flow is less than expected. Visually inspect the secondary AIR inlet hose.
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P260F - Evaporative System Monitoring Processor Performance
Description: This DTC sets when a concern is detected internal to the powertrain control module
(PCM). The microprocessor that controls the engine off natural vacuum (EONV) leak check
monitor is separate from the main processor within the PCM.
Possible
Causes:
Module communications network concerns
PCM calibration level
Damaged PCM
Diagnostic
Aids:
Verify the PCM is at the latest calibration level. Reprogram if necessary.
Pxxxx -
Description:
Possible
Causes:

Diagnostic
Aids:

All For Pxxxx DTCs not listed in this chart, refer to the customer's symptom to determine
the applicable Workshop Manual section for diagnosis.
U0101 - Lost Communication With Transaxle Control Module (TCM)
Description: The powertrain control module (PCM) continuously monitors the controller area network
(CAN) for messages from the TCM. This DTC sets when the PCM fails to receive the TCM
message within the defined amount of time.
Possible
Causes:
Damaged CAN communication bus circuit
Diagnostic
Aids:
Network DTC concerns occur during module-to-module communication. For additional
description and operation of the vehicle communication network, refer to the Workshop
Manual Section 418-00, Module Communications Network.
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All
U0121 - Lost Communication With The Anti-lock Brake System (ABS) Control Module
Description: The powertrain control module (PCM) continuously monitors the controller area network
(CAN) for messages from the ABS. This DTC sets when the PCM fails to receive the ABS
message within the defined amount of time.
Possible
Causes:
Damaged CAN communication bus circuit
Diagnostic
Aids:
Network DTC concerns occur during module-to-module communication. For additional
description and operation of the vehicle communication network, refer to the Workshop
Manual Section 418-00, Module Communications Network.
All
U0155 - Lost Communication With Instrument Panel Cluster Control Module
Description: Missing message concerns are logged by a module upon failure to receive a message
from another module within a defined retry period.
Possible
Causes:
Open VPWR circuit to the sending module
Open GND circuit to the sending module
Open network circuits to the sending module
Diagnostic
Aids:
Carry out the diagnostics for the associated network module.
All Refer to the Workshop Manual Section 413-01, Instrument Cluster.
U0300 - Internal Control Module Software Incompatibility
Description: This DTC indicates that there are incompatible software levels within the powertrain control
module (PCM) that control the electronic throttle control (ETC) system. The ETC system
uses 3 different microprocessors within the PCM, each having its own software level and
function. The 3 microprocessors must have the correct level of software in order to
communicate and function together.
Possible
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Causes:
Diagnostic
Aids:
U1039 - SCP (J1850) Invalid or Missing Data for Vehicle Speed
Description:
Possible
Causes:
Network DTC(s) occur during module-to-module communication concerns. Two types of
network concerns can be categorized:
Invalid data network concerns - data is transferred within the normal inter-module
message, but contains known invalid data. The transmitting module logs a DTC
related to the invalid data concern.
Missing message network concerns - missing message concerns are logged by the
module upon failure to receive a message from another module within a defined
retry period.
Diagnostic
Aids:
Carry out the on-board diagnostics for the associated network module. For additional
information concerning the description and operation of the vehicle communication
network, refer to the Workshop Manual Section 418-00, Module Communications Network.
All Refer to the Workshop Manual Section 206-09, Anti-Lock Control.
Uxxxx - Network Communication Diagnostic Trouble Code (DTC)
Description: Powertrain related DTC from another module.
Possible
Causes:

Diagnostic
Aids:

All For U DTC(s) received during self-test of a module other than the powertrain control
module (PCM), refer to Section 3, QT Step 1: Powertrain Control Module QT (PCM)
Quick Test.
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Note: 'x' equals any number 0 through 9 or letter A through F.
Note 1: Reprogram or update the calibration. Check for other DTCs and diagnose those first. Make sure to
check for aftermarket performance products before installing a new PCM. Clear the DTCs, repeat the self-
test. If the DTC is retrieved again, install a new PCM. Refer to Section 2, Flash Electrically Erasable
Note 2: DTC P1000 is ignored in the key on engine off (KOEO) and key on engine running (KOER) self-
tests. Disregard DTC P1000 and continue as directed.

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4.0L Mustang

Typical Diagnostic Reference Values
2007 PCED On Board Diagnostics SECTION 6: Reference Values
Sensors/Inputs
PCM
Pin/PID
only
Measured/PID Values
Units
Measured/PID KOEO Hot Idle
48 KM/H (30
MPH)
89 KM/H (55
MPH)
FTP V/FTP B3 2.6/0 2.6/0 2.6/0 2.6/0 DCV/IN-H20
APP1 B5 4.1 4.1 4.1 4.1 DCV
SMR B7 VBAT (V) 0 0 0 DCV
BPP B8 VBAT/OFF 0.1/ON (E) VBAT/OFF VBAT/OFF DCV/OFF-ON
BPS C9 0.1/OFF VBAT/ON (E) 0.1/OFF 0.1/OFF DCV/OFF-ON
ACCS B15 0.1/OFF VBAT/ON (A) 0.1/OFF 0.1/OFF DCV/OFF-ON
APP2 B17 1.5 1.5 1.5 1.5 DCV
FPM B21 3.5/100 3.5/100 3.5/100 3.5/100 DCV/%
ACP B26 1.2/111 1.2/110 0.90/76 0.90/76 DCV/PSI
APP3 B28 1.0 1.1 1.3 1.5 DCV
TCS (A/T) B29 Not
Depressed
Depressed
(G)
Not
Depressed
Not
Depressed
Depressed/ Not
Depressed
CPP-BT B33 CLOSED CLOSED CLOSED CLOSED OPEN -CLOSED
PSP B34 0.1/LOW VBAT/HIGH
(I)
0.1/LOW 0.1/LOW DCV/HIGH- LOW
PATS IN B42 VBAT VBAT VBAT VBAT DCV
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FEPS B44 0.5-0.6 0.5-0.6 0.5-0.6 0.5-0.6 DCV
GENMN (GFS) E5 0 30-60 21-30 21-30 %
ECT E18 0.4-1/200-
160
0.4-1/200-
160
0.4-1/200-
160
0.4-1/200-
160
DCV/DEG
FRT E19 0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
DCV/DEG
DPFEGR E21 0.25-1.3 0.25-1.3 0.25-4.65 0.25-4.65 DCV
IAT E22 1.7-3.5/120-
50 (K)
1.7-3.5/120-
50 (K)
1.7-3.5/120-
50 (K)
1.7-3.5/120-
50 (K)
DCV/DEG
MAF V (A/T) E25 0 0.8-1.23 0.8-1.6 1.1-2.3 DCV
MAF V (M/T) E25 0 0.6-0.9 0.8-1.6 1.1-2.3 DCV
HO2S11 E28 (L) switching (C) switching (C) switching (C) DCV
HO2S21 E29 0 switching (C) switching (C) switching (C) DCV
FRP V/FRP E32 3.35/53 2.8/48 2.8/39 2.8/39 DCV/PST
CMP E45 0 5-7 9-11 10-15 Hz
CKP E47 0 390-450 650-700 875-1000 Hz
KS E49 32.7 k 241 273 361 DCV
TP2 PS E60 1.2 0.8 1.5 1.3 DCV
TP1 NS E61 4.1 4.3 4.2 4.0 DCV
MAP E62 4/99 (W) 1.0-1.4/30
(W)
1.4-2.1/25
(W)
1.8-2.3/25
(W)
DCV/kPa
OSS T3 0 0 460-500/
1150-1300
960/2400 Hz/RPM
ISS (A/T) T4 0 365-380/
630-720
595/1080 1070/1640-
2060
Hz/RPM
TSS (A/T) T15 0 365-380/
680-720
595/1080 1070/2060 Hz/RPM
TR 1 (A/T) T16 0 0 11.5 11.5 DCV
TR 2 (A/T) T17 0 0 11.5 11.5 DCV
HO2S12 T24 (L) (D) (D) (D) DCV
HO2S22 T25 0.1 (D) (D) (D) DCV
TR 3 (A/T) T27 0/PARK 0/PARK 1.7/OD 1.7/OD DCV/MODE
TR 4 (A/T) T28 0 0 11.5 11.5 DCV
TFT (A/T) T29 0.5-2.1/210- 0.5-2.1/210- 0.5-2/210- 0.5-2/210- DCV/DEG
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110 (K) 110 (K) 110 (K) 110 (K)
CPP/PNP PID NEUTRAL NEUTRAL DRIVE DRIVE NEUTRAL/
DRIVE
FLI PID 50 (H) 50 (H) 50 (H) 50 (H) %
FRT PID 50-120 (K) 50-120 (K) 50-120 (K) 50-120 (K) DEG
GEAR PID 1 1 5 5 GEAR
LOAD PID (L) 10-20 16-36 25-35 %
MISF PID OFF OFF OFF OFF OFF-ON
RPM PID 0 630-730 1000-1300 1500-1700 RPM
VSS PID 0 0 30 55 MPH
Actuators/Outputs
PCM
Pin/PID
only
Measured/PID Values
Units
48 KM/H (30
MPH)
89 KM/H (55
MPH)
PATSTRT/SMR B2 0 0 0 0 DCV
FP B12 3.7/75 1.2/26 1.2/26 1.2/26 DCV/%
CANV B13 VBAT/0 VBAT/0 VBAT/0 (R) VBAT/0 (R) DCV/%
ACCR (WAC) B14 VBAT/OFF 0.1/ON (A) VBAT/OFF VBAT/OFF DCV/OFF-ON
PATS OUT B31 10.5 VBAT (A) VBAT VBAT DCV
GENRC B32 0/0 0-130/0-100
(Q)
0/0 0/0 Hz/%
PCVHC E3 0.1/ON 0.1/ON VBAT/OFF 0.1/ON DCV/OFF-ON
HFC E4 VBAT/OFF 0.1/ON (B) VBAT/OFF VBAT/OFF DCV/OFF-ON
EVMV E6 0 0-10/0-100 0-10/0-100 0-10/0-100 Hz/%
LFC E7 VBAT/OFF 0.1/ON (B) VBAT/OFF VBAT/OFF DCV/OFF-ON
EVAPPDC E8 0 0-10/0-100 0-10/0-100 0-10/0-100 Hz/%
CDB (CYL 3 and 4) E12 VBAT VBAT VBAT VBAT DCV
CDC (CYL 2 and 6) E16 VBAT VBAT VBAT VBAT DCV
CDA (CYL 1 and 5) E17 VBAT VBAT VBAT VBAT DCV
TACM (+) E34 3.7 VBAT VBAT VBAT DCV
INJ2 E35 0 3.8-4.9 5.3-10.1 6.5-12 mS
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INJ4 E36 0 3.8-4.9 5.3-10.1 6.5-12 mS
INJ6 E37 0 3.8-4.9 5.3-10.1 6.5-12 mS
TACM (-) E51 3.7 VBAT VBAT VBAT DCV
INJ1 E52 0 3.8-4.9 5.3-10.1 6.5-12 mS
INJ3 E53 0 3.8-4.9 5.3-10.1 6.5-12 mS
INJ5 E54 0 3.8-4.9 5.3-10.1 6.5-12 mS
EGRVR E63 VBAT/0 VBAT/0 (T) (T) DCV/%
HTR11 E69 0.1/ON
(O)
0.1/ON 0.1/ON 0.1/ON DCV/OFF-ON
HTR21 E70 0.1/ON
(O)
PC1 (A/T) T11 7/8 9/8 9-9.8/12-22 9-10.7/18-22 DCV/PSI
PC2 (A/T) T23 8.6 10.7 10.4 10.5 DCV
PC3 (A/T) T34 5.8 8.1 VBAT VBAT DCV
SSA (SS1) (A/T) T42 0.1/ON 0.1/ON VBAT/OFF VBAT/OFF DCV/OFF-ON
SSB (SS2) (A/T) T43 VBAT/OFF VBAT/OFF VBAT/OFF VBAT/OFF DCV/OFF-ON
SSC (SS3) (A/T) T44 VBAT/OFF VBAT/OFF 0.35/ON 0.1/ON DCV/OFF-ON
SSD (SS4) (A/T) T45 0.1/ON 0.1/ON 0.35/ON 0.1/ON DCV/OFF-ON
TCC (A/T) T46 0.2/100 VBAT/0 11.1-VBAT/
0-45
0.2/95-100 DCV/%
HTR12 T47 0.2/ON
(O)
HTR22 T48 0.2/ON
(O)
LONGFT1 PID (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
LONGFT2 PID (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
MIL PID OFF OFF OFF OFF OFF-ON
SHRTFT1 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SHRTFT2 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SPARKADV PID 0-10 17-23 30-40 31-40 DEG
TCIL PID OFF OFF OFF OFF OFF-ON
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Other
PCM Pin/PID
only
Measured/PID Values
Units
Measured/PID KOEO
Hot
Idle
48 KM/H (30
MPH)
89 KM/H (55
MPH)
VPWR B35/36 VBAT VBAT VBAT VBAT DCV
VREF B40/E57 5 5 5 5 DCV
KAPWR B45 VBAT VBAT VBAT VBAT DCV
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4.6L 3V Mustang

Sensors/Inputs
PCM
Pin/PID
only
Measured/PID Values
Units
48 KM/H (30
MPH)
89 KM/H (55
MPH)
FTP V/FTP B3 2.6/0.5-1.4 2.6/0.5-1.4 2.6/0.5-1.4 2.6/0.5-1.4 DCV/IN-H20
APP1 B5 4.0 4.0 3.7 3.7 DCV
BPP B8 OFF ON (E) OFF OFF OFF-ON
BPS B9 0.1/OFF VBAT/ON
(E)
0.1/OFF 0.1/OFF DCV/OFF-ON
ACCS B15 OFF ON (A) OFF OFF OFF-ON
APP2 B17 1.5 1.5 1.7 1.7 DCV
FPM B21 3.5/100 3.5/100 3.5/100 3.5/100 DCV/%
ACP B26 1.3/80 1.4/75 1.3/80 1.3/80 DCV/PSI
APP3 B28 1.0 1.1 1.3 1.5 DCV
TCS (A/T) B29 0.1/OFF VBAT/ON
(G)
FEPS B44 0.1 0.1 0.1 0.1 DCV
GENMN (GFS) E5 0 20-38 20-37 20-36 %
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FRT E19 0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-110
(K)
DCV/DEG
IAT E22 1.7-3.5/120-
50 (K)
1.7-3.5/120-
50 (K)
1.7-4.1/120-
32 (K)
1.7-4.1/120-
32 (K)
DCV/DEG
MAF V (A/T) E25 0 0.88-0.97 0.8-1.2 1.4-1.9 DCV
MAF V (M/T) E25 0 0.88-0.94 0.8-1.5 1.3-1.9 DCV
EOT E27 0.4-1/200-
160
0.4-1/200-
160
0.4-1/200-
160
0.4-1/200-160 DCV/DEG
HO2S11 E28 (L) switching
(C)
switching (C) switching (C) DCV
HO2S21 E29 0 switching
(C)
switching (C) switching (C) DCV
KS2 E31 0 288 218 292 DCV
FRP V/FRP E32 3.35/56 3/39 2.8/40 2.8/39 DCV/PSI
CHT E41 3.6/199 3.6/199 3.58/201 3.45/208 DCV/DEG
CMP2 E44 0 5-7 10-12 12-16 Hz
CMP1 E45 0 5-7 10-12 12-16 Hz
CKP E47 0 390-450 650-760 980-1020 Hz
KS1 E49 0 235 266 357 DCV
TP2 PS E60 1.2 0.7 0.9 1.2 DCV
TP1 NS E61 4.1 4.3 4.2 4.1 DCV
OSS (A/T) T3 0 0 540-564/
1385-1420
960-1020/
2400-2500
Hz/RPM
OSS (M/T) T3 0 0 540-564/
1275-1420
960-1020/
2200-2500
Hz/RPM
ISS (A/T) T4 0 365-390/
680-720
595/1080 1070/2060 Hz/RPM
TSS (A/T) T15 0 365-390/
680-720
595/1080 1070/2060 Hz/RPM
TR 1 (A/T) T16 0 0 11.5 11.5 DCV
TR 2 (A/T) T17 0 0 11.5 11.5 DCV
HO2S12 T24 (L) (D) (D) (D) DCV
HO2S22 T25 0.1 (D) (D) (D) DCV
TR V/TR (A/T) T27 0/PARK 0/PARK 1.7/OD 1.7/OD DCV/MODE
TR 4 (A/T) T28 0 0 11.5 11.5 DCV
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TFT (A/T) T29 0.5-2/210-
110 (K)
0.5-2/210-
110 (K)
0.5-2/210-
110 (K)
0.5-2/210-110
(K)
DCV/DEG
CPP-BT (M/T) T33 NO YES (J) NO NO YES-NO
CPP/PNP PID NEUTRAL DRIVE DRIVE DRIVE NEUTRAL/
DRIVE
FLI PID 50 (H) 50 (H) 50 (H) 50 (H) %
FRT PID 120-50 (K) 120-50 (K) 120-50 (K) 120-50 (K) DEG
GEAR (A/T) PID 1 1 4 4 GEAR
LOAD PID (L) 10-20 16-30 17-30 %
MISFIRE PID NO NO NO NO YES-NO
RPM PID 0 660-780 1200-1300 1450-1740 RPM
Actuators/Outputs
PCM
Pin/PID
only
Measured/PID Values
Units
48 KM/H (30
MPH)
89 KM/H (55
MPH)
PATSTRT B2 0 0 0 0 DCV
FP B12 3.7/75 1.3/28 1.3/28 1.3/28 DCV/%
ACCR (WAC) B14 0.1/ON VBAT/OFF
(A)
0.1/ON 0.1/ON DCV/OFF-ON
GENRC B32 0/0 0-130/0-100
(Q)
0/0 0/0 Hz/%
EVMV E6 0 0-10/0-100 0-10/0-100 0-10/0-100 Hz/%
CDH (CYL 8) E9 VBAT VBAT VBAT 1.3/28 DCV
CDF (CYL 5) E10 VBAT VBAT VBAT VBAT DCV
CDD (CYL 2) E11 VBAT VBAT VBAT VBAT DCV
CDB (CYL 3) E12 VBAT VBAT VBAT VBAT DCV
CDG (CYL 4) E14 VBAT VBAT VBAT VBAT DCV
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CDE (CYL 6) E15 VBAT VBAT VBAT VBAT DCV
CDC (CYL 7) E16 VBAT VBAT VBAT VBAT DCV
CDA (CYL 1) E17 VBAT VBAT VBAT VBAT DCV
INJ2 E35 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ4 E36 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ6 E37 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ8 E38 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
IMRC E50 5/2.5 5/2.5 5/2.5 5/2.5 DCV
INJ1 E52 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ3 E53 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ5 E54 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ7 E55 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
VCT1 E67 VBAT VBAT 8.5-VBAT 8.5-VBAT DCV
VCT2 E68 VBAT VBAT 8.5-VBAT 8.5-VBAT DCV
HTR11 E69 0.1/ON
(O)
HTR21 E70 0.1/ON
(O)
PC1 (A/T) T11 7.6/20 9-9.5/15-20 9-9.8/40 9-9.8/40 DCV/PSI
PC2 (A/T) T23 8.6 10.7 10.4 10.5 DCV
PC3 (A/T) T34 5.8 8.1 VBAT VBAT DCV
SSA (SS1) (A/T) T42 0.1/ON 0.1/ON VBAT/OFF VBAT/OFF DCV/OFF-ON
SSB (SS2) (A/T) T43 VBAT/OFF VBAT/OFF VBAT/OFF VBAT/OFF DCV/OFF-ON
SSC (SS3) (A/T) T44 VBAT/OFF VBAT/OFF 0.35/ON 0.1/ON DCV/OFF-ON
SSD (SS4) (A/T) T45 0.1/ON 0.1/ON 0.35/ON 0.1/ON DCV/OFF-ON
TCC (A/T) T46 0.1/100 VBAT/0 VBAT/0 0.2/95-100 DCV/%
HTR12 T47 0.2/ON
(O)
HTR22 T48 0.2/ON
(O)
LONGFT1 PID (L) (L) (-)20-(+)20 (-)20-(+)20 %
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LONGFT2 PID (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
SHRTFT1 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SHRTFT2 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SPARKADV PID -10-0 15-20 29-38 34-41 DEG
TCIL PID OFF OFF OFF OFF OFF-ON
Other
PCM Pin/PID
only
Measured/PID Values
Units
Measured/PID KOEO
Hot
Idle
48 KM/H (30
MPH)
89 KM/H (55
MPH)
VREF B40/E57 5 5 5 5 DCV
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5.4L 4V Mustang

Sensors/Inputs
PCM
Pin/PID
only
Measured/PID Values
Units
48 KM/H (30
MPH)
89 KM/H (55
MPH)
FTP V/FTP B3 2.6/0.5-1.4 2.6/0.5-1.4 2.6/0.5-1.4 2.6/0.5-1.4 DCV/IN-H20
APP1 B5 4.0 4.0 3.8 3.6 DCV
BPP B8 OFF ON (E) OFF OFF ON-OFF
BPS B9 0.1/OFF VBAT/ON
(E)
APP2 B17 1.5 1.5 1.7 1.7 DCV
ACP B26 1.3/80 1.4/75 1.3/80 1.3/80 DCV/PSI
APP3 B28 1.0 1.1 1.3 1.5 DCV
CPP-BT B33 OFF OFF ON ON ON-OFF
FEPS B44 0.1 0.1 0.1 0.1 DCV
GENMN (GFS) E5 0 20-38 20-37 20-36 %
ACCS E15 OFF ON (A) OFF OFF OFF-ON
ECT E18 0.5-
2.7/220-110
0.5-2.7/220-
110
0.5-2.7/210-
110
0.5-2.7/210-
110
DCV/DEG F
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FRT E19 0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
0.5-3/210-
110 (K)
DCV/DEG
DPFE E21 0.25-1.3 0.25-1.3 0.25-4.65 0.25-4.65 DCV/DEG
IAT E22 1.7-
3.5/170-50
(K)
1.7-3.5/145-
50 (K)
1.7-4.1/120-
32 (K)
1.7-4.1/120-
32 (K)
DCV/DEG
MAF V E25 0 0.42-0.50 1.01-1.2 .81-1.9 DCV
IAT2 E27 1.7-
3.5/120-50
(K)
1.7-3.5/120-
50 (K)
1.7-4.1/120-
32 (K)
1.7-4.1/120-
32 (K)
DCV/DEG
HO2S11 E28 (L) switching (C) switching (C) switching (C) DCV
HO2S21 E29 0 switching (C) switching (C) switching (C) DCV
FRP V/FRP E32 2.6/36 3/44 3/44 3/44 DCV/PSI
CHT E41 3.6/199 3.6/199 3.58/201 3.45/208 DCV/DEG
CMP E45 0 5-7 10-12 12-16 Hz
CKP E47 0 390-450 650-760 980-1020 Hz
TP2 PS E60 1.3 0.80 0.90-1.10 1.10-1.49 DCV
TP1 NS E61 4.1 4.3 4.2 4.1 DCV
MAP E62 4/99 (W) 1-1.4/30 (W) 1.8-2.1/25
(W)
1.9-2.3/25
(W)
DCV/kPa
EGRVR E63 VBAT/0 VBAT/0 (T) (T) DCV/%
OSS T3 0 0 540-564/
1275-1420
960-1020/
2200-2500
Hz/RPM
HO2S12 T24 (L) (D) (D) (D) DCV
HO2S22 T25 0.1 (D) (D) (D) DCV
CPP/PNP PID OFF OFF ON ON ON/OFF
FLI PID 50 (H) 50 (H) 50 (H) 50 (H) %
FRT PID 120-50 (K) 120-50 (K) 120-50 (K) 120-50 (K) DEG
GEAR PID 0 0 4 6 GEAR
LOAD PID (L) 10-20 19-60 31-50 %
MISFIRE PID OFF OFF OFF OFF ON-OFF
RPM PID 0 660-780 1200-1300 1450-1740 RPM
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Actuators/Outputs
PCM
Pin/PID
only
Measured/PID Values
Units
48 KM/H (30
MPH)
89 KM/H (55
MPH)
PATSTRT B2 0 0 0 0 DCV
FP B12 3.7/75 1.3/21 1.3/19 1.3/21 DCV/%
ACCR (WAC) B14 0.1/ON VBAT/OFF
(A)
0.1/ON 0.1/ON DCV/OFF-ON
FPM1 B21 50 50 50 50 %
GENRC B32 0/0 0-130/0-100
(Q)
0/0 0/0 Hz/%
EVMV E6 0 0-10/0-100 0-10/0-100 0-10/0-100 Hz/%
CDH (CYL 8) E9 VBAT VBAT VBAT 1.3/28 DCV
CDF (CYL 5) E10 VBAT VBAT VBAT VBAT DCV
CDD (CYL 2) E11 VBAT VBAT VBAT VBAT DCV
CDB (CYL 3) E12 VBAT VBAT VBAT VBAT DCV
CDG (CYL 4) E14 VBAT VBAT VBAT VBAT DCV
CDE (CYL 6) E15 VBAT VBAT VBAT VBAT DCV
CDC (CYL 7) E16 VBAT VBAT VBAT VBAT DCV
CDA (CYL 1) E17 VBAT VBAT VBAT VBAT DCV
INJ2 E35 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ4 E36 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ6 E37 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ8 E38 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ1 E52 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ3 E53 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
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INJ5 E54 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
INJ7 E55 0 3.5-3.7 3.8-5.5 4.9-9.6 mS
PCVHC E67 0.1/ON 0.1/ON VBAT/OFF 0.1/ON DCV/OFF-ON
HTR11 E69 0.1/ON
(O)
HTR21 E70 0.1/ON
(O)
FPM2 T18 50 50 50 50 %
HTR12 T47 0.2/ON
(O)
HTR22 T48 0.2/ON
(O)
LONGFT1 PID (L) (L) (-)20-(+)20 (-)20-(+)20 %
LONGFT2 PID (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
SHRTFT1 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SHRTFT2 PID (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SPARKADV PID 10 15-20 29-39 34-41 DEG
Other
PCM Pin/PID
only
Measured/PID Values
Units
Measured/PID KOEO
Hot
Idle
48 KM/H (30
MPH)
89 KM/H (55
MPH)
VREF B40/E57 5 5 5 5 DCV
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Notes:
Footnotes are referenced throughout the Typical Diagnostic Reference Value Charts. A letter in parentheses
next to a value indicates supplemental information is applicable.
An attempt is made to provide as much information as possible; some vehicles may not display all input and
output signals.
The Typical Diagnostic Reference Value Charts do not display fault parameter identifications (PIDs). These
are PIDs which indicate a hard fault with the circuit. They display a value of YES or NO and are PIDs ending
with the letter F.
Reference values may vary +/-20% depending on operating conditions, altitude, and other factors. RPM
values are axle and tire dependent.
Values are taken at an altitude of approximately 600 ft above sea level.
Refer to the Introduction Section, Acronyms and Definitions for technical terms applicable to Ford Motor
Company products.
Refer to Section 2, Parameter Identification (PID) , for PID descriptions.
For detailed transmission diagnostics, refer to the Workshop Manual. Transmission signals may be referred
to in either alpha or numeric form. For example, 1=A, 2=B, 3=C.
A. A/C on.
B. Cooling fan on (single, low or high speed).
C. Heated oxygen sensors (HO2S) should switch from rich to lean at least once every 3 seconds. HO2S
voltage should toggle above and below 0.450 DCV and never be a negative value. Valid HO2S
switching occurs only during closed loop fuel control operation.
D. Downstream HO2S(s) stay close to a constant voltage when the catalyst monitor is off (positive value
only). When the catalyst monitor is on, the HO2S switches rich to lean above and below 0.450 DCV
and never be a negative value. For downstream HO2S(s) (12, 13, 22) greater activity results when
the catalyst monitor is active.
E. Brake pedal applied.
F. The electric vapor management valve (VMV) commanded current varies from 0 mA - 1000 mA
depending on the PCM command to purge the EVAP system.
G. While pressing the transmission control switch (TCS) or switching to manual drive mode.
H. Value is dependent on fuel tank level. Typical operating range is 15% (empty) to 90% (full).
I. Steering wheel turned.
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J. Clutch pedal applied.
K. Value is dependent upon ambient air temperature and may fall outside of range.
L. Value is not useful under this condition.
M. If equipped.
N. Transmission in selected range.
O. May change state under this condition.
P. While pressing switch.
Q. Frequency cycles high within a few seconds of turning headlamps on. Frequency cycles back to 0 Hz
shortly after cycling high.
R. Canister vent duty cycles to 100% (close) when EVAP monitor test is running.
S. Refer to Workshop Manual Section 419-01.
T. EGR voltage and duty cycle will vary from 0-VBAT or 0-100% depending on EGR demand.
U. RPM dependent. If signal is 0 Hz at idle, check signal at 900 RPM.
V. Crank position.
W. Value may vary +/-20% depending on altitude, operating conditions, weather, and other factors.

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Reference Value Parameter Identification (PID)/Measured Signal
Chart
The following listing reflects PIDS and/or measured values which may reveal a possible concern within each
system shown. Match the category number with the related PID/measured signal and go to the Typical
Diagnostic Reference Value Charts.

PID/Measured Signal Chart
Category Number Related PIDS/Measured Signals
5-9-10-17 ACCR (WAC)
5-9-10-17 ACCS
5-10-17 ACP
5-10-17 ACP V
5-21 AIR
5-21 AIRF
5-21 AIRM
1-23 APP1
1-23 APP2
1-23 APP3
23 BPP (BOO)
18-19 CHT
18-19 CHT V
1-2-3-5-6-7-11-12-13-14-15-16-17-20-21 CMP
1-2-3-5-6-7-11-12-13-14-15-16-17-20-21 CKP
1-2-3-5-6-7-11-12-13-14-15-16-17-20-21 CMP1/2
10 CPP/PNP
3-5-6-7-9-11-15-16-20-21 DPFEGR
4-18-19-21-22
ECT
a
4-18-19-21-22 ECT V
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3-5-6-7-9-11-15-16-20-21 EGRMC1-4
3-5-6-7-9-11-15-16-20-21 EGRMDSD
3-5-6-7-9-11-15-16-20-21 EGRVR
5-18-19-20-21 EOT
5-18-19-20-21 EOT V
22 EPC/EPC1/EPC2/EPC3
22 EPC V
3-5-6-11-21 EVAPC V
3-5-6-11-21 EVAPPDC
3-5-6-11-21 EVMV
19 FCV 3
20 FLI (H)
20 FLI V
1 thru 21 FP
1 thru 21 FPM or FP M
1 thru 21 FRP
1 thru 21 FRP V
1 thru 21 FRT
5 FTP
5 FTP V
1 thru 21 FUELPW1/2
1 thru 21
FUELSYS (OL/CLSD-LP)
a
22-23 GEAR
5 GENFDC/GENRC
5 GFS/GENLI
19 HFC (FC3)
1 thru 21 HTR11/12/13/21/22
1 thru 21 IAC
2-3-5-7-8-10-22
IAT
a
2-3-5-7-8-10-22
IAT2
a
2-3-5-7-8-10-22
IAT V
a
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2-3-5-7-8-10-22
IAT2 V
a
5-14-15-16-17-20 IMRC
5-14-15-16-17-20 IMRCM
5-14-15-16-17-20 IMTV
6-11-12-14 thru 18-20-21 INJ x F
4-5-16-18-19-20-21
KS1
a
4-5-16-18-19-20-21
KS2
a
19 LFC (FCI)
1 thru 21
LONGFT1/2
a
1 thru 23
MAF
a
1 thru 23 MAF V
1 thru 23 MAP V
1 thru 22 MISF
1 thru 21 HO2S11/12/13/21/22
15-18-20-21 OCTADJ
22 OSS
10 PSP
10 PSPT
10 PSP V
5 PTO
1 thru 23
RPM
a
5-14-16-17 SCBC
5-14-16-17 SCIPC
1 thru 21 SHRTFT1/2/11/12/21/22
15-16-18-19-20-21
SPRKADV
a
22-23 SS1(SSA)/SS2(SSB)/SS3(SSC)/SS4(SSD)
1-23 TACM (-)
1-23 TACM (+)
6-14-16-20 TCC
22 TCIL
22-23 TCS
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a
Generic PID

Some signals can only be measured and require the use of a digital multimeter (DMM).

22-23 TFT
22-23 TFT V
1-23 TP
1-23 TP1 NS
1-23 TP2 PS
1-23 TP V
22-23 TR
22-23 TR 1-4
22-23 TR V
22-23 TR D
22-23 TSS
2-4-5-9-10-11-16-17-18-19-20-21 VCT
2-4-5-9-10-11-16-17-18-19-20-21 VCT1/2
1-2-3-5-6-11-12-13-14 VPWR
22-23 VSS
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Reference Value Symptom Chart
The Reference Value Symptom Chart provides guidance in selecting the appropriate parameter
identification (PID) or measured signal related to the fault area. Select a symptom from the symptom chart
along with the category number and go to the PID/Measured Signal Chart. For multiple symptoms, select the
symptom that is the most evident.
Symptom Chart
Symptom Occurs During Symptom Category Number
Startup: No start/Normal crank 1
Hard start/Long crank 2
Stall after start 3
Diesels/Runs on 4

Idle: MIL 5
Stalls/Quits 6
Slow 7
Slow return 8
Rolling 9
Fast 10
Rough 11
Misses 12
Backfires 13

Acceleration: Stalls/Quits 6
Misses 12
Bucks/Jerks 14
Backfires 13
Hesitation 15
Lack/Loss of power 16
17
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Surge
Spark knock 18
Cooling system temperature 19
Poor fuel economy 20
Emissions compliance 21

Cruise: Stalls/Quits 6
Misses 12
Bucks/Jerks 14
Backfires 13
Lack/Loss of power 16
Surge 17
Spark knock 18
Cooling system temperature 19
Poor fuel economy 20
Emissions compliance 21

Deceleration: Stalls/Quits 6
Backfires 13

Transmission Operation: (Automatic) Shift/engagement concerns 22
No overdrive 23
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MBC (50 States) Calibration Parts List
MBC (50 States)

Instruction Vacuum

CALIBRATION: 5-ZF1-B60-508 (DUR2) MUSTANG 4.0L SOHC
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CALIBRATION PARTS LIST

NAME/DESCRIPTION ENGINEERING NO. SERVICE NO.
SENSOR ASSY., (Cylinder Head Temperature) 3L7U 6G004-BA 3L7Z 6G004-BA
SENSOR ASSY., (Camshaft Position) 1W7E 6B288-AB 1W7Z 6B288-AB
SENSOR ASSY., (Crankshaft Position) 1W7E 6C315-AA 1W7Z 6C315-AB
SENSOR ASSY., (Catalyst Monitor) XR3F 9G444-HA XR3Z 9G444-HA
SENSOR ASSY., (Heated Exhaust Gas Oxygen) 5C5A 9F472-AA 5C5Z 9F472-AA
SENSOR ASSY., (Throttle Position) 3L5E 9U515-AA 3L5Z 9B989-AA
VALVE ASSY., (EGR) 3W7E 9Y456-B3C 3W7Z 9D475-BA
TUBE ASSY., (Fuel Injector) 4R3E 9F792-BD 4R3Z 9F792-BA
INJECTOR ASSY., (Fuel) 4L8E 9F593-A4A 4L8Z 9F593-AA
TUBE ASSY., (EGR Valve to Exhaust Manifold) 5R3E 9A469-FA 5R3Z 9E469-FA
SENSOR ASSY., (Fuel Pressure) 3F2E 9G756-AC 3F2Z 9G756-AC
PROCESSOR AND CALIBRATOR ASSY.,
(Powertrain Control Module)
5R3A 12A650-ADC 5R3Z 12A650-ADC
SENSOR ASSY., (Mass Air Flow) 3L3A 12B579-BA 3L3Z 12B579-BA
SENSOR ASSY., (Engine Coolant Temperature) 3L8A 12A648-BA 3L8Z 12A648-BA
SENSOR ASSY., (Knock) XL3F 12A699-AA XL3Z 12A699-AA
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MAJ (50 States) MBC (50 States) Calibration Parts List
MAJ (50 States)

Instruction Vacuum

CALIBRATION: 5-ZF1-B60-510 (DUR3) MUSTANG 4.0L SOHC
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MBC (50 States)

Instruction Vacuum

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5R3A 12A650-ADD 5R3Z 12A650-ADD
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MAJ (50 States) Calibration Parts List
MAJ (50 States)

Instruction Vacuum

CALIBRATION: 5-ZF2-B60-506 (FJY1) MUSTANG 4.0L SOHC
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TUBE ASSY., (Fuel Injection) 4R3E 9F792-BD 4R3Z 9F792-BA
5R3A 12A650-AFB 5R3Z 12A650-AFB
SENSOR ASSY., (Mass Air flow) 3L3A 12B579-BA 3L3Z 12B579-BA
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MBC (50 States)

Instruction Vacuum

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5R3A 12A650-AFA 5R3Z 12A650-AFA
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MBC (50 States)

Instruction Vacuum

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5R3A 12A650-AFB 5R3Z 12A650-AFB
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MPL (50 States, EFF: 2-14-05) Calibration Parts List
MPL (50 States, EFF: 2-14-05)

Instruction Vacuum

CALIBRATION: 5-ZF1-G80-508 (BKT2) MUSTANG 4.6L SOHC
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SENSOR ASSY., (Camshaft Position) 1L2E 6B288-AA 1L2Z 6B288-AA
SENSOR ASSY., (Catalyst Monitor) XR3F 9G444-AA XR3Z 9G444-HA
VALVE ASSY., (EGR) 5R3E 9Y456-AA 5R3Z 9D475-AA
TUBE ASSY., (EGR to Exhaust Manifold) 5R3E 9E469-FA 5R3Z 9E469-FA
SENSOR ASSY., (Knock) 1S7A 12A699-BA 1L2Z 12A699-AA
SENSOR ASSY., (Engine Coolant Temperature) F5AF 12A648-AB F5AZ 12A648-AB
5R3A 12A650-ABC 5R3Z 12A650-ABC
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MPL (50 States, Prior: 2-14-05) MDH (50 States, Prior: 2-14-05) Calibration Parts
List
MPL (50 States, Prior: 2-14-05)

Instruction Vacuum

CALIBRATION: 5-ZF1-G80-510 (BKT3) MUSTANG 4.6L SOHC
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MDH (50 States, Prior: 2-14-05)

Instruction Vacuum

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SENSOR ASSY., (Camshaft Position) 1L2E 6B288-AA 1L2Z 6B288-AA
VALVE ASSY., (EGR) 5R3E 9Y456-AA 5R3Z 9D475-AA
TUBE ASSY., (EGR to Exhaust Manifold) 5R3E 9E469-FA 5R3Z 9E469-FA
5R3A 12A650-ABD 5R3Z 12A650-ABD
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MPL (50 States, Prior: 2-14-05) Calibration Parts List
MPL (50 States, Prior: 2-14-05)

Instruction Vacuum

CALIBRATION: 5-ZF2-G80-508 (CDC2) MUSTANG 4.6L SOHC
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SENSOR ASSY., (Camshaft Position) 1W7E 6B288-AA 1W7Z 6B288-AA
(Powertrain Control Module EEC-V TYPE: MPC-
14D REPROGRAMMABLE)
5R3A 12A650-ACC 5R3Z 12A650-ACC
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MDH (50 States, EFF: 2-14-05) MPL (50 States) Calibration Parts List
MDH (50 States, EFF: 2-14-05)

Instruction Vacuum

CALIBRATION: 5-ZF2-G80-510 (CDC3) MUSTANG 4.6L SOHC
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MPL (50 States)

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SENSOR ASSY., (Camshaft Position) 1W7E 6B288-AA 1W7Z 6B288-AA
5R3A 12A650-ACD 5R3Z 12A650-ACD
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310-02-1 310-02-1 Acceleration Control
The engine management system electronically
Acceleration Control
operates the throttle of the engine in response to
The acceleration control consists of an accelerator
throttle pedal movements initiated by the driver. In
pedal and sensor assembly.
the event of a system failure, the engine
management system provides a limp home mode
which allows the car to be driven with limited
performance.
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Acceleration Control
(PC/ED) manual.
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Accelerator Pedal
2. Disconnect the accelerator pedal sensor
1 14A464 Accelerator pedal sensor
electrical connector Upon installation, make sure that the red
lock tab on the electrical connector is fully 2 W711330 Accelerator pedal sensor
retaining nuts (3 required) engaged to make sure of a complete
connection. 3 9F836 Accelerator pedal and sensor
assembly
3. Remove the 3 accelerator pedal and sensor
Removal and Installation retaining nuts.
additional information, refer to Section 414-01. 4. Remove the accelerator pedal and sensor
assembly.
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310-01-1 310-01-1 Fuel Tank and Lines
Fuel Filter
4. Remove the 2 fuel tube bundle shield retaining
bolts.
5. Remove the 2 fuel tube bundle shield retaining
nuts.
6. Remove the fuel tube bundle shield pushpin
WARNING: Do not carry personal
retainer clip and position the fuel tube bundle
electronic devices such as cell phones, pagers or
shield aside.
audio equipment of any type when working on or
near any fuel-related components. Highly
7. Disconnect the front fuel supply tube-to-fuel
filter quick connect coupling. For additional
8. Disconnect the rear fuel supply tube-to-fuel
9. CAUTION: Some residual fuel may
remain in the fuel filter. Upon removal,
carefully drain into a suitable container.
Remove the fuel filter from the fuel filter
WARNING: Fuel supply tubes on all
bracket.
vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after
10. CAUTION: Make sure the fuel tubes
engine shutdown. Fuel system pressure must be
are completely seated and that the quick
relieved prior to fuel system service to prevent
connect couplings are locked correctly in
possible personal injury or a fire hazard.
place. Pull on the tube to make sure it is
fully seated. Upon completion, pressurize the
WARNING: This procedure involves fuel
system and check for leaks.
handling. Be prepared for fuel spillage at all
times and always observe fuel handling
precautions. Failure to follow these instructions
Section 100-02.
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Fuel Level Sensor
Special Tool(s)
Fuel Storage Tanker
3. Release the fuel tank filler cap and position
aside.
Fuel Tank Lockring Wrench
310-D006
Material
Item Specification
4. Insert a suitable fuel drain tube into the fuel
tank filler pipe until it reaches the fuel tank Motor Oil
XO-5W20-QSP (US); inlet tube.
CXO-5W20-LSP12
handling. Be prepared for spillage at all times
and always observe fuel handling precautions.
personal injury.
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10. NOTE: Place absorbent pads in the general
5. CAUTION: The fuel pump (FP)
work area in case of fuel spillage.
module and fuel level sensor will be below
the fuel level in the tank when the tank is
Disconnect the rear fuel supply tube-to-FP
full. Make sure to drain 1/8 of the fuel
module quick connect coupling. For additional
capacity through the filler pipe prior to
removing the FP module or fuel spillage will
occur.
NOTE: When draining a completely full fuel
tank, this step will remove approximately 1/8 of
fuel from the LH side of the fuel tank.
Attach the fuel storage tanker to a suitable fuel
drain tube and remove as much fuel as possible
from the fuel tank filler pipe.
7. Position any insulation padding covering the FP
module and fuel level sensor access covers
aside.
FP module retaining lock ring.
8. Remove the FP module and fuel level sensor
access covers and position aside.
12. Position the FP module aside. Using the fuel
storage tanker and a suitable fuel drain tube,
completely drain the remaining fuel from the
9. Disconnect the FP module electrical connector.
LH side of the fuel tank.
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13. NOTE: Draining the remainder of the fuel in
the RH side of the fuel tank should be done
immediately to prevent siphoning of the fuel
back into the LH side of the fuel tank.
Carefully lift the FP module out of the fuel
tank enough to allow access to the crossover
fuel tube-to-FP module quick connect coupling.
14. Disconnect the crossover fuel tube-to-FP
fuel level sensor retaining lock ring.
15. Insert a suitable fuel drain tube into the
crossover fuel tube quick connect coupling.
20. Carefully lift the fuel level sensor out of the
fuel tank enough to allow access to the
crossover fuel tube-to-fuel level sensor quick
connect coupling.
21. Disconnect the crossover fuel tube-to-fuel level
sensor quick connect coupling. For additional
16. Attach the fuel storage tanker to the suitable
fuel drain tube and completely drain the
remainder of the fuel from the RH side of the
fuel tank.
17. Remove and discard the FP module O-ring seal.
18. Disconnect the fuel level sensor electrical
connector.
22. Completely remove the fuel level sensor from
the fuel tank.
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23. Remove and discard the fuel level sensor
O-ring seal.
Installation
1. CAUTION: Inspect the surfaces of the
fuel level sensor mounting flange and the fuel
tank O-ring seal contact surfaces. Do not
polish or adjust the O-ring contact area of
the fuel tank flange or the fuel tank. Install a
new fuel level sensor or fuel tank if the
O-ring seal contact area is bent, scratched or
corroded.
5. Connect the fuel level sensor electrical
CAUTION: Make sure to install a new
connector.
fuel level sensor O-ring seal and lock ring.
NOTE: Prior to installing the fuel level sensor
and O-ring seal, thoroughly clean any
contaminants from fuel level sensor and fuel
tank mounting flanges.
NOTE: Upon installation, apply clean engine
oil to the O-ring seal.
Install the new fuel level sensor O-ring seal.
2. Position the fuel level sensor into the fuel tank.
3. Connect the crossover fuel tube-to fuel level
sensor quick connect coupling. For additional
6. CAUTION: Make sure to install a new
FP module O-ring seal and lock ring.
CAUTION: Inspect the surfaces of the
FP module mounting flange and the fuel
tank O-ring seal contact surfaces. Do not
polish or adjust the O-ring contact area of
the fuel tank flange or the fuel tank. Install a
new FP module or fuel tank if the O-ring
seal contact area is bent, scratched or
corroded.
NOTE: Prior to installing the FP module and
O-ring seal, thoroughly clean any contaminants
from FP module and fuel tank mounting
flanges.
4. NOTE: Make sure the alignment arrows on the
NOTE: Upon installation, apply clean engine
fuel level sensor and the fuel tank meet before
oil to the O-ring seal.
tightening the fuel level sensor lock ring.
Install the new FP module O-ring seal.
Using the special tool, install the new fuel level
sensor retaining lock ring.
7. Position the FP module into the fuel tank.
Tighten the lock ring until it meets the stops
on the fuel tank.
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8. Connect the crossover fuel tube-to- the FP 11. Connect the FP module electrical connector.
12. NOTE: Remove and discard the absorbent
pads.
Install the FP module and the fuel level sensor
FP module and the fuel tank meet before
access covers.
tightening the FP module lock ring.
Using the special tool, install the new FP
module retaining lock ring.
on the fuel tank.
10. Connect the rear fuel supply tube-to-FP module
13. Install any insulation padding covering the FP
module and fuel level sensor access covers.
14. Install the rear seat cushion. For additional
15. Using the fuel storage tanker, refuel the fuel
tank.
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16. Install the fuel tank filler cap. 17. Connect the battery ground cable. For additional
18. NOTE: It may take more than one key cycle to
pressurize the fuel system. Cycle the ignition
key and wait 3 seconds to pressurize the fuel
system.
Check for leaks before starting the engine.
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Fuel Lines and Fuel Filter
Exploded View
4 9E313 Fuel tube bundle shield 1 Fuel tube bundle shield
pushpin (part of 9E313)
5 W712583 Fuel tube bundle bracket
retaining bolt 2 W704652 Fuel tube bundle shield
retaining bolt (2 required)
6 Fuel tube bundle bracket (part
of 9J279) 3 W520101 Fuel tube bundle clip
retaining nut (2 required)
7 9J279 Front fuel supply tube
(Continued)
(Continued)
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8 Fuel tube bundle double 12 Fuel tube bundle pushpin
pushpin retainer clip (part of retainer clip (2 required)
9J279)
13 9J279 Rear fuel supply tube
9 Front fuel supply tube-to fuel
14 Rear fuel supply tube-to-fuel
filter quick connect coupling
pump (FP) quick connect
(part of 9J279)
coupling (part of 9J279)
10 9155B Fuel filter
11 Rear fuel supply tube-to-fuel
filter quick connect coupling
(part of 9J279)
(Continued)
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6. Remove the fuel tube bundle bracket and
Fuel Lines
retaining bolt.
Removal and Installation To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 fuel tube bundle shield retainer
bolts.
8. Remove the 2 fuel tube bundle clip retainer
nuts.
9. Release the pushpin retainer clips and remove
the fuel tube bundle shield.
flammable mixtures are always present and may 10. Remove the 3 fuel tube bundle retainer clips.
information, refer to Section 310-00. WARNING: Fuel in the fuel system
remain in the fuel tubes. Upon removal,
Remove the front fuel supply tube.
13. Disconnect the rear fuel supply tube-to-fuel
14. Remove 2 nuts, 1 bolt and the LH foreign
personal injury.
material deflector.
Section 100-02.
supply hose quick connect coupling. For
5. Remove the LH front splash shield. For
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16. Position aside any insulation padding covering
the fuel pump (FP) module access cover.
17. Remove the FP module access cover and
position aside.
remain in the fuel tubes. Upon removal,
Remove the rear fuel supply tube.
18. NOTE: 4.0L and 4.6L FP modules shown, 5.4L
FP module similar.
Disconnect the rear fuel supply tube quick
connect coupling-to-FP module. For additional
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Fuel Pump Module
Special Tool(s)
Fuel Storage Tanker
aside.
Fuel Tank Lock Ring Wrench
310-D006
Material
Item Specification
4. Insert a suitable fuel drain hose into the fuel
tank filler pipe until it reaches the fuel tank Motor Oil
XO-5W20-QSP (US); inlet tube.
CXO-5W20-LSP12
personal injury.
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10. NOTE: Place absorbent pads in the general
module and fuel level sensor will be below
the fuel level in the tank when the tank is
full. Make sure to drain 1/8 of the fuel
capacity through the filler pipe prior to
removing the pumps or fuel spillage will
occur.
tank, this step will remove approximately 1/8 of
fuel from the LH side of the fuel tank.
Attach the fuel storage tanker to the fuel drain
hose and remove as much fuel as possible from
the fuel tank filler pipe.
module access cover aside.
FP module retaining lock ring.
8. Remove the FP module access cover and
position aside.
12. CAUTION: The FP module must be
handled carefully to avoid damage to the
9. NOTE: 4.0L and 4.6L FP modules shown, 5.4L
float arm, filter and the convolute hoses.
FP module similar.
Disconnect the FP module electrical connector.
tank enough to access the fuel crossover
tube-to-FP module quick connect coupling.
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13. Disconnect the fuel crossover tube-to-FP
FP module and the fuel tank meet before
tightening the FP module lock ring.
Using the special tool, install the FP module
14. Completely remove the FP module from the
and lock ring.
fuel tank.
on the fuel tank.
15. Remove the FP module O-ring seal.
Installation
1. CAUTION: Inspect the surfaces of the
FP module mounting flange and fuel tank
O-ring seal contact surfaces. Do not polish or
adjust the O-ring seal contact area of the
fuel tank flange or the fuel tank. Install a
new FP module or fuel tank if the O-ring
seal contact area is bent, scratched or
corroded.
CAUTION: Make sure to install a new
FP module O-ring seal and lock ring.
5. Connect the rear fuel supply tube-to-FP module
NOTE: Prior to installing the FP module and
O-ring seal, thoroughly clean any contaminants
from FP module and fuel tank mounting
flanges.
NOTE: To install, apply clean engine oil to the
O-ring seal.
Install the FP module O-ring seal.
2. Position the FP module into the fuel tank.
3. Connect the fuel crossover tube-to-FP module
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6. Connect the FP module electrical connector. 8. Install any insulation padding covering the FP
module.
10. Install the fuel tank filler cap.
12. NOTE: It may take more than one key cycle to
pressurize the fuel system. Cycle the ignition
key and wait 3 seconds to pressurize the fuel
system.
7. NOTE: Remove and discard the absorbent
Check for leaks before starting the engine.
pads.
Install the FP module access cover.
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310-00-1 310-00-1 Fuel System General Information
GENERAL PROCEDURES
Fuel System Pressure Release
relieved to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.
1. NOTE: The fuel pump module fuse is located
in the bussed electrical center, location F41.
Remove the fuel pump module fuse.
2. Start the engine and allow it to idle until it
stalls.
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3. After the engine stalls, crank the engine for 6. NOTE: It may take more than one key cycle to
approximately 5 seconds to make sure the fuel pressurize the fuel system.
injection supply manifold pressure has been
Cycle the ignition key and wait 3 seconds to
released.
pressurize the fuel system. Check for leaks
before starting the engine.
7. Start the vehicle and check the fuel system for
5. When fuel system service is complete, install
leaks.
the fuel pump module fuse.
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The vehicle:
Fuel System
uses a returnless fuel system.
is equipped with a multiport fuel injection (MFI)
system.
uses separately controlled fuel injectors for each
cylinder. The fuel injectors are mounted to the
intake manifold.
fuel injectors are supplied with pressurized fuel
from the fuel pump through the fuel injection
supply manifold.
fuel injection supply manifold is controlled by the
electronic fuel delivery module which is enabled
by the powertrain control module (PCM).
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Fuel System
(PC/ED) manual.
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Fuel Tank and Filler Pipe Exploded
View
4 14A474 FP module electrical 1 9C335A Fuel level sensor access cover
connector
2 9C335A Fuel pump (FP) module
5 Rear fuel supply tube-to-FP access cover
module quick connect
3 14A474 Fuel level sensor electrical
coupling (part of 9J279)
connector
6 9C385 Fuel level sensor lock ring
(Continued)
(Continued)
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7 9C385 FP module lock ring 9 9H307 FP module
8 9275 Fuel level sensor
(Continued)
12 W710947 Fuel tank strap retainer bolt 10 W525937 Fuel tank filler hose-to-fuel
(2 required) tank clamp
13 9055 Fuel tank strap (2 required) 11 W710861 Fuel tank strap retainer pin (2
(Continued)
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14 Fuel vapor control tube 16 9034 Fuel tank filler pipe
assembly valve-to fuel tank
17 9002 Fuel tank
quick connect coupling (part
of 9E325)
15 W506033 Fuel tank filler pipe bracket
bolt
(Continued)
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a fuel tank filler pipe assembly that cannot be
Fuel Tank and Lines
modified in any way. The fuel tank filler pipe is
serviced only by installing a new filler pipe
assembly.
a 1/4 turn fuel tank filler cap.
an electronic returnless fuel system.
a fuel filter that is mounted in front of the fuel
tank on the left hand side of the vehicle providing
filtration to protect the fuel injectors.
audio equipment of any type when working on or fuel tubes (liquid and vapor) combined in a
near any fuel-related components. Highly bundle along with the brake tubes mounted on the
flammable mixtures are always present and may underside of the floorpan and covered with a
be ignited. Failure to follow these instructions protective cover shield.
quick connect and spring lock fuel tube couplings.
The vehicle utilizes a returnless fuel system
The fuel pump module is controlled by the
consisting of:
powertrain control module (PCM). Electrical power
to the pump is provided through the inertia fuel
a dual-container (saddle type) stamped steel fuel
shutoff (IFS) switch located in the passenger
tank, each half equipped with a fuel level sensor.
footwell area.
a fuel tank filler pipe which contains a restrictor
plate to permit only unleaded fuel to be pumped
into the fuel tank.
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Fuel Tank and Lines
(PC/ED) manual.
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GENERAL PROCEDURES
Fuel Tank Draining
Special Tool(s)
Fuel Storage Tanker
Socket, Fuel Tank Sender Unit
310-D006 (D90P-9275-A)
tank filler pipe until it reaches the fuel tank
inlet tube.
personal injury.
module and the fuel level sensor will be
below the fuel level in the tank when the
tank is full. Make sure to drain 1/8 of the
fuel capacity through the filler pipe prior to
removing the FP module or fuel spillage will
occur.
tank, this step will remove approximately 1/8th
of fuel from the LH side of the fuel tank.
Attach the fuel storage tanker to the fuel drain
information, refer to Fuel System Pressure
tube and remove as much fuel as possible from
Release in this section.
aside.
module access cover aside.
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8. Remove the FP module access cover and 11. Using the special tool, remove the FP module
position aside. retaining lock ring.
9. NOTE: 4.0L and 4.6L fuel pump (FP) module 12. Position the FP module aside. Using the fuel
shown, 5.4L similar. storage tanker and a suitable fuel drain tube,
completely drain the LH side of the fuel tank.
Disconnect the FP module electrical connector.
10. NOTE: Place absorbant pads in the general
module must be handled carefully to avoid
damage to the float arm, filter and the
convolute hoses.
tank enough to access the fuel cross over
tube-to-FP module quick connect coupling.
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14. Disconnect the fuel cross over tube-to-FP 16. Insert a suitable fuel drain tube into the cross
module quick connect coupling. For additional over fuel tube quick connect coupling.
17. Attach the fuel storage tanker to the fuel drain
tube and completely drain the remainder of the
fuel from the RH side of the fuel tank.
module must be removed and handled
carefully to avoid damage to the float arm.
Completely remove the FP module from the
fuel tank.
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Fuel Tank Filler Pipe WARNING: The fuel in the tank may be
pressurized. Remove the fuel tank cap slowly. If
a hissing sound is heard, wait until the condition Special Tool(s)
stops before removing the fuel tank filler cap. If
Fuel Storage Tanker
these precautions are not followed, fuel may
spray and cause personal injury.
Section 100-02.
Material
Item Specification
Motorcraft SAE 5W-20 WSS-M2C930-A 3. Release the fuel tank filler cap and position
aside.
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
tank filler pipe until it reaches the fuel tank WARNING: Do not carry personal
inlet tube.
WARNING: The evaporative emissions
vapor. Although not present in large quantities,
it still presents the danger of explosion or fire.
electrical spark occurring, and possibly causing a
fire or explosion if fuel vapor or liquid fuel are
5. Attach the fuel storage tanker to the fuel drain
present in the area. Failure to follow these
tube and remove as much fuel as possible from
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6. Remove the lateral stiffener bar. For additional 9. Release the clamp and disconnect the fuel tank
information, refer to Section 204-02. filler pipe hose-to-fuel tank.
7. Release the 4 fuel tank filler pipe bezel retainer
clips.
10. CAUTION: Some fuel may remain in
the fuel tank filler pipe after draining.
Carefully remove the fuel tank filler pipe
assembly from the vehicle and drain any
residual fuel into a suitable container.
Remove the fuel tank filler pipe support bracket
bolt.
11. Remove the fuel tank filler pipe.
8. Remove the fuel tank filler pipe bezel.
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Fuel Tank
Material
4. Drain the fuel tank. For additional information,
Item Specification
Premium Synthetic Blend 5. If equipped, remove the rear support braces. For
Motor Oil
XO-5W20-QSP (US);
Vehicles with 4.0L SOHC engine
CXO-5W20-LSP12
6. Remove the exhaust intermediate pipe. For
Vehicles with 4.6L (3V) and 5.4L (4V)
engines
WARNING: Do not carry lighted tobacco
or open flame of any type when working on or
7. Remove the exhaust intermediate pipes. For
flammable vapors are always present and can
ignite. Failure to follow these instructions can
All vehicles
valve-to-fuel tank quick connect coupling. For
10. Release the clamp and disconnect the fuel tank
WARNING: Fuel supply tubes on all filler pipe hose-to-fuel tank.
vehicles equipped with fuel injected engines will
To install, tighten clamp to 3 Nm (27 lb-in).
remain pressurized for long periods of time after
engine shutdown. Fuel system pressure must be
11. Position a suitable lifting device under the fuel
released prior to fuel system service to prevent
tank.
possible personal injury or a fire hazard.
12. Remove the 2 fuel tank strap retaining bolts.
handling. Be prepared for fuel spillage at all
times and always observe fuel handling
13. Position the emergency brake cables aside.
precautions. Failure to follow these instructions
14. Remove the 2 fuel tank strap retainer pins and
straps.
All vehicles
15. Partially lower the fuel tank enough to allow
access to the fuel level sensor electrical
connector.
Section 100-02.
16. Disconnect the fuel level sensor electrical
connector.
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17. Complete the lowering and removal of the fuel
tank.
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Inertia Fuel Shutoff (IFS) Switch
3. Remove the LH lower A-pillar trim panel.
Remove the pin-type retainer and the trim
Item Part Number Description panel.
1 14A464 Inertia fuel shutoff (IFS)
2 W504148 IFS mounting bolts (2
required)
3 9341 IFS switch
2. Remove the LH sill plate.
4. Disconnect the inertia fuel shutoff (IFS) switch
5. Remove the 2 bolts and the IFS switch.
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GENERAL PROCEDURES
Installation
Quick Connect Coupling Retainer Clip
1. Install the tool into the quick connect coupling
Removal
body.
1. Insert the tool that is supplied with the new
2. Insert the legs of the new retainer clip into the
replacement retainer clip into the quick connect
windows on the body of the quick connect
coupling body until it engages and spreads the
coupling body.
retainer legs.
3. Push the retainer clip straight into the quick
2. Grasp the retainer clip under the lip on each
connect coupling body until it is flush with the
side, pull outward and remove while
top lip and the side of the connector body.
simultaneously removing the tool from the
quick connect coupling body.
The legs of the retainer clip may catch on
the quick connect coupling body just prior
to removal and you may need to open the
legs of the retainer clip slightly to complete
removal.
4. NOTE: If the retainer clip is properly installed,
the tool should be locked into the quick connect
coupling body and can only be removed when
the center of the retaining clip is depressed.
Push down the center of the retainer clip and
remove the tool. Upon release the retainer clip
should remain in the quick connect coupler
3. Discard the quick connect coupling retainer
body.
clip.
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GENERAL PROCEDURES
1. If servicing a liquid fuel tube, release the fuel
Quick Connect Coupling
system pressure. For additional information,
refer to Fuel System Pressure Release in this
Material
section.
Item Specification
Motorcraft SAE 5W-20 WSS-M2C930-A 2. Disconnect the battery ground cable. For
Motor Oil
XO-5W20-QSP (US);
3. Disconnect the quick connect coupling from the
tube.
CXO-5W20-LSP12
Press the quick connect coupling release tab
and pull the tube to disconnect.
Disconnect Type I
Connect Type I
1. CAUTION: Make sure the tube clicks
into place upon installation. To make sure
CAUTION: If the liquid or vapor tube is
that the tube is fully seated, pull on the tube.
damaged (torn, holes or delaminated), the
NOTE: Apply clean engine oil to O-ring seals.
affected tube assembly must be replaced with a
new tube assembly. Do not use aftermarket Install the quick connect coupling onto the tube
sleeving. Do not re-adhere loose sleeving until it is fully seated.
material.
CAUTION: When reusing liquid or vapor
tube connectors, make sure to use compressed air
to remove any foreign material from the
connector retaining clip area before separating
from the tube. Apply clean engine oil to the end
of the tube before inserting the tube into the
connector.
CAUTION: Fuel injection equipment is
manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute
cleanliness is observed when working with these
components. Always install blanking plugs to any
open orifices or tubes.
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Disconnect Type II
3. Separate the quick connect coupling from the
fitting.
CAUTION: If the liquid or vapor tube is
new tube assembly. Do not use aftermarket
sleeving. Do not re-adhere loose sleeving
material.
Connect Type II
connector.
1. CAUTION: Make sure the tube clicks
into place upon installation. To make sure
that the tube is fully seated, pull on the tube.
NOTE: Apply clean engine oil to O-ring seals.
Release the lock tab and install the quick
connect coupling onto the fitting.
2. Release the lock tab on the quick connect
coupling.
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2. Apply lock tab into the latched position.
1. If servicing a liquid fuel tube, release the fuel
system pressure. For additional information,
refer to Fuel System Pressure Release in this
section.
Disconnect Type III
3. Release the quick connect coupling primary
lock tab.
4. Rotate the primary locking tab to the fully
opened position and squeeze the secondary CAUTION: If the liquid or vapor tube is
locking tabs to release the locking mechanism.
material.
connector.
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5. Push the locking mechanism outward and
release the tube.
3. CAUTION: To make sure that the
tube is fully seated, pull on the tube.
Rotate the primary locking tab on the retainer
Connect Type III
clip to the closed position.
1. NOTE: Apply clean engine oil to O-ring seals.
Install the tube into the quick connect coupling
until it is fully seated.
2. CAUTION: Make sure the retainer
clip clicks into place when installing.
Depress the retainer clip until it is flush with
the quick connect coupler housing and it is
fully seated on the tube.
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SPECIFICATIONS
Item Specification
Lubricant
Item Specification
Motorcraft SAE 5W-20 WSS-MC930-A
Fuel tank capacity 60.56 liters (16 gallons) Premium Synthetic Blend
Key on, engine off fuel 207-345 kPa (30-50 psi)
pressure
5W-20 Super Premium
Engine running fuel 152-255 kPa (27-37 psi)
Motor Oil
pressure (idle)
CXO-5W20-LSP12
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SPECIFICATIONS
Fuel tank hose clamp 3 27
Item Specification
Fuel filter bracket 5 44
Lubricant retaining bolt
Motorcraft SAE 5W-20 WSS-MC930-A Fuel tube bundle shield 5 44
Premium Synthetic Blend retaining bolts
Fuel tube bundle clip 5 44
retaining nuts
5W-20 Super Premium
Motor Oil Inertia fuel shutoff 2 18
CXO-5W20-LSP12 (IFS) switch
Fuel tube bundle 8 71
bracket retaining bolt
Foreign material shield 25 18 Torque Specifications
bolt
Foreign material shield 25 18
Fuel tank support strap 53 39
nuts
bolts
Fuel tank filler pipe 35 26
support bracket bolt
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SPECIFICATIONS
Accelerator pedal nuts 9 80
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310-03-1 310-03-1 Speed Control
Speed Control Deactivator Switch
Speed Control Deactivator Switch Brake Pedal
1 9C872 Speed control deactivator
switch
2 Speed control deactivator
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310-03-2 310-03-2 Speed Control
Speed Control Deactivator Switch Clutch Pedal
Item Part Number Description 1. CAUTION: Do not press the pedal
when removing or installing the speed
1 Speed control deactivator
switch electrical connector control deactivator switch, as the switch will
be damaged.
2 7C534 Speed control deactivator
switch
Remove the speed control deactivator switch.
Disconnect the electrical connector.
Rotate the speed control deactivator switch
counterclockwise 45 degrees and remove the
CAUTION: Do not service the brake pedal,
deactivator switch.
brake booster, or master cylinder without first
removing the stoplamp switch. Do not install the
2. NOTE: When installing the speed control
stoplamp switch without the brake pedal arm
deactivator switch, it is automatically
secured to the brake booster push rod. Do not
self-adjusting to the proper position. Do not
press or pull on the brake pedal when installing
pull up or push down on the pedal during
or removing the stoplamp switch otherwise
installation. Initial installation of the speed
misadjustment or damage to the stoplamp switch
control deactivator switch allows for one
could occur.
adjustment. If additional adjustments are
necessary, install a new switch.
NOTE: This procedure is for both speed control
deactivator switches. To install, reverse the removal procedure.
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310-03-1 310-03-1 Speed Control
Speed Control Switch
2. NOTE: Carefully grasp and pull the edges to
remove the steering wheel spoke finish panels.
1 3F830 Steering wheel spoke finish
panels (if equipped) If equipped, remove the steering wheel spoke
finish panels. 2 9E740 Speed control switches
3 Speed control switch
3. NOTE: Using a small, flat-bladed screwdriver,
electrical connectors
gently pry up the speed control switches from
the steering wheel, beginning at the outer edge.
Use care not to damage the steering wheel.
Remove the speed control switches.
Disconnect the electrical connectors.
501-20B.
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310-03-1 310-03-1 Speed Control
Speed Control
The speed control system consists of the following
components:
Speed control switches
Speed control deactivator switch
Clutch pedal speed control deactivator switch
(manual transmission)
Speed control indicator
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310-03-1 310-03-1 Speed Control
Decelerating the vehicle speed
Speed Control
Turning the vehicle speed control system off
Special Tool(s)
Cancelling the speed control
Pressing and releasing the ON switch turns the
speed control system on. Pressing and releasing the
SET+ or SET- switch while the vehicle is traveling
at the desired speed activates the speed control
system.
Tapping the SET+ or the SET- switch while in the
set mode increases or decreases the maintained
(VCM) and Integrated vehicle speed by 1.6 km/h (1 mph) per tap,
respectively. If either button is pressed and held, the
vehicle speed continues to accelerate (SET+) or
decelerate (SET-) until the button is released.
tool
Pressing and releasing the OFF switch, or switching
the ignition switch to the OFF position, turns the
Diagnostic Tool, Restraint speed control system off. Applying the brake pedal
System (2 required)
puts the speed control system into the standby
418-F395
mode. Pressing the RESUME button when the
speed control system is in the standby mode causes
the vehicle to accelerate to the last set speed.
RESUME does not function if the OFF button is
pressed or if the current vehicle speed is below the
Flex Probe Kit minimum operational speed.
105-R025C or equivalent
The clutch pedal speed control deactivator switch is
used on vehicles equipped with a manual
transmission. When the clutch pedal is applied with
the vehicle speed control system engaged, the
normally closed switch opens and signals the PCM
to deactivate the speed control.
Principles of Operation The speed control deactivator switch is provided as
an additional safety feature. When the brake pedal
The speed control system is controlled by the
is applied, an electrical signal from the stoplamp
powertrain control module (PCM). The speed
switch is sent to the smart junction box (SJB),
control system is designed to maintain a selected
which then sends a message to the PCM to
vehicle speed between 48 and 200 km/h (30 and
deactivate the speed control system. Under increased
124 mph). The speed control system is controlled
brake pedal effort, the speed control deactivator
by the steering wheel mounted switches (ON, OFF,
switch opens and removes the voltage signal from
SET+, SET-, and RESUME), the stoplamp switch,
the PCM input circuit, deactivating the speed
the clutch pedal speed control deactivator switch
control system.
(manual transmission), and the speed control
deactivator switch. The steering wheel mounted Whenever the speed control system is engaged and
switches are hardwired to the PCM through the active, a speed control icon on the instrument
clockspring. cluster is illuminated.
The speed control functions include: The inputs to the PCM are:
Turning the speed control system on Output shaft speed (OSS) sensor
Setting and maintaining the desired vehicle speed Transmission range (TR) sensor
Accelerating the vehicle speed Speed control switch
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310-03-2 310-03-2 Speed Control
Clutch pedal speed control deactivator switch Vehicle speed loss from set speed of greater than
16 km/h (10 mph) occurs
Vehicle speed falls below the minimum allowable
Accelerator pedal position sensor
limit of 48 km/h (30 mph)
SJB
Parking brake is applied
Parking brake
Speed control switch is pressed or stuck for
The outputs of the PCM for the speed control
longer than 2 minutes
system are:
Speed control indicator lamp
Throttle command
2. Visually inspect the following for obvious signs
The speed control system throttle position is
of mechanical or electrical damage.
completely controlled by the PCM through the
electronically controlled throttle body. Speed control
electronics are contained entirely within the PCM.
When the speed control system is active, the PCM
Throttle body Smart junction box
corrects for deviations in the actual vehicle speed by
(SJB) fuse 18 (10A)
proportionally moving the throttle plate. The PCM
Circuitry
modulates the throttle to minimize error between
Speed control switch
actual, and desired vehicle speed. Clutch pedal speed
control deactivator
The PCM strategy uses the throttle control for
switch
smooth accelerations.
Speed control
deactivator switch
The PCM sends a message over the controller area
Stoplamp switch
network (CAN) to the instrument cluster whenever
Powertrain control
the speed control telltale should be turned on or off.
module (PCM)
In the event of an OFF command or a deactivation
request from any source, the speed control system
carries out a deactivation and immediately returns
the throttle to the idle position.
The speed control system provides self-diagnostics.
4. Verify the speedometer operates correctly
The speed control is disabled anytime an error is
without speed control by test driving the
detected in the system. No cluster telltale or
vehicle. If the speedometer does not operate
message center messages are displayed when faults
correctly, refer to Section 413-01.
occur. Fault codes are logged by the PCM.
5. Verify the stoplamps operate correctly with the
An electronically controlled throttle system fault
ignition switch in the ON position. If the
also causes the speed control system to be disabled
stoplamps do not operate correctly, refer to
and a warning telltale (wrench light) or a message
Section 417-01.
center message is displayed.
6. Verify the parking brake warning indicator is
Additionally, the following conditions cause the
operating correctly. If the parking brake
speed control system to deactivate:
warning indicator does not operate correctly,
Transmission gear selector in a position other than
D or OD (automatic transmission)
software release.
Vehicle clutch pedal is applied
Speed control set speed is over-ridden with the
accelerator pedal for a period longer than 5
minutes
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310-03-3 310-03-3 Speed Control
8. NOTE: The vehicle communication module Refer to Section 418-00 to diagnose no
(VCM) LED prove-out confirms power and response from the PCM.
10. Carry out the network test:
VCM.
VCM:
Check the VCM connection to the vehicle.
Check the scan tool connection to the VCM. record the continuous memory DTCs.
Refer to Section 418-00, No Power To The 11. Clear the continuous DTCs and carry out the
Scan Tool, to diagnose no communication self-test diagnostics for the PCM.
with the scan tool.
9. If the scan tool does not communicate with the go to the Powertrain Control Module (PCM)
vehicle: Diagnostic Trouble Code (DTC) Index. For all
Verify the ignition key is in the ON
position. 13. If no DTCs related to the concern are retrieved,
Verify the scan tool operation with a known
good vehicle.
Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index
DTCs Description Action
P0579 Cruise Control Multifunction Input A Circuit GO to Pinpoint Test C.
Range/Performance
P0581 Cruise Control Multifunction Circuit High GO to Pinpoint Test C.
P1703 Brake Switch Out of Self-Test Range GO to Pinpoint Test B.
All other DTCs REFER to the Powertrain Control/Emissions
Symptom Chart
Symptom Chart
The speed control is Speed control switch GO to Pinpoint Test A.
inoperative Digital transmission range
(TR) sensor alignment
Clutch pedal speed control
deactivator switch
(PCM)
The speed control does not Circuitry GO to Pinpoint Test A.
disengage when the clutch is Clutch pedal speed control
applied deactivator switch
PCM
The speed control indicator Circuitry REFER to Section 413-01.
lamp is inoperative/always on Instrument cluster
PCM
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310-03-4 310-03-4 Speed Control
Pinpoint Tests Vehicles equipped with a manual transmission have
an additional clutch pedal speed control deactivator
Pinpoint Test A: The Speed Control Is
switch. The clutch pedal speed control deactivator
Inoperative
switch, normally closed, supplies a ground signal to
the powertrain control module (PCM) through
Normal Operation
circuit 1899 (WH). When the clutch pedal is
The powertrain control module (PCM) sends a
pressed, the clutch pedal speed control deactivator
signal through circuit 248 (TN/OG) to the speed
switch moves to the open position, removing the
control switches, which passes through the
ground signal from the PCM, which deactivates the
clockspring. The return signal is sent to the PCM
speed control. Circuit 1205 (BK) supplies ground
through circuit 133 (BK) and the clockspring. When
to the clutch pedal speed control deactivator switch.
the brake pedal is applied, the smart junction box
(SJB) sends a message to the PCM to deactivate the
Possible Causes
speed control, if engaged.
The speed control deactivator switch interrupts
TR sensor alignment
circuit 535 (LB/RD), removing the voltage signal to
the PCM, when the brake pedal is applied firmly Clutch pedal speed control deactivator switch
and passes the stoplamp switch trip point. This is a
PCM
redundant signal to the PCM.
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE
CAUTION: Use the correct probe adaptor(s) when making measurements. Failure
to use the correct probe adaptor(s) may damage the connector.
A1 CHECK FOR DTCs
Review the recorded DTCs from the PCM self-test. Yes
Are any DTCs recorded? REFER to the Powertrain Control Module
(PCM) Diagnostic Trouble Code (DTC)
Index for correct diagnosis.
No
GO to A2.
A2 CHECK THE SPEED CONTROL SWITCH
Disconnect: PCM C175b.
Measure the resistance between the PCM C175b-19, circuit 248
(TN/OG), harness side and the PCM C175b-30, circuit 133 (BK),
harness side, while pressing the speed control switches as
follows:
Speed Control Switch Resistance Value
OFF Less than 5 ohms
SET - 285 - 315 ohms
SET + 570 - 630 ohms
RESUME 1,054 - 1,165 ohms
ON 2,004 - 2,215 ohms
No switch pressed 4,094 - 4,525 ohms
(Continued)
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310-03-5 310-03-5 Speed Control
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE (Continued)
A2 CHECK THE SPEED CONTROL SWITCH (Continued)
Yes
If equipped with an automatic
transmission, GO to A3.
If equipped with a manual transmission,
GO to A5.
No
INSTALL a new speed control switch.
REFER to Speed Control Switch in this
Are the speed control switch resistance values OK? self-test.
A3 CHECK THE DIGITAL TRANSMISSION RANGE (TR) SENSOR
Connect: PCM C175b.
Apply the parking brake.
Key in ON position.
Enter the following diagnostic mode on the scan tool: PCM TR
Sensor PID.
Yes
Monitor the PCM TR sensor PID.
GO to A4.
Select DRIVE.
Does the PID value agree with the transmission range No
selector lever position? REFER to Section 307-01.
A4 CHECK THE DIGITAL TR SENSOR FOR CORRECT ALIGNMENT
Check the digital TR sensor alignment. Refer to Section 307-01. Yes
Is the digital TR sensor aligned correctly? GO to A5.
No
ADJUST the digital TR sensor. REFER to
normal operation.
A5 CHECK THE VEHICLE SPEED
NOTE: This step may require an assistant.
Key in ON position.
Enter the following diagnostic mode on the scan tool: Anti-lock
Yes
Brake System (ABS) Wheel Speed PID.
Monitor and record the ABS module wheel speed PID while
transmission, GO to A9.
driving the vehicle at 48 km/h (30 mph) as indicated on the
If equipped with a manual transmission
speedometer.
GO to A6.
Enter the following diagnostic mode on the scan tool: PCM
Vehicle Speed PID. No
Monitor and record the PCM vehicle speed PID while driving the REFER to the Powertrain
vehicle at 48 km/h (30 mph). Control/Emissions Diagnosis (PC/ED)
Does the speed indicated by the ABS module wheel speed manual to diagnose the output shaft speed
PID match the PCM vehicle speed PID? (OSS) sensor signal.
A6 CHECK THE CLUTCH PEDAL SPEED CONTROL DEACTIVATOR
SWITCH PID
Clutch Pedal Speed Control Deactivator Switch PID.
Yes
Monitor the PCM clutch pedal speed control deactivator switch
GO to A9.
PID while pressing and releasing the clutch pedal.
Does the clutch pedal speed control deactivator switch PID No
agree with the clutch pedal position? GO to A7.
A7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Clutch Pedal Speed Control Deactivator Switch
C277.
(Continued)
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310-03-6 310-03-6 Speed Control
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE (Continued)
A7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between the clutch pedal speed control
deactivator switch C277-3, circuit 1205 (BK), harness side and
ground.
Yes
GO to A8.
No
REPAIR the circuit. CLEAR the DTCs.
Is the resistance less than 5 ohms? REPEAT the self-test.
A8 CHECK CIRCUIT 1899 (WH) FOR AN OPEN OR A SHORT TO
GROUND
Measure the resistance between the PCM C175b-39, circuit
1899 (WH), harness side and the clutch pedal speed control
deactivator switch C277-1, circuit 1899 (WH), harness side; and
between the PCM C175b-39, circuit 1899 (WH), harness side
and ground.
Yes
INSTALL a new clutch pedal speed control
deactivator switch. REFER to Speed
Control Deactivator Switch in this section.
Is the resistance less than 5 ohms between the PCM and No
the clutch pedal speed control deactivator switch, and REPAIR the circuit. CLEAR the DTCs.
greater than 10,000 ohms between the PCM and ground? REPEAT the self-test.
A9 CHECK FOR CORRECT PCM OPERATION
Disconnect all the PCM connectors. Yes
Check for: INSTALL a new PCM. REFER to Section
corrosion 303-14. TEST the system for normal
damaged pins operation.
pushed-out pins
No
Connect all the PCM connectors and make sure they seat
correctly.
Operate the system and verify the concern is still present.
Pinpoint Test B: DTC P1703 Brake On/Off Normal Operation
Circuit Failure
When the brake pedal is applied, the smart junction
box (SJB) sends a message to the powertrain control
Refer to Wiring Diagrams Cell 31, Speed Control
module (PCM) to deactivate the speed control if
engaged.
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310-03-7 310-03-7 Speed Control
The speed control deactivator switch receives Circuit 535 (LB/RD) open, or short to voltage
voltage through circuit 391 (RD/YE). The switch
removes voltage from circuit 535 (LB/RD) to the
PCM when the brake pedal is applied firmly and
Bussed electrical center (BEC)
passes the stoplamp switch trip point. This is a
redundant signal to the PCM.
SJB
Possible Causes
PCM
Fuse
Circuit 391 (RD/YE) open
PINPOINT TEST B: DTC P1703 BRAKE ON/OFF CIRCUIT FAILURE
B1 CHECK THE OPERATION OF THE STOPLAMPS
Operate the stoplamps. GO to B2.
Do the stoplamps operate correctly?
No
B2 CHECK CIRCUIT 535 (LB/RD) FOR VOLTAGE
Key in ON position.
Measure the voltage between the PCM C175b-9, circuit 535
(LB/RD), harness side and ground.
Yes
GO to B3.
No
(Continued)
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310-03-8 310-03-8 Speed Control
PINPOINT TEST B: DTC P1703 BRAKE ON/OFF CIRCUIT FAILURE (Continued)
B3 CHECK THE SPEED CONTROL DEACTIVATOR SWITCH FOR
CORRECT OPERATION
While firmly applying and releasing the brake pedal, measure
the voltage between the PCM C175b-9, circuit 535 (LB/RD),
harness side and ground.
Yes
GO to B10.
Is the voltage greater than 10 volts with the brake pedal No
released and 0 volts with the brake pedal firmly applied? GO to B4.
B4 CHECK CIRCUIT 535 (LB/RD) FOR A SHORT TO VOLTAGE
Disconnect: Speed Control Deactivator Switch C278.
Key in ON position.
Measure the voltage between the speed control deactivator
switch C278-1, circuit 535 (LB/RD), harness side and ground.
Yes
GO to B5.
No
INSTALL a new speed control deactivator
switch. REFER to Speed Control
Deactivator Switch in this section. CLEAR
Is any voltage present? the DTCs. REPEAT the self test.
B5 CHECK THE ABS MODULE FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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310-03-9 310-03-9 Speed Control
B5 CHECK THE ABS MODULE FOR A SHORT TO VOLTAGE
(Continued)
switch C278-1, circuit 535 (LB/RD), harness side and ground.
Yes
No
Is any voltage present? GO to B9.
B6 CHECK CIRCUIT 391 (RD/YE) FOR AN OPEN
Disconnect: Speed Control Deactivator Switch C278.
Key in ON position.
switch C278-2, circuit 391 (RD/YE), harness side and ground.
Yes
GO to B7.
No
VERIFY the SJB fuse 18 (10A) is OK. If
OK, REPAIR the circuit. CLEAR the DTCs.
Is the voltage greater than 10 volts? REPEAT the self-test.
B7 CHECK CIRCUIT 535 (LB/RD) FOR AN OPEN
(Continued)
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310-03-10 310-03-10 Speed Control
B7 CHECK CIRCUIT 535 (LB/RD) FOR AN OPEN (Continued)
(LB/RD), harness side and the speed control deactivator switch
C278-1, circuit 535 (LB/RD), harness side.
Yes
INSTALL a new speed control deactivator
switch. REFER to Speed Control
Deactivator Switch in this section. CLEAR
No
Is the resistance less than 5 ohms? GO to B8.
B8 CHECK THE BEC FOR AN OPEN
Disconnect: BEC C1035a.
Disconnect: BEC C1035b.
Measure the resistance between the BEC C1035a pin E2,
component side and the BEC C1035b pin F3, component side.
Yes
REPAIR circuit 535 (LB/RD). CLEAR the
No
INSTALL a new BEC. CLEAR the DTCs.
(Continued)
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310-03-11 310-03-11 Speed Control
Disconnect the ABS module connector. Yes
corrosion Section 206-09. CLEAR the DTCs.
damaged pins REPEAT the self test.
pushed-out pins
No
Connect the ABS module connector and make sure it is seated
correctly.
B10 CHECK FOR CORRECT PCM OPERATION
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test C: DTC P0579 or DTC P0581
Speed Control Switch Circuit Failure
Circuit 133 (BK) open, short to voltage or ground
Refer to Wiring Diagrams Cell 31, Speed Control
Circuit 248 (TN/OG) open or short to ground
Clockspring
Normal Operation
PCM
signal through circuit 248 (TN/OG) to the speed
control switches. The return signal is sent through
circuit 133 (BK). Both circuits pass through the
clockspring.
PINPOINT TEST C: DTC P0579 OR DTC P0581 SPEED CONTROL SWITCH CIRCUIT FAILURE
C1 CHECK THE SPEED CONTROL SWITCH CIRCUITRY FOR A
SHORT TO VOLTAGE
Key in ON position.
Turn the parking lamps on.
(Continued)
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310-03-12 310-03-12 Speed Control
(Continued)
SHORT TO VOLTAGE (Continued)
(TN/OG), harness side and ground; and between the PCM
C175b-30, circuit 133 (BK), harness side and ground.
Yes
TURN the parking lamps off. GO to C2.
No
Is any voltage present? TURN the parking lamps off. GO to C4.
C2 CHECK CIRCUITS 248 (TN/OG) AND 133 (BK) FOR A SHORT
TO VOLTAGE
Disconnect: Clockspring C2274.
Key in ON position.
Yes
REPAIR the circuit in question. CLEAR the
No
Is any voltage present? TURN the parking lamps off. GO to C3.
C3 CHECK THE CLOCKSPRING FOR A SHORT TO VOLTAGE
Connect: Clockspring C2274.
Remove the driver air bag module. Refer to Section 501-20B.
Connect the restraint system diagnostic tools (418-F395) to the
upper clockspring air bag connector.
Disconnect: Upper Clockspring.
WARNING: Make sure there is no one inside the
vehicle and that there is nothing blocking or set in front of
any air bag module when the battery is connected. Failure
to follow these instructions may result in personal injury.
Connect the battery.
Key in ON position.
(Continued)
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310-03-13 310-03-13 Speed Control
(Continued)
C3 CHECK THE CLOCKSPRING FOR A SHORT TO VOLTAGE
(Continued)
Yes
INSTALL a new clockspring. REFER to
Section 501-20B. DISCONNECT the
battery. INSTALL the driver air bag
module. REFER to Section 501-20B.
No
section. DISCONNECT the battery.
INSTALL the driver air bag module.
REFER to Section 501-20B. CLEAR the
Is any voltage present? DTCs. REPEAT the self-test.
SHORT TO GROUND
Yes
GO to C7.
No
Are the resistances greater than 10,000 ohms? GO to C5.
C5 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
(Continued)
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310-03-14 310-03-14 Speed Control
(Continued)
C5 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
(Continued)
Yes
No
Are the resistances greater than 10,000 ohms? GO to C6.
C6 CHECK CIRCUITS 248 (TN/OG) AND 133 (BK) FOR A SHORT
TO GROUND
Yes
No
REPAIR the circuit in question. INSTALL
the driver air bag module. REFER to
Section 501-20B. CLEAR the DTCs.
Are the resistances greater than 10,000 ohms? REPEAT the self-test.
(Continued)
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310-03-15 310-03-15 Speed Control
(Continued)
C7 CHECK THE SPEED CONTROL SWITCH CIRCUITRY FOR AN
OPEN
(TN/OG), harness side and the PCM C175b-30, circuit 133 (BK),
harness side.
Yes
GO to C10.
No
Is the resistance between 4,100 and 4,500 ohms? GO to C8.
C8 CHECK CIRCUITS 248 (TN/OG) AND 133 (BK) FOR AN OPEN
(TN/OG), harness side and the clockspring C2274-4, circuit 248
(TN/OG), harness side; and between the PCM C175b-30, circuit
133 (BK), harness side and the clockspring C2274-5, circuit 133
(BK), harness side.
Yes
GO to C9.
No
C9 CHECK THE CLOCKSPRING
(Continued)
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310-03-16 310-03-16 Speed Control
(Continued)
C9 CHECK THE CLOCKSPRING (Continued)
Measure the resistance between the clockspring C2274 pin 4,
component side and the upper clockspring connector pin 2,
component side; and between the clockspring C2274 pin 5,
component side and the upper clockspring connector pin 3,
component side.
Yes
No
Are the resistances less than 5 ohms? CLEAR the DTCs. REPEAT the self-test.
C10 CHECK FOR CORRECT PCM OPERATION
corrosion 303-14. INSTALL the driver air bag
damaged pins module. REFER to Section 501-20B.
pushed-out pins TEST the system for normal operation.
No
correctly.
by a loose or corroded connector.
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GENERAL PROCEDURES
Spring Lock Couplings CAUTION: If the liquid or vapor tube is
affected tube assembly must be replaced with a Special Tool(s)
Disconnect Tool, Spring Lock
Coupling (3/8 inch yellow)
material.
310-D004 (D87L-9280-A) or
equivalent
Disconnect Tool, Spring Lock
Coupling (1/2 inch green)
310-D005 (D87L-9280-B) or
connector.
equivalent
Material
Item Specification
Motor Oil
information, refer to Fuel System Pressure
XO-5W20-QSP (US);
Release in this section.
2. Remove the fuel tube safety clip. CXO-5W20-LSP12
Disconnect
ignite. Failure to follow these instructions may
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3. Install the special tool. 6. Remove the special tool.
Connect
4. Close and push the special tool into the open
side of the cage.
1. NOTE: Inspect and clean both the coupling
ends. Lubricate the O-ring seals with clean
engine oil.
Connect the fuel tube to the spring lock
coupling.
Pull on the spring lock coupling to make
sure it is fully engaged.
Install the safety clip.
5. Separate the fuel tube from the spring lock
coupling.
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412-00-1 412-00-1 Climate Control System General Information and Diagnostics
GENERAL PROCEDURES
2. Remove the clutch plate. Add or remove
Air Conditioning (A/C) Clutch Air Gap
spacers between the clutch plate hub and the
Adjustment
compressor shaft until the clearance is within
specification.
1. Check the A/C clutch air gap at 3 equally
spaced places between the clutch plate and the
A/C clutch pulley.
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412-01-1 412-01-1 Climate Control
Air Conditioning (A/C) Compressor
4.0L
Material
Item Specification
PAG Refrigerant WSH-M1C231-B
Compressor Oil (R-134a
Systems)
YN-12-D
9 N811329 Compressor bolt 1 N805334 Compressor manifold bolt
10 N520112 Upper LH compressor nut 2 N520112 Line bracket nut
11 19E889 O-ring (2 required) 3 19D734 Compressor manifold and
tube
Removal and Installation 4 W520112 Compressor manifold and
tube bracket nut
5 180101 Field coil electrical connector
CAUTION: If installing a new air
6 19703 A/C compressor conditioning compressor due to an internal
failure of the old unit, you must carry out the 7 W704795 Upper compressor stud (2
required) following procedures to remove contamination
from the air conditioning system. 8 W707821 Lower LH compressor stud
(Continued)
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If A/C flushing equipment is available, carry 6. Loosen the compressor manifold bolt and
out flushing of the air conditioning system detach the compressor manifold.
prior to installing a new air conditioning
compressor. For additional information, refer
to Section 412-00.
If A/C flushing equipment is not available,
7. Remove the line bracket nut.
carry out filtering of the air conditioning
system after a new air conditioning compressor
8. Remove the compressor manifold and tube
has been installed. For additional information,
bracket nut, and detach the compressor
manifold and tube.
Install a new evaporator core orifice, as
directed by the A/C flushing or filtering
procedure.
9. Remove the upper LH compressor nut.
Install a new suction accumulator as directed
by the A/C flushing or filtering procedure.
10. Remove the 2 upper compressor studs.
NOTE: Installation of a new suction accumulator is
not required when repairing the air conditioning
system except when there is physical evidence of
11. Remove the lower LH compressor stud.
system contamination from a failed A/C compressor
or damage to the suction accumulator.
12. Remove the compressor bolt.
NOTE: If installing a new A/C compressor, the
A/C clutch disc and hub, A/C compressor pulley
and A/C clutch field coil must be inspected and
transferred from the old unit to the new unit if
13. Remove the A/C compressor.
suitable for reuse.
If a new A/C compressor is to be installed,
the clutch assembly must be transferred
Section 100-02.
from the old unit to the new unit. For
additional information, refer to Clutch and
2. If flushing of the air conditioning system has
Clutch Field Coil in this section.
not been carried out, recover the refrigerant. For
Install new O-ring seals.
If filtering of the refrigerant system is not to
3. Remove the air cleaner outlet tube. For
be carried out, lubricate the refrigerant
system with the correct amount of clean
PAG oil. For additional information, refer to
4. Remove the drive belt from the A/C compressor
Section 412-00.
pulley.
15. If filtering of the refrigerant system is not to be
5. Disconnect the field coil electrical connector.
carried out, evacuate, leak test and charge the
refrigerant system. For additional information,
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Air Conditioning (A/C) Compressor
4.6L, 5.4L
Material
Item Specification
Systems)
YN-12-D
7 19703 A/C compressor 1 N805334 Compressor fitting nut (2
required)
8 19E889 O-ring seal (2 required)
2 180101 Wire harness retainer (2
9 19588 Gasket seal (2 required)
required)
3 180101 Field coil electrical connector
4 W705811 A/C compressor stud (3
required)
CAUTION: If installing a new air
5 W505255 Power steering pressure hose
conditioning compressor due to an internal
bracket bolt
failure of the old unit, you must carry out the
6 12A581 Crankshaft position sensor
following procedures to remove contamination
from the air conditioning system.
(Continued)
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If A/C flushing equipment is available, carry 4. Remove the 2 compressor fitting nuts and
out flushing of the air conditioning system disconnect the fittings.
prior to installing a new air conditioning
compressor. For additional information, refer
To install tighten to 15 Nm (11 lb-ft).
to Section 412-00.
If A/C flushing equipment is not available,
5. Remove the power steering pressure hose
carry out filtering of the air conditioning
bracket bolt.
system after a new air conditioning compressor
has been installed. For additional information,
6. Disconnect the crankshaft position sensor
Install a new evaporator core orifice, as
directed by the A/C flushing or filtering
procedure.
7. Disconnect the field coil electrical connector.
Install a new suction accumulator as directed
8. Detach the 2 wire harness retainers from the
by the A/C flushing or filtering procedure.
A/C compressor studs.
9. Remove the 3 A/C compressor studs.
contamination from a failed A/C compressor or
damage to the suction accumulator.
If a new A/C compressor is to be installed,
the clutch assembly must be transferred
A/C clutch disc and hub, A/C compressor pulley
from the old unit to the new unit. For
and A/C clutch field coil must be inspected and
additional information, refer to Clutch and
transferred from the old unit to the new unit if
Clutch Field Coil in this section.
suitable for reuse.
Install new O-ring seals and gasket seals.
If filtering of the refrigerant system is not to
be carried out, lubricate the refrigerant
Section 100-02.
system with the correct amount of clean
PAG oil. For additional information, refer to
2. If flushing of the air conditioning system has
Section 412-00.
not been carried out, recover the refrigerant. For
11. If filtering of the refrigerant system is not to be
carried out, evacuate, leak test and charge the
3. Remove the drive belt from the A/C compressor
refrigerant system. For additional information,
pulley.
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GENERAL PROCEDURES
Connect
Air Conditioning Line (Peanut) Fitting
1. Clean all dirt or foreign material from the
Disconnect
fittings.
1. CAUTION: Support the female fitting
2. CAUTION: Use only the new O-ring
with a wrench to prevent the tubes from
seals. The use of any O-ring seals other than
twisting.
those specified in the Ford Master Parts
Remove the nut and separate the 2 halves of
Catalog may result in intermittent leakage
the peanut fitting.
during vehicle operation.
Install the O-ring seal.
2. CAUTION: Do not use metal tools to
remove the O-ring seal. They can cause axial
3. NOTE: When correctly assembled, the male
scratches across the O-ring seal groove,
and female fittings should be flush.
resulting in refrigerant leaks.
Assemble the male and female fittings together.
Remove the O-ring seal with a non-metallic
tool.
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GENERAL PROCEDURES
Chemical odors
Air Conditioning (A/C) Odor
Treatment Environmental odors
Human and other interior-generated odors
Special Tool(s)
Microbiological odors
Flexible Applicator Tool Kit
Before determining that A/C order treatment is
258-00004
required, the source and the circumstances under
which the odor occurs must be determined.
NOTE: Chemical odors are usually constant
regardless of the climate control system setting
although they may be enhanced by A/C operation.
30 oz Sure Shot Pressure Most chemical odors are caused by fluid leaks or
Sprayer
incorrectly cured adhesives. Chemical odors can be
eliminated by repairing the leaking component and
removing any residue.
NOTE: Environmental odors usually occur for a
short time and diminish after the vehicle passes
through the affected area. These odors are typically
Material
only detected when the vehicle windows are open,
or when the climate control system is operating in a
Item Specification
mode that allows for fresh air. Environmental odors
A/C Cooling Coil Coating
cannot be eliminated because they are external in
YN-29
source, but they may be minimized by switching to
A/C Odor Treatment a climate control setting that uses recirculated air.
NOTE: Human and other interior-generated odors
WARNING: Avoid contact with eyes and
occur while the source is present and may linger for
skin. Contact with eyes and skin will cause
a short time after. These odors may be more
irritation. Wear chemical goggles when using the
noticeable during A/C operation. Human odors may
A/C cooling coil coating.
be eliminated by removing the source and cleaning
the affected area.
WARNING: This procedure should only be
carried out in well ventilated areas. Open all
windows and doors of the vehicle. Leave doors
and windows open during the entire procedure.
Avoid breathing vapors.
WARNING: Read all instructions and
warnings packaged with the A/C cooling coil
coating. For additional information, see the
material safety data sheet (MSDS) for this
product.
NOTE: There are typically 4 types of objectionable
odors found in a vehicle:
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Odor Source Odor Description
NOTE: Microbiological odors, if in the A/C
system, usually last for about 30 seconds after the Environmental Odors
system is turned on. They will be detected while the
Exhaust Exhaust, fuel or burning
A/C is turned on and using either outside or
type smell
recirculated air. Microbiological odors that occur in
Industrial Pollutants Various smells
areas other than the A/C system (for example, water
Dust Musty, mildew or wet
in doors or wet carpeting) may last indefinitely and
cement type smell
will be more intense when recirculated air is used.
Pollen Sweet smell
Microbiological odors will not be present at
Tobacco Burning, tar smell temperatures at or below 10C (50F).
Human and Other Interior Generated Odors
Microbiological odors can be eliminated by
removing the source and treating the affected area. Body Secretions Body odor
Standing water must be allowed to drain and dry
Perfuming Agents Sweet or fragrance smell
out. A/C systems may be treated by using A/C
Clothing Musty, mildew or body
cooling coil coating as described in the service
odors
procedure below.
Food/Beverage Sweet, musty, mildew or
Microbiological odors result from microbial growth
fishy smell
supported by warm temperatures and moisture.
Microbiological Odors
Microbiological odors are described as
Microbiological Odors Musty, mildew smell
musty/mildew type smells and may occur on/in:
Occurring Inside of A/C lasting about 30 seconds
System after A/C is turned on
foam seals.
Microbiological Odors Musty, mildew smell
rubber seals.
Occurring Outside of A/C lasting indefinitely and
adhesives. System possibly more pronounced
when using recirculated
standing water.
air
water soaked carpet/trim.
1. Identify the type of odor present in the vehicle. 2. Identify the source of the odor.
Do not proceed with A/C odor treatment if the
Check the passenger and driver side carpet
odor source is found to be outside of the A/C
for moisture. Continue diagnosis if moisture
system. Refer to the following chart for
is found.
examples.
Check the blower motor and blower motor
cover (if equipped) for moisture resulting
Odor Source Odor Description
from water bypassing the cowl baffling
Chemical Odors
system. Continue diagnosis if moisture is
Coolant Sweet smell
present.
Fuel Gasoline or diesel fuel
Check the evaporator core drain tube for
smell
restriction.
Oil Oil type or burning smell
Check the cowl top panel and air inlet
Power Steering Fluid Oil type or burning smell
screen for standing water or foreign
Transmission Fluid Oil type or burning smell
material. If possible, remove any standing
Washer Fluid Alcohol type smell water and clean the air inlet screen using a
wet/dry vacuum.
Gear Lube Garlic/sulfur smell
Refrigerant Oil Ether type smell
3. Open all vehicle windows.
Carpet/trim Adhesives Fishy, urine or sweet
smell
4. Disconnect the low-side A/C pressure switch
Evaporator Core Coating Wet cement type smell (cycling or low-charge protection) electrical
connector.
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5. Remove the evaporator air discharge
temperature sensor (if equipped).
vehicle interior, do not spill or spray this
product on any interior surface.
6. Set the following.
Add one full bottle of A/C cooling coil coating
Enable the A/C using fresh air inlet.
to the applicator or sprayer.
Adjust the temperature setting to full warm.
12. Insert the nozzle into the evaporator housing
Adjust the blower motor speed to HI.
and direct the spray toward the evaporator core
face. Spray the entire evaporator core face until
7. Run the engine for 25 minutes to dry out the
empty.
A/C system.
13. Install the blower motor and blower motor
8. Turn the ignition OFF.
resistor (if equipped) or blower motor speed
control (if equipped).
9. Remove the blower motor.
14. Install the evaporator air discharge temperature
10. NOTE: Blower motor speed controls that are
sensor (if equipped),
mounted outside of the evaporator core housing
and not exposed to the blower motor airflow do
15. Repeat Steps 6 through 8 to cure the evaporator
not need to be removed.
core coating.
Remove the blower motor resistor (if equipped)
or blower motor speed control (if equipped and
16. Connect the low-side A/C pressure switch
exposed to the inside of the evaporator core
(cycling or low-charge protection) electrical
housing).
connector.
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GENERAL PROCEDURES
Air Conditioning (A/C) System CAUTION: An A/C refrigerant analyzer
must be used before the recovery of any vehicles Flushing
A/C refrigerant. Failure to do so puts the shops
bulk refrigerant at risk of contamination. If the
Special Tool(s)
vehicles A/C refrigerant is contaminated, refer
A/C Flush and Purge Machine
the customer to the service facility that carried
219-00022 (part of 219-00023)
out the last A/C service. If the customer wishes
or equivalent
to pay the additional cost, use the A/C recovery
equipment that is designated for recovering
contaminated A/C refrigerant. All contaminated
A/C refrigerant must be disposed of as
hazardous waste. For all equipment, follow the
A/C Flush and Purge Fitting Kit
equipment manufacturer procedures and
219-00024 (part of 219-00023)
instructions.
or equivalent
CAUTION: Suction accumulator or
receiver/drier, thermal expansion valve (TXV)
and/or evaporator core orifice, and hoses with
mufflers, should be removed when flushing the
A/C Flush Adapter Kit
A/C system. Internal plumbing of these devices
makes it impossible to correctly remove any
residual-flushing agent. These components are
typically discarded after A/C system
contamination. Hoses without mufflers can
normally be reused unless they are clogged with
foreign material. The 3.785 liters (1 gallon) of
A/C System Flushing Solvent YN-23 and FL1-A
Material
filter used in A/C Flush and Purge Machine
Item Specification
219-00022 are intended for use on one vehicle
only. They may be used to flush both the A/C A/C System Flushing
Solvent condenser core and the A/C evaporator core on
YN-23
an individual vehicle, but under no
PAG Refrigerant WSH-M1C231-B circumstances should they be used on more than
one vehicle.
Systems)
YN-12-D
NOTE: Prior to using the A/C Flush and Purge
Machine 219-00022 for the first time, review the
WARNING: Use extreme care and observe
operating instructions.
all safety and service precautions related to the
use of refrigerants.
NOTE: Only the A/C Flush and Purge Machine kit
219-00023, which includes A/C Flush and Purge
WARNING: Due to refrigerant hazards,
Machine 219-00022, A/C Flush and Purge Fitting
always wear safety goggles and non-penetrable
Kit 219-00024 and A/C Systems Flushing Solvent,
gloves when working on or flushing A/C systems.
is approved for use on Ford vehicles. No other
flushing device or solvent is approved for flushing
heat exchangers (A/C condenser, A/C evaporator).
Use of any other flusher or solvent may cause
damage to the A/C system and the flushing unit.
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NOTE: Ford Motor Company has approved a 4. NOTE: Use 3.785L (1 gal) of A/C Systems
procedure to provide technicians with a non-CFC Flushing Solvent to flush the heat exchanger for
method of flushing contaminated A/C system heat a minimum of 15 minutes. The flush solvent
exchangers. The procedure allows the specific may be used for one or both heat exchangers in
components to be cleaned and flushed while the A/C system. However, the flush solvent is
installed in their normal in-vehicle location. The intended for one vehicle only. The filter used
types of contamination flushed include particle on the flushing unit is also intended for use on
matter that results from A/C compressor or one vehicle only.
desiccant failure and gummy residue that can form
Flush the heat exchanger for a minimum of 15
when refrigerant oil is overheated during A/C
minutes.
compressor seizure. The flushing process is a
2-step procedure that involves the use of an A/C
5. Apply 621-862 kPa (90-125 psi) pressurized air
Flush and Purge Machine 219-00022 to:
to the component for a minimum of 30 minutes.
The 30-minute purge time is required to force
circulate the flushing solvent through the heat
and evaporate all residual solvent from the A/C
exchanger in the reverse direction of normal
system component. Failure to successfully
refrigerant flow (back-flushing). Particulate matter
remove all residual solvent within the
picked up during flushing is filtered from the
component can result in system damage when
returning solvent before the solvent is returned to
reconnected and operated. Dispose of the used
the reservoir for continued circulation.
flush solvent and filter in accordance with local,
remove the flushing solvent from the heat
state and federal regulations.
exchanger. In this step of the procedure,
pressurized air 621-862 kPa (90-125 psi) is used
6. NOTE: A/C system filtering as described in
to push and evaporate any remaining flush solvent
this section is optional if system flushing is
from the heat exchanger.
carried out. However, the filter kit use is
recommended after flushing if the A/C system
1. Recover the refrigerant. For additional
contamination is extensive.
information, refer to Air Conditioning (A/C)
Install a new A/C evaporator core orifice (if
System Recovery, Evacuation and Charging in
equipped) and/or TXV (if equipped) in any
this section.
vehicle being serviced for an internal A/C
compressor or desiccant failure.
2. Disconnect the refrigerant lines from the heat
exchanger(s) to be flushed.
7. Install new refrigerant hoses with mufflers if
clogged with foreign material.
3. Connect the A/C flush and purge machine
fitting kit and the A/C flush and purge machine
8. Install a new suction accumulator (if equipped),
to the heat exchanger to be flushed. Do not
receiver/drier (if equipped) or receiver/drier
flush through the evaporator core orifice (if
cartridge (if equipped) in any vehicle being
equipped), TXV (if equipped) or hoses with
serviced for an internal A/C compressor or
mufflers. Internal plumbing and material
desiccant failure.
make-up of these components make it
impossible to correctly remove foreign material
9. Reconnect the heat exchanger being serviced.
or residual flushing solvent.
10. If a new A/C compressor is not to be installed,
lubricate the refrigerant system with the correct
amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding in
this section.
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11. If a new A/C compressor is not to be installed,
evacuate, leak test and charge the A/C system.
For additional information, refer to Air
Conditioning (A/C) System Recovery,
Evacuation and Charging in this section.
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Refrigerant flow into the evaporator core is metered
Air Conditioning
by an evaporator core orifice tube.
The air conditioning system components are:
For information concerning the refrigerant cycle and
A/C compressor
principles of A/C operation, refer to Section 412-00.
A/C condenser core
A/C Compressor and Clutch Assembly
A/C evaporator core
NOTE: Internal FS18 A/C compressor components
Suction accumulator
are not serviced separately. The A/C compressor is
Connecting refrigerant lines
serviced only as an assembly. The clutch disc and
hub, A/C compressor pulley and bearing and clutch
Evaporator core orifice
field coil are serviceable.
A/C cycling switch
A/C pressure transducer (4.0L)
Dual-function pressure switch (4.6L and 5.4L)
A/C compressor pressure relief valve
The refrigerant system incorporates an A/C
The FS18 A/C compressor:
compressor controlled by the powertrain control
module (PCM) through an A/C clutch relay.
uses a non-serviceable shaft seal.
The A/C compressor clutch will only be engaged by
has a pressure relief valve installed in the rear of
the PCM if all of the following conditions are met:
the compressor on 4.6L and 5.4L vehicles to
protect the refrigerant system against excessively
The climate control assembly is set to a mode
high refrigerant pressures.
which provides an A/C request to the PCM.
uses PAG oil or equivalent. This oil contains
The A/C cycling switch is not open due to
special additives required for the A/C compressor.
excessively low suction pressure in the
low-pressure side of the refrigerant system.
PAG oil may have some slightly dark-colored
streaks while maintaining normal oil viscosity.
The A/C pressure transducer is not reading
This is normal for this A/C compressor
excessively high discharge pressure in the
because of break-in wear that can discolor the
high-pressure side of the refrigerant system
oil.
(4.0L).
Use standard oil matching procedures when
The dual-function pressure switch is not open due
installing new compressors.
to excessively high discharge pressure in the
high-pressure side of the refrigerant system (4.6L
and 5.4L).
The A/C compressor relay is switched to the
closed position by the PCM.
The engine coolant temperature is not excessively
high.
The PCM has not detected a wide open throttle
(WOT) condition.
For information concerning operating specifications,
An A/C compressor pressure relief valve is installed
in the compressor manifold and tube assembly (4.0L
vehicles) or the A/C compressor (4.6L or 5.4L
vehicles) to protect the refrigerant system against
excessively high refrigerant pressures.
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A/C Compressor Clutch Assembly
A/C Cycling Switch
NOTE: It is not necessary to recover the refrigerant
before removing the A/C cycling switch.
The A/C cycling switch (ACCS) is used to prevent
icing of the evaporator core by cycling OFF the
A/C compressor clutch when the suction pressure in
the low-pressure side of the refrigerant system drops
below acceptable levels. The PCM monitors the
A/C cycling switch (and dual-function pressure
switch on 4.6L and 5.4L vehicles) through the
ACCS circuit. When the ACCS circuit is open, the
PCM will disengage the A/C compressor clutch. For
specifications regarding operating pressure(s), refer
to Section 412-00.
1 A/C clutch bolt
A/C Pressure Transducer (4.0L)
2 19D786 A/C clutch disc and hub
before removing the A/C pressure transducer.
spacer
The A/C pressure transducer is used by the PCM to
4 A/C compressor pulley snap
monitor the discharge pressure in the high-pressure
ring
side of the refrigerant system. The PCM monitors
the A/C pressure transducer through the ACP
6 19D798 A/C clutch field coil
circuit. When the A/C pressure transducer is
reading a discharge pressure above acceptable
The magnetic A/C clutch has the following
levels, the PCM will disengage the A/C compressor
characteristics:
clutch.
The A/C clutch drives the compressor shaft.
Dual-Function Pressure Switch (4.6L and
When battery positive voltage (B+) is applied to
5.4L)
the A/C clutch field coil, the clutch plate and hub
assembly is drawn toward the A/C clutch pulley.
before removing the dual-function pressure switch.
The magnetic force locks the clutch plate and hub
The dual-function pressure switch includes 2
assembly and the A/C clutch pulley together as
separate sets of contacts that are opened at 2
one unit, causing the compressor shaft to rotate.
different pressures.
When B+ is removed from the A/C clutch field
The first set of contacts in the dual-function
coil, springs in the clutch plate and hub assembly
pressure switch is used to interrupt A/C compressor
move the clutch plate away from the A/C clutch
operation in the event of excessively high discharge
pulley.
pressure in the high-pressure side of the refrigerant
Evaporator Core Orifice
system. The PCM monitors the first set of contacts
in the dual-function pressure switch (and A/C
The evaporator core orifice is located in the
cycling switch) through the ACCS circuit. When the
evaporator inlet line at the condenser-to-evaporator
ACCS circuit is open, the PCM will disengage the
line fitting. The evaporator core orifice provides a
A/C compressor clutch.
restriction to the flow of refrigerant from the
high-pressure side of the refrigerant system, and
The second set of contacts in the dual-function
separates the low-pressure and high-pressure sides
pressure switch is used by the PCM to engage the
of the refrigerant system.
high speed cooling fan. The PCM monitors the
second set of contacts through the ACP circuit.
When the A/C pressure rises above a preset level,
the second set of contacts will close and the
high-speed cooling fan will be engaged.
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A/C Compressor Pressure Relief Valve
For specifications regarding operating pressure(s),
An A/C compressor pressure relief valve is
incorporated in the compressor manifold and tube
Condenser Core
assembly (4.0L) or the A/C compressor (4.6L or
5.4L) to prevent damage to the A/C compressor and
other system components, and to avoid total
refrigerant loss by relieving unusually high
refrigerant system discharge pressure buildups. For
specifications regarding operating pressure(s), refer
to Section 412-00.
The condenser is an aluminum fin and tube design
heat exchanger, located in front of the vehicle
Spring Lock Coupling
radiator. It cools compressed refrigerant gas by
allowing air to pass over fins and tubes to extract
heat, and by condensing gas to liquid refrigerant as
it is cooled.
Evaporator Core
NOTE: The evaporator core is not individually
serviced. It is serviced only with the heater core and
evaporator core housing.
The evaporator core is an aluminum plate/fin type
1 Plastic indicator ring
and is located in the heater core and evaporator core
2 Female fitting
housing. A mixture of refrigerant and oil enters the
3 19E746 A/C tube lock coupling clip
bottom of the evaporator core through the
4 19E576 A/C tube lock coupling spring
evaporator core inlet tube and then moves out of
5 Cage
the evaporator core through the evaporator core
6 19E889 O-ring seals
outlet tube. Air from the blower motor is cooled
7 Male fitting and dehumidified as it flows through the evaporator
core fins.
The spring lock coupling is a refrigerant line
coupling held together by a garter spring inside a
Suction Accumulator
circular cage.
not required when repairing the refrigerant system
When the coupling is connected together, the
except when there is physical evidence of
flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
The garter spring and cage then prevent the flared
The suction accumulator is located at the LH rear of end of the female fitting from pulling out of the
the engine compartment and is used to prevent cage.
residual liquid refrigerant from reaching the A/C
Three O-ring seals are used to seal between the 2
compressor after leaving the evaporator core. The
halves of the coupling.
suction accumulator allows the accumulated heavier
Use only the O-ring seals listed in the Ford
liquid refrigerant and oil mixture to re-enter the
Master Parts Catalog for the spring lock coupling.
compressor suction line at a controlled rate. A
desiccant bag is mounted inside the canister to
absorb any moisture which may be in the refrigerant
system.
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A plastic indicator ring is used on the spring lock
couplings of the A/C evaporator core to indicate,
during vehicle assembly, that the coupling is
connected. Once the coupling is connected, the
indicator ring is no longer necessary but will
remain captive by the coupling near the cage
opening.
The indicator ring may also be used during
service operations to indicate connection of the
coupling.
An A/C tube lock coupling clip may be used to
secure the coupling.
Peanut Fitting
When disconnecting or connecting peanut fittings,
observe the following.
The male and female blocks of the peanut fitting
are retained with a nut.
Support the female fitting with a wrench to
prevent twisting of the tubes.
An O-ring seal is installed around the tube on the
male block.
On 4.6L and 5.4L vehicles, a gasket seal is
installed along with the O-ring seal on the male
Item Part Number Description block.
1 19D702 Low-pressure service gauge
When correctly assembled, the male and female
port valve cap
fittings should be flush.
2 Low-pressure service gauge
Use only the seals listed in the Ford Master Parts
port valve
Catalog.
3 19D701 Low-pressure Schrader-type
valve
Service Gauge Port Valves
4 19D701 High-pressure Schrader-type
The high-pressure service gauge port valve is
valve
located on the condenser-to-evaporator line.
5 High-pressure service gauge
The low-pressure service gauge port valve is located port valve
on the suction accumulator.
6 19D702 High-pressure service gauge
port valve cap
The fitting is an integral part of the refrigerant
system line or component.
Special couplings are required for both the
high-side and low-side service gauge ports.
A very small amount of leakage will always be
detectable around the Schrader-type valve with the
service gauge port valve cap removed, and is
considered normal. A new Schrader-type valve
core can be installed if the seal leaks excessively.
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Refrigerant System Dye
The service gauge port valve caps are used as
primary seals in the refrigerant system to prevent
Fluorescent refrigerant system dye is added to the
leakage through the Schrader-type valves from
refrigerant system at the factory to assist in
reaching the atmosphere. Always install and
refrigerant system leak diagnosis using a
tighten the A/C service gauge port valve caps to
Rotunda-approved ultraviolet blacklight. It is not
the correct torque after they are removed.
necessary to add additional dye to the refrigerant
system before diagnosing leaks, even if a significant
amount of refrigerant has been removed from the
system. New suction accumulators are shipped with
a fluorescent dye wafer included in the desiccant
bag which will dissolve after approximately 30
minutes of continued A/C operation. It is not
necessary to add dye after flushing or filtering the
refrigerant system because a new suction
accumulator is installed as part of the flushing or
filtering procedure. Additional refrigerant system
dye should only be added if more than 50% of the
refrigerant system lubricant capacity has been lost
due to a fitting separation, hose rupture or other
damage. Refer to Section 412-00.
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Cabin Air Filter
Air Distribution and Filtering
The cabin air filter is located under the RH cowl
NOTE: The air distribution system of this vehicle is
vent screen. To install a new cabin air filter, remove
factory equipped with a cabin air filter.
the RH cowl vent screen. Refer to Section 501-02.
There are 2 sources of air available to the air
distribution system:
Plenum Chamber
The plenum chamber is used to distribute airflow
Outside air
from the heater core and evaporator core housing to
Recirculated air
the airflow outlets. It is mounted to the instrument
Recirculated air is only used when the climate
panel and can be replaced separately from the heater
control assembly is set to the MAX A/C and OFF
core and evaporator core housing. The plenum
modes.
chamber contains the PANEL and DEFROST mode
Air distribution within the vehicle is determined by doors which cannot be separately replaced.
the function selector switch position. Airflow mode
Air Inlet Duct
doors are used to direct airflow within the plenum
chamber. Electric mode door actuators are used to The air inlet duct is used to switch between FRESH
position the airflow mode doors. Refer to Section and RECIRCULATED air inlet. It is mounted to the
412-00 for a description and operation of each heater core and evaporator core housing and can be
mode. replaced separately. The air inlet duct contains the
air inlet mode door which cannot be separately
Air enters the passenger compartment from the:
replaced.
instrument panel registers.
floor ducts.
windshield defroster duct.
side window demisters.
Passenger compartment air is exhausted from the
vehicle through open windows or body air vents.
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Air Inlet Duct
2. Disconnect the blower motor resistor electrical
connector.
1 W701696 Air inlet duct screw (7
required)
3. Disconnect the air inlet mode door actuator
2 19A648 Air inlet duct
3 18574 Blower motor resistor
4. Detach the heater core and evaporator core
4 18574 Heater core and evaporator
housing harness electrical connector from the
core housing harness
bracket.
5 18574 Air inlet mode door actuator
5. Remove the 7 air inlet duct screws.
6. Remove the air inlet duct.
1. Remove the heater core and evaporator core
housing. For additional information, refer to
Section 412-01.
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Blower Motor Resistor
1 18B574 Blower motor resistor
2 W701696 Blower motor resistor screw
(2 required)
3 18591 Blower motor resistor
NOTE: The blower motor resistor can be accessed
from below the RH side of the instrument panel.
1. Disconnect the blower motor resistor electrical
connector.
2. Remove the 2 blower motor resistor screws.
3. Remove the blower motor resistor.
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Blower Motor
1 W701696 Blower motor screw (3
required)
2 18B574 Blower motor electrical
connector
3 19805 Blower motor
4 19834 Blower motor wheel
5 18A287 Blower motor wheel clip
1. Disconnect the blower motor electrical
connector.
2. Remove the 3 blower motor screws.
3. Remove the blower motor.
4. Remove the blower motor wheel clip.
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5. Remove the blower motor wheel. 6. To install, reverse the removal procedure.
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Climate Control Assembly
1 W505944 Climate control assembly
screw (4 required)
2 19980 Climate control assembly
1. Remove the center instrument panel finish
Section 501-12.
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.
4. NOTE: Be sure that all climate control
assembly electrical connectors are securely
fastened before installing the center instrument
panel finish panel.
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Special Tool(s)
Climate Control System
Pressure Tester
Special Tool(s)
tool
Fluke 77 III Automotive Meter
R-134a Manifold Gauge Set
176-R032A or equivalent
Connector, Refrigerant Pressure
Line
412-093 (T94P-19623-E)
Loose, missing or Smart junction box
Set, A/C Fittings
damaged A/C (SJB) fuse(s):
412-DS028 (D93L-19703-B) or
compressor drive belt 3 (10A)
equivalent
Loose or disconnected 14 (5A)
A/C clutch 19 (5A)
Broken or binding Bussed electrical center
door/actuator (BEC) fuse(s):
Broken or leaking 2 (30A)
refrigerant lines 47 (15A)
49 (15A)
Refrigerant Leak Detector
Blower motor
inoperative
A/C compressor
inoperative
Circuitry open/shorted
Disconnected electrical
connectors
Cooling fan inoperative
(Continued)
3. As pinpoint tests and measurements are being
carried out, be sure to inspect for any
disconnected, loose-fitting, or incorrectly
installed components, module and in-line
electrical connectors and pins.
4. If the inspection reveals obvious concern(s) that
can be readily identified, repair as required.
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5. NOTE: Make sure to use the latest scan tool 9. Clear the continuous DTCs and carry out the
software release. self-test diagnostics for the SJB or PCM.
If the cause is not visually evident, connect the 10. If the SJB DTCs retrieved are related to the
scan tool to the data link connector (DLC). concern, go to the Smart Junction Box (SJB)
Diagnostic Trouble Code (DTC) Chart. If the
PCM DTCs retrieved are related to the concern,
(VCM) LED prove-out confirms power and
go to the Powertrain Control/Emissions
VCM.
VCM:
check the VCM connection to the vehicle. Electronic Manual Temperature Control
(EMTC) Module Cold Boot Process
The purpose of the cold boot process is to allow the
EMTC module to reinitialize and calibrate the
actuators. To carry out the cold boot process, follow
with the scan tool.
the steps below.
vehicle:
2. Disconnect the EMTC module electrical
connectors.
3. Wait one minute.
good vehicle.
4. Connect the EMTC module electrical
connectors.
response from the smart junction box (SJB)
or powertrain control module (PCM). 5. Turn the ignition switch to the ON position.
8. Carry out the network test. 6. Select any position except OFF on the EMTC
module.
communication from one or more modules, The EMTC module will now initialize and calibrate
refer to Section 418-00. the actuators. Calibration of the actuators will take
approximately 30 seconds.
record the continuous memory diagnostic
DTC Description Action to Take
B2175 A/C request signal circuit short to GO to Pinpoint Test E.
ground
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Symptom Chart
Symptom Chart
NOTE: Some PCM DTCs may inhibit air conditioning (A/C) operation. If any PCM
DTCs are retrieved, diagnose those first. Refer to Powertrain Control/Emissions
The air inlet door is Circuitry short/open GO to Pinpoint Test A.
inoperative Electronic manual
temperature control (EMTC)
module
Air inlet door actuator/linkage
Incorrect/erratic direction of Circuitry GO to Pinpoint Test B.
airflow from outlets Door actuator
Mode door binding or stuck
EMTC module
Door actuator arm not
connected to the door crank
Insufficient, erratic or no heat Low engine coolant level GO to Pinpoint Test C.
Engine overheating
Plugged or partially plugged
heater core
Temperature blend door is
binding or stuck
Temperature blend door
actuator
Heater hose is kinked or
binding
The air conditioning (A/C) is Fuse GO to Pinpoint Test D.
inoperative/does not operate Circuitry short/open
correctly A/C system discharged/low
charge
A/C dual function pressure
switch
PCM
EMTC module
A/C cycling switch
A/C compressor clutch air
gap
A/C clutch relay
The air conditioning (A/C) is Circuitry short GO to Pinpoint Test E.
always ON PCM
A/C compressor clutch air
gap
A/C clutch relay
Temperature control is Circuitry open/shorted GO to Pinpoint Test B.
inoperative/does not operate EMTC module
correctly Temperature blend door
actuator
The blower motor is Fuse(s) GO to Pinpoint Test F.
inoperative Circuitry open/shorted
A/C blower motor switch
Blower motor relay
A/C blower motor
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The blower motor does not Circuitry short GO to Pinpoint Test G.
operate correctly A/C blower motor resistor
A/C blower motor switch
Insufficient air conditioning Low refrigerant level GO to Pinpoint Test B.
(A/C) cooling Temperature blend door
actuator
An open, short to voltage, ground or together in
Pinpoint Test A: The Air Inlet Door Is
circuits 1116 (DG) or 1117 (LG)
Inoperative
Air inlet door actuator
Refer to Wiring Diagrams Cell 54, Manual Climate
Control System for schematic and connector EMTC module
information.
Stuck or bound linkage or door
Normal Operation
Under normal operation, the air inlet door actuator
motors are supplied voltage or ground on circuit
1116 (DG), depending on desired actuator rotation,
by the electronic manual temperature control
(EMTC) module. The EMTC module then supplies
the appropriate voltage or ground to the other side
of the actuator motor on circuit 1117 (LG).
PINPOINT TEST A: THE AIR INLET DOOR IS INOPERATIVE
A1 CHECK THE AIR INLET DOOR ACTUATOR CLOCKWISE
OPERATION
Disconnect: EMTC Module C294a.
Remove the door actuator and disengage the actuator driveshaft
from the actuator door.
Mark the door actuator driveshaft position.
Connect a fused jumper wire between:
EMTC module C294a-8, circuit 1116 (DG) and C294a-1,
circuit 1205 (BK).
EMTC module C294a-9, circuit 1117 (LG) and C294a-26,
circuit 1566 (RD/YE).
Yes
GO to A2.
No
Does the actuator motor move in the clockwise direction? GO to A3.
(Continued)
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PINPOINT TEST A: THE AIR INLET DOOR IS INOPERATIVE (Continued)
A2 CHECK THE AIR INLET DOOR ACTUATOR
COUNTERCLOCKWISE OPERATION
Connect a fused jumper wire between:
EMTC module C294a-8, circuit 1116 (DG) and C294a-26,
circuit 1566 (RD/YE).
EMTC module C294a-9, circuit 1117 (LG) and C294a-1,
circuit 1205 (BK).
Yes
INSPECT for binding or broken door and
linkage. If no condition is found, GO to A9.
Does the actuator motor move in the counterclockwise No
direction? GO to A3.
A3 CHECK CIRCUIT 1116 (DG) FOR A SHORT TO GROUND
Disconnect: Recirc Door Actuator C2325.
Measure the resistance between ground and EMTC module
C294a-8, circuit 1116 (DG).
Yes
GO to A4.
No
REPAIR circuit 1116 (DG) for a short to
ground. TEST the system for normal
Is the resistance greater than 10,000 ohms? operation.
(Continued)
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A4 CHECK CIRCUIT 1117 (LG) FOR A SHORT TO GROUND
Measure the resistance between ground and EMTC module
C294a-9, circuit 1117 (LG).
Yes
GO to A5.
No
REPAIR circuit 1117 (LG) for a short to
A5 CHECK CIRCUIT 1116 (DG) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between ground and EMTC module
C294a-8, circuit 1116 (DG).
Yes
REPAIR circuit 1116 (DG) for a short to
voltage. TEST the system for normal
operation.
No
Is voltage present? GO to A6.
A6 CHECK CIRCUIT 1117 (LG) FOR A SHORT TO VOLTAGE
Measure the voltage between ground and EMTC module
C294a-9, circuit 1117 (LG).
Yes
REPAIR circuit 1117 (LG) for a short to
operation.
No
(Continued)
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A7 CHECK CIRCUIT 1116 (DG) FOR AN OPEN (Continued)
Measure the resistance between EMTC module C294a-8, circuit
1116 (DG) and recirc door actuator C2325-1, circuit 1116 (DG).
Yes
GO to A8.
No
REPAIR circuit 1116 (DG) for an open.
Is the resistance less than 5 ohms? TEST the system for normal operation.
A8 CHECK CIRCUIT 1117 (LG) FOR AN OPEN
1117 (LG) and recirc door actuator C2325-6, circuit 1117 (LG).
Yes
INSPECT for binding or broken linkage. If
no condition is found, INSTALL a new
door actuator. TEST the system for normal
operation.
No
REPAIR circuit 1117 (LG) for an open.
A9 CHECK THE MODULE CONNECTION
Carry out the Electronic Manual Temperature Control (EMTC) Yes
Module Cold Boot Process. INSTALL a new EMTC module. REFER to
Operate the system. Section 412-01. TEST the system for
Does the concern return? normal operation.
No
by a loose or corroded connector. TEST
Pinpoint Test B: Incorrect/Erratic Direction Normal Operation
Of Airflow From Outlet(s)
Under normal operation, to rotate the mode door
actuator clockwise, the EMTC module supplies
voltage to the BLEND, DEFROST and
Control System for schematic and connector
FLOOR/PANEL mode door actuator motors through
information.
the door actuator feed B circuits, and supplies
ground through the door actuator feed A circuits.
To rotate the mode door actuator counterclockwise,
the EMTC module reverses the voltage and ground
circuits.
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Door actuator reference circuits
The mode door actuator feedback resistors are
supplied a ground from the EMTC module by the
Blend 436 (RD/LG)
mode door actuator return circuits and a 5-volt
Defrost 436 (RD/LG)
reference voltage on the mode door actuator
Floor/Panel 436 (RD/LG)
reference circuits. The EMTC module reads the
voltage on the mode door actuator feedback circuits
Door actuator feedback circuits
to determine the mode door actuator position by the
Blend 437 (YE/LG)
position of the actuator feedback resistor wiper arm.
Defrost 1982 (LB/BK)
Door actuator feed B circuits
Floor/Panel 435 (YE/LB)
Blend 1376 (BK/LB)
Possible Causes
Defrost 1137 (YE/LG)
An open, short to voltage, ground or together in
Floor/Panel 1129 (BN/WH)
door actuator open, close, return, reference or
Door actuator feed A circuits
feedback circuits
Blend 1375 (PK/YE)
Blend, air inlet, defrost and floor/panel mode door
actuator motor
Defrost 1136 (RD/WH)
EATC module
Floor/Panel 1128 (GY/LB)
Manual climate control module
Door actuator return circuits
Stuck or bound linkage or door
Blend 438 (RD/WH)
Defrost 438 (RD/WH)
Floor/Panel 438 (RD/WH)
PINPOINT TEST B: INCORRECT/ERRATIC DIRECTION OF AIRFLOW FROM OUTLET(S)
B1 CHECK THE AIRFLOW
Check the air discharge temperature in full cool and full warm The system is operating normally.
and airflow in the PANEL, DEFROST and FLOOR modes.
No
Is the air discharge temperature and airflow correct in each
If the airflow is from the floor only or panel
setting?
only in any mode except OFF and
DEFROST and airflow is from defrost only
on DEFROST mode, follow diagnostics for
floor/panel door actuator. GO to B2.
If the airflow is from the defrost only in all
modes except OFF or from floor/panel in
DEFROST mode, follow diagnostics for
defrost door actuator. GO to B2.
If the temperature control is
inoperative/does not operate correctly,
follow diagnostics for the blend door
actuator. GO to B2.
If the RECIRC button does not change the
air inlet door position, GO to Pinpoint Test
A.
B2 CHECK THE FEEDBACK POTENTIOMETER TOTAL
RESISTANCE
Disconnect: For Floor/Panel Door Actuator: Temperature Blend
Door Actuator C289 and Defrost Door Actuator C232.
Disconnect: For Defrost Door Actuator: Temperature Blend Door
Actuator C289 and Floor/Panel Door Actuator C234.
Disconnect: For Blend Door Actuator: Defrost Door Actuator
C232 and Floor/Panel Door Actuator C234.
Remove the door actuator and disengage the actuator driveshaft
from the actuator door.
Mark the door actuator driveshaft position.
(Continued)
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PINPOINT TEST B: INCORRECT/ERRATIC DIRECTION OF AIRFLOW FROM OUTLET(S) (Continued)
B2 CHECK THE FEEDBACK POTENTIOMETER TOTAL
RESISTANCE (Continued)
436 (RD/LG) and EMTC module C294a-15, circuit 438 (RD/WH).
Yes
GO to B3.
No
If the resistance is greater than 6,000
ohms, GO to B5.
If the resistance is less than 5,000 ohms,
Is the resistance between 5,000 and 6,000 ohms? GO to B7.
B3 CHECK THE POTENTIOMETER LOW SIDE RESISTANCE
Measure the resistance between EMTC module C294a-15,
circuit 438 (RD/WH) and the following:
For floor/panel door actuator: EMTC module C294a-16,
circuit 435 (YE/LB).
For defrost door actuator: EMTC module C294a-17, circuit
1982 (LB/BK).
For blend door actuator: EMTC module C294a-18, circuit
437 (YE/LG).
Yes
GO to B4.
No
ohms, GO to B8.
If the resistance is less than 250 ohms,
Is the resistance between 250 and 5,500 ohms? GO to B9.
(Continued)
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B4 CHECK THE POTENTIOMETER HIGH SIDE RESISTANCE
436 (RD/LG) and the following:
1982 (LB/BK).
437 (YE/LG).
Yes
GO to B11.
No
ohms, INSTALL a new door actuator.
If the resistance is less than 250 ohms,
Is the resistance between 250 and 5,500 ohms? GO to B10.
B5 CHECK CIRCUIT 436 (RD/LG) FOR AN OPEN
Disconnect: Floor/Panel Door Actuator C234, Defrost Door
Actuator C232 or Blend Door Actuator C289.
For floor/panel: floor/panel door actuator C234-3, circuit 436
(RD/LG).
For defrost: defrost door actuator C232-3, circuit 436
(RD/LG).
For blend: blend door actuator C289-3, circuit 436 (RD/LG).
Yes
GO to B6.
No
REPAIR circuit 436 (RD/LG) for an open.
(Continued)
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B6 CHECK THE ACTUATOR RETURN CIRCUIT 438 (RD/WH) FOR
AN OPEN
For floor/panel: floor/panel door actuator C234-2, circuit 438
(RD/WH).
For defrost: defrost door actuator C232-2, circuit 438
(RD/WH).
For blend: blend door actuator C289-2, circuit 438 (RD/WH).
Yes
INSTALL a new door actuator. TEST the
No
REPAIR circuit 438 (RD/WH) for an open.
B7 CHECK CIRCUITS 438 (RD/WH) AND 436 (RD/LG) FOR A
SHORT TOGETHER
436 (RD/LG) and EMTC module C294a-15, circuit 438 (RD/WH).
Yes
No
REPAIR circuit 438 (RD/WH) and circuit
436 (RD/LG) for a short together. TEST
Is the resistance greater than 10,000 ohms? the system for normal operation.
B8 CHECK CIRCUITS 435 (YE/LB), 1982 (LB/BK) OR 437 (YE/LG)
FOR AN OPEN
(Continued)
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B8 CHECK CIRCUITS 435 (YE/LB), 1982 (LB/BK) OR 437 (YE/LG)
FOR AN OPEN (Continued)
Measure the resistance between the following:
circuit 435 (YE/LB) and floor/panel door actuator C234-4,
1982 (LB/BK) and defrost door actuator C232-4, circuit 1982
(LB/BK).
437 (YE/LG) and floor door actuator C289-4, circuit 437
(YE/LG).
Yes
No
REPAIR circuit 435 (YE/LB), 1982 (LB/BK)
or 437 (YE/LG) for an open. TEST the
B9 CHECK CIRCUIT 438 (RD/WH) FOR A SHORT TO CIRCUITS 435
(YE/LB), 1982 (LB/BK) OR 437 (YE/LG)
1982 (LB/BK).
437 (YE/LG).
Yes
No
REPAIR circuit 438 (RD/WH) and circuits
435 (YE/LB), 1982 (LB/BK) or 437
(YE/LG) for a short together. TEST the
Is the resistance greater than 10,000 ohms? system for normal operation.
B10 CHECK CIRCUIT 436 (RD/LG) FOR A SHORT TO CIRCUITS 435
(YE/LB), 1982 (LB/BK) OR CIRCUIT 437 (YE/LG)
(Continued)
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B10 CHECK CIRCUIT 436 (RD/LG) FOR A SHORT TO CIRCUITS 435
(YE/LB), 1982 (LB/BK) OR CIRCUIT 437 (YE/LG) (Continued)
1982 (LB/BK).
437 (YE/LG).
Yes
No
REPAIR circuits 436 (RD/LG) and circuits
435 (YE/LB), 1982 (LB/BK) or 437
(YE/LG) for a short together. TEST the
B11 CHECK CIRCUITS 436 (RD/LG), 437 (YE/LG), 435 (YE/LB) OR
1982 (LB/BK) FOR A SHORT TO GROUND
Measure the resistance between ground and the following:
EMTC module C294a-5, circuit 436 (RD/LG).
1982 (LB/BK).
437 (YE/LG).
Yes
GO to B12.
No
REPAIR circuit(s) for a short to ground.
Is the resistance greater than 10,000 ohms? TEST the system for normal operation.
B12 CHECK CIRCUITS 438 (RD/WH), 437 (YE/LG), 435 (YE/LB) OR
1982 (LB/BK) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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B12 CHECK CIRCUITS 438 (RD/WH), 437 (YE/LG), 435 (YE/LB) OR
1982 (LB/BK) FOR A SHORT TO VOLTAGE (Continued)
Measure the voltage between ground and the following:
EMTC module C294a-15, circuit 438 (RD/WH).
1982 (LB/BK).
437 (YE/LG).
Yes
REPAIR circuit(s) for a short to voltage.
No
Is voltage present? GO to B13.
B13 CHECK THE DOOR ACTUATOR CLOCKWISE OPERATION
Connect a fused jumper wire between EMTC module C294a-26,
circuit 1566 (RD/YE) and:
circuit 1129 (BN/WH).
1137 (YE/LG).
1376 (BK/LB).
(Continued)
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B13 CHECK THE DOOR ACTUATOR CLOCKWISE OPERATION
(Continued)
Connect a second fused jumper wire between EMTC module
C294a-1, circuit 1205 (BK) and:
circuit 1128 (GY/LB).
1136 (RD/WH).
1375 (PK/YE).
Yes
GO to B14.
No
Does the actuator motor move in the clockwise direction? GO to B15.
B14 CHECK THE DOOR ACTUATOR COUNTERCLOCKWISE
OPERATION
Connect a fused jumper wire between EMTC module C294a-1,
circuit 1205 (BK) and:
1137 (YE/LG).
1376 (BK/LB).
(Continued)
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B14 CHECK THE DOOR ACTUATOR COUNTERCLOCKWISE
OPERATION (Continued)
Connect a second fused jumper wire between EMTC module
C294a-26, circuit 1566 (RD/YE) and:
1136 (RD/WH).
1375 (PK/YE).
Yes
INSPECT for binding or broken door and
linkage. If no condition is found, GO to
B19.
Does the actuator motor move in the counterclockwise No
direction? GO to B15.
B15 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR AN
OPEN
circuit 1129 (BN/WH) and floor/panel door actuator C234-6,
1137 (YE/LG) and defrost door actuator C232-6, circuit
1997 BN/YE).
1376 (BK/LB) and blend door actuator C289-6, circuit 1376
(BK/LB).
(Continued)
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B15 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR AN
OPEN (Continued)
circuit 1128 (GY/LB) and floor/panel door actuator C234-1,
1136 (RD/WH) and defrost door actuator C232-1, circuit
1136 (RD/WH).
1375 (PK/YE) and blend door actuator C289-1, circuit 1375
(PK/YE).
Yes
GO to B16.
No
REPAIR the circuit(s) for an open. TEST
Are the resistances less than 5 ohms? the system for normal operation.
B16 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR A
SHORT TO GROUND
1137 (YE/LG).
1376 (BK/LB).
(Continued)
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SHORT TO GROUND (Continued)
1136 (RD/WH).
1375 (PK/YE).
Yes
GO to B17.
No
REPAIR the circuit(s) for a short to
Are the resistances greater than 10,000 ohms? operation.
SHORT TO VOLTAGE
Key in ON position.
1137 (YE/LG).
1376 (BK/LB).
(Continued)
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1136 (RD/WH).
1375 (PK/YE).
Yes
REPAIR the circuit(s) for a short to
operation.
No
Is voltage present? GO to B18.
SHORT TOGETHER
NOTE: For floor/panel door actuator:
circuit 1128 (GY/LB) and EMTC module C294a-20, circuit 1129
(BN/WH).
(Continued)
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SHORT TOGETHER (Continued)
NOTE: For defrost door actuator:
circuit 1136 (RD/WH) and EMTC module C294a-25, circuit 1137
(YE/LG).
NOTE: For blend door actuator:
1375 (PK/YE) and EMTC module C294a-7, circuit 1376 (BK/LB).
Yes
INSPECT for binding or broken linkage. If
no condition is found, INSTALL a new
door actuator. TEST the system for normal
operation.
No
REPAIR circuit(s) for a short together.
Is the resistance greater than 10,000 ohms? TEST the system for normal operation.
B19 CHECK THE MODULE CONNECTION
No
Possible Causes
Pinpoint Test C: Insufficient, Erratic Or No
Heat
Plugged heater core
Normal Operation
Coolant level
Under normal operation, warm coolant flows from
the engine through the heater core and back to the
engine.
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PINPOINT TEST C: INSUFFICIENT, ERRATIC OR NO HEAT
C1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
Check the engine coolant level when hot and cold. GO to C3.
Is the engine coolant at the correct level (hot/cold) as
No
indicated on the engine coolant recovery reservoir?
GO to C2.
C2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS
Pressure test the cooling system for leaks. Refer to Section Yes
303-03A. REPAIR the engine coolant leak. TEST
Does the engine cooling system leak? the system for normal operation.
No
GO to C3.
C3 CHECK FOR COOLANT FLOW TO THE HEATER CORE
WARNING: The heater core inlet hose will become too
hot to handle and may cause serious burns if the system is
working correctly.
Key in ON position.
Run the engine until it reaches normal operating temperature.
Select the FLOOR position on the control assembly. Set the
temperature control to full warm.
Feel the heater core inlet hose to see if it is hot.
Yes
GO to C4.
No
REFER to Section 303-03A to check
Is the heater core inlet hose hot? cooling system function.
C4 CHECK FOR A PLUGGED OR RESTRICTED HEATER CORE
WARNING: The heater core outlet hose will become too
hot to handle and may cause serious burns if the system is
Feel the heater core outlet hose to see if it is hot.
Yes
GO to Pinpoint Test B and diagnose for a
blend door actuator.
No
INSTALL a new heater core. TEST the
Is the heater core outlet hose hot? system for normal operation.
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Possible Causes
Pinpoint Test D: The Air Conditioning (A/C)
Is Inoperative/Does Not Operate Correctly
Fuse
An open in circuit 420 (DB/YE), 1397 (GY/RD),
883 (PK/LB), 198 (DG/OG), 1205 (BK), 391
information.
(RD/YE) or 321 (GY/WH)
Normal Operation
A short to voltage in circuit 1397 (GY/RD)
Under normal operation, when A/C is requested, a
PCM
ground signal is sent to the smart junction box
EMTC module
(SJB) through circuit 1397 (GY/RD) then a message
is sent from the SJB through the CAN bus to the
A/C cycling switch
PCM. Voltage is provided to the A/C cycling
Dual function pressure switch
switch through circuit 391 (RD/YE). The PCM
A/C compressor clutch field coil
receives input from the A/C cycling switch through
circuit 420 (DB/YE) and (4.6L only) through the A/C control relay
dual function pressure switch to circuit 198
A/C clutch air gap
(DG/OG).
The PCM provides a ground for the A/C clutch
relay coil through circuit 321 (GY/WH). When the
relay is activated, ignition voltage is supplied to the
A/C clutch solenoid through circuit 883 (PK/LB).
Ground is supplied for the A/C clutch through
circuit 1205 (BK).
PINPOINT TEST D: THE AIR CONDITIONING (A/C) IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: Some PCM DTCs may inhibit air conditioning (A/C) operation. If any PCM DTCs are
retrieved, diagnose those first. Refer to Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
NOTE: Before carrying out the following test, check that the A/C system pressure is above
290 kPa (42 psi). If the pressure is below 290 kPa (42 psi), refer to Fluorescent Dye Leak
Detection in this section.
D1 CHECK THE A/C SWITCH PID WITH THE A/C ON
Key in ON position.
Enter the following diagnostic mode on the scan tool: SJB A/C
Yes
Switch PID.
GO to D5.
With the engine running, select PANEL mode and press the A/C
button on the EMTC module. No
Does the SJB A/C switch PID read ACTIVE? GO to D2.
D2 CHECK THE EMTC A/C SIGNAL WITH THE A/C ON
Disconnect: Smart Junction Box (SJB) C2280b.
Key in ON position.
Select PANEL mode and press the A/C button on the EMTC
module.
(Continued)
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(Continued)
D2 CHECK THE EMTC A/C SIGNAL WITH THE A/C ON (Continued)
Measure the resistance between SJB C2280b-29, circuit 1397
(GY/RD) and ground.
Yes
GO to D17.
No
Is the resistance less than 5 ohms? GO to D3.
D3 CHECK CIRCUIT 1397 (GY/RD) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between EMTC module C294a-3, circuit
1397 (GY/RD) and ground.
Yes
REPAIR circuit 1397 (GY/RD) for a short
to voltage. TEST the system for normal
operation.
No
Is voltage present? GO to D4.
D4 CHECK CIRCUIT 1397 (GY/RD) FOR AN OPEN
(Continued)
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(Continued)
D4 CHECK CIRCUIT 1397 (GY/RD) FOR AN OPEN (Continued)
1397 (GY/RD) and SJB C2280b-29, circuit 1397 (GY/RD).
Yes
GO to D18.
No
REPAIR circuit 1397 (GY/RD) for an open.
D5 CHECK THE ACCS PID WITH THE A/C ON
Yes
ACCS PID.
GO to D12.
module. No
Does the PCM ACCS PID read ON? GO to D6.
D6 CHECK THE ACCS PCM INPUT
Disconnect: PCM C175e.
Key in ON position.
Measure the voltage between PCM C175e-4, circuit (4.0L) 420
(DB/YE) or (4.6L) 198 (DG/OG) and ground.
Yes
For 4.0L, GO to D7.
For 4.6L, GO to D19.
No
D7 CHECK THE A/C PRESSURE PCM PID
Connect: PCM C175e.
Key in ON position.
Enter the following diagnostic mode on the scan tool: A/C
Yes
Pressure PCM PID.
GO to D19.
With the manifold gauge set connected, compare the pressure
readings of the manifold gauge set and the A/C pressure PID. No
Are the pressure values of the manifold gauge set and the INSTALL a new A/C pressure transducer.
A/C pressure PID similar? TEST the system for normal operation.
D8 CHECK THE A/C CYCLING SWITCH VOLTAGE
Disconnect: A/C Cycling Switch C130.
Key in ON position.
(Continued)
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(Continued)
D8 CHECK THE A/C CYCLING SWITCH VOLTAGE (Continued)
Measure the voltage between ground and A/C cycling switch
C130-1, circuit (Coupe) 391 (RD/YE) or (Convertible) 298
(VT/OG).
Yes
GO to D9.
No
VERIFY the smart junction box (SJB) fuse
14 (5A) is OK. If OK, REPAIR circuit 298
(VT/OG or 391 (RD/YE) for an open.
Is the voltage greater than 10 volts? TEST the system for normal operation.
D9 CHECK CIRCUIT 420 (DB/YE) FOR AN OPEN
Disconnect: PCM C175e (4.0L only).
Disconnect: Dual Function Pressure Switch C1078 (4.6L only).
NOTE: 4.0L only.
Measure the resistance between A/C cycling switch C130-4,
circuit 420 (DB/YE) and PCM C175e-4, circuit 420 (DB/YE).
(Continued)
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(Continued)
D9 CHECK CIRCUIT 420 (DB/YE) FOR AN OPEN (Continued)
NOTE: 4.6L only.
Measure the resistance between A/C cycling switch C130-4,
circuit 420 (DB/YE) and dual function pressure switch C1078-1,
circuit 420 (DB/YE).
Yes
For 4.0L, INSTALL a new A/C cycling
switch. TEST the system for normal
operation.
For 4.6L, GO to D10.
No
REPAIR circuit 420 (DB/YE) for an open.
D10 CHECK VOLTAGE TO THE DUAL FUNCTION PRESSURE
SWITCH
Connect: A/C Cycling Switch C130.
Key in ON position.
Measure the voltage between dual function pressure switch
C1078-1, circuit 420 (DB/YE) and ground.
Yes
GO to D11.
No
INSTALL a new A/C cycling switch. TEST
Is the voltage greater than 10 volts? the system for normal operation.
D11 CHECK CIRCUIT 198 (DG/OG) FOR AN OPEN
(Continued)
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(Continued)
D11 CHECK CIRCUIT 198 (DG/OG) FOR AN OPEN (Continued)
Measure the resistance between dual function pressure switch
C1078-4, circuit 198 (DG/OG) and PCM C175e-4, circuit 198
(DG/OG).
Yes
INSTALL a new dual function pressure
operation.
No
REPAIR circuit 198 (DG/OG) for an open.
D12 CHECK THE GROUND AT THE A/C COMPRESSOR CLUTCH
FIELD COIL
Disconnect: A/C Compressor Clutch Field Coil C100.
Measure the resistance between A/C compressor clutch field coil
C100-2, circuit 1205 (BK) and ground.
Yes
GO to D13.
No
REPAIR circuit 1205 (BK) for an open.
D13 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH
FIELD COIL
Key in ON position.
module.
(Continued)
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(Continued)
D13 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH
FIELD COIL (Continued)
Measure the voltage between A/C compressor clutch field coil
C100-1, circuit 883 (PK/LB) and ground.
Yes
GO to D14.
No
D14 CHECK THE A/C COMPRESSOR CLUTCH AIR GAP
Measure the A/C compressor clutch air gap at 3 equally spaced
locations between the clutch hub and the A/C compressor clutch
pulley.
Yes
ADJUST the A/C compressor clutch gap.
REFER to Air Conditioning (A/C) Clutch
Air Gap Adjustment in this section. TEST
No
INSTALL a new A/C compressor clutch
Is the A/C compressor clutch air gap greater than 0.030 in field coil. TEST the system for normal
(0.75 mm)? operation.
D15 CHECK VOLTAGE TO RELAY SWITCH
Disconnect: A/C Clutch Relay.
Key in ON position.
(Continued)
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(Continued)
D15 CHECK VOLTAGE TO RELAY SWITCH (Continued)
Measure the voltage between A/C control relay socket pin 30
and ground.
Yes
GO to D16.
No
VERIFY the bussed electrical center
(BEC) fuse 49 (15A) is OK. If OK,
(Continued)
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(Continued)
D16 CHECK CIRCUIT 883 (PK/LB)
Measure the resistance between A/C control relay socket pin 87,
circuit 883 (PK/LB) and A/C compressor clutch field coil C100-1,
circuit 883 (PK/LB).
Yes
INSTALL a new A/C control relay. TEST
No
REPAIR circuit 883 (PK/LB) for an open.
D17 CHECK THE SJB MODULE CONNECTION
Clear the DTCs.
corrosion.
operation.
pushed-out pins.
incorrectly seated connector. No
Connect and correctly seat all the SJB connectors. The system is operating correctly at this
Operate the system. time. The concern may have been caused
Does the concern return? by a loose or corroded connector.
D18 CHECK THE MODULE CONNECTION
No
D19 CHECK THE PCM MODULE CONNECTION
Clear the DTCs.
Disconnect all the PCM connectors.
(Continued)
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(Continued)
D19 CHECK THE PCM MODULE CONNECTION (Continued)
Check for: Yes
corrosion.
pushed-out pins.
Connect and correctly seat all the PCM connectors. The system is operating correctly at this
Pinpoint Test E: The Air Conditioning (A/C)
The PCM provides a ground for the A/C clutch
Is Always On
relay coil through circuit 321 (GY/WH). When the
relay is activated, ignition voltage is supplied to the
A/C clutch solenoid through circuit 883 (PK/LB).
Ground is supplied for the A/C clutch through
information.
circuit 1205 (BK).
Normal Operation
Possible Causes
Under normal operation, when A/C is requested, a
ground signal is sent to the smart junction box
A short to voltage in circuit 883 (PK/LB), 198
(SJB) through circuit 1397 (GY/RD) then a message
(DG/OG) or 420 (DB/YE)
is sent from the SJB through the CAN bus to the
A short to ground in circuit 1397 (GY/RD)
PCM. Voltage is provided to the A/C cycling
PCM
switch through circuit 391 (RD/YE). The PCM
receives input from the A/C cycling switch through Smart junction box (SJB)
circuit 420 (DB/YE) and (4.6L only) through the
EMTC module
dual function pressure switch to circuit 198
A/C cycling switch
(DG/OG).
A/C control relay
A/C clutch air gap
PINPOINT TEST E: THE AIR CONDITIONING (A/C) IS ALWAYS ON
E1 CHECK THE A/C SWITCH PID WITH THE A/C OFF
Enter the following diagnostic mode on the scan tool: PCM A/C Yes
Switch PID. GO to E2.
Does the PCM A/C switch PID read ON?
No
GO to E4.
E2 CHECK THE EMTC A/C SIGNAL WITH THE A/C OFF
Disconnect: Smart Junction Box (SJB) C2280e.
Key in ON position.
Select the OFF position on the EMTC module.
(Continued)
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PINPOINT TEST E: THE AIR CONDITIONING (A/C) IS ALWAYS ON (Continued)
E2 CHECK THE EMTC A/C SIGNAL WITH THE A/C OFF
(Continued)
Measure the resistance between SJB C2280e-29, circuit 1397
(GY/RD) and ground.
Yes
GO to E3.
No
Is the resistance less than 5 ohms? GO to E11.
E3 CHECK CIRCUIT 1397 (GY/RD) FOR A SHORT TO GROUND
Measure the resistance between SJB C2280e-29, circuit 1397
(GY/RD) and ground.
Yes
GO to E12.
No
REPAIR circuit 1397 (GY/RD) for a short
to ground. TEST the system for normal
E4 CHECK THE ACCS PID WITH THE A/C OFF
Select the OFF position on the EMTC module. Yes
Enter the following diagnostic mode on the scan tool: PCM GO to E5.
ACCS PID.
No
Does the PCM ACCS PID read ON?
GO to E9.
E5 CHECK THE A/C CYCLING SWITCH
Disconnect: A/C Cycling Switch C130. For 4.0L, GO to E6.
Key in ON position.
For 4.6L, GO to E7.
No
ACCS PID.
INSTALL a new A/C cycling switch. TEST
E6 CHECK CIRCUIT 420 (DB/YE) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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E6 CHECK CIRCUIT 420 (DB/YE) FOR A SHORT TO VOLTAGE
(Continued)
Measure the voltage between PCM C175e-4, circuit 420
(DB/YE) and ground.
Yes
GO to E13.
No
REPAIR circuit 420 (DB/YE) for a short to
Is voltage present? operation.
E7 CHECK THE DUAL FUNCTION SWITCH
Disconnect: Dual Function Pressure Switch C1078. GO to E8.
Key in ON position.
No
REPAIR circuit 420 (DB/YE) for a short to
ACCS PID.
operation.
E8 CHECK CIRCUIT 198 (DG/OG) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between PCM C175e-4, circuit 198
(DG/OG) and ground.
Yes
GO to E13.
No
REPAIR circuit 198 (DG/OG) for a short to
Is voltage present? operation.
E9 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR CLUTCH
FIELD COIL
Disconnect: A/C Compressor Clutch Field Coil C100.
Key in ON position.
Select the OFF position on the EMTC module.
(Continued)
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E9 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR CLUTCH
FIELD COIL (Continued)
Yes
GO to E10.
No
ADJUST the A/C compressor clutch gap.
REFER to Air Conditioning (A/C) Clutch
Air Gap Adjustment in this section. TEST
E10 CHECK CIRCUIT 883 (PK/LB) FOR A SHORT TO VOLTAGE
Disconnect: A/C Control Relay.
Key in ON position.
Yes
REPAIR circuit 883 (PK/LB) for a short to
operation.
No
INSTALL a new A/C clutch relay. Check
the A/C clutch diode. INSTALL a new
diode if necessary. TEST the system for
Is voltage present? normal operation.
E11 CHECK THE SJB MODULE CONNECTION
Clear the DTCs.
corrosion.
operation.
pushed-out pins.
Connect and correctly seat all the SJB connectors. The system is operating correctly at this
E12 CHECK THE MODULE CONNECTION
No
(Continued)
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E13 CHECK THE PCM MODULE CONNECTION
Clear the DTCs.
Check for: Yes
corrosion.
pushed-out pins.
Connect and correctly seat all the PCM connectors. The system is operating correctly at this
Possible Causes
Pinpoint Test F: The Blower Motor Is
Inoperative
An open in circuit 261 (DG/BK), 1205 (BK), 371
(PK/WH), 364 (BK/LG) or the relay coil and
switch supply voltage circuit
information.
Blower motor
Normal Operation
Blower motor relay
Under normal operation, the blower motor relay coil
EMTC module
receives ignition voltage. The coil receives ground
from the EMTC module through circuit 364
(BK/LG) if any position but OFF is selected.
Voltage is supplied to the relay switch contact.
When the relay coil is energized, voltage is
delivered to the blower motor through circuit 371
(PK/WH). Ground for the blower motor is provided
through circuit 261 (DG/BK) from the blower
resistor or the blower switch (HI). The blower
resistor and blower switch is grounded through
circuit 1205 (BK).
PINPOINT TEST F: THE BLOWER MOTOR IS INOPERATIVE
F1 CHECK CIRCUIT 261 (DG/BK) FOR GROUND
Disconnect: Blower Motor C2066.
Turn the function selector switch to the PANEL position.
Turn the blower motor switch to the high position.
Measure the resistance between A/C blower motor connector
C2066-2, circuit 261 (DG/BK) and ground.
Yes
GO to F4.
No
Is the resistance less than 5 ohms? GO to F2.
F2 CHECK CIRCUIT 261 (DG/BK) FOR AN OPEN
Disconnect: Blower Motor Switch C294b.
(Continued)
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PINPOINT TEST F: THE BLOWER MOTOR IS INOPERATIVE (Continued)
F2 CHECK CIRCUIT 261 (DG/BK) FOR AN OPEN (Continued)
Measure the resistance between blower motor switch C294b-2,
circuit 261 (DG/BK) and blower motor C2066-2, circuit 261
(DG/BK).
Yes
GO to F3.
No
REPAIR circuit 261 (DG/BK) for an open.
F3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
circuit 1205 (BK) and ground.
Yes
INSTALL a new blower motor switch.
No
F4 CHECK A/C BLOWER MOTOR CIRCUIT 371 (PK/WH) FOR
VOLTAGE
Key in ON position.
Measure the voltage between A/C blower motor connector
C2066-1, circuit 371 (PK/WH) and ground.
Yes
INSTALL a new blower motor. TEST the
No
Is the voltage greater than 10 volts? GO to F5.
(Continued)
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F5 CHECK CIRCUIT 371 (PK/WH) FOR AN OPEN
Disconnect: Blower Motor Relay.
Measure the resistance between blower motor relay connector
pin 30, circuit 371 (PK/WH) and blower motor C2066-1, circuit
371 (PK/WH).
Yes
GO to F6.
No
REPAIR circuit 371 (PK/WH) for an open.
F6 CHECK THE BLOWER MOTOR RELAY
Connect: Blower Motor C2066.
Key in ON position.
(Continued)
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F6 CHECK THE BLOWER MOTOR RELAY (Continued)
Connect a fused jumper lead between blower motor relay socket
pin 87 and pin 30, circuit 371 (PK/WH).
Yes
GO to F7.
No
(BEC) fuse 2 (30A) is OK. If OK, INSTALL
a new BEC. TEST the system for normal
Does the blower motor operate? operation.
F7 CHECK THE RELAY COIL SUPPLY VOLTAGE
(Continued)
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F7 CHECK THE RELAY COIL SUPPLY VOLTAGE (Continued)
Measure the voltage between blower motor relay socket pin 86,
circuit 1322 (BN/WH) and ground.
Yes
GO to F8.
No
3 (10A) is OK. If OK, REPAIR circuit 1322
(BN/WH) for an open. TEST the system
F8 CHECK THE BLOWER MOTOR RELAY
Key in ON position.
(Continued)
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F8 CHECK THE BLOWER MOTOR RELAY (Continued)
Measure the voltage between blower motor relay socket pin 85,
circuit 364 (BK/LG) and socket pin 86, circuit 1322 (BN/WH).
Yes
INSTALL a new blower motor relay. TEST
No
F9 CHECK CIRCUIT 364 (BK/LG) FOR AN OPEN
Disconnect: EMTC module C294a.
(Continued)
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F9 CHECK CIRCUIT 364 (BK/LG) FOR AN OPEN (Continued)
Measure the resistance between blower motor relay connector
pin 85, circuit 364 (BK/LG) and EMTC module C294a-23, circuit
364 (BK/LG).
Yes
GO to F10.
No
REPAIR circuit 364 (BK/LG) for an open.
F10 CHECK THE MODULE CONNECTION
No
Pinpoint Test G: The Blower motor Does Not Normal Operation
Operate Correctly
Under normal operation, the blower motor is
provided a ground from the blower resistor through
circuit 261 (DG/BK). The resistor gets a ground
from circuit 1205 (BK) in the lowest blower setting.
information.
In MED-LO and MED-HI the resistor gets a ground
through circuit 754 (LG/WH) or 752 (YE/RD),
depending on selected speed. In HI, the blower
motor is grounded directly through the blower
switch from circuit 261 (DG/BK) to circuit 1205
(BK). The blower switch receives its ground from
circuit 1205 (BK).
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Possible Causes
A short together circuits 261 (DG/BK), 754
(LG/WH) or 752 (YE/RD)
An open in circuit 1205 (BK), 261 (DG/BK), 754
(LG/WH) or 752 (YE/RD) Blower motor resistor
A short to ground in circuit 261 (DG/BK), 754 Blower motor switch
(LG/WH) or 752 (YE/RD)
PINPOINT TEST G: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY
G1 CHECK THE BLOWER MOTOR OPERATION
Turn the function selector switch to the FLOOR position. If the blower motor does not operate in HI,
Select all blower speed positions. GO to G2.
Does the blower motor operate in any position?
If the blower motor does not operate in
MED-HI, GO to G3.
MED-LO, GO to G4.
LO, GO to G5.
For all other symptoms, GO to G9.
No
GO to Pinpoint Test F.
G2 CHECK CIRCUIT 261 (DG/BK) FOR AN OPEN
(DG/BK).
Yes
GO to G6.
No
G3 CHECK CIRCUIT 754 (LG/WH) FOR AN OPEN
Disconnect: Blower Motor Resistor C2185.
(Continued)
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PINPOINT TEST G: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY (Continued)
G3 CHECK CIRCUIT 754 (LG/WH) FOR AN OPEN (Continued)
circuit 754 (LG/WH) and blower motor resistor C2185-3, circuit
754 (LG/WH).
Yes
GO to G6.
No
REPAIR circuit 754 (LG/WH) for an open.
G4 CHECK CIRCUIT 752 (YE/RD) FOR AN OPEN
circuit 752 (YE/RD) and blower motor resistor C2185-1, circuit
752 (YE/RD).
Yes
GO to G6.
No
REPAIR circuit 752 (YE/RD) for an open.
(Continued)
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G5 CHECK BLOWER MOTOR RESISTOR GROUND CIRCUIT 1205
(BK) FOR AN OPEN
Measure the resistance between blower motor resistor C2185-4,
Yes
GO to G6.
No
G6 CHECK BLOWER MOTOR RESISTOR CIRCUIT 261 (DG/BK)
FOR AN OPEN
Connect: Blower Motor C2066.
Measure the resistance between blower motor resistor C2185-2,
(DG/BK).
Yes
GO to G7.
No
G7 CHECK THE BLOWER MOTOR RESISTOR
Carry out the blower motor resistor component test in this Yes
section. GO to G8.
Does the blower motor resistor test good?
No
INSTALL a new blower motor resistor.
(Continued)
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G8 CHECK BLOWER MOTOR SWITCH CIRCUIT 1205 (BK) FOR AN
OPEN
Yes
No
G9 CHECK CIRCUITS 261 (DG/BK), 752 (YE/RD) AND 754 (LG/WH)
FOR A SHORT TO GROUND
Place the blower switch in the lowest setting.
Measure the resistance between ground and blower motor
resistor C2185, circuit:
752 (YE/RD) pin 1.
261 (DG/BK) pin 2.
754 (LG/WH) pin 3.
Yes
GO to G10.
No
REPAIR the affected circuit. TEST the
Are the resistances less than 5 ohms? system for normal operation.
(Continued)
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G10 CHECK THE BLOWER MOTOR CIRCUITS FOR SHORTS
TOGETHER
Measure the resistance between blower motor resistor C2185:
pin 1, circuit 752 (YE/RD) and pin 2, circuit 261 (DG/BK).
pin 1, circuit 752 (YE/RD) and pin 3, circuit 754 (LG/WH).
pin 2, circuit 261 (DG/BK) and pin 3, circuit 754 (LG/WH).
Yes
No
REPAIR the affected circuits. TEST the
Are the resistances greater than 10,000 ohms? system for normal operation.
Component Tests Heater Core
WARNING: Carbon monoxide is colorless,
Resistor Blower Motor
odorless and dangerous. If it is necessary to
operate the engine with the vehicle in a closed
area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the
closed area.
1. NOTE: Testing of returned heater cores reveals
that a large percentage of heater cores were
good and did not require replacement. If a
heater core leak is suspected, the heater core
must be tested by carrying out the plugged
heater core component test before the heater
core pressure test. Carry out a system
inspection by checking the heater system
thoroughly as follows:
Inspect for evidence of coolant leakage at the Pins Resistance
heater water hose to heater core attachments. A
4 and 2 2.0-2.6 ohms
coolant leak in the heater water hose could
2 and 3 0.2-0.4 ohms
follow the heater core tube to the heater core
2 and 1 0.8-1.1 ohms
and appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as
original equipment. Installation and
overtightening of non-specification clamps can
cause leakage at the heater water hose
connection and damage the heater core.
Check the integrity of the heater water hose
clamps.
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Heater Core Plugged
5. Attach the pump and gauge assembly from the
Radiator/Heater Core Pressure Tester to the
WARNING: The heater core inlet hose will
adapter.
become too hot to handle if the system is
6. Close the bleed valve at the base of the gauge.
working correctly.
Pump 138 kPa (20 psi) of air pressure into the
1. Check to see that the engine coolant is at the
heater core.
correct level.
7. Observe the pressure gauge for a minimum of 3
2. Start the engine and turn on the heater.
minutes.
3. When the engine coolant reaches operating
8. If the pressure drops, check the heater water
temperature, feel the heater core inlet and outlet
hose connections to the core tubes for leaks. If
hose to see if they are hot.
the heater water hoses do not leak, remove the
If the inlet hose is not hot:
heater core from the vehicle and carry out the
bench test.
the thermostat is not working correctly.
If the outlet hose is not hot:
Heater Core Bench Test
1. Remove the heater core from the vehicle. Refer
the heater core may have an air pocket.
to Section 412-01.
the heater core may be restricted or plugged.
2. Drain all of the coolant from the heater core.
Heater Core Pressure Test
3. Connect the 101 mm (4 in) test heater water
Use the Radiator/Heater Core Pressure Tester to
hoses with plug and adapter to the core tubes.
carry out the pressure test.
Then connect the Radiator/Heater Core Pressure
Tester to the adapter.
1. NOTE: Due to space limitations, a bench test
may be necessary for pressure testing.
4. Apply 138 kPa (20 psi) of air pressure to the
heater core. Submerge the heater core in water.
Clamp off the heater hoses.
5. If a leak is observed, install a new heater core.
2. Disconnect the heater water hoses from the
heater core.
3. Install a short piece of heater water hose,
approximately 101 mm (4 inches) long on each
heater core tube.
4. Fill the heater core and heater water hoses with
water and install Plug BT-7422-B and Adapter
BT-7422-A from the Radiator/Heater Core
Pressure Tester in the heater water hose ends.
Secure the heater water hoses, plug and adapter
with hose clamps.
A/C Evaporator/Condenser Core On
Vehicle Leak Test
1. Recover the refrigerant. Refer to Air
2. NOTE: DO NOT leak test an A/C evaporator
core with the suction accumulator/drier attached
to the core tubes.
Disconnect the suspect A/C evaporator core or
A/C condenser core from the A/C system. Refer
to Section 412-01.
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3. Clean the spring lock couplings. Refer to If a very small leak is suspected, wait 30
Spring Lock Coupling in this section. minutes and observe the vacuum gauge.
4. Connect the appropriate test fittings from the If a small amount of vacuum is lost, operate
R-12/R-134a Air Conditioning Test Fitting Set the vacuum pump with gauge valves open
to the evaporator or condenser tube connections. for an additional 30 minutes to remove any
remaining refrigerant from the oil in the
5. NOTE: The automatic shut-off valves on some
A/C evaporator core or A/C condenser core.
gauge set hoses do not open when connected to
Then recheck for loss of vacuum.
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves If a very small leak is suspected, allow the
are used, make sure the valve opens when system to set overnight with vacuum applied
attached to the test fittings or install an adapter and check for vacuum loss.
which will activate the valve. The test is not
9. If the A/C evaporator core or A/C condenser
valid if the shut-off valve does not open.
core does leak, as verified by the above
Connect the red and blue hoses from the procedure, install a new A/C evaporator core or
R-134a Manifold Gauge Set to the test fittings A/C condenser core. Refer to Section 412-01.
on the A/C evaporator core or A/C condenser
A/C Compressor External Leak Test
core. Connect the yellow hose to a known good
vacuum pump. 1. Install the A/C Pressure Test Adapter on the
rear head of the A/C compressor, using the
6. Open both gauge set valves and start the
existing manifold retaining bolt.
vacuum pump. Allow the vacuum pump to
operate for a minimum of 45 minutes after the 2. Connect the high and low pressure lines of a
gauge set low pressure gauge indicates 101 kPa manifold gauge set or a refrigerant
(30 in-Hg). The 45 minute evacuation is recovery/recycling station such as the R-134a
necessary to remove any refrigerant from oil A/C Service Center to the corresponding fittings
left in the A/C evaporator core or A/C on the A/C Pressure Test Adapter.
condenser core. If the refrigerant is not
3. Attach the center hose of the manifold gauge
completely removed from the oil, outgassing
set to a refrigerant container standing in an
will degrade the vacuum and appear as a
upright position.
refrigerant leak.
4. Hand-rotate the compressor shaft 10 complete
7. If the low pressure gauge reading will not drop
revolutions to distribute the oil inside the A/C
to 101 kPa (30 in-Hg) when the valves on the
compressor.
gauge and manifold set are open and the
5. Open the low pressure gauge valve, the high
vacuum pump is operating, close the gauge set
pressure gauge valve and the valve on the
valves and observe the low pressure gauge. If
refrigerant container to allow the refrigerant
the pressure rises rapidly to zero, a large leak
vapor to flow into the A/C compressor.
is indicated. Recheck the test fitting connections
6. Using the Automatic Calibration Halogen Leak
and gauge set connections before installing a
Detector, check the entire A/C compressor for
new A/C evaporator core or A/C condenser
leaks.
core.
7. If an external leak is found, install a new A/C
8. After evacuating for 45 minutes, close the
compressor. Refer to Section 412-01.
gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should
8. When the leak test is complete, recover the
remain at the 101 kPa (30 in-Hg) mark.
refrigerant from the compressor.
If the low pressure gauge reading rises 34 or
more kPa (10 or more in-Hg) of vacuum
from the 101 kPa (30 in-Hg) position in 10
minutes, a leak is indicated.
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Do not add R-12 refrigerant to an A/C system
Climate Control System
that requires the use of R-134a refrigerant.
WARNING: Carbon monoxide is colorless,
These 2 types of refrigerant must never be
odorless and dangerous. If it is necessary to
mixed. Doing so can damage the A/C system.
operate the engine with vehicle in a closed area
Charge the A/C system with the engine
such as a garage, always use an exhaust collector
running only at the low-pressure side to
to vent the exhaust gases outside the closed area.
prevent refrigerant slugging from damaging the
WARNING: R-134a is classified as a safe
A/C compressor.
refrigerant, but misuse can make it dangerous.
Use only R-134a refrigerant. Due to
The following precautions must be observed.
environmental concerns, when the air
conditioning system is drained, the refrigerant
Always wear safety goggles when repairing an
must be collected using refrigerant
air conditioning system.
recovery/recycling equipment. Federal law
Avoid contact with liquid refrigerant R-134a.
REQUIRES that R-134a be recovered into
R-134a vaporizes at approximately -25C
appropriate recovery equipment and the
(-13F) under atmospheric pressure and it will
process be conducted by qualified technicians
freeze skin tissue.
who have been certified by an approved
Never allow refrigerant R-134a gas to escape in
organization, such as MACS, ASI, etc. The use
quantity in an occupied space. R-134a is
of a recovery machine dedicated to R-134a is
non-toxic, but it will displace the oxygen
necessary to reduce the possibility of oil and
needed to support life.
refrigerant incompatibility concerns. Refer to
the instructions provided by the equipment
Never use a torch in an atmosphere containing
manufacturer when removing refrigerant from
R-134a gas. R-134a is non-toxic in all normal
or charging the air conditioning system.
conditions, but when it is exposed to high
temperatures, such as a torch flame, it
Refrigerant R-134a must not be mixed with air
decomposes. During decomposition it releases
for leak testing or used with air for any other
irritating and toxic gases (as described in the
purpose above atmospheric pressure. R-134a is
MSDS sheet from the manufacturer).
combustible when mixed with high
Decomposition products are hydrofluoric acid,
concentrations of air and higher pressures.
carbon dioxide and water.
A number of manufacturers are producing
Do not allow any portion of the charged air
refrigerant products that are described as
conditioning system to become too hot. The
direct substitutes for refrigerant R-134a. The
pressure in an air conditioning system rises as
use of any unauthorized substitute refrigerant
the temperature rises and temperatures of
can severely damage the A/C components. If
approximately 85C (185F) can be dangerous.
repair is required, use only new or recycled
refrigerant R-134a.
Allow the engine to cool sufficiently prior to
carrying out maintenance or serious burns and
CAUTION: To avoid contamination of the
injury can occur.
A/C system:
CAUTION: To avoid damaging the vehicle
Never open or loosen a connection before
or A/C components, the following precautions
recovering the refrigerant.
must be observed.
When loosening a connection, if any residual
The A/C refrigerant of all vehicles must be
pressure is evident, allow it to leak out before
identified and analyzed prior to refrigerant
opening the fitting.
charging. Failure to do so can contaminate the
Evacuate a system that has been opened to
shop bulk refrigerant and other vehicles.
install a new component, or one that has
discharged through leakage before charging.
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Principles of Operation Seal open fittings with a cap or plug
immediately after disconnecting a component
There are 4 main principles involved with the basic
from the system.
theory of operation:
Clean the outside of the fittings thoroughly
Heat transfer
before disconnecting a component from the
Latent heat of vaporization
system.
Relative humidity
Do not remove the sealing caps from a new
component until ready to install.
Effects of pressure
Refrigerant oil will absorb moisture from the
Heat Transfer
atmosphere if left uncapped. Do not open an
If 2 substances of different temperature are placed
oil container until ready to use and install the
near each other, the heat in the warmer substance
cap immediately after using. Store the oil in a
will transfer to the colder substance.
clean, moisture-free container.
Install a new O-ring seal before connecting an
Latent Heat of Vaporization
open fitting. Coat the fitting and O-ring seal
When a liquid boils (converts to gas) it absorbs heat
with mineral oil before connecting.
without raising the temperature of the resulting gas.
When installing a refrigerant line, avoid sharp
When the gas condenses (converts back to a liquid),
bends. Position the line away from the exhaust
it gives off heat without lowering the temperature of
or any sharp edges that can chafe the line.
the resulting liquid.
Tighten threaded fittings only to specifications.
Relative Humidity
The steel and aluminum fittings used in the
The amount of moisture (water vapor content) that
refrigerant system will not tolerate
the air can hold is directly related to the air
overtightening.
temperature. The more heat there is in the air, the
When disconnecting a fitting, use a wrench on
more moisture the air can hold. The lower the
both halves of the fitting to prevent twisting
moisture content in the air, the more comfortable
the refrigerant lines or tubes.
you feel. Removing the moisture from the air
Do not open a refrigerant system or uncap a
lowers its relative humidity and improves personal
new component unless it is as close as possible
comfort.
to room temperature. This will prevent
Effects of Pressure on Boiling or
condensation from forming inside a component
Condensation
that is cooler than the surrounding air.
As the pressure is increased on a liquid, the
The electronic manual temperature control (EMTC)
temperature at which the liquid boils (converts to
system heats or cools the vehicle depending on the
gas) also increases. Conversely, when the pressure
function and temperature selected.
on a liquid is reduced, its boiling point is also
The function selected on the climate control
reduced. When in the gas state, an increase in
assembly determines heating or cooling, air
pressure causes an increase in temperature, while a
distribution and enables blower motor operation.
decrease in pressure will decrease the temperature
The temperature control setting determines the air of the gas.
temperature.
Compressor Anti-Slugging Strategy
The blower motor setting varies the blower motor
Liquid refrigerant may accumulate in the A/C
speed.
compressor under certain conditions. To alleviate
damage to the A/C compressor, compressor
anti-slugging strategy (CASS) is utilized.
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CASS is initiated only under specific conditions: The suction accumulator is designed to remove
moisture from the refrigerant and to prevent any
When the ignition is OFF for more than 8 hours
liquid refrigerant that may not have been vaporized
When the ambient temperature is above -4C
in the evaporator core from reaching the A/C
(25F)
compressor. The A/C compressor is designed to
pump refrigerant vapor only, as liquid refrigerant
When battery voltage is above 8.5 volts during
will not compress and can damage the A/C
engine cranking
compressor.
When these conditions are present, the powertrain
The refrigerant cycle is now repeated with the A/C
control module (PCM) will activate the A/C control
compressor again increasing the pressure and
relay prior to cranking of the engine. The A/C
temperature of the refrigerant.
control relay engages the A/C compressor for
approximately 4-15 A/C compressor revolutions or a
The A/C cycling switch interrupts compressor
maximum of 2 seconds (depending upon vehicle
operation before the external temperature of the
application), allowing the liquid refrigerant to be
evaporator core gets low enough to cause the
pushed from the A/C compressor. CASS is initiated
condensed water vapor (excess humidity) to turn to
by the PCM regardless of the function selector
ice. It does this by monitoring low side line
switch position or the EATC system settings. pressure. It is known that a refrigerant pressure of
approximately 210 kPa (30 psi) will yield an
The Refrigerant Cycle
operating temperature of 0C (32F). The A/C
During stabilized conditions (air conditioning system cycling switch controls system operation in an effort
shutdown), the refrigerant is in a vaporized state to maintain this temperature.
and pressures are equal throughout the system.
The high side line pressure is also monitored so that
When the A/C compressor is in operation it
A/C compressor operation can be interrupted if
increases pressure on the refrigerant vapor, raising
system pressure becomes too high. When the A/C
its temperature. The high-pressure and
compressor discharge pressure rises, the A/C dual
high-temperature vapor is then released into the top
function pressure switch contacts open (4.6L) or
of the condenser core.
the A/C pressure transducer value changes (4.0L),
The condenser core, being close to ambient disengaging the A/C compressor. When the pressure
temperature, causes the refrigerant vapor to drops, operation of the A/C compressor resumes.
condense into a liquid when heat is removed by
The A/C pressure relief valve will open and vent
ambient air passing over the fins and tubing. The
refrigerant to relieve unusually high system
now liquid refrigerant, still at high pressure, exits
pressure.
from the bottom of the condenser core and enters
the inlet side of the evaporator core orifice.
The evaporator core orifice is the restriction in the
refrigerant system that creates the low pressure drop
in the evaporator core and separates the high and
low pressure sides of the A/C system. As the liquid
refrigerant leaves this restriction, its pressure and
boiling point are reduced.
The liquid refrigerant is now at its lowest pressure
and temperature. As it passes through the evaporator
core, it absorbs heat from the passenger
compartment airflow passing over the plate/fin
sections of the evaporator core. This addition of
heat causes the refrigerant to boil (convert to gas).
The now cooler passenger compartment air can no
longer support the same humidity level of the
warmer air and this excess moisture condenses on
the exterior of the evaporator coils and fins and
drains outside the vehicle.
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Clutch Cycling Orifice Tube Type Refrigerant System
6 19D594 A/C dual function pressure 1 19E762 A/C charge valve port (low
switch (4.6L) side)
7 19E762 A/C charge valve port (high 2 19E561 A/C cycling switch
side)
3 19C836 Suction accumulator
8 19712 Condenser core
9 19D990 Evaporator core orifice tube
5 19D644 A/C compressor pressure
10 19860 Evaporator core relief valve
11 Low pressure vapor 6 19D594 A/C pressure transducer
(4.0L)
12 High pressure vapor
(Continued)
(Continued)
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NOTE: Recirculated air only is used when the
electronic manual temperature control mode selector
13 Low pressure liquid
is set in the MAX A/C or OFF modes or if the
14 High pressure liquid
RECIRC request button is selected in any mode
except MAX A/C, OFF or DEFROST.
Climate Control System Operation
The air recirculation button:
Electronic Manual Temperature Control
selects either recirculated or outside air source.
System
is serviced only with the climate control
assembly.
system operation is determined by the settings on
the climate control assembly. The climate control
System Airflow Description
assembly includes a serviceable blower motor
switch.
Max A/C
The blower motor switch:
When MAX A/C is selected:
sets the blower motor speed.
the air inlet door actuator closes off outside air
and admits only recirculated air.
directs the blower motor path to ground through
the blower motor resistor to allow blower motor
the recirc button is disabled and the indicator is
operation in LO, MED LO and MED HI.
illuminated.
directs the blower motor path directly to ground,
the defrost door actuator is in the full closed
bypassing the blower motor resistor, to allow
position, directing airflow to the floor/panel door.
blower motor operation in HI.
the floor/panel door actuator is in the full panel
The A/C request switch:
position, directing airflow to the instrument panel
A/C registers. A small amount of airflow from the
can command the A/C compressor ON when the
floor duct will be present.
function selector switch is in PANEL,
blended air temperature is available.
FLOOR/PANEL, FLOOR/DEFROST and FLOOR
when the A/C request switch is pressed. Indicator
the A/C request button is illuminated and will be
illuminates when A/C request switch is toggled
disabled.
ON.
the A/C compressor will operate if the outside
can command the A/C compressor OFF in
temperature is above approximately 2C (35F).
FLOOR/DEFROST if RECIRC is commanded
the blower motor is ON.
OFF.
PANEL
is inoperative in MAX A/C, OFF and DEFROST.
When PANEL is selected:
indicator illuminates when the function selector
switch is in MAX A/C and cannot be toggled.
the recirc request button is enabled. If the recirc
indicator does not illuminate in OFF and cannot
request button is selected (indicator ON), the air
be toggled.
inlet door actuator closes off outside air from
entering the passenger compartment. If the recirc
indicator in FLOOR/DEFROST and DEFROST
request button is not selected (indicator OFF), the
does not change. The A/C compressor will
air inlet door actuator admits only outside air into
operate regardless of indicator status if the outside
the passenger compartment.
air temperature is above 2C (35F).
is serviced only with the climate control
assembly.
the floor/panel door actuator is in the full panel
The function selector switch:
position, directing airflow to the instrument panel
selects airflow direction.
A/C registers. A small amount of airflow from the
is serviced only with the climate control floor duct will be present.
assembly.
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FLOOR
the A/C request button is enabled. The A/C
compressor will operate and the indicator will
When FLOOR is selected:
illuminate if the A/C request button is selected
and the outside temperature is above
approximately 2C (35F).
PANEL/FLOOR
When PANEL/FLOOR is selected:
the floor/panel door is in the floor position and
the defrost door fully closes, directing airflow to
the floor duct. A small amount of airflow from
the defrost duct and side demisters will be
present.
the floor/panel door actuator is positioned partially
between the floor and panel position, directing
airflow to the floor duct and the instrument panel
A/C registers.
FLOOR/DEFROST
When the FLOOR/DEFROST is selected:
OFF
When OFF is selected:
the floor/panel door actuator is in the full floor
position and the defrost door is partially open,
the recirc request button is disabled.
directing airflow to the floor duct, the defroster
the air inlet door actuator closes off outside air.
duct and the side window demisters.
position and floor/panel door actuator is in the
partially open position.
the A/C request button is disabled.
the blower motor is OFF.
DEFROST
When DEFROST is selected:
the air inlet door actuator opens, admitting only
outside air into the passenger compartment.
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the floor/panel door actuator is in the full floor the A/C request button will illuminate and is
position. enabled. To reduce fogging, the A/C compressor
will operate automatically, regardless of indicator
the defrost door is in the fully open position,
status, if the outside temperature is above
directing airflow to the defroster duct and side
window demisters. A small amount of airflow
from the floor duct will be present. the blower motor is ON.
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Clutch and Clutch Field Coil
Special Tool(s)
Holding Fixture, Compressor
Clutch
412-134
Remover, Compressor Pulley
412-001 (T71P-19703-B)
Installer, A/C Compressor Coil
412-065 (T89P-19623-EH)
Installer, A/C Compressor Field
Coil
412-078 (T91L-19623-CH)
Remover, A/C Compressor
Field Coil
412-067 (T89P-19623-FH)
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1 N805332 A/C clutch disc and hub bolt
spacer
4 A/C compressor pulley snap
ring
6 19D798 A/C clutch field coil
Removal
3. Remove the A/C clutch disc and hub.
1. Remove the A/C compressor. For additional
4. Remove the A/C clutch disc and hub spacer(s).
Compressor 4.0L or Air Conditioning (A/C)
Compressor 4.6L, 5.4L in this section.
5. Remove the A/C compressor pulley snap ring.
2. Remove the A/C clutch disc and hub bolt.
1 Using the special tool, hold the A/C clutch
disc and hub.
2 Remove the A/C clutch disc and hub bolt.
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Installation
6. CAUTION: Do not use air tools.
Damage to the A/C compressor pulley or
A/C compressor may result.
A/C clutch components should be reused unless
Remove the A/C compressor pulley.
obvious signs of damage are found. If excessive
grooving is found, a new A/C clutch disc and hub
and A/C compressor pulley must be installed
2 Remove the A/C compressor pulley.
together. Otherwise, each component can be
installed individually where needed.
1. Visually inspect the A/C clutch disc and hub,
A/C compressor pulley and A/C clutch field
coil for damage.
Inspect for physical damage, including
cracked or melted components or
discoloration due to excessive heat.
Inspect for excessive wear, including
grooving in the A/C clutch disc and hub or
A/C compressor pulley that is more than
fingernail depth.
Inspect for roughness in the A/C compressor
pulley bearing.
Damage to the A/C clutch field coil or A/C
compressor may result.
2. Clean the A/C clutch field coil and pulley
Remove the A/C clutch field coil.
mounting surfaces.
3 Remove the A/C clutch field coil.
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Damage to the A/C clutch field coil or A/C
compressor may result.
Install the A/C clutch field coil.
1 Place the A/C clutch field coil on the A/C
compressor with the A/C clutch field coil
electrical connector correctly positioned.
2 Place the special tool on the A/C clutch
field coil.
3 Place special tool 412-065 on special tool
412-078.
4 Use the special tool to install the A/C
8. Measure and adjust the clutch air gap by adding
clutch field coil.
or removing A/C clutch disc and hub spacers.
4. Install the A/C compressor pulley.
9. Install the A/C compressor. For additional
5. Install the A/C compressor pulley snap ring.
Compressor 4.0L or Air Conditioning (A/C)
Compressor 4.6L, 5.4L in this section.
6. Install the A/C clutch disc and hub spacer(s)
and the A/C clutch disc and hub.
7. Install the A/C clutch disc and hub bolt.
1 Hold the A/C clutch disc and hub with the
special tool.
2 Tighten to 13 Nm (10 lb-ft).
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Compressor Manifold and Tube
Assembly 4.0L
Material
Item Specification
Systems)
YN-12-D
1 W520413 Condenser inlet fitting nut
2 N805334 Compressor manifold bolt
3 Suction accumulator outlet
system, except when there is physical evidence of
fitting (part of 19D734)
4 W520112 Compressor manifold and
tube bracket nut
5 12B637 A/C pressure transducer
6 19D734 Compressor manifold and
tube assembly
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2. Loosen the compressor manifold bolt and 6. Remove the condenser inlet fitting nut and
detach the compressor manifold. disconnect the fitting.
Discard the O-ring seals. Discard the O-ring seal.
To install, tighten to 21 Nm (15 lb-ft). To install, tighten to 8 Nm (71 lb-in).
3. Remove the compressor manifold and tube 7. To install, reverse the removal procedure.
bracket nut.
Lubricate the refrigerant system with the
correct amount of clean PAG oil. For
4. Disconnect the pressure transducer electrical
connector.
412-00.
5. Disconnect the suction accumulator outlet
8. Evacuate, leak test and charge the refrigerant
fitting.
system. For additional information, refer to
Section 412-00.
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Compressor to Condenser Discharge
Line
Material
Item Specification
Systems)
YN-12-D
1 Compressor discharge fitting
(part of 19972)
2 19E889 O-ring (4 required)
3 19B632 A/C line bracket
4 Dual-function pressure switch
5 W520413 Condenser inlet fitting nut 5.4L (4V) vehicles
6 19972 Compressor-to-condenser
discharge line
Section 100-02.
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4.6L vehicles
7. Detach the compressor-to-condenser discharge
line from the A/C line bracket.
2. Remove the air cleaner outlet tube. For
8. Remove the compressor-to-condenser discharge
line.
All vehicles
4. Disconnect the compressor discharge fitting.
412-00.
5. Disconnect the dual-function pressure switch
electrical connector and remove the
Section 412-00.
dual-function pressure switch.
6. Remove the condenser inlet fitting nut and
disconnect the fitting.
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Condenser Core
Material
Item Specification
Systems)
YN-12-D
1 W520413 Condenser outlet fitting nut
2 W520101 Cooler line fitting nut (2
required)
4 W520413 Condenser inlet fitting nut
5 19712 Condenser core
All vehicles
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All vehicles
Section 100-02.
6. Remove the lower radiator air deflector.
3. Remove the condenser inlet fitting nut and
7. Remove the condenser outlet fitting nut and
5.4L (4V) vehicles
8. Remove the 2 cooler line bracket nuts and
position the cooler line aside.
4. Remove the front bumper cover. For additional
9. Remove the condenser core.
5. NOTE: RH air deflector shown, LH similar.
Remove the pin-type retainers and detach the
RH and LH air deflectors from the condenser
core.
412-00.
Section 412-00.
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Condenser to Evaporator Line
Material
Item Specification
PAG Refrigerant WSH-M1C231-B contamination from a failed A/C compressor or
Systems)
YN-12-D
Section 100-02.
3. Disconnect the evaporator inlet line fitting.
4. Detach the condenser-to-evaporator line clip.
5. Remove the condenser outlet fitting nut and
6. Remove the condenser-to-evaporator line.
412-00.
Section 412-00.
1 W520413 Condenser outlet fitting nut
2 19835 Condenser-to-evaporator line
3 Evaporator inlet line fitting
(part of 19835)
5 9A317 Condenser-to-evaporator line
clip
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Climate Control System Outputs
Control Components
system control components are used to select:
The blower motor resistor adjusts the blower motor
speed based on the blower motor switch setting.
air inlet source (outside or recirculated).
The blower motor resistor contains 3 resistor coils
blower motor speed.
in series. The end of each resistor coil is wired to a
discharge air temperature (temperature blend).
setting in the blower motor switch. Voltage is
discharge air location (defrost, panel, floor). available at the blower motor at all times when the
ignition is in the RUN position and the function
A/C compressor operation.
selector is not OFF. The ground side of the circuit
Climate Control System Inputs then continues to the blower motor resistor. The
blower motor switch will allow a path to ground
Climate Control Assembly (EMTC Module)
with the addition of 1, 2 or 3 coils in the blower
The climate control assembly integrates the motor resistor to the circuit. When the blower motor
temperature control, airflow mode selection, A/C switch is in the MED HI position, the blower motor
request button, recirculated air request button and switch will add a path to ground through one coil in
rear defog switch into a single unit. the blower motor resistor. When the blower motor
switch is in the MED LO position, the blower
The temperature control switch setting determines
motor switch will add a path to ground through 2
air temperature. Movement of the temperature
coils (in series) in the blower motor resistor. When
display from COOL (blue) to WARM (red) causes a
the blower motor switch is in the LO position, the
corresponding movement of the temperature blend
blower motor switch will add a path to ground
door and determines the air discharge temperature
through 3 coils (in series) in the blower motor
that the air distribution system will maintain. The
resistor. When the blower motor switch is in the HI
temperature control switch is an integral part of the
position, the blower motor resistor is bypassed.
climate control assembly and cannot be installed
separately.
Mode Door Actuators
The A/C request button determines A/C compressor
The 3 airflow mode door actuators move the airflow
operation, except when the function selector is in
mode doors on command from the EMTC module.
the OFF, MAX or DEFROST mode. The A/C
The panel/floor door and defrost door mode door
request button is an integral part of the climate
actuators each contain a reversible electric motor
control assembly and cannot be installed separately.
and a potentiometer. The EMTC module applies a
The recirculated air request button can select
5-volt signal to one end of the potentiometer and
recirculated air in any mode except DEFROST, and
ground to the other. The potentiometer wiper is
fresh air in any mode except MAX A/C or OFF.
connected to the actuator output shaft and moves
The rear defog button signals activation of the
with the output shaft. The voltage available at the
heated backlight. The rear defog button is an
wiper indicates the position of the airflow mode
integral part of the climate control assembly and
door. The actuator wiper voltage is sent to the
cannot be installed separately.
EMTC module which drives the actuator motor in
whichever direction is necessary to make the
The EMTC module is not equipped with self-test
actuator wiper voltage agree with the expected
capabilities.
EMTC module wiper voltage value.
Blower Motor Switch
The blower motor switch controls blower motor
speed (by adding or bypassing resistors in the
blower motor resistor) in all modes except OFF.
The blower motor switch is mounted to the climate
control assembly and can be installed separately.
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The air inlet mode door actuator is a reversible The temperature blend door actuator contains a
electric motor which moves the air inlet door reversible electric motor and a potentiometer. The
between the outside and recirculated air inlets on EMTC module applies a 5-volt signal to one end of
command from the EMTC module. When RECIRC the potentiometer and ground to the other. The
is requested, the air inlet mode door actuator moves potentiometer wiper is connected to the actuator
to the RECIRC position, allowing only recirculated output shaft and moves with the output shaft. The
air inlet. When FRESH air inlet is requested, the air voltage available at the wiper indicates the position
inlet mode door actuator moves to the FRESH air of the temperature blend door. The actuator wiper
inlet position, allowing only outside air inlet. voltage is sent to the EMTC module which drives
the actuator motor in whichever direction is
Temperature Blend Door Actuator
necessary to make the actuator wiper voltage agree
The temperature blend door actuator moves the with the expected EMTC module wiper voltage
temperature blend door on command from the value.
EMTC module.
The temperature blend door actuator is located on
the heater core and evaporator core housing.
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GENERAL PROCEDURES
Electronic Leak Detection
Special Tool(s)
H10PM Refrigerant Leak
Detector With Battery
CAUTION: Good ventilation is necessary
in the area where electronic A/C leak testing is to
2. If a leak is found, recover the refrigerant. For
be carried out. If the surrounding air is
additional information, refer to Air Conditioning
contaminated with refrigerant gas, the leak
(A/C) System Recovery, Evacuation and
detector will indicate this gas all the time. Odors
Charging in this section.
from other chemicals such as antifreeze, diesel
Repair the system.
fuel, disc brake cleaner or other cleaning solvents
can cause the same problem. Using a fan to
ventilate the area to be tested before proceeding
with the leak detection procedure is helpful in
removing small traces of contamination from the
air, but the fan should be turned off during
actual testing.
1. NOTE: The system pressure should be between
413-551 kPa (60-80 psi) at 24C (75F) with
the engine off.
Leak test the refrigerant system using the leak
detector. Follow the instructions included with
the leak detector for handling and operation
techniques.
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Evaporator Outlet Line
Material
Item Specification
Systems)
YN-12-D
1 54042A06 Body ground strap bolt
2 Suction accumulator inlet
fitting (part of 19835)
3 9C482 Brake booster vacuum hose
4 19E561 A/C cycling switch
5 12B637 A/C cycling switch electrical
connector All vehicles
6 W701838 Evaporator fitting nut (2
required)
7 9A317 Evaporator inlet line clip
9 Evaporator inlet line fitting
(part of 19835)
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5.4L (4V) vehicles
12. Detach the evaporator inlet line clip.
13. Disconnect the suction accumulator inlet fitting.
information, refer to Section 303-03A. Discard the O-ring seals.
3. Remove the brake booster. For additional 14. Remove the 2 evaporator fitting nuts and
information, refer to Section 206-07. disconnect the fitting.
4. Disconnect the 2 heater hose connections at the
rear of the RH cylinder head and position the
heater hoses aside.
15. Remove the evaporator tube bracket.
1 Rotate the evaporator tube bracket
downward.
2 Remove the evaporator tube bracket.
system module tube. For additional information,
4.0L and 4.6L vehicles
16. Remove the evaporator core manifold and tube
assembly.
6. Remove the LH cowl vent screen. For
7. Remove the body ground strap bolt.
8. Disconnect the brake booster vacuum hose at
the brake booster.
412-00.
All vehicles
5.4L (4V) vehicles
9. Disconnect the A/C cycling switch electrical
18. Fill the engine cooling system. For additional
connector and detach the wire harness from the
evaporator outlet line.
All vehicles
10. Remove the A/C cycling switch.
11. Disconnect the evaporator inlet line fitting.
Section 412-00.
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GENERAL PROCEDURES
Special Tool(s)
Fluorescent Dye Leak Detection
Deluxe Injector Loop Kit
Special Tool(s)
R-134a Refrigerant Center
R-134a Leak Detection Dye
164-R6060
R-134a Refrigerant Center
Fluorescent Dye Detection
R-134a Manifold Gauge Set NOTE: Ford Motor Company vehicles are produced
with R-134a fluorescent dye installed in the
refrigerant system from the factory. The location of
leaks can be pinpointed by the bright yellow-green
glow of the fluorescent dye under a UV lamp. Since
more than one leak can exist, make sure to inspect
each component, line and fitting in the refrigerant
system for a leak. 120 Watt UV Spot Lamp
1. Check for leaks using a Rotunda-approved UV
lamp.
Inspect all components, lines and fittings of
the refrigerant system.
High Intensity UV Lamp 12
Volt
R-134a Fluorescent Dye Injector
2. If a leak is found, recover the refrigerant. For
additional information, refer to Air Conditioning (Continued)
(A/C) System Recovery, Evacuation and
Charging in this section.
3. Repair the refrigerant system leak(s).
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4. Evacuate and charge the refrigerant system. For NOTE: Only connect the R-134a fluorescent dye
injector to a manifold and gauge set or R-134a additional information, refer to Air Conditioning
service center when fluorescent dye is to be (A/C) System Recovery, Evacuation and
injected. The R-134a fluorescent dye injector has a Charging in this section.
one way check valve that will prevent refrigerant
5. After the leak(s) is repaired, remove any traces system recovery and evacuation.
of fluorescent dye with a general purpose oil
NOTE: Refrigerant system pressure should be
solvent.
between 413-551 kPa (60-80 psi) at 24C (75F)
with the engine off.
6. Verify the repair by running the vehicle for a
short period of time and rechecking the area of
1. Connect an R-134a A/C refrigerant service
the leak with a Rotunda-approved UV lamp.
center or a manifold and gauge set to the
refrigerant system service port valves.
2. Verify that the valves on the fluorescent dye
injector are closed.
Fluorescent Dye Injection Using an A/C
Refrigerant Center and Dye Injector
NOTE: Fluorescent refrigerant system dye is added
to the refrigerant system at the factory to assist in
3. Fill the fluorescent dye injector reservoir with 7
ml (0.25 oz) of fluorescent dye.
system. Replacement suction accumulators and
receiver/driers are shipped with a fluorescent dye
wafer included in the desiccant bag which will
dissolve after approximately 30 minutes of
continued A/C operation. It is not necessary to add
dye after flushing or filtering the refrigerant system
because a new suction accumulator or receiver/drier
is installed as part of the flushing or filtering
procedure. Additional refrigerant system dye should
only be added if more than 50% of the refrigerant
system lubricant capacity has been lost due to a
4. Install the fluorescent dye injector between the
fitting separation, hose rupture or other damage.
low-pressure service gauge port valve and the
R-134a refrigerant service center or manifold
NOTE: Before using the R-134a fluorescent dye
gauge set.
injector for the first time, refer to the
manufacturers instructions on evacuation of any
non-condensable gasses from the hoses.
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5. Open all valves and inject the fluorescent dye
into the refrigerant system.
6. When fluorescent dye injection is complete,
close all valves.
7. Recover the refrigerant from the R-134a
fluorescent dye injector.
8. Remove the fluorescent dye injector from the
low-pressure service gauge port valve and the
R-134a A/C refrigerant service center or
manifold gauge set.
2. Fill the deluxe injector loop kit reservoir with 7
Fluorescent Dye Injection Using a Dye
ml (0.25 oz) of fluorescent dye.
Injector Loop Kit
NOTE: Fluorescent refrigerant system dye is added
to the refrigerant system at the factory to assist in
system. Replacement suction accumulators and
receiver/driers are shipped with a fluorescent dye
wafer included in the desiccant bag which will
dissolve after approximately 30 minutes of
continued A/C operation. It is not necessary to add
dye after flushing or filtering the refrigerant system
3. Install the deluxe injector loop kit between the
because a new suction accumulator or receiver/drier
high-pressure and low-pressure service gauge
is installed as part of the flushing or filtering
port valves.
procedure. Additional refrigerant system dye should
only be added if more than 50% of the refrigerant
4. CAUTION: Make sure all tools and
system lubricant capacity has been lost due to a
hoses are clear of the engine cooling fan and
fitting separation, hose rupture or other damage.
drive belt before starting the engine.
NOTE: Before using the R-134a fluorescent dye Start the engine.
injector for the first time, refer to the equipment
5. Open the high-pressure service valve.
manufacturers instructions on evacuation of
non-condensable gasses from the hoses.
NOTE: Refrigerant system pressure should be
between 413-551 kPa (60-80 psi) at 24C (75F).
1. Verify that the valves on the deluxe injector
loop kit are closed.
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6. Open the deluxe injector loop kit valves and 8. NOTE: Close the valves on the deluxe injector
inject the fluorescent dye into the refrigerant loop kit while the A/C compressor is operating.
system.
Close the valves on the deluxe injector loop kit.
7. Close the high-pressure service valve to allow
9. NOTE: Leave all valves on the special tool
the pressure inside the deluxe injector loop kit
closed when not in use.
to equalize with the suction side of the
Disconnect the high-pressure and low-pressure
refrigerant system.
service valves and remove the deluxe injector
loop kit from the vehicle.
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Heater Core And Evaporator Core
Housing
Material
Item Specification
Systems)
YN-12-D
4 18472 Heater core inlet hose 1 W704904 Exterior heater core and
evaporator core housing nut
5 18472 Heater core outlet hose
(2 required)
2 19E889 O-ring seals (2 required)
3 W701838 Evaporator fitting nut (2
required)
(Continued)
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6 W702751 Interior heater core and
evaporator core housing nut
7 18812 Antenna cable
8 19850 Heater core and evaporator
core housing
All vehicles
NOTE: The heater core and evaporator core are not
individually serviced. They are serviced only with
2. Drain the engine coolant. For additional
the heater core and evaporator core housing.
NOTE: If a heater core leak is suspected, the heater
3. Remove the instrument panel. For additional
core must be leak tested before it is removed from
the vehicle.
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5.4L (4V) vehicles
7. Remove the 2 exterior heater core and
evaporator core housing nuts at the dash panel.
4. Disconnect the heater hose fittings at the rear of
the RH cylinder head and position the heater
hoses aside. 8. Detach the antenna cable from the heater core
and evaporator core housing.
9. Remove the interior heater core and evaporator
core housing nut.
housing.
All vehicles additional information, refer to Section
412-00.
5. Disconnect the heater core inlet and outlet
12. Fill the engine cooling system. For additional
hoses at the heater core.
6. Remove the 2 evaporator fitting nuts and
disconnect the evaporator core fitting.
Section 412-00.
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Heater Core
Heater Core And Evaporator Core Housing in
this section.
NOTE: If a heater core leak is suspected, the heater
2. Transfer the heater core and evaporator core
core must be leak tested before it is removed from
housing components as needed.
the vehicle.
3. Install the heater core and evaporator core
NOTE: The heater core is not individually serviced.
It is serviced only with the heater core and
Heater Core And Evaporator Core Housing in
this section.
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GENERAL PROCEDURES
Heater Hose Coupling
Special Tool(s)
Remover, Heater Hose Inlet
Tube
412-042 (T85T-18539-AH)
Disconnect Tool, Heater Hose
412-127
4. NOTE: A slight twisting motion while pulling
on the heater water hose may be necessary to
assist in the removal.
Pull the heater hose away from the heater core
tube.
Disconnect
CAUTION: Do not attempt to install a new
bushing, spacer or O-rings in the heater hose
coupling; damage to the heater hose coupling can
result. If the heater hose coupling is the cause of
a coolant leak, the affected heater hose must be
replaced as an assembly.
1. WARNING: The engine must be off,
fully cool and the cooling system fully
depressurized before attempting to
disconnect any heater water hoses. Failure to
comply with this warning can result in
5. Spread the retainer tabs apart and slide the
serious injury or burns from hot liquid
retainer off the tube.
escaping out of the engine cooling system.
Discard the retainer.
Depressurize the engine cooling system.
2. Push the heater hose toward the tube to fully
expose the locking tabs.
3. NOTE: When compressing the white coupling
retainer with the special tool, the special tool
must be perpendicular to and on the highest
point of the coupling.
NOTE: If the heater hose coupling is
accessible, the retainer tabs can be compressed
by hand to disconnect the heater hose.
Push the special tool over the coupling retainer
windows to compress the retainer locking tabs.
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Connect
3. Push the heater hose coupling onto the tube.
1. Clean the tubes and lubricate with plain water.
2. Install a new coupling retainer into the heater
hose coupling housing.
4. Make sure the heater hose coupling is fully
engaged by lightly pulling on the heater hose.
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Heater Core and Evaporator Core
Heating and Ventilation
Housing
The heating and ventilation system has the
The heater core and evaporator core housing directs
following features:
airflow from the blower motor through the
Controls the temperature and, during A/C
evaporator core and heater core. All airflow from
operation, reduces the relative humidity of the air
the blower motor passes through the evaporator
inside the vehicle
core. The airflow is then directed through or around
the heater core by the temperature blend door. After
Delivers heated or cooled air to maintain the
passing through the heater core, the airflow is
vehicle interior temperature and comfort level
distributed to the selected outlet by the plenum
Cooling or heating can be adjusted to maintain the
chamber.
desired temperature
Heater Core The heating and ventilation system includes the:
NOTE: The heater core is not individually serviced.
Blower motor
It is serviced only with the heater core and
Heater core and evaporator core housing
Heater core
The heater core receives a flow of coolant from the
engine cooling system through the heater core inlet.
Blower Motor
A restrictor is installed in the heater core inlet hose
The blower motor pulls air from the air inlet and
on V8 models to eliminate noise. The heater core
forces it into the heater core and evaporator core
consists of fins and tubes arranged to extract heat
housing where it is mixed and distributed. The
from the engine coolant and transfer it to air passing
blower motor receives battery voltage when the
through the heater core. The engine coolant is then
ignition is in the RUN position and the function
returned to the engine cooling system through the
selector is in an ON position, and is grounded by
heater core outlet.
the blower motor switch.
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Mode Door Actuator Air Inlet Door
1 18B574 Air inlet mode door actuator
2 W701696 Air inlet mode door actuator
screw (2 required)
3 19E616 Air inlet mode door actuator
1. Lower the glove compartment.
2. Disconnect the air inlet mode door actuator
3. Remove the 2 air inlet mode door actuator
screws.
4. Remove the air inlet mode door actuator.
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Mode Door Actuator Defrost Door
1 18B574 Defrost door mode door
actuator electrical connector
2 W701696 Defrost door mode door
actuator screw (2 required)
3 19E616 Defrost door mode door
actuator
2. Disconnect the defrost door mode door actuator
3. Remove the 2 defrost door mode door actuator
screws.
4. Remove the defrost door mode door actuator.
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Mode Door Actuator Panel/Floor
Door
1 18B574 Panel/floor door mode door
2 W701696 Panel/floor door mode door
3 19E616 Panel/floor door mode door
actuator
NOTE: The panel door mode door actuator can be
accessed from below the LH side of the instrument
panel.
1. Disconnect the panel/floor door mode door
actuator electrical connector.
2. NOTE: The top panel/floor door mode door
actuator screw can be removed using a shallow
universal socket.
Remove the 2 panel/floor door mode door
actuator screws.
3. Remove the panel/floor door mode door
actuator.
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Plenum Chamber
1 W710480 Defroster duct screw (4
1. Remove the instrument panel. For additional required)
2 18490 Defroster duct
3 19E630 Demister duct (2 required)
2. Remove the RH floor duct screw and the RH
4 W701696 Panel mode door actuator
floor duct.
screw (2 required)
5 19E616 Panel mode door actuator
3. Remove the LH floor duct screw and the LH
6 W701696 Defrost mode door actuator
floor duct.
screw (2 required)
7 19E616 Defrost mode door actuator 4. Remove the 4 defroster duct screws.
8 19B680 RH floor duct
5. Detach the 2 demister ducts from the defroster
9 W701506 RH floor duct screw
duct.
10 W505156 Plenum chamber bolt (2
required)
6. Remove the defroster duct.
11 W710506 Plenum chamber screw (2
required)
7. Remove the 2 defrost mode door actuator
12 18471 Plenum chamber
screws and position the defrost mode door
13 W710506 LH floor duct screw
actuator aside.
14 19B680 LH floor duct
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8. Remove the 2 panel mode door actuator screws 10. Remove the 2 plenum chamber screws.
and position the panel mode door actuator
11. Remove the plenum chamber.
aside.
9. Remove the 2 plenum chamber bolts.
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GENERAL PROCEDURES
3. The percentage of air contained in the sample
Refrigerant Identification Testing
will be displayed if the R-134a content is 98%
or greater. The scan tool eliminates the effect of
Special Tool(s)
air when determining the refrigerant sample
Refrigerant Identifier with
content because air is not considered a
Air-Radiator
contaminant, although air can affect A/C
system performance. When the scan tool has
determined that a refrigerant source is pure
(R-134a is 98% or greater by weight) and air
concentration levels are 2% or greater by
weight, the scan tool will prompt the user if an
air purge is desired.
Refrigerant Identification
4. If contaminated refrigerant is detected, repeat
1. NOTE: An A/C refrigerant analyzer must be
the refrigerant identification test to verify that
used to identify gas samples taken directly from
the refrigerant is indeed contaminated.
the refrigeration system or storage containers
prior to recovering or charging the refrigerant Contaminated Refrigerant Handling
system.
Follow the instructions included with the CAUTION: If contaminated refrigerant is
refrigerant identifier to obtain the sample for detected, DO NOT recover the refrigerant into
testing. R-134a recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier
2. The scan tool will display one of the following:
must be installed as directed by the air conditioning
If the purity level of R-134a is 98% or
system flushing procedure.
greater by weight, the green PASS light
emitting diode (LED) will light. The weight
1. Recover the contaminated refrigerant using
concentrations of R-134a, R-12, R-22,
suitable recovery-only equipment designed for
hydrocarbons and air will be displayed on
capturing and storing contaminated refrigerant
the digital display.
only.
If refrigerant R-134a does not meet the 98%
If this equipment is not available, contact an
purity level, the red FAIL LED will light
A/C service facility in your area with the
and an alarm will sound alerting the user of
correct equipment to carry out this service.
potential hazards. The weight concentrations
of R-134a, R-12, R-22 and hydrocarbons
2. Determine and correct the cause of the
will be displayed on the digital display.
customers initial concern.
If hydrocarbon concentrations are 2% or
greater by weight, the red FAIL LED will 3. Flush the air conditioning system.
light, Hydrocarbon High will be
displayed on the digital display, and an
alarm will sound alerting the user of
potential hazards. The weight concentrations
of R-134a, R-12, R-22 and hydrocarbons
will also be displayed on the digital display.
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4. Dispose of the contaminated refrigerant in
accordance with all federal, state and local
regulations.
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GENERAL PROCEDURES
Refrigerant Oil Adding
Refrigerant Oil Adding
CAUTION: During normal A/C operation, Special Tool(s)
oil is circulated through the system with the
Dye/Lubricant Injector
refrigerant, and a small amount is retained in
164-R0775
each component. If certain components of the
system are removed, some of the refrigerant oil
will go with the component. To maintain the
original total oil charge, it is necessary to
compensate for the oil lost by adding oil to the
system with the new part.
Add-On Module Kit
219-00069
1. Refer to the chart below for refrigerant oil
adding amounts and methods of installation.
Material
Item Specification
Systems)
YN-12-D
Component PAG Oil Amount Method of Adding
A/C See heading below Add directly to A/C compressor before
Compressor installation.
Suction See heading below Add directly to suction accumulator inlet port or
Accumulator or inject to low-side service port during system
Receiver/Drier charging.
Evaporator Core 45 ml (1.5 fl oz) added to the amount collected Add directly to evaporator core inlet tube or
during refrigerant recovery inject to low-side service port during system
charging.
Condenser Core 60 ml (2 fl oz) added to the amount collected Add directly to condenser core inlet or inject to
during refrigerant recovery low-side service port during system charging.
Evaporator Core The amount collected during refrigerant recovery Inject to low-side service port during system
Orifice or charging.
Thermostatic
Expansion
Valve
A/C Pressure 60 ml (2 fl oz) added to the amount collected Inject to low-side service port during system
Relief Valve during refrigerant recovery charging.
Refrigerant 60 ml (2 fl oz) added to the amount collected Inject to low-side service port during system
Hose/Line during refrigerant recovery
a
charging.
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Component PAG Oil Amount Method of Adding
O-ring Leak 60 ml (2 fl oz) added to the amount collected Inject to low-side service port during system
Repair during refrigerant recovery
b
charging.
Service Port 60 ml (2 fl oz) added to the amount collected Inject to low-side service port during system
Leak Repair during refrigerant recovery charging.
a If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the total system
refrigerant oil capacity must be added.
b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the refrigerant oil
amount by the number of O-ring leaks being repaired.
Refrigerant Oil Adding for New A/C 3. Verify that all the valves on the dye/lubricant
Compressor Installation
injector are closed.
NOTE: Service A/C compressors are shipped
without refrigerant oil.
1. Rotate the old A/C compressor shaft 8 to 10
full rotations (clockwise) while collecting the
refrigerant oil in a clean measuring cup.
Add the same amount plus the amount
collected during refrigerant recovery.
Refrigerant Oil Adding for New Suction
Accumulator or Receiver/Drier
Installation
4. Fill the dye/lubricant injector with the correct
1. Drill one 12.7 mm (1/2 in) hole in the old
amount of clean, new PAG oil.
suction accumulator or receiver/drier cylinder
and drain the oil into a clean measuring cup.
2. Add the quantity of oil drained, plus the
amount collected during refrigerant recovery
and 60 ml (2 fl oz).
Oil Injection Using a Dye/Lubricant
Injector
NOTE: If fluorescent leak detection dye is also to
be added during A/C charging, the dye may be
added to the dye/lubricant injector along with the
refrigerant oil.
1. Evacuate the refrigerant system. For additional
5. Install the dye/lubricant injector between the
low-side service gauge port valve and the
System Recovery, Evacuation and Charging in
refrigerant service station or manifold gauge set.
this section.
2. Assemble the dye/lubricant injector using the
correct adapters to match the amount of
refrigerant compressor oil to be injected.
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6. Open all valves and charge the refrigerant
system. For additional information, refer to Air
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Register Instrument Panel
1 Instrument panel register
barrel (4 required) (part of
19893)
2 Instrument panel register
housing (4 required) (part of
19893)
1. Pull and remove the instrument panel register
barrel.
2. Release the tabs and remove the instrument
panel register housing.
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SPECIFICATIONS
Item Specification
Refrigerant Lubricant and Capacity
Item Specification
A/C Compressor Compressor Oil (R-134a
Systems) YN-12-D
Type FS-18
Capacity 207 ml (7 oz)
Displacement 180 cc (11 cu in)
Refrigerant and Capacity
Rotation Clockwise
R134a Refrigerant YN-19 WSH-M17B19-A
A/C Pressure Relief Valve
a
(US); CYN-16-P or
Open pressures 3,792-4,137 kPa (550-600
CYN-16-R (Canada)
psi)
Capacity 0.74 kg (26 oz)
A/C Pressure Refer to Powertrain
Refrigerant System Cleaner
Transducer (V6) Control/Emissions
Diagnosis (PC/ED) A/C Systems Flushing
manual. Solvent YN-23
Evaporator Core Orifice A/C Odor Treatment
Color Blue A/C Cooling Coil Coating
YN-29
Magnetic Clutch
Refrigerant System Dye
Air gap clearance 0.35-0.65 mm
(0.014-0.026 in) R-134a Leak Detection
Dye 164-R6060 or
Dual Function Pressure Switch (V8)
a
164-R6081
Fan on/open 2,137-2,344 kPa (310-340
psi) a Manifold gauge set pressures may vary slightly
depending on the distance between the service
Fan off/closed 1,655-2,137 kPa (240-310
gauge port valve and the A/C pressure relief valve,
psi)
the A/C cycling switch, the A/C pressure transducer
Clutch off/open 2,999-3,275 kPa (435-475 (V6) and the dual function pressure switch (V8)
psi) location.
Clutch on/closed 1,517-1,931 kPa (220-280
psi)
A/C Cycling Switch Open and Closed Pressures
a
Open pressure 145-159 kPa (21-23 psi)
Peanut fitting nut 8 71
Closed pressure 290 kPa (42 psi)
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SPECIFICATIONS
Upper compressor 4 35
Item Specification studs (4.0L)
Magnetic Clutch LH lower compressor 25 18
stud (4.0L)
Clutch air gap 0.35-0.65 mm
(0.014-0.026 in) Compressor bolt (4.0L) 25 18
Lubricant Compressor fitting nuts 15 11
(4.6L or 5.4L)
Compressor Oil (R-134a Power steering pressure 8 71
Systems) YN-12-D hose bracket bolt
Compressor studs (4.6L 25 18
or 5.4L)
A/C clutch disc and 13 10
hub bolt
Low-pressure service 0.8 7
Condenser inlet fitting 8 71
gauge port valve cap
nut
High-pressure service 0.8 7
Condenser outlet fitting 8 71
gauge port valve cap
nut
Low-pressure 1.8 16
Evaporator fitting nuts 8 71
Schrader-type valve
Exterior heater core 7 62
High-pressure 2.5 22
and evaporator core
Schrader-type valve
housing nuts
Compressor manifold 21 15
Interior heater core and 5 44
bolt
evaporator core
housing nut
Compressor manifold 25 18
and tube bracket nut
Upper LH compressor 25 18
nut (4.0L)
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GENERAL PROCEDURES
Spring Lock Coupling 3. CAUTION: Do not use a screwdriver
or similar tool to remove the A/C tube lock
coupling spring; this can cause axial Special Tool(s)
scratches across the O-ring seal grooves
Remover, Refrigerant Coupling
resulting in refrigerant leaks.
Spring
412-039 (T84L-19623-B) Remove the spring lock coupling spring with a
small hooked wire.
Material
Item Specification
Systems)
YN-12-D
Disconnect
1. Remove the spring lock coupling clip, if
Cleaning
equipped.
1. Fabricate a cleaning tool from a 1/8 inch
2. CAUTION: Do not use metal tools to
diameter brazing rod.
remove the O-ring seals. They can cause
axial scratches across the O-ring seal
grooves, resulting in refrigerant leaks.
Push the tool into the cage opening to release
the female fitting from the spring lock coupling
spring and pull the fitting apart.
Remove the O-ring seals using a
non-metallic tool.
2. Cut an abrasive pad from maroon colored 3M
Scotch Brite with the dimensions
corresponding to the coupling size.
Coupling Size Pad Size
3/8 in 25 x 50 mm (1 x 2 in)
1/2 in 25 x 50 mm (1 x 2 in)
5/8 in 25 x 76 mm (1 x 3 in)
3/4 in 25 x 102 mm (1 x 4 in)
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3. Assemble the pad to the tool.
10. Remove any foreign material from the grooves
with a lint-free cloth.
4. Coat the abrasive pad with mineral oil.
Connect
5. Roll the pad on the tool and install it in a
variable speed drill motor.
1. Install the spring lock coupling spring.
6. CAUTION: Maintain low speed drill
rotation when inserting or removing the
cleaning tool to prevent axial scratches which
may cause future leaks.
Polish for one minute at moderate speed (less
than 1,500 rpm) or until the surface is clean
and free of scratches or foreign material.
2. Lubricate the inside of the coupling with PAG
oil.
7. Clean the fitting with a lint-free cloth.
8. Inspect the surface for grooves or scratches. If
grooves and scratches are still present, install a
new component.
9. Clean the O-ring seal grooves with a 300 mm
(12 in) length of natural fiber string.
Loop the string around the grooves and pull
the string back and forth.
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4. Connect the spring lock coupling fittings with a
3. CAUTION: Use only the new O-ring
twisting motion until the spring lock coupling
seals. The use of any O-ring seals other than
spring snaps over the flared end of the female
those specified in the Ford Master Parts
fitting.
Catalog may result in intermittent leakage
during vehicle operation.
Install the O-ring seals.
5. Install the spring lock coupling clip.
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Suction Accumulator to Compressor Item Part Number Description
Line 6 19D742 Suction
accumulator-to-compressor
line
Material
Item Specification
fitting (part of 19D742)
Compressor Oil (R-134a Removal and Installation
Systems)
YN-12-D
2. Remove the engine cooling fan and shroud. For
303-03A.
3. Remove the air cleaner. For additional
4. Disconnect the compressor manifold and tube
suction fitting.
fitting.
6. Disconnect the dual-function pressure switch
7. Detach the suction accumulator-to-compressor
line from the A/C line bracket.
8. Remove the suction accumulator-to-compressor
2 Compressor manifold and
line.
tube suction fitting (part of
19D742)
3 19B632 A/C line bracket
4 12B637 Dual-function pressure switch
Lubricate the refrigerant system with the electrical connector
5 19B632 Suction
additional information, refer to Section accumulator-to-compressor
line clip 412-00.
(Continued)
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Section 412-00.
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Suction Accumulator
Material
Item Specification
PAG Refrigerant WSH-M1C231-B contamination from a failed A/C compressor or
Compressor Oil (R134a
Systems) YN-12-D
2. Disconnect the suction accumulator inlet fitting.
fitting.
4. Remove the 2 suction accumulator bolts.
5. Remove the suction accumulator.
412-00.
1 W705800 Suction accumulator bolt (2
required)
fitting (4.0L, part of 19D734)
(4.6L, part of 19D742)
3 Suction accumulator inlet
fitting (part of 19835)
5 19C836 Suction accumulator
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Section 412-00.
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Temperature Blend Door Actuator
1 18A654 Temperature blend door
2 W701696 Temperature blend door
3 19E616 Temperature blend door
actuator
2. Disconnect the temperature blend door actuator
3. Remove the 2 temperature blend door actuator
screws.
4. Remove the temperature blend door actuator.
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413-06-1 413-06-1 Horn
Horn switch (part of the steering wheel)
Horn
Horn relay, located in the bussed electrical center
The horn system consists of the following:
(BEC)
Dual tone horns, attached to the front radiator
support
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413-06-1 413-06-1 Horn
Horn
Special Tool(s)
Horns Bussed electrical center
73III Automotive Meter Horn switch (part of the (BEC) fuse 46 (25A)
105-R0057 or equivalent steering wheel) Circuitry
Clockspring Horn relay
Horn switch (part of the
steering wheel)
Vehicle Communications
before proceeding to the next step. Module (VCM) and Integrated
release software.
tool
Flex Probe Kit
VCM.
VCM:
Check the scan tool connection to the VCM.
Refer to Section 418-00, No Power To The
The horn switch is incorporated within the steering
wheel. When the switch is closed, ground is
with the vehicle.
supplied through the clockspring from the vehicle
harness. The horn relay is than energized, supplying
voltage to the horn enabling the horn to sound. The
vehicle:
horn relay is located in the bussed electrical center
(BEC).
position.
good vehicle.
Refer to Section 418-00 to diagnose no
(PCM).
communication with one or more modules,
record the continuous memory DTCs.
self-test diagnostics for the Smart Junction Box
(SJB).
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413-06-2 413-06-2 Horn
9. If the DTCs retrieved are related to the concern, 10. If no DTCs related to the concern are retrieved,
go to the Smart Junction Box (SJB) Diagnostic GO to Symptom Chart.
Trouble Code (DTC) Index. For all other DTCs,
Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index
B1217 Horn Relay Coil Circuit Failure GO to Pinpoint Test A.
B1897 Horn Switch Circuit Failure GO to Pinpoint Test B.
All other DTCs REFER to Section 419-10.
Symptom Chart
Symptom Chart
The horn is inoperative Fuse GO to Pinpoint Test A.
Circuitry
Horn relay
steering wheel)
Horns
Clockspring
(BEC)
The horn is always on Circuitry GO to Pinpoint Test B.
steering wheel)
Clockspring
Horn relay
BEC
SJB
Pinpoint Tests DTC B1217 sets when a short to voltage is
detected on circuit 1323 (OG/RD).
Pinpoint Test A: The Horn Is Inoperative
Possible Causes
Refer to Wiring Diagrams Cell 44, Horn/Cigar
Fuse
Lighter for schematic and connector information.
Circuit 1 (DB) open
Normal Operation
Circuit 6 (YE/LG) open The horn relay control and switched voltage is
supplied by the bussed electrical center (BEC)
Circuit 1205 (BK) open
through circuit 2037 (RD). The smart junction box
Circuit 1323 (OG/RD) open or short to voltage
(SJB) receives the horn signal through circuit 1
Horn relay
(DB) from the horn switch (part of the steering
wheel). When the horn switch is pressed, ground is
Horn switch (part of the steering wheel)
supplied through the clockspring to the vehicle
Horns
harness through circuit 1205 (BK). The SJB then
Clockspring
activates the horn relay through circuit 1323
BEC (OG/RD). Voltage is then sent to the horn through
circuit 6 (YE/LG), enabling the horns to sound.
SJB
Ground is provided to the horns through circuit
1205 (BK).
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413-06-3 413-06-3 Horn
PINPOINT TEST A: THE HORN IS INOPERATIVE
CAUTION: Use the correct probe adapter(s) when making measurements. Failure
to use the correct probe adapter(s) may damage the connector.
A1 TRIGGER THE SJB HORN CONTROL ACTIVE COMMAND
Key in ON position.
Enter the following diagnostic mode on the scan tool: SJB Active
Yes
Commands.
GO to A11.
Select the SJB active command for the horn.
Trigger the SJB horn active command on. No
Does the horn sound? GO to A2.
A2 CHECK THE HORN RELAY FOR CORRECT OPERATION
Disconnect: Horn Relay. GO to A3.
Carry out the horn relay component test. Refer to Wiring
No
Diagrams Cell 149 for component testing. INSTALL a new horn relay. TEST the
Is the horn relay OK? system for normal operation.
A3 CHECK THE SJB OUTPUT
Connect: Horn Relay.
Connect a fused (10A) jumper wire between the SJB
C2280c-29, circuit 1323 (OG/RD), harness side and ground.
Yes
REMOVE the jumper wire. GO to A12.
No
LEAVE the jumper wire connected. GO to
Does the horn sound? A4.
A4 CHECK THE HORN RELAY CONTROL FOR AN OPEN
Disconnect: Horn Relay.
(Continued)
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413-06-4 413-06-4 Horn
PINPOINT TEST A: THE HORN IS INOPERATIVE (Continued)
A4 CHECK THE HORN RELAY CONTROL FOR AN OPEN
(Continued)
Measure the resistance between the horn relay pin 85, harness
side and ground.
Yes
No
Is the resistance less than 5 ohms? REMOVE the jumper wire. GO to A5.
A5 CHECK CIRCUIT 1323 (OG/RD) FOR A SHORT TO VOLTAGE
Measure the voltage between the SJB C2280c-29, circuit 1323
(OG/RD), harness side and ground.
Yes
normal operation.
No
Is any voltage present? GO to A6.
A6 CHECK CIRCUIT 1323 (OG/RD) FOR AN OPEN
(Continued)
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413-06-5 413-06-5 Horn
A6 CHECK CIRCUIT 1323 (OG/RD) FOR AN OPEN (Continued)
Measure the resistance between the SJB C2280c-29, circuit
1323 (OG/RD), harness side and the BEC C1035a-A1, circuit
1323 (OG/RD), harness side.
Yes
No
A7 CHECK THE VOLTAGE SUPPLY TO THE HORN RELAY
Disconnect: Horn Relay.
Measure the voltage between the horn relay pin 86, harness
side and ground; and between the horn relay pin 87, harness
side and ground.
Yes
GO to A8.
No
VERIFY the BEC fuse 46 (25A) is OK. If
OK, INSTALL a new BEC. TEST the
Are the voltages greater than 10 volts? system for normal operation.
A8 CHECK CIRCUIT 6 (YE/LG) FOR AN OPEN
Disconnect: BEC C1035c.
Disconnect: Horn C131.
(Continued)
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413-06-6 413-06-6 Horn
A8 CHECK CIRCUIT 6 (YE/LG) FOR AN OPEN (Continued)
Measure the resistance between the horn C131-2, circuit 6
(YE/LG), harness side and the BEC C1035c-D4, circuit 6
(YE/LG), harness side.
Yes
GO to A9.
No
Measure the resistance between the horn C131-1, circuit 1205
(BK), harness side and ground.
Yes
GO to A10.
No
A10 CHECK THE BEC FOR AN INTERNAL OPEN
Connect: BEC C1035c.
(Continued)
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413-06-7 413-06-7 Horn
A10 CHECK THE BEC FOR AN INTERNAL OPEN (Continued)
Connect a fused (5A) jumper wire between the horn relay pin
30, harness side and the horn relay pin 87, harness side.
Measure the voltage between the horn C131-2, circuit 6
Yes
INSTALL a new horn. REFER to Horn in
operation.
No
A11 CHECK THE HORN SIGNAL TO THE SJB
Disconnect: SJB C2280b.
(Continued)
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413-06-8 413-06-8 Horn
A11 CHECK THE HORN SIGNAL TO THE SJB (Continued)
Measure the resistance between the SJB C2280b-39, circuit 1
(DB), harness side and ground, while pressing and releasing the
horn switch.
Yes
GO to A12.
Is the resistance less than 5 ohms with the horn switch
pressed, and greater than 10,000 ohms with the horn switch No
released? GO to A13.
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Connect all the SJB connectors and make sure they seat No
Is the concern still present? by a loose or corroded connector.
A13 CHECK CIRCUIT 1 (DB) FOR AN OPEN
Depower the supplemental restraint system (SRS). Refer to
Section 501-20B.
(DB), harness side and the clockspring C2274-7, circuit 1 (DB),
harness side.
Yes
GO to A14.
No
REPAIR the circuit. REPOWER the SRS.
REFER to Section 501-20B. TEST the
A14 CHECK THE CLOCKSPRING FOR AN OPEN
Remove the driver side air bag module. Refer to Section
501-20B.
Disconnect: Upper Clockspring Connector.
(Continued)
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413-06-9 413-06-9 Horn
A14 CHECK THE CLOCKSPRING FOR AN OPEN (Continued)
Measure the resistance between the upper clockspring
connector pin 5, component side and the clockspring C2274 pin
7, component side; and between the upper clockspring
connector pin 4, component side and the clockspring C2274 pin
6, component side.
Yes
GO to A15.
No
Section 501-20B. TEST the system for
Are the resistances less than 5 ohms? normal operation.
A15 CHECK THE HORN SWITCH FOR CORRECT OPERATION
connector pin 5, circuit 1 (BK), harness side and the upper
clockspring connector pin 4, circuit 1205 (GN), harness side,
while pressing and releasing the horn switch.
Yes
REPAIR circuit 1205 (BK) between the
clockspring and ground. INSTALL the
driver air bag module. REFER to Section
501-20B. TEST the system for normal
operation.
No
INSTALL a new steering wheel. REFER to
Is the resistance less than 5 ohms with the horn switch Section 211-04. INSTALL the driver air
pressed, and greater than 10,000 ohms with the horn switch bag module. REFER to Section 501-20B.
released? TEST the system for normal operation.
Pinpoint Test B: The Horn Is Always On Normal Operation
The horn relay control and switched voltage is
Refer to Wiring Diagrams Cell 44, Horn/Cigar
supplied by the bussed electrical center (BEC)
Lighter for schematic and connector information.
through circuit 2037 (RD). The smart junction box
(SJB) receives the horn signal through circuit 1
(DB) from the horn switch (part of the steering
wheel). When the horn switch is pressed, ground is
supplied through the clockspring to the vehicle
harness through circuit 1205 (BK). The SJB then
activates the horn relay through circuit 1323
(OG/RD). Voltage is then sent to the horn through
circuit 6 (YE/LG), enabling the horns to sound.
Ground is provided to the horns through circuit
1205 (BK).
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413-06-10 413-06-10 Horn
DTC B1897 sets when a short to ground is Horn switch (part of the steering wheel)
detected on circuit 1 (DB).
Clockspring
Possible Causes
Horn relay
Circuit 1 (DB) short to ground
BEC
Circuit 6 (YE/LG) short to voltage
SJB
Circuit 1323 (OG/RD) short to ground
PINPOINT TEST B: THE HORN IS ALWAYS ON
B1 RETRIEVE THE SJB DTCs
Check the recorded results from the SJB self-test. Yes
Is DTC B1897 retrieved? GO to B2.
No
GO to B7.
B2 CHECK THE HORN SWITCH FOR A SHORT TO GROUND
Disconnect: Upper Clockspring Connector.
connector pin 5, circuit 1 (BK), harness side and the upper
clockspring connector pin 4, circuit 1205 (GN), harness side.
Yes
GO to B3.
No
INSTALL a new steering wheel. REFER to
Section 211-04. INSTALL the driver air
bag module. REFER to Section 501-20B.
Is the resistance greater than 10,000 ohms? CLEAR the DTCs. REPEAT the self-test.
B3 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
Connect: Upper Clockspring Connector.
(Continued)
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413-06-11 413-06-11 Horn
PINPOINT TEST B: THE HORN IS ALWAYS ON (Continued)
B3 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
(Continued)
component side and the clockspring C2274 pin 6, component
side.
Yes
GO to B4.
No
Section 501-20B. INSTALL the driver air
Is the resistance greater than 10,000 ohms? CLEAR the DTCs. REPEAT the self-test.
B4 CHECK CIRCUIT 1 (DB) FOR A SHORT TO GROUND
Install the driver air bag module. Refer to Section 501-20B.
(DB), harness side and ground.
Yes
GO to B5.
No
Is the resistance greater than 10,000 ohms? REPEAT the self-test.
B5 CHECK THE SJB FOR CORRECT OPERATION
Disconnect: SJB C2280c. GO to B6.
Does the horn continue to sound?
No
GO to B9.
B6 CHECK CIRCUIT 1323 (OG/RD) FOR A SHORT TO GROUND
Disconnect: BEC C1035a. Yes
Does the horn continue to sound? INSTALL a new BEC. CLEAR the DTCs.
No
normal operation.
B7 CHECK CIRCUIT 6 (YE/LG) FOR A SHORT TO VOLTAGE
Disconnect: Horn C131.
(Continued)
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413-06-12 413-06-12 Horn
PINPOINT TEST B: THE HORN IS ALWAYS ON (Continued)
B7 CHECK CIRCUIT 6 (YE/LG) FOR A SHORT TO VOLTAGE
(Continued)
Measure the voltage between the horn C131-2, circuit 6
Yes
normal operation.
No
B8 CHECK THE HORN RELAY FOR CORRECT OPERATION
Disconnect: Horn Relay. Yes
Carry out the horn relay component test. Refer to Wiring INSTALL a new BEC. TEST the system
Diagrams Cell 149 for component testing. for normal operation.
Is the horn relay OK?
No
INSTALL a new horn relay. TEST the
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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413-06-1 413-06-1 Horn
Horn
4 8226 Radiator support bracket (2 1 W705436 Upper radiator sight shield
required) pin-type retainers (6 required)
5 W709450 Horn bracket nuts (2 2 8C291 Upper radiator sight shield
required)
3 W505424 Radiator support bracket bolt
6 13832 Horn (4 required)
(Continued)
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413-06-2 413-06-2 Horn
5. Remove the 2 horn bracket nuts.
hoist. For additional information, REFER to
6. If equipped, remove the 6 front bumper
Section 100-02.
cover-to-valance panel screws and remove the
valence panel.
2. Remove the 6 pin-type retainers and the upper
7. Disconnect the electrical connector and remove
the horn.
3. Remove the 4 bolts and the 2 radiator support
brackets.
4. Position the top of the radiator and condenser
assembly toward the engine.
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413-08-1 413-08-1 Information and Message Center
Information And Message Center
The message center is a vacuum fluorescent, fixed
format display that is integrated into the center of
the instrument cluster. The message center functions
are controlled by the message center switches. The
message center displays important vehicle
information by constantly monitoring different
vehicle systems. The message center displays a
warning message pertaining to the system in which
a fault has been detected. Refer to the Owners
Literature for operating instructions.
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The message center information can be selected
Information And Message Center
through a set of 3 buttons:
Special Tool(s)
SET
INFO
RESET
Information Mode
The information displays are non-timed modes. The
selected mode remains on until the driver presses a
message center button to change the mode or it is
overridden by another mode. The information (VCM) and Integrated
Diagnostic System (IDS) display modes are:
Trip/total odometer hardware, or equivalent scan
tool
Trip odometer
Distance to empty
Flex Probe Kit
Average fuel economy
Fuel used
Instantaneous fuel economy
Trip elapsed drive time
Average speed
Blank display
For additional information regarding the odometer
The message center is a vacuum fluorescent display,
and trip odometer, refer to Section 413-01.
which is part of the instrument cluster. The message
Setup Mode
center electronic functions use both hardwired and
controller area network (CAN) circuits to transmit
The setup mode provides a list of items that can be
and receive information.
configured by the driver. The setup modes are:
As a technician it is very important to understand:
SYSTEM CHECK
where the input (command) originates from.
COLOR SELECTION
all the information (messages) necessary in order
UNITS (English/Metric)
for a feature to operate.
DISPLAY MODE (Single/Dual)
which module(s) receive(s) the input or command
LANGUAGES
message.
Warnings Mode
does the module which received the input
(message) control the output of the feature, or
A single chime sounds when a warning message is
does it output a message over the communication
displayed. The warning messages display once
network circuits to another module.
whenever the ignition switch is turned to the ON
position or a fault occurs in a system.
which module controls the output of the feature.
The warning messages are:
The message center provides the following features:
DRIVER DOOR AJAR
Information displays
PASSENGER DOOR AJAR
Setup displays
TRUNK AJAR
Warning messages
CHECK CHARGING SYSTEM
System check messages
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CHECK FUEL CAP
Mechanical Electrical CHECK TRAC CONTROL
Engine coolant level Instrument cluster
LOW BRAKE FLUID LEVEL
Accessory drive belt Message center switches
BRAKE SYSTEM FAILURE
Engine oil level Circuitry
Brake fluid level
PARK BRAKE ON
LOW FUEL LEVEL
LOW OIL PRESSURE
TURN SIGNAL ON
System Check
software release.
Selecting this function from the SETUP menu
causes the message center to cycle through each of
the systems being monitored. For each of the
monitored systems, the message center indicates
either an OK message or a warning message for 2
to 4 seconds. The sequence of the system check
report is as follows:
VCM.
OIL PRESSURE OK If the scan tool does not communicate with the
VCM:
CHARGING SYSTEM OK
DRIVERS DOOR CLOSED
PASSENGER DOOR CLOSED
TRUNK CLOSED
BRAKE SYSTEM OK
with the scan tool.
TRAC CONTROL OK
FUEL CAP OK
vehicle:
FUEL LEVEL OK
position.
XXX MILES TO EMPTY
Performance Mode Configuration (GT 500
good vehicle.
Only)
The message center provides the ability to configure
the performance shift warning indicator and the
(PCM).
performance shift warning chime features
independent of each other. The 2 configurable items
for each feature are the feature on/off and the shift
points (engine rpm). Refer to Message Center
Configuration in this section for additional
information on configuring these 2 items. Refer to
Section 413-09 for additional information on the
performance shift warning chime.
Inspection and Verification self-test diagnostics for the instrument cluster.
1. Verify the customer concern. 9. If the DTCs retrieved are related to the concern,
refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index.
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Instrument Cluster Diagnostic Trouble Code (DTC) Index
B1205 EIC Switch-1 Assembly Circuit Failure GO to Pinpoint Test B.
Symptom Chart
Symptom Chart
The message center is not Message center switch GO to Pinpoint Test A.
operating correctly Instrument cluster
The message center display is Instrument cluster PRESS the message center
blank INFO button. If the message
center display is still blank,
INSTALL a new instrument
cluster. REFER to Section
413-01. TEST the system for
normal operation.
The message center switch Circuitry GO to Pinpoint Test B.
does not operate correctly Message center switch
Instrument cluster
The CHECK TRAC Instrument cluster CHECK the traction control
CONTROL warning is system for correct operation.
inoperative If the traction control
system does not operate
correctly, REFER to
Section 206-09.
If the traction control
system operates
correctly, INSTALL a
new instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
The TURN SIGNAL ON Instrument cluster CHECK the turn signal
warning is inoperative indicators for correct
operation.
If the turn signal
indicators do not operate
correctly, REFER to
Section 413-01.
If the turn signal
indicators operate
REFER to Section
413-01. TEST the
system for normal
operation.
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The CHECK CHARGING Instrument cluster CHECK the charging system
SYSTEM warning is warning indicator for correct
inoperative operation.
If the charging system
warning indicator does
not operate correctly,
REFER to Section
413-01.
If the charging system
warning indicator
operates correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
The BRAKE SYSTEM Instrument cluster CHECK the brake warning
FAILURE warning is indicator for correct
inoperative operation.
If the brake warning
indicator does not
operate correctly,
REFER to Section
413-01.
indicator operates
REFER to Section
413-01. TEST the
system for normal
operation.
The LOW FUEL LEVEL Instrument cluster CHECK the fuel gauge for
warning is inoperative correct operation.
If the fuel gauge does
REFER to Section
413-01.
If the fuel gauge
operates correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
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The LOW OIL PRESSURE Instrument cluster CHECK the oil pressure
warning is inoperative gauge for correct operation.
If the oil pressure gauge
does not operate
correctly, REFER to
Section 413-01.
If the oil pressure gauge
operates correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
The CHECK FUEL CAP Instrument cluster CHECK for powertrain
warning is inoperative control module (PCM) DTCs.
If PCM DTCs are
present, REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
If no PCM DTCs are
present, INSTALL a
REFER to Section
413-01. TEST the
system for normal
operation.
The DRIVER DOOR, Instrument cluster CHECK the interior lamps for
PASSENGER DOOR, AND correct operation.
TRUNK AJAR warning is If the interior lamps do
inoperative not operate correctly,
REFER to Section
417-02.
If the interior lamps
operate correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
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The PARK BRAKE ON Instrument cluster CHECK the brake warning
warning is inoperative indicator for correct
operation.
indicator does not
operate correctly,
REFER to Section
413-01.
indicator operates
REFER to Section
413-01. TEST the
system for normal
operation.
Message center switch
Pinpoint Test A: The Message Center Is Not
Operating Correctly Instrument cluster
Normal Operation
The message center display is located below the
speedometer in the instrument cluster. The message
center functionality is controlled through the
message center switches, which are hardwired to the
instrument cluster through circuits 1410 (TN/OG)
and 1411 (GY/OG). The message center switches
use a different resistance value for each switch,
allowing the instrument cluster to determine which
switch is pressed.
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY
A1 CHECK THE MESSAGE CENTER DISPLAY OPERATION USING
THE SCAN TOOL
Enter the following diagnostic mode on the scan tool: Instrument The system is OK. If the SET, INFO or
Cluster Active Command. RESET buttons are inoperative, GO to
Select the instrument cluster display segment control active Pinpoint Test B.
command on. Observe the message center display.
No
Does the message center display illuminate all segments?
GO to A2.
Disconnect the instrument cluster connector.
Yes
Check for:
corrosion
damaged pins
pushed-out pins
Connect the instrument cluster connector and make sure it seats No
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Possible Causes
Pinpoint Test B: The Message Center Switch
Does Not Operate Correctly
Circuit 1410 (TN/OG) open, short to ground or
voltage
Circuit 1411 (GY/OG) open, short to ground or
voltage
Normal Operation
The message center switch assembly uses circuits
Message center switch assembly
1410 (TN/OG) and 1411 (GY/OG) to communicate
Instrument cluster
the requested switch function to the message center.
DTC B1205 is a continuous and on-demand
DTC that sets if the instrument cluster detects any
of the message center buttons pressed.
PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
B1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER
SELF-TESTS
Check the recorded instrument cluster DTCs from the Yes
continuous and on-demand self-tests. For DTC B1205, GO to B3.
Are any instrument cluster DTCs recorded?
For all other instrument cluster DTCs,
No
GO to B2.
B2 CHECK THE INSTRUMENT CLUSTER PID FOR THE MESSAGE
CENTER SWITCH USING THE SCAN TOOL
Key in ON position.
Enter the following diagnostic mode on the scan tool: Instrument
Cluster PIDs.
Yes
Select and monitor the instrument cluster message center switch
GO to B6.
PIDs, INFOSW, SETUPSW and RES_SW while pressing each
message center switch (INFO, SETUP, and RESET). No
Does the PID agree with the switch position? GO to B3.
B3 CHECK CIRCUITS 1410 (TN/OG) AND 1411 (GY/OG) FOR A
SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between the instrument cluster C220-7,
circuit 1410 (TN/OG), harness side and ground; and between
the instrument cluster C220-6, circuit 1411 (GY/OG), harness
side and ground.
Yes
No
(Continued)
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PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (Continued)
B4 CHECK CIRCUIT 1410 (TN/OG) FOR AN OPEN AND SHORT TO
GROUND
Disconnect: Message Center Switch C253.
Measure the resistance between the instrument cluster C220-7,
circuit 1410 (TN/OG), harness side and the message center
switch C253-3, circuit 1410 (TN/OG), harness side; and between
the instrument cluster C220-7, circuit 1410 (TN/OG), harness
side and ground.
Yes
GO to B5.
Is the resistance less than 5 ohms between the instrument No
cluster and the message center switch, and greater than REPAIR the circuit. CLEAR the DTCs.
10,000 ohms between the instrument cluster and ground? REPEAT the self-test.
B5 CHECK CIRCUIT 1411 (GY/OG) FOR AN OPEN AND SHORT TO
GROUND
circuit 1411 (GY/OG), harness side and the message center
switch C253-2, circuit 1411 (GY/OG), harness side; and between
the instrument cluster C220-6, circuit 1411 (GY/OG), harness
side and ground.
Yes
INSTALL a new message center switch.
REFER to Message Center Switch in this
self-test.
Is the resistance less than 5 ohms between the instrument No
cluster and the message center switch, and greater than REPAIR the circuit. CLEAR the DTCs.
10,000 ohms between the instrument cluster and ground? REPEAT the self-test.
(Continued)
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PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (Continued)
B6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Disconnect the instrument cluster connector. Yes
corrosion REFER to Section 413-01. TEST the
damaged pins system for normal operation.
pushed-out pins
No
Connect the instrument cluster connector and make sure it seats
correctly.
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GENERAL PROCEDURES
3. Press the RESET button to toggle the shift tone
Message Center Configuration
on or off. Once the shift tone has been selected
on or off, press the SETUP BUTTON.
Performance Shift Indicator, Shift Tone
and Shift Point
4. NOTE: The shift points can be configured from
1,500-6,000 rpm.
1. NOTE: The vehicle must be at a complete stop
Press the INFO button to lower the shift points
before configuring the performance shift
in increments of 100 rpm.
indicator, shift tone or shift point.
Press and release the SETUP button until the
5. Press the RESET button to raise the shift points
message center displays PRESS RESET TO
in increments of 100 rpm.
SET SHIFTPOINT.
2. Press the RESET button to toggle the
performance shift indicator on or off. Once the
performance shift indicator has been selected on
or off, press the SETUP BUTTON.
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413-00-1 413-00-1 Instrument Cluster and Panel Illumination
Headlamp switch
Instrument Cluster and Panel
Illumination Instrument panel dimmer switch
The instrument cluster and panel illumination Climate control assembly
system illuminates the following components:
Transmission range (TR) indicator
Instrument cluster
Door lock control switches
Instrument panel center switches
Window control switches
Steering wheel switches
Convertible top switch (part of the overhead
console) (if equipped)
Message center (if equipped)
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Convertible top switch (part of the overhead
Instrument Cluster and Panel
console) (if equipped)
Illumination
Steering wheel switches
Special Tool(s)
Headlamp switch
Non-Dimmable Backlighting
When the key is in the ACC or RUN positions, the
SJB energizes the accessory delay relay, providing
switched voltage to the non-dimmable components
and switches. The non-dimmable components
consist of the:
Vehicle Communications
Driver window control switch
Module (VCM) and Integrated
Passenger window control switch
Driver door lock control switch
Passenger door lock control switch
tool
Fault Management
The dimmable backlighting defaults to full intensity
Flex Probe Kit
if the instrument panel dimmer switch or circuitry
fails.
Dimmable Backlighting
When the parking lamps are on, the smart junction
box (SJB) provides a pulse-width modulated (PWM) Instrument panel Smart junction box
dimmer switch (SJB) fuse 6 (5A) voltage to the dimmable instrument panel switches
Miniature bulb(s)
and components. The instrument panel dimmer
Circuitry
switch allows the brightness level of the dimmable
Accessory delay relay
backlights and displays to be adjusted.
Instrument cluster
Headlamp switch
The SJB communicates with the instrument cluster
through the controller area network (CAN). The
instrument cluster then increases or decreases the
intensity of the instrument cluster backlighting
accordingly. The dimmable components consist of
the:
Instrument cluster
release software.
Message center switch
Hazard flasher switch
Climate control assembly
Transmission range (TR) indicator
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5. NOTE: The vehicle communication module Refer to Section 418-00 to diagnose no
(VCM) LED prove-out confirms power and response from the powertrain control module
ground from the DLC are provided to the (PCM).
VCM.
VCM:
communication with the SJB, refer to
Check the VCM connection to the vehicle. Section 418-00.
Check the scan tool connection to the VCM. If the network test passes, retrieve and
Scan Tool, to diagnose no communication 8. Clear the continuous DTCs and carry out the
with the scan tool. self-test diagnostics for the SJB.
6. If the scan tool does not communicate with the 9. If the DTCs retrieved are related to the concern,
vehicle: go to the Smart Junction Box (SJB) Diagnostic
position.
good vehicle.
B1247 Instrument Panel Dimmer Switch Circuit Open GO to Pinpoint Test B.
B2027 LED Backlighting Output Circuit Failure GO to Pinpoint Test C.
B2132 Dimmer Switch Circuit Short to Ground GO to Pinpoint Test B.
Symptom Chart
Symptom Chart
No communication with the Fuse(s) REFER to Section 418-00.
smart junction box (SJB) Circuitry
SJB
The control illumination is SJB GO to Pinpoint Test A.
inoperative
The instrument cluster Circuitry CHECK the operation of the
illumination is inoperative Instrument cluster other backlighting
components.
If the other backlighting
components operate
REFER to Section
413-01. TEST the
system for normal
operation.
If the other backlighting
components are
inoperative, GO to
Pinpoint Test A.
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The instrument panel Circuitry GO to Pinpoint Test B.
illumination does not dim Instrument panel dimmer
switch
SJB
One or more smart junction Fuse GO to Pinpoint Test C.
box (SJB) controlled Circuitry
illumination source(s) is Illuminated component
inoperative Clockspring
SJB
Pinpoint Tests Normal Operation
When the headlamp switch is placed in the
Pinpoint Test A: The Control Illumination is
PARKING or HEADLAMP ON position, the smart
Inoperative
junction box (SJB) supplies either a pulse width
Refer to Wiring Diagrams Cell 71, Cluster and
modulated (PWM) signal or 12 volts to the various
Panel Illumination for schematic and connector
backlighting sources in the instrument panel, doors
information.
and console.
Possible Causes
SJB
PINPOINT TEST A: THE CONTROL ILLUMINATION IS INOPERATIVE
A1 CHECK THE PARKING LAMPS OPERATION
Monitor the parking lamps in the OFF position and in the PARK Yes
position. GO to A2.
Do the parking lamps operate correctly?
No
diagnosis of the exterior lighting system.
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test B: The Instrument Panel Normal Operation
Illumination Does Not Dim
With the parking lamps on, a voltage signal is
supplied to the instrument panel dimmer switch
through circuit 1036 (BN/WH) from the smart
junction box (SJB). The dimmer switch passes this
information.
voltage through a variable resistor and then returns
the signal to the SJB on circuit 1035 (OG/RD).
The SJB uses the return signal to determine the
backlighting intensity desired by the operator. A
pulse-width modulated (PWM) signal is sent from
the SJB to each of the dimmable backlights,
maintaining the operators desired level of lighting
intensity.
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The dimmable backlighting defaults to full intensity Circuit 1036 (BN/WH) open, short to ground or
if the instrument panel dimmer switch or circuitry voltage
fails.
Circuit 1405 (LB/BK) open, short to ground or
DTC B1247 sets when the illumination dimmer voltage
switch detects a open circuit from the SJB circuitry.
Instrument panel dimmer switch
DTC B2132 sets when the illumination dimmer
SJB
switch detects a short to the reference signal or a
short to ground.
Possible Causes
Circuit 1035 (OG/RD) open, short to ground or
voltage
PINPOINT TEST B: THE INSTRUMENT PANEL ILLUMINATION DOES NOT DIM
B1 MONITOR THE INSTRUMENT PANEL ILLUMINATION
OPERATION
With the parking lamps on, rotate the dimmer switch from Yes
maximum brightness to minimum brightness. The system is OK.
Monitor all instrument panel illumination sources for correct
No
operation.
If only the instrument cluster does not dim,
Do all the dimmable instrument panel illumination sources
dim correctly?
For all others, GO to B2.
B2 CHECK THE SJB INSTRUMENT PANEL DIMMER SWITCH PIDs
Key in ON position.
Enter the following diagnostic mode on the scan tool: SJB
Instrument Panel Dimmer Switch PIDs.
Monitor the SJB instrument panel dimmer switch PIDs while
Yes
rotating the instrument panel dimmer switch from the full OFF to
GO to B7.
the full ON position.
Do the SJB instrument panel dimmer switch PIDs agree with No
the instrument panel dimmer switch position? GO to B3.
B3 CHECK THE INSTRUMENT PANEL DIMMER SWITCH
OPERATION
Carry out the instrument panel dimmer switch component test. Yes
Refer to Wiring Diagrams Cell 149 for component testing. GO to B4.
Does the instrument panel dimmer switch pass the
No
component test?
INSTALL a new instrument panel dimmer
switch. CLEAR the DTCs. REPEAT the
self-test.
B4 CHECK CIRCUITS 1035 (OG/RD), 1036 (BN/WH) AND 1405
(LB/BK) FOR A SHORT TO VOLTAGE
Disconnect: SJB C2280d.
Measure the voltage between the SJB, harness side and ground
as follows:
(Continued)
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PINPOINT TEST B: THE INSTRUMENT PANEL ILLUMINATION DOES NOT DIM (Continued)
(LB/BK) FOR A SHORT TO VOLTAGE (Continued)
Connector-Pin Circuit
C2280b-43 1035 (OG/RD)
Yes
C2280b-32 1036 (BN/WH)
normal operation.
C2280b-1 1405 (LB/BK)
No
Is any voltage indicated? GO to B5.
(LB/BK) FOR A SHORT TO GROUND
Measure the resistance between the SJB, harness side and
ground as follows:
C2280b-43 1035 (OG/RD)
Yes
C2280b-32 1036 (BN/WH)
GO to B6.
C2280b-1 1405 (LB/BK)
No
Is the resistance greater than 10,000 ohms? normal operation.
(LB/BK) FOR AN OPEN
Measure the resistance between the SJB, harness side and the
instrument panel dimmer switch, harness side as follows:
Connector-Pin Circuit Connector-Pin Circuit
C2280b-43 1035 (OG/RD) C2298-6 1035 (OG/RD)
Yes
C2280b-32 1036 (BN/WH) C2298-1 1036 (BN/WH)
GO to B7.
C2280b-1 1405 (LB/BK) C2298-4 1405 (LB/BK)
No
pushed-out pins
No
correctly.
Pinpoint Test C: One Or More Smart
Junction Box (SJB) Controlled Illumination
Source(s) Is Inoperative
information.
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Normal Operation Dimmable Backlighting
Circuit 203 (OG/LB) open or short to ground
With the parking lamps on, a voltage signal is
Circuit 293 (OG/RD) open or short to ground
supplied to the instrument panel dimmer switch
Circuit 333 (YE/RD) open or short to ground
through circuit 1036 (BN/WH) from the SJB. The
dimmer switch passes this voltage through a Circuit 984 (YE/LB) open or short to ground
variable resistor and then returns the signal to the
Circuit 985 (RD/LB) open or short to ground
SJB on circuit 1035 (OG/RD). The SJB uses the
return signal to determine the backlighting intensity
Circuit 1403 (BK/WH) open or short to ground
desired by the operator. A pulse-width modulated
(PWM) signal is sent from the SJB to each of the
Circuit 1425 (GY/WH) open or short to ground
dimmable backlights maintaining the operators
Circuit 2023 (YE/LB) open or short to ground
desired level of lighting intensity.
Circuit 2029 (LB/WH) open or short to ground
DTC B2027 sets when the LED backlighting
Circuit 2030 (YE/WH) open or short to ground
detects a short to voltage or ground.
Illuminated component
Normal Operation Non-Dimmable
Backlighting Clockspring
When the ignition switch is placed in the ACCY or
the ON position, a voltage signal is supplied to the
SJB. The SJB activates the accessory delay relay,
SJB
supplying voltage to the non-dimmable backlights.
Possible Causes
Fuse
Circuit 19 (LB/RD) open or short to ground
PINPOINT TEST C: ONE OR MORE SMART JUNCTION BOX (SJB) CONTROLLED ILLUMINATION
SOURCE(S) IS INOPERATIVE
C1 CHECK THE INSTRUMENT PANEL ILLUMINATION OPERATION
Key in ON position.
Yes
Place the headlamp switch in the PARK position.
Rotate the dimmer switch to the maximum brightness position.
No
Monitor all instrument panel illumination sources for correct
If the inoperable illumination source(s) are
operation.
non-dimmable, GO to C2.
Are all the instrument panel illumination sources
inoperable? For all others, GO to C6.
C2 CHECK THE NON-DIMMABLE BACKLIGHTING OPERATION
Monitor all instrument panel illumination non-dimmable sources Yes
for correct operation. VERIFY the SJB fuse 6 (5A) is OK. If OK,
Are all the instrument panel non-dimmable illumination GO to C3.
sources inoperable?
No
GO to C4.
C3 CHECK THE ACCESSORY DELAY RELAY
Carry out the accessory delay relay component test. Refer to GO to C11.
Wiring Diagrams Cell 149 for component testing.
No
Does the accessory delay relay pass the component test?
INSTALL a new accessory delay relay.
CLEAR the DTCs. REPEAT The self-test.
C4 CHECK CIRCUITS 333 (YE/RD), 984 (YE/LB) AND 985 (RD/LB)
FOR AN OPEN AND SHORT TO GROUND
Disconnect: SJB C2280e.
Disconnect: Suspect Illuminated Component.
(Continued)
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SOURCE(S) IS INOPERATIVE (Continued)
C4 CHECK CIRCUITS 333 (YE/RD), 984 (YE/LB) AND 985 (RD/LB)
FOR AN OPEN AND SHORT TO GROUND (Continued)
suspect illuminated component, harness side; and between the
SJB, harness side and ground as follows:
Suspect
Illuminated Illuminated
Component SJB Component
Location Connector-Pin Connector-Pin Circuit
Driver door C2280e-26 C505-3 985 (RD/LB)
lock control
switch
Driver door C2280e-26 C504-3 985 (RD/LB)
window control
switch
Passenger door C2280e-25 C605-3 984 (YE/LB)
lock control
switch
Passenger C2280e-25 C604-5 984 (YE/LB)
window control
switch
Rear window C2280e-23 C566-5 333 (YE/RD)
Yes
control switch
GO to C5.
Is the resistance less than 5 ohms between the SJB and the No
suspect illuminated component, and greater than 10,000 REPAIR the circuit in question. CLEAR the
ohms between the SJB and ground? DTCs. REPEAT the self-test.
C5 CHECK NON-DIMMABLE LAMPS CIRCUIT 1205 (BK) FOR AN
OPEN
Measure the resistance between the suspect illuminated
component, harness side and ground as follows:
Suspect
Illuminated
Component
Location Connector-Pin Circuit
Driver door lock C505-1 1205 (BK)
control switch
Driver door control C504-1 1205 (BK)
switch
Passenger door lock C605-1 1205 (BK)
control switch
Passenger window C604-1 1205 (BK) Yes
INSTALL a new illuminated component in
control switch
question. CLEAR the DTCs. REPEAT the
Rear window control C566-1 1205 (BK) self-test.
switch
No
(Continued)
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C6 CHECK THE DIMMABLE BACKLIGHTING OPERATION
Monitor all instrument panel illumination dimmable sources for Yes
correct operation. GO to C11.
Are all the instrument panel dimmable illumination sources
No
inoperable?
GO to C7.
C7 CHECK THE INOPERABLE ILLUMINATED COMPONENT
CIRCUIT FOR VOLTAGE
Disconnect: Suspect Illuminated Component.
Key in ON position.
Turn the parking lamps on, rotate the instrument panel dimmer
switch to the full intensity position.
Measure the voltage between the suspect illuminated component
and ground as follows:
Suspect
Illuminated
Component
Transmission range C307-4 19 (LB/RD)
(TR) indicator
Speed control switch C2274-3 203 (OG/LB)
Convertible top switch C9013-8 293 (OG/RD)
Instrument panel C2298-3 1403 (BK/WH)
dimmer switch
Climate control C294a-2 1425 (GY/WH)
assembly
Headlamp switch C205-2 2023 (YE/LB) Yes
INSTALL a new instrument panel dimmer
Hazard flasher switch C2039-6 2029 (LB/WH)
switch. GO to C10.
For all others, GO to C9.
Message center switch C253-1 2030 (YE/WH)
No
C8 CHECK CIRCUITS 19 (LB/RD), 203 (OG/LB), 293 (OG/RD), 1403
(BK/WH), 1425 (GY/WH), 2023 (YE/LB), 2029 (LB/WH) AND 2030
(YE/WH) FOR AN OPEN AND A SHORT TO GROUND
Turn the headlamp switch OFF.
Disconnect: SJB.
Disconnect: Suspect Lamp.
suspect illuminated component, harness side; and between the
SJB, harness side and ground as follows:
(Continued)
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C8 CHECK CIRCUITS 19 (LB/RD), 203 (OG/LB), 293 (OG/RD), 1403
(BK/WH), 1425 (GY/WH), 2023 (YE/LB), 2029 (LB/WH) AND 2030
(YE/WH) FOR AN OPEN AND A SHORT TO GROUND
(Continued)
Suspect
Illuminated Illuminated
Component SJB Component
Location Connector-Pin Connector-Pin Circuit
Speed control C2280b-10 Clockspring 203 (OG/LB)
switch C2274-3
Convertible top C2280f-6 Overhead 293 (OG/RD)
switch console
C9013-8
Instrument C2280b-8 C2298-3 1403 (BK/WH)
panel dimmer
switch
Climate control C2280b-23 C294a-2 1425 (GY/WH)
assembly
Headlamp C2280b-6 C205-2 2023 (YE/LB)
switch
Hazard flasher C2280b-11 Center stack 2029 (LB/WH)
switch C2039-6
Message center C2280b-9 C253-1 2030 (YE/WH)
switch
Yes
TR indicator C2280e-12 C307-4 19 (LB/RD)
GO to C11.
suspect illuminated component, and greater than 10,000 REPAIR the circuit in question. CLEAR the
ohms between the SJB and ground? DTCs. REPEAT the self-test.
C9 CHECK DIMMABLE LAMPS CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between the suspect illuminated
component, harness side and ground as follows:
Suspect
Illuminated
Component
TR indicator Clockspring C307-1 1205 (BK)
Speed control switch Clockspring C2274-6 1205 (BK)
Convertible top switch Overhead console 1205 (BK)
C9013-3
Climate control C294a-1 1205 (BK)
assembly
Headlamp switch C205-1 1205 (BK)
Yes
For the speed control switch, GO to C10.
Hazard flasher Center stack C2039-1 1205 (BK)
For all others, INSTALL a new component.
switches
Message center switch C253-4 1205 (BK)
No
(Continued)
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C10 CHECK THE CLOCKSPRING FOR AN OPEN
Disconnect: Steering Wheel Control Harness.
component side, and the top of the clockspring pin 1,
component side and between the clockspring C2274 pin 6,
component side and the top of the clockspring pin 4, component
side.
Yes
REFER to Section 310-03. INSTALL the
driver air bag module. REFER to Section
501-20B. CLEAR the DTCs. REPEAT the
self-test.
No
Section 501-20B. INSTALL the driver air
Are the resistances less than 5 ohms? CLEAR the DTCs. REPEAT the self-test.
pushed-out pins
No
correctly.
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413-01-1 413-01-1 Instrument Cluster
Instrument Cluster Lens
1. Remove the instrument cluster. For additional
information, refer to Instrument Cluster in this
section.
2. Unclip the retaining tabs and remove the
instrument cluster lens.
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Instrument Cluster
The instrument cluster is available either with a
message center or without a message center (base
cluster). The instrument cluster contains gauges,
indicator lamps, and warning lamps that are
designed to provide the driver with system status,
and to alert the driver that certain conditions exist in
the vehicle. Gauges provide information to the
driver indicating the status of systems. Examples of
the gauges include vehicle speed, fuel level, engine
coolant temperature, and engine rpm. Indicator
lamps provide information to the driver of
conditions that exist in the vehicle. The indicator
lamps include the turn signal, high beam, and speed
control. Warning indicator lamps provide
information to the driver of conditions that could
potentially alter vehicle performance. Examples of
the warning indicators include the anti-lock brake
system (ABS), BRAKE, and low oil pressure. The
instrument cluster lens, and the indicator bulbs are
the only parts that may be installed separately.
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The instrument cluster receives the information over
Instrument Cluster
the controller area network (CAN) circuits. The
Special Tool(s)
instrument cluster carries out a display prove-out to
verify that the warning/indicator lamps and
monitored systems are operating correctly. When
the ignition switch is turned to the ON position, the
charging system warning indicator, the low oil
pressure warning indicator, and the malfunction
indicator lamp (MIL) illuminate until the engine is
started and operating normally. The safety belt
warning indicator proves out for 65 seconds or until
the safety belt is fastened.
Each time the ignition switch is turned from the
OFF to the ON positions, the following instrument
cluster warning indicators prove out for 3 seconds:
tool
ABS warning indicator
Air bag warning indicator (6 seconds)
Flex Probe Kit
BRAKE warning indicator
Fail safe cooling warning indicator
Low fuel warning indicator
Traction control indicator
Anti-theft indicator
Check fuel cap warning indicator
Wrench warning indicator
When installing a new instrument cluster, it is
necessary to upload the module configuration
Tire pressure monitoring system (TPMS) warning
information to the scan tool. Following installation
indicator
of the instrument cluster, download the module
Instrument Cluster Gauges
configuration information from the scan tool into
the new instrument cluster. Refer to Section 418-01.
Tachometer
The following items are configurable:
The instrument cluster receives the tachometer data
from the powertrain control module (PCM) over the
Speedometer calibration
communication network and commands the
Brake system (base, anti-lock brake system
tachometer pointer between 0 and 7,000 rpm (4.0L
(ABS), ABS/traction control [TC])
engines), or between 0 and 8,000 rpm (4.6L
Door ajar engines) according to the data.
Shift indicator lamp
Speedometer
The instrument cluster receives the vehicle speed
Daytime running lamps (DRL)
information from the PCM over the communication
Door ajar warning chime
network and displays it on the speedometer gauge.
Overspeed warning chime
If the instrument cluster receives no vehicle speed
Back-up warning chime signal after 1 second, the speedometer defaults to
0.
Key in warning chime
Security system
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Odometer
The key ON fueling mode (approximately 90
The instrument cluster receives an odometer
seconds to read empty [E] to full [F]) requires 3
message from the PCM and stores the mileage in
conditions be met:
memory. When the instrument cluster fails to
The transmission is in PARK (P) (automatic
receive the odometer message for more than 2
transmissions), or the parking brake applied
seconds, the odometer displays dashes.
(manual transmissions).
Fuel Gauge
The key is in the RUN position.
The instrument cluster receives the fuel level signal
At least 15% of the vehicles fuel capacity must
from the fuel level sensor, part of the fuel pump
be added to the fuel tank.
module. The fuel level sensor measures variable
resistance in the fuel tank depending on the current In key ON fueling mode, a 30 second timer
fuel level. When the fuel level is low, the activates after the transmission is put into the PARK
resistance in the unit is low (15 ohms 2 ohms). (P) position (automatic transmissions) or when the
When the fuel level is high, the resistance in the parking brake is applied (manual transmissions).
unit is high (160 ohms 4 ohms). When the 30 second time has elapsed and at least
15% of the vehicles fuel capacity has been added,
The instrument cluster uses 4 different operating
the fuel gauge response time is 90 seconds to read
modes to calculate the fuel level:
from empty (E) to full (F). When the transmission
Key OFF fueling
is shifted out of PARK (P) or the parking brake is
released, the fuel gauge strategy reverts to the
Anti-slosh (default mode)
anti-slosh mode. The key ON fueling mode prevents
Key ON fueling
slow to read full events from happening if the
Recovery
customer refuels the vehicle with the key in the
RUN position.
After a fuel fill up, the time for the fuel gauge to
move from empty (E) to full (F) ranges from 2
Recovery mode is incorporated into the instrument
seconds to 55 minutes depending on which
cluster strategy to recover from missing fuel level
operating mode the fuel gauge is in.
inputs during a refueling event. Missing fuel level
input result from intermittent opens in the fuel
The key OFF fueling mode (2 seconds to read
sender or its circuits. Recovery mode (empty [E] to
empty [E] to full [F]) requires 3 conditions be met:
full [F] approximately 20 minutes) is initiated when
The key must be in the OFF position throughout
the following 2 conditions are met:
the entire refueling of the vehicle.
The instrument cluster is in the anti-slosh (default)
At least 15% of the vehicles fuel capacity must
mode.
be added to the fuel tank.
The actual fuel level in the tank is greater than
The instrument cluster must receive a valid key
what is being displayed by the fuel gauge.
ON fuel sender reading within 1 second of the
key being put into the RUN position. The key ON
Engine Coolant Temperature Gauge
sample readings are considered valid if the fuel
The PCM receives the engine coolant temperature
sender reading is between 15 ohms 2 ohms and
status through hardwired circuitry to the engine
160 ohms 4 ohms.
coolant temperature (ECT) sensor. The instrument
cluster receives the engine coolant temperature data
If these conditions are not met, the fuel gauge
from the PCM over the communication network.
stays in the anti-slosh mode, which results in a
The instrument cluster monitors the engine coolant
slow to read full (F) event.
temperature data received from the PCM and
The default fuel gauge mode is called the anti-slosh
commands the engine coolant temperature gauge
mode. To prevent fuel gauge changes from fuel
pointer.
slosh (gauge instability due to changes in fuel
sender readings caused by fuel moving around in
Voltage Gauge
the tank), the fuel gauge takes approximately 55
The voltage gauge displays the system battery
minutes to go from empty (E) to full (F).
voltage as measured at the instrument cluster run
input circuit.
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Oil Pressure Gauge Safety Belt Warning Indicator
The smart junction box (SJB) is hardwired to the oil The safety belt warning indicator informs the driver
pressure switch. The oil pressure switch unit that his/her safety belt and/or the front passengers
consists of a diaphragm and contact points, which safety belt is unbuckled. The first 65 seconds after
are normally open. When there is low (under 41 the ignition switch transitions from OFF or ACC to
kPa [6 psi]) or no oil pressure, the oil pressure RUN or START, the safety belt warning indicator
switch remains open, removing the ground to the and the associated chime are used as a reminder to
SJB. When sufficient oil pressure exists, the oil the driver that the front row safety belts are not
pressure switch closes providing a ground signal to buckled. In this first 65 seconds the indicator
the SJB. The SJB monitors the oil pressure ground illuminates when the driver and/or front passenger
signal and sends a message to the instrument safety belt is unbuckled (with a person in the seat)
cluster to operate the oil pressure gauge according
and turns off whenever the safety belt(s) in the
to the engine oil pressure.
occupied front row seat(s) is buckled. The indicator
illuminates again if a safety belt is unbuckled after
Boost Gauge (GT 500 Only)
both are buckled and the 65 seconds has not yet
The boost gauge measures the amount of engine
expired. After 65 seconds, the indicator turns off
boost provided by the supercharger in pounds per
regardless of the front row safety belts status.
square inch (PSI). The instrument cluster receives
the boost gauge data from the powertrain control
Anti-Lock Brake System (ABS) Warning
module (PCM) over the high speed controller area Indicator
network (CAN) communication bus lines. The ABS warning indicator informs the driver of a
malfunction in the ABS system. Inputs are provided
Indicators
by the ABS module over the communication
network. For additional information, refer to
Low Fuel Warning Indicator
Section 206-09.
The low fuel warning indicator is controlled by the
instrument cluster and warns the driver when the
Malfunction Indicator Lamp (MIL)
fuel level is 1/16 of a tank or lower.
The MIL is illuminated when a DTC is detected by
the PCM. The instrument cluster receives the MIL
Check Fuel Cap Warning Indicator
data from the PCM through the communication
The PCM monitors pressure in the fuel evaporative
network.
system and detects massive or critical losses of
pressure. When a critical loss of pressure in the fuel
Wrench Warning Indicator
evaporative system is detected, the PCM provides a
The PCM monitors the electronic throttle control
message over the communication network and the
(ETC) system and provides the instrument cluster
instrument cluster illuminates the check fuel cap
with the ETC status over the communication
warning indicator.
network. When a system concern is detected, the
PCM provides the instrument cluster with a signal
BRAKE Warning Indicator
commanding the instrument cluster to illuminate the
The brake warning indicator alerts the driver if any
wrench indicator or display a message if equipped
of the following brake system conditions are
with a message center.
present: the parking brake is set, the brake fluid
level is low, the ABS module detects a base brake
High Beam Indicator
system failure, there is a loss of communication
When the high beams are turned on, the SJB sends
between the instrument cluster and the SJB, or there
a signal to the instrument cluster through the
is a loss of communication between the instrument
communication network to illuminate the high beam
cluster and the ABS module.
indicator.
Turn Indicators
The SJB sends a message to the instrument cluster
over the communication network when the
multifunction switch is in the RH and LH turn
signal position. When the multifunction switch is in
the RH or LH turn signal position, the instrument
cluster flashes the RH or LH turn indicators.
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Air Bag Warning Indicator Daytime Running Lamp (DRL) Indicator
The air bag warning indicator is used to provide a When the DRL is on, the SJB sends a message over
status of the supplemental restraint system. The the communication network, to the instrument
instrument cluster receives a message from the cluster, illuminating the DRL indicator.
restraint control module (RCM) over the hard wired
Low Oil Pressure Warning Indicator
circuits. If an air bag system concern is detected, a
The SJB is hardwired to the oil pressure switch.
DTC is logged and the RCM sends a message to
The oil pressure switch unit consists of a diaphragm
the instrument cluster to illuminate the air bag
and contact points, which are normally open. When
warning indicator.
there is low (under 41 kPa [6 psi]) or no oil
Speed Control Indicator pressure, the oil pressure switch remains open,
The instrument cluster receives the speed control removing the ground to the SJB. When sufficient oil
data from the PCM through the communication pressure exists, the oil pressure switch closes,
network. When the speed control is engaged, the providing a ground signal to the SJB. The SJB
PCM provides a signal to the instrument cluster to monitors the oil pressure ground signal and sends a
illuminate the speed control indicator. message to the instrument cluster to turn the
indicator on or off according to the engine oil
Charging System Warning Indicator
pressure.
The PCM constantly monitors the generator
regulator output. When the PCM detects a Door/Trunk Ajar Warning Indicator
continuous high or low output signal, or when the The door ajar indicator informs the driver that one
ignition switch is ON and the engine is OFF, the or more doors, or the decklid is open while the
PCM sends a message over the communication ignition switch is in the RUN position. When a door
network to the instrument cluster to illuminate the or decklid is ajar, the SJB sends a message to the
charging system warning indicator. When the instrument cluster to illuminate the door ajar
ignition switch is in the ON position, with the indicator.
engine running, and the PCM determines that the
Traction Control Indicator
set point for the regulator has been met, the PCM
The traction control indicator flashes when the
sends a message to the instrument cluster to turn
vehicle traction control is in active mode or is being
off the charging system warning indicator.
controlled by the ABS module. The instrument
Failsafe Cooling Warning Indicator cluster receives the traction control signal from the
The failsafe cooling warning indicator informs the ABS module through the communication network.
driver the engine coolant is overheating due to loss The instrument cluster monitors the traction control
of engine coolant fluid or other cause, and the PCM signal, and when the ABS module detects a traction
is taking on limp home strategy. The other purpose control concern, the instrument cluster illuminates
is to inform the driver the engine cannot be cooled the traction control indicator.
enough with the limp home strategy and the engine
Anti-Theft Indicator
is about to be shut down by the PCM. The failsafe
The anti-theft indicator is used to deter potential
cooling information is sent from the PCM to the
thefts of the vehicle by providing a conspicuous
instrument cluster to illuminate the failsafe cooling
indicator that flashes every 2 seconds with the
warning indicator.
ignition off when the passive anti-theft system
Overdrive Off (O/D OFF) Indicator (PATS) is armed. The instrument cluster receives
The instrument cluster receives the overdrive off the anti-theft status from the PCM over the high
signal from the PCM through the communication speed CAN communication bus lines.
network. When the transmission overdrive is
Shift Indicator (GT 500 Only)
selected off, the overdrive off switch provides a
The shift indicator is used to inform the driver of
ground signal to the PCM. The PCM, upon receipt
shift points that provide the highest fuel economy.
of the overdrive off ground signal, provides an
The PCM uses engine throttle position, engine load
overdrive off signal to the instrument cluster and the
and engine rpm information to determine what the
instrument cluster illuminates the overdrive off
optimum shift point is to provide the greatest fuel
indicator.
economy.
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Performance Shift Warning Indicator (GT 500
Only)
software release.
The performance shift warning indicator shares the
SVT logo on the tachometer. The performance shift
indicator is configurable on or off and uses engine
rpm to determine when to illuminate. The SVT logo
is normally backlight in red when the performance
indicator is configured off. When the performance
VCM.
shift warning indicator is configured on, the SVT
logo red backlighting is turned off. When a preset
engine rpm is reached, the SVT logo illuminates
VCM:
orange to alert the driver of the selected shift point.
The performance shift warning indicator can be
configured on or off through the message center.
Refer to Section 413-08, Message Center Refer to Section 418-00, No Power To The
Configuration. Scan Tool, to diagnose no communication
with the scan tool.
Tire Pressure Monitoring System (TPMS)
Warning Indicator
vehicle:
The tire pressure warning indicator alerts the driver
that one or more of the tires on the vehicle has low
tire pressure or is flat. The tire pressure monitoring
position.
system (TPMS) system consists of a tire pressure
sensor and a transmitter located on each tire. The
good vehicle.
SJB receives the data from each tire and transmits
the status over the medium speed CAN
communication bus lines to the instrument cluster to
(PCM).
indicate whether the low tire pressure warning
indicator telltale should be illuminated, flashed, or
turned off.
Visual Inspection Chart self-test diagnostics for the instrument cluster,
anti-lock brake system (ABS) module,
powertrain control module (PCM), smart
Fuel tank Smart junction box
junction box (SJB) and restraints control
Engine coolant level (SJB) fuse(s):
module (RCM).
Engine oil level 8 (10A)
Brake fluid level 16 (5A) 9. If the DTCs retrieved are related to the concern,
19 (5A)
go to the Instrument Cluster Diagnostic Trouble
Circuitry
Code (DTC) Index, the Smart Junction Box
Instrument cluster
(SJB) Diagnostic Trouble Code (DTC) Index, or
the Powertrain Control Module (PCM)
Diagnostic Trouble Code (DTC) Index.
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B1202 Fuel Sender Circuit Open (fuel pump module GO to Pinpoint Test A.
sender)
B1204 Fuel Sender Circuit Short To Ground (fuel GO to Pinpoint Test A.
pump module sender)
B1205 EIC Switch-1 Assembly Circuit Failure If equipped with a base instrument cluster,
VERIFY that the instrument cluster bezel is
aligned correctly and the SELECT/RESET
button is not binding. REPAIR as necessary. If
the switch is not binding, INSTALL a new
instrument cluster. REFER to Instrument
Cluster in this section.
If equipped with a message center, REFER to
Section 413-08.
B1317 Battery Voltage High CLEAR the DTCs. REPEAT the self-test. If
DTC B1317 is retrieved, REFER to Section
414-00 to diagnose the charging system for
overcharging.
B1318 Battery Voltage Low CLEAR the DTCs. REPEAT the self-test. If
DTC B1318 is retrieved, REFER to Section
414-00 to diagnose the charging system for low
voltage.
B1342 ECU is Faulted INSTALL a new instrument cluster. REFER to
Instrument Cluster in this section. TEST the
B1556 Ignition RUN/START Circuit Open GO to Pinpoint Test AD.
B1557 Ignition RUN/START Circuit Short to Battery GO to Pinpoint Test AE.
B2143 NVM Memory Failure CLEAR the DTCs. REPEAT the self-test. If the
DTC is still present, INSTALL a new
instrument cluster. REFER to Instrument Cluster
in this section. TEST the system for normal
operation.
B2477 Module Configuration Error RECONFIGURE the module. REFER to Section
418-01. CLEAR the DTCs. REPEAT the
self-test. If DTC B2477 returns, INSTALL a
new instrument cluster. REFER to Instrument
Cluster in this section.
B2627 Fuel Sender Circuit Open #2 (remote fuel GO to Pinpoint Test A.
sender)
B2628 Fuel Sender Circuit Short to Ground #2 (remote GO to Pinpoint Test A.
fuel sender)
B2879 Fuel Tank Jet Pump Fault GO to Pinpoint Test A.
U0073 Control Module Communication Off Bus REFER to Section 418-00.
U2050 No Application Present REFLASH the instrument cluster. If the DTC
occurs after a software reflash, REFLASH the
instrument cluster again.
If the DTC reappears after each attempt to
reflash, INSTALL a new instrument cluster.
REFER to Section 413-01. TEST the system for
normal operation.
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B1201 Fuel Sender Circuit Failure (fuel pump module GO to Pinpoint Test A.
sender)
B1202 Fuel Sender Circuit Open (fuel pump module GO to Pinpoint Test A.
sender)
B2479 Brake Park Switch Circuit Short to Ground GO to Pinpoint Test K.
B2627 Fuel Sender Circuit Open #2 (remote fuel GO to Pinpoint Test A.
sender)
B2628 Fuel Sender Circuit Short to Ground #2 (remote GO to Pinpoint Test A.
fuel sender)
C1189 Brake Fluid Level Sensor Input Short Circuit to GO to Pinpoint Test K.
Ground
P0457 Evaporative Emission System Leak Detected GO to Pinpoint Test J.
(fuel cap loose/off)
Symptom Chart
Symptom Chart
instrument cluster Circuitry
Instrument cluster
Incorrect fuel gauge Circuitry GO to Pinpoint Test A.
indication Fuel tank
Fuel pump module
Remote fuel sender
Instrument cluster
The boost gauge is Powertrain control module GO to Pinpoint Test B.
inoperative (GT 500 only) (PCM)
Instrument cluster
Incorrect temperature gauge PCM GO to Pinpoint Test C.
indication Instrument cluster
Incorrect voltage gauge PCM GO to Pinpoint Test D.
indication Instrument cluster
The tachometer is inoperative PCM GO to Pinpoint Test E.
Instrument cluster
Incorrect oil pressure gauge Circuitry GO to Pinpoint Test F.
indication Engine oil pressure switch
SJB
Instrument cluster
The speedometer/odometer is PCM GO to Pinpoint Test G.
inoperative Instrument cluster
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The safety belt warning Circuitry GO to Pinpoint Test H.
indicator is inoperative/does Restraint control module
not operate correctly (RCM)
Instrument cluster
The O/D off indicator is PCM GO to Pinpoint Test I.
never/always on Instrument cluster
The check fuel cap warning PCM GO to Pinpoint Test J.
indicator is never/always on Instrument cluster
The brake warning indicator Circuitry GO to Pinpoint Test K.
is never/always on Parking brake switch
module
SJB
Instrument cluster
The charging system warning Charging system GO to Pinpoint Test L.
indicator is never/always on PCM
Instrument cluster
The high beam indicator is SJB GO to Pinpoint Test M.
The turn signal indicator is SJB GO to Pinpoint Test N.
The anti-lock brake system ABS module GO to Pinpoint Test O.
(ABS) warning indicator is Instrument cluster
never/always on
The low oil pressure warning Circuitry GO to Pinpoint Test P.
indicator is never/always on Engine oil pressure switch
SJB
Instrument cluster
The malfunction indicator PCM GO to Pinpoint Test Q.
lamp (MIL) is never/always Instrument cluster
on
The air bag warning indicator Circuitry GO to Pinpoint Test R.
is never/always on Restraints control module
(RCM)
Instrument cluster
The speed control indicator is PCM GO to Pinpoint Test S.
The wrench warning indicator PCM GO to Pinpoint Test T.
is never/always on Instrument cluster
The failsafe cooling warning PCM GO to Pinpoint Test U.
The door ajar warning SJB GO to Pinpoint Test V.
indicator is inoperative/does Instrument cluster
not operate correctly
The traction control indicator ABS module GO to Pinpoint Test W.
is never/always on Instrument cluster
The daytime running lamps SJB GO to Pinpoint Test X.
(DRL) indicator is Instrument cluster
never/always on
The low fuel warning Instrument cluster GO to Pinpoint Test Y.
indicator is never/always on
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The performance shift PCM GO to Pinpoint Test Z.
warning indicator is Instrument cluster
never/always on (GT 500
only)
The shift indicator is PCM GO to Pinpoint Test AA.
never/always on (GT 500 Instrument cluster
only)
The tire pressure monitoring TPMS concern GO to Pinpoint Test AB.
system (TPMS) warning SJB
The anti-theft indicator is PCM GO to Pinpoint Test AC.
The instrument cluster is Fuse(s) GO to Pinpoint Test AD.
Instrument cluster
The fuel tank is a saddle tank design with variable
Pinpoint Test A: Incorrect Fuel Gauge
resistance senders in each side of the tank. The fuel
Indication
pump module and the remote fuel sender are driven
by floats that provide resistances related to the fuel
level on each side of the tank to the smart junction
box (SJB). The fuel pump module and the remote
NOTE: The fuel pump module may also be called
fuel sender uses an approximate resistance range
the fuel tank unit.
between 15 ohms 2 ohms at empty (E) and 160
NOTE: The remote fuel sender may also be called
ohms 4 ohms at full (F). The fuel pump module
the fuel sender or fuel level sensor.
is hardwired to the SJB through the signal circuit
1356 (LG/VT) and the return circuit 1357 (LB/YE).
The remote fuel sender is hardwired to the SJB
through the signal circuit 29 (YE/WH) and the
return circuit 1357 (LB/YE). The SJB monitors the
resistance readings that are sent to the SJB from
the fuel pump module and the remote fuel sender
and sends the instrument cluster a message over the
communication network to command the fuel gauge
with a corresponding movement of the pointer. If
the remote fuel sender is open, the fuel gauge
defaults to the fuel pump sender value only and the
fuel gauge indicates E to 1/2 tank. If the fuel pump
sender is open, the fuel gauge defaults to the empty
position.
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NOTE: For system testing during the pinpoint test, DTC B2628 is a continuous DTC set in the
make sure to use only the SJB self-test and SJB instrument cluster if the message from the SJB
DTCs B1201, B1202, B2627 and B2628. Once the indicates a short to ground on the input from circuit
repairs are complete, clear the SJB and instrument 29 (YE/WH) or if circuit 29 (YE/WH) is shorted to
cluster DTCs. circuit 1357 (LB/YE).
The only the instrument cluster DTC used for NOTE: Normal operation of the fuel delivery
diagnosis is B2879. system allows the remote side of the fuel tank (the
side opposite the fuel filler hose inlet) to have less
DTC B1201 sets in the SJB on-demand if the
fuel than the fuel pump module side of the tank (the
SJB detects a short to ground on the input from
side with the fuel filler hose inlet).
circuit 1356 (LG/VT) or if circuit 1356 (LG/VT) is
shorted to circuit 1357 (LB/YE). DTC B2879 is a continuous DTC set in the
instrument cluster if the fuel level message from the
SJB indicates a large discrepancy in the amount of
SJB detects an open or short to voltage on the input
fuel between the fuel pump module and the remote
from circuits 1356 (LG/VT) or 1357 (LB/YE).
fuel sender sides of the tank. The fuel level in the
remote fuel sender side of the tank (the side
SJB detects an open or short to voltage on the input
opposite the fuel filler hose inlet) has significantly
from circuits 29 (YE/WH) or 1357 (LB/YE).
more fuel than the fuel pump module side of the
tank (the side with the fuel filler hose inlet).
SJB detects a short to ground on the input from
Possible Causes
circuit 29 (YE/WH) or if circuit 29 (YE/WH) is
Circuit 29 (YE/WH) short to circuit 1357
shorted to circuit 1357 (LB/YE).
(LB/YE)
DTC B1202 is a continuous DTC set in the
Circuit 29 (YE/WH) open, short to ground or
instrument cluster if the message from the SJB
voltage
indicates an open or short to voltage on the input
from circuits 1356 (LG/VT) or 1357 (LB/YE) for
Circuit 1356 (LG/VT) open, short to ground or
33 seconds.
voltage
Circuit 1356 (LG/VT) short to circuit 1357
(LB/YE)
indicates a short to ground on the input from circuit
Circuit 1357 (LB/YE) open or voltage
1356 (LG/VT) or if circuit 1356 (LG/VT) is shorted
Fuel pump module
to circuit 1357 (LB/YE) for 33 seconds.
Remote fuel sender
SJB
indicates an open or short to voltage on the input
Fuel tank
from circuits 29 (YE/WH) or 1357 (LB/YE).
Instrument cluster
PINPOINT TEST A: INCORRECT FUEL GAUGE INDICATION
A1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE
ACTIVE COMMAND USING THE SCAN TOOL
Key in ON position.
Cluster Active Command.
Yes
Select the instrument cluster fuel level control active command
GO to A2.
and scroll the fuel level at: 0%, 50%, and 100%.
Does the fuel gauge needle start at empty (E), move to half No
at 50%, and full (F) at 100%? GO to A22.
(Continued)
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PINPOINT TEST A: INCORRECT FUEL GAUGE INDICATION (Continued)
A2 RETRIEVE THE RECORDED DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER AND
SJB SELF-TESTS
NOTE: For system testing during the pinpoint test, make sure to Yes
use only the SJB self-test and SJB DTCs B1201, B1202, B2627 For DTCs B1201 or B2628, GO to A3.
and B2628. Once the repairs are complete, clear the SJB and
If both DTCs B1202 and B2627 are
instrument cluster DTCs.The only the instrument cluster DTC used
retrieved, GO to A7.
for diagnosis is B2879.
For DTC B1202, GO to A8.
Check for recorded instrument cluster and SJB DTCs from the
continuous and on-demand self-tests.
Are any DTCs recorded? For DTC B2879 (instrument cluster only),
GO to A17.
No
GO to A17.
A3 CHECK THE FUEL SENDER FOR A SHORT TO GROUND
NOTE: The fuel pump module may also be called the fuel tank unit.
NOTE: The remote fuel sender may also be called the fuel sender
or fuel level sensor.
Disconnect: Fuel Pump Module C433 (4.0L and 4.6L) or C4331
(5.4L) (DTC B1201 or B1204) or Remote Fuel Sender C434
(DTC B2628).
Key in ON position.
On-Demand Self-Test.
Yes
NOTE: Make sure to use only the SJB self-test and SJB
retrieved DTCs for this step. Once the repairs are complete,
clear the SJB and instrument cluster DTCs. For DTC B2628, INSTALL a new remote
fuel sender. REFER to Section 310-01.
NOTE: It is normal for DTCs B1201 and B2628 to be present
during this step and should be ignored.
Clear the SJB DTCs. Repeat the SJB on-demand self-test. No
Is DTC B1202 or B2627 retrieved? GO to A4.
A4 CHECK CIRCUITS 29 (YE/WH) OR 1356 (LG/VT) FOR A SHORT
TO GROUND
Measure the resistance between the SJB C2280c-43, circuit 29
(YE/WH), harness side and ground; or between the SJB
C2280c-44, circuit 1356 (LG/VT), harness side and ground.
Yes
No
Is the resistance greater than 10,000 ohms? DTCs. REPEAT the self-test.
(Continued)
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A5 CHECK CIRCUITS 1356 (LG/VT) AND 1357 (LB/YE) FOR A
SHORT TOGETHER
1357 (LB/YE), harness side and the SJB C2280c-44, circuit
1356 (LG/VT), harness side.
Yes
GO to A21.
No
A6 CHECK CIRCUITS 29 (YE/WH) AND 1357 (LB/YE) FOR A SHORT
TOGETHER
(YE/WH), harness side and the SJB C2280c-31, circuit 1357
(LB/YE), harness side.
Yes
GO to A21.
No
A7 CHECK THE FUEL LEVEL RETURN CIRCUITRY
NOTE: Make sure to use only the SJB self-test and SJB retrieved
DTCs for this step. Once the repairs are complete, clear the SJB
and instrument cluster DTCs.
Key in ON position.
(Continued)
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A7 CHECK THE FUEL LEVEL RETURN CIRCUITRY (Continued)
(LB/YE), harness side and ground.
Yes
REPAIR circuit 1357 (LB/YE) for a short to
voltage. CLEAR the DTCs. REPEAT the
self-test.
No
REPAIR circuit 1357 (LB/YE) for an open.
Is any voltage present? CLEAR the DTCs. REPEAT the self-test.
A8 CHECK THE FUEL PUMP MODULE CIRCUITRY FOR A SHORT
TO VOLTAGE
Key in ON position.
(LG/VT), harness side and ground.
Yes
GO to A9.
No
A9 CHECK CIRCUIT 1356 (LG/VT) FOR A SHORT TO VOLTAGE
Disconnect: Fuel Pump Module C433 (4.0L and 4.6L) or C4331
(5.4L).
Key in ON position.
(Continued)
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A9 CHECK CIRCUIT 1356 (LG/VT) FOR A SHORT TO VOLTAGE
(Continued)
(LG/VT), harness side and ground.
Yes
No
INSTALL a new fuel pump module.
Is any voltage present? DTCs. REPEAT the self-test.
A10 CHECK THE FUEL PUMP MODULE CIRCUITRY FOR AN OPEN
Disconnect: Fuel Pump Module C433.
On 4.0L and 4.6L engines, connect a fused (5A) jumper wire
between the fuel pump module C433-2, circuit 1357 (LB/YE),
harness side and the fuel pump module C433-4, circuit 1356
(LG/VT), harness side.
On 5.4L engines, connect a fused (5A) jumper wire between the
fuel pump module C4331-2, circuit 1357 (LB/YE), harness side
and the fuel pump module C4331-5, circuit 1356 (LG/VT),
harness side.
(Continued)
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A10 CHECK THE FUEL PUMP MODULE CIRCUITRY FOR AN OPEN
(Continued)
1357 (LB/YE), harness side; and between the SJB C2280c-44,
circuit 1356 (LG/VT), harness side.
Yes
No
A11 CHECK CIRCUIT 1356 (LG/VT) FOR AN OPEN
On 4.0L and 4.6L engines, measure the resistance between the
SJB C2280c-44, circuit 1356 (LG/WH), harness side and the fuel
pump module C433-4, circuit 1356 (LG/WH), harness side.
On 5.4L engines, measure the resistance between the SJB
C2280c-44, circuit 1356 (LG/WH), harness side and the fuel
pump module C4331-5, circuit 1356 (LG/WH), harness side.
Yes
No
REPAIR circuit 1356 (LG/VT) for an open.
Is the resistance less than 5 ohms? CLEAR the DTCs. REPEAT the self-test.
(Continued)
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A12 CHECK THE FUEL PUMP MODULE FOR AN OPEN
NOTE: The fuel pump module resistance varies from 15 2 ohms
when empty (E) to 160 4 ohms when full (F).
On 4.0L and 4.6L engines, measure the resistance between the
fuel pump module C433 pin 2, component side and the fuel
pump module C433 pin 4, component side.
On 5.4L engines, measure the resistance between the fuel pump
module C4331 pin 2, component side and the fuel pump module
C4331 pin 5, component side.
Yes
GO to A21.
No
Is the resistance between 15 and 160 ohms? GO to A20.
A13 CHECK CIRCUIT 29 (YE/WH) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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A13 CHECK CIRCUIT 29 (YE/WH) FOR A SHORT TO VOLTAGE
(Continued)
(YE/WH), harness side and ground.
Yes
No
A14 CHECK THE REMOTE FUEL SENDER CIRCUITRY FOR AN
OPEN
Disconnect: Remote Fuel Sender C434.
Connect a fused (5A) jumper wire between the remote fuel
sender C434-2, circuit 1357 (LB/YE), harness side and the
remote fuel sender C434-4, circuit 29 (YE/WH), harness side.
1357 (LB/YE), harness side; and between the SJB C2280c-43,
circuit 29 (YE/WH), harness side.
Yes
No
(Continued)
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A15 CHECK CIRCUIT 29 (YE/WH) FOR AN OPEN
(YE/WH), harness side and the remote fuel sender C433-4,
circuit 29 (YE/WH), harness side.
Yes
No
REPAIR circuit 29 (YE/WH) for an open.
Is the resistance less than 5 ohms? CLEAR the DTCs. REPEAT the self-test.
A16 CHECK THE REMOTE FUEL SENDER FOR AN OPEN
NOTE: The fuel pump module resistance varies from 19 2 ohms
when empty (E) to 160 4 ohms when full (F).
Measure the resistance between the remote fuel sender C434
pin 2, component side and the remote fuel sender C434 pin 4,
component side.
Yes
GO to A21.
No
INSTALL a new remote fuel sender.
Is the resistance between 19 and 160 ohms? DTCs. REPEAT the self-test.
A17 INSPECT THE FUEL TANK
Check the fuel tank for any damage or deformation. Yes
Is the fuel tank OK? GO to A18.
No
VERIFY that the fuel pump module or
remote fuel sender are not damaged.
INSTALL a new fuel tank. REFER to
Section 310-01. CLEAR the DTCs.
A18 INSPECT THE FUEL PUMP MODULE, REMOTE FUEL SENDER
AND FUEL TRANSFER TUBES
Remove the fuel pump module and remote fuel sender. Refer to Yes
Section 310-01. GO to A19.
Inspect the fuel transfer tube, connections, fuel pump module
No
and remote sender for any damage or deformation.
REPAIR or INSTALL a new fuel tank (for
Are the fuel transfer tube, connections, fuel pump module
fuel transfer tube concerns), fuel pump
and the remote fuel sender OK?
module or remote fuel sender as
(Continued)
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A19 CHECK THE FUEL PUMP MODULE AND REMOTE FUEL
SENDER RESISTANCE READINGS
NOTE: The fuel pump module and remote fuel sender resistance
values vary from 15 2 ohms when empty (E) to 160 4 ohms
when full (F).
For the fuel pump module, measure the resistance between the
fuel pump module C433 pin 4 (4.0L and 4.6L) or C4331 pin 5
(5.4L), component side and the fuel pump module C433 pin 2
(4.0L and 4.6L) or C4331 pin 2 (5.4L), component side while
slowly moving the float arm from the bottom to the top of travel.
For the remote fuel sender, measure the resistance between the
remote fuel sender C434 pin 4, component side and the remote
fuel sender C434 pin 2, component side while slowly moving the
float arm from the bottom to the top of travel.
Yes
INSTALL a new fuel tank. REFER to
No
For the fuel pump module, GO to A20.
For the remote fuel sender, INSTALL a
Does the resistance start at approximately 15 ohms with the new remote fuel sender. REFER to
float at the bottom of the travel and slowly increase to Section 310-01. CLEAR the DTCs.
approximately 160 ohms at the top of the travel? REPEAT the self-test.
A20 CHECK THE FUEL LEVEL SENSOR
NOTE: The fuel level sensor resistance will measure between
15 ohms 2 ohms at the lower stop position and 160 ohms 4
ohms at the upper stop position.
Remove the fuel pump module. Refer to Section 310-01.
(Continued)
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A20 CHECK THE FUEL LEVEL SENSOR (Continued)
NOTE: Disconnect the fuel level sensor input wire from the fuel
level sensor for this measurement.
Measure the resistance between the fuel level sensor input wire
and the fuel level sensor ground while slowly moving the float
arm between the lower stop and the upper stop position.
Yes
INSTALL a new fuel pump module.
No
INSTALL a new fuel level sensor. REFER
Does the resistance slowly increase within specification to Section 310-01. TEST the system for
from approximately 15 ohms to 160 ohms? normal operation.
pushed-out pins
No
correctly.
corrosion REFER to Instrument Cluster in this
damaged pins section. TEST the system for normal
pushed-out pins operation.
No
correctly.
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Possible Causes
Pinpoint Test B: The Boost Gauge Is
Inoperative (GT 500 Only)
PCM
Normal Operation
Instrument cluster
The boost gauge measures the amount of engine
boost provided by the supercharger in pounds per
square inch (PSI). The instrument cluster receives
the boost gauge data from the powertrain control
module (PCM) over the high speed controller area
network (CAN) communication bus lines. If the
boost gauge status message is invalid or missing for
more than 5 seconds, the boost gauge indication is
zero. If the message is invalid or missing for less
than 5 seconds, the boost gauge displays the last
valid data received. The missing or invalid data may
make the gauge appear sluggish or unresponsive to
engine boost changes.
PINPOINT TEST B: THE BOOST GAUGE IS INOPERATIVE (GT 500 ONLY)
CONTINUOUS AND ON-DEMAND PCM SELF-TESTS
Check for recorded PCM DTCs from the continuous and Yes
on-demand self-tests. REFER to the Powertrain
Are there any DTCs retrieved? Control/Emissions Diagnosis (PC/ED)
manual.
No
GO to B2.
B2 CARRY OUT THE INSTRUMENT CLUSTER GAUGES ACTIVE
COMMAND USING THE SCAN TOOL
Key in ON position.
Yes
GO to B3.
Select the instrument cluster boost gauge active command and
monitor the gauge. No
Does the boost gauge sweep correctly? GO to B4.
Disconnect all PCM connectors. Yes
Check for: INSTALL a PCM. REFER to Section
pushed-out pins
No
Connect all PCM connectors and make sure they seat correctly.
B4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Disconnect all instrument cluster connectors. Yes
Connect all instrument cluster connectors and make sure they
No
seat correctly.
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Possible Causes
Pinpoint Test C: Incorrect Temperature
Gauge Indication
PCM
Normal Operation
Instrument cluster
The engine coolant temperature (ECT) sensor unit
monitors the coolant temperature and is hardwired
directly to the powertrain control module (PCM).
The status of the engine coolant temperature is sent
from the PCM to the instrument cluster over the
communication network.
PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION
C1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
Are any DTCs recorded? Control/Emissions Diagnosis (PC/ED)
manual.
No
GO to C2.
C2 CARRY OUT THE INSTRUMENT CLUSTER COOLANT
TEMPERATURE GAUGE ACTIVE COMMAND USING THE SCAN
TOOL
Key in ON position.
Yes
Select the instrument cluster temperature gauge active
GO to C4.
command and scroll in 2 increments of 0%, and 100%.
Does the temperature gauge start at C (cold) when at 0%, No
and move to H (hot) at 100%? GO to C3.
C3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Connect all the PCM connectors and make sure they seat No
Possible Causes
Pinpoint Test D: Incorrect Voltage Gauge
Indication
PCM
Normal Operation
Instrument cluster
The voltage gauge displays the system battery
voltage as measured at the instrument cluster RUN
input circuit.
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PINPOINT TEST D: INCORRECT VOLTAGE GAUGE INDICATION
D1 CHECK THE CHARGING SYSTEM FOR CORRECT OPERATION
Check the charging system. Refer to Section 414-00. Yes
Does the charging system operate correctly? GO to D2.
No
REPAIR the charging system. REFER to
Section 414-00.
D2 CARRY OUT THE INSTRUMENT CLUSTER VOLTMETER
Key in ON position.
Yes
Select the instrument cluster voltmeter active command and
GO to Pinpoint Test AD.
scroll the voltmeter in 2 increments 0%, and 100%.
Does the voltmeter start at L (low) when at 0%, and move to No
H (high) at 100%? GO to D3.
D3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test E: The Tachometer Is
Inoperative
PCM
Normal Operation
Instrument cluster
Engine rpm data is provided to the instrument
cluster by the powertrain control module (PCM)
through the communication network.
PINPOINT TEST E: THE TACHOMETER IS INOPERATIVE
E1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to E2.
E2 CARRY OUT THE INSTRUMENT CLUSTER TACHOMETER
Key in ON position.
Select the instrument cluster tachometer active command and
scroll in increments of 10% while monitoring the tachometer. The
Yes
tachometer should increase in increments of approximately 700
GO to E3.
rpm (4.0L engine), or 800 rpm (4.6L engine) for each 10%
change. No
Does the tachometer gauge increase within specifications? GO to E4.
(Continued)
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PINPOINT TEST E: THE TACHOMETER IS INOPERATIVE (Continued)
E3 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
E4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test F: Incorrect Oil Pressure
Gauge Indication
Circuit 208 (GY) open or short to ground
Engine oil pressure switch
SJB
Normal Operation
Instrument cluster
The oil pressure switch is a normally open switch
that is hardwired to the smart junction box (SJB)
through circuit 208 (GY). When the oil pressure is
within normal ranges, the oil pressure switch closes,
grounding the signal to the SJB. The SJB then
sends a command signal to the instrument cluster
through the communication network, to turn off the
oil pressure warning indicator. When engine oil
pressure is low, the oil pressure switch opens,
removing the ground to the SJB. The SJB sends a
low oil pressure command to the instrument cluster
through the communication network to illuminate
the oil pressure warning indicator.
PINPOINT TEST F: INCORRECT OIL PRESSURE GAUGE INDICATION
F1 CARRY OUT THE INSTRUMENT CLUSTER TACHOMETER
Enter the following diagnostic mode on the scan tool: Instrument If the oil pressure gauge always indicates
Cluster Active Command. normal, GO to F2.
Select the instrument cluster oil pressure gauge active command
If the oil pressure gauge always indicates
on and off.
low, GO to F4.
Does the oil pressure gauge start at the low range and
No
increase to the normal range when selected on?
GO to F8.
(Continued)
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PINPOINT TEST F: INCORRECT OIL PRESSURE GAUGE INDICATION (Continued)
F2 CHECK THE OIL PRESSURE SWITCH
Disconnect: Engine Oil Pressure Switch C103. INSTALL a new engine oil pressure
Key in ON position. switch. TEST the system for normal
With the oil pressure switch disconnected, monitor the oil operation.
pressure gauge.
No
Does the oil pressure gauge indicate low?
GO to F3.
F3 CHECK CIRCUIT 208 (GY) FOR A SHORT TO GROUND
Disconnect: Engine Oil Pressure Switch C103.
(GY), harness side and ground.
Yes
GO to F7.
No
F4 CHECK THE OIL PRESSURE SWITCH
Disconnect: Oil Pressure Switch C103.
Connect a fused (5A) jumper wire between the oil pressure
switch C103-1, circuit 208 (GY), harness side and ground.
Yes
REMOVE the jumper wire. GO to F5.
Key in ON position. No
Does the oil pressure gauge indicate normal? REMOVE the jumper wire. GO to F6.
F5 CHECK CIRCUIT 208 (GY) FOR AN OPEN
(Continued)
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PINPOINT TEST F: INCORRECT OIL PRESSURE GAUGE INDICATION (Continued)
F5 CHECK CIRCUIT 208 (GY) FOR AN OPEN (Continued)
(GY), harness side and the engine oil pressure switch C103-1,
circuit 208 (GY), harness side.
Yes
GO to F8.
No
F6 CHECK THE OIL PRESSURE
Carry out the engine oil pressure test. Refer to Section 303-00. Yes
Is the oil pressure within specification? INSTALL a new engine oil pressure
operation.
No
F7 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
F8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test G: The Speedometer/Odometer
Is Inoperative
PCM
Normal Operation
Instrument cluster
Vehicle speed information is sent to the powertrain
control module (PCM) from the output shaft speed
(OSS) sensor. The instrument cluster receives the
vehicle speed data from the PCM over the
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PINPOINT TEST G: THE SPEEDOMETER/ODOMETER IS INOPERATIVE
G1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
Are any PCM DTCs recorded? Control/Emissions Diagnosis (PC/ED)
manual.
No
For an inoperative or inaccurate
speedometer, GO to G2.
For an inoperative odometer, GO to G3.
G2 CARRY OUT THE INSTRUMENT CLUSTER SPEEDOMETER
Key in ON position.
Select the instrument cluster speedometer active command.
Trigger the speedometer and scroll in increments of 10% while
monitoring the speedometer. The speedometer should increase
Yes
in increments of approximately 19 km/h (12 mph) (4.0L engine),
GO to G5.
or 23 km/h (14 mph) (4.6L engine) for each 10% change.
Does the speedometer begin at 0 and increase within No
specifications? GO to G4.
G3 MONITOR THE MESSAGE CENTER CIRCUIT DISPLAYS
Select the message center active command. Trigger the
Yes
message center active command and illuminate the display
GO to G5.
segments.
Do the message center display segments illuminate No
correctly? GO to G4.
G4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
G5 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test H: The Safety Belt Warning Normal Operation
Indicator Is Inoperative/Does Not Operate
The safety belt switch is hardwired to the restraints
Correctly
control module (RCM). The instrument cluster
receives the safety belt switch status from the RCM
through circuit 1083 (LB/PK). When the safety belt
is unfastened, the RCM signals the instrument
cluster to illuminate the safety belt warning
indicator. A safety belt minder chime that is
operating correctly indicates the RCM is monitoring
and transmitting the correct operation of the safety
belt status to the instrument cluster.
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Possible Causes
Circuit 1083 (LB/PK) open, short to ground
voltage
RCM
Instrument cluster
PINPOINT TEST H: THE SAFETY BELT WARNING INDICATOR IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
H1 CHECK THE SAFETY BELT WARNING INDICATOR OPERATION
Deactivate the supplemental restraint system (SRS). Refer to
Section 501-20B.
Disconnect: RCM C2041a.
Connect a fused (10A) jumper wire between the RCM
C2041a-22, circuit 1083 (LB/PK), harness side and ground.
Observe the safety belt warning indicator with the jumper wire
connected and disconnected.
Yes
Key in ON position.
GO to H5.
Does the safety belt warning indicator lamp illuminate with
the jumper wire disconnected, and turn off when the jumper No
wire is connected? GO to H2.
H2 CHECK CIRCUIT 1083 (LB/PK) FOR AN OPEN OR A SHORT TO
GROUND
(Continued)
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CORRECTLY (Continued)
H2 CHECK CIRCUIT 1083 (LB/PK) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
circuit 1083 (LB/PK), harness side and the RCM C2041a-22,
circuit 1083 (LB/PK), harness side; and between the instrument
cluster C220-23, circuit 1083 (LB/PK), harness side and ground.
Yes
GO to H3.
No
Is the resistance less than 5 ohms between the instrument REPAIR the circuit. ACTIVATE the SRS.
cluster and the RCM, and greater than 10,000 ohms between REFER to Section 501-20B. TEST the
the instrument cluster and ground? system for normal operation.
H3 CHECK CIRCUIT 1083 (LB/PK) FOR A SHORT TO VOLTAGE
Key in ON position.
circuit 1083 (LB/PK), harness side and ground.
Yes
REPAIR the circuit. ACTIVATE the SRS.
No
Is any voltage present? GO to H4.
H4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
damaged pins section. ACTIVATE the SRS. REFER to
pushed-out pins Section 501-20B. TEST the system for
Connect the instrument cluster connector and make sure it seats normal operation.
correctly.
No
ACTIVATE the SRS. REFER to Section
501-20B.
(Continued)
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H5 CHECK FOR CORRECT RCM OPERATION
Disconnect all the RCM connectors. Yes
Check for: INSTALL a new RCM. REFER to Section
corrosion 501-20B. ACTIVATE the SRS. REFER to
damaged pins Section 501-20B. TEST the system for
pushed-out pins normal operation.
Connect all the RCM connectors and make sure they seat
No
correctly.
501-20B.
Possible Causes
Pinpoint Test I: The O/D Off Indicator Is
Never/Always On
PCM
Normal Operation
Instrument cluster
The overdrive (O/D) off function is controlled by
the O/D off switch located on the shifter assembly.
The O/D off status is transmitted to the instrument
cluster from the powertrain control module (PCM)
over the communication network.
PINPOINT TEST I: THE O/D OFF INDICATOR IS NEVER/ALWAYS ON
I1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to I2.
I2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
CONTROL ACTIVE COMMAND USING THE SCAN TOOL
Key in ON position.
Yes
Select the instrument cluster O/D OFF active command on and
GO to I4.
off. Observe the O/D OFF indicator.
Does the O/D OFF indicator illuminate when selected on, No
and turn off when selected off? GO to I3.
No
correctly.
I4 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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Pinpoint Test J: The Check Fuel Cap
DTC P0457 sets in the PCM if the PCM detects
Warning Indicator Is Never/Always On
a fuel tank pressure change greater than -23.7 kPa
(-7 in-Hg) of water within 30 seconds after
Normal Operation
refueling occurs, or if there is an excessive purge
The powertrain control module (PCM) monitors the
(fuel vapor) flow of greater than 0.45 gm/s (0.06
fuel tank evaporative emission system for significant
lb) per minute.
leaks that occur following refueling of the vehicle.
If the PCM detects that the fuel cap has been left Possible Causes
off following vehicle refueling, the PCM sends a
PCM
message to the instrument cluster over the
Instrument cluster
communication network to turn on the check fuel
cap warning indicator.
PINPOINT TEST J: THE CHECK FUEL CAP WARNING INDICATOR IS NEVER/ALWAYS ON
J1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to J2.
J2 CARRY OUT THE INSTRUMENT CLUSTER INDICTOR LAMP
Key in ON position.
Yes
Select the instrument cluster check fuel cap indicator on and off.
GO to J4.
Observe the check fuel cap indicator.
Does the check fuel cap indicator illuminate when selected No
on, and turn off when selected off? GO to J3.
J3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
J4 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test K: The Brake Warning
Indicator Is Never/Always On
information.
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Normal Operation
DTC C1189 sets on-demand or continuously if
When the parking brake is applied, circuit 1309
the SJB detects that the brake fluid is low or there
(RD/YE) to the smart junction box (SJB) is
is a short to ground on the brake fluid level input
grounded by the parking brake switch through
circuit 547 (LG/YE).
circuit 1205 (BK). The SJB receives the ground
Possible Causes
signal and sends the instrument cluster a message
Circuit 512 (TN/LG) open or short to ground
over the communication network to illuminate the
brake warning indicator. When the brake fluid level
Circuit 547 (LG/YE) open or short to ground
is low, the brake fluid level switch closes, providing
a signal to the SJB on circuit 547 (LG/YE) is
Circuit 1309 (RD/YE) open or short to ground
routed back to the SJB on the signal return circuit
512 (TN/LG). When a base brake system concern
is detected, the anti-lock brake system (ABS)
module sends a signal to the instrument cluster over
SJB
the communication network to illuminate the brake
system warning indicator. Instrument cluster
DTC B2479 sets on-demand if the SJB detects
that the parking brake is applied during the
on-demand self-test or if there is a short to ground
on the parking brake input circuit 1309 (RD/YE).
PINPOINT TEST K: THE BRAKE WARNING INDICATOR IS NEVER/ALWAYS ON
K1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND SJB SELF-TESTS
Check for recorded SJB DTCs from the continuous and Yes
on-demand self-tests. For DTC B2479, GO to K4.
Are any SJB DTCs recorded?
For DTC C1189, GO to K9.
All other SJB DTCs, REFER to the Smart
Junction Box (SJB) Diagnostic Trouble
Code (DTC) Index.
No
GO to K2.
K2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster brake warning indictor active
GO to K3.
command on and off. Observe the brake warning indicator.
Does the brake warning indicator illuminate when selected No
on, and turn off when selected off? GO to K13.
K3 CHECK THE PARKING BRAKE SWITCH PID
Enter the following diagnostic mode on the scan tool: SJB GO to K9.
Parking Brake Switch PID.
No
Monitor the SJB parking brake switch PID while applying and
If the PID indicates that the parking brake
releasing the parking brake.
is always applied, GO to K4.
Does the PID agree with the parking brake position?
If the PID indicates that the parking brake
is never applied, GO to K6.
(Continued)
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PINPOINT TEST K: THE BRAKE WARNING INDICATOR IS NEVER/ALWAYS ON (Continued)
K4 CHECK THE PARKING BRAKE SWITCH (INDICATOR ALWAYS
ON)
Disconnect: Parking Brake Switch C306. Yes
Observe the brake warning indicator. GO to K5.
Does the brake warning indicator continue to illuminate?
No
K5 CHECK CIRCUIT 1309 (RD/YE) FOR A SHORT TO GROUND
1309 (RD/YE), harness side and ground.
Yes
GO to K14.
No
K6 CHECK THE PARKING BRAKE SWITCH (INDICATOR
INOPERATIVE)
Disconnect: Parking Brake Switch C306.
Connect a fused (5A) jumper wire between the parking brake
switch C306-1, circuit 1309 (RD/YE), harness side and the
parking brake switch C306-2, circuit 1205 (BK), harness side.
Yes
No
Does the brake warning indicator illuminate? REMOVE the jumper wire. GO to K7.
K7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
(Continued)
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K7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between the parking brake switch
C306-2, circuit 1205 (BK), harness side and ground.
Yes
GO to K8.
No
K8 CHECK CIRCUIT 1309 (RD/YE) FOR AN OPEN
1309 (RD/YE), harness side and the parking brake switch
C306-1, circuit 1309 (RD/YE), harness side.
Yes
GO to K14.
No
K9 CHECK THE SJB OPERATION USING THE SCAN TOOL
Enter the following diagnostic mode on the scan tool: SJB Brake
Fluid Level PID.
Disconnect: Brake Fluid Level Switch C124.
Key in ON position.
Monitor the brake fluid level PID.
(Continued)
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K9 CHECK THE SJB OPERATION USING THE SCAN TOOL
(Continued)
Connect a fused (10A) jumper wire between the brake fluid level
switch C124-1, circuit 547 (LG/YE), harness side and the brake
fluid level switch C124-2, circuit 512 (TN/LG), harness side.
Yes
REMOVE the jumper wire. GO to K10.
Does the PID indicate OK with the brake fluid level switch
disconnected, and indicate low brake fluid level when the No
jumper wire is in place? REMOVE the jumper wire. GO to K11.
K10 CHECK THE BRAKE FLUID LEVEL SWITCH PID USING THE
SCAN TOOL
Enter the following diagnostic mode on the scan tool: SJB Brake
Fluid Level PID.
Connect: Brake Fluid Level Switch C124.
Key in ON position.
CAUTION: Do not spill brake fluid onto painted or
plastic surfaces. If spilled, wipe up immediately before
damage to the painted or plastic surface occurs.
Yes
Using a suitable tool, lightly push the brake fluid level float to the
GO to K14.
bottom of the reservoir. Monitor the SJB brake fluid PID.
Does the PID indicate low fluid level with the brake fluid No
level float pushed down, and indicate normal with the brake INSTALL a new brake fluid level switch.
fluid level float released? TEST the system for normal operation.
K11 CHECK CIRCUITS 512 (TN/LG) AND 547 (LG/YE) FOR AN OPEN
(TN/LG), harness side and the brake fluid level switch C124-2,
circuit 512 (TN/LG), harness side; and between the SJB
C2280c-48, circuit 547 (LG/YE), harness side and the brake fluid
level switch C124-1, circuit 547 (LG/YE), harness side.
Yes
GO to K12.
No
(Continued)
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K12 CHECK CIRCUITS 512 (TN/LG) AND 547 (LG/YE) FOR A SHORT
TO GROUND
(TN/LG), harness side and ground; and between the SJB
C2280c-48, circuit 547 (LG/YE), harness side and ground.
Yes
GO to K14.
No
K13 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Disconnect all the instrument cluster connectors. Yes
Connect all the instrument cluster connectors and make sure
No
they seat correctly.
Operate the system and verify that the concern is still present.
K14 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
Operate the system and verify that the concern is still present.
Possible Causes
Pinpoint Test L: The Charging System
Charging system
Normal Operation
PCM
The charging system warning indicator is controlled
Instrument cluster
by the instrument cluster based upon data received
from the powertrain control module (PCM) over the
PINPOINT TEST L: THE CHARGING SYSTEM WARNING INDICATOR IS NEVER/ALWAYS ON
L1 CHECK THE CHARGING SYSTEM FOR CORRECT OPERATION
Check the charging system operation. Refer to Section 414-00. Yes
Is the charging system operating correctly? GO to L2.
No
(Continued)
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PINPOINT TEST L: THE CHARGING SYSTEM WARNING INDICATOR IS NEVER/ALWAYS ON (Continued)
L2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster charging system warning indicator
GO to L3.
active command on. Observe the charging system warning
indicator. No
Is the charging system warning indicator illuminated? GO to L4.
L3 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
L4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test M: The High Beam Indicator Is
Never/Always On
SJB
Normal Operation
Instrument cluster
When the high beams are turned on, the smart
junction box (SJB) sends a signal to the instrument
cluster through the communication network to
illuminate the high beam indicator.
PINPOINT TEST M: THE HIGH BEAM INDICATOR IS NEVER/ALWAYS ON
M1 CHECK THE HIGH BEAM HEADLAMPS OPERATION
Place the headlamp switch in the HIGH BEAMS ON position. GO to M2.
Observe the high beam headlamps.
No
Do the high beam headlamps operate correctly?
M2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster high beam indicator active
GO to M4.
command on and off. Observe the high beam indicator.
Does the high beam indicator illuminate when selected on, No
and turn off when selected off? GO to M3.
(Continued)
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PINPOINT TEST M: THE HIGH BEAM INDICATOR IS NEVER/ALWAYS ON (Continued)
M3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
M4 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Possible Causes
Pinpoint Test N: The Turn Signal Indicator Is
Never/Always On
SJB
Normal Operation
Instrument cluster
When the multifunction switch is in the left or the
right turn position, a message is sent to the
instrument cluster from the smart junction box
(SJB) through the communication network, and the
left or the right turn signal indicator flashes on and
off.
PINPOINT TEST N: THE TURN SIGNAL INDICATOR IS NEVER/ALWAYS ON
N1 CHECK THE TURN SIGNAL LAMPS OPERATION
Operate the LH and RH turn signals. GO to N2.
Do the turn signals operate correctly?
No
N2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster all warning lamps active command
GO to N4.
on and off. Observe the LH and RH turn signal indicators.
Do the LH and RH turn signal indicators illuminate when No
selected on, and turn off when selected off? GO to N3.
N3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
(Continued)
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PINPOINT TEST N: THE TURN SIGNAL INDICATOR IS NEVER/ALWAYS ON (Continued)
N4 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Possible Causes
Pinpoint Test O: The Anti-Lock Brake
System (ABS) Warning Indicator Is
ABS module
Never/Always On
Instrument cluster
Normal Operation
The status of the ABS system is sent to the
instrument cluster from the ABS module over the
communication network. The instrument cluster
monitors the ABS input and illuminates the ABS
warning indicator when a concern is present.
PINPOINT TEST O: THE ANTI-LOCK BRAKE SYSTEM (ABS) WARNING INDICATOR IS NEVER/ALWAYS
ON
O1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND ABS MODULE SELF-TESTS
Check for recorded ABS module DTCs from the continuous and Yes
on-demand self-tests. REFER to Section 206-09.
Are any ABS module DTCs recorded?
No
GO to O2.
O2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster ABS warning indicator active
GO to O3.
command on and off. Observe the ABS warning indicator.
Does the ABS warning indicator illuminate when selected No
on, and turn off when selected off? GO to O4.
O3 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect the ABS module connector.
Yes
Check for:
INSTALL a new ABS module. REFER to
corrosion
damaged pins
normal operation.
pushed-out pins
O4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
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Possible Causes
Pinpoint Test P: The Low Oil Pressure
Circuit 208 (GY) open or short to ground
Engine oil pressure switch
SJB
Normal Operation
Instrument cluster
The oil pressure switch is a normally open switch
that is hardwired to the smart junction box (SJB)
through circuit 208 (GY). When the oil pressure is
within normal ranges, the oil pressure switch closes,
grounding the signal to the SJB. The SJB then
sends a command signal to the instrument cluster
through the communication network, to turn off the
oil pressure warning indicator. When engine oil
pressure is low, the oil pressure switch opens,
removing the ground to the SJB. The SJB sends a
low oil pressure command to the instrument cluster
through the communication network to illuminate
the oil pressure warning indicator.
PINPOINT TEST P: THE LOW OIL PRESSURE WARNING INDICATOR IS NEVER/ALWAYS ON
P1 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
If the low oil pressure warning indicator is
never on, GO to P2.
Select the instrument cluster low oil pressure warning indicator
If the low oil pressure warning indicator is
active command on and off. Observe the low oil pressure
always on, GO to P4.
warning indicator.
Does the low oil pressure warning indicator illuminate when No
selected on, and turn off when selected off? GO to P8.
P2 CHECK THE OIL PRESSURE SWITCH
Disconnect: Engine Oil Pressure Switch C103. INSTALL a new engine oil pressure
Key in ON position. switch. TEST the system for normal
With the oil pressure switch disconnected, monitor the low oil operation.
pressure warning indicator.
No
Is the low oil pressure warning indicator illuminated?
GO to P3.
P3 CHECK CIRCUIT 208 (GY) FOR A SHORT TO GROUND
Disconnect: Engine Oil Pressure Switch C103.
(Continued)
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(Continued)
P3 CHECK CIRCUIT 208 (GY) FOR A SHORT TO GROUND
(Continued)
(GY), harness side and ground.
Yes
GO to P7.
No
P4 CHECK THE OIL PRESSURE SWITCH
Disconnect: Oil Pressure Switch C103.
Connect a fused (5A) jumper wire between the oil pressure
switch C103-1, circuit 208 (GY), harness side and ground.
Yes
REMOVE the jumper wire. GO to P5.
Does the low oil pressure warning indicator illuminate? REMOVE the jumper wire. GO to P6.
P5 CHECK CIRCUIT 208 (GY) FOR AN OPEN
(Continued)
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(Continued)
P5 CHECK CIRCUIT 208 (GY) FOR AN OPEN (Continued)
(GY), harness side and the engine oil pressure switch C103-1,
circuit 208 (GY), harness side.
Yes
GO to P8.
No
P6 CHECK THE OIL PRESSURE
Carry out the engine oil pressure test. Refer to Section 303-00. Yes
Is the oil pressure within specification? INSTALL a new engine oil pressure
operation.
No
P7 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
P8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test Q: The Malfunction Indicator
Lamp (MIL) Is Never/Always On
PCM
Normal Operation
Instrument cluster
The MIL is controlled by the instrument cluster
using data sent from the powertrain control module
(PCM) over the communication network.
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PINPOINT TEST Q: THE MALFUNCTION INDICATOR LAMP (MIL) IS NEVER/ALWAYS ON
Q1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to Q2.
Q2 CARRY OUT THE INSTRUMENT CLUSTER INDICTOR LAMP
Key in ON position.
Yes
Select the instrument cluster warning MIL indicator active
GO to Q4.
command on and off. Observe the MIL indicator.
Does the MIL indicator illuminate when selected on, and No
turn off when selected off? GO to Q3.
Q3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Q4 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Possible Causes
Pinpoint Test R: The Air Bag Warning
Circuit 608 (BK/YE) open or short to ground
Restraints control module (RCM)
Instrument cluster
Normal Operation
The air bag warning indicator provides an indication
that there is a restraint system concern present and
the air bag may be inoperative or have degraded
performance. If the instrument cluster does not
receive the air bag warning indicator command
over circuit 608 (BK/YE), the instrument cluster
illuminates the air bag warning indicator.
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PINPOINT TEST R: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON
R1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND RCM SELF-TESTS
Check for recorded RCM DTCs from the continuous and Yes
on-demand self-tests. REFER to Section 501-20B.
Are any RCM DTCs recorded?
No
GO to R2.
R2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Enter the following diagnostic mode on the scan tool: Instrument If the air bag indicator is never on, GO to
Cluster Active Command. R5.
Select the instrument cluster air bag warning indicator active
If the air bag indicator is always on, GO to
command on and off. Observe the air bag warning indicator.
R3.
Does the air bag warning indicator illuminate when selected
No
on, and turn off when selected off?
GO to R6.
R3 CHECK THE RCM FOR CORRECT OPERATION
Deactivate the supplemental restraint system (SRS). Refer to
Section 501-20B.
Connect a fused (5A) jumper wire between the RCM C2041a-19,
circuit 608 (BK/YE), harness side and ground.
Yes
REMOVE the jumper wire. GO to R4.
Key in ON position.
Does the air bag indicator lamp illuminate after the No
instrument cluster proves out? REMOVE the jumper wire. GO to R8.
R4 CHECK CIRCUIT 608 (BK/YE) FOR AN OPEN
(Continued)
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PINPOINT TEST R: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON (Continued)
R4 CHECK CIRCUIT 608 (BK/YE) FOR AN OPEN (Continued)
circuit 608 (BK/YE), harness side and the RCM C2041a-19,
circuit 608 (BK/YE), harness side.
Yes
GO to R7.
No
REPAIR the circuit. REACTIVATE the
SRS. REFER to Section 501-20B. TEST
Is the resistance less than 5 ohms? the system for normal operation.
R5 ISOLATE THE RCM
Deactivate the SRS. Refer to Section 501-20B.
Yes
GO to R8.
Observe the air bag warning indicator.
Does the air bag warning indicator illuminate? GO to R6.
R6 CHECK CIRCUIT 608 (BK/YE) FOR A SHORT TO GROUND
circuit 608 (BK/YE), harness side and ground.
Yes
GO to R7.
No
REPAIR the circuit. ACTIVATE the SRS.
R7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
damaged pins section. ACTIVATE the SRS. REFER to
pushed-out pins Section 501-20B. TEST the system for
Connect the instrument cluster connector and make sure it seats normal operation.
correctly.
No
501-20B.
(Continued)
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PINPOINT TEST R: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON (Continued)
R8 CHECK FOR CORRECT RCM OPERATION
Check for: INSTALL a new RCM and ACTIVATE the
corrosion SRS. REFER to Section 501-20B. TEST
damaged pins the system for normal operation.
pushed-out pins
No
correctly.
501-20B.
Possible Causes
Pinpoint Test S: The Speed Control Indicator
Is Never/Always On
PCM
Normal Operation
Instrument cluster
The speed control status information is sent to the
instrument cluster from the powertrain control
module (PCM) over the communication network.
PINPOINT TEST S: THE SPEED CONTROL INDICATOR IS NEVER/ALWAYS ON
S1 CHECK THE SPEED CONTROL OPERATION
Test drive the vehicle and operate the speed control. Yes
Does the speed control operate correctly? GO to S2.
No
S2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster speed control indicator active
GO to S3.
command on and off. Observe the speed control indicator.
Does the speed control indicator illuminate when selected No
on, and turn off when selected off? GO to S4.
S3 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
S4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
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Possible Causes
Pinpoint Test T: The Wrench Warning
Indicator is Never/Always On
PCM
Normal Operation
Instrument cluster
The instrument cluster receives the electronic
throttle control (ETC) status from the powertrain
control module (PCM) over the communication
network. When a system concern is detected, the
PCM sends the instrument cluster a command signal
to illuminate the wrench warning indicator.
PINPOINT TEST T: THE WRENCH WARNING INDICATOR IS NEVER/ALWAYS ON
T1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to T2.
T2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster wrench warning indicator active
GO to T4.
command on and off. Observe the wrench warning indicator.
Does the wrench warning indicator illuminate when selected No
on, and turn off when selected off? GO to T3.
T3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
T4 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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Possible Causes
Pinpoint Test U: The Failsafe Cooling
PCM
Normal Operation
Instrument cluster
The failsafe cooling warning indicator informs the
driver that the engine coolant is overheating due to
loss of engine coolant fluid or other cause, and that
the powertrain control module (PCM) is taking on
limp home strategy. The other purpose is to inform
the driver the engine cannot be cooled enough with
the limp home strategy and the engine is about to
be shut down by the PCM. The failsafe cooling
information is sent from the PCM to the instrument
cluster to illuminate the failsafe cooling warning
indicator.
PINPOINT TEST U: THE FAILSAFE COOLING WARNING INDICATOR IS NEVER/ALWAYS ON
U1 RETRIEVE THE RECORDED DTCs FROM THE CONTINUOUS
AND ON-DEMAND PCM SELF-TESTS
manual.
No
GO to U2.
U2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Select the instrument cluster failsafe warning indicator active
Yes
command on and off. Observe the failsafe cooling warning
GO to U3.
indicator.
Does the failsafe cooling warning indicator illuminate when No
selected on, and turn off when selected off? GO to U4.
U3 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
U4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
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Possible Causes
Pinpoint Test V: The Door Ajar Warning
Indicator Is Inoperative/Does Not Operate
SJB
Correctly
Instrument cluster
Normal Operation
The door ajar indicator informs the driver if any of
the doors, or the decklid is not completely closed.
The information is sent from the smart junction box
(SJB) to the instrument cluster over the
PINPOINT TEST V: THE DOOR AJAR WARNING INDICATOR IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
V1 CHECK THE OPERATION OF THE INTERIOR LAMPS
Open and close each door and the decklid, and monitor the Yes
interior lamps. GO to V2.
Do the interior lamps operate correctly?
No
V2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument door ajar warning indicator active
GO to V3.
command on and off. Observe the door ajar warning indicator.
Does the door ajar warning indicator illuminate when No
selected on, and turn off when selected off? GO to V4.
V3 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
V4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test W: The Traction Control
Normal Operation
Instrument cluster
The traction control indicator informs the driver that
a traction control event is taking place, by flashing
the indicator. It is also used to indicate a
malfunction in the traction control system by
illuminating the indicator constantly (not flashing).
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PINPOINT TEST W: THE TRACTION CONTROL INDICATOR IS NEVER/ALWAYS ON
W1 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster traction control indicator active
GO to W3.
command on and off. Observe the traction control indicator.
Does the traction control indicator illuminate when selected No
on, and turn off when selected off? GO to W2.
W2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
W3 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect the ABS module connector.
Yes
Check for:
INSTALL a new ABS module. REFER to
corrosion
damaged pins
normal operation.
pushed-out pins
Possible Causes
Pinpoint Test X: The Daytime Running
Lamps (DRL) Indicator Is Never/Always On
SJB
Normal Operation
Instrument cluster
When the DRL is on, the smart junction box (SJB)
sends a message over the communication network to
the instrument cluster to illuminate the DRL
indicator.
PINPOINT TEST X: THE DAYTIME RUNNING LAMPS (DRL) INDICATOR IS NEVER/ALWAYS ON
X1 CHECK THE DRL OPERATION
Check the operation of the DRL. Yes
Does the DRL operate correctly? GO to X2.
No
X2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster all warning lamps active command
GO to X4.
on and off. Observe the DRL indicator.
Does the DRL indicator illuminate when selected on, and No
turn off when selected off? GO to X3.
(Continued)
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PINPOINT TEST X: THE DAYTIME RUNNING LAMPS (DRL) INDICATOR IS NEVER/ALWAYS ON
(Continued)
X3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
X4 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Possible Causes
Pinpoint Test Y: The Low Fuel Warning
Instrument cluster
Normal Operation
The low fuel indicator is on when the fuel level
reaches a predetermined level of approximately 1/16
tank. The low fuel level warning indicator and the
fuel gauge are controlled by the instrument cluster
based upon the fuel level data provided by the
smart junction box (SJB). When the instrument
cluster receives the data, the fuel gauge indicates
low fuel and the instrument cluster illuminates the
low fuel warning indicator.
PINPOINT TEST Y: THE LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON
Y1 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the instrument cluster low fuel warning indicator active
GO to Y2.
command on and off. Observe the low fuel warning indicator.
Does the low fuel warning indicator illuminate when No
selected on and turn off when selected off? GO to Y3.
Y2 CHECK THE FUEL GAUGE FOR CORRECT OPERATION
Check the fuel gauge. GO to Y3.
Does the fuel gauge operate correctly?
No
(Continued)
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PINPOINT TEST Y: THE LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON (Continued)
Y3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Possible Causes
Pinpoint Test Z: The Performance Shift
Warning Indicator Is Never/Always On (GT
PCM
500 Only)
Instrument cluster
Normal Operation
The performance shift indicator shares the SVT logo
on the tachometer. The performance shift indicator
is configurable on or off and uses engine rpm to
determine when to illuminate. The performance shift
indicator receives the engine rpm status from the
powertrain control module (PCM) over the high
speed controller area network (CAN)
communication bus lines. When the engine rpm is
equal to the preset (configured) shift rpm, the
instrument cluster turns on the performance shift
indicator.
PINPOINT TEST Z: THE PERFORMANCE SHIFT WARNING INDICATOR IS NEVER/ALWAYS ON (GT 500
ONLY)
Z1 CHECK THE PERFORMANCE SHIFT CONFIGURATION
Verify that the performance shift indicator is configured on. Refer Yes
to the Owners Literature for additional information. GO to Z2.
Is the performance shift indicator configured on?
No
CONFIGURE the performance shift
indicator on. REFER to the Owners
Literature for additional information. TEST
Z2 RETRIEVE THE RECORDED DTCs FROM BOTH THE
Retrieve the recorded DTCs from the PCM continuous and Yes
manual.
No
GO to Z3.
Z3 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
CONTROL ACTIVE COMMAND
Key in ON position.
Select the instrument cluster indicator lamp control.
Yes
Select the performance shift indicator active command on then
GO to Z4.
off again while observing the performance shift indicator.
Does the performance shift indicator turn on when No
commanded on and turn off when commanded off? GO to Z5.
(Continued)
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PINPOINT TEST Z: THE PERFORMANCE SHIFT WARNING INDICATOR IS NEVER/ALWAYS ON (GT 500
ONLY) (Continued)
Z4 CHECK FOR CORRECT PCM OPERATION
pushed-out pins
No
Z5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
seat correctly.
Possible Causes
Pinpoint Test AA: The Shift Indicator Is
Never/Always On (GT 500 Only)
PCM
Normal Operation
Instrument cluster
The shift indicator is used to inform the driver of
shift points that provide the highest fuel economy.
The shift indicator is controlled by the instrument
cluster based upon a shift message sent from the
powertrain control module (PCM) over the high
speed controller area network (CAN)
communication bus lines.
PINPOINT TEST AA: THE SHIFT INDICATOR IS NEVER/ALWAYS ON (GT 500 ONLY)
AA1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
manual.
No
GO to AA2.
AA2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the gear shift up indicator active command on then off
GO to AA3.
again while observing the shift indicator.
Does the shift indicator turn on when commanded on and No
turn off when commanded off? GO to AA4.
(Continued)
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PINPOINT TEST AA: THE SHIFT INDICATOR IS NEVER/ALWAYS ON (GT 500 ONLY) (Continued)
AA3 CHECK FOR CORRECT PCM OPERATION
pushed-out pins
No
AA4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
seat correctly.
Possible Causes
Pinpoint Test AB: The Tire Pressure
Monitoring System (TPMS) Warning Indicator
TPMS concern
Is Never/Always On
SJB
Normal Operation
Instrument cluster
The instrument cluster receives the TPMS status
message(s) from the smart junction box (SJB) over
the medium speed controller area network (CAN)
communication bus lines. If a low tire is detected
by the TPMS, the SJB sends a message to the
instrument cluster and the instrument cluster turns
on the TPMS warning indicator. If there is a
problem or fault detected in the TPMS, the SJB
sends the appropriate message to the instrument
cluster and the instrument cluster flashes the TPMS
warning indicator. If the TPMS status message is
invalid or missing for more than 5 seconds, the
instrument cluster flashes the TPMS warning
indicator for 75 seconds then turns the indicator on
steady.
PINPOINT TEST AB: THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WARNING INDICATOR IS
NEVER/ALWAYS ON
AB1 CHECK THE INSTRUMENT CLUSTER CONFIGURATION
Verify that the TPMS is configured on in the instrument cluster Yes
using as-built data. Refer to Section 418-01. GO to AB2.
Is the TPMS configured on?
No
CONFIGURE the TPMS in the instrument
cluster. REFER to Section 418-01.
AB2 RETRIEVE THE RECORDED DTCs FROM BOTH THE
Retrieve the recorded DTCs from the SJB continuous and Yes
on-demand self-tests. REFER to Section 419-10.
Are there any SJB DTCs retrieved?
No
GO to AB3.
(Continued)
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PINPOINT TEST AB: THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WARNING INDICATOR IS
NEVER/ALWAYS ON (Continued)
AB3 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the tire pressure indicator active command on then off
GO to AB4.
again while observing the TPMS warning indicator.
Does the TPMS warning indicator turn on when commanded No
on and turn off when commanded off? GO to AB5.
AB4 CHECK FOR CORRECT SJB OPERATION
Disconnect all SJB connectors. Yes
Check for: INSTALL a SJB. REFER to Section
pushed-out pins
No
Connect all SJB connectors and make sure they seat correctly.
AB5 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
seat correctly.
Possible Causes
Pinpoint Test AC: The Anti-Theft Indicator Is
Never/Always On
PCM
Normal Operation
Instrument cluster
The instrument cluster receives the anti-theft status
from the PCM over the high speed CAN
communication bus lines. The anti-theft indicator
proves out for 3 seconds when the ignition switch is
turned to the RUN or the START position. If there
is a passive anti-theft system (PATS) concern, the
indicator either flashes rapidly or glows steadily (for
more than 3 seconds) when the ignition switch is
turned to the RUN or START position. PATS also
flashes the anti-theft indicator every 2 seconds at
ignition OFF to act as a visual theft deterrent.
PINPOINT TEST AC: THE ANTI-THEFT INDICATOR IS NEVER/ALWAYS ON
AC1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
on-demand self-tests. If there are any PATS DTCs present,
Are there any DTCs retrieved? REFER to Section 419-01B.
For all other PCM DTCs, REFER to the
Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
No
GO to AC2.
(Continued)
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PINPOINT TEST AC: THE ANTI-THEFT INDICATOR IS NEVER/ALWAYS ON (Continued)
AC2 CARRY OUT THE INSTRUMENT CLUSTER INDICATOR LAMP
Key in ON position.
Yes
Select the anti-theft indicator active command on then off again
GO to AC3.
while observing the shift indicator.
Does the anti-theft indicator turn on when commanded on No
and turn off when commanded off? GO to AC4.
AC3 CHECK FOR CORRECT PCM OPERATION
pushed-out pins
No
AC4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
seat correctly.
Pinpoint Test AD: The Instrument Cluster Is
DTC B1556 is set continuous DTC and
Inoperative
on-demand if the instrument cluster receives a
network message from the SJB indicating that the
ignition switch is in the RUN or START position
and there is no voltage on the instrument cluster
Normal Operation
run/start circuit 489 (PK/BK).
With the ignition switch in the START or RUN
Possible Causes
position, the instrument cluster receives voltage
from the smart junction box (SJB) through circuits
Fuse(s)
489 (PK/BK) and 1266 (RD/YE). With the ignition
Circuit 489 (PK/BK) open
switch in the OFF position, the instrument cluster
Circuit 1001 (WH/YE) open
receives its keep-alive voltage from the SJB through
circuit 1001 (WH/YE). The instrument cluster is Circuit 1205 (BK) open
grounded through circuit 1205 (BK).
Instrument cluster
PINPOINT TEST AD: THE INSTRUMENT CLUSTER IS INOPERATIVE
AD1 CHECK THE INSTRUMENT CLUSTER VOLTAGE SUPPLY
Key in ON position.
Measure the voltage between the instrument cluster, harness
side and ground as follows:
(Continued)
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PINPOINT TEST AD: THE INSTRUMENT CLUSTER IS INOPERATIVE (Continued)
AD1 CHECK THE INSTRUMENT CLUSTER VOLTAGE SUPPLY
(Continued)
Instrument Cluster
Yes
C220-3 1001 (WH/YE)
GO to AD2.
C220-25 1266 (RD/YE) No
VERIFY the SJB fuses 8 (10A), 16 (5A),
C220-26 489 (PK/BK)
and 19 (5A) are OK. If OK, REPAIR the
circuit in question. CLEAR the DTCs.
Are the voltages greater than 10 volts? REPEAT the self-test.
AD2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
circuit 1205 (BK) harness side and ground.
Yes
GO to AD3.
No
AD3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
Pinpoint Test AE: DTC B1557 Ignition
DTC B1557 is a continuous DTC that sets if the
RUN/START Circuit Short To Battery
instrument cluster receives a voltage input on circuit
489 (PK/BK) and a message from the SJB
indicating that the ignition switch has transitioned to
the OFF or ACC position.
Normal Operation
Possible Causes
With the ignition switch in the START or RUN
position, the instrument cluster receives voltage
Circuit 489 (PK/BK) short to voltage
from the smart junction box (SJB) through circuits
SJB
489 (PK/BK) and 1266 (RD/YE). With the ignition
Instrument cluster
switch in the OFF position, the instrument cluster
receives its keep-alive voltage from the SJB through
circuit 1001 (WH/YE). The instrument cluster is
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PINPOINT TEST AE: DTC B1357 IGNITION RUN/START CIRCUIT SHORT TO BATTERY
AE1 CHECK THE INSTRUMENT CLUSTER VOLTAGE SUPPLY
circuit 489 (PK/BK), harness side and ground.
Yes
No
Is voltage present? GO to AE2.
AE2 CHECK THE SJB IGNITION SWITCH PIDs
Key in ON position.
Yes
Ignition Switch PIDs.
GO to AE3.
Monitor the SJB ignition switch PIDs while moving the ignition
switch from the RUN/START position to the OFF and ACC No
positions. VERIFY that all SJB controlled systems
Do the PIDs agree with the ignition switch position? function correctly. GO to AE4.
AE3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
No
correctly.
AE4 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
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Instrument Cluster
2. NOTE: The instrument cluster finish panel is
held in place with retaining clips that are
1 63044D70 Instrument cluster finish panel
attached to the bezel.
2 W705314 Instrument cluster screws (4
Remove the instrument cluster finish panel. required)
3 Instrument cluster electrical
3. Remove the 4 screws and the instrument
cluster.
4 10849 Instrument cluster
1. NOTE: If installing a new instrument cluster, it If a new instrument cluster was installed,
is necessary to upload the instrument cluster download the instrument cluster
configuration information to the diagnostic tool. configuration information from the
For additional information, refer to Section diagnostic tool into the new instrument
418-01. cluster. For additional information, refer to
Section 418-01.
Depower the supplemental restraint system
Section 501-20B.
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Message Center Switch
Section 501-12.
2. Press the retaining tabs and remove the message
center switches.
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413-09-1 413-09-1 Warning Devices
GENERAL PROCEDURES
NOTE: The programming sequence terminates if a
Safety Belt Minder
system fault occurs that requires the illumination of
Deactivating/Activating
the safety belt, or air bag warning indicator at any
time during the programming or confirmation.
Preparation
1. Turn the ignition switch to the RUN position
1. Before deactivating/activating the belt minder,
(do not start the engine).
set the parking brake.
2. Wait until the safety belt warning indicator
2. Place the gearshift in PARK (P) (automatic
turns off (approximately one minute).
transmission) or the NEUTRAL (N) position
(manual transmission).
3. NOTE: Step 4 must be completed within 60
seconds.
3. Place the ignition switch in the OFF position.
Buckle and unbuckle the driver or passenger
safety belt 9 times, ending with the safety belt
4. Close all the vehicle doors.
unbuckled. The air bag warning indicator
illuminates for 3 seconds after this step.
5. Unbuckle the driver and passenger safety belt.
4. After the air bag warning indicator turns off,
6. Place the parklamps/headlamps switch in the
buckle and unbuckle the safety belt again. This
OFF position.
enables the belt minder if disabled or disables
Deactivating/Activating the belt minder if enabled.
5. Confirmation of the belt minder being enabled
NOTE: Steps 1-7 using only the driver safety belt
is by the air bag warning indicator flashing 4
permanently enables/disables the belt minder
times per second for 3 seconds, followed by 3
feature.
seconds again.
NOTE: Steps 1-7 using only the passenger safety
belt permanently enables/disables the belt minder 6. Confirmation of the belt minder being disabled
feature. is by the air bag warning indicator flashing 4
times per second for 3 seconds.
NOTE: Only one side (driver or passenger) can be
enabled/disabled per ignition switch cycle. While
7. After confirmation, the deactivation/activation
programming the driver side, any activity on the
procedure is complete.
passenger side terminates the programming
sequence. While programming the passenger side,
any activity on the driver side terminates the
programming sequence.
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413-06-1 413-06-1 Horn
SPECIFICATIONS
Radiator bracket bolts 10 89
Horn bracket nut 9 80
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The instrument cluster uses various inputs to
Warning Devices
determine when to sound the warning chime. The
The instrument cluster controls the warning chime
warning chime sounds:
function. The warning chime sounds to remind the
driver:
if the headlamps are left on with the ignition
switch in the OFF position and the driver door
to turn the headlamps off when exiting the
ajar.
vehicle.
if the key is in the ignition in the OFF position,
to remove the ignition key when exiting the
with the ignition key removed, and the driver
vehicle.
door ajar.
to close the doors/decklid after starting the
if a door/decklid is ajar while the ignition switch
vehicle.
is in the RUN position.
to fasten the safety belt after starting the vehicle.
the safety belts are not fastened and the ignition
to disengage the parking brake after driving the
switch is in the RUN position.
vehicle.
the parking brake is engaged while the vehicle is
to turn off the turn signal after driving the
in motion.
vehicle.
the turn signal is left on for more than 0.8 km
(0.5 mile).
the air bag warning indicator is inoperative when
there are diagnostic trouble codes (DTCs) present.
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Door/Trunk Ajar Warning Chime
Warning Devices
The door/trunk ajar warning chime warns that a
Special Tool(s)
door, or the trunk, is not fully closed. The chime
sounds when any door or the trunk becomes ajar 73III Automotive Meter
105-R0057 or equivalent while the ignition switch is in the RUN position.
Headlamps On Warning Chime
The headlamps on warning chime is activated when
the instrument cluster receives the parking lamps
ON signal from the smart junction box (SJB), the
Flex Probe Kit
key is out of the ignition, and the driver door is
ajar. The warning consists of repeated one-half
second bursts and continues to sound until the
exterior lamps are turned off, the driver door is
closed, or 10 minutes have elapsed, at which time
the battery saver turns the exterior lamps off.
Safety Belt Warning Chime
The safety belt warning chime is activated when the
ignition switch is in the RUN position and the RCM
detects an unbuckled driver safety belt. The
instrument cluster generates the chime for a duration
tool
of 6 seconds or until the safety belt is buckled.
Safety Belt Minder
NOTE: The safety belt minder is a configurable
item. To configure using a scan tool, refer to
Key-In-Ignition Warning Chime
Section 418-01. To configure without using a scan
When the key-in-ignition switch closes, it sends a
tool, refer to Safety Belt Minder
voltage signal to the instrument cluster, which then
Deactivating/Activating in this section.
sounds a warning chime, provided the ignition key
The safety belt minder feature supplements the
is in the ignition lock cylinder, the ignition switch is
current safety belt warning function. The safety belt
in the OFF position, and the driver door is open.
minder feature is enabled after the current safety
The instrument cluster sounds a steady tone, which
belt warning is complete. The safety belt minder
continues until the key is removed, the ignition
reminds the driver that his/her safety belt is
switch is rotated to the RUN position, or the driver
unbuckled by intermittently sounding a chime and
door is closed.
illuminating the safety belt warning lamp in the
Air Bag Warning Chime
instrument cluster once the vehicle speed has
exceeded 5 km/h (3 mph). While activated, the
The air bag warning chime warns the driver that the
safety belt minder alternates the chime and indicator
air bag warning indicator lamp is not working and a
from ON for 6 seconds, to OFF for 30 seconds.
fault has occurred by sounding a chime when the
ignition switch is in the RUN position for more than
The safety belt minder reminder stops when:
20 seconds. When these conditions exist, the
the driver or passenger safety belt is buckled.
restraints control module (RCM) sends a chime
the ignition switch is turned to the OFF or ACC
request through the communication network to the
position.
instrument cluster. The instrument cluster then
activates the warning chime. The warning consists
five minutes have elapsed since belt minder has
of 5 sets of five 1-second tone bursts. Each set is
started.
separated by 5 seconds of silence. The warning is
repeated every 30 minutes.
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Message Center Warning Chime
software release.
The message center warning chime accompanies any
initial warning message display, as well as any
repeated initial warning message. As the message
center is an integral part of the instrument cluster,
the interaction between the message center and the
chime function is also integral to the instrument
cluster.
VCM.
The message center switch tone sounds when any
switch on the message center is pressed. The
VCM:
message center switches are supplied with a voltage
reference signal from the instrument cluster. When a
switch is pressed, it routes the signal through a Check the scan tool connection to the VCM.
specific resistor in the switch assembly and then to
ground. Refer to Section 413-08.
with the scan tool.
Performance Shift Warning Chime
The performance shift warning chime provides an
vehicle:
audible alert to inform the driver to shift the
vehicle. The chime is configured through the
position.
message center independently of the visual
performance shift indicator. The chime feature
on/off status and the desired rpm for the chime to
good vehicle.
sound are configurable items. The instrument cluster
uses engine data rpm sent to the instrument cluster
over the high speed controller area network (CAN)
(PCM).
communication lines and compares the value against
the customer preset engine rpm to determine when
to sound the chime. When the actual engine rpm
matches the preset engine rpm, the instrument
cluster sounds the chime.
self-test diagnostics for the instrument cluster.
of electrical damage.
Visual Inspection Chart refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index.
Electrical
Circuitry
Connector(s)
Key-in ignition warning switch (part of the ignition
switch)
Instrument cluster
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B1353 Ignition Key-In Circuit Open GO to Pinpoint Test A.
B236A Chime Output Circuit Open INSTALL a new instrument cluster. REFER to
Section 413-01. TEST the system for normal
operation.
B2903 Chime Output Circuit Short to Battery INSTALL a new instrument cluster. REFER to
operation.
B2940 Chime Output Circuit Short to Ground INSTALL a new instrument cluster. REFER to
operation.
Symptom Chart
Symptom Chart
All the chimes are inoperative Instrument cluster INSTALL a new instrument
cluster. REFER to Section
normal operation.
The safety belt warning Instrument cluster CHECK the safety belt
chime is inoperative warning indicator operation.
If the safety belt
warning indicator
operates correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01.
If the safety belt
REFER to Section
413-01 to continue
diagnosis of the safety
belt warning indicator.
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The safety belt minder feature Safety belt minder deactivated ACTIVATE the safety belt
does not operate correctly minder feature. REFER to
Safety Belt Minder
Deactivating/Activating in
this section.
Instrument cluster CHECK the safety belt
warning indicator operation.
If the safety belt
warning indicator
operates correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01.
If the safety belt
REFER to Section
413-01 to continue
diagnosis of the safety
belt warning indicator.
The key-in-ignition chime is Circuitry GO to Pinpoint Test A.
inoperative Key-in-ignition switch (part
of the ignition switch)
Instrument cluster
The headlamps on warning Smart junction box (SJB) GO to Pinpoint Test B.
chime is inoperative
The chime sounds when the Circuitry GO to Pinpoint Test C.
driver door is ajar (no key in Key-in-ignition switch (part
the ignition and the of the ignition switch)
headlamps are off) Instrument cluster
The performance shift Instrument cluster GO to Pinpoint Test D.
warning chime does not configuration
operate correctly Instrument cluster
The air bag warning chime Restraints control module CHECK the operation of the
does not operate correctly (RCM) safety belt and air bag
Instrument cluster warning indicators.
If the safety belt and air
bag warning indicators
operate correctly,
INSTALL a new
instrument cluster.
REFER to Section
413-01. TEST the
system for normal
operation.
If the safety belt and air
bag warning indicators
do not operate correctly,
REFER to Section
413-01 to continue
diagnosis of the warning
indicators.
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The message center switch Instrument cluster CHECK the operation of the
tone is inoperative message center switches.
If the message center
switches operate
REFER to Section
413-01. TEST the
system for normal
operation.
If the message center
switches do not operate
correctly, REFER to
Section 413-08 to
continue diagnosis of the
message center switches.
Pinpoint Tests DTC B1353 is a continuous and on-demand
DTC that sets if the instrument cluster detects a
Pinpoint Test A: The Key-In-Ignition Chime
run/start input on circuit 489 (PK/BK) with no
Is Inoperative
key-in-ignition input on circuit 1414 (LG/VT).
Possible Causes
Circuit 1414 (LG/VT) open
Normal Operation
Key-in-ignition switch (part of the ignition switch)
When the key is inserted into the ignition lock
cylinder, the key-in-ignition switch (part of the Instrument cluster
ignition switch) closes and routes a voltage signal to
the instrument cluster through circuit 1414 (LG/VT).
The voltage signal indicates to the instrument
cluster the key is inserted into the ignition lock
cylinder. If the instrument cluster detects that the
ignition switch is in the OFF or ACC position with
the key inserted in the ignition lock cylinder and the
driver door is ajar, the key-in-ignition warning
chime (located in the instrument cluster) sounds.
PINPOINT TEST A: THE KEY-IN-IGNITION CHIME IS INOPERATIVE
A1 CHECK FOR DRIVER DOOR AJAR INPUT TO THE SMART
JUNCTION BOX (SJB)
Check the operation of the interior lamps while opening and Yes
closing the driver door. GO to A2.
No
diagnosis of the interior lamps.
A2 CHECK THE INPUT TO THE INSTRUMENT CLUSTER FOR DTC
B1353
Insert the ignition key into the ignition lock cylinder.
(Continued)
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PINPOINT TEST A: THE KEY-IN-IGNITION CHIME IS INOPERATIVE (Continued)
A2 CHECK THE INPUT TO THE INSTRUMENT CLUSTER FOR DTC
B1353 (Continued)
circuit 1414 (LG/VT), harness side and ground.
Yes
GO to A4.
No
A3 CHECK CIRCUIT 1414 (LG/VT) FOR AN OPEN
circuit 1414 (LG/VT), harness side and the ignition switch
C250-5, circuit 1414 (LG/VT), harness side.
Yes
No
damaged pins system for normal operation.
pushed-out pins
No
correctly.
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Possible Causes
Pinpoint Test B: The Headlamps On Warning
Chime Is Inoperative
SJB
Normal Operation
cylinder, the key-in-ignition switch (part of the
When the ignition key is not inserted into the
ignition lock cylinder, the driver door is ajar and the
headlamps are on, the smart junction box (SJB)
sends a message to the instrument cluster over the
medium speed controller area network (MS-CAN).
The instrument cluster interprets this signal and
sounds the headlamps on warning chime.
PINPOINT TEST B: THE HEADLAMPS ON WARNING CHIME IS INOPERATIVE
B1 CHECK THE EXTERIOR LIGHTING
Check the operation of the exterior lighting. Yes
Does the exterior lighting operate correctly? GO to B2.
No
diagnosis of the exterior lighting.
B2 CHECK THE OPERATION OF THE KEY-IN IGNITION WARNING
CHIME
Verify the key-in-ignition warning chime operates correctly. Yes
Does the key-in-ignition warning chime operate correctly? GO to B3.
No
Disconnect all of the SJB connectors.
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Connect all of the SJB connectors and make sure they seat No
Pinpoint Test C: The Chime Sounds When Normal Operation
The Driver Door Is Ajar (No Key In The
Ignition And The Headlamps Are Off)
cylinder, the key-in-ignition switch (part of the
The voltage signal indicates to the instrument
cluster the key is inserted into the ignition lock
cylinder. If the instrument cluster detects that the
ignition switch is in the OFF or ACC position with
the key inserted in the ignition lock cylinder and the
driver door is ajar, the key-in-ignition warning
chime (located in the instrument cluster) sounds.
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Possible Causes
Circuit 1414 (LG/VT) short to voltage
Key-in-ignition switch (part of the ignition switch)
Instrument cluster
PINPOINT TEST C: THE CHIME SOUNDS WHEN THE DRIVER DOOR IS AJAR (NO KEY IN THE IGNITION
AND THE HEADLAMPS ARE OFF)
C1 CHECK THE INSTRUMENT CLUSTER ILLUMINATION
Check the operation of the instrument cluster illumination. Yes
Does the instrument cluster illumination operate correctly? GO to C2.
No
diagnosis of the instrument cluster
illumination.
C2 CHECK THE INPUT TO THE INSTRUMENT CLUSTER
Remove the ignition key from the ignition lock cylinder.
Yes
GO to C3.
No
Is any voltage present? GO to C4.
C3 CHECK CIRCUIT 1414 (LG/VT) FOR A SHORT TO VOLTAGE
Yes
normal operation.
No
Is any voltage present? normal operation.
(Continued)
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PINPOINT TEST C: THE CHIME SOUNDS WHEN THE DRIVER DOOR IS AJAR (NO KEY IN THE IGNITION
AND THE HEADLAMPS ARE OFF) (Continued)
Yes
Check for:
corrosion
damaged pins
pushed-out pins
Possible Causes
Pinpoint Test D: The Performance Shift
Warning Chime Does Not Operate Correctly
Instrument cluster configuration
Normal Operation
Instrument cluster
The chime feature on/off status and the desired rpm
for the chime to sound are configurable items that
are configured through the message center. The
instrument cluster uses actual engine rpm sent to the
instrument cluster over the high speed controller
area network (CAN) communication lines and
compares the value against the customer preset
engine rpm to determine when to sound the chime.
When actual engine rpm matches the preset engine
rpm, the instrument cluster sounds the chime
PINPOINT TEST D: THE PERFORMANCE SHIFT WARNING CHIME DOES NOT OPERATE CORRECTLY
D1 CHECK THE INSTRUMENT CLUSTER CONFIGURATION
Verify that the performance warning shift chime (tone) is Yes
configured on and that the desired rpm setting is configured. GO to D2.
Refer to the Owners Literature for additional information.
No
Is the performance shift chime (tone) configured on and the
CONFIGURE the performance warning
desired rpm selected?
shift chime (tone) on and configure the
desired rpm setting. REFER to the
Owners Literature for additional
information. TEST the system for normal
operation.
D2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
Yes
Check for:
corrosion
damaged pins
pushed-out pins
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414-01-1 414-01-1 Battery, Mounting and Cables
Battery and Battery Tray Exploded
View
1 10A687 Battery heat shield
2 10756 Battery hold-down bolt/clamp
3 10655 Battery
4 W503923 Battery tray bolts (3 required)
5 10723 Battery tray
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Battery and Cables
Vehicles are equipped with a 12-volt,
maintenance-free battery.
The battery and cable system consists of the
Battery
Battery cable assembly
Battery tray
Ford Motor Company strongly recommends that
lead-acid batteries be returned to an authorized
recycling facility for disposal.
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Battery Cables 4.0L SOHC
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2. Disconnect the battery. For additional
information, refer to Battery Disconnect in this
section.
cover
2 W706414-S413 Starter solenoid positive cable
terminal nut
3 Starter solenoid positive cable
4. Remove the nut and position the starter
terminal (part of 14300)
solenoid positive cable terminal aside.
4 W705790-S901 Starter solenoid wire terminal
To install, tighten to 12 Nm (9 lb-ft). nut
5 Starter solenoid wire terminal
(part of 14300)
solenoid wire terminal aside.
6 W506031 Battery cable harness bracket
bolt
7 Battery cable harness bracket
(part of 14300) 6. Remove the bolt and position the battery cable
harness bracket aside. 8 Battery cable harness locator
(LH) (part of 14300)
9 W506031 Battery ground cable engine
terminal bolt
7. Remove the battery cable harness locator from
10 Battery ground cable engine
behind the LH cylinder head.
11 Battery cable harness locator 8. Remove the bolt and position the battery
(RH) (part of 14300)
ground cable engine terminal aside.
12 Battery cable harness locator
(part of 14300)
13 54042A06 Battery ground cable body
terminal bolt
behind the RH cylinder head.
14 Battery ground cable body
the bulkhead.
(part of 14300)
16 Bussed electrical center
11. Remove the bolt and position the battery
(BEC) terminal bolt
ground cable body terminal aside.
17 BEC terminal (part of 14300)
(part of 14300)
19 W705790-S901 Generator B+ terminal nut
the RH strut tower.
20 Generator B+ terminal (part
of 14300)
13. Open the BEC cover, remove the bolt and
21 Battery cable in-line position the BEC terminal aside.
22 14300 Battery cables
the engine bracket.
15. Position aside the generator B+ boot, remove
the nut and position the generator B+ terminal
aside.
Section 100-02.
16. Disconnect the battery cable in-line connector.
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17. Remove the battery cables. 18. To install, reverse the removal procedure.
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Battery Cables 4.6L (3V)
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3. Position the positive battery terminal cover
aside, remove the nut and position the generator
1 W705790-S901 Generator harness terminal
harness terminal aside.
nut
To install, tighten to 8 Nm (71 lb-in). 2 Generator harness terminal
(part of 14305)
cover
4 W706414-S413 Starter solenoid positive cable
solenoid positive cable terminal aside. terminal nut
5 Starter solenoid positive cable To install, tighten to 12 Nm (9 lb-ft).
6 Battery cable clip (part of 6. Remove the battery cable clip from the
14300)
transmission cooler lines.
7 W520213 Battery ground cable engine
terminal nut 7. Remove the nut and position the battery ground
cable engine terminal aside. 8 Battery ground cable engine
9 Starter solenoid wire harness
locator
8. Remove the starter solenoid wire harness
10 Battery cable harness locators
locator from the battery cable harness.
11 Battery cable harness locator 9. Remove the 2 battery cable harness locators
(part of 14300)
from the subframe.
12 Battery cable harness locators
(2 required) (RH tower) (part
of 14300)
the body.
13 54042A06 Battery ground cable body
terminal bolt
11. Remove the 2 battery cable harness locators
14 Battery ground cable body from the RH strut tower.
15 Battery cable harness locator 12. Remove the bolt and position the battery
(part of 14300)
16 Bussed electrical center
(BEC) harness locator (part of
14300)
17 BEC terminal bolt
the battery tray.
18 BEC terminal (part of 14300)
19 14300 Battery cables 14. Remove the battery cable harness locator from
the RH strut tower.
position the BEC terminal aside.
hoist. For additional information, refer to To install, tighten to 20 Nm (15 lb-ft).
Section 100-02.
16. Remove the battery cables.
section.
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Battery Cables 5.4L (4V)
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1 W705790-S901 Generator harness terminal
nut
solenoid positive cable terminal aside.
2 Generator harness terminal
(part of 14300) To install, tighten to 12 Nm (9 lb-ft).
3 Battery cable terminal bolt
7. Remove the nut and position the battery ground (part of 14300)
cable engine terminal aside.
4 Battery ground cable body
bolt
5 Battery harness to distribution
box
8. Remove the starter solenoid wire harness
6 W706414-S413 Starter solenoid positive cable locator from the A/C compressor.
terminal nut
9. Remove the battery cable harness locators from 7 11N087 Starter solenoid terminal
cover the body.
8 Starter solenoid positive cable
terminal (part of 14300) 10. Remove the battery cable harness locators from
the oil pan.
9 W520213-S440 Battery ground cable engine
terminal nut
11. Remove the 2 battery cable harness locators
10 W705790-S901 Battery cable harness locator
from the RH strut tower. nut
11 W705790-S901 Battery cable terminal nut
12. Remove the bolt and position the battery
the battery tray.
Section 100-02.
the RH strut tower.
section.
position the BEC terminal aside.
3. Position the positive battery terminal cover
aside, remove the nut and position the generator To install, tighten to 20 Nm (15 lb-ft).
harness terminal aside.
16. Remove the battery cables.
4. Remove the locator from the dash panel.
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GENERAL PROCEDURES
Battery Disconnect WARNING: When lifting a battery,
excessive pressure on the end walls could cause
acid to spew through the vent caps, resulting in
WARNING: Batteries normally produce
personal injury. Lift with a battery carrier or
explosive gases. Therefore, do not allow flames,
with your hands on opposite corners. Failure to
sparks or lighted substances to come near the
battery. When charging or working near a
injury.
battery, always shield your face and protect your
eyes. Always provide ventilation. Failure to
WARNING: Keep out of the reach of
children. Batteries contain sulfuric acid. Avoid
injury.
contact with skin, eyes or clothing. Also, shield
your eyes when working near the battery to
WARNING: To avoid accidental
protect against possible splashing of the acid
deployment and possible injury, the backup
solution. In case of acid contact with the skin or
power supply must be depleted before repairing
eyes, flush immediately with water for a
or installing any front or side air bag
minimum of 15 minutes and get prompt medical
supplemental restraint system (SRS) components
attention. If acid is swallowed, call a physician
and before repairing, installing, adjusting or
immediately. Failure to follow these instructions
striking components near the front or side air
bag sensors, such as doors, instrument panel,
console, door latches, strikers, seats and hood
NOTE: When the battery (or powertrain control
latches. Failure to follow these procedures may
module [PCM]) is disconnected and connected,
some abnormal drive symptoms may occur while
Refer to the appropriate vehicle shop manual to
the vehicle relearns its adaptive strategy. The
determine location of the front air bag sensors.
charging system setpoint may also vary. The vehicle
may need to be driven to relearn its strategy.
To deplete the backup power supply energy,
disconnect the battery ground cable and wait at
1. Disconnect the battery ground terminal.
least 1 minute. Be sure to disconnect auxiliary
batteries and power supplies (if equipped). To connect, tighten to 5 Nm (44 lb-in).
Failure to follow these instructions may result in
2. Disconnect the positive battery terminal.
personal injury.
To connect, tighten to 5 Nm (44 lb-in).
3. To connect, reverse the disconnect procedure.
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2. Remove the 3 bolts and the battery tray.
Battery Tray
Material
Item Specification
For GT500 models, apply threadlock and
sealer to the battery tray bolt threads.
TA-25
1. Remove the battery. For additional information,
refer to Battery in this section.
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Battery
Special Tool(s)
Micro 490 Digital Battery
Analyzer Mechanical Electrical
Battery Battery cables
Battery mounting Battery posts
3. If an obvious cause for a concern is found,
correct the cause before proceeding to the next
step.
4. If the fault is not visually evident, proceed to
the pinpoint test.
Pinpoint Tests
PINPOINT TEST A: BATTERY CONDITION TEST
A1 TEST THE BATTERY CONDITION
NOTE: No battery with a red test-eye should be replaced. The red Yes
eye only means the battery is discharged, not necessarily defective. If the meter reads GOOD BATTERY,
RETURN the battery to service. REFER to
NOTE: Failure to fully charge the battery before retesting may
Section 414-00.
cause false readings.
If the meter reads GOOD-RECHARGE, Verify the battery condition using the battery analyzer.
CHARGE the battery and RETURN it to Is the battery OK?
service. REFER to Section 414-00.
If the meter reads CHARGE & RETEST,
fully CHARGE and RETEST the battery.
No
If the meter reads REPLACE BATTERY,
INSTALL a new battery.
If the meter reads BAD CELL-REPLACE,
INSTALL a new battery.
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Battery WARNING: Keep out of the reach of
children. Batteries contain sulfuric acid. Avoid
contact with skin, eyes, or clothing. Also, shield Removal and Installation
your eyes when working near the battery to
protect against possible splashing of the acid
solution. In case of acid contact with the skin or
explosive gases which can cause personal injury.
Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When
charging or working near a battery, always
immediately. Failure to follow these instructions
shield your face and protect your eyes. Always
provide ventilation. Failure to follow these
WARNING: When lifting a battery,
section.
2. Remove the battery heat shield.
personal injury, damage to the vehicle, or
damage to the battery. Lift with a battery carrier
3. Remove the bolt and the battery hold-down
or with your hands on opposite corners. Failure
clamp.
to follow these instructions may result in
personal injury.
4. Remove the battery.
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414-00-1 414-00-1 Charging System General Information
Battery
Charging System
The battery is a 12-volt DC source connected in a
The charging system is a negative ground system.
negative ground system. The battery case is sealed
The generator (including an internal voltage
with 2 vent holes to release gases. The battery has 3
regulator) is belt-driven by the engine accessory
major functions:
drive system. When the engine is started, the
generator begins to generate alternating current
Engine cranking power source
(AC), which is internally converted to direct
Voltage stabilizer for the electrical system
current (DC). This current is then supplied to the
Temporary power source when electrical loads
vehicle electrical system through the output (B+)
exceed the generator output current
terminal of the generator.
Vehicles equipped with a 4.6L (3V) have a one way
clutch (OWC) in the generator pulley. The OWC
pulley temporarily disengages the generator rotor
from the front end accessory drive (FEAD) system
during high deceleration rates on the engine. This
may decrease noise/vibration/harshness (NVH) (belt
chirp) and may increase belt life. The OWC pulley
and generator/regulator must be installed as an
assembly.
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The charging system voltage is controlled by the
Charging System
PCM. The generator charges the battery, and at the
Special Tool(s)
same time supplies power for all of the electrical
loads that are required. The battery is more
effectively charged with a higher voltage when the
battery is cold and a lower voltage when the battery
is warm. The PCM is able to adjust the charging
voltage according to the battery temperature by
using a signal from the intake air temperature (IAT)
sensor. This means the voltage setpoint is
calculated by the PCM and communicated to the
regulator by a communication link.
Electrical System Tester
The PCM simultaneously controls and monitors the
output of the generator. When the current
consumption is high or the battery is discharged, the
system is able to increase the idle speed.
To minimize the engine drag when starting the
engine, the PCM controls the generator. The
generator does not produce any output until the
engine has started. The PCM then progressively
increases the output of the generator.
tool
The PCM controls the operation of the charging
system warning indicator in the instrument cluster.
The PCM is responsible for turning the charging
Flex Probe Kit
system warning indicator off after the engine is
105-R025B
started and illuminating it under fault conditions
(when the generator is not generating the correct
amount of current with the engine running). The
charging system warning indicator is illuminated by
the PCM at key ON engine OFF, and stall
condition.
Principles of Operation This is a System 4 charging system, which uses the
GEN MON and GEN COM lines to control and
The powertrain control module (PCM) controlled
monitor the charging system through the PCM.
charging system determines the optimal voltage
System 4 charging systems are virtually identical in
setpoint for the charging system and communicates
design and therefore, share the same diagnostics.
this information to the voltage regulator. This
The circuit numbers and colors may be different,
system is unique in that it has 2 unidirectional
but the functions are the same. System 4 charging
communication lines between the PCM and the
systems may use any type of generator, as the
generator/regulator. Both of these communication
generator type usually depends on the engine
lines are pulse-width modulated (PWM). The
packaging and/or output requirements versus cost.
generator communication (GEN COM) line
communicates the desired setpoint from the PCM to
Circuit Description
the voltage regulator. The generator monitor (GEN
MON) line communicates the generator load and
Positive Battery Output (B+) Terminal Circuit
error conditions to the PCM. The third pin on the
2037 (RD)
voltage regulator, the A circuit pin, is a dedicated
The generator output voltage is supplied to the
battery voltage sense line.
battery and electrical system through the positive
battery output (B+) terminal circuit 2037 (RD) on
the rear of the generator.
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A Circuit 35 (OG/LB)
CAUTION: Do not allow any metal object
The A circuit or battery sense circuit is used to to come in contact with the generator housing
sense battery voltage. This voltage is used by the and internal diode cooling fins. A short circuit
regulator to determine generator output. This circuit may result and burn out the diodes.
is also used to supply current to the generator field
NOTE: While carrying out any pinpoint test,
(rotor). The amount of current supplied to the rotor
disregard any diagnostic trouble codes (DTCs) set
determines generator output.
while following any specific pinpoint test. After the
completion of any test, be sure to clear all DTCs in
Circuit 1817 (YE)
the PCM.
The GEN MON circuit communicates the generator
NOTE: All voltage measurements are referenced to
load and error conditions to the PCM.
the negative (-) battery post unless otherwise
specified.
Circuit 1816 (YE/LB)
This is the GEN COM circuit. The PCM determines
the optimal voltage setpoint for the charging system
and communicates this information to the voltage
regulator on the GEN COM circuit.
WARNING: Batteries contain sulfuric acid.
Battery Bussed electrical center
Avoid contact with skin, eyes, or clothing. Also,
Generator drive belt (BEC) fuse 43 (10A)
shield your eyes when working near batteries to Generator pulley Circuitry
Cables protect against possible splashing of the acid
Fusible links
solution. In case of acid contact with skin or
Charging system
warning indicator
Generator
Powertrain control
immediately. Failure to follow these instructions module (PCM)
explosive gases. Therefore, do not allow flames,
sparks or lighted substances to come near the
battery. When charging or working near a
4. Verify the battery condition. Refer to Section
battery, always shield your face and protect your
414-01.
eyes. Always provide ventilation. Failure to
5. Check the operation of the charging system
warning indicator (instrument cluster). Normal
injury.
operation is as follows:
WARNING: When lifting a battery,
With the key OFF, the charging system
warning indicator should be off.
With the key ON and the engine off, the
personal injury, damage to the vehicle or battery.
charging system warning indicator should be
Lift with a battery carrier or with your hands on
on.
opposite corners. Failure to follow these
With the engine running, the charging
system warning indicator should be off.
CAUTION: Do not make jumper
6. Turn off the headlamps and the A/C system (if
connections except as directed. Incorrect
equipped). Turn the climate control blower to
connections may damage the voltage regulator
low/off. Check the battery voltage before and
test terminals, fuses, or fusible links.
after starting the engine to determine if the
battery voltage increases.
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7. NOTE: Make sure to use the latest scan tool If the network test passes, retrieve and
software release. record continuous memory diagnostic
scan tool to the data link connector (DLC). 11. Clear the continuous DTCs and carry out the
self-test diagnostics for the powertrain control
module (PCM) and the instrument cluster.
ground from the DLC are provided to the 12. If the DTCs retrieved are related to the concern,
VCM. go to Powertrain Control Module (PCM)
Diagnostic Trouble Code (DTC) Index or the
Instrument Cluster Diagnostic Trouble Code
VCM:
(DTC) Index. For all other DTCs, refer to
Section 419-10.
NOTE: DTC P0622 can be set by the loss of the
with the scan tool.
communication lines between the generator and the
PCM. The charging system warning indicator then
vehicle:
illuminates until the engine is operated at greater
than 4,500 rpm (approximately wide open throttle
[WOT]) for a minimum of 3 seconds. At this time,
the generator self-excites. The charging system
warning indicator remains illuminated, and the
(PCM).
generator operates in a default mode (approximately
13.5 volts) until the engine is turned off.
P0622 Generator Field Term Cir PCM GO to Symptom Chart.
All Other DTCs PCM REFER to the Powertrain
Control/Emissions
B1317 Battery Voltage High Instrument Cluster GO to Pinpoint Test C.
B1318 Battery Voltage Low Instrument Cluster GO to Pinpoint Test A.
All Other DTCs Instrument Cluster REFER to Section 419-10.
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Symptom Chart
Symptom Chart
The battery is discharged or Circuitry GO to Pinpoint Test A.
battery voltage is low High key-off current drain(s)
Battery
Generator
The charging system warning Generator GO to Pinpoint Test B.
indicator is on with the Fusible links
engine running (the charging Circuitry
system voltage does not Powertrain control module
increase) (PCM)
The charging system Fuse GO to Pinpoint Test C.
overcharges (battery voltage Generator
is greater than 15.5 volts) Circuitry
(PCM)
The charging system warning Generator GO to Pinpoint Test D.
indicator is on with the Instrument cluster
engine running and the Powertrain control module
battery increases voltage (PCM)
The charging system warning Instrument cluster GO to Pinpoint Test E.
indicator is off with the Powertrain control module
ignition switch in the RUN (PCM)
position and the engine off
The charging system warning Instrument cluster INSTALL a new instrument
indicator flickers or is cluster. REFER to Section
intermittent 413-01.
The generator is noisy Loose bolts/brackets GO to Pinpoint Test F.
Drive belt
Generator or pulley
(conventional)
One-way-clutch (OWC)
pulley
Radio interference Generator GO to Pinpoint Test G.
Wiring/routing
In-vehicle entertainment
system
The generator output is supplied through the
Pinpoint Test A: The Battery is Discharged
positive battery output (B+) circuit 2037 (RD)
or Battery Voltage is Low
terminal on the rear of the generator to the battery
Refer to Wiring Diagrams Cell 12, Charging System
and electrical system. During normal operation, the
charging system warning indicator is off with the
key in the ON position and the engine running. The
charging system warning indicator is on with the
key in the ON position and the engine off.
Possible Causes
Engine, generator and battery grounds
Positive battery cable
Generator B+ circuit 2037 (RD) high resistance
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High key-off current drain(s)
Battery
Generator
PINPOINT TEST A: THE BATTERY IS DISCHARGED OR BATTERY VOLTAGE IS LOW
A1 CHECK THE BATTERY CONDITION
Carry out the Battery Condition Test to determine if the Yes
battery can hold a charge and is OK for use. Refer to Section GO to A2.
414-01.
No
Does the battery pass the condition test?
INSTALL a new battery. REFER to
normal operation.
A2 CHECK THE GENERATOR OUTPUT
Carry out the Generator On-Vehicle Load Test and No Load Yes
Test. Refer to the Component Tests in this section. GO to A3.
Does the generator pass the component tests?
No
INSTALL a new generator. REFER to
normal operation.
A3 CHECK FOR CURRENT DRAINS
Carry out the Battery Drain Testing. Refer to the Component Yes
Tests in this section. REPAIR as necessary. TEST the system
Are any circuits causing excessive current drains? for normal operation.
No
GO to A4.
A4 CHECK THE VEHICLE GROUNDS
With the engine running, measure the voltage drop between the
generator housing and the negative battery terminal.
Yes
GO to A5.
No
CHECK the engine ground, generator
ground and the battery ground for
corrosion. TEST the system for normal
Is the voltage drop less than 0.1 volt? operation.
(Continued)
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PINPOINT TEST A: THE BATTERY IS DISCHARGED OR BATTERY VOLTAGE IS LOW (Continued)
A5 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT 2037 (RD)
With the engine running, measure the voltage drop between the
generator B+ C102b, circuit 2037 (RD) and the positive battery
terminal.
Yes
CHECK if the customer left any
component(s) on or if there is an
intermittent excessive battery draw. TEST
No
CHECK for any corrosion in the generator
B+ circuit 2037 (RD), positive battery
cable and/or connections. REPAIR as
Is the voltage drop less than 0.1 volt? operation.
Possible Causes
Pinpoint Test B: The Charging System
Warning Indicator is ON With the Engine
Generator
Running (The Charging System Voltage
Fusible links
Does Not Increase)
GEN COM circuit 1816 (YE/LB) open or short to
ground
GEN MON circuit 1817 (YE) open or short to
Normal Operation
ground
With the engine running, the charging system
Generator B+ circuit 2037 (RD) open or high warning indicator is off. The sense A circuit 35
resistance (OG/LB) to the generator field coil is 13-15 volts.
The S (stator) circuit (internal to the generator) is
PCM
used to feed back a voltage signal from the
generator to the voltage regulator. This voltage is
used by the powertrain control module (PCM) to
turn off the charging system warning indicator. The
positive battery output (B+) circuit 2037 (RD) is the
generator output supplied to the battery and the
electrical system.
PINPOINT TEST B: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING (THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE)
B1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE
(PCM)
Connect the scan tool. REFER to the Powertrain
Key in ON position. Control/Emissions Diagnosis (PC/ED)
Enter the following diagnostic mode on the scan tool: Retrieve manual. If referred here by the Powertrain
PCM DTCs. Control/Emissions Diagnosis (PC/ED)
Check the recorded PCM DTCs from the continuous and manual, GO to B2.
on-demand self tests.
No
Are any PCM DTCs recorded?
GO to B2.
B2 CHECK THE GENERATOR B+ CIRCUIT 2037 (RD) FOR
VOLTAGE
(Continued)
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RUNNING (THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE) (Continued)
B2 CHECK THE GENERATOR B+ CIRCUIT 2037 (RD) FOR
VOLTAGE (Continued)
Measure the voltage between the generator C102b, circuit 2037
(RD) and ground.
Yes
GO to B3.
No
Is the voltage equal to battery voltage? normal operation.
B3 CHECK THE GENERATOR INTEGRITY
Disconnect: Generator C102a (4.0L), C133 (4.6L) (in-line
generator harness connector).
Key in ON position, engine OFF.
Measure and record the battery voltage.
(Continued)
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B3 CHECK THE GENERATOR INTEGRITY (Continued)
NOTE: If the generator communication lines are disconnected
(DTC P0622 may set), the generator self-excites if it is operated
at greater than 4,500 rpm (approximately wide open throttle
[WOT]) for a minimum of 3 seconds. It then operates in a
default mode of 13.5 volts until the engine is turned off.
With the engine running (after the brief WOT is carried out),
measure the battery voltage.
Yes
GO to B4.
Does the battery voltage increase a minimum of 0.5 volt No
from the key ON, engine off measurement to the key ON, INSTALL a new generator. REFER to
engine running measurement (after the brief WOT or snap Section 414-02. TEST the system for
acceleration is carried out)? normal operation.
B4 CHECK CIRCUIT 1816 (YE/LB) FOR AN OPEN OR A SHORT TO
GROUND
Connect: C133 (4.6L only) (in-line generator harness connector).
Disconnect: Generator C102a (4.6L only).
Measure the resistance between the generator C102a-2, circuit
1816 (YE/LB), harness side and the PCM C175e-13, circuit 1816
(YE/LB), harness side; and between the generator C102a-2,
circuit 1816 (YE/LB), harness side and ground.
Yes
GO to B5.
Is the resistance less than 5 ohms between the generator No
and the PCM, and greater than 10,000 ohms between the REPAIR the circuit. TEST the system for
generator and ground? normal operation.
(Continued)
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B5 CHECK CIRCUIT 1817 (YE) FOR AN OPEN OR A SHORT TO
GROUND
Measure the resistance between the generator C102a-1, circuit
1817 (YE), harness side and the PCM C175e-5, circuit 1817
(YE), harness side; and between the generator C102a-1, circuit
1817 (YE), harness side and ground.
Yes
GO to B6.
Is the resistance less than 5 ohms between the generator No
and the PCM, and greater than 10,000 ohms between the REPAIR the circuit. TEST the system for
generator and ground? normal operation.
Disconnect all of the PCM connectors. Yes
303-14. REPEAT the self-test. TEST the
corrosion.
pushed-out pins.
Connect all of the PCM connectors and make sure they seat No
the DTCs. REPEAT the self-test. TEST
Possible Causes
Pinpoint Test C: The Charging System
Overcharges (Battery Voltage Is Greater
Fuse
Than 15.5 Volts)
Generator
A circuit 35 (OG/LB)
Normal Operation
The generator output is determined by the voltage
of the A circuit 35 (OG/LB). The A circuit voltage
is compared to a set voltage internal to the regulator
and the regulator controls the generator field current
to maintain the correct generator output. The set
voltage varies with temperature and is typically
higher in cold temperatures and lower in warm
temperatures.
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PINPOINT TEST C: THE CHARGING SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN
15.5 VOLTS)
C1 CHECK THE DTCS IN THE PCM
Check the recorded PCM DTCs from the continuous and manual, GO to C2.
No
GO to C2.
C2 CHECK THE BATTERY VOLTAGE
Disconnect the scan tool.
With the engine running and all of the accessories turned off,
measure the voltage at the battery while varying the engine rpm.
Yes
GO to C3.
No
Is the voltage greater than 15.5 volts? GO to C4.
C3 CHECK FOR A VOLTAGE DROP IN CIRCUIT 35 (OG/LB)
Disconnect: Generator C102a.
Measure the voltage between the generator C102a-3, circuit 35
(OG/LB), harness side and ground.
Yes
CONNECT the generator C102a. GO to
C4.
No
REPAIR the circuit for high resistance.
Is the voltage within 0.5 volt from battery voltage? TEST the system for normal operation.
C4 CHECK THE GENERATOR PIDS
Enter the following diagnostic mode on the scan tool: Monitor
Yes
PCM PIDs.
GO to C5.
With the engine running, monitor the generator output fault PID
in the PCM. No
Does the PID read YES? GO to C6.
(Continued)
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PINPOINT TEST C: THE CHARGING SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN
15.5 VOLTS) (Continued)
C5 CHECK THE GENERATOR INTEGRITY
Disconnect: Generator C102a (4.0L), C133 (4.6L) (in-line
generator harness connector).
Key in ON position, engine OFF.
Measure and record the battery voltage.
NOTE: If the generator communication lines are disconnected
(DTC P0622 may be set), the generator self-excites if it is
operated at greater than 4,500 rpm (approximately wide open
throttle [WOT]) for a minimum of 3 seconds. It then operates in
a default mode at 13.5 volts until the engine is turned off.
With the engine running (after the brief WOT is carried out)
measure the battery voltage.
Yes
GO to C6.
Does the battery voltage increase a minimum of 0.5 volt No
from the key ON, engine off measurement to the key ON, INSTALL a new generator. REFER to
engine running measurement (after the brief WOT or snap Section 414-02. TEST the system for
acceleration is carried out)? normal operation.
Disconnect all of the PCM connectors. INSTALL a new PCM. REFER to Section
Check for: 303-14. REPEAT the self-test. TEST the
corrosion.
pushed-out pins. No
Connect all of the PCM connectors and make sure they seat The system is operating correctly at this
Is the concern still present? the DTCs. REPEAT the self-test. TEST
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Possible Causes
Pinpoint Test D: The Charging System
Warning Indicator is On with the Engine
Generator
Running and the Battery Increases Voltage
Instrument cluster
PCM
Normal Operation
With the engine running, the charging system
warning indicator is off. The sense A circuit 35
(OG/LB) to the generator field coil is 13-15 volts.
The S (stator) circuit (internal to the generator) is
used to feed back a voltage signal from the
generator to the voltage regulator. This voltage is
monitored by the powertrain control module (PCM)
to turn off the charging system warning indicator.
The positive battery output (B+) circuit 2037 (RD)
is the generator output supplied to the battery and
the electrical system.
PINPOINT TEST D: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING AND THE BATTERY INCREASES VOLTAGE
D1 CHECK THE DTCS IN THE PCM
Check the recorded PCM DTCs from the continuous and manual, GO to D2.
No
GO to D2.
D2 CHECK THE SYSTEM FOR OVERCHARGING
With the engine running and all of the accessories off, measure
the voltage at the battery terminals while varying the engine
rpm.
Yes
No
Is the voltage greater than 15.5 volts? GO to D3.
D3 CHECK THE PCM PIDS
Enter the following diagnostic mode on the scan tool: Monitor Yes
PCM PIDs. GO to D4.
With the engine running, monitor the generator output fault PID
No
in the PCM.
REFER to Section 413-01 to diagnose the
Does the PID read YES?
charging system warning indicator.
(Continued)
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PINPOINT TEST D: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING AND THE BATTERY INCREASES VOLTAGE (Continued)
D4 CHECK THE GENERATOR OUTPUT
Verify the generator output. Refer to the Component Tests, Yes
Generator On-Vehicle Tests in this section. GO to D5.
Does the generator pass the component tests?
No
REPEAT the self-test. TEST the system
D5 CHECK FOR CORRECT PCM OPERATION
corrosion.
pushed-out pins. No
Pinpoint Test E: The Charging System Normal Operation
Warning Indicator is Off With the Ignition
Under normal operation, the charging system
Switch in the RUN Position and the Engine
warning indicator is on with the key ON and the
Off
engine off.
Possible Causes
Instrument cluster
PINPOINT TEST E: THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION
SWITCH IN THE RUN POSITION AND THE ENGINE OFF
E1 CHECK THE CHARGING SYSTEM WARNING INDICATOR
OPERATION
Key in ON position.
Yes
GO to E2.
Commands.
Using Active Commands, turn on the charging system warning No
indicator in the instrument cluster. REFER to Section 413-01 to diagnose the
Is the charging system warning indicator on? charging system warning indicator.
corrosion.
pushed-out pins. No
Pinpoint Test F: The Generator is Noisy Normal Operation
The generator is belt-driven by the engine accessory
drive system.
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Possible Causes
Loose bolts/brackets
Drive belt
One-way-clutch (OWC) pulley
Generator/pulley
PINPOINT TEST F: THE GENERATOR IS NOISY
F1 CHECK FOR ACCESSORY DRIVE NOISE AND MOUNTING
BRACKETS
Check the accessory drive belt for damage and correct If equipped with an OWC pulley, GO to
installation. Refer to Section 303-05. F2. If not equipped with a OWC pulley,
Check the accessory mounting brackets and the generator GO to F3.
pulley for looseness or misalignment.
No
Is the accessory drive OK?
F2 CHECK THE OWC PULLEY
With the accessory drive belt removed, spin the OWC pulley in a
clockwise direction, then reverse the direction of the pulley by
Yes
spinning it in a counterclockwise direction. If necessary, refer to
GO to F3.
Section 303-05 for the belt removal.
Does the OWC pulley engage with the rotor when spun in a No
clockwise direction and free-wheel when spun in a INSTALL a new generator assembly with
counterclockwise direction with minimal noise as compared OWC pulley. REFER to Section 414-02.
to a known good vehicle? TEST the system for normal operation.
F3 CHECK THE GENERATOR FOR EXCESSIVE ELECTRICAL
NOISE
Disconnect: Generator C102b (4.0L), C1100a (4.6L) (generator Yes
B+ harness connector at the battery). GO to F4.
No
With the engine running, determine if the generator is still noisy.
Is the noise still present?
normal operation.
F4 CHECK THE GENERATOR FOR MECHANICAL NOISE
Turn all of the accessories off. With the engine running, use a Yes
stethoscope or equivalent listening device to probe the generator INSTALL a new generator. REFER to
for unusual mechanical noise. Section 414-02. TEST the system for
Is the generator the noise source? normal operation.
No
source of the engine noise.
Possible Causes
Pinpoint Test G: Radio Interference
Refer to Wiring Diagrams Cell 12, Charging System Generator
Wiring/routing
Normal Operation
In-vehicle entertainment system
The generator radio suppression equipment reduces
interference transmitted through the speakers by the
vehicle electrical system.
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PINPOINT TEST G: RADIO INTERFERENCE
G1 VERIFY THE GENERATOR IS THE SOURCE OF THE RADIO
INTERFERENCE
NOTE: If the original equipment manufactured (OEM) audio unit has
been replaced with an aftermarket unit, the vehicle may not pass
this test. Return the vehicle to OEM condition before following this
pinpoint test.
Start and run the engine.
Tune the audio unit to a station where the interference is
Yes
present.
REFER to Section 415-00 for diagnosis
and testing of the in-vehicle entertainment
Disconnect: Generator C102b (4.0L), C1100a (4.6L) (generator
system.
B+ harness connector at the battery).
Key in START position. No
With the engine running, determine if the interference is still INSTALL a new generator. REFER to
present. Section 414-02. TEST the system for
Is the interference present with the generator disconnected? normal operation.
Component Tests Check for current drains on the battery in excess of
50 mA (0.050 amp) with all of the electrical
Battery Drain Testing
accessories off and the vehicle at rest for at least 40
minutes. Current drains can be tested with the
WARNING: Do not attempt this test on a
following procedure:
lead-acid battery that has recently been
recharged. Explosive gases may cause personal
1. Make sure the bussed electrical center (BEC)
injury. Failure to follow these instructions may
and smart junction box (SJB) are accessible
without turning on the interior or the underhood
lights.
CAUTION: To prevent damage to the
2. Drive the vehicle at least 5 minutes and over 48
meter, do not crank the engine or operate
km/h (30 mph) to turn on and activate the
accessories that draw more than 10A.
vehicle systems.
NOTE: No factory-equipped vehicle should have
3. Allow the vehicle to sit with the key off for at
more than a 50 milliamps (mA) or 0.050 amp draw.
least 40 minutes to allow the modules to time
NOTE: Many electronic modules draw 10 mA
out/power down.
(0.010 amp) or more continuously.
4. Connect a fused (10A) jumper wire between the
NOTE: Use an in-line ammeter between the
negative battery cable and the negative battery
negative battery post and its respective cable.
post to prevent the modules from resetting and
NOTE: Typically, a drain of approximately one
to catch capacitive drains.
amp can be attributed to an engine compartment
5. Disconnect the negative battery cable from the
lamp, glove compartment lamp, or an interior lamp
negative battery post without breaking the
staying on continually. Other component failures or
connection of the jumper wire.
wiring shorts are located by selectively pulling fuses
6. NOTE: It is very important that continuity is
to pinpoint the location of the current drain. When
not broken between the negative battery cable
the current drain is found, the meter reading falls to
and the negative battery post when connecting
an acceptable level. If the drain is still not located
the meter. If this happens, the entire procedure
after checking all of the fuses, it is due to the
must be repeated.
generator.
Connect the battery tester between the negative
NOTE: To accurately test the drain on a battery,
battery cable and the post. The meter must be
an in-line ammeter must be used. Use of a test lamp
capable of reading milliamps and should have a
or voltmeter is not an accurate method due to the
10 amp capability.
number of electronic modules.
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Generator On-Vehicle Tests
7. NOTE: If the meter settings need to be
switched or the test leads need to be moved to
CAUTION: To prevent damage to the
another jack, the jumper wire must be
generator, do not make the jumper wire
reinstalled to avoid breaking continuity.
connections except as directed.
Remove the jumper wire.
CAUTION: Do not allow any metal object
8. NOTE: Amperage draw varies from vehicle to
to come in contact with the housing and the
vehicle depending on the equipment package.
internal diode cooling fins with the key in the
Compare to a similar vehicle for reference.
ON or OFF positions. A short circuit may result
NOTE: No factory-equipped vehicle should
and burn out the diodes.
have more than a 50 mA (0.050 amp) draw.
NOTE: Battery posts and cable clamps must be
Note the amperage draw.
clean and tight for accurate meter indications.
9. If the draw is found to be excessive, remove
NOTE: Refer to the battery tester manual for
the fuses from the SJB one at a time and note
complete directions for testing the charging system.
the current reading. Do not reinstall the fuses
1. Turn off all of the lamps and the electrical
until you have finished testing. To properly
components.
isolate each of the circuits, all of the fuses may
2. Place the transmission in NEUTRAL and apply
need to be removed and install one fuse, note
the parking brake.
the amperage draw, then remove the fuse and
install the next fuse, until all of the circuits are 3. Carry out the Load Test and No Load Test
checked. When the current level drops to an according to the following component tests:
acceptable level after removing a fuse, the
Generator On-Vehicle Tests Load Test
circuit containing the excessive draw has been
located. 1. Switch the tester to the ammeter function.
10. If the current draw is still excessive, remove the 2. Connect the positive and negative leads of the
fuses from the BEC one at a time and note the tester to the corresponding battery terminals.
current drop. Do not reinstall the fuses until
3. Connect the current probe to the generator B+
you have finished testing. To properly isolate
output terminal, circuit 2037 (RD).
each of the circuits, all of the fuses may need
4. With the engine running at approximately 2,000
to be removed and install one fuse, note the
rpm, adjust the tester load bank to determine
amperage draw, then remove the fuse and
the output of the generator. The generator
install the next fuse, until all of the circuits are
output should be greater than the graph shown
checked. When the current level drops to an
below. If not, refer back to the pinpoint test or
acceptable level after removing a fuse, the
circuit containing the excessive draw has been
located.
11. Check the Wiring Diagrams for any circuits that
run from the battery without passing through
the BEC/SJB. If the current draw is still
excessive, disconnect these circuits until the
draw is found. Also, disconnect the generator
electrical connections if the draw can not be
located. The generator may be internally
shorted, causing the current drain.
Generator On-Vehicle Tests No Load Test
1. Switch the tester to the voltmeter function.
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2. Connect the voltmeter positive lead to the 4. With the engine running at approximately 2,000
generator B+ output terminal, circuit 2037 (RD) rpm, check the generator output voltage. The
and the negative lead to ground. voltage should be between 13.2 and 15.5 volts.
If not, refer back to the pinpoint test or GO to
3. Turn all of the electrical accessories off.
Symptom Chart.
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414-02-1 414-02-1 Generator and Regulator
Generator 4.0L SOHC
5 Generator B+ terminal (part 1 6B209 Front end accessory drive belt
of 14B060) tensioner
6 W520414 Generator stud nut 2 8620 Front end accessory drive belt
7 W606068 Generator bolts (2 required) 3 Generator electrical connector
(part of 12B637)
8 10300 Generator
4 W705790 Generator B+ terminal nut
(Continued)
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4. Position the generator B+ protective boot aside,
remove the nut and position the generator B+
terminal aside.
2. Rotate the front end accessory drive belt
5. Remove the generator stud nut.
tensioner counterclockwise and position the
front end accessory drive belt aside.
6. Remove the 2 bolts and the generator.
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Generator 4.6L (3V)
5 N807309-S Generator bracket bolts 1 6B209 Front end accessory drive belt
(inner) (2 required) tensioner
6 Generator harness locator 2 8620 Front end accessory drive belt
(part of 14305)
3 Generator bolts (2 required)
7 10153 Generator bracket
4 N807309-S Generator bracket bolts
8 Generator electrical connector (outer) (2 required)
(part of 14305)
(Continued)
(Continued)
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5. Remove the 2 generator bolts.
9 W705790-S Generator B+ terminal nut To install, tighten to 25 Nm (18 lb-ft).
10 Generator B+ terminal (part
6. Remove the 2 outer generator bracket bolts and of 14305)
position the generator aside.
11 10300 Generator
7. Remove the 2 inner generator bracket bolts.
8. Remove the generator harness locator and
2. Press the lock tab, remove the crankcase vent
remove the generator bracket.
tube from the air cleaner outlet pipe and
position it aside. 9. Disconnect the generator electrical connector.
3. Loosen the clamp, remove the air cleaner outlet 10. Position the generator B+ protective boot aside,
pipe from the throttle body and position it remove the nut and position the generator B+
aside. terminal aside.
tensioner clockwise and position the front end
11. Remove the generator.
accessory drive belt aside.
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Generator 5.4L (4V)
5 Power steering fluid line 1 Generator electrical connector
bracket (part of 12B637)
6 W704893 Lower generator bolt 2 Generator B+ terminal (part
of 14B060)
7 N805424 Upper generator bolts (2
required) 3 W705790 Generator B+ terminal nut
8 10300 Generator 4 W520111 Generator stud nut
(Continued)
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5. Remove the lower generator bolt.
7. Position the generator B+ protective boot aside,
tensioner clockwise and position the front end
remove the nut and position the generator B+
accessory drive belt aside.
terminal aside.
3. Remove the 2 upper generator bolts.
8. Remove the generator.
4. Remove the power steering line bracket nut and
position the bracket aside.
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Vehicles equipped with 4.6L 3V have a one-way
Generator
clutch (OWC) in the generator pulley. The OWC
The charging system consists of the:
pulley temporarily disengages the generator rotor
generator. from the front end accessory drive (FEAD) system
during high deceleration rates on the engine. This
internal voltage regulator.
may decrease noise/vibration/harshness (NVH) (belt
The generator has an internal voltage regulator that
chirp) and may increase belt life. A new OWC
is not installed separately. A new generator and
pulley and generator/regulator must be installed as
voltage regulator must be installed as an assembly.
an assembly.
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Generator
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SPECIFICATIONS
Item Specification
Generator amps 80/135 amps (max) @
Item Specification 1,800-6,000 generator
rpm, approximately
Voltage 12 volts
500-2,000 engine rpm
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SPECIFICATIONS
Battery ground cable 25 18
Item Specification engine terminal nut
(4.6L, 5.4L)
Battery
Voltage 12 volts
terminal nut
Cold cranking amps 500 CCA
Battery hold-down bolt 8 71
(CCA) measured at 590 CCA
-18C (0F) Battery tray bolts 11 8
Battery amps rating 52 amp/hr Bussed electrical center 20 15
60 amp/hr (BEC) terminal bolt
nut (4.0L)
Generator harness 8 71
terminal nut (4.6L,
5.4L)
Battery cable harness 27 20
bracket bolt (4.0L)
Starter solenoid 12 9
positive cable terminal
Battery cable terminal 5 44
nut
bolts
Starter solenoid wire 5 44
terminal nut (4.0L)
body bolt
engine terminal bolt
(4.0L)
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SPECIFICATIONS
Item Specification nut
Generator (4.0L) Generator bolts (4.6L) 25 18
Rating 80/135 amp (max) @ Generator bolts/stud 48 35
1,800-6,000 generator nut (4.0L)
rpm, approximately
Generator bracket bolts 10 89
(4.6L)
Generator pulley ratio 2.59:1
Lower generator stud 25 18
Voltage regulator type Electronic internal with nut (5.4L)
generator
Upper/lower generator 48 35
Generator (4.6L, 5.4L) bolts (5.4L)
Rating 80/135 amp (max) @
1,800-6,000 generator
rpm, approximately
Generator pulley ratio 2.72:1
Voltage regulator type Electronic internal with
generator
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415-02-1 415-02-1 Antenna
Antenna Satellite Radio
2. Remove the satellite radio antenna.
Disconnect the electrical connector. 1 Satellite radio antenna cable
Remove the antenna and wiring through the
19B516)
hole in the luggage compartment lid.
2 Satellite radio antenna bolt
(part of 18C964)
3 18C964 Satellite radio antenna
1. Loosen the satellite radio antenna bolt.
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415-02-1 415-02-1 Antenna
Antenna Base
3. Lower the glove compartment door.
1 19A136 Antenna in-line connector
4. Disconnect the antenna in-line connector.
2 18A984 Antenna cable grommet (part
of 18A984)
5. Push the antenna cable grommet through the
3 18813 Antenna mast
bulkhead.
4 18A927 Antenna base cover
6. Remove the antenna base cover. 5 W710248 Antenna base screws (3
required)
7. Remove the 3 screws and the antenna base and
6 18A984 Antenna base
cable.
1. Remove the antenna mast.
2. Remove the fender splash shield. For additional
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415-02-1 415-02-1 Antenna
Antenna Lead-In Cable
2. Lower the glove compartment door.
1 19A136 Antenna in-line connector
3. Disconnect the antenna in-line connector.
2 Pin-type retainers (part of
18812)
4. Disconnect the pin-type retainers and remove
3 18812 Antenna lead-in cable
the antenna lead-in cable.
1. Remove the audio unit. For additional
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415-02-1 415-02-1 Antenna
The satellite antenna (if equipped) consists of a
Antenna
roof-mounted antenna capable of receiving digital
The antenna system consists of:
satellite audio signals. A one-piece antenna cable
Antenna mast connects the satellite antenna to the satellite radio
receiver. The cable is part of the luggage
Antenna base cover
compartment lid harness and cannot be replaced
Antenna base and cable
separately.
Antenna lead-in cable
The radio antenna uses a 2-piece coaxial cable to
connect the audio unit to the antenna. The front
antenna lead-in cable is connected to the audio unit
and has an in-line connector behind the glove
compartment.
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415-02-1 415-02-1 Antenna
Antenna
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415-00-1 415-00-1 Entertainment System General Information
Subwoofers
Audio System
The subwoofer speakers on the 500-watt system are
Special Tool(s)
located in the front doors and are powered by
individual amplifiers located on each speaker. In 73III Automotive Meter
105-R0057 or equivalent addition to these subwoofer speakers, the 1000-watt
system includes an enclosure with 2 subwoofer
speakers powered by 2 amplifiers, each. The
enable/clip circuit carries out 2 functions: to turn on
the subwoofer amplifier, and to monitor an overload
condition to the subwoofer amplifier. In the event of
an overload, the audio unit clips the audio output
(VCM) and Integrated signal to the subwoofer amplifier (heard as
distortion).
Satellite Audio
tool
The satellite audio system consists of a satellite
radio receiver, a satellite radio antenna, and antenna
cable (part of the decklid harness). The satellite
Flex Probe Kit
radio antenna receives digital audio signals and 105-R025C or equivalent
sends them to the satellite radio receiver, where the
signals are converted and sent to the audio unit. The
wake-up signal for the satellite radio receiver is sent
from the audio unit through the controller area
network (CAN).
Audio Input Jack
The audio input jack allows for a portable MP3
Audio Unit
player to be connected to the vehicle audio system.
NOTE: The audio unit is also referred to as the
When a portable MP3 player is connected, audio
audio control module.
from the MP3 player can be played through the
vehicle speakers.
The audio unit can be powered up when the ignition
is in the ON or ACC position. When on, the audio
unit directs audio signals to the speakers through
separate positive and negative circuits for each of
the audio channels. The audio unit provides
internal circuit protection for shorts to ground, of mechanical or electrical damage.
shorts to voltage, or shorts between any output
circuits.
Noise Suppression Equipment
The radio interference suppression equipment
reduces interference transmitted through the
speakers by the engine ignition and electrical
systems.
Antenna
The antenna is a fixed mast antenna mounted on the
exterior of the vehicle. The antenna receives both
AM and FM radio waves. The audio signals are
then sent to the audio unit through the antenna
cables.
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Mechanical Electrical If the scan tool responds with no
Audio unit Smart junction box
Antenna or antenna (SJB) fuse(s): refer to Section 418-00.
cable(s) 6 (5A) (audio unit)
Satellite radio antenna 20 (10A) (audio
Speakers, unit)
trouble codes (DTCs). mounting/speaker cones Bussed electrical center
Radio ignition (BEC) fuse(s):
interference capacitors, 6 (30A) (luggage
self-test diagnostics for the audio unit.
radio frequency compartment
interference suppression amplifiers)
bond, and radio receiver 9 (30A) (luggage
go to the Audio Unit Diagnostic Trouble Code
hood bonding strap compartment
(DTC) Index or the Satellite Radio Receiver
amplifiers)
Diagnostic Trouble Code (DTC) Index.
16 (30A) (door
amplifiers)
56 (20A) (audio
go to the Speaker Walk-Around Test, the Audio
unit, satellite radio
Unit Self-Diagnostic Mode, or the Satellite
receiver)
Audio Bezel Diagnostic Test.
Circuitry
Speaker Walk-Around Test
NOTE: To enter the speaker walk-around test or
audio unit self-diagnostic mode, the audio unit must
be on and in radio tuner mode (AM/FM).
1. To enter the speaker walk-around test,
software release.
simultaneously press and hold the audio unit
preset buttons 3 and 6.
2. The speaker walk-around test stops at each
speaker and applies sound to each speaker for
about 1-2 seconds. Each speaker is tested and
displayed on the audio unit in the following
VCM.
sequence: RF, LF, LR, RR, and SUBWOOFER.
3. To exit the speaker walk-around test, turn the
VCM:
key to OFF, turn the audio unit off, or press
preset button 1 for diagnostics (DIA).
Audio Unit Self-Diagnostic Mode
NOTE: To enter the audio unit self-diagnostic
mode, the audio unit must be on and in radio tuner
with the scan tool.
mode (AM/FM).
1. To enter the following tests, press the desired
vehicle:
preset button while in the speaker walk-around
test.
position.
2. To exit the audio unit self-diagnostic mode,
turn the key to OFF or turn the audio unit off.
good vehicle.
3. If the concern remains and the fault is not
detected, GO to Symptom Chart.
(PCM).
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Satellite Audio Bezel Diagnostic Test
4. The self-diagnostic mode has the following
functions available:
NOTE: To enter the audio unit self-diagnostic
mode, the audio unit must be on and in SAT mode.
Preset button 1 = On-Demand Self-Test.
This button runs the on-demand self-test.
1. To enter the satellite audio bezel diagnostic test,
simultaneously press and hold the AUX button X Pressing the MENU DOWN button
and preset button 2.
allows scrolling of any DTCs found
during the test while in this menu.
2. Upon entering the self-test, the audio unit
produces 2 continuously alternating tones of
Preset button 2 = Display Continuous DTCs.
different pitch, one for the right channel, then
This button enables viewing of any
one for the left.
continuous DTCs that have been logged.
3. The test continues by displaying any DTCs X Pressing the MENU UP button allows
currently present. If no DTCs are present, NO
scrolling of any DTCs while in this
DTCS will be displayed. If there are DTCs
menu.
present, the audio unit will auto-scroll through
X While continuous DTCs are being
the list of active DTCs.
displayed, pressing the EJECT button will
4. Historical DTCs can be viewed by pressing the
clear all present DTCs. The key must be
AUX button and preset button 2 simultaneously
cycled OFF, then ON, to permanently
while in the active DTC mode.
clear DTCs.
If any DTCs are present, pressing the AUX
Preset button 3 = Signal Strength Test. This
button and preset button 2 will prompt
button displays the signal strength.
CLEAR DTCS? on the audio unit.
Preset button 4 = Software Version Display.
To clear historical DTCs, press preset
This button displays the audio unit software
buttons 1, 2, and 3 consecutively within 4
version.
seconds.
X Pressing the MENU UP button allows
To exit historical DTCs (with or without
scrolling of all audio subsystem software
clearing DTCs), press the AUX button and
versions while in this menu.
preset button 2 simultaneously.
Preset button 5 = Display Test. This test
5. If no historical DTCs are present, pressing the
illuminates all the display segments for 5
AUX button and preset button 2 simultaneously
seconds, then either turns all segments off or
while in active DTC mode will display the DLP
indicates DISPLAY TEST on the screen.
software version.
Preset button 6 = Configuration Status. This
6. To exit the satellite audio bezel diagnostic test,
button enables audio unit configuration
press the AUX button and preset button 2
status.
simultaneously while the DLP software version
X Pressing the MENU UP button displays
is displayed, or turn the audio unit off.
the ACM part number while in this
menu.
5. To exit the self-diagnostic mode, turn the key
to OFF or turn the audio unit off.
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Audio Unit Diagnostic Trouble Code (DTC) Index
B1117 Audio Steering Wheel Button Stuck DTC is not applicable. The vehicle is not
equipped with steering wheel controls.
DISREGARD the DTC. CLEAR the DTCs.
DTC B1318 is retrieved again, REFER to
Section 414-00 to diagnose the low battery
voltage condition.
B1342 ECU is Faulted CLEAR the DTCs. REPEAT the self-test. If
DTC B1342 is retrieved again, REMOVE the
audio unit and SEND it to an authorized audio
system repair facility. REFER to Section 415-01.
TEST the system for normal operation after the
repair.
B2103 Antenna Not Connected GO to Pinpoint Test A.
B2274 Phone Transceiver Active Circuit Failure DTC is not applicable. The vehicle is not
equipped with cellular phone functionality.
B2384 Audio Reverse Aid Mute Input Ckt Failure DTC is not applicable. The vehicle is not
equipped with parking aid. DISREGARD the
DTC. CLEAR the DTCs. REPEAT the self-test.
B2404 Audio Steering Wheel Switch Circuit Fault DTC is not applicable. The vehicle is not
B2405 Audio Disc CD Player Thermal Shutdown Fault ALLOW the unit to cool. DISREGARD the
B2406 Audio Disc CD Player Internal Fault CLEAR the DTCs. REPEAT the self-test. If
repair.
B2477 Module Configuration Failure REFER to Section 418-01 to diagnose the
module configuration.
B2924 Audio Button Stuck VERIFY no audio unit buttons are stuck.
CLEAR the DTCs. REPEAT the self-test. If
system repair facility. REFER to Section
415-01. TEST the system for normal operation
after the repair.
B2965 Audio System Speaker Circuit Fault GO to Pinpoint Test B.
C1992 Vehicle Speed Circuit Failure VERIFY the audio unit is configured to receive
the vehicle speed signal through the medium
speed controller area network (MS-CAN).
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Audio Unit Diagnostic Trouble Code (DTC) Index (Continued)
NOTE: Diagnose DTC B1318 (if present) U0140 Lost Communication With Body Control
before diagnosing DTC U0140.
Module (GEM)
VERIFY the operation of the vehicle
illumination and the accessory delay.
If the vehicle illumination or accessory delay
does not operate correctly, REFER to
Section 413-00 (illumination) or Section
501-11 (accessory delay).
If the vehicle illumination and accessory
delay operate correctly, REMOVE the audio
unit and SEND it to an authorized audio
operation after the repair.
NOTE: Diagnose DTC B1318 (if present)
U0155 Lost Communication With Instrument Panel
Cluster (IC) Control Module
VERIFY the operation of the speedometer.
If the speedometer operates correctly,
REMOVE the audio unit and SEND it to an
authorized audio system repair facility.
REFER to Section 415-01. TEST the system
for normal operation after the repair.
If the speedometer does not operate
correctly, REFER to Section 413-01.
U0159 Lost Communication With Parking Assist DTC is not applicable. The vehicle is not
Control Module (PAM) equipped with parking aid. DISREGARD the
U0193 Lost Communication With Digital Audio GO to Pinpoint Test F.
Control Module (SDARS)
U0196 Lost Communication With Entertainment DTC is not applicable. The vehicle is not
Control Module - Rear (AUX) equipped with rear audio controls. DISREGARD
the DTC. CLEAR the DTCs. REPEAT the
self-test.
U0197 Lost Communication With Telephone Control DTC is not applicable. The vehicle is not
Module equipped with cellular phone functionality.
U0238 Lost Communication With Digital Audio DTC is not applicable. The vehicle is not
Control Module D (DSP) equipped with a DSP module. DISREGARD the
Control Module - Rear B (RCU) equipped with rear audio controls. DISREGARD
self-test.
U2050 No Application Present CONFIGURE the audio unit. REFER to Section
418-01 to carry out programmable module
installation (PMI). CLEAR the DTCs. REPEAT
the self-test. If DTC U2050 is retrieved again,
authorized audio system repair facility. REFER
to Section 415-01. TEST the system for normal
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U2051 One or More Calibration Files Missing/Corrupt CONFIGURE the audio unit. REFER to Section
418-01 to carry out PMI. CLEAR the DTCs.
REPEAT the self-test. If DTC U2051 is
retrieved again, REMOVE the audio unit and
SEND it to an authorized audio system repair
facility. REFER to Section 415-01. TEST the
system for normal operation after the repair.
Satellite Radio Receiver Diagnostic Trouble Code (DTC) Index
NOTE: While running the satellite audio bezel diagnostic test, DTCs contain the characters
SAT after the 5-digit DTC.
B1031 SDARS Satellite Antenna Open GO to Pinpoint Test G.
B1032 SDARS Satellite Antenna Short GO to Pinpoint Test G.
Section 414-00 to diagnose the low battery
voltage condition.
satellite radio receiver and SEND it to an
U0184 Lost Communication With Radio (ACM) DISREGARD the DTC. CLEAR the DTC.
self-test.
self-test.
U2050 No Application Present CONFIGURE the satellite radio receiver.
REFER to Section 418-01 to carry out PMI.
DTC U2050 is retrieved again, REMOVE the
satellite radio receiver and SEND it to an
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Symptom Chart
Symptom Chart
No communication with the Fuse REFER to Section 418-00.
audio unit Circuitry
Audio unit
satellite radio receiver Circuitry
Audio unit
The audio unit is Circuitry GO to Pinpoint Test F.
inoperative/does not operate Satellite radio receiver
correctly satellite audio Audio unit
The audio unit is Circuitry REFER to Section 419-07.
inoperative/does not operate Audio unit
correctly navigation
The audio unit backlighting Module configuration VERIFY the audio unit is
does not operate correctly Circuitry configured for network-based
Audio unit illumination.
If the audio unit is
configured correctly,
REFER to Section
413-00, to diagnose a
single illumination
source inoperative.
If the audio unit is not
configured correctly,
CONFIGURE the audio
unit. REFER to Section
418-01, to carry out
programmable module
installation (PMI). TEST
the system for normal
operation.
Poor reception AM/FM Antenna GO to Pinpoint Test A.
Antenna cable(s)
Charging system
Ignition system
Noise suppression equipment
Audio unit
Poor reception satellite Obstructions to the line of DRIVE the vehicle to an
audio sight open area and TEST the
reception.
If the reception is OK,
INFORM the customer
of the normal condition.
If the reception is not
OK, GO to Pinpoint
Test G.
Satellite antenna GO to Pinpoint Test G.
Satellite antenna cable
Satellite radio receiver
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Continuous seek/scan in RDS function setting VERIFY the RDS is set to
AM/FM ALL SCAN.
If a good channel is
found, the cause of the
concern was that no
RDS channel in the
selected category was
found. The system is
OK.
If a good channel is not
found, GO to Pinpoint
Test A.
Antenna cable(s) GO to Pinpoint Test A.
Antenna
Audio unit
Poor quality/distorted/no Circuitry GO to Pinpoint Test B.
sound from one or more Speaker
speakers (not all speakers) Audio unit
except subwoofers
Poor quality/distorted/no Circuitry With the key in any position
sound from all speakers Audio unit except START, MEASURE
the voltage between the audio
unit C290d-15, circuit 1000
(RD/BK), harness side and
ground.
If any voltage is present,
REPAIR the circuit.
TEST the system for
normal operation.
If no voltage is present,
REMOVE the audio unit
and SEND it to an
authorized audio system
repair facility. REFER to
Section 415-01. TEST
operation after the
repair.
The subwoofer is Fuse GO to Pinpoint Test C.
inoperative/does not operate Circuitry
correctly front subwoofers Subwoofer amplifier
Front subwoofer
Audio unit
The subwoofer is Fuse GO to Pinpoint Test D.
inoperative/does not operate Circuitry
correctly rear subwoofers Subwoofer amplifier
Rear subwoofer
Audio unit
Loud popping sound when Fuse GO to Pinpoint Test E.
cycling the ignition switch Circuitry
Subwoofer amplifier
Audio unit
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The speed sensitive volume Instrument cluster CHECK for audio unit DTCs.
does not operate correctly. Audio unit If DTC U0155 is
present, REFER to the
Audio Unit Diagnostic
Trouble Code (DTC)
Chart.
If no DTCs related to
the concern are present,
REMOVE the audio unit
and SEND it to an
authorized audio system
repair facility. REFER to
Section 415-01. TEST
operation after the
repair.
The audio unit is Circuitry GO to Pinpoint Test H.
inoperative/does not operate Audio input jack
correctly audio input jack Audio unit
Antenna
Pinpoint Test A: Poor Reception AM/FM
Antenna cable(s)
Normal Operation
Charging system
The noise suppression equipment reduces
interference transmitted through the speakers by the Ignition system
engine ignition and electrical systems.
DTC B2103 sets when an open is detected in the
Audio unit
antenna circuit.
PINPOINT TEST A: POOR RECEPTION AM/FM
A1 REVIEW THE DTCs
Review the DTCs from the audio unit self-test. Yes
Is DTC B2103 present? GO to A7.
No
GO to A2.
A2 CHECK THE AUDIO UNIT RECEPTION
Check the audio unit signal reception with the engine running, Yes
and with the engine off. GO to A3.
Does the poor reception only occur with the engine
No
running?
GO to A7.
A3 CHECK THE SUPPRESSION EQUIPMENT/MOUNTING AND
CONNECTING CIRCUITS
Check all necessary suppression equipment and the radio
frequency interference suppression bond.
NOTE: The capacitor mounting points are used to complete the
electrical circuit and must be mounted securely to clean
Yes
surfaces.
GO to A4.
Check the mounting and connecting circuits of the radio
interference capacitor for integrity, cleanliness, and No
metal-to-metal contact. CLEAN, SECURE, or INSTALL new
Are the connections clean, secure, and in metal-to-metal suppression equipment as necessary.
contact? TEST the system for normal operation.
(Continued)
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PINPOINT TEST A: POOR RECEPTION AM/FM (Continued)
A4 CHECK THE RADIO INTERFERENCE CAPACITOR
Check the operation of the radio interference capacitor by Yes
installing a known good component. INSTALL a new radio interference
Start the vehicle. capacitor. TEST the system for normal
Operate the audio unit in radio tuner mode. operation.
Is the reception OK?
No
INSTALL the original radio interference
capacitor. GO to A5.
A5 CHECK THE GENERATOR
Check the generator by disconnecting the voltage regulator. INSTALL a new generator. REFER to
Start the vehicle. Section 414-02. TEST the system for
Operate the audio unit in radio tuner mode. normal operation.
No
TURN the key to OFF. CONNECT the
voltage regulator. GO to A6.
A6 CHECK THE IGNITION CIRCUITS
Check the ignition circuits for correct routing, ground, and Yes
integrity of connections. GO to A10.
Check the spark plugs and ignition coils.
No
Are the ignition components OK?
REPAIR the ignition system as necessary.
A7 CHECK THE ANTENNA GROUND
Measure the resistance between the antenna base and the GO to A9.
battery ground cable.
No
Is the resistance less than 5 ohms?
GO to A8.
A8 CHECK THE ANTENNA CABLE CONNECTIONS
Check the antenna connections, including the extension cable. Yes
Check to make sure the antenna is securely mounted to the GO to A9.
vehicle body at ground points.
No
Are the connections clean, secure, and in metal-to-metal
CLEAN and SECURE the antenna
contact?
connections as necessary. CLEAR the
A9 SUBSTITUTE THE ANTENNA
Substitute a known good antenna. Yes
Key in ON position. INSTALL a new antenna. CLEAR the
Operate the audio unit in radio tuner mode. DTCs. REPEAT the self-test.
No
TURN the key to OFF. INSTALL the
original antenna. GO to A10.
A10 SUBSTITUTE THE ANTENNA CABLE
Substitute a known good antenna cable. Yes
Key in ON position. INSTALL a new antenna cable. REFER to
Operate the audio unit in radio tuner mode. Section 415-02. CLEAR the DTCs.
Is the reception OK? REPEAT the self-test.
No
TURN the key to OFF. INSTALL the
original antenna cable. GO to A11.
A11 SUBSTITUTE THE AUDIO UNIT
Substitute a known good audio unit. Yes
Start the vehicle. SEND the original audio unit to an
Operate the audio unit in radio tuner mode. authorized audio system repair facility.
Is the reception OK? TEST the system for normal operation
after the repair.
No
INSTALL the original audio unit. GO to
A12.
(Continued)
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PINPOINT TEST A: POOR RECEPTION AM/FM (Continued)
A12 REPOSITION THE COMPONENTS
Determine if the concern can be corrected by repositioning the Yes
antenna extension cable, speaker circuits, or audio unit power Permanently REPOSITION the
feed circuits away from other circuits and brackets. components as needed. TEST the system
Start the vehicle. for normal operation.
Operate the audio unit in radio tuner mode.
No
GROUND various parts of the vehicle to
the frame using a jumper cable (for
example: engine, fenders, quarter panels,
stone deflectors, body sheet metal). When
the concern is corrected, PROVIDE a
permanent ground where necessary.
Pinpoint Test B: Poor Quality/Distorted/No
Circuit 1723 (OG/LG) open, short to ground or
Sound from One or More Speakers (Not All
voltage
Speakers) Except Subwoofers
Circuit 1725 (TN/YE) open, short to ground or
Refer to Wiring Diagrams Cell 130, Audio
voltage
System/Navigation for schematic and connector
Circuit 1726 (GY/LB) open, short to ground or
information.
voltage
Normal Operation
Circuit 1777 (DG/OG) open, short to ground or
The audio unit directs the audio signals to the
voltage
speakers through separate positive and negative
Circuit 1778 (WH/LG) open, short to ground or
circuits for each of the audio channels. The audio
voltage
unit provides internal circuit protection for shorts to
Circuit 1780 (BN/PK) open, short to ground or
ground, shorts to voltage, or shorts between any
voltage
output circuits.
Circuit 1781 (OG/RD) open, short to ground or
DTC B2965 sets when a short to ground is
voltage
detected on any of the speaker circuits. For all
audio units except single CD, DTC B2965 also sets
Speaker
when an open circuit or short to voltage is detected.
Audio unit
Possible Causes
Circuit 1722 (LB/WH) open, short to ground or
voltage
PINPOINT TEST B: POOR QUALITY/DISTORTED/NO SOUND FROM ONE OR MORE SPEAKERS (NOT
ALL SPEAKERS) EXCEPT SUBWOOFERS
B1 CHECK THE SPEAKER CIRCUITS FOR VOLTAGE
Disconnect: Suspect Speaker.
Key in ON position.
Measure the AC voltage between the suspect speaker pin 1 and
pin 2, harness side as follows:
(Continued)
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ALL SPEAKERS) EXCEPT SUBWOOFERS (Continued)
B1 CHECK THE SPEAKER CIRCUITS FOR VOLTAGE (Continued)
Connector-Pin/ Connector-Pin/
Suspect Speaker Circuit Circuit
LH front C523-1 C523-2
1723 (OG/LG) 1722 (LB/WH)
RH front C612-1 C612-2
1778 (WH/LG) 1777 (DG/OG)
LH rear C484-1 C484-2 Yes
INSTALL a new speaker for the suspect
1726 (GY/LB) 1725 (TN/YE)
speaker. REFER to Section 415-03.
RH rear C485-1 C485-2 CLEAR the DTCs. REPEAT the speaker
walk-around test.
1781 (OG/RD) 1780 (BN/PK)
No
Is an alternating AC voltage present? GO to B2.
B2 CHECK THE SPEAKER CIRCUITS FOR A SHORT TO VOLTAGE
Disconnect: Audio Unit C290d.
Key in ON position.
Measure the voltage between the suspect speaker, harness side
Suspect Speaker Connector-Pin Circuit
LH front C523-1 1723 (OG/LG)
C523-2 1722 (LB/WH)
RH front C612-1 1778 (WH/LG)
C612-2 1777 (DG/OG)
LH rear C484-1 1726 (GY/LB)
Yes
C484-2 1725 (TN/YE)
RH rear C485-1 1781 (OG/RD) DTCs. REPEAT the speaker walk-around
test.
C485-2 1780 (BN/PK)
No
B3 CHECK THE SPEAKER CIRCUITS FOR AN OPEN OR SHORT
TO GROUND
Measure the resistance between the suspect speaker, harness
side and the audio unit, harness side; and between the suspect
speaker, harness side and ground as follows:
(Continued)
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ALL SPEAKERS) EXCEPT SUBWOOFERS (Continued)
B3 CHECK THE SPEAKER CIRCUITS FOR AN OPEN OR SHORT
TO GROUND (Continued)
Speaker Audio Unit
Suspect Connector- Connector-
Speaker Pin Pin Circuit
LH front C523-1 C290d-8 1723 (OG/LG)
LH front C523-2 C290d-21 1722 (LB/WH)
RH front C612-1 C290d-11 1778 (WH/LG)
RH front C612-2 C290d-12 1777 (DG/OG)
LH rear C484-1 C290d-9 1726 (GY/LB)
LH rear C484-2 C290d-22 1725 (TN/YE)
RH rear C485-1 C290d-10 1781 (OG/RD)
Yes
GO to B4.
RH rear C485-2 C290d-23 1780 (BN/PK)
No
Is the resistance less than 5 ohms between the suspect REPAIR the circuit in question. CLEAR the
speaker and the audio unit, and greater than 10,000 ohms DTCs. REPEAT the speaker walk-around
between the suspect speaker and ground? test.
B4 CHECK FOR CORRECT AUDIO UNIT OPERATION
Disconnect the audio unit connectors. Yes
Check for: REMOVE the audio unit and SEND it to
corrosion an authorized audio system repair facility.
damaged pins REFER to Section 415-01. TEST the
pushed-out pins system for normal operation after the
Connect the audio unit connectors and make sure they seat repair.
correctly.
No
Operate the system and determine if the concern is still present.
Possible Causes
Pinpoint Test C: The Subwoofer is
Inoperative/Does Not Operate Correctly
Fuse
Front Subwoofer
Circuit 167 (BN/OG) open, short to ground or
voltage
Circuit 168 (RD/BK) open, short to ground or
information.
voltage
Normal Operation
Circuit 173 (DG/VT) open or short to ground
The front subwoofers are powered by a separate
Circuit 804 (OG/LG) open, short to ground or
subwoofer amplifier for each subwoofer speaker.
voltage
The enable/clip circuit 173 (DG/VT) carries out 2
functions: to turn on the subwoofer amplifiers, and
monitor an overload condition to the subwoofer
voltage
amplifier. In the event of an overload, the audio unit
Circuit 811 (DG/OG) open, short to ground or
clips the audio output signal to the subwoofer
voltage
amplifiers (heard as distortion). The front subwoofer
amplifiers receive voltage through circuit 829
voltage
(WH/VT), and ground through circuit 1204
(BK/OG).
Circuit 815 (LG/OG) open, short to ground or
voltage
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Circuit 816 (LG/VT) open, short to ground or Circuit 829 (WH/VT) open
voltage
Circuit 1204 (BK/OG) open
Circuit 819 (LG/WH) open, short to ground or
Subwoofer amplifier
voltage
Subwoofer
Circuit 820 (DB/YE) open, short to ground or
Audio unit
voltage
PINPOINT TEST C: THE SUBWOOFER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY FRONT
SUBWOOFER
C1 CHECK CIRCUIT 829 (WH/VT) FOR VOLTAGE
Disconnect: Left Front Subwoofer Amplifier C2993a and Right
Front Subwoofer Amplifier C2994a.
Measure the voltage between the left front subwoofer amplifier
C2993a-5, circuit 829 (WH/VT), harness side and ground; and
between the right front subwoofer amplifier C2994a-5, circuit
829 (WH/VT), harness side and ground.
Yes
GO to C2.
No
REPAIR the circuit in question. TEST the
Are the voltages greater than 10 volts? system for normal operation.
C2 CHECK CIRCUIT 1204 (BK/OG) FOR AN OPEN
Measure the resistance between the left front subwoofer
amplifier C2993a-2, circuit 1204 (BK/OG), harness side and
ground; and between the right front subwoofer amplifier
C2994a-2, circuit 1204 (BK/OG), harness side and ground.
Yes
GO to C3.
No
C3 CHECK CIRCUIT 173 (DG/VT) FOR VOLTAGE
Key in ON position.
(Continued)
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SUBWOOFER (Continued)
C3 CHECK CIRCUIT 173 (DG/VT) FOR VOLTAGE (Continued)
C2993a-1, circuit 173 (DG/VT), harness side and ground; and
173 (DG/VT), harness side and ground.
Yes
GO to C6.
No
If the voltage is incorrect at one amplifier
only, REPAIR the circuit in question. TEST
If the voltage is incorrect at both
Is the voltage between 3.8 and 6.7 volts at both amplifiers? amplifiers, GO to C4.
C4 CHECK CIRCUIT 173 (DG/VT) FOR A SHORT TO VOLTAGE
Disconnect: Audio Unit C290b.
Key in ON position.
C2993a-1, circuit 173 (DG/VT), harness side and ground.
Yes
normal operation.
No
C5 CHECK CIRCUIT 173 (DG/VT) FOR AN OPEN OR SHORT TO
GROUND
amplifier C2993a-1, circuit 173 (DG/VT), harness side and the
audio unit C290b-4, circuit 173 (DG/VT); and between the left
front subwoofer amplifier C2993a-1, circuit 173 (DG/VT),
Yes
GO to C13.
Is the resistance less than 5 ohms between the left front
subwoofer amplifier and the audio unit, and greater than No
10,000 ohms between the left front subwoofer amplifier and REPAIR the circuit. TEST the system for
ground? normal operation.
C6 CHECK THE AUDIO SIGNALS TO THE FRONT SUBWOOFER
AMPLIFIER
(Continued)
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C6 CHECK THE AUDIO SIGNALS TO THE FRONT SUBWOOFER
AMPLIFIER (Continued)
Measure the AC voltage between the left front subwoofer
amplifier C2993a-7, circuit 167 (BN/OG), harness side and the
left front subwoofer amplifier C2993a-8, circuit 168 (RD/BK),
harness side; and between the right front subwoofer amplifier
C2994a-7, circuit 167 (BN/OG), harness side and the right front
subwoofer amplifier C2994a-8, circuit 168 (RD/BK), harness
side.
Yes
GO to C10.
No
If the voltage is incorrect at one amplifier
only, GO to C7.
If the voltage is incorrect at both
Is a fluctuating AC voltage present at both amplifiers? amplifiers, GO to C8.
C7 CHECK CIRCUIT 167 (BN/OG) ) FOR AN OPEN
NOTE: Carry out this step only for the inoperative subwoofer.
amplifier C2993a-7, circuit 167 (BN/OG), harness side and the
audio unit C290b-1, circuit 167 (BN/OG), harness side; or
167 (BN/OG), harness side and the audio unit C290b-1, circuit
167 (BN/OG), harness side.
Yes
REPAIR circuit 168 (RD/BK). TEST the
No
REPAIR circuit 167 (BN/OG). TEST the
C8 CHECK CIRCUITS 167 (BN/OG) AND 168 (RD/BK) FOR A
SHORT TO VOLTAGE
Key in ON position.
(Continued)
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C8 CHECK CIRCUITS 167 (BN/OG) AND 168 (RD/BK) FOR A
C2993a-7, circuit 167 (BN/OG), harness side and ground; and
between the left front subwoofer amplifier C2993a-8, circuit 168
(RD/BK), harness side and ground.
Yes
No
C9 CHECK CIRCUITS 167 (BN/OG) AND 168 (RD/BK) FOR AN
OPEN OR SHORT TO GROUND
amplifier, harness side and the audio unit, harness side; and
between the left front subwoofer amplifier, harness side and
ground as follows:
Subwoofer
Amplifier Audio Unit
Connector-Pin Connector-Pin Circuit
C2993a-7 C290b-1 167 (BN/OG)
C2993a-8 C290b-2 168 (RD/BK)
Yes
GO to C13.
Is the resistance less than 5 ohms between the left front
10,000 ohms between the left front subwoofer amplifier and REPAIR the circuit in question. TEST the
ground? system for normal operation.
C10 CHECK THE AUDIO CIRCUITS TO THE SUSPECT FRONT
SUBWOOFER
Connect: Left Front Subwoofer Amplifier C2993a and Right Front
Subwoofer Amplifier C2994a.
Disconnect: Left Front Subwoofer C536 or Right Front
Subwoofer C628.
Key in ON position.
Measure the AC voltage between the suspect front subwoofer
circuits, harness side as follows:
(Continued)
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C10 CHECK THE AUDIO CIRCUITS TO THE SUSPECT FRONT
Subwoofer Subwoofer
Suspect Connector-Pin/ Connector-Pin/
Subwoofer Circuit Circuit
Left front C536-1 C536-2
804 (OG/LG) 813 (LB/WH)
Left front C536-3 C536-4
820 (DB/YE) 819 (LG/WH)
Right front C628-1 C628-2
Yes
805 (WH/LG) 811 (DG/OG)
INSTALL a new subwoofer for the suspect
Right front C628-3 C628-4 subwoofer. REFER to Section 415-03.
816 (LG/VT) 815 (LG/OG)
No
Is a fluctuating AC voltage present? GO to C11.
C11 CHECK THE AUDIO CIRCUITS TO THE SUSPECT SUBWOOFER
FOR A SHORT TO VOLTAGE
Disconnect: Left Front Subwoofer Amplifier C2993a and Right
Front Subwoofer Amplifier C2994a.
Key in ON position.
Measure the voltage between the suspect front subwoofer,
harness side and ground as follows:
Suspect Subwoofer
Subwoofer Connector-Pin Circuit
Left front C536-1 804 (OG/LG)
C536-2 813 (LB/WH)
C536-3 820 (DB/YE)
C536-4 819 (LG/WH)
Right front C628-1 805 (WH/LG)
C628-2 811 (DG/OG)
Yes
C628-3 816 (LG/VT)
C628-4 815 (LG/OG)
No
FOR AN OPEN OR SHORT TO GROUND
Measure the resistance between the suspect front subwoofer,
harness side and the front amplifier, harness side; and between
the suspect front subwoofer, harness side and ground as
follows:
(Continued)
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FOR AN OPEN OR SHORT TO GROUND (Continued)
Subwoofer Audio Unit
Suspect Connector- Connector-
Subwoofer Pin Pin Circuit
Left front C536-1 C2993b-1 804 (OG/LG)
C536-2 C2993b-2 813 (LB/WH)
C536-3 C2993b-3 820 (DB/YE)
C536-4 C2993b-4 819 (LG/WH)
Right front C628-1 C2994b-1 805 (WH/LG)
C628-2 C2994b-2 811 (DG/OG)
Yes
C628-3 C2994b-3 816 (LG/VT)
INSTALL a new front subwoofer amplifier
for the suspect amplifier. REFER to
C628-4 C2994b-4 815 (LG/OG)
normal operation.
Is the resistance less than 5 ohms between the suspect
front subwoofer and the front subwoofer amplifier, and No
greater than 10,000 ohms between the suspect front REPAIR the circuit in question. TEST the
subwoofer and ground? system for normal operation.
C13 CHECK FOR CORRECT AUDIO UNIT OPERATION
correctly.
No
Possible Causes
Pinpoint Test D: The Subwoofer is
Fuse
Rear Subwoofer
Circuit 174 (GY/BK) open or short to ground
Circuit 176 (PK/LG) open or short to ground
information.
Circuit 800 (GY/LB) open or short to ground
Normal Operation
The rear subwoofers are powered by a separate
Circuit 801 (TN/YE) open or short to ground
subwoofer amplifier for each subwoofer speaker.
The enable/clip circuit 174 (GY/BK) carries out 2
Circuit 803 (BN/PK) open or short to ground
functions: to turn on the subwoofer amplifiers, and
monitor an overload condition to the subwoofer
Circuit 806 (PK/LB) open or short to ground
amplifiers. In the event of an overload, the audio
Circuit 807 (PK/LG) open or short to ground
unit clips the audio output signal to the subwoofer
Circuit 825 (TN/LG) open or short to ground
amplifiers (heard as distortion). The rear subwoofer
amplifiers receive voltage through circuit 828 Circuit 827 (TN/WH) open or short to ground
(VT/LB) (right subwoofers) or circuit 830 (PK/YE)
Circuit 828 (VT/LB) open
(left subwoofers), and ground through circuit 1204
Circuit 830 (PK/YE) open
(BK/OG).
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Subwoofer amplifier
Subwoofer
Audio unit
PINPOINT TEST D: THE SUBWOOFER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY REAR
SUBWOOFER
D1 CHECK CIRCUIT 828 (VT/LB) OR 830 (PK/YE) FOR VOLTAGE
Disconnect: Suspect Subwoofer Amplifier(s).
Measure the voltage between the suspect subwoofer amplifier,
Suspect Subwoofer
Subwoofer Amplifier
Amplifier Connector-Pin Circuit
Left outboard C4157a-5 830 (PK/YE)
Yes
Left inboard C4158a-5 828 (VT/LB)
GO to D2.
Right inboard C4159a-5 830 (PK/YE) No
Right outboard C4160a-5 828 (VT/LB)
(BEC) fuse 6 (30A) or fuse 9 (30A) is OK.
If OK, REPAIR the circuit in question.
D2 CHECK CIRCUIT 1204 (BK/OG) FOR AN OPEN
Measure the resistance between the suspect subwoofer
amplifier, harness side and ground as follows:
Suspect Subwoofer
Subwoofer Amplifier
Left outboard C4157a-2 1204 (BK/OG)
Left inboard C4158a-2 1204 (BK/OG)
Yes
Right inboard C4159a-2 1204 (BK/OG)
GO to D3.
Right outboard C4160a-2 1204 (BK/OG)
No
D3 CHECK CIRCUIT 174 (GY/BK) FOR VOLTAGE
Key in ON position.
Measure the voltage between the suspect subwoofer speaker,
Suspect Subwoofer
Subwoofer Amplifier
Left outboard C4157a-1 174 (GY/BK)
Left inboard C4158a-1 174 (GY/BK)
Right inboard C4159a-1 174 (GY/BK)
Yes
GO to D6.
Right outboard C4160a-1 174 (GY/BK)
No
Is the voltage between 3.8 and 6.7 volts? GO to D4.
(Continued)
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D4 CHECK CIRCUIT 174 (GY/BK) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between the audio unit C290b-8, circuit 174
(GY/BK), harness side and ground.
Yes
normal operation.
No
Is any voltage present? GO to D5.
D5 CHECK CIRCUIT 174 (GY/BK) FOR AN OPEN OR SHORT TO
GROUND
Measure the resistance between the suspect subwoofer amplifier
pin 8, circuit 174 (GY/BK), harness side and the audio unit
C290b-8, circuit 174 (GY/BK), harness side; and between the
suspect subwoofer speaker pin 8, circuit 174 (GY/BK), harness
side and ground.
Yes
GO to D12.
10,000 ohms between the suspect subwoofer amplifier and REPAIR the circuit. TEST the system for
D6 CHECK THE AUDIO SIGNALS TO THE SUSPECT SUBWOOFER
AMPLIFIER
Measure the AC voltage at the suspect subwoofer amplifier,
harness side as follows:
(Continued)
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D6 CHECK THE AUDIO SIGNALS TO THE SUSPECT SUBWOOFER
AMPLIFIER (Continued)
Subwoofer Subwoofer
Suspect Amplifier Amplifier
Subwoofer Connector-Pin/ Connector-Pin/
Amplifier Circuit Circuit
Left outboard C4157a-7 C4157a-8
179 (OG/RD) 176 (PK/LG)
Left inboard C4158a-7 C4158a-8
179 (OG/RD) 176 (PK/LG)
Right inboard C4159a-7 C4159a-8
179 (OG/RD) 176 (PK/LG)
Right outboard C4160a-7 C4160a-8 Yes
GO to D9.
179 (OG/RD) 176 (PK/LG)
No
Is a fluctuating AC voltage present? GO to D7.
D7 CHECK CIRCUITS 176 (PK/LG) AND 179 (OG/RD) FOR A
SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between the audio unit C290b-5, circuit 176
(PK/LG), harness side and ground; and between the audio unit
C290b-6, circuit 179 (OG/RD), harness side and ground.
Yes
No
D8 CHECK CIRCUITS 176 (PK/LG) AND 179 (OG/RD) FOR AN
Measure the resistance between the suspect subwoofer
amplifier, harness side and the audio unit, harness side; and
between the suspect subwoofer amplifier, harness side and
ground as follows:
(Continued)
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D8 CHECK CIRCUITS 176 (PK/LG) AND 179 (OG/RD) FOR AN
OPEN OR SHORT TO GROUND (Continued)
Subwoofer
Suspect Amplifier Audio Unit
Subwoofer Connector- Connector-
Amplifier Pin Pin Circuit
Left outboard C4157a-8 C290b-6 179 (OG/RD)
C4157a-8 C290b-5 176 (PK/LG)
Left inboard C4158a-8 C290b-6 179 (OG/RD)
C4158a-8 C290b-5 176 (PK/LG)
Right inboard C4159a-8 C290b-6 179 (OG/RD)
C4159a-8 C290b-5 176 (PK/LG)
Right outboard C4160a-8 C290b-6 179 (OG/RD)
C4160a-8 C290b-5 176 (PK/LG)
Yes
GO to D12.
10,000 ohms between the suspect subwoofer amplifier and REPAIR the circuit in question. TEST the
D9 CHECK THE AUDIO CIRCUITS TO THE SUSPECT REAR
SUBWOOFER
Connect: Suspect Subwoofer Amplifier.
Disconnect: Suspect Rear Subwoofer.
Key in ON position.
Measure the AC voltage between the suspect rear subwoofer
circuits, harness side as follows:
Subwoofer Subwoofer
Suspect Connector-Pin/ Connector-Pin/
Subwoofer Circuit Circuit
Left outboard C4161-1 C4161-2
800 (GY/LB) 801 (TN/YE)
Left inboard C4161-3 C4161-4
806 (PK/LB) 807 (PK/LG)
Right inboard C4162-1 C4162-2
Yes
802 (OG/RD) 803 (BN/PK)
INSTALL a new subwoofer for the suspect
Right outboard C4162-3 C4162-4 subwoofer. REFER to Section 415-03.
825 (TN/LG) 827 (TN/WH)
No
Is a fluctuating AC voltage present? GO to D10.
D10 CHECK THE AUDIO CIRCUITS TO THE SUSPECT SUBWOOFER
Disconnect: Suspect Subwoofer Amplifier C4157b, C4158b,
C4159b, or C4160b.
Key in ON position.
Measure the voltage between the suspect rear subwoofer,
(Continued)
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FOR A SHORT TO VOLTAGE (Continued)
Suspect Subwoofer
Subwoofer Connector-Pin Circuit
Left outboard C4161-1 800 (GY/LB)
C4161-2 801 (TN/YE)
Left inboard C4161-3 806 (PK/LB)
C4161-4 807 (PK/LG)
Right inboard C4162-1 802 (OG/RD)
C4162-2 803 (BN/PK)
Yes
Right outboard C4162-3 825 (TN/LG)
C4162-4 827 (TN/WH)
No
FOR AN OPEN OR SHORT TO GROUND
Measure the resistance between the suspect rear subwoofer,
harness side and the rear amplifier, harness side; and between
the suspect rear subwoofer, harness side and ground as follows:
Rear
Suspect Subwoofer Amplifier
Subwoofer Connector-Pin Connector-Pin Circuit
Left outboard C4161-1 C4157b-4 800 (GY/LB)
C4161-2 C4157b-3 801 (TN/YE)
Left inboard C4161-3 C4158b-4 806 (PK/LB)
C4161-4 C4158b-3 807 (PK/LG)
Right inboard C4162-1 C4159b-4 802 (OG/RD)
C4162-2 C4159b-3 803 (BN/PK)
Yes
Right outboard C4162-3 C4160b-4 825 (TN/LG)
INSTALL a new rear subwoofer amplifier
for the suspect amplifier. REFER to
C4162-4 C4160b-3 827 (TN/WH)
normal operation.
Is the resistance less than 5 ohms between the suspect rear
subwoofer and the rear subwoofer amplifier, and greater No
than 10,000 ohms between the suspect rear subwoofer and REPAIR the circuit in question. TEST the
D12 CHECK FOR CORRECT AUDIO UNIT OPERATION
correctly.
No
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Possible Causes
Pinpoint Test E: Loud Popping Sound When
Cycling The Ignition Switch
Fuse
Circuit 1000 (RD/BK) open
Circuit 173 (DG/VT) short to voltage
information.
Circuit 174 (GY/BK) short to voltage
Normal Operation
Subwoofer amplifier
Voltage is supplied to the audio unit through circuit
1000 (RD/BK) when the ignition switch is turned to
Audio unit
the START position. When the audio unit receives
this voltage, it mutes all speaker outputs and
subwoofer amplifier enable circuits to eliminate the
possibility of speaker pops during engine cranking.
PINPOINT TEST E: LOUD POPPING SOUND WHEN CYCLING THE IGNITION SWITCH
E1 CHECK CIRCUIT 1000 (RD/BK) FOR VOLTAGE
Disconnect: Starter Relay.
Measure the voltage between the audio unit C290d-15 circuit
1000 (RD/BK), harness side and ground.
Yes
GO to E2.
No
20 (10A) is OK. If OK, REPAIR the circuit.
E2 ISOLATE THE FRONT/REAR SUBWOOFERS
NOTE: Repeat this step for each subwoofer amplifier. Yes
INSTALL a new subwoofer amplifier for
the suspect subwoofer amplifier. REFER
Connect: Audio Unit C290d.
to Section 415-01 or Section 415-03.
Disconnect: Suspect Subwoofer Amplifier.
Cycle the key through all of the ignition switch positions.
Is a loud popping sound present for only one subwoofer
No
amplifier?
GO to E3.
E3 CHECK FOR CORRECT AUDIO UNIT OPERATION
Connect: Starter Relay. Yes
Disconnect the audio unit connectors. REMOVE the audio unit and SEND it to
Check for: an authorized audio system repair facility.
damaged pins system for normal operation after the
pushed-out pins repair.
Connect the audio unit connectors and make sure they seat
No
correctly.
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Possible Causes
Pinpoint Test F: The Audio Unit is
Circuit 1594 (WH) open, short to ground or
Satellite Audio
voltage
Circuit 1595 (RD) open, short to ground or
voltage
information.
Circuit 1596 (PK) open, short to ground or
Normal Operation
voltage
The satellite radio receiver receives voltage through
Circuit 1597 (OG) open, short to ground or
circuit 729 (RD/WH), and ground through circuit
voltage
1204 (BK/OG). Digital signals are received by the
satellite antenna and sent to the satellite radio
receiver, which then provides audio signals to the
Audio unit
audio unit. The satellite radio receiver and the audio
unit communicate using the controller area network
(CAN) through circuits 1847 (WH/OG) and 1848
(PK/OG).
PINPOINT TEST F: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
SATELLITE AUDIO
F1 VERIFY AN ACTIVE SUBSCRIPTION
Enter satellite mode on the audio unit and observe the display. Yes
Does the display read CALL SIRIUS? The subscription has expired. INFORM the
customer to contact Sirius to re-activate
the subscription.
No
GO to F2.
F2 CHECK SATELLITE RADIO RECEIVER OPERATION
Perform the satellite bezel diagnostic self-test. Yes
Are alternating LH/RH tones audible? GO to F6.
No
GO to F3.
F3 CHECK THE RECORDED DTCs
Perform the satellite audio bezel diagnostic test. Yes
Are any satellite audio system DTCs present? If DTC B1031 SAT or DTC B1032 SAT is
present, GO to Pinpoint Test G.
For all other DTCs, REFER to the Satellite
Radio Receiver Diagnostic Trouble Code
(DTC) Index in this section.
No
GO to F4.
F4 CHECK THE AUDIO CIRCUITS FROM THE SATELLITE RADIO
RECEIVER FOR A SHORT TO VOLTAGE
Disconnect: Audio Unit C290a.
Disconnect: Satellite Radio Receiver C3290.
Key in ON position.
Measure the voltage between the satellite radio receiver,
(Continued)
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PINPOINT TEST F: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
SATELLITE AUDIO (Continued)
RECEIVER FOR A SHORT TO VOLTAGE (Continued)
Satellite Radio Receiver
C3290-5 1595 (RD)
C3290-6 1597 (OG)
Yes
C3290-11 1594 (WH)
C3290-12 1596 (PK)
No
Is any voltage present? GO to F5.
RECEIVER FOR AN OPEN OR SHORT TO GROUND
Measure the resistance between the satellite radio receiver,
harness side and the audio unit, harness side; and between the
satellite radio receiver, harness side and ground as follows:
Satellite Radio
Receiver Audio Unit
C3290-5 C290a-1 1595 (RD)
C3290-6 C290a-9 1597 (OG)
C3290-11 C290a-2 1594 (WH)
Yes
C3290-12 C290a-10 1596 (PK)
GO to F6.
Is the resistance less than 5 ohms between the satellite No
radio receiver and the audio unit, and greater than 10,000 REPAIR the circuit in question. TEST the
ohms between the satellite radio receiver and ground? system for normal operation.
F6 ISOLATE THE SATELLITE RADIO RECEIVER
Substitute a known good satellite radio receiver. SEND the original satellite radio receiver
Key in ON position. to an authorized audio system repair
Operate the audio unit in satellite audio mode. facility. TEST the system for normal
Does the system operate correctly? operation.
No
INSTALL the original satellite radio
receiver. REMOVE the audio unit and
SEND it to an authorized audio system
repair facility. REFER to Section 415-01.
TEST the system for normal operation
after the repair.
Pinpoint Test G: Poor Reception Satellite
DTC B1032 sets when a short to ground is
Audio
detected in the satellite antenna circuit.
Normal Operation Possible Causes
Digital signals are received by the satellite antenna
Satellite antenna cable
and sent to the satellite radio receiver, which then
Satellite antenna
converts the signals and provides audio signals to
the audio unit. Satellite radio receiver
DTC B1031 sets when an open or high
resistance is detected in the satellite antenna circuit.
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PINPOINT TEST G: POOR RECEPTION SATELLITE AUDIO
G1 REVIEW THE DTCs
Review the DTCs from the satellite radio receiver self-test. Yes
Is DTC B1031 or B1032 present? GO to G3.
No
GO to G2.
G2 CHECK THE OPERATION OF THE SATELLITE AUDIO
Drive the vehicle to an open location, free of obstacles. Yes
Operate the audio unit in satellite audio mode. The system is OK at this time. ADVISE
Is the reception OK? the customer of the condition.
No
GO to G3.
G3 CHECK THE SATELLITE ANTENNA CABLE
Disconnect: Satellite Antenna Connection (at satellite radio
receiver).
Yes
Disconnect: Satellite Antenna Connection (at satellite antenna).
GO to G4.
Measure the resistance of the satellite radio antenna cable
between the satellite radio receiver and the satellite antenna No
connection. INSTALL a new satellite antenna cable.
Is the resistance less than 1 ohm? CLEAR the DTCs. REPEAT the self-test.
G4 SUBSTITUTE THE SATELLITE ANTENNA
Install a known good satellite antenna. Yes
Operate the audio unit in satellite audio mode. INSTALL a new satellite antenna. REFER
Is the reception OK? to Section 415-02. CLEAR the DTCs.
No
REMOVE the satellite radio receiver and
SEND it to an authorized audio system
repair facility. REFER to Section 415-01.
TEST the system for normal operation
after the repair.
Pinpoint Test H: The Audio Unit is
Circuit 2048 (RD/BK) open, short to ground or
voltage
Audio Input Jack
Circuit 2049 (LG/WH) open, short to ground or
voltage
Circuit 2050 (LG/BK) open, short to ground or
information.
voltage
Normal Operation
Audio input jack
Audio signals are sent from the audio input jack to
Audio unit
the audio unit. There are no external power or
ground circuits to the audio input jack.
Possible Causes
Circuit 2047 (RD/WH) open, short to ground or
voltage
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PINPOINT TEST H: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY AUDIO
INPUT JACK
NOTE: Before performing this pinpoint test, be sure the MP3 device is operating correctly.
H1 CHECK THE AUDIO INPUT JACK CIRCUITS FOR A SHORT TO
VOLTAGE
Disconnect: Audio Input Jack C3312.
Key in ON position.
Measure the voltage between the audio input jack, harness side
Audio Input Jack
C3312-1 2048 (RD/BK)
C3312-2 2047 (RD/WH)
Yes
C3312-3 2049 (LG/WH)
C3312-4 2050 (LG/BK)
No
H2 CHECK THE AUDIO INPUT JACK CIRCUITS FOR AN OPEN OR
SHORT TO GROUND
Disconnect: Audio Unit C290a.
Measure the resistance between the audio input jack, harness
side and the audio unit, harness side; and between the audio
input jack, harness side and ground as follows:
Audio Input Jack Audio Unit
C3312-1 C290a-6 2048 (RD/BK)
C3312-2 C290a-14 2047 (RD/WH)
C3312-3 C290a-8 2049 (LG/WH)
Yes
C3312-4 C290a-7 2050 (LG/BK)
GO to H3.
Is the resistance less than 5 ohms between the audio input No
jack and the audio unit, and greater than 10,000 ohms REPAIR the circuit in question. TEST the
between the audio input jack and ground? system for normal operation.
H3 SUBSTITUTE THE AUDIO INPUT JACK
Install a known good audio input jack. Yes
Operate the audio unit in auxiliary audio mode. INSTALL a new audio input jack. TEST
Does the system operate correctly? the system for normal operation.
No
INSTALL the original audio input jack.
REMOVE the audio unit and SEND it to
an authorized audio system repair facility.
system for normal operation after the
repair.
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415-01-1 415-01-1 Audio Unit
The 1,000 watt system consists of the 500 watt
Audio System
system components with the addition of a luggage
The base audio system consists of an AM/FM single
compartment 2-speaker subwoofer enclosure with an
CD audio unit and 4 full range speakers.
amplifier rack. The amplifier rack is mounted with
The 500 watt system consists of the AM/FM 6-CD
4 amplifiers.
audio unit (MP3 capable) with:
The optional satellite audio system (available with
Two full range speakers all audio units) consists of:
Two Audiophile 2-way speakers
Two 8-inch door mounted subwoofer speakers
Satellite antenna
Two door subwoofer amplifiers
Satellite antenna cable (part of the luggage
compartment lid harness)
Refer to the Owners Literature for complete audio
system operating controls and functions.
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415-01-1 415-01-1 Audio Unit
Audio System
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415-01-1 415-01-1 Audio Unit
Audio Unit
1 W705314S Audio unit screws (4
Section 501-12.
required)
2 14401 Audio unit electrical
3. Remove the 4 screws and the audio unit.
connectors
Disconnect the electrical connectors and the
3 18C815 Audio unit
antenna lead-in cable.
NOTE: If installing a new navigation audio unit, Download the configuration information to
remove the navigation digital versatile disc (DVD), the audio unit. For additional information,
if possible, before sending the audio unit to an refer to Section 418-01, to carry out PMI.
1. NOTE: Module configuration is only required
if a new audio unit is being installed.
Upload the audio unit configuration information
to the scan tool. For additional information,
refer to Section 418-01, to carry out
programmable module installation (PMI).
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415-03-1 415-03-1 Speakers
Door Speaker
1 W709996 Door speaker screws (4
1. Remove the door trim panel. For additional required)
2 Door speaker electrical
connector (part of
14630/14631) 2. Remove the 4 screws and the door speaker.
3 18808 Door speaker
4 W701930 Door speaker mounting
bracket screws (3 required) 3. To install, reverse the removal procedure.
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415-03-1 415-03-1 Speakers
Parcel Shelf Speaker
1 W709996 Parcel shelf speaker screws (4
1. Remove the 4 screws and the parcel shelf required per speaker)
speaker.
2 980519 Parcel shelf speaker
Disconnect the electrical connector. 3 Parcel shelf speaker electrical
4 W700578 Push nut (4 required per
speaker)
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415-03-1 415-03-1 Speakers
Quarter Panel Speaker
1 W709996 Quarter panel speaker screws
1. Remove the quarter trim panel. For additional (4 required)
2 18808 Quarter panel speaker
3 Quarter panel speaker
2. Remove the 4 screws and the quarter panel
speaker.
14A005)
4 W701930 Quarter panel speaker Disconnect the electrical connector.
mounting bracket screws (3
required)
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415-01-1 415-01-1 Audio Unit
Satellite Radio Receiver
2. NOTE: When installing the nuts, tighten the 2
rear nuts before tightening the front 2 nuts.
1 Satellite radio receiver
electrical connector (part of Remove the 4 nuts and the satellite radio
14A005)
receiver.
2 Satellite radio antenna cable
19B516) To install, tighten the nuts to 7 Nm (62
lb-in).
3 W520412-S Satellite radio receiver nuts (4
required)
4 18C963 Satellite radio receiver
1. Set the RH luggage compartment trim aside.
Remove the push-pins, as required.
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415-03-1 415-03-1 Speakers
Speaker Enclosure
1 W505433 Speaker enclosure bolts (3
1. Remove the 3 speaker enclosure bolts. required)
2 W705047 Speaker enclosure nut To install, tighten to 11 Nm (8 lb-ft).
3 Speaker enclosure electrical
connectors (part of 14N128) 2. Remove the nut and the speaker enclosure.
4 19A067 Speaker enclosure
5 W505416 L-bracket screws (2 required)
6 19B187 L-bracket
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415-03-1 415-03-1 Speakers
The 1,000 watt system, in addition to the features of
Speakers
the 500 watt system, is equipped with 2 subwoofer
The base audio system is equipped with speakers in
speakers in a single enclosure located in the luggage
each door and 2 rear speakers. These speakers are
compartment. These speakers are powered by 4
powered by the audio unit.
amplifiers.
The 500 watt system, in addition to the features of
the base system, is equipped with a subwoofer
speaker in each door. These speakers are each
powered by their own amplifier.
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415-03-1 415-03-1 Speakers
Speakers
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415-01-1 415-01-1 Audio Unit
SPECIFICATIONS
Luggage compartment 15 11
Description Nm lb-ft lb-in subwoofer amplifier
rack bolts
Audio unit screws 3 27
Door subwoofer 3 27
subwoofer amplifier
amplifier nuts
rack nut
Satellite radio receiver 7 62
subwoofer amplifier
nuts
nuts
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415-02-1 415-02-1 Antenna
SPECIFICATIONS
Satellite radio antenna bolt 5 44
Antenna mast 3 27
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415-03-1 415-03-1 Speakers
SPECIFICATIONS
Parcel shelf speaker 1 9
Description Nm lb-ft lb-in screws
Speaker enclosure nut 11 8 Quarter panel speaker 1 9
screws
Speaker enclosure bolts 11 8
Quarter panel speaker 1 9
L-bracket screws 3 27
mounting bracket
Door speaker screws 1 9
screws
Door speaker mounting 1 9
bracket screws
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415-01-1 415-01-1 Audio Unit
Subwoofer Amplifier Door
1 19B113 Door subwoofer amplifier
1. Remove the 3 nuts and the door subwoofer electrical connectors
amplifier.
2 W520210 Door subwoofer amplifier
nuts (3 required per amplifier)
3 18C808 Door subwoofer amplifier
(RH door)
4 18C808 Door subwoofer amplifier
(LH door)
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415-01-1 415-01-1 Audio Unit
Subwoofer Amplifier Luggage
Compartment
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415-01-2 415-01-2 Audio Unit
1 Luggage compartment
1. Remove the speaker enclosure. For additional subwoofer amplifier jumper
harness electrical connector information, refer to Section 415-03.
(part of 14A005)
2 W505433 Luggage compartment 2. Disconnect the luggage compartment subwoofer
subwoofer amplifier rack
amplifier jumper harness electrical connector.
bolts (3 required)
3 W520212 Luggage compartment 3. Remove the 3 luggage compartment subwoofer
subwoofer amplifier rack nut
amplifier rack bolts.
4 18T806 Luggage compartment
subwoofer amplifier rack
5 N621903 Luggage compartment
4. Remove the nut and the luggage compartment
subwoofer amplifier nuts (4
subwoofer amplifier rack.
required per pair of
amplifiers) To install, tighten to 15 Nm (11 lb-ft).
6 N606663 Luggage compartment
subwoofer amplifier bolts (4 5. Remove the 4 nuts and bolts and the pair of
required per pair of
luggage compartment subwoofer amplifiers.
amplifiers)
7 19B113 Luggage compartment
To install, tighten to 5 Nm (44 lb-in). subwoofer amplifier electrical
connectors
8 18C088 Luggage compartment
subwoofer amplifiers
9 19B187 Attachment bracket
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415-03-1 415-03-1 Speakers
Subwoofer Speaker
2. Remove the door subwoofer speaker grille trim.
1 W707281 Door subwoofer speaker bolt
3. Remove the door subwoofer speaker bolt.
2 18978 Door subwoofer speaker grille
trim
4. Remove the 8 screws and the door subwoofer
3 N606674 Door subwoofer speaker
speaker.
screws (8 required)
Push the wiring harness grommet through
4 18808 Door subwoofer speaker
the door trim panel.
1. Remove the door trim panel. For additional
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417-04-1 417-04-1 Daytime Running Lamps
Daytime Running Lamps (DRL)
If the smart junction box (SJB) is configured for
DRL, this feature illuminates the low beam
headlamps at a reduced intensity when the following
conditions exist:
The ignition switch is in the RUN position.
The headlamp switch is in the OFF position.
The parking brake is not engaged.
For additional information on the low beam
headlamps, refer to Section 417-01.
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417-04-1 417-04-1 Daytime Running Lamps
2. Verify the parking lamp operation.
Daytime Running Lamps (DRL)
Place the headlamp switch in the PARKING
LAMPS ON position.
NOTE: When installing a new smart junction box
If the parking lamps do not operate
(SJB), it must be reconfigured for this feature, if
correctly, refer to Section 417-01.
originally equipped. Refer to Section 418-01.
3. Verify the high beam operation.
Place the headlamp switch in the
DRL following these steps:
HEADLAMPS ON position.
Place the ignition switch in the RUN
Place the multifunction switch in the HIGH
position.
BEAM position.
Place the headlamp switch in the OFF
If the high beams operate correctly and the
position.
DRL operation is incorrect, install a new
Verify that the parking brake is not engaged.
SJB. Refer to Section 419-10. Test the
If the DRL does not operate, make sure the
SJB is configured for DRL before
If the high beams do not operate correctly,
proceeding to the next step.
refer to Section 417-01 for correct diagnosis.
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417-01-1 417-01-1 Exterior Lighting
Parking, Rear or License Plate Lamps
Exterior Lighting
The parking, rear, license plate and side marker
Headlamps
lamps are controlled by the SJB. The headlamp
The headlamps are controlled by the smart junction
switch is monitored by the SJB. When the headlamp
box (SJB). The headlamp and multifunction
switch is in the HEADLAMPS ON or PARKING
switches are constantly monitored by the SJB. The
LAMPS ON position, SJB processes this
SJB processes information (such as low beam, high
information and outputs voltage to the parking,
beam or flash-to-pass requests) from these switches
rear, licence plate and side marker lamps.
and outputs voltage to the headlamps. This is the
Fog Lamps
same for the low and high beams and flash-to-pass
positions. In the event of headlamp switch invalid
The fog lamps are controlled by the SJB. The SJB
or missing data failures, the exterior lamps are
monitors inputs from the headlamp switch and the
illuminated. There is also a headlamp battery saver
multifunction switch. The SJB will only turn the fog
feature. This feature turns off the headlamps 10
lamps on when ignition switch is in the RUN
minutes after the ignition switch is turned OFF.
position, the parking lamps are on and the high
beams are off. When the fog lamp switch is
Stoplamps
engaged, the SJB then activates the fog lamp relay,
The stoplamp outputs are controlled by the SJB.
providing power to the fog lamps.
The stoplamp switch is monitored by the SJB.
Reversing Lamps
When the SJB detects the brake pedal is applied,
the SJB processes this information and outputs
The reversing lamps are controlled by the SJB. The
voltage to the stoplamps.
powertrain control module (PCM) sends a message
through the communication network indicating the
Turn Signal and Hazard Lamps
transmission is in REVERSE (R). The SJB
All turn signal outputs are controlled by the SJB.
processes this information and outputs voltage to the
The multifunction switch and the hazard switch are
reversing lamps.
monitored by the SJB. When the multifunction
switch is in the left or right turn position, or the
hazard switch is engaged, the SJB processes this
information and outputs voltage to the appropriate
turn signal and hazard lamps. All turn signal lamps
provide a lamp outage indication.
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Fog Lamp Bulb
4.0L and 4.6L Vehicles
NOTE: 4.0L fog lamp shown, 4.6L fog lamp similar.
1 Fog lamp bulb electrical
2 13N021 Fog lamp bulb
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5.4L Vehicles
NOTE: Make sure the headlamp switch and the
ignition switch are in the OFF position.
1 Fog lamp bulb electrical
4.0L and 4.6L vehicles
2 13N021 Fog lamp bulb
WARNING: The fog lamp bulb contains
gas under pressure. The bulb may shatter if the
the fog lamp bulb.
glass envelope is scratched or if the bulb is
dropped. Handle the bulb carefully. Grasp the
5.4L vehicles
bulb only by its base. Avoid touching the glass
envelope. Failure to follow these instructions
Section 100-01.
NOTE: The fog lamp bulb should not be removed
from the fog lamp until just before a new bulb is
4. Release (squeeze) the tabs and remove the fog
installed. Removing the bulb for an extended period
lamp bulb.
of time may affect fog lamp bulb performance.
Contaminants may enter the fog lamp where they
can settle on the lens and reflector. Never turn on
the fog lamps with the bulb removed.
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All vehicles
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Fog Lamp
4.0L Vehicles
1 W707607S Fog lamp mounting screws (4
required)
2 15200 Fog lamp
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4.6L Vehicles
1 W505974S Fog lamp mounting screws (4
required)
2 15K201/15201 Fog lamp (RH/LH)
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5.4L Vehicles
5.4L vehicles
1 15K201 Fog lamp
2 Fog lamp electrical connector
(part of 14290)
Section 100-01.
4. Release the tabs and remove the fog lamp.
Disconnect the electrical connector. 4.0L and 4.6L vehicles
All vehicles
2. Remove the 4 screws and the fog lamp.
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Fog Lamps
software release.
Special Tool(s)
73III Automotive Meter scan tool to the data link connector (DLC).
VCM.
VCM:
(VCM) and Integrated Check the VCM connection to the vehicle.
hardware, or equivalent scan Refer to Section 418-00, No Power To The
tool
with the scan tool.
Flex Probe Kit
vehicle:
position.
good vehicle.
Inspection and Verification response from the powertrain control module
(PCM).
of mechanical or electrical damage. If the scan tool responds with no
record the continuous memory DTCs. Headlamp switch Bussed electrical center
(BEC) fuse 58 (15A)
(fog lamp relay)
self-test diagnostics for the SJB.
Circuitry
Fog lamp relay
Bulbs
go to the Smart Junction Box (SJB) Diagnostic
BEC
Smart junction box
(SJB)
NOTE: Make sure the headlamp switch is in the
OFF position.
NOTE: Make sure the multifunction switch is in
the LOW BEAM position.
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B1342 ECU is Faulted REPAIR all other DTCs first. CLEAR the
DTCs. RETRIEVE the DTCs. If DTC B1342 is
retrieved again, INSTALL a new SJB. REFER
operation.
B2030 Front Fog Lamp Relay Ckt Failure If the fog lamps are inoperative, GO to Pinpoint
Test O.
If the fog lamps are always on, GO to Pinpoint
Test Q.
B2254 Front Fog Lamp Switch Failure GO to Pinpoint Test Q.
Symptom Chart
Symptom Chart
No communication with the Circuitry REFER to Section 418-00.
smart junction box (SJB) SJB
The fog lamps are inoperative Fuse GO to Pinpoint Test O.
Circuitry
Fog lamp relay
Headlamp switch
(BEC)
SJB
An individual fog lamp is Circuitry GO to Pinpoint Test P.
inoperative BEC
The fog lamps are on Circuitry GO to Pinpoint Test Q.
continuously Fog lamp relay
Headlamp switch
BEC
SJB
The fog lamp on indicator is Circuitry GO to Pinpoint Test R.
inoperative Headlamp switch
BEC
Pinpoint Tests
Pinpoint Test O: The Fog Lamps Are
Inoperative
Refer to Wiring Diagrams Cell 86, Fog Lamps for
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Normal Operation
DTC B2030 sets when the SJB detects an open
The smart junction box (SJB) sends a voltage
or short to voltage on the fog lamp relay coil
reference signal to the headlamp switch through
ground controlled circuit.
circuit 1669 (OG/LG). When the fog lamp switch is
Possible Causes
engaged, the voltage signal is routed to ground. The
Fuse
fog lamp relay is provided voltage through the
bussed electrical center (BEC). When the ignition
switch is in the ON position, the parking lamps are
Circuit 1347 (DB/WH) open or short to voltage
on and the SJB detects a request for the fog lamps,
Circuit 1669 (OG/LG) open
the SJB provides a ground for the fog lamp relay
coil through circuit 1347 (DB/WH). When the
Fog lamp relay
relay is energized, voltage is routed through circuits
Headlamp switch
1721 (LB/BK) and 1776 (TN/OG) to the LH and
BEC
RH fog lamps, respectively. The fog lamps share a
common ground provided through the BEC on SJB
circuit 1205 (BK).
PINPOINT TEST O: THE FOG LAMPS ARE INOPERATIVE
O1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Using the recorded results from the SJB self-test: GO to O2.
Was DTC B2030 present?
No
GO to O8.
O2 CHECK THE FOG LAMP RELAY (DTC B2030)
Disconnect: Fog Lamp Relay. Yes
Carry out the fog lamp relay component test. Refer to Wiring GO to O3.
Diagrams Cell 149 for component testing.
No
Is the fog lamp relay OK?
INSTALL a new fog lamp relay. CLEAR
(Continued)
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PINPOINT TEST O: THE FOG LAMPS ARE INOPERATIVE (Continued)
O3 CHECK VOLTAGE TO THE RELAY COIL
Measure the voltage between the fog lamp relay pin 86, harness
side and ground.
Yes
GO to O4.
No
OK, INSTALL a new BEC. CLEAR the
O4 CHECK THE FOG LAMP RELAY COIL GROUND CONTROL
CIRCUIT FOR SHORT TO VOLTAGE
Key in ON position.
(Continued)
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CIRCUIT FOR SHORT TO VOLTAGE (Continued)
Measure the voltage between the fog lamp relay pin 85, circuit
1347 (DB/WH), harness side and ground.
Yes
GO to O5.
No
Is any voltage present? GO to O6.
O5 CHECK CIRCUIT 1347 (DB/WH) FOR SHORT TO VOLTAGE
Key in ON position.
(Continued)
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O5 CHECK CIRCUIT 1347 (DB/WH) FOR SHORT TO VOLTAGE
(Continued)
Measure the voltage between the fog lamp relay pin 85, circuit
1347 (DB/WH), harness side and ground.
Yes
No
Is any voltage present? REPEAT the self-test.
CIRCUIT 1347 (DB/WH) FOR AN OPEN
(Continued)
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CIRCUIT 1347 (DB/WH) FOR AN OPEN (Continued)
Measure the resistance between the fog lamp relay pin 85,
circuit 1347 (DB/WH), harness side and the SJB C2280c-2,
circuit 1347 (DB/WH), harness side.
Yes
GO to O13.
No
Is the resistance less than 5 ohms? GO to O7.
O7 CHECK CIRCUIT 1347 (DB/WH) FOR AN OPEN
Measure the resistance between the BEC C1035a-A3, circuit
1347 (DB/WH), harness side and the SJB C2280c-2, circuit
1347 (DB/WH), harness side.
Yes
No
O8 CHECK THE FOG LAMP SWITCH INPUT
Key in ON position.
(Continued)
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O8 CHECK THE FOG LAMP SWITCH INPUT (Continued)
Headlamp Switch PID.
Yes
Monitor the SJB headlamp switch PID while placing the
GO to O11.
headlamp switch in the PARKING LAMPS ON position and
engaging the fog lamp switch. No
Does the PID indicate the fog lamp switch is active? GO to O9.
O9 CHECK THE HEADLAMP SWITCH
Yes
Place the headlamp switch in the OFF position.
GO to O10.
Disconnect: Headlamp Switch C205.
Carry out the headlamp switch component test. Refer to Wiring No
Diagrams Cell 149 for component testing. INSTALL a new headlamp switch. TEST
Is the headlamp switch OK? the system for normal operation.
O10 CHECK CIRCUIT 1669 (OG/LG) FOR AN OPEN
Measure the resistance between the headlamp switch C205-6,
circuit 1669 (OG/LG), harness side and the SJB C2280b-34,
circuit 1669 (OG/LG), harness side.
Yes
GO to O13.
No
O11 CHECK THE FOG LAMP RELAY (NO DTCs)
Yes
GO to O12.
Disconnect: Fog Lamp Relay.
Carry out the fog lamp relay component test. Refer to Wiring No
Diagrams Cell 149 for component testing. INSTALL a new fog lamp relay. TEST the
Is the fog lamp relay OK? system for normal operation.
O12 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between the BEC C1035c-E11, circuit
1205 (BK), harness side and ground.
Yes
No
(Continued)
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O13 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
Possible Causes
Pinpoint Test P: An Individual Fog Lamp Is
Inoperative
Circuit 1721 (LB/BK) open
Circuit 1776 (TN/OG) open
Normal Operation
BEC
When the fog lamp relay is energized, voltage is
routed through circuits 1721 (LB/BK) and 1776
(TN/OG) to the LH and RH fog lamps, respectively.
The fog lamps are provided ground through circuit
1205 (BK).
PINPOINT TEST P: AN INDIVIDUAL FOG LAMP IS INOPERATIVE
P1 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Inoperative Fog Lamp.
Measure the resistance between the LH fog lamp C152-2, circuit
1205 (BK), harness side and the BEC C1035c-E10, circuit 1205
(BK), harness side; or between the RH fog lamp C162-2, circuit
1205 (BK), harness side and the BEC C1035c-C11, circuit 1205
(BK), harness side.
Yes
GO to P2.
No
(Continued)
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PINPOINT TEST P: AN INDIVIDUAL FOG LAMP IS INOPERATIVE (Continued)
P2 CHECK CIRCUIT 1776 (TN/OG) OR CIRCUIT 1721 (LB/BK) FOR
AN OPEN
Measure the resistance between the LH fog lamp C152-1, circuit
1721 (LB/BK), harness side and the BEC C1035c-B5, circuit
1721 (LB/BK), harness side; or between the RH fog lamp
C162-1, circuit 1776 (TN/OG), harness side and the BEC
C1035c-E7, circuit 1776 (TN/OG), harness side.
Yes
No
Pinpoint Test Q: The Fog Lamps Are On
DTC B2030 sets when the SJB detects a short to
Continuously
ground on the fog lamp relay coil ground controlled
circuit.
ground on the fog lamp switch input circuit.
Normal Operation
The smart junction box (SJB) sends a voltage Possible Causes
Circuit 1347 (DB/WH) short to ground
circuit 1669 (OG/LG). When the fog lamp switch is
Circuit 1669 (OG/LG) short to ground
engaged, the voltage signal is routed to ground. The
fog lamp relay is provided voltage through the Circuit 1721 (LB/BK) short to voltage
bussed electrical center (BEC). When the ignition
Circuit 1776 (TN/OG) short to voltage
switch is in the ON position, the parking lamps are
Circuit 2024 (VT/OG) short to voltage
on, and the SJB detects a request for the fog lamps,
Fog lamp relay the SJB provides a ground for the fog lamp relay
coil through circuit 1347 (DB/WH). When the
Headlamp switch
relay is energized, voltage is routed through circuits
BEC
1721 (LB/BK) and 1776 (TN/OG) to the LH and
SJB
RH fog lamps, respectively.
PINPOINT TEST Q: THE FOG LAMPS ARE ON CONTINUOUSLY
Q1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Using the recorded results from the SJB self-test: For DTC B2254, GO to Q2.
Was DTC B2030 or B2254 present?
For DTC B2030, GO to Q4.
No
GO to Q6.
(Continued)
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PINPOINT TEST Q: THE FOG LAMPS ARE ON CONTINUOUSLY (Continued)
Q2 CHECK THE HEADLAMP SWITCH
Disconnect: Headlamp Switch C205. GO to Q3.
Carry out the headlamp switch component test. Refer to Wiring
No
INSTALL a new headlamp switch. CLEAR
Is the headlamp switch OK?
Q3 CHECK CIRCUIT 1669 (OG/LG) FOR A SHORT TO GROUND
circuit 1669 (OG/LG), harness side and ground.
Yes
GO to Q9.
No
Q4 CHECK THE SJB
Disconnect: SJB C2280c. Yes
Key in ON position. GO to Q5.
Do the fog lamps continue to illuminate?
No
GO to Q9.
Q5 CHECK CIRCUIT 1347 (DB/WH) FOR A SHORT TO GROUND
Disconnect: BEC C1035a. INSTALL a new BEC. CLEAR the DTCs.
Key in ON position. REPEAT the self-test.
No
Q6 CHECK THE FOG LAMP RELAY
Disconnect: Fog Lamp Relay. Yes
Key in ON position. GO to Q7.
No
INSTALL a new fog lamp relay. TEST the
Q7 CHECK CIRCUIT 2024 (VT/OG) FOR A SHORT TO VOLTAGE
Disconnect: BEC C1035a. GO to Q8.
Key in ON position.
No
normal operation.
Q8 CHECK CIRCUITS 1721 (LB/BK) AND 1776 (TN/OG) FOR A
SHORT TO VOLTAGE
Disconnect: BEC C1035c. REPAIR circuit 1721 (LB/BK) (LH fog
Key in ON position. lamp) or circuit 1776 (TN/OG) (RH fog
Does either fog lamp continue to illuminate? lamp) as necessary. TEST the system for
normal operation.
No
(Continued)
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PINPOINT TEST Q: THE FOG LAMPS ARE ON CONTINUOUSLY (Continued)
Q9 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
Possible Causes
Pinpoint Test R: The Fog Lamp On Indicator
Is Inoperative
Circuit 2024 (VT/OG) open
Headlamp switch
BEC
Normal Operation
When the fog lamp relay is energized, the bussed
electrical center (BEC) routes voltage through
circuit 2024 (VT/OG) to the headlamp switch.
PINPOINT TEST R: THE FOG LAMPS ON INDICATOR IS INOPERATIVE
R1 CHECK CIRCUIT 2024 (VT/OG) FOR VOLTAGE
Disconnect: Fog Lamp Relay.
(Continued)
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PINPOINT TEST R: THE FOG LAMPS ON INDICATOR IS INOPERATIVE (Continued)
R1 CHECK CIRCUIT 2024 (VT/OG) FOR VOLTAGE (Continued)
Connect a fused (15A) jumper wire between the fog lamp relay
pin 87, harness side and the fog lamp relay pin 30, circuit 2024
(VT/OG), harness side.
Measure the voltage between the headlamp switch C205-3,
circuit 2024 (VT/OG), harness side and ground.
Yes
INSTALL a new headlamp switch. TEST
No
Is the voltage greater than 10 volts? REMOVE the jumper wire. GO to R2.
R2 CHECK CIRCUIT 2024 (VT/OG) FOR AN OPEN
(Continued)
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PINPOINT TEST R: THE FOG LAMPS ON INDICATOR IS INOPERATIVE (Continued)
R2 CHECK CIRCUIT 2024 (VT/OG) FOR AN OPEN (Continued)
Measure the resistance between the BEC C1035a-B7, circuit
2024 (VT/OG), harness side and the headlamp switch C205-3,
circuit 2024 (VT/OG), harness side.
Yes
No
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GENERAL PROCEDURES
Front Fog Lamp Adjustment
1. NOTE: Horizontal aim is not required for this
vehicle and is not adjustable. Consult your state
vehicle inspection center for recommended
tolerance ranges for visual aiming.
Before starting the fog lamp assembly
adjustment:
Check the tire inflation.
Make sure there are no other loads in the
vehicle other than a half tank of fuel.
Make sure the vehicle is on level ground.
3. The correct visual aim for the fog lamps is with
the top edge of the high-intensity zone 10 cm
Make sure the fog lamps and headlamps are
(4 in) below the horizontal center of the fog
clean.
lamps.
Make sure the headlamps are operating and
are correctly aimed.
2. NOTE: The vertical wall screen must be a
minimum of 2.4 meters (8 ft) wide.
Park the vehicle on a level surface
approximately 7.6 meters (25 ft) from the
vertical wall or screen directly in front of it.
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Hazard Flasher Lamp Switch
1 6304302 Instrument panel center finish
panel
2 13D734 Hazard flasher lamp switch
Section 501-12.
2. Release the tabs and remove the hazard flasher
lamp switch.
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GENERAL PROCEDURES
NOTE: The sight shield may need to be positioned
Headlamp Adjustment
or removed for access to the adjusters.
Headlamp Aiming
1. Before starting headlamp adjustment:
Check the tire inflation.
1. The headlamp aiming procedure depends on the
type of beam pattern the headlamp is equipped Check that no other load is in the vehicle
with. Vehicles may come equipped with visual other than a half tank of fuel.
optical right (VOR), visual optical left (VOL),
Check that the headlamps are clean.
or SAE only (includes sealed beam-type)
Check for correct headlamp operation.
headlamps. To identify the headlamp beam
Check that the vehicle is on level ground.
pattern, look on the headlamp lens. Molded in
small letters on the headlamp lens is one of the
If the vehicle is equipped with air
following:
suspension, make sure that the switch is on.
SAE
2. NOTE: The vertical wall or screen must be a
VOR or SAE
minimum of 2.4-meters (8-feet) wide.
VOL or SAE
Park the vehicle on a level surface
approximately 7.6 meters (25 feet) from the
2. Once the headlamp beam pattern is identified,
vertical wall or screen directly in front of it.
aim the headlamps using one of the following
methods as applicable.
Photometric aimers can aim SAE-, VOR-
and VOL- type headlamps. This is the
preferred method of headlamp aiming.
Visual or screen method aiming can be used
to aim SAE-, VOR- and VOL-type
headlamps.
Mechanical aimers can be used only with
SAE-type headlamps. Lamps that can be
aimed mechanically will have three nibs
molded into the lens of the lamp.
Photometric Aiming
1. For the photometric aiming procedure, refer to
the appropriate photometric headlamp aimer
instruction manual.
Screen Method Aiming
All headlamp types
NOTE: Horizontal aim is not necessary for VOR or
VOL headlamps.
NOTE: Consult your state vehicle inspection
manual for recommended tolerance ranges for visual
aiming.
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3. NOTE: The center of the lamp is marked either
on the lens (circle, crosshair or other mark) or
on the bulb shield internal to the lamp
(crosshair or other mark).
Mark a horizontal reference line on the vertical
wall or screen.
1 Measure the center of the headlamp height
to ground and record.
2 Make a 2.4-meter (8-foot) horizontal mark
(masking tape) on the vertical wall or
screen at the same distance from the ground
as previously recorded.
VOL-type headlamps
7. For VOL-type headlamps, there will be a
distinct cutoff in the left portion of the beam
pattern. The edge of this cutoff should be
positioned 50.2 mm (2 in) below the horizontal
reference line.
1 Horizontal reference line.
2 Top edge of the beam pattern.
3 High intensity zone.
4. NOTE: This procedure should be done in a
dark environment to effectively see the
headlamp beam pattern.
Turn on the low beam headlamps to illuminate
the wall or screen and open the hood.
5. NOTE: For SAE type headlamps, the
appearance of the beam pattern may vary
between vehicles.
On the wall or screen, locate the high intensity
area of the beam pattern. Place the top edge of
the high intensity zone even with the horizontal
reference line.
VOR-type headlamps
6. NOTE: The appearance of the VOR beam
pattern may vary between vehicles.
Identify at the top edge of this high intensity
area a distinct horizontal cutoff in the beam
pattern. If the top edge of this cutoff is not
even with the horizontal reference line, the
headlamp beam will need to be adjusted.
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Mechanical Aiming
1. For the mechanical aiming procedure, refer to
the appropriate mechanical headlamp aimer
instruction manual.
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Headlamp Assembly
2. Remove the pushpin.
1 58403D24 Pushpin
3. Remove the 3 bolts and the headlamp assembly.
2 W712277 Headlamp assembly bolts (3
required)
3 13008/13035 Headlamp assembly (RH/LH) To install, tighten the bolts to 8 Nm (71
lb-in).
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Headlamp Bulb
NOTE: The air cleaner assembly is shown removed for clarity.
1 Headlamp bulb electrical
connector (part of 14290) WARNING: The headlamp bulb contains
gas under pressure. The bulb may shatter if the
2 13N021 Headlamp bulb
glass envelope is scratched or if the bulb is
dropped. Handle the bulb only by its base. Avoid
touching the glass envelope. Failure to follow
NOTE: The headlamp bulb should not be removed
from the headlamp until just before a new bulb is
installed. Removing the bulb for an extended period
of time may affect headlamp bulb performance.
Contaminants may enter the headlamp where they
can settle on the lens and reflector. Never turn on
the headlamps with the bulb removed from the
headlamp.
NOTE: Make sure the headlamp switch and the
ignition switch are in the OFF position.
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1. NOTE: To remove, rotate the headlamp bulb 2. To install, reverse the removal procedure.
approximately 1/8 turn counterclockwise.
Remove the headlamp bulb.
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Headlamp Switch
1 6304481 Instrument panel side finish
1. Remove the instrument panel side finish panel. panel
2 11654 Headlamp switch
2. NOTE: The headlamp switch is removed by
3 Headlamp switch electrical
pushing from behind.
connectors (part of 14401)
Remove the headlamp switch.
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Headlamps
Special Tool(s)
Headlamp switch Bussed electrical center
73III Automotive Meter (BEC) fuse(s):
105-R0057 or equivalent 50 (15A) (high
beams)
67 (30A)
Circuitry
Bulbs
Smart junction box
(SJB)
before proceeding to the next step. hardware, or equivalent scan
tool
OFF position.
Flex Probe Kit
105-R025C or equivalent the LOW BEAM position.
software release.
ground from the DLC are provided to the The smart junction box (SJB) monitors the
VCM. headlamp switch position by sending multiple
voltage reference signals to the headlamp switch.
When the headlamp switch is in any given position,
VCM:
that input signal is routed to ground.
The SJB also monitors the multifunction switch for
a flash-to-pass or high beam request. There are 2
voltage reference circuits which monitor this. When
Scan Tool, to diagnose no communication the multifunction switch is in the FLASH-TO-PASS
with the scan tool. or HIGH BEAM position, the voltage signal is
routed to ground.
vehicle: NOTE: The flash-to-pass feature does not require
any input from the headlamp switch.
position. When the SJB receives an input requesting the
headlamps on, the SJB supplies voltage to the low
beam and high beam bulbs as necessary.
good vehicle.
(PCM).
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If the network test passes, retrieve and 9. If the DTCs retrieved are related to the concern,
record the continuous memory DTCs. go to the Smart Junction Box (SJB) Diagnostic
operation.
B1470 Lamp Headlamp Input Circuit Failure GO to Pinpoint Test E.
B2501 LF Lamp Low Beam Circuit Failure If the low beam is inoperative, GO to Pinpoint
Test C.
If the low beam is always on, GO to Pinpoint
Test E.
B2503 RF Lamp Low Beam Circuit Failure If the low beam is inoperative, GO to Pinpoint
Test C.
If the low beam is always on, GO to Pinpoint
Test E.
B2586 Headlamp Mode Select Circuit Failure GO to Pinpoint Test E.
B2598 Headlamp Relay Circuit Failure If the high beams are inoperative, GO to
Pinpoint Test B.
If the high beams are always on, GO to Pinpoint
Test E.
Symptom Chart
Symptom Chart
The low beams are Fuse GO to Pinpoint Test A.
(BEC)
SJB
The high beams are Fuse GO to Pinpoint Test B.
High beam relay
Multifunction switch
BEC
SJB
One low beam headlamp is Circuitry GO to Pinpoint Test C.
inoperative BEC
SJB
One high beam headlamp is Circuitry GO to Pinpoint Test D.
inoperative BEC
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The headlamps are on Circuitry GO to Pinpoint Test E.
continuously High beam relay
Headlamp switch
BEC
SJB
The flash-to-pass feature is Circuitry GO to Pinpoint Test F.
inoperative Multifunction switch
SJB
Fuse
Pinpoint Test A: The Low Beams Are
Inoperative Circuit 1052 (TN/BK) open
Refer to Wiring Diagrams Cell 85, Headlamps for Circuit 1205 (BK) open
BEC
Normal Operation
SJB
The smart junction box (SJB) is supplied voltage for
the low beams through circuit 1052 (TN/BK) from
the bussed electrical center (BEC). When a request
for the low beams is detected, the SJB provides
voltage to the low beams. The headlamps share a
common ground through circuit 1205 (BK).
PINPOINT TEST A: THE LOW BEAMS ARE INOPERATIVE
A1 CHECK CIRCUIT 1052 (TN/BK) FOR A VOLTAGE
Disconnect: SJB C2280h.
Measure the voltage between the SJB C2280h-32, circuit 1052
(TN/BK), harness side and ground.
Yes
GO to A3.
No
Is the voltage greater than 10 volts? OK, GO to A2.
A2 CHECK CIRCUIT 1052 (TN/BK) FOR AN OPEN
(Continued)
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PINPOINT TEST A: THE LOW BEAMS ARE INOPERATIVE (Continued)
A2 CHECK CIRCUIT 1052 (TN/BK) FOR AN OPEN (Continued)
Measure the resistance between the SJB C2280h-32, circuit
1052 (TN/BK), harness side and the BEC C1035a-A5, circuit
1052 (TN/BK), harness side.
Yes
No
Measure the resistance between the BEC C1035c-E11, circuit
Yes
GO to A4.
No
(Continued)
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PINPOINT TEST A: THE LOW BEAMS ARE INOPERATIVE (Continued)
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test B: The High Beams Are
Inoperative
or short to voltage on the high beam relay coil
ground controlled circuit.
Refer to Wiring Diagrams Cell 85, Headlamps for
Possible Causes
Normal Operation
Fuse
When the headlamp switch is placed in the
Circuit 1394 (WH/RD) open
HEADLAMPS ON position, the smart junction box
Circuit 1396 (VT/WH) open
(SJB) monitors the multifunction switch by sending
a voltage reference signal through circuit 1394 Circuit 1708 (LG/BK) open or short to voltage
(WH/RD). When the multifunction switch is placed
High beam relay
in the HIGH BEAM position, the signal is routed
to an internal ground within the SJB through circuit
BEC 1396 (VT/WH). The SJB then supplies ground for
the high beam relay coil through circuit 1708
SJB
(LG/BK). The high beam relay is supplied voltage
at all times from the bussed electrical center
(BEC). When the high beam relay is energized,
voltage is routed to the high beams.
PINPOINT TEST B: THE HIGH BEAMS ARE INOPERATIVE
B1 CHECK THE LOW BEAMS
Place the headlamp switch in the HEADLAMPS ON position. GO to B2.
Do the low beams illuminate?
No
B2 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Place the headlamp switch in the OFF position. Yes
Using the recorded results from the SJB self-test: GO to B3.
No
GO to B9.
B3 CHECK THE HIGH BEAM RELAY (DTC B2598)
Disconnect: High Beam Relay. Yes
Carry out the high beam relay component test. Refer to Wiring GO to B4.
No
Is the high beam relay OK?
INSTALL a new high beam relay. CLEAR
B4 CHECK THE HIGH BEAM RELAY CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE
Key in ON position.
(Continued)
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PINPOINT TEST B: THE HIGH BEAMS ARE INOPERATIVE (Continued)
B4 CHECK THE HIGH BEAM RELAY CONTROL CIRCUIT FOR A
Measure the voltage between the high beam relay pin 86, circuit
1708 (LG/BK), harness side and ground.
Yes
GO to B5.
No
B5 CHECK CIRCUIT 1708 (LG/BK) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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B5 CHECK CIRCUIT 1708 (LG/BK) FOR A SHORT TO VOLTAGE
(Continued)
Measure the voltage between the high beam relay pin 86, circuit
1708 (LG/BK), harness side and ground.
Yes
No
B6 CHECK THE VOLTAGE FEED TO THE HIGH BEAM RELAY COIL
(Continued)
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B6 CHECK THE VOLTAGE FEED TO THE HIGH BEAM RELAY COIL
(Continued)
Measure the voltage between the high beam relay pin 85,
Yes
GO to B7.
No
OK, INSTALL a new BEC. CLEAR the
(Continued)
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B7 CHECK THE HIGH BEAM RELAY CONTROL CIRCUIT FOR AN
OPEN
Measure the resistance between the high beam relay pin 86,
circuit 1708 (LG/BK), harness side and the SJB C2280c-1,
circuit 1708 (LG/BK), harness side.
Yes
GO to B13.
No
Is the resistance less than 5 ohms? GO to B8.
B8 CHECK CIRCUIT 1708 (LG/BK) FOR AN OPEN
Measure the resistance between the BEC C1035a-B11, circuit
1708 (LG/BK), harness side and the SJB C2280c-1, circuit 1708
(LG/BK), harness side.
Yes
No
B9 CHECK THE HIGH BEAM SWITCH INPUT
Key in ON position.
(Continued)
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B9 CHECK THE HIGH BEAM SWITCH INPUT (Continued)
Yes
Multifunction Switch PID.
GO to B10.
Monitor the SJB multifunction switch status PID while placing the
multifunction switch in the HIGH BEAM position. No
Does the PID indicate HIGH BEAM position is active? GO to B11.
B10 CHECK THE HIGH BEAM RELAY (NO DTCs)
Place the headlamp switch in the OFF position. INSTALL a new BEC. TEST the system
Disconnect: High Beam Relay. for normal operation.
Carry out the high beam relay component test. Refer to Wiring
No
INSTALL a new high beam relay. TEST
Is the high beam relay OK?
B11 CHECK THE MULTIFUNCTION SWITCH
Disconnect: Multifunction Switch C202.
Connect a fused (5A) jumper wire between the multifunction
switch C202-8, circuit 1394 (WH/RD), harness side and the
multifunction switch C202-10, circuit 1396 (VT/WH), harness
side.
Yes
INSTALL a new multifunction switch.
Key in ON position.
Place the headlamp switch in the HEADLAMPS ON position. No
Is the high beam indicator illuminated? REMOVE the jumper wire. GO to B12.
B12 CHECK CIRCUITS 1394 (WH/RD) AND 1396 (VT/WH) FOR AN
OPEN
(Continued)
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B12 CHECK CIRCUITS 1394 (WH/RD) AND 1396 (VT/WH) FOR AN
OPEN (Continued)
Measure the resistance between the SJB C2280b-45, circuit
1394 (WH/RD), harness side and the multifunction switch
C202-8, circuit 1394 (WH/RD), harness side; and between the
SJB C2280b-4, circuit 1396 (VT/WH) and the multifunction
switch C202-10, circuit 1396 (VT/WH).
Yes
GO to B13.
No
pushed-out pins
No
correctly.
Pinpoint Test C: One Low Beam Headlamp
Is Inoperative
or short to ground on the LH headlamp voltage
supply circuit.
or short to ground on the RH headlamp voltage
Normal Operation
supply circuit.
When the smart junction box (SJB) receives a
request for the low beams, the SJB provides voltage Possible Causes
through circuits 1338 (WH) and 1336 (LG/WH) to
the bussed electrical center (BEC). The BEC then
Circuit 1336 (LG/WH) open or short to ground
routes the voltage to the LH and RH low beams.
Ground for the low beams is provided through Circuit 1338 (WH) open or short to ground
circuit 1205 (BK) which is routed through the BEC.
BEC
SJB
PINPOINT TEST C: ONE LOW BEAM HEADLAMP IS INOPERATIVE
C1 CHECK THE HEADLAMP GROUND CIRCUIT
Disconnect: Inoperative Headlamp.
(Continued)
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PINPOINT TEST C: ONE LOW BEAM HEADLAMP IS INOPERATIVE (Continued)
C1 CHECK THE HEADLAMP GROUND CIRCUIT (Continued)
Measure the resistance between the LH headlamp C1021-2,
circuit 1205 (BK), harness side and ground; or between the RH
headlamp C1041-2, circuit 1205 (BK), harness side and ground.
Yes
GO to C4.
No
Is the resistance less than 5 ohms? GO to C2.
C2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (HEADLAMP TO
BEC)
circuit 1205 (BK), harness side and the BEC C1035c-D5, circuit
1205 (BK), harness side; or between the RH headlamp
C1041-2, circuit 1205 (BK), harness side and the BEC
C1035c-D11, circuit 1205 (BK), harness side.
Yes
GO to C3.
No
(Continued)
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C3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (BEC TO GROUND)
Measure the resistance between the BEC C1035c-F5 (LH
headlamp), circuit 1205 (BK), harness side and ground; or
between the BEC C1035c-E11 (RH headlamp), circuit 1205
Yes
No
C4 CHECK CIRCUIT 1336 (LG/WH) OR CIRCUIT 1338 (WH) FOR A
SHORT TO GROUND
circuit 1338 (WH), harness side and ground; or between the RH
headlamp C1041-1, circuit 1336 (LG/WH), harness side and
ground.
Yes
GO to C7.
No
Is the resistance greater than 10,000 ohms? GO to C5.
SHORT TO GROUND (SJB TO BEC)
(Continued)
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SHORT TO GROUND (SJB TO BEC) (Continued)
ground.
Yes
No
Is the resistance greater than 10,000 ohms? GO to C6.
SHORT TO GROUND (BEC TO HEADLAMP)
ground.
Yes
No
C7 CHECK CIRCUIT 1336 (LG/WH) OR CIRCUIT 1338 (WH) FOR AN
OPEN (BEC TO HEADLAMP)
(Continued)
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OPEN (BEC TO HEADLAMP) (Continued)
circuit 1338 (WH), harness side and the BEC C1035c-A6, circuit
1338 (WH), harness side; or between the RH headlamp
C1041-1, circuit 1336 (LG/WH), harness side and the BEC
C1035c-A2, circuit 1336 (LG/WH), harness side.
Yes
GO to C8.
No
OPEN (SJB TO BEC)
Measure the resistance between the BEC C1035a-F6 (LH
headlamp), circuit 1338 (WH), harness side and the SJB
C2280d-51, circuit 1338 (WH), harness side; or between the
BEC C1035a-F2 (RH headlamp), circuit 1336 (LG/WH), harness
side and the SJB C2280d-48, circuit 1336 (LG/WH), harness
side.
Yes
GO to C9.
No
C9 CHECK THE BEC
Connect: BEC C1035a.
Connect: BEC C1035c.
(Continued)
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C9 CHECK THE BEC (Continued)
circuit 1338 (WH), harness side and the SJB C2280d-51, circuit
1338 (WH), harness side; or between the RH headlamp
C1041-1, circuit 1336 (LG/WH), harness side and the SJB
C2280d-48, circuit 1336 (LG/WH), harness side.
Yes
GO to C10.
No
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test D: One High Beam Headlamp
Is Inoperative
Circuit 1335 (YE/WH) open
Circuit 1337 (VT/YE) open
BEC
Normal Operation
When the high beam relay is energized, voltage is
provided through circuits 1337 (VT/YE) and 1335
(YE/WH) to the LH and RH high beams,
respectively.
PINPOINT TEST D: ONE HIGH BEAM HEADLAMP IS INOPERATIVE
D1 CHECK THE LOW BEAMS
Yes
NOTE: Make sure the multifunction switch is in the LOW BEAM
GO to D2.
position.
Place the headlamp switch in the HEADLAMPS ON position. No
Does the low beam illuminate? GO to Pinpoint Test C.
D2 CHECK CIRCUIT 1335 (YE/WH) OR CIRCUIT 1337 (VT/YE) FOR
AN OPEN
Place the headlamp switch in the OFF position
Disconnect: Inoperative Headlamp.
(Continued)
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PINPOINT TEST D: ONE HIGH BEAM HEADLAMP IS INOPERATIVE (Continued)
D2 CHECK CIRCUIT 1335 (YE/WH) OR CIRCUIT 1337 (VT/YE) FOR
AN OPEN (Continued)
circuit 1337 (VT/YE), harness side and the BEC C1035c-F6,
circuit 1337 (VT/YE), harness side; or between the RH
headlamp C1041-3, circuit 1335 (YE/WH), harness side and the
BEC C1035c-F7, circuit 1335 (YE/WH), harness side.
Yes
No
Pinpoint Test E: The Headlamps Are On
The SJB sends a voltage reference signal to the
Continuously
multifunction switch through circuits 1394
(WH/RD) and 1395 (RD/PK). When the
multifunction switch is placed in the
FLASH-TO-PASS or HIGH BEAM position, the
Normal Operation
signal is routed back to the SJB (ground internal to
The smart junction box (SJB) sends voltage
the SJB). When the SJB detects a request for
reference signals to the headlamp switch through
flash-to-pass or high beams, the SJB provides
circuits 1400 (TN/WH), 1401 (BK/LG), and 1402
ground to the high beam relay through circuit 1708
(RD/WH). At any given time, the headlamp switch
(LG/BK). When the high beam relay is energized,
routes one of the input circuits to ground through
voltage is provided through circuits 1337 (VT/YE)
circuit 1205 (BK).
and 1335 (YE/WH) to the LH and RH high beams,
When the SJB detects the headlamp switch in the respectively.
HEADLAMPS ON position and the multifunction
DTC B1470 sets when the SJB detects an
switch in the LOW BEAM position, the SJB sends
unexpected or conflicting value from the headlamp
voltage through circuits 1338 (WH) and 1336
switch input circuits, such as an open or short to
(LG/WH) to the LH and RH low beams,
ground.
respectively.
voltage on the LH headlamp voltage supply circuit.
voltage on the RH headlamp voltage supply circuit.
ground from either of the multifunction switch input
circuits.
ground on the high beam relay coil ground
controlled circuit.
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Possible Causes
Circuit 1401 (BK/LG) open
Circuit 1205 (BK) open Circuit 1402 (RD/WH) short to ground
Circuit 1335 (YE/WH) short to voltage Circuit 1708 (LG/BK) short to ground
Circuit 1336 (LG/WH) short to voltage High beam relay
Circuit 1337 (VT/YE) short to voltage Headlamp switch
Circuit 1338 (WH) short to voltage Multifunction switch
Circuit 1394 (WH/RD) short to ground BEC
Circuit 1395 (RD/PK) short to ground SJB
Circuit 1400 (TN/WH) open
PINPOINT TEST E: THE HEADLAMPS ARE ON CONTINUOUSLY
E1 DETERMINE IF THE HIGH BEAMS ARE ALWAYS ON
While observing the headlamps, engage the flash-to-pass GO to E2.
feature.
No
Does the headlamp brightness increase?
GO to E10.
E2 USE THE RECORDED DTCs FROM THE SJB SELF-TEST (LOW
BEAMS ALWAYS ON)
Using the recorded results from the SJB self-test: GO to E3.
Was DTC B1470 recorded?
No
GO to E7.
E3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Yes
GO to E4.
No
E4 CHECK THE HEADLAMP SWITCH
Carry out the headlamp switch component test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to E5.
No
INSTALL a new headlamp switch. REFER
to Headlamp Switch in this section.
E5 CHECK THE HEADLAMP SWITCH INPUT CIRCUITS FOR A
SHORT TO GROUND
(Continued)
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PINPOINT TEST E: THE HEADLAMPS ARE ON CONTINUOUSLY (Continued)
E5 CHECK THE HEADLAMP SWITCH INPUT CIRCUITS FOR A
Measure the resistance between the headlamp switch, harness
Headlamp Switch
C205-9 1400 (TN/WH)
Yes
C205-5 1401 (BK/LG)
GO to E6.
C205-10 1402 (RD/WH)
No
E6 CHECK THE HEADLAMP SWITCH INPUT CIRCUITS FOR AN
OPEN
Measure the resistance between the headlamp switch, harness
side and the SJB, harness side as follows:
Headlamp Switch
Connector-Pin SJB Connector-Pin Circuit
C205-9 C2280b-27 1400 (TN/WH)
Yes
C205-5 C2280b-31 1401 (BK/LG)
GO to E17.
C205-10 C2280b-46 1402 (RD/WH)
No
E7 CHECK THE SJB
Disconnect: SJB C2280d. GO to E8.
Key in ON position.
No
Does either headlamp continue to illuminate?
GO to E17.
E8 CHECK CIRCUITS 1336 (LG/WH) AND 1338 (WH) FOR A SHORT
TO VOLTAGE (SJB TO BEC)
Disconnect: BEC C1035a. GO to E9.
Key in ON position.
No
Does either headlamp continue to illuminate?
REPAIR circuit 1338 (WH) (LH headlamp)
or circuit 1336 (LG/WH) (RH headlamp).
E9 CHECK CIRCUITS 1336 (LG/WH) AND 1338 (WH) FOR A SHORT
TO VOLTAGE (BEC TO HEADLAMP)
Disconnect: BEC C1035c. REPAIR circuit 1338 (WH) (LH headlamp)
Key in ON position. or circuit 1336 (LG/WH) (RH headlamp).
Does either headlamp continue to illuminate? CLEAR the DTCs. REPEAT the self-test.
No
E10 USE THE RECORDED DTCs FROM THE SJB SELF-TEST (HIGH
BEAMS ALWAYS ON)
Using the recorded results from the SJB self-test: For DTC B2586, GO to E11.
Was DTC B2586 or B2598 recorded?
For DTC B2598, GO to E13.
No
GO to E15.
(Continued)
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E11 VERIFY DTC B2586
NOTE: Make sure the multifunction switch is in the LOW BEAM
position.
1394 (WH/RD), harness side and ground; and between the SJB
C2280b-40, circuit 1395 (RD/PK), harness side and ground.
1394 (WH/RD), harness side and the SJB C2280b-4, circuit
1396 (VT/WH), harness side; and between the SJB C2280b-40,
circuit 1395 (RD/PK), harness side and the SJB C2280b-4,
circuit 1396 (VT/WH), harness side.
Yes
GO to E17.
No
Are the resistances greater than 10,000 ohms? GO to E12.
E12 CHECK CIRCUITS 1394 (WH/RD) AND 1395 (RD/PK) FOR A
SHORT TO GROUND
(Continued)
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E12 CHECK CIRCUITS 1394 (WH/RD) AND 1395 (RD/PK) FOR A
1394 (WH/RD), harness side and ground; and between the SJB
C2280b-40, circuit 1395 (RD/PK), harness side and ground.
Yes
No
E13 CHECK THE SJB HIGH BEAM CONTROL
Disconnect: SJB C2280c. Yes
Do the headlamps continue to illuminate?
No
GO to E17.
E14 CHECK CIRCUIT 1708 (LG/BK) FOR A SHORT TO GROUND
Disconnect: BEC C1035a. INSTALL a new BEC. CLEAR the DTCs.
Key in ON position. REPEAT the self-test.
No
E15 CHECK THE HIGH BEAM RELAY
Disconnect: High Beam Relay. Yes
No
INSTALL a new high beam relay. TEST
E16 CHECK CIRCUITS 1335 (YE/WH) AND 1337 (VT/YE) FOR A
SHORT TO VOLTAGE
Disconnect: BEC C1035c. REPAIR circuit 1337 (VT/YE) (LH
Key in ON position. headlamp) or circuit 1335 (YE/WH) (RH
Does either headlamp continue to illuminate? headlamp). TEST the system for normal
operation.
No
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
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Possible Causes
Pinpoint Test F: The Flash-to-Pass Feature
is Inoperative
Circuit 1395 (RD/PK) open
SJB
Normal Operation
reference signal to the multifunction switch through
circuit 1395 (RD/PK). When the flash-to-pass
feature is activated, the multifunction switch routes
the signal back to the SJB. The SJB then provides
voltage to the high beams.
PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE
F1 CHECK THE HIGH BEAM OPERATION
Place the headlamp switch in the HEADLAMPS ON position. GO to F2.
Place the multifunction switch in the HIGH BEAM position.
No
Do the high beams illuminate?
F2 CHECK CIRCUIT 1395 (RD/PK) FOR AN OPEN
Measure the resistance between the multifunction switch
C202-9, circuit 1395 (RD/PK), harness side and the SJB
C2280b-40, circuit 1395 (RD/PK), harness side.
Yes
GO to F3.
No
F3 CHECK THE MULTIFUNCTION SWITCH
Connect: Multifunction Switch C202.
Place the multifunction switch in the FLASH-TO-PASS position.
(Continued)
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PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE (Continued)
F3 CHECK THE MULTIFUNCTION SWITCH (Continued)
1395 (RD/PK), harness side and the SJB C2280b-4, circuit 1396
(VT/WH), harness side.
Yes
GO to F4.
No
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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High Mounted Stoplamp
1 13A613 High mounted stoplamp
assembly
1. Remove the decklid latch trim cover.
2. Release the locking tabs and remove the high
mounted stoplamp assembly.
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417-02-1 417-02-1 Interior Lighting
The bussed electrical center (BEC) supplies power
Interior Lighting
to the interior lighting system through the SJB. The
The interior lighting system consists of 2
SJB will set DTCs if certain circuit failures exist
subsystems:
with the interior lighting system.
Courtesy lamps
Demand lamps
The courtesy lamps are controlled by the smart
junction box (SJB). The courtesy lamp subsystem
consists of the interior dome lamps. The SJB
controls the courtesy lamps by providing power to
the lamps. The SJB also provides the ground circuit
for the courtesy lamps. The courtesy lighting feature
will request the courtesy lamps to be illuminated
when any of the vehicle doors are opened or
become ajar and the vehicle speed is less than 15
km/h (9 mph). The courtesy lamps will turn off,
when the doors are closed or the vehicle speed
reaches 15 km/h (9 mph). The courtesy lamps can
also be turned on by rotating the instrument panel
dimmer switch to the highest point. The theatre
dimming option raises the courtesy lamps over 0.7
seconds when courtesy lamp activation is requested,
and lowers the courtesy lamps over 1.7 seconds
when courtesy lighting deactivation is requested.
The demand lamp subsystem consists of the map
lamps and the luggage compartment lamp. Map
lamps are switched individually and share a
common ground circuit. The luggage compartment
lamp is illuminated when the trunk is opened.
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Interior Lighting
Special Tool(s)
Electrical
Fuse
Circuitry
Loose or corroded connections
Vehicle Communications Lamp(s)
Module (VCM) and Integrated Dimmer switch
Diagnostic System (IDS) Door ajar switches
software with appropriate Smart junction box (SJB)
tool
Flex Probe Kit before proceeding to the next step.
release software.
When the smart junction box (SJB) detects a request VCM.
for lighting, it turns on the interior lamps by
supplying power and ground to the lamps. The
VCM:
request for lighting can be an open door signal from
a door ajar switch, an interior lighting on command
from the instrument panel dimmer switch or an
unlock command from a remote keyless entry
(RKE) transmitter.
with the scan tool.
The door ajar switches are hard-wired directly to the
SJB. The 2 door ajar switches are normally closed
when the doors are closed. The luggage
vehicle:
compartment lid ajar switch is normally closed
when the luggage compartment lid is closed. All
position.
door ajar switches receive voltage from the SJB
and each has its own ground circuit.
good vehicle.
The instrument panel dimmer switch receives a
voltage signal from the SJB. The instrument panel
dimmer switch provides variable resistance for
(PCM).
backlighting the instrument cluster and a toggle
7. Carry out the network test. on/off function for the courtesy lamps.
If the scan tool responds with no The RKE receiver is contained inside the SJB.
communication with the SJB, refer to When the SJB receives an unlock request from a
Section 418-00. RKE transmitter, it unlocks the doors and turns on
the courtesy lamps.
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If the network test passes, retrieve and 9. If the DTCs retrieved are related to the concern,
record the continuous memory DTCs. go to the Smart Junction Box (SJB) Diagnostic
B1084 Trunk Lamp Circuit Failure If the luggage compartment lamp is inoperative,
GO to Pinpoint Test F.
If the luggage compartment lamp is always on,
GO to Pinpoint Test G.
B1319 Drivers Door Ajar Circuit Failure GO to Pinpoint Test D.
B1327 Passengers Door Ajar Circuit Failure GO to Pinpoint Test D.
B2021 Dome Lamp Output Return Circuit Failure GO to Pinpoint Test A.
B2550 Lamp Dome Output Circuit Short to Ground GO to Pinpoint Test A.
B2554 Lamp Dome Output Circuit Failure If the interior lamps are inoperative, GO to
Pinpoint Test A
If the interior lamps are always on, GO to
Pinpoint Test D.
Symptom Chart
Symptom Chart
The courtesy lamps are Fuse GO to Pinpoint Test A.
Interior lamp
SJB
The courtesy lamps do not Circuitry GO to Pinpoint Test B.
turn on with one door open Door ajar switch
SJB
The courtesy lamps are Circuitry GO to Pinpoint Test C.
inoperative using the Dimmer switch
dimmer switch SJB
The courtesy lamps stay on Circuitry GO to Pinpoint Test D.
continuously Door ajar switch
Dimmer switch
SJB
The demand lamps are Circuitry GO to Pinpoint Test E.
inoperative Interior lamp
The luggage compartment Circuitry GO to Pinpoint Test F.
lamp is inoperative Luggage compartment lamp
Luggage compartment lid ajar
switch
SJB
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The luggage compartment Circuitry GO to Pinpoint Test G.
lamp stays on continuously Luggage compartment lid ajar
switch
SJB
The illuminated entry is RKE system GO to Pinpoint Test H.
inoperative when using the SJB
remote keyless entry (RKE)
transmitter
Pinpoint Tests DTC B2021 sets when the SJB detects a short to
voltage on the dome lamp return circuit.
Pinpoint Test A: The Courtesy Lamps Are
Inoperative
ground on the dome lamp output supply circuit.
Refer to Wiring Diagrams Cell 89, Interior Lamps
on the dome lamp supply or return circuits.
Normal Operation
Possible Causes
Power is supplied to the smart junction box (SJB)
through the bussed electrical center (BEC) fuse 67 Fuse
(30A) to the SJB. When a door is opened, the ajar
Circuit 53 (BK/LB) open or short to ground
switch opens, signaling the SJB. The SJB monitors
Circuit 54 (LG/YE) open or short to voltage
the ajar circuits, and based on the ajar status, the
Interior lamp SJB will supply voltage to the courtesy lamps on
circuit 53 (BK/LB). Ground for the courtesy lamps
SJB
is supplied by the SJB through circuit 54 (LG/YE).
PINPOINT TEST A: THE COURTESY LAMPS ARE INOPERATIVE
A1 CHECK THE SJB DTCs
Check the SJB for DTCs. For DTC B2021, GO to A2.
Is DTC B2021 or B2554 present?
No
GO to A4.
A2 CHECK CIRCUIT 54 (LG/YE) FOR A SHORT TO VOLTAGE
Disconnect: Overhead Console C930.
Disconnect: Overhead Console (With Convertible Top) C9013.
Disconnect: SJB C2280f.
Key in ON position.
(Continued)
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PINPOINT TEST A: THE COURTESY LAMPS ARE INOPERATIVE (Continued)
A2 CHECK CIRCUIT 54 (LG/YE) FOR A SHORT TO VOLTAGE
(Continued)
For vehicles without a convertible top, measure the voltage
between the overhead console C930-4, circuit 54 (LG/YE),
For vehicles with a convertible top, measure the voltage
Yes
No
A3 CHECK CIRCUIT 53 (BK/LB) FOR A SHORT TO GROUND
For vehicles without a convertible top, measure the resistance
between the overhead console C930-5, circuit 53 (BK/LB),
(Continued)
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A3 CHECK CIRCUIT 53 (BK/LB) FOR A SHORT TO GROUND
(Continued)
For vehicles with a convertible top, measure the resistance
Yes
GO to A9.
No
A4 CHECK THE SJB DOOR AJAR AND THE DIMMER SWITCH PIDs
Enter the following diagnostic mode on the scan tool: SJB Door Yes
Ajar and the Dimmer Switch PIDs. GO to A9.
Open all the doors and operate the dimmer switch.
No
Do the SJB door ajar and dimmer switch PIDs correspond?
For door ajar, GO to Pinpoint Test B.
For dimmer switch, GO to Pinpoint Test C.
A5 CHECK CIRCUIT 53 (BK/LB) FOR VOLTAGE
Key in ON position.
(Continued)
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A5 CHECK CIRCUIT 53 (BK/LB) FOR VOLTAGE (Continued)
Yes
GO to A7.
No
A6 CHECK CIRCUIT 53 (BK/LB) FOR AN OPEN
harness side and the SJB C2280f-26, circuit 53 (BK/LB),
harness side.
harness side and the SJB C2280f-26, circuit 53 (BK/LB),
harness side.
Yes
OK, GO to A9.
No
(Continued)
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A7 CHECK CIRCUIT 1052 (TN/BK) FOR AN OPEN
Disconnect: BEC C1035A.
1052 (TN/BK), harness side and the BEC C1035a-A5, circuit
1052 (TN/BK, harness side.
Yes
OK, GO to A8.
No
A8 CHECK THE GROUND CIRCUIT TO THE OVERHEAD CONSOLE
harness side and the overhead console C930-4, circuit 54
(LG/YE), harness side.
harness side and the overhead console C930-4, circuit 54
(LG/YE), harness side.
Yes
INSTALL a new interior lamp. CLEAR the
No
(Continued)
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A9 CHECK CIRCUIT 54 (LG/YE) FOR AN OPEN
harness side and the SJB C2280f-25, circuit 54 (LG/YE),
harness side.
harness side and the SJB C2280f-25, circuit 54 (LG/YE),
harness side.
Yes
GO to A10.
No
pushed-out pins
No
correctly.
Pinpoint Test B: The Courtesy Lamps Do Normal Operation
Not Turn On With One Door Open
When a door is open, the ajar switch opens the
circuit to the smart junction box (SJB). The SJB
monitors the ajar circuits, and based on the ajar
status, the SJB will supply voltage to the courtesy
lamps on circuit 53 (BK/LB).
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Possible Causes
Circuit 1312 (LG/BK) short to ground
Circuit 1314 (YE/LG) short to ground
Door ajar switch
SJB
PINPOINT TEST B: THE COURTESY LAMPS DO NOT TURN ON WITH ONE DOOR OPEN
B1 CHECK THE SJB DOOR AJAR PIDs
Key in ON position.
Enter the following diagnostic mode on the scan tool: SJB Door
Ajar PIDs.
Yes
Check the SJB door ajar PIDs while opening and closing all the
GO to B4.
doors.
Do all the door ajar PID values agree with the door No
positions? GO to B2.
B2 CHECK THE DOOR AJAR SWITCH OPERATION
Disconnect: Suspect Door Ajar Switch.
Measure the resistance between the suspect door ajar switch
pins, component side, while toggling the switch open and closed
as follows:
Location Connector Pins
Yes
LH door C526 1 and 2
GO to B3.
RH door C602 1 and 2
No
INSTALL a new door ajar switch for the
Is the resistance less than 5 ohms when the door ajar switch in question. REFER to Section
switch is closed, and greater than 10,000 ohms when the 501-14. TEST the system for normal
door ajar switch is open? operation.
B3 CHECK THE DOOR AJAR SWITCH SIGNAL CIRCUIT FOR A
SHORT TO GROUND
Measure the resistance between the suspect door ajar switch,
Yes
LH door C526-2 1312 (LG/BK)
GO to B4.
RH door C602-2 1314 (YE/LG)
No
pushed-out pins
No
correctly.
Pinpoint Test C: The Courtesy Lamps Are
Inoperative Using The Dimmer Switch
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Possible Causes
Normal Operation
The smart junction box (SJB) monitors the dimmer
Circuit 2085 (VT/YE) open
switch status on circuit 2085 (VT/YE) to determine
Dimmer switch
if the courtesy lamps are requested. Based on the
SJB dimmer switch status, the SJB supplies voltage to
the courtesy lamps through circuit 53 (BK/LB).
PINPOINT TEST C: THE COURTESY LAMPS ARE INOPERATIVE USING THE DIMMER SWITCH
C1 CHECK CIRCUIT 2085 (VT/YE) FOR AN OPEN
Disconnect: Dimmer Switch C2298.
2085 (VT/YE), harness side and the dimmer switch C2298-5,
circuit 2085 (VT/YE), harness side.
Yes
GO to C2.
No
C2 CHECK THE DIMMER SWITCH
Carry out the dimmer switch component test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to C3.
Is the dimmer switch OK?
No
INSTALL a new dimmer switch. TEST the
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test D: The Courtesy Lamps Stay
On Continuously
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Normal Operation
When a door is opened, the door ajar input from
voltage on the dome lamp output supply circuit.
circuit 1312 (LG/BK) or circuit 1314 (YE/GN) to
Possible Causes
the smart junction box (SJB) open. When the SJB
Circuit 53 (BK/LB) short to voltage
identifies that the circuit is open, the SJB provides
voltage to the courtesy lamps through circuit 53
Circuit 54 (LG/YE) short to ground
(BK/LB). The door ajar switches are grounded
through circuit 1205 (BK). When the dimmer switch
Circuit 1312 (LG/BK) open
is rotated to the interior lamps ON position, the SJB
receives a signal through circuit 2085 (VT/YE),
Circuit 1314 (YE/LG) open
requesting the courtesy lamps.
Circuit 2085 (VT/YE) short to ground
Door ajar switch
on the driver door ajar switch circuit.
Dimmer switch
SJB
on the passenger door ajar switch circuit.
PINPOINT TEST D: THE COURTESY LAMPS STAY ON CONTINUOUSLY
D1 CHECK THE SJB DTCs
Check the SJB for DTCs. For DTC B1319 or B1327, GO to D2.
Is DTC B1319, B1327 or B2554 present?
For DTC B2554, GO to D6.
No
GO to D7.
D2 CHECK THE AJAR SIGNAL CIRCUIT FOR GROUND
Measure the resistance between the SJB, harness side and
ground as follows:
Connector-Pin/
DTC Location Circuit
B1319 LH door C2280e-2
1312 (LG/BK)
B1327 RH door C2280e-6
1314 (YE/LG)
Yes
GO to D11.
No
(Continued)
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PINPOINT TEST D: THE COURTESY LAMPS STAY ON CONTINUOUSLY (Continued)
D3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Suspect Door Ajar Switch.
Connector-Pin/
B1319 LH door C526-1
1205 (BK)
B1327 RH door C602-1
1205 (BK)
Yes
GO to D4.
No
D4 CHECK THE DOOR AJAR SIGNAL CIRCUIT FOR A SHORT TO
VOLTAGE
Key in ON position.
Measure the voltage between the suspect door ajar switch,
Connector-Pin/
B1319 LH door C526-2
1312 (LG/BK)
B1327 RH door C602-2
1314 (YE/LG)
Yes
No
(Continued)
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D5 CHECK THE DOOR AJAR SIGNAL CIRCUIT FOR AN OPEN
harness side and the SJB, harness side as follows:
SJB Ajar Switch
Connector- Connector-
DTC Location Pin/Circuit Pin/Circuit
B1319 LH door C2280e-2 C526-2
1312 (LG/BK) 1312 (LG/BK)
B1327 RH door C2280e-6 C602-2
1314 (YE/LG) 1314 (YE/LG)
Yes
INSTALL a new door ajar switch. REFER
to Section 501-14. CLEAR the DTCs.
No
D6 CHECK CIRCUIT 53 (BK/LB) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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D6 CHECK CIRCUIT 53 (BK/LB) FOR A SHORT TO VOLTAGE
(Continued)
Yes
No
D7 CHECK THE SJB DOME LAMP SWITCH PID
Key in ON position.
Enter the following diagnostic mode on the scan tool: SJB Dome
Yes
Lamp Switch PID.
GO to D8.
Close all doors and rotate the dimmer switch to the dome lamp
OFF position. No
Does the dome lamp switch PID read active? GO to D10.
D8 CHECK CIRCUIT 2085 (VT/YE) FOR A SHORT TO GROUND
Disconnect: Dimmer Switch C2298.
Measure the resistance between the dimmer switch C2298-5,
circuit 2085 (VT/YE), harness side and ground.
Yes
GO to D9.
No
D9 CHECK THE DIMMER SWITCH
Carry out the dimmer switch component test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to D11.
Is the dimmer switch OK?
No
INSTALL a new dimmer switch. TEST the
D10 CHECK CIRCUIT 54 (LG/YE) FOR A SHORT TO GROUND
(Continued)
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D10 CHECK CIRCUIT 54 (LG/YE) FOR A SHORT TO GROUND
(Continued)
Yes
GO to D11.
No
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test E: The Demand Lamps Are
Inoperative
Interior lamp
Normal Operation
The smart junction box (SJB) provides voltage to
the demand lamps through circuit 53 (BK/LB).
Ground for the demand lamps is provided through
circuit 1205 (BK).
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PINPOINT TEST E: THE DEMAND LAMPS ARE INOPERATIVE
between the overhead console C930-3, circuit 1205 (BK),
between the overhead console C9013-3, circuit 1205 (BK),
Yes
If the courtesy lamps are inoperative, GO
to Pinpoint Test A.
If the courtesy lamps operate correctly,
INSTALL a new lamp. TEST the system
No
Pinpoint Test F: The Luggage Compartment
Lamp Is Inoperative
or short to ground on the luggage compartment
lamp supply circuit.
Possible Causes
Normal Operation
Circuit 707 (WH/YE) open or short to ground
When the luggage compartment lid is open, circuit
1351 (TN) to the smart junction box (SJB) opens.
Circuit 1351 (TN) short to ground
When the SJB identifies that the circuit is open, the
SJB provides voltage to the luggage compartment Luggage compartment lamp
lamp through circuit 707 (WH/YE). The luggage
Luggage compartment lid ajar switch
compartment lid ajar switch and the luggage
SJB
compartment lamp are grounded through circuit
1205 (BK).
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PINPOINT TEST F: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE
F1 CHECK THE SJB DTCs
Check the SJB for DTCs. GO to F2.
Is DTC B1084 present?
No
GO to F6.
Disconnect: Luggage Compartment Lamp C428.
Measure the resistance between the luggage compartment lamp
Yes
GO to F3.
No
F3 CHECK CIRCUIT 707 (WH/YE) FOR VOLTAGE
Key in ON position.
Measure the voltage between the luggage compartment lamp
C428-1, circuit 707 (WH/YE), harness side and ground.
Yes
INSTALL a new lamp. CLEAR the DTCs.
No
F4 CHECK CIRCUIT 707 (WH/YE) FOR A SHORT TO GROUND
(Continued)
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PINPOINT TEST F: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE (Continued)
F4 CHECK CIRCUIT 707 (WH/YE) FOR A SHORT TO GROUND
(Continued)
Yes
GO to F5.
No
F5 CHECK CIRCUIT 707 (WH/YE) FOR AN OPEN
C428-1, circuit 707 (WH/YE), harness side and the SJB
C2280e-15, circuit 707 (WH/YE), harness side.
Yes
GO to F9.
No
F6 CHECK THE SJB LUGGAGE COMPARTMENT LID AJAR PID
Enter the following diagnostic mode on the scan tool: SJB Yes
Luggage Compartment Lid Ajar PID. GO to F9.
Open the luggage compartment lid.
No
Does the luggage compartment lid ajar PID read open?
GO to F7.
F7 CHECK THE SJB LUGGAGE COMPARTMENT LID AJAR
SWITCH PID
Yes
Disconnect: Luggage Compartment Lid Ajar Switch C429.
INSTALL a new luggage compartment lid
Key in ON position.
ajar switch. REFER to Section 501-14.
Luggage Compartment Lid Ajar PID.
Monitor the luggage compartment lid ajar PID. No
Does the luggage compartment lid ajar PID read open? GO to F8.
F8 CHECK CIRCUIT 1351 (TN) FOR A SHORT TO GROUND
(Continued)
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PINPOINT TEST F: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE (Continued)
F8 CHECK CIRCUIT 1351 (TN) FOR A SHORT TO GROUND
(Continued)
Measure the resistance between the luggage compartment lid
ajar switch C429-1, circuit 1351 (TN), harness side and ground.
Yes
GO to F9.
No
pushed-out pins
No
correctly.
Pinpoint Test G: The Luggage Compartment
Lamp Stays On Continuously
voltage on the luggage compartment lamp supply
circuit.
Possible Causes
Normal Operation
Circuit 707 (WH/YE) short to voltage
When the luggage compartment lid is open, circuit
1351 (TN) to the smart junction box (SJB) opens.
Circuit 1351 (TN) open
When the SJB identifies that the circuit is open, the
SJB provides voltage to the luggage compartment Luggage compartment lid ajar switch
lamp through circuit 707 (WH/YE). The luggage
SJB
compartment lid ajar switch is grounded through
circuit 1205 (BK).
PINPOINT TEST G: THE LUGGAGE COMPARTMENT LAMP STAYS ON CONTINUOUSLY
G1 CHECK THE SJB DTCs
Check the SJB for DTCs. GO to G2.
Is DTC B1084 present?
No
GO to G3.
G2 CHECK CIRCUIT 707 (WH/YE) FOR A SHORT TO VOLTAGE
(Continued)
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PINPOINT TEST G: THE LUGGAGE COMPARTMENT LAMP STAYS ON CONTINUOUSLY (Continued)
G2 CHECK CIRCUIT 707 (WH/YE) FOR A SHORT TO VOLTAGE
(Continued)
Disconnect: Luggage Compartment Lamp C428.
Key in ON position.
Measure the voltage between the luggage compartment lamp
Yes
No
Is any voltage present? GO to G7.
G3 CHECK THE AJAR SIGNAL CIRCUIT FOR GROUND
NOTE: The luggage compartment lid must be closed.
1351 (TN), harness side and ground.
Yes
GO to G7.
No
Is the resistance less than 5 ohms? GO to G4.
G4 CHECK THE LUGGAGE COMPARTMENT LID AJAR SWITCH
Disconnect: Luggage Compartment Lid Ajar Switch C429.
(Continued)
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G4 CHECK THE LUGGAGE COMPARTMENT LID AJAR SWITCH
(Continued)
Place a fused (10A) jumper between the luggage compartment
lid ajar switch C429-2, circuit 1205 (BK), harness side and the
luggage compartment lid ajar switch C429-1, circuit 1351 (TN),
harness side.
1351 (TN), harness side and ground.
Yes
INSTALL a new ajar switch. REFER to
normal operation.
No
Is the resistance less than 5 ohms? REMOVE the jumper wire. GO to G5.
G5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
ajar switch C429-2, circuit 1205 (BK), harness side and ground.
Yes
GO to G6.
No
(Continued)
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G6 CHECK CIRCUIT 1351 (TN) FOR AN OPEN
1351 (TN), harness side and the luggage compartment lid ajar
switch C429-1, circuit 1351 (TN), harness side.
Yes
GO to G7.
No
G7 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test H: The Illuminated Entry is
Inoperative When Using The Remote Keyless
RKE system
Entry (RKE) Transmitter
SJB
Normal Operation
The illuminated entry provides courtesy lighting
whenever the smart junction box (SJB) receives a
doors unlock request from the RKE transmitter. The
SJB provides voltage on circuit 53 (BK/LB) for the
courtesy lamps.
PINPOINT TEST H: THE ILLUMINATED ENTRY IS INOPERATIVE WHEN USING THE REMOTE KEYLESS
ENTRY (RKE) TRANSMITTER
H1 CHECK THE VEHICLE EQUIPMENT
Check to see if the vehicle is equipped with RKE. Yes
Is the vehicle equipped with RKE? GO to H2.
No
operation.
(Continued)
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PINPOINT TEST H: THE ILLUMINATED ENTRY IS INOPERATIVE WHEN USING THE REMOTE KEYLESS
ENTRY (RKE) TRANSMITTER (Continued)
H2 CHECK THE RKE TRANSMITTER
Using the RKE transmitter, lock and unlock the doors. Yes
Do the doors lock and unlock? INSTALL a new SJB. REFER to Section
operation.
No
diagnosis of the RKE system.
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Parking, Rear and License Plate
Lamps
VCM. Special Tool(s)
VCM: 105-R0057 or equivalent
with the scan tool.
vehicle:
tool position.
good vehicle.
Flex Probe Kit
Refer to Section 418-00 to diagnose no 105-R025C or equivalent
(PCM).
go to the Smart Junction Box (SJB) Diagnostic Mechanical Electrical
Headlamp switch Circuitry
Bulbs
Smart junction box
(SJB)
OFF position.
software release.
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operation.
B1470 Lamp Headlamp Input Circuit Failure GO to Pinpoint Test N.
B2035 LF Side Repeater Lamp Output Ckt Failure If the lamps are inoperative, GO to Pinpoint
Test M.
If the lamps are always on, GO to Pinpoint Test
N.
B2491 RF Park Lamp Output Circuit Short to Battery If the lamp is inoperative, GO to Pinpoint Test
M.
If the lamp is always on, GO to Pinpoint Test
N.
B2493 LF Park Lamp Output Circuit Short to Battery If the lamp is inoperative, GO to Pinpoint Test
M.
N.
B2523 License Lamp Circuit Failure If the lamps are inoperative, GO to Pinpoint
Test M
If the lamps are always on, GO to Pinpoint Test
N.
Symptom Chart
Symptom Chart
One or more parking, rear, or Circuitry GO to Pinpoint Test M.
license plate lamp is Bussed electrical center
inoperative (BEC)
SJB
The parking, rear, or license Circuitry GO to Pinpoint Test N.
plate lamps are on Headlamp switch
continuously BEC
SJB
Pinpoint Test M: One Or More Parking, Rear
Or License Plate Lamp Is Inoperative
circuit 1401 (BK/LG). When the headlamp switch is
Refer to Wiring Diagrams Cell 92, Parking Rear
placed in the PARKING LAMPS ON position, the
and License Lamps for schematic and connector
SJB provides voltage to the parking, rear, license
information.
plate and side marker lamps. The lamps are
or short to ground to all the side marker lamps
voltage supply circuit.
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DTC B2491 sets when the SJB detects an open Circuit 1339 (BK/PK) open or short to ground
to the RH front parking lamp voltage supply circuit.
Circuit 1340 (DG) open or short to ground
Circuit 1361 (RD/PK) open or short to ground
to the LH front parking lamp voltage supply circuit.
Circuit 1366 (TN/RD) open or short to ground
Circuit 1364 (DB/YE) open or short to ground
or short to ground to both license plate lamps and
Circuit 1370 (DG/LG) open or short to ground
both rear lamp 3 voltage supply circuits.
Circuit 1729 (DB/YE) open or short to ground
Possible Causes
Circuit 1784 (TN/RD) open or short to ground
Circuit 14 (BN) open or short to ground
BEC
Circuit 667 (WH/RD) open or short to ground
SJB
PINPOINT TEST M: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMP IS INOPERATIVE
M1 CHECK THE STOPLAMP OPERATION
Apply and release the brake pedal while observing the GO to M2.
stoplamps.
No
REFER to Stoplamps in this section.
M2 CHECK THE TURN SIGNAL OPERATION
Place the multifunction switch in the LH and then RH TURN GO to M3.
position.
No
Do the turn lamps operate correctly?
REFER to Turn Signal and Hazard Lamps
in this section.
M3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Inoperative Parking Lamp.
Measure the resistance between the inoperative parking lamp,
(Continued)
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(Continued)
M3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Inoperative Parking Lamp
LH front C1023-1 1205 (BK)
RH front C1043-1 1205 (BK)
LH front side marker C151-2 1205 (BK)
RH front side marker C161-2 1205 (BK)
LH rear side marker C481-2 1205 (BK)
RH rear side marker C482-2 1205 (BK)
LH rear 1 C4112-1 1205 (BK)
LH rear 2 C4113-1 1205 (BK)
LH tail C412-1 1205 (BK)
RH rear 1 C4114-1 1205 (BK)
RH rear 2 C4115-1 1205 (BK) Yes
GO to M5.
RH tail C415-1 1205 (BK)
No
For a front side marker lamp, GO to M4. License plate C4046-2 1205 (BK)
For all others, REPAIR the circuit. CLEAR
Is the resistance less than 5 ohms? the DTCs. REPEAT the self-test.
M4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (SIDE LAMP TO
BEC)
Measure the resistance between the LH front side marker
C1035c-F3, circuit 1205 (BK), harness side; or between the RH
front side marker C161-2, circuit 1205 (BK), harness side and
the BEC C1035c-F10, circuit 1205 (BK), harness side.
Yes
No
M5 CHECK THE PARKING LAMP VOLTAGE SUPPLY CIRCUIT FOR
A SHORT TO GROUND
NOTE: If testing at a rear side marker lamp, both rear side marker
lamps must be disconnected for correct test results.
NOTE: If testing at the rear lamp 1 or rear lamp 2, both lamps must
be disconnected for correct test results.
(Continued)
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(Continued)
A SHORT TO GROUND (Continued)
LH front C1023-2 1340 (DG)
RH front C1043-2 1339 (BK/PK)
LH front side marker C151-1 667 (WH/RD)
RH front side marker C161-1 14 (BN)
LH rear side marker C481-1 1361 (RD/PK)
RH rear side marker C482-1 1361 (RD/PK)
LH rear 1 C4112-2 1364 (DB/YE)
LH rear 2 C4113-2 1364 (DB/YE)
LH tail C412-2 1784 (TN/RD)
RH rear 1 C4114-2 1366 (TN/RD)
Yes
RH rear 2 C4115-2 1366 (TN/RD) GO to M8.
No
RH tail C415-2 1729 (DB/YE)
For a front lamp, GO to M6.
License plate C4046-1 1370 (DG/LG)
For all others, REPAIR the circuit in
Is the resistance greater than 10,000 ohms? self-test.
A SHORT TO GROUND (BEC TO SJB)
LH front C1023-2 1340 (DG)
Yes
No
Is the resistance greater than 10,000 ohms? GO to M7.
A SHORT TO GROUND (BEC TO FRONT LAMP)
(Continued)
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(Continued)
A SHORT TO GROUND (BEC TO FRONT LAMP) (Continued)
LH front C1023-2 1340 (DG)
Yes
No
AN OPEN (SJB TO LAMP)
harness side and the SJB harness side as follows:
Inoperative Parking
Lamp
LH front C1023-2 C2280d-29 1340 (DG)
RH front C1043-2 C2280d-31 1339 (BK/PK)
LH front side marker C2280d-16 667 (WH/RD)
C151-1
RH front side marker C2280d-17 14 (BN)
C161-1
LH rear side marker C2280d-15 1361 (RD/PK)
C481-1
RH rear side marker C2280d-15 1361 (RD/PK)
C482-1
LH rear 1 C4112-2 C2280d-30 1364 (DB/YE)
LH rear 2 C4113-2 C2280d-30 1364 (DB/YE)
LH rear 3 C412-2 C2280d-24 1784 (TN/RD)
RH rear 1 C4114-2 C2280d-32 1366 (TN/RD)
Yes
RH rear 2 C4115-2 C2280d-32 1366 (TN/RD) GO to M11.
No
RH rear 3 C415-2 C2280d-38 1729 (DB/YE)
For a front lamp, GO to M9.
License plate C4046-1 C2280d-37 1370 (DG/LG)
For all others, REPAIR the circuit in
Is the resistance less than 5 ohms? self-test.
AN OPEN (SJB TO BEC)
Measure the resistance between the BEC, harness side and the
SJB, harness side as follows:
(Continued)
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(Continued)
AN OPEN (SJB TO BEC) (Continued)
Inoperative BEC SJB
Parking Lamp Connector-Pin Connector-Pin Circuit
LH front C1035a-D3 C2280d-29 1340 (DG)
RH front C1035a-D1 C2280d-31 1339 (BK/PK)
LH front side C1035a-A6 C2280d-16 667 (WH/RD)
marker
Yes
RH front side C1035a-D10 C2280d-17 14 (BN) GO to M10.
marker
No
AN OPEN (BEC TO LAMP)
harness side and the BEC, harness side as follows:
Inoperative Parking
Lamp
Connector-Pin BEC Connector-Pin Circuit
LH front C1023-2 C1035c-A3 1340 (DG)
RH front C1043-2 C1035c-C1 1339 (BK/PK)
LH front side marker C1035c-D1 667 (WH/RD)
Yes
C151-1
RH front side marker C1035c-B10 14 (BN) REPEAT the self-test.
C161-1
No
M11 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
Pinpoint Test N: The Parking, Rear Or Normal Operation
License Plate Lamps Are On Continuously
Refer to Wiring Diagrams Cell 92, Parking Rear
circuit 1401 (BK/LG). When the headlamp switch is
and License Lamps for schematic and connector
placed in the PARKING LAMPS ON position, the
information.
SJB provides voltage to the parking, license plate
and side marker lamps.
ground from the headlamp switch input circuit
(parking lamps).
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DTC B2035 sets when the SJB detects a short to Circuit 1339 (BK/PK) short to voltage
voltage to the side marker lamps voltage supply
Circuit 1340 (DG) short to voltage
circuit.
Circuit 1361 (RD/PK) short to voltage
Circuit 1366 (TN/RD) short to voltage
voltage to the RH front parking lamp voltage supply
Circuit 1364 (DB/YE) short to voltage
circuit.
Circuit 1370 (DG/LG) short to voltage
voltage to the LH front parking lamp voltage supply
Circuit 1401 (BK/LG) short to ground
circuit.
Circuit 1729 (DB/YE) short to voltage
Circuit 1784 (TN/RD) short to voltage
voltage to the license plate lamp and both tail lamp
Headlamp switch
voltage supply circuits.
BEC
Possible Causes
SJB
Circuit 14 (BN) short to voltage
Circuit 667 (WH/RD) short to voltage
PINPOINT TEST N: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY
N1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Using the recorded results from the SJB self-test: GO to N2.
No
GO to N4.
N2 CHECK THE HEADLAMP SWITCH
Disconnect: Headlamp Switch C205. Yes
Carry out the headlamp switch component test. Refer to Wiring GO to N3.
No
INSTALL a new headlamp switch. REFER
to Headlamp Switch in this section.
N3 CHECK CIRCUIT 1401 (BK/LG) FOR A SHORT TO GROUND
circuit 1401 (BK/LG), harness side and ground.
Yes
GO to N7.
No
(Continued)
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PINPOINT TEST N: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY
(Continued)
N4 CHECK THE PARKING LAMP VOLTAGE SUPPLY CIRCUITS
Disconnect: SJB C2280d. Yes
Key in ON position. If a front parking or front side marker
Does any parking lamp continue to illuminate? continue to illuminate, GO to N5.
For all other lamps, REPAIR the voltage
supply circuit in question. CLEAR the
No
GO to N7.
FOR A SHORT TO VOLTAGE (SJB to BEC)
Disconnect: BEC C1035a. GO to N6.
Key in ON position.
No
Does any parking lamp continue to illuminate?
REPAIR the voltage supply circuit in
question between the SJB and the BEC.
FOR A SHORT TO VOLTAGE (BEC to LAMP)
Disconnect: Suspect Parking Lamp.
Key in ON position.
Measure the voltage between suspect parking lamp, harness
Suspect Lamp Connector-Pin Circuit
LH front C1023-2 1340 (DG)
Yes
REPAIR the voltage supply circuit in
LH side marker C151-1 667 (WH/RD)
self-test.
RH side marker C161-1 14 (BN)
No
N7 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
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Rear Lamp Assembly
2. Remove the pushpin retainer and position the
trim panel aside.
1 N621926-S424 Rear lamp mounting nuts (3
required)
3. Remove the LH side luggage compartment trim
2 13B404/13B405 Rear lamp assembly (RH/LH)
panel.
4. Remove the 3 rear lamp mounting nuts.
NOTE: If the vehicle is equipped with a factory
installed subwoofer, the subwoofer must be removed
5. Remove the rear lamp assembly.
before removing the right side rear lamp.
Remove the bulbs from the rear lamp
1. Remove the rear luggage compartment trim assembly.
panel.
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Reversing Lamp Switch
NOTE: T5OD transmission shown, TR3650 transmission similar.
1 Reversing lamp switch
12B637)
2 15520 Reversing lamp switch
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T56 transmission
the reversing lamp switch.
1 Reversing lamp switch
jumper harness To install, tighten to 37 Nm (27 lb-ft)
(T5OD transmission). 2 15520 Reversing lamp switch
3 Reversing lamp switch To install, tighten to 27 Nm (20 lb-ft)
(TR3650 or T56 transmission).
12B637)
Section 100-01.
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Reversing Lamps
software release.
Special Tool(s)
73III Automotive Meter scan tool to the data link connector (DLC).
VCM.
VCM:
(VCM) and Integrated Check the VCM connection to the vehicle.
hardware, or equivalent scan Refer to Section 418-00, No Power To The
tool
with the scan tool.
Flex Probe Kit
vehicle:
position.
good vehicle.
Inspection and Verification response from the powertrain control module
(PCM).
of mechanical or electrical damage. If the scan tool responds with no
record the continuous memory DTCs. Reversing lamp switch Bussed electrical center
Digital transmission (BEC) fuse 62 (20A)
range (TR) sensor Circuitry
Bulbs
Smart junction box
(SJB)
OFF position.
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operation.
B2525 Left Rear Backup Lamp Circuit Failure If the reversing lamp is inoperative, GO to
Pinpoint Test T.
If the reversing lamp is always on, GO to
Pinpoint Test U.
B2532 Right Rear Backup Lamp Circuit Short to If the reversing lamp is inoperative, GO to
Battery Pinpoint Test T.
If the reversing lamp is always on, GO to
Pinpoint Test U.
Symptom Chart
Symptom Chart
The reversing lamps are Fuse GO to Pinpoint Test S.
Reversing lamp switch
(BEC)
SJB
(PCM)
An individual reversing lamp Circuitry GO to Pinpoint Test T.
is inoperative SJB
The reversing lamps are on Circuitry GO to Pinpoint Test U.
continuously Reversing lamp switch
SJB
PCM
Pinpoint Tests Normal Operation Manual Transmission
Pinpoint Test S: The Reversing Lamps Are
voltage reference signal to the reversing lamp
Inoperative
switch through circuit 1789 (VT/WH). When the
Refer to Wiring Diagrams Cell 93, Reversing
transmission is placed in REVERSE (R), the
Lamps for schematic and connector information.
reversing lamp switch closes and routes the signal
back to the PCM through circuit 359 (GY/RD).
The PCM then sends a signal to the smart junction
box (SJB), via the instrument cluster, over the
communication network. The SJB then provides
voltage to the reversing lamps. The SJB is provided
voltage from the bussed electrical center (BEC)
through circuit 1679 (WH/YE) to power the
reversing lamps.
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Possible Causes
Normal Operation Automatic
Transmission
Fuse
When the PCM detects the transmission is in
Circuit 359 (GY/RD) open
REVERSE (R), a signal is sent to the SJB over the
communication network. The SJB then provides Circuit 1679 (WH/YE) open
voltage to the reversing lamps. The SJB is provided
Circuit 1789 (VT/WH) open
voltage from the BEC through circuit 1679
(WH/YE) to power the reversing lamps.
BEC
The PCM sets DTCs if any faults with the digital
SJB transmission range (TR) sensor inputs are detected.
PCM
PINPOINT TEST S: THE REVERSING LAMPS ARE INOPERATIVE
S1 CHECK THE REVERSING LAMP SWITCH INPUT
Enter the following diagnostic mode on the scan tool: PCM Yes
Transmission Status PID. GO to S4.
Monitor the PCM transmission status PID while placing the
No
transmission in REVERSE (R).
For a manual transmission, GO to S2.
Does the PID indicate the transmission is in REVERSE (R)?
For an automatic transmission, REFER to
Section 307-01 to continue diagnosis of
the digital transmission range (TR) sensor
DTCs.
S2 CHECK THE REVERSING LAMP SWITCH
Disconnect: Reversing Lamp Switch C169.
Connect a fused (5A) jumper wire between the reversing lamp
switch C169-A, circuit 1789 (VT/WH), harness side and the
reversing lamp switch C169-B, circuit 359 (GY/RD), harness
side.
Yes
INSTALL a new reversing lamp switch.
REFER to Reversing Lamp Switch in this
operation.
Do the reversing lamps illuminate? REMOVE the jumper wire. GO to S3.
S3 CHECK CIRCUITS 1789 (VT/WH) AND 359 (GY/RD) FOR AN
OPEN
Disconnect: PCM C175t.
(Continued)
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PINPOINT TEST S: THE REVERSING LAMPS ARE INOPERATIVE (Continued)
S3 CHECK CIRCUITS 1789 (VT/WH) AND 359 (GY/RD) FOR AN
OPEN (Continued)
Measure the resistance between the reversing lamp switch
C169-A, circuit 1789 (VT/WH), harness side and the PCM
C175t-21, circuit 1789 (VT/WH), harness side; and between the
reversing lamp switch C169-B, circuit 359 (GY/RD), harness
side and the PCM C175t-41, circuit 359 (GY/RD), harness side.
Yes
GO to S7.
No
S4 CHECK CIRCUIT 1679 (WH/YE) FOR VOLTAGE
Yes
GO to S6.
No
Is the voltage greater than 10 volts? OK, GO to S5.
S5 CHECK CIRCUIT 1679 (WH/YE) FOR AN OPEN
(Continued)
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PINPOINT TEST S: THE REVERSING LAMPS ARE INOPERATIVE (Continued)
S5 CHECK CIRCUIT 1679 (WH/YE) FOR AN OPEN (Continued)
1679 (WH/YE), harness side and the BEC C1035a-D9, circuit
1679 (WH/YE), harness side.
Yes
No
S6 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
S7 CHECK FOR CORRECT PCM OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
Pinpoint Test T: An Individual Reversing
Lamp Is Inoperative
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Normal Operation
When the transmission is placed in REVERSE (R),
or short to ground on the RH reversing lamp
the powertrain control module (PCM) sends a signal
to the smart junction box (SJB) over the
Possible Causes
voltage through circuits 1362 (DG/OG) and 1367
(WH/YE) to the LH and RH reversing lamps,
Circuit 1362 (DG/OG) open or short to ground
respectively. Ground for the lamps is provided
SJB
or short to ground on the LH reversing lamp voltage
supply circuit.
PINPOINT TEST T: AN INDIVIDUAL REVERSING LAMP IS INOPERATIVE
T1 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Inoperative Reversing Lamp.
Measure the resistance between the LH reversing lamp C451-1,
reversing lamp C461-1, circuit 1205 (BK), harness side and
ground.
Yes
GO to T2.
No
T2 CHECK CIRCUIT 1362 (DG/OG) OR CIRCUIT 1367 (WH/YE) FOR
A SHORT TO GROUND
(Continued)
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PINPOINT TEST T: AN INDIVIDUAL REVERSING LAMP IS INOPERATIVE (Continued)
A SHORT TO GROUND (Continued)
circuit 1362 (DG/OG), harness side and ground; or between the
RH reversing lamp C461-2, circuit 1367 (WH/YE), harness side
and ground.
Yes
GO to T3.
No
AN OPEN
circuit 1362 (DG/OG), harness side and the SJB C2280d-26,
circuit 1362 (DG/OG), harness side; or between the RH
reversing lamp C461-2, circuit 1367 (WH/YE), harness side and
the SJB C2280d-13, circuit 1367 (WH/YE), harness side.
Yes
GO to T4.
No
(Continued)
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PINPOINT TEST T: AN INDIVIDUAL REVERSING LAMP IS INOPERATIVE (Continued)
T4 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
Pinpoint Test U: The Reversing Lamps Are Normal Operation Automatic
On Continuously Transmission
When the PCM detects the transmission is in
REVERSE (R), a signal is sent to the SJB over the
Normal Operation Manual Transmission
voltage through circuits 1362 (DG/OG) and 1367
(WH/YE) to the LH and RH reversing lamps,
voltage reference signal to the reversing lamp
respectively. The PCM sets DTCs if any faults
switch through circuit 1789 (VT/WH). When the
with the digital transmission range (TR) sensor
transmission is placed in REVERSE (R), the
inputs are detected. The SJB sets DTCs if a fault is
reversing lamp switch closes and routes the signal
detected on the reversing lamp output circuits.
back to the PCM through circuit 359 (GY/RD).
The PCM then sends a signal to the smart junction
voltage on the LH reversing lamp voltage supply
box (SJB) over the communication network. The
circuit.
SJB then provides voltage through circuits 1362
(DG/OG) and 1367 (WH/YE) to the LH and RH
reversing lamps, respectively. The PCM sets DTCs
voltage on the RH reversing lamp voltage supply
if any faults with the digital transmission range
circuit.
(TR) sensor inputs are detected.
Possible Causes
Circuit 1362 (DG/OG) short to voltage
Circuit 1367 (WH/YE) short to voltage
Circuit 1789 (VT/WH) short to ground
SJB
PCM
PINPOINT TEST U: THE REVERSING LAMPS ARE ON CONTINUOUSLY
U1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Using the recorded results from the SJB self-test: GO to U2.
Was DTC B2525 or B2532 present?
No
GO to U3.
(Continued)
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PINPOINT TEST U: THE REVERSING LAMPS ARE ON CONTINUOUSLY (Continued)
U2 CHECK CIRCUITS 1362 (DG/OG) AND 1367 (WH/YE) FOR A
SHORT TO VOLTAGE
Key in ON position. REPAIR circuit 1362 (DG/OG) (LH
Does either reversing lamp continue to illuminate? reversing lamp) or circuit 1367 (WH/YE)
(RH reversing lamp) as necessary. CLEAR
No
GO to U6.
U3 CHECK THE PCM
Disconnect: PCM C175t. Yes
Key in ON position. GO to U6.
Do the reversing lamps continue to illuminate?
No
If equipped with a manual transmission,
GO to U4.
transmission, REFER to Section 307-01 to
continue diagnosis of the digital
transmission range (TR) sensor DTCs.
U4 CHECK THE REVERSING LAMP SWITCH
Connect: PCM C175t. GO to U5.
Disconnect: Reversing Lamp Switch C169.
No
Key in ON position.
INSTALL a new reversing lamp switch.
Do the reversing lamps continue to illuminate?
REFER to Reversing Lamp Switch in this
operation.
U5 CHECK CIRCUIT 1789 (VT/WH) FOR A SHORT TO GROUND
Disconnect: PCM C175t.
Measure the resistance between the reversing lamp switch
C169-A, circuit 1789 (VT/WH), harness side and ground.
Yes
GO to U7.
No
U6 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
U7 CHECK FOR CORRECT PCM OPERATION
(Continued)
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PINPOINT TEST U: THE REVERSING LAMPS ARE ON CONTINUOUSLY (Continued)
U7 CHECK FOR CORRECT PCM OPERATION (Continued)
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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Side Lamp/Front Turn Signal Lamp
Bulb
1 13411 Bulb socket
2 13411 Bulb socket
3 13200/13201 Front side marker lamp
assembly (RH/LH)
1. Remove the front fender splash shield. For
2. Release the 2 locking tabs and remove the front
side marker lamp assembly.
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Side Marker Lamp Rear
1 15A201 Rear side marker lamp
1. NOTE: Using a suitable thin-bladed tool,
2 Rear side marker lamp
separate the rear of the side marker lamp from
the bumper cover first. 13A444)
Remove the rear side marker lamp.
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SPECIFICATIONS
Description Nm lb-ft lb-in (T5OD transmission)
Headlamp assembly 8 71 Reversing lamp switch 27 20
nuts (TR3650 or T56
transmission)
Rear lamp assembly 6 53
nuts
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Stoplamp Switch
1 Stoplamp switch electrical
2 13480 Stoplamp switch
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CAUTION: Do not service the brake pedal,
brake booster, or master cylinder without first
removing the stoplamp switch. Do not install the
stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not
press or pull on brake pedal when installing or
removing the stoplamp switch otherwise
misadjustment or damage to the stoplamp switch
could occur.
1. NOTE: Rotate the stoplamp switch clockwise
approximately 1/8 turn to remove.
Remove the stoplamp switch.
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Stoplamps
OFF position.
Special Tool(s)
73III Automotive Meter the LOW BEAM position.
software release.
(VCM) and Integrated ground from the DLC are provided to the
VCM.
VCM: tool
Flex Probe Kit
with the scan tool.
vehicle:
Inspection and Verification position.
1. Verify the customer concern. Verify the scan tool operation with a known
good vehicle.
of mechanical or electrical damage. Refer to Section 418-00 to diagnose no
(PCM).
Stoplamp switch Bussed electrical center
(BEC) fuse:
59 (30A) (RH
stoplamps)
63 (30A) (LH
stoplamps)
67 (30A) (high
8. Clear the continuous DTCs and carry out the mounted stoplamp)
Smart junction box self-test diagnostics for the SJB.
(SJB) fuse 15 (10A)
(stoplamp switch)
Circuitry
Bulbs Trouble Code (DTC) Index. For all other DTCs,
SJB
3. If an obvious cause for an observed or reported GO to Symptom Chart.
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operation.
B1485 Brake Pedal Input Short to Battery GO to Pinpoint Test H.
B2044 Left Rear Stop Lamp Circuit Short to Ground GO to Pinpoint Test G.
B2046 Right Rear Stop Lamp Circuit Short to Ground GO to Pinpoint Test G.
B2048 Left Rear Turn Lamp Circuit Short to Ground GO to Pinpoint Test G.
B2049 Left Rear Turn Lamp Circuit Open If the lamp is inoperative, GO to Pinpoint Test
G.
H.
B2050 Right Rear Turn Lamp Circuit Short to Ground GO to Pinpoint Test G.
B2051 Right Rear Turn Lamp Circuit Open If the lamp is inoperative, GO to Pinpoint Test
G.
H.
B2519 High Mount Stop Lamp Circuit Failure If the lamp is inoperative, GO to Pinpoint Test
G.
H.
B2527 Left Rear Stop Lamp Circuit Failure GO to Pinpoint Test G.
B2528 Left Rear Stop Lamp Circuit Short to Battery If the lamp is inoperative, GO to Pinpoint Test
G.
H.
B2529 Left Rear Turn Lamp Circuit Failure If the lamp is inoperative, GO to Pinpoint Test
G.
H.
B2533 Right Rear Stop Lamp Circuit Failure GO to Pinpoint Test G.
B2534 Right Rear Stop Lamp Circuit Short to Battery If the lamp is inoperative, GO to Pinpoint Test
G.
H.
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Symptom Chart
Symptom Chart
One or more stoplamps are Fuse GO to Pinpoint Test G.
Stoplamp switch
(BEC)
SJB
The stoplamps are on Circuitry GO to Pinpoint Test H.
continuously Stoplamp switch
SJB
(PCM)
Pinpoint Tests DTC B2050 sets when the SJB detects a short to
ground on the RH stoplamp 1 voltage supply
Pinpoint Test G: One Or More Stoplamps
circuit.
Are Inoperative
Refer to Wiring Diagrams Cell 90, Turn
or short to ground on the LH stoplamp 1 voltage
Signal/Stop/Hazard Lamps for schematic and
supply circuit.
connector information.
Normal Operation
or short to ground on the high mounted stoplamp
Voltage is supplied from the bussed electrical center
(BEC) to the smart junction box (SJB) through
circuits 1523 (DG), 905 (GY/LB), and 1052
ground on the LH stoplamp 2 voltage supply circuit.
(TN/BK) to power the LH stoplamps, RH
DTC B2528 sets when the SJB detects an open stoplamps, and the high mounted stoplamp.
on the LH stoplamp 2 voltage supply circuit.
The stoplamp switch is provided voltage through
DTC B2529 sets when the SJB detects an open circuit 10 (LG/RD). When the brake pedal is
or short to ground on the LH stoplamp 1 voltage applied, the stoplamp switch routes voltage to the
SJB through circuit 511 (LG). The SJB then supply circuit.
provides voltage to the stoplamps through circuits
1783 (RD/WH), 1374 (TN/LB), 1728 (LB/OG),
and 1363 (WH/RD). Ground for the stoplamps is
circuit.
provided through circuit 1205 (BK).
on the RH stoplamp 2 voltage supply circuit.
Possible Causes
Fuse
circuit.
Circuit 10 (LG/RD) open
Circuit 511 (LG) open
Circuit 905 (GY/LB) open
Circuit 1052 (TN/BK) open
or short to ground on the LH stoplamp 1 voltage
supply circuit.
Circuit 1363 (WH/RD) open or short to ground
Circuit 1374 (TN/LB) open or short to ground
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Circuit 1523 (DG) open Stoplamp switch
Circuit 1728 (LB/OG) open or short to ground SJB
Circuit 1783 (RD/WH) open or short to ground BEC
PINPOINT TEST G: ONE OR MORE STOPLAMPS ARE INOPERATIVE
G1 DETERMINE IF ALL THE STOPLAMPS ARE INOPERATIVE
Apply the brake pedal and observe the rear lamps. GO to G2.
Are all the stoplamps inoperative?
No
GO to G8.
G2 CHECK CIRCUIT 1523 (DG) FOR VOLTAGE
Yes
GO to G4.
No
Is the voltage greater than 10 volts? OK, GO to G3.
G3 CHECK CIRCUIT 1523 (DG) FOR AN OPEN
(Continued)
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PINPOINT TEST G: ONE OR MORE STOPLAMPS ARE INOPERATIVE (Continued)
G3 CHECK CIRCUIT 1523 (DG) FOR AN OPEN (Continued)
1523 (DG), harness side and BEC C1035a-C5, circuit 1523
(DG), harness side.
Yes
No
G4 CHECK CIRCUIT 10 (LG/RD) FOR VOLTAGE
Connect: SJB C2280h.
Disconnect: Stoplamp Switch C2314.
Measure the voltage between the stoplamp switch C2314-1,
circuit 10 (LG/RD), harness side and ground.
Yes
GO to G6.
No
Is the voltage greater than 10 volts? OK, GO to G5.
G5 CHECK CIRCUIT 10 (LG/RD) FOR AN OPEN
(Continued)
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G5 CHECK CIRCUIT 10 (LG/RD) FOR AN OPEN (Continued)
Measure the resistance between the stoplamp switch C2314-1,
circuit 10 (LG/RD), harness side and the SJB C2280h-10, circuit
10 (LG/RD), harness side.
Yes
GO to G13.
No
G6 CHECK THE STOPLAMP SWITCH
Connect a fused (5A) jumper wire between the stoplamp switch
C2314-1, circuit 10 (LG/RD), harness side and the stoplamp
switch C2314-2, circuit 511 (LG), harness side.
Yes
INSTALL a new stoplamp switch. REFER
to Stoplamp Switch in this section. TEST
No
Do the stoplamps illuminate? REMOVE the jumper wire. GO to G7.
G7 CHECK CIRCUIT 511 (LG) FOR AN OPEN
Measure the resistance between the stoplamp switch C2314-2,
circuit 511 (LG), harness side and the SJB C2280h-16, circuit
511 (LG), harness side.
Yes
GO to G13.
No
(Continued)
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G8 CHECK THE VOLTAGE TO THE SJB
as follows:
SJB Connector-Pin Circuit
Yes
C2280h-31 905 (GY/LB)
GO to G10.
C2280h-32 1052 (TN/BK)
No
VERIFY the BEC fuses 59 (30A) and 67
Are the voltages greater than 10 volts? (30A) are OK. If OK, GO to G9.
G9 CHECK THE VOLTAGE SUPPLY CIRCUITS TO THE SJB FOR
AN OPEN
BEC, harness side as follows:
SJB Connector-Pin BEC Connector-Pin Circuit
Yes
C2280h-31 C1035a-F8 905 (GY/LB)
C2280h-32 C1035a-A5 1052 (TN/BK)
No
Disconnect: Inoperative Stoplamp.
Measure the resistance between the inoperative stoplamp,
Inoperative
Stoplamp Connector-Pin Circuit
High mounted C475-1 1205 (BK)
stoplamp
LH rear lamp 1 C4112-1 1205 (BK)
LH rear lamp 2 C4113-1 1205 (BK)
Yes
RH rear lamp 1 C4114-1 1205 (BK)
GO to G11.
RH rear lamp 2 C4115-1 1205 (BK)
No
G11 CHECK THE STOPLAMP VOLTAGE SUPPLY CIRCUIT FOR A
SHORT TO GROUND
(Continued)
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G11 CHECK THE STOPLAMP VOLTAGE SUPPLY CIRCUIT FOR A
Inoperative
Stoplamp Connector-Pin Circuit
High mounted C475-2 1374 (TN/LB)
stoplamp
LH rear lamp 1 C4112-3 1363 (WH/RD)
LH rear lamp 2 C4113-3 1728 (LB/OG)
Yes
RH rear lamp 1 C4114-3 1783 (RD/WH)
GO to G12.
RH rear lamp 2 C4115-3 1783 (RD/WH)
No
G12 CHECK THE STOPLAMP VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
harness side and the SJB, harness side as follows:
Inoperative
Stoplamp
High mounted C2280d-39 1374 (TN/LB)
stoplamp C475-2
LH rear lamp 1 C2280d-14 1363 (WH/RD)
C4112-3
LH rear lamp 2 C2280d-18 1728 (LB/OG)
C4113-3
RH rear lamp 1 C2280d-47 1783 (RD/WH)
C4114-3
Yes
RH rear lamp 2 C2280d-40 1783 (RD/WH) GO to G13.
C4115-3
No
pushed-out pins
No
correctly.
Pinpoint Test H: The Stoplamps Are On
Continuously
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Normal Operation
When the brake pedal is applied, the stoplamp
voltage on the LH stoplamp 2 voltage supply
switch routes voltage to the smart junction box
circuit.
(SJB) through circuit 511 (LG). Voltage is also
routed to the powertrain control module (PCM)
through circuit 599 (PK/LG). The SJB then provides
circuit.
voltage to the stoplamps through circuits 1783
(RD/WH), 1374 (TN/LB), 1728 (LB/OG), and 1363
voltage on the RH stoplamp 2 voltage supply
(WH/RD). Ground for the stoplamps is provided
circuit.
Possible Causes
voltage from the stoplamp switch input.
Circuit 511 (LG) short to voltage
Circuit 599 (PK/LG) short to voltage
Circuit 1363 (WH/RD) short to voltage
circuit.
Circuit 1374 (TN/LB) short to voltage
Circuit 1728 (LB/OG) short to voltage
circuit.
Circuit 1783 (RD/WH) short to voltage
Stoplamp switch
voltage on the high mounted stoplamp voltage
SJB
supply circuit.
PCM
PINPOINT TEST H: THE STOPLAMPS ARE ON CONTINUOUSLY
H1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Using the recorded results from the SJB self-test: GO to H2.
No
GO to H5.
H2 CHECK THE STOPLAMP SWITCH
Disconnect: Stoplamp Switch C2314. Yes
Do the stoplamps continue to illuminate? GO to H3.
No
INSTALL a new stoplamp switch. REFER
to Stoplamp Switch in this section. CLEAR
H3 CHECK THE PCM
Disconnect: PCM C175b. Yes
Do the stoplamps continue to illuminate? GO to H4.
No
GO to H6.
H4 CHECK CIRCUITS 511 (LG) AND 599 (PK/LG) FOR A SHORT TO
VOLTAGE
(Continued)
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PINPOINT TEST H: THE STOPLAMPS ARE ON CONTINUOUSLY (Continued)
H4 CHECK CIRCUITS 511 (LG) AND 599 (PK/LG) FOR A SHORT TO
VOLTAGE (Continued)
(LG), harness side and ground; and between the SJB C2280h-4,
circuit 599 (PK/LG), harness side and ground.
Yes
No
H5 CHECK CIRCUITS 1363 (WH/RD), 1728 (LB/OG), 1783 (RD/WH)
AND 1374 (TN/LB) FOR A SHORT TO VOLTAGE
Do any stoplamps continue to illuminate? For the high mounted stoplamp, REPAIR
circuit 1374 (TN/LB). CLEAR the DTCs.
For the LH rear stoplamp 1, REPAIR
circuit 1363 (WH/RD). CLEAR the DTCs.
For the LH rear stoplamp 2, REPAIR
circuit 1728 (LB/OG). CLEAR the DTCs.
For either RH rear stoplamp, REPAIR
circuit 1783 (RD/WH). CLEAR the DTCs.
No
GO to H7.
H6 CHECK FOR CORRECT PCM OPERATION
corrosion 303-14. CLEAR the DTCs. REPEAT the
damaged pins self-test.
pushed-out pins
No
correctly.
H7 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
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Turn Signal and Hazard Lamps
Special Tool(s)
VCM.
VCM:
(VCM) and Integrated with the scan tool.
vehicle:
tool
position.
Flex Probe Kit
good vehicle.
(PCM).
Inspection and Verification communication for one or more modules,
go to the Smart Junction Box (SJB) Diagnostic Multifunction switch Circuitry
Hazard flasher switch Bulbs Trouble Code (DTC) Index. For all other DTCs,
Smart junction box
(SJB)
OFF position.
software release.
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operation.
B1499 Lamp Turn Signal Left Circuit Failure GO to Pinpoint Test K.
B1502 Lamp Turn Signal Left Circuit Short to Ground GO to Pinpoint Test K.
B1503 Lamp Turn Signal Right Circuit Failure GO to Pinpoint Test K.
B1506 Lamp Turn Signal Right Circuit Short to GO to Pinpoint Test K.
Ground
B2048 Left Rear Turn Lamp Circuit Short to Ground REFER to Stoplamps in this section to continue
diagnosis.
B2049 Left Rear Turn Lamp Circuit Open REFER to Stoplamps in this section to continue
diagnosis.
B2050 Right Rear Turn Lamp Circuit Short to Ground REFER to Stoplamps in this section to continue
diagnosis.
B2051 Right Rear Turn Lamp Circuit Open REFER to Stoplamps in this section to continue
diagnosis.
B2071 Hazard Switch Signal Short to Ground If the hazard lamps are inoperative, GO to
Pinpoint Test L.
If the hazard lamps are always on, GO to
Pinpoint Test M.
B2281 Right Turn Switch Short to Ground GO to Pinpoint Test J.
B2282 Left Turn Switch Short to Ground GO to Pinpoint Test J.
B2529 Left Rear Turn Lamp Circuit Failure REFER to Stoplamps in this section to continue
diagnosis.
Symptom Chart
Symptom Chart
The turn signal lamps are Circuitry GO to Pinpoint Test I.
inoperative Multifunction switch
SJB
The turn signal lamps are Circuitry GO to Pinpoint Test J.
always on Multifunction switch
SJB
One turn signal lamp is Circuitry GO to Pinpoint Test K.
inoperative/always on Bussed electrical center
(BEC)
SJB
The hazard lamps are Circuitry GO to Pinpoint Test L.
inoperative/always on Hazard flasher switch
SJB
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Pinpoint Test I: The Turn Signal Lamps Are
Inoperative
circuit 1393 (LB/RD) (LH turn signal) and circuit
1392 (LG/OG) (RH turn signal). When the
multifunction switch is placed in the LH or RH
TURN position, the signal is routed to ground
through the SJB.
Possible Causes
Circuit 1392 (LG/OG) open or short to voltage
Circuit 1393 (LB/RD) open or short to voltage
SJB
PINPOINT TEST I: THE TURN SIGNAL LAMPS ARE INOPERATIVE
I1 CHECK THE HIGH BEAM OPERATION
Place the headlamp switch in the HEADLAMPS ON position. GO to I2.
Place the multifunction switch in the HIGH BEAM position.
No
Do the high beams operate correctly?
REFER to Headlamps in this section.
I2 CHECK CIRCUIT 1393 (LB/RD) OR CIRCUIT 1392 (LG/OG) FOR
A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between the multifunction switch C202-6
(LH turn signal), circuit 1393 (LB/RD), harness side and ground;
and between the multifunction switch C202-7 (RH turn signal),
circuit 1392 (LG/OG), harness side and ground.
Yes
No
Is any voltage present? GO to I3.
AN OPEN
(Continued)
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PINPOINT TEST I: THE TURN SIGNAL LAMPS ARE INOPERATIVE (Continued)
AN OPEN (Continued)
Measure the resistance between the multifunction switch C202-6
(LH turn signal), circuit 1393 (LB/RD) and the SJB C2280b-48,
circuit 1393 (LB/RD), harness side; and between the
multifunction switch C202-7 (RH turn signal), circuit 1392
(LG/OG) and the SJB C2280b-17, circuit 1392 (LG/OG), harness
side.
Yes
GO to I4.
No
I4 CHECK THE MULTIFUNCTION SWITCH
Connect: SJB C2280b.
Connect a fused (5A) jumper wire between the multifunction
switch C202-6 (LH turn signal), circuit 1393 (LB/RD) and the
multifunction switch C202-10, circuit 1396 (VT/WH), harness
side; or between the multifunction switch C202-7 (RH turn
signal), circuit 1392 (LG/OG) and the multifunction switch
C202-10, circuit 1396 (VT/WH), harness side.
Yes
Does the LH or RH turn signal operate? REMOVE the jumper wire. GO to I5.
I5 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
damaged pins
operation.
pushed-out pins
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Pinpoint Test J: The Turn Signal Lamps Are
Always On
ground from the RH turn signal input circuit.
ground from the LH turn signal input circuit.
Possible Causes
Normal Operation
Circuit 1392 (LG/OG) short to ground
Circuit 1393 (LB/RD) short to ground
circuit 1393 (LB/RD) (LH turn signal) and circuit Multifunction switch
1392 (LG/OG) (RH turn signal). When the
SJB
multifunction switch is placed in the LH or RH
TURN position, the signal is routed to ground
through the SJB.
PINPOINT TEST J: THE TURN SIGNAL LAMPS ARE ALWAYS ON
J1 CHECK THE MULTIFUNCTION SWITCH
Disconnect: Multifunction Switch C202. GO to J2.
Key in ON position.
No
Do the turn signal lamps continue to flash on and off?
J2 CHECK CIRCUIT 1393 (LB/RD) OR CIRCUIT 1392 (LG/OG) FOR
A SHORT TO GROUND
Measure the resistance between the multifunction switch C202-6
(LH turn signal), circuit 1393 (LB/RD), harness side and ground;
and between the multifunction switch C202-7 (RH turn signal),
circuit 1392 (LG/OG), harness side and ground.
Yes
GO to J3.
No
J3 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
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Pinpoint Test K: One Turn Signal Lamp Is
Inoperative/Always On
or short to voltage from the RH front turn signal
ground from the RH front turn signal voltage supply
circuit.
Normal Operation
When the smart junction box (SJB) detects a request Possible Causes
for the LH or RH turn signal, the SJB provides
Circuit 1341 (DB/OG) open, short to ground or
voltage, through the bussed electrical center (BEC),
voltage
to the front turn lamps through circuit 1342
Circuit 1342 (GY/BK) open, short to ground or
(GY/BK) (LH front turn lamp) or circuit 1341
voltage
(DB/OG) (RH front turn lamp). The turn lamps are
grounded through circuit 1205 (BK) through the Circuit 1205 (BK) open
BEC.
BEC
SJB
or short to voltage from the LH front turn signal
ground from the LH front turn signal voltage supply
circuit.
PINPOINT TEST K: ONE TURN SIGNAL LAMP IS INOPERATIVE/ALWAYS ON
K1 CHECK THE STOPLAMPS
Apply and release the brake pedal, while observing the GO to K2.
stoplamps.
No
REFER to Stoplamps in this section.
K2 DETERMINE IF A LAMP IS ALWAYS ON
NOTE: Make sure the multifunction switch is in the NEUTRAL Yes
position. GO to K3.
Observe the front turn lamps.
No
Is either turn lamp illuminated?
GO to K6.
K3 CHECK THE TURN LAMP VOLTAGE SUPPLY CIRCUIT FOR A
SHORT TO VOLTAGE
Disconnect: SJB 2280d. GO to K4.
Key in ON position.
No
Does either turn lamp continue to illuminate?
GO to K15.
K4 CHECK CIRCUIT 1341 (DB/OG) OR CIRCUIT 1342 (GY/BK) FOR
A SHORT TO VOLTAGE (SJB TO BEC)
Disconnect: BEC C1035a. GO to K5.
Key in ON position.
No
Does either turn lamp continue to illuminate?
REPAIR circuit 1342 (GY/BK) (LH turn
signal) or circuit 1341 (DB/OG) (RH turn
signal). CLEAR the DTCs. REPEAT the
self-test.
A SHORT TO VOLTAGE (BEC TO TURN LAMP)
(Continued)
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PINPOINT TEST K: ONE TURN SIGNAL LAMP IS INOPERATIVE/ALWAYS ON (Continued)
A SHORT TO VOLTAGE (BEC TO TURN LAMP) (Continued)
Disconnect: Always On Lamp.
Key in ON position.
Measure the voltage between the LH front turn lamp C1023-3,
circuit 1342 (GY/BK), harness side and ground; or between the
RH front turn lamp C1043-3, circuit 1341 (DB/OG), harness side
and ground.
Yes
No
K6 CHECK THE TURN LAMP GROUND CIRCUIT FOR AN OPEN
Disconnect: Inoperative Turn Lamp.
Measure the resistance between the LH turn lamp C1023-1,
turn lamp C1043-1, circuit 1205 (BK), harness side and ground.
Yes
GO to K9.
No
Is the resistance less than 5 ohms? GO to K7.
K7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (BEC TO GROUND)
(Continued)
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K7 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (BEC TO GROUND)
(Continued)
Measure the resistance between the BEC C1035c-F5 (LH turn
lamp), circuit 1205 (BK), harness side and ground; or between
the BEC C1035c-E11 (RH turn lamp), circuit 1205 (BK), harness
side and ground.
Yes
GO to K8.
No
K8 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (TURN LAMP TO
BEC)
Measure the resistance between the LH front turn lamp
C1035c-F4, circuit 1205 (BK), harness side; or between the RH
front turn lamp C1043-1, circuit 1205 (BK), harness side and
the BEC C1035c-F11, circuit 1205 (BK), harness side.
Yes
No
SHORT TO GROUND
(Continued)
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RH turn lamp C1043-3, circuit 1341 (DB/OG), harness side and
ground.
Yes
GO to K12.
No
Is the resistance greater than 10,000 ohms? GO to K10.
A SHORT TO GROUND (SJB TO BEC)
ground.
Yes
No
Is the resistance greater than 10,000 ohms? GO to K11.
A SHORT TO GROUND (BEC TO TURN LAMP)
(Continued)
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A SHORT TO GROUND (BEC TO TURN LAMP) (Continued)
ground.
Yes
No
K12 CHECK THE TURN LAMP VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Measure the resistance between the LH front turn lamp
C1023-3, circuit 1342 (GY/BK), harness side and the SJB
C2280d-46, circuit 1342 (GY/BK), harness side; or between the
RH front turn lamp C1043-3, circuit 1341 (DB/OG), harness
side and the SJB C2280d-41, circuit 1341 (DB/OG), harness
side.
Yes
GO to K15.
No
Is the resistance less than 5 ohms? GO to K13.
AN OPEN (SJB TO BEC)
(Continued)
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AN OPEN (SJB TO BEC) (Continued)
Measure the resistance between the SJB C2280d-46 (LH turn
lamp), circuit 1342 (GY/BK), harness side and the BEC
C1035a-E1, circuit 1342 (GY/BK), harness side; or between the
SJB C2280d-41 (RH turn lamp), circuit 1341 (DB/OG), harness
side and the BEC C1035a-E6, circuit 1341 (DB/OG), harness
side.
Yes
GO to K14.
No
AN OPEN (BEC TO TURN LAMP)
circuit 1342 (GY/BK), harness side and the BEC C1035c-A1,
circuit 1342 (GY/BK), harness side; or between the RH turn
lamp C1043-3, circuit 1341 (DB/OG), harness side and the BEC
C1035c-B6, circuit 1341 (DB/OG), harness side.
Yes
No
K15 CHECK FOR CORRECT SJB OPERATION
Yes
Check for:
corrosion
operation.
damaged pins
pushed-out pins No
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Pinpoint Test L: The Hazard Lamps Are
Inoperative/Always On
ground from the hazard lamp switch input circuit.
Possible Causes
Circuit 1689 (RD/WH) open or short to ground
Normal Operation
Hazard flasher switch
reference signal to the hazard flasher switch through SJB
circuit 1689 (RD/WH). When the hazard flasher
switch is pressed, the signal is routed to ground
PINPOINT TEST L: THE HAZARD LAMPS ARE INOPERATIVE/ALWAYS ON
L1 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Disconnect: Hazard Flasher Switch C2039.
Measure the resistance between the hazard flasher switch
Yes
GO to L2.
No
L2 CHECK CIRCUIT 1689 (RD/WH) FOR SHORT TO GROUND
Measure the resistance between the hazard flasher switch
C2039-5, circuit 1689 (RD/WH), harness side and ground.
Yes
GO to L3.
No
(Continued)
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PINPOINT TEST L: THE HAZARD LAMPS ARE INOPERATIVE/ALWAYS ON (Continued)
L3 CHECK CIRCUIT 1689 (RD/WH) FOR AN OPEN
1689 (RD/WH), harness side and the hazard flasher switch
C2039-5, circuit 1689 (RD/WH), harness side.
Yes
GO to L4.
No
Is resistance less than 5 ohms? REPEAT the self-test.
L4 CHECK THE HAZARD FLASHER SWITCH
Connect: Hazard Flasher Switch C2039.
While pressing and releasing the hazard flasher switch, measure
the resistance between the SJB C2280b-24, circuit 1689
(RD/WH), harness side and ground.
Yes
GO to L5.
Is the resistance less than 5 ohms with the hazard flasher No
switch pressed and greater than 10,000 ohms with the INSTALL a new hazard flasher switch.
hazard flasher switch released? CLEAR the DTCs. REPEAT the self-test.
L5 CHECK FOR CORRECT SJB OPERATION
pushed-out pins
No
correctly.
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418-00-1 418-00-1 Module Communications Network
The 3 module communication networks are:
Communications Network
Vehicle communication utilizes the International
ISO 9141
Standards Organization (ISO) 9141 network, the
Medium speed (MS) CAN
medium speed controller area network (MS-CAN),
High speed (HS) CAN
and the high speed controller area network
(HS-CAN) network. Information is sent to and from All 3 networks are connected to the DLC. This
individual control modules that each control specific makes diagnosis and testing of these systems easier
functions. All 3 networks are connected to the data by allowing one scan tool to be able to diagnose
link connector (DLC). The DLC can be found under and control any module on the 3 networks from one
the instrument panel between the steering column connector. The DLC can be found under the
and the audio unit. instrument panel between the steering column and
the audio unit.
Network Topology
Termination
Module Name Network Type Module
Anti-lock brake system (ABS) module (if equipped) HS-CAN No
Audio control module (ACM) MS-CAN No
Instrument cluster (IC) (gateway module) HS-CAN Yes
MS-CAN Yes
Powertrain control module (PCM) HS-CAN Yes
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Termination
Module Name Network Type Module
Restraints control module (RCM) ISO 9141 N/A
Satellite digital audio radio system (SDARS) (if equipped) MS-CAN No
Smart junction box (SJB) MS-CAN Yes
ISO 9141 Network Operation Network Termination
The ISO 9141 communication network is a single The CAN network uses a network termination
wire network, used for diagnostic purposes only. circuit to improve communication reliability. The
network termination of the CAN bus takes place
The ISO 9141 communication network is used for
inside the termination modules by termination
the following module:
resistors. Termination modules are located at either
RCM
end of the bus network. As network messages are
broadcast in the form of voltage signals, the
MS-CAN Network Operation
network voltage signals are stabilized by the
The MS-CAN network communicates using bussed
termination resistors. Each termination module has a
messages. The MS-CAN has an unshielded twisted
120 ohm resistor across the positive and negative
pair cable, data bus (+) and data bus (-) circuits. In
bus connection in the termination module. With 2
addition to scan tool communication, this network
termination modules on each network, and the 120
allows sharing of information between all modules
ohm resistors located in a parallel circuit
on the network.
configuration, the total network impedance, or total
resistance is 60 ohms.
The MS-CAN is a medium speed communication
network used for the following modules:
Network termination improves bus message
reliability by:
Instrument cluster
stabilizing bus voltage.
Audio control module
eliminating electrical interference.
SJB
SDARS (if equipped)
Gateway Module
The instrument cluster is the gateway module,
HS-CAN Network Operation
translating HS-CAN to MS-CAN and vice versa.
The HS-CAN network uses an unshielded twisted
This information allows a message to be distributed
pair cable, data bus (+) and data bus (-) circuits. In
throughout both networks. The instrument cluster is
addition to scan tool communication, this network
the only module on this vehicle that has this
allows sharing of information between all modules
ability.
on the network.
The HS-CAN is a high speed communication
network used for the following modules:
Instrument cluster
PCM
ABS module (if equipped)
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The following fault chart describes the specific ISO
Communications Network
9141 network failures and their resulting symptom:
Special Tool(s)
ISO 9141 Network Communication Fault Chart
105-R0057 or equivalent Failure Description Symptom
ISO circuit open No communication
ISO circuit short to No communication
voltage
ISO circuit short to No communication
ground
Module loss of voltage or No communication
ground
Module internal failure No communication software with appropriate
tool
MS-CAN
The MS-CAN network uses an unshielded twisted
Flex Probe Kit
pair cable of data (+) and data (-) circuits. The data
(+) and the data (-) circuits are each regulated to
approximately 2.5 volts during neutral or rested
network traffic. As bus messages are sent on the
data (+) circuit, voltage is increased by
approximately 1.0 volt. Inversely, the data (-) circuit
is reduced by approximately 1.0 volt when a bus
message is sent. Multiple bus messages can be sent Principles of Operation
over the network CAN circuits allowing multiple
Vehicle communication utilizes both International
modules to communicate with each other. The
Standards Organization (ISO) 9141 and controller
MS-CAN is used for the instrument cluster, the
area network (CAN) communications. ISO 9141 is
audio unit, the satellite radio receiver (if equipped)
used for diagnostic use only, and CAN is a method
and the smart junction box (SJB) communications,
for transferring data among distributed electronic
and designed for general information transfer. The
modules via a serial data bus.
MS-CAN network will not communicate while
The vehicle is equipped with 3 module
certain faults are present, but will operate with
communication networks:
diminished performance with other faults present.
The MS-CAN bus may remain operational when 1
ISO 9141
of the 2 termination resistors are not present.
Medium speed (MS) CAN
The following fault chart describes the specific
High speed (HS) CAN
MS-CAN network failures and their resulting
symptom:
ISO 9141 Communications Network
The ISO 9141 communications network is a single
MS-CAN Network Communication Fault Chart
wire network. The ISO 9141 communications
Failure Description Symptom
network does not permit intermodule
MS-CAN (+) shorted to No communication
communication. The ISO 9141 is used for the
MS-CAN (-)
restraints control module (RCM). The ISO 9141 is
MS-CAN (+) short to No communication used for diagnostic use only. When the scan tool
voltage
communicates to the RCM, the scan tool must
request all information, the module cannot initiate MS-CAN (-) short to No communication
voltage
communications.
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MS-CAN Network Communication Fault
The following fault chart describes the specific
Chart (Continued)
HS-CAN network failures and their resulting
Failure Description Symptom symptom:
MS-CAN (+) short to No communication
HS-CAN Network Communication Fault Chart
ground
Failure Description Symptom
MS-CAN (-) short to Unreliable communication
ground
HS-CAN (+) shorted to No communication
HS-CAN (-)
MS-CAN (+) open Unreliable communication
HS-CAN (+) short to No communication
MS-CAN (-) open Unreliable communication
voltage
HS-CAN (-) short to No communication
ground
voltage
Module internal failure No communication
HS-CAN (+) short to No communication
ground
HS-CAN (-) short to Unreliable communication HS-CAN
ground
The HS-CAN network uses an unshielded twisted
HS-CAN (+) open Unreliable communication
pair cable of data (+) and data (-) circuits. The data
HS-CAN (-) open Unreliable communication (+) and the data (-) circuits are each regulated to
approximately 2.5 volts during neutral or rested
network traffic. As bus messages are sent on the ground
data (+) circuit, voltage is increased by
Module internal failure No communication
approximately 1.0 volt. Inversely, the data (-) circuit
is reduced by approximately 1.0 volt when a bus
The following chart describes the specific CAN
message is sent. Multiple bus messages can be sent
network messages broadcast by each module, and
over the network CAN circuits allowing multiple
the module(s) that receive the message:
modules to communicate with each other. The
HS-CAN is a high speed communication network
used for the instrument cluster, the powertrain
control module (PCM) and the anti-lock brake
system (ABS) module (if equipped)
communications, and designed for real time
information transfer and control. The HS-CAN
network will not communicate while certain faults
are present, but will operate with diminished
performance with other faults present. The HS-CAN
bus may remain operational when 1 of the 2
termination resistors are not present.
CAN Network Module Communication Message Chart
Broadcast Message Originating Module Network Type Receiving Module(s)
ABS indicator request Anti-lock brake system High speed controller area Instrument cluster
(ABS) module network (HS-CAN)
ABS/trac control system ABS module HS-CAN Instrument cluster
configuration
Accelerator pedal position Powertrain control module HS-CAN ABS module
(PCM)
Accessory delay status Smart junction box (SJB) Medium speed controller ACM
area network (MS-CAN)
A/C clutch request SJB MS-CAN Instrument cluster
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CAN Network Module Communication Message Chart (Continued)
A/C clutch request Instrument cluster HS-CAN PCM
(gateway)
A/C clutch status PCM HS-CAN Instrument cluster
Axle ratio PCM HS-CAN ABS module
Barometric pressure PCM HS-CAN ABS module
Instrument cluster
Barometric pressure Instrument cluster MS-CAN SJB
(gateway)
Batter saver status SJB MS-CAN Instrument cluster
Brake deactivator switch PCM HS-CAN ABS module
status
Brake fluid level SJB MS-CAN Instrument cluster
Brake fluid level (gateway) Instrument cluster HS-CAN ABS module
Brake malfunction indicator ABS module HS-CAN Instrument cluster
request
Brake switch status SJB MS-CAN Instrument cluster
Brake switch status Instrument cluster HS-CAN ABS module
(gateway)
Charging system PCM HS-CAN Instrument cluster
malfunction indicator
request
Door ajar status (LF, RF, SJB MS-CAN Instrument cluster
trunk)
DRL indicator request SJB MS-CAN Instrument cluster
Engine coolant temperature PCM HS-CAN Instrument cluster
Engine fail-safe cooling PCM HS-CAN Instrument cluster
mode
Engine fail-safe (wrench) PCM HS-CAN Instrument cluster
indicator request
Engine fuel consumption PCM HS-CAN Instrument cluster
data
Engine malfunction PCM HS-CAN Instrument cluster
indicator lamp (MIL)
request
Engine oil pressure SJB MS-CAN Instrument cluster
Engine RPM PCM HS-CAN ABS module
Instrument cluster
Engine supercharger boost PCM HS-CAN Instrument cluster
pressure
Engine torque data PCM HS-CAN ABS module
Engine torque reduction ABS module HS-CAN PCM
request
Engine vacuum PCM HS-CAN ABS module
Fuel cap off indicator PCM HS-CAN Instrument cluster
request
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Fuel level input status, SJB MS-CAN Instrument cluster
sender 1 and 2
Fuel level input status, Instrument cluster HS-CAN PCM
sender 1 and 2 (gateway)
Headlamp high beam status SJB MS-CAN Instrument cluster
Headlamp low beam status SJB MS-CAN Instrument cluster
Headlamp on warning SJB MS-CAN Instrument cluster
chime request
Ignition switch position SJB MS-CAN Audio control module
Instrument cluster
Ignition switch position Instrument cluster HS-CAN ABS module
(gateway) PCM
Illumination dimmer level SJB MS-CAN Audio control module
Instrument cluster
Key-in-ignition status Instrument cluster MS-CAN SJB
Odometer count PCM HS-CAN Instrument cluster
Parking brake status SJB MS-CAN Instrument cluster
Parking brake status Instrument cluster HS-CAN ABS module
(gateway) PCM
Parking lamp status SJB MS-CAN Instrument cluster
PATS indicator status PCM HS-CAN Instrument cluster
Perimeter anti-theft status SJB MS-CAN Instrument cluster
Speed control set indicator PCM HS-CAN ABS module
request Instrument cluster
Tire size information ABS module HS-CAN PCM
TPMS system status SJB MS-CAN Instrument cluster
TPMS sensor status (LF, SJB MS-CAN Instrument cluster
RF, RR, LR, spare)
Transmission clutch pedal PCM HS-CAN ABS module
position
Traction control disable Instrument cluster HS-CAN ABS module
switch status
Traction control event in ABS module HS-CAN PCM
progress
Traction control indicator ABS module HS-CAN Instrument cluster
request
Transmission overdrive PCM HS-CAN Instrument cluster
indicator status
Transmission selector PCM HS-CAN ABS module
(PRNDL) range Instrument cluster
Transmission selector Instrument cluster MS-CAN SJB
(PRNDL) range (gateway)
Transmission shift in PCM HS-CAN ABS module
progress
Transmission type PCM HS-CAN ABS module
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Turn signal indicator SJB MS-CAN Instrument cluster
request
Vehicle speed PCM HS-CAN ABS module
Instrument cluster
Vehicle speed (gateway) Instrument cluster MS-CAN ACM
SJB
VIN information PCM HS-CAN ABS module
Instrument cluster
Wheel speed output (RF, ABS module HS-CAN PCM
LF, RR, LR)
Inspection and Verification 4. NOTE: Make sure to use the latest scan tool
software release.
scan tool to the DLC.
NOTE: The vehicle communication module (VCM)
LED prove-out confirms power and ground from the
DLC are provided to the VCM. Electrical
Bussed electrical center (BEC) fuse(s): If the scan tool does not communicate with the
42 (15A) (no communication with powertrain
VCM:
control module [PCM])
44 (10A) (no communication with smart junction Check the VCM connection to the vehicle.
box [SJB])
45 (10A) (no communication with PCM)
56 (20A) (no communication with audio unit, GO to Pinpoint Test J, to diagnose no power to
satellite radio receiver)
the scan tool.
59 (30A) (no communication with SJB)
5. NOTE: During the network test, the scan tool
63 (30A) (no communication with SJB) will first attempt to communicate with the
65 (30A) (no communication with anti-lock brake
PCM, after establishing communication with the
system [ABS] module)
PCM, the scan tool will then attempt to
communicate with all other modules on the
Smart junction box (SJB) fuse(s):
vehicle.
6 (5A) (no communication with audio unit)
8 (10A) (no communication with instrument
Carry out the network test.
cluster, no power to scan tool)
16 (5A) (no communication with instrument
cluster) record the continuous memory DTCs and
17 (10A) (no communication with restraints
proceed to Step 6.
control module [RCM])
If the network test fails, GO to Symptom
18 (10A) (no communication with ABS)
Chart to identify the module not 19 (5A) (no communication with instrument
cluster, PCM) communicating.
Data link connector (DLC)
Wiring harness
go to the Communication Network Diagnostic
Circuitry
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Communication Network Diagnostic Trouble Codes (DTC) Index
NOTE: DTC U1900 will set in a module that is reporting a communication fault from another
module on the data bus. The module that reports the fault is not the problem module.
U0073 Control Module Communication Bus Off Anti-lock DTC U0073 indicates the module could
brake system not communicate on the network at a
(ABS) point in time. The fault is currently not
module present. CLEAR the DTC. REPEAT the
network test with the scan tool.
U0073 Control Module Communication Bus Off Instrument DTC U0073 indicates the module could
cluster not communicate on the network at a
point in time. The fault is currently not
present. CLEAR the DTC. REPEAT the
U0073 Control Module Communication Bus Off Smart DTC U0073 indicates the module could
junction box not communicate on the network at a
(SJB) point in time. The fault is currently not
present. CLEAR the DTC. REPEAT the
U0140 Lost Communication With Body Control Audio control CLEAR the DTC. If the SJB failed the
Module (GEM) module network test, GO to Pinpoint Test D.
Otherwise, DISREGARD the DTC.
U0155 Lost Communication With Instrument Audio control If the instrument cluster failed the
Panel Cluster (IC) Control Module module network test, GO to Pinpoint Test C.
Otherwise, REFER to Section 413-01.
U0159 Lost Communication With Parking Assist Audio control DISREGARD this DTC.
Control Module (PAM) module
U0184 Lost Communication With Radio Satellite If the audio unit fails the network test,
digital audio GO to Pinpoint Test E. Otherwise,
receiver REFER to Section 415-00.
system
(SDARS)
U0193 Lost Communication With Digital Audio Audio control If the SDARS fails the network test, GO
Control Module (SDARS) module to Pinpoint Test F.
U0196 Lost Communication With Entertainment Audio control REFER to Section 415-01.
Control Module - Rear (AUX) module
U0196 Lost Communication With Entertainment SDARS REFER to Section 415-01.
Control Module - Rear (AUX)
U0197 Lost Communication With Telephone Audio control REFER to Section 415-01.
Control Module module
U0197 Lost Communication With Telephone SDARS REFER to Section 415-01.
Control Module
U0238 Lost Communication With Digital Audio Audio control REFER to Section 415-01.
Control Module D module
U0249 Lost Communication With Entertainment Audio control REFER to Section 415-01.
Control Module - Rear B module
U0249 Lost Communication With Entertainment SDARS REFER to Section 415-01.
Control Module - Rear B
U1900 CAN Communication Bus Fault-Receive ABS module GO to Symptom Chart for module that
Error failed network test.
U1900 CAN Communication Bus Fault-Receive Audio unit GO to Symptom Chart for module that
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Communication Network Diagnostic Trouble Codes (DTC) Index (Continued)
U1900 CAN Communication Bus Fault-Receive Instrument GO to Symptom Chart for module that
Error cluster failed network test.
U1900 CAN Communication Bus Fault-Receive SJB GO to Symptom Chart for module that
U2011 Module Transmitted Invalid Data (Non ABS module RETRIEVE AND FOLLOW
SCP) non-network DTCs from module with
non-network fault code present. REFER
to Section 419-10.
U2023 Fault Received From External Node Instrument RETRIEVE AND FOLLOW
cluster non-network DTCs from module with
non-network fault code present. REFER
to Section 419-10.
Symptom Chart
Symptom Chart
The powertrain control Fuse GO to Pinpoint Test A.
module (PCM) does not Circuitry
respond to the scan tool or no PCM
high speed controller area Anti-lock brake system (ABS)
network (HS-CAN) module (if equipped)
communication Instrument cluster
The anti-lock brake system Fuse GO to Pinpoint Test B.
(ABS) module does not Circuitry
respond to the scan tool ABS module
The instrument cluster does Fuse GO to Pinpoint Test C.
not respond to the scan tool Circuitry
Instrument cluster
The smart junction box (SJB) Fuse GO to Pinpoint Test D.
does not respond to the scan Circuitry
tool SJB
The audio unit does not Fuse GO to Pinpoint Test E.
respond to the scan tool Circuitry
Audio unit
The satellite radio receiver Fuse GO to Pinpoint Test F.
does not respond to the scan Circuitry
tool Satellite radio receiver
The restraints control module Fuse GO to Pinpoint Test G.
(RCM) does not respond to Circuitry
the scan tool RCM
No International Standards Circuitry GO to Pinpoint Test H.
Organization (ISO) 9141 RCM
network communication
No medium speed controller Circuitry GO to Pinpoint Test I.
area network (MS-CAN) SJB
communication, all modules Audio unit
are not responding Satellite radio receiver (if
equipped)
Instrument cluster
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No high speed controller area Circuitry GO to Pinpoint Test A.
network (HS-CAN) ABS module (if equipped)
communication, all modules Instrument cluster
are not responding PCM
No power to the scan tool Fuse GO to Pinpoint Test J.
Circuitry
Scan tool
Fuse
Pinpoint Test A: The Powertrain Control
Module (PCM) Does Not Respond To The Circuit 570 (BK/WH) open
Scan Tool or No High Speed Controller Area
Network (HS-CAN) Communication
Circuit 1118 (RD) open
Refer to Wiring Diagrams Cell 14, Module
Circuit 1683 (DG) open
Communications Network for schematic and
voltage (HS-CAN +)
Refer to Wiring Diagrams Cell 23, Electronic
Engine Controls - 4.0L for schematic and connector
Circuit 1828 (PK/LG) open, short to ground or
information.
voltage (HS-CAN -)
Circuit 1827 (WH/LG) (HS-CAN +) and circuit
1828 (PK/LG) (HS-CAN -) shorted together
information.
ABS module (if equipped)
Instrument cluster
PCM
information.
Normal Operation
The PCM communicates with the scan tool through
the HS-CAN. Circuits 1827 (WH/LG) (HS-CAN +)
and 1828 (PK/LG) (HS-CAN -) provide the network
connection to the PCM. The PCM shares the
HS-CAN network with the anti-lock brake system
(ABS) module (if equipped), and the instrument
cluster. Voltage for the PCM is provided by circuits
1118 (RD) and 1683 (DG). Circuits 570 (BK/WH)
and 1205 (BK) provide ground.
PINPOINT TEST A: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE SCAN
TOOL OR NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION
A1 CHECK THE DATA LINK CONNECTOR (DLC) PINS FOR
DAMAGE
NOTE: Most faults are due to connector and/or wiring concerns.
Carry out a thorough inspection and verification before proceeding
with the pinpoint test.
Disconnect the scan tool cable from the DLC.
(Continued)
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TOOL OR NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION (Continued)
A1 CHECK THE DATA LINK CONNECTOR (DLC) PINS FOR
DAMAGE (Continued)
Inspect DLC pins 6 and 14 for damage.
Yes
GO to A2.
No
REPAIR the DLC as necessary. CLEAR
the DTCs. REPEAT the network test with
Are DLC pins 6 and 14 OK? the scan tool.
A2 CHECK THE HS-CAN TERMINATION RESISTANCE
NOTE: Failure to disconnect the battery will result in false
resistance readings.
Disconnect the battery ground cable.
Measure the resistance between the DLC C251-6, circuit 1827
(WH/LG), harness side and the DLC C251-14, circuit 1828
(PK/LG), harness side.
Yes
GO to A5.
No
(Continued)
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A3 CHECK THE HS-CAN TERMINATION RESISTOR
Yes
GO to A9.
No
A4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A
SHORT TOGETHER
Yes
GO to A10.
No
(Continued)
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SHORT TO GROUND
(WH/LG), harness side and ground; and between the DLC
C251-14, circuit 1828 (PK/LG), harness side and ground.
Yes
GO to A6.
No
Are the resistances greater than 5,000 ohms? GO to A14.
SHORT TO VOLTAGE
Connect the battery ground cable.
Key in ON position.
Measure the voltage between the DLC C251-6, circuit 1827
Yes
REPEAT the network test with the scan
tool.
No
A7 CHECK THE PCM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN
Key in ON position.
Measure the voltage between the PCM, harness side and
ground as follows:
Yes
Connector-Pin Circuit GO to A8.
No
C175b-35 1118 (RD)
C175b-36 1118 (RD) (BEC) fuse 42 (15A) or fuse 45 (10A) is
OK. If OK, REPAIR the circuit in question.
C175b-45 1683 (DG)
CONNECT the PCM. CLEAR the DTCs.
Are the voltages greater than 10 volts? tool.
A8 CHECK THE PCM GROUND CIRCUITS FOR AN OPEN
(Continued)
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A8 CHECK THE PCM GROUND CIRCUITS FOR AN OPEN
(Continued)
Measure the resistance between the PCM, harness side and
ground as follows:
C175b-10 1205 (BK)
C175b-47 570 (BK/WH)
C175b-48 570 (BK/WH)
Yes
GO to A18.
C175b-49 570 (BK/WH)
No
C175b-50 570 (BK/WH)
DTCs. REPEAT the network test with the
Are the resistances less than 5 ohms? scan tool.
A9 CHECK THE CAN CIRCUITS BETWEEN THE DLC AND THE
PCM FOR AN OPEN
1827 (WH/LG), harness side and the DLC C251-6, circuit 1827
(WH/LG), harness side.
1828 (PK/LG), harness side and the DLC C251-14, circuit 1828
Yes
GO to A18.
No
SHORT TOGETHER WITH THE PCM DISCONNECTED
(Continued)
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SHORT TOGETHER WITH THE PCM DISCONNECTED
(Continued)
Yes
GO to A11.
No
A11 VERIFY VEHICLE EQUIPMENT - ABS MODULE
Inspect the vehicle for ABS module. Yes
Is the vehicle equipped with ABS? GO to A12.
No
GO to A13.
SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED
Yes
GO to A13.
No
SHORT TOGETHER WITH THE INSTRUMENT CLUSTER
DISCONNECTED
(Continued)
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DISCONNECTED (Continued)
Yes
REPAIR the circuit. CONNECT all
modules. CLEAR the DTCs. REPEAT the
No
SHORT TO GROUND WITH THE PCM DISCONNECTED
Yes
GO to A18.
No
A15 VERIFY VEHICLE EQUIPMENT ABS
Inspect the vehicle for ABS module. Yes
Is the vehicle equipped with ABS? GO to A16.
No
GO to A17.
SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED
(Continued)
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SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED
(Continued)
Yes
GO to A19.
No
SHORT TO GROUND WITH THE INSTRUMENT CLUSTER
DISCONNECTED
Yes
GO to A20.
No
modules. CLEAR the DTCs. REPEAT the
Are the resistances greater than 5,000 ohms? network test with the scan tool.
corrosion 303-14. CONNECT all modules.
damaged pins CONNECT the battery ground cable.
pushed-out pins CLEAR the DTCs. CLEAR the DTCs.
Connect all the PCM connectors and make sure they seat REPEAT the network test with the scan
correctly. tool.
No
CONNECT the battery ground cable.
CLEAR the DTCs. REPEAT the network
test with the scan tool.
(Continued)
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A19 CHECK FOR CORRECT ABS MODULE OPERATION
corrosion Section 206-09. CONNECT all modules.
damaged pins CONNECT the battery ground cable.
pushed-out pins CLEAR the DTCs. REPEAT the network
Connect the ABS module connector and make sure it seats test with the scan tool.
correctly.
No
corrosion REFER to Section 413-01. CONNECT all
damaged pins modules. CONNECT the battery ground
pushed-out pins cable. CLEAR the DTCs. REPEAT the
Connect the instrument cluster connector and make sure it seats network test with the scan tool.
correctly.
No
Possible Causes
Pinpoint Test B: The Anti-Lock Brake
System (ABS) Module Does Not Respond To
Fuse
The Scan Tool
Circuit 601 (LB/PK) open
Circuit 1827 (WH/LG) open (HS-CAN +)
Circuit 1828 (PK/LG) open (HS-CAN -)
information.
ABS module
Normal Operation
The ABS module communicates with the scan tool
through the high speed controller area network
(HS-CAN). Circuits 1827 (WH/LG) (HS-CAN +)
and 1828 (PK/LG) (HS-CAN -) provide the network
connection to the ABS module. The ABS module
shares the HS-CAN network with the powertrain
control module (PCM) and the instrument cluster.
Voltage for the ABS module is provided by circuits
601 (LB/PK) and 1844 (LG/RD). Both circuits 1205
(BK) provide ground.
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PINPOINT TEST B: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE
SCAN TOOL
B1 CHECK THE ABS MODULE VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
Key in ON position.
Measure the voltage between the ABS module C135-2, circuit
601 (LB/PK), harness side and ground; and between the ABS
module C135-32, circuit 1844 (LG/RD), harness side and
ground.
Yes
GO to B2.
No
VERIFY SJB fuse 18 (10A) is OK. If OK,
REPAIR circuit 1844 (LG/RD) for an open.
VERIFY BEC fuse 65 (30A) and fuse 8
(40A) are OK. If OK, REPAIR circuit 601
(LB/PK) for an open.
Are the voltages greater than 10 volts? test with the scan tool.
B2 CHECK THE ABS MODULE GROUND CIRCUITS FOR AN OPEN
Measure the resistance between the ABS module C135-16,
circuit 1205 (BK), harness side and ground; and between the
ABS module C135-45, circuit 1205 (BK), harness side and
ground.
Yes
GO to B3.
No
(Continued)
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PINPOINT TEST B: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE
SCAN TOOL (Continued)
B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE DATA LINK
CONNECTOR (DLC) AND THE ABS MODULE FOR AN OPEN
Measure the resistance between the ABS module C135-3, circuit
1827 (WH/LG), harness side and the DLC C251-6, circuit 1827
(WH/LG), harness side.
Measure the resistance between the ABS module C135-18,
circuit 1828 (PK/LG), harness side and the DLC C251-14, circuit
1828 (PK/LG), harness side.
Yes
GO to B4.
No
corrosion Section 206-09. CLEAR the DTCs.
damaged pins REPEAT the network test with the scan
pushed-out pins tool.
Connect the ABS module connector and make sure it seats
No
correctly.
the scan tool.
Pinpoint Test C: The Instrument Cluster
Does Not Respond To The Scan Tool
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Normal Operation
DTC U0155 will set in other network modules
The instrument cluster communicates with the scan
when there is a loss of communication with the
tool through the high speed controller area network
instrument cluster.
(HS-CAN). Circuits 1827 (WH/LG) (HS-CAN +)
Possible Causes
and 1828 (PK/LG) (HS-CAN -) provide the
Fuse
HS-CAN network connection to the instrument
cluster and circuits 1847 (WH/OG) (MS-CAN +)
Circuit 489 (PK/BK) open
and 1848 (PK/OG) (MS-CAN -) provide the
MS-CAN network connection to the instrument
cluster. The instrument cluster shares the HS-CAN
network with the powertrain control module (PCM),
and the anti-lock brake system (ABS) module (if
Circuit 1827 (WH/LG) open (HS-CAN +)
equipped). Voltage for the instrument cluster is
Circuit 1828 (PK/LG) open (HS-CAN -)
provided by circuits 489 (PK/BK), 1001 (LG/RD)
and 1266 (RD/YE). Circuit 1205 (BK) provides Instrument cluster
ground.
PINPOINT TEST C: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE SCAN TOOL
C1 CHECK THE HS-CAN TERMINATION RESISTANCE
Disconnect the scan tool cable from the data link connector
(DLC).
Yes
GO to C2.
No
Is the resistance between 54 and 66 ohms? GO to C4.
C2 CHECK THE INSTRUMENT CLUSTER VOLTAGE SUPPLY
CIRCUITS FOR AN OPEN
Key in ON position.
Measure the voltage between the instrument cluster, harness
(Continued)
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(Continued)
C2 CHECK THE INSTRUMENT CLUSTER VOLTAGE SUPPLY
CIRCUITS FOR AN OPEN (Continued)
Connector-Pin Circuit Yes
GO to C3.
C220-3 1001 (LG/RD)
No
C220-25 1266 (RD/YE) VERIFY the SJB fuses 8 (10A), 16 (5A),
and 19 (5A) are OK. If OK, REPAIR the
C220-26 489 (PK/BK)
circuit in question. CLEAR the DTCs.
Are the voltages greater than 10 volts? tool.
C3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
circuit 1205 (BK) harness side and ground.
Yes
GO to C5.
No
Is the resistance less than 5 ohms? tool.
C4 CHECK HIGH SPEED CAN CIRCUITS BETWEEN THE DLC AND
THE INSTRUMENT CLUSTER FOR AN OPEN
circuit 1827 (WH/LG), harness side and the DLC C251-6, circuit
1827 (WH/LG), harness side.
(Continued)
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(Continued)
C4 CHECK HIGH SPEED CAN CIRCUITS BETWEEN THE DLC AND
THE INSTRUMENT CLUSTER FOR AN OPEN (Continued)
circuit 1828 (PK/LG), harness side and the DLC C251-14, circuit
1828 (PK/LG), harness side.
Yes
GO to C5.
No
corrosion REFER to Section 413-01. CLEAR the
damaged pins DTCs. REPEAT the network test with the
pushed-out pins scan tool.
No
correctly.
the scan tool.
Pinpoint Test D: The Smart Junction Box
DTC U0140 sets when there is a loss of
(SJB) Does Not Respond To The Scan Tool
communication with the SJB
Refer to Wiring Diagrams Cell 10, Grounds for
Possible Causes
Fuse
Circuit 905 (GY/LB) open
Circuit 1052 (TN/BK) open information.
Circuit 1205 (BK) open Refer to Wiring Diagrams Cell 14, Module
Circuit 1523 (DG) open
Circuit 1847 (WH/OG) open (MS-CAN +)
Normal Operation
Circuit 1848 (PK/OG) open (MS-CAN -)
The SJB communicates with the scan tool through
SJB
the medium speed controller area network
(MS-CAN). Circuits 1847 (WH/OG) (MS-CAN +)
and 1848 (PK/OG) (MS-CAN -) provide the
network connection to the SJB. The SJB shares the
MS-CAN network with the audio control module,
the satellite radio receiver (if equipped) and the
instrument cluster. Voltage for the SJB is provided
by circuits 905 (GY/LB), 1052 (TN/BK) and 1523
(DG). Both circuits 1205 (BK) provide ground.
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PINPOINT TEST D: THE SMART JUNCTION BOX (SJB) DOES NOT RESPOND TO THE SCAN TOOL
D1 CHECK THE SJB VOLTAGE SUPPLY CIRCUITS FOR AN OPEN
Key in ON position.
as follows:
Connector-Pin Circuit Yes
GO to D2.
C2280h-11 1523 (DG)
No
C2280h-31 905 (GY/LB) VERIFY the BEC fuse(s) 44 (10A), 59
(30A), 63 (30A) and 67 (30A) are OK. If
C2280h-32 1052 (TN/BK)
OK, REPAIR the circuit in question.
Are the voltages greater than 10 volts? test with the scan tool.
D2 CHECK THE SJB GROUND CIRCUITS FOR AN OPEN
Measure the resistance between the SJB C2280h-8, circuit 1205
(BK), harness side and ground; and between the SJB
C2280h-22, circuit 1205 (BK), harness side and ground.
Yes
GO to D3.
No
Disconnect: SJB C2280a.
Measure the resistance between the SJB C2280a-1, circuit 1205
Yes
GO to D4.
No
(Continued)
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PINPOINT TEST D: THE SMART JUNCTION BOX (SJB) DOES NOT RESPOND TO THE SCAN TOOL
(Continued)
D4 CHECK THE MS-CAN CIRCUITS BETWEEN THE DATA LINK
CONNECTOR (DLC) AND THE SJB FOR AN OPEN
1847 (WH/OG), harness side and the DLC C251-3, circuit 1847
(WH/OG), harness side.
1848 (PK/OG), harness side and the DLC C251-11, circuit 1848
(PK/OG), harness side.
Yes
GO to D5.
No
corrosion 419-10. CLEAR the DTCs. REPEAT the
damaged pins network test with the scan tool.
pushed-out pins
No
correctly.
the scan tool.
Pinpoint Test E: The Audio Unit Does Not
Respond To The Scan Tool
information.
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Possible Causes
Normal Operation
The audio unit communicates with the scan tool
Fuse
through the medium speed controller area network
Circuit 687 (GY/YE) open
(MS-CAN). Circuits 1847 (WH/OG) (MS-CAN +)
Circuit 729 (RD/WH) open and 1848 (PK/OG) (MS-CAN -) provide the
network connection to the audio unit. The audio
unit shares the MS-CAN network with the smart
junction box (SJB), the satellite radio receiver (if
equipped), and the instrument cluster. Voltage for
the audio unit is provided by circuits 687 (GY/YE)
Audio unit
and 729 (RD/WH). Circuit 1204 (BK/OG) provides
ground.
communication with the audio unit.
PINPOINT TEST E: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL
E1 CHECK THE AUDIO UNIT VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
Key in ON position.
Measure the voltage between the audio unit C290d-1, circuit 729
(RD/WH), harness side and ground; and between the audio unit
C290d-2, circuit 687 (GY/YE), harness side and ground.
Yes
GO to E2.
No
(BEC) fuse 56 (20A) or the smart junction
box (SJB) fuse 6 (5A) is OK. If OK,
Are the voltages greater than 10 volts? scan tool.
E2 CHECK CIRCUIT 1204 (BK/OG) FOR AN OPEN
(Continued)
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PINPOINT TEST E: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL (Continued)
E2 CHECK CIRCUIT 1204 (BK/OG) FOR AN OPEN (Continued)
Measure the resistance between the audio unit C290d-13, circuit
1204 (BK/OG), harness side and ground.
Yes
GO to E3.
No
E3 CHECK THE MS-CAN CIRCUITS BETWEEN THE DATA LINK
CONNECTOR (DLC) AND THE AUDIO UNIT FOR AN OPEN
Measure the resistance between the audio unit C290a-15, circuit
(WH/OG), harness side.
Measure the resistance between the audio unit C290a-16, circuit
1848 (PK/OG), harness side and the DLC C251-11, circuit 1848
Yes
GO to E4.
No
(Continued)
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PINPOINT TEST E: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL (Continued)
E4 CHECK FOR CORRECT AUDIO UNIT OPERATION
Disconnect all the audio unit connectors. Yes
Check for: INSTALL a new audio unit. REFER to
corrosion Section 415-01. TEST the system for
damaged pins normal operation.
pushed-out pins
No
Connect all the audio unit connectors and make sure they seat
correctly.
the scan tool.
Pinpoint Test F: The Satellite Radio Receiver
Does Not Respond To The Scan Tool
communication with the satellite radio receiver.
The satellite radio receiver communicates with the
Fuse
scan tool through the medium speed controller area
Circuit 729 (RD/WH) open
network (MS-CAN). Circuits 1847 (WH/OG)
(MS-CAN +) and 1848 (PK/OG) (MS-CAN -) Circuit 1204 (BK/OG) open
provide the network connection to the satellite radio
receiver. The satellite radio receiver shares the
MS-CAN network with the smart junction box
Satellite radio receiver (SJB), the audio unit and the instrument cluster.
Voltage for the satellite radio receiver is provided
by circuit 729 (RD/WH). Ground is provided by
circuit 1204 (BK/OG).
PINPOINT TEST F: THE SATELLITE RADIO RECEIVER DOES NOT RESPOND TO THE SCAN TOOL
F1 CHECK CIRCUIT 729 (RD/WH) FOR VOLTAGE
Disconnect: Satellite Radio Receiver C3290.
Measure the voltage between the satellite radio receiver
Yes
GO to F2.
No
Is the voltage greater than 10 volts? scan tool.
(Continued)
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(Continued)
F2 CHECK CIRCUIT 1204 (BK/OG) FOR AN OPEN
Measure the resistance between the satellite radio receiver
C3290-3, circuit 1204 (BK/OG), harness side and ground.
Yes
GO to F3.
No
F3 CHECK THE MS-CAN CIRCUITS BETWEEN THE DATA LINK
CONNECTOR (DLC) AND THE SATELLITE RADIO RECEIVER
FOR AN OPEN
C3290-1, circuit 1847 (WH/OG), harness side and the DLC
C251-3, circuit 1847 (WH/OG), harness side.
C3290-7, circuit 1848 (PK/OG), harness side and the DLC
C251-11, circuit 1848 (PK/OG), harness side.
Yes
GO to F4.
No
Are the resistances less than 5 ohms? tool.
(Continued)
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(Continued)
F4 CHECK FOR CORRECT SATELLITE RADIO RECEIVER
OPERATION
Disconnect the satellite radio receiver connector. Yes
Check for: INSTALL a new satellite radio receiver.
corrosion REFER to Section 415-01. CLEAR the
damaged pins DTCs. REPEAT the network test with the
pushed-out pins scan tool.
Connect the satellite radio receiver connector and make sure it
No
seats correctly.
the scan tool.
Possible Causes
Pinpoint Test G: The Restraints Control
Module (RCM) Does Not Respond To The
Fuse
Scan Tool
Circuit 70 (LB/WH) open
Circuit 937 (RD/WH) open
Circuit 1203 (BK/LB) open
Refer to Wiring Diagrams Cell 46, Supplemental
RCM
Restraint System for schematic and connector
information.
Normal Operation
The RCM communicates with the scan tool through
the ISO 9141 communications network, circuit 70
(LB/WH). The RCM is the only module on the ISO
9141 network. Voltage for the RCM is provided by
circuit 937 (RD/WH). Ground is provided by circuit
1203 (BK/LB).
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PINPOINT TEST G: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO THE SCAN
TOOL
WARNING: Never probe the connectors on the air bag module. Doing so can result
in air bag deployment, which can result in personal injury.
WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear
safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner
electrical connector. Doing so could result in pretensioner or air bag deployment and
could result in personal injury.
NOTE: The supplemental restraint system (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough
inspection and verification before proceeding with the pinpoint test.
G1 CHECK THE RCM CONNECTION
Depower the SRS. Refer to Section 501-20B. GO to G2.
No
Are RCM C2041a pins 11, 12 and 16 OK?
REPAIR the RCM connector pins as
necessary. REPOWER the SRS. REFER
to Section 501-20B. CLEAR the DTCs.
tool.
G2 CHECK CIRCUIT 937 (RD/WH) FOR AN OPEN
Repower the SRS. Refer to Section 501-20B.
Key in ON position.
Measure the voltage between RCM C2041a-12, circuit 937
(RD/WH), harness side and ground.
Yes
GO to G3.
No
REACTIVATE the SRS. REFER to Section
Is the voltage greater than 10 volts? network test with the scan tool.
G3 CHECK GROUND CIRCUIT 1203 (BK/LB) FOR AN OPEN
(Continued)
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PINPOINT TEST G: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO THE SCAN
TOOL (Continued)
G3 CHECK GROUND CIRCUIT 1203 (BK/LB) FOR AN OPEN
(Continued)
Measure the resistance between RCM C2041a-16, circuit 1203
(BK/LB), harness side and a sheet metal ground near the RCM.
Yes
GO to G4.
No
SRS. REFER to Section 501-20B. CLEAR
Is the resistance less than 5 ohms? the scan tool.
G4 CHECK THE HS-CAN CIRCUITS BETWEEN THE DATA LINK
CONNECTOR (DLC) AND THE RCM FOR AN OPEN
Measure the resistance between the RCM C2041a-11, circuit 70
(LB/WH), harness side and the DLC C251-7, circuit 70 (LB/WH),
harness side.
Yes
GO to G5.
No
REPAIR the circuit in question.
Is the resistance less than 5 ohms? network test with the scan tool.
G5 CHECK FOR CORRECT RCM OPERATION
Check for: INSTALL a new RCM. REACTIVATE the
corrosion SRS. REFER to Section 501-20B. CLEAR
damaged pins the DTCs. REPEAT the network test with
pushed-out pins the scan tool.
No
correctly.
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Possible Causes
Pinpoint Test H: No International Standards
Organization (ISO) 9141 Network
Communication
voltage (ISO 9141)
RCM
Normal Operation
The restraints control module (RCM) communicates
with the scan tool through the ISO 9141
communications network, circuit 70 (LB/WH).
PINPOINT TEST H: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141 NETWORK
COMMUNICATION
H1 CHECK THE DATA LINK CONNECTOR (DLC) PINS FOR
DAMAGE
Inspect the DLC pin 7 for damage.
Yes
GO to H2.
No
Is the DLC pin 7 OK? the scan tool.
H2 CHECK THE ISO 9141 CIRCUIT FOR A SHORT TO VOLTAGE
Depower the SRS. Refer to Section 501-20B.
Repower the SRS. Refer to Section 501-20B.
Key in ON position.
(Continued)
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COMMUNICATION (Continued)
H2 CHECK THE ISO 9141 CIRCUIT FOR A SHORT TO VOLTAGE
(Continued)
(LB/WH), harness side and ground.
Yes
the scan tool.
No
H3 CHECK THE ISO 9141 CIRCUIT FOR A SHORT TO GROUND
(LB/WH), harness side and ground.
Yes
GO to H4.
No
Is the resistance greater than 10,000 ohms? the scan tool.
H4 CHECK CIRCUIT 70 (LB/WH) BETWEEN THE RCM AND THE
DLC FOR AN OPEN
Measure the resistance between the RCM C2041a-11, circuit 70
(LB/WH), harness side and the DLC C251-7, circuit 70 (LB/WH),
harness side.
Yes
GO to H5.
No
Is the resistance less than 5 ohms? the scan tool.
(Continued)
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COMMUNICATION (Continued)
H5 CHECK THE ISO 9141 CIRCUIT OPERATION WITH THE RCM
CONNECTED
Connect: RCM C2041a. Yes
Key in ON position. The system is operating correctly at this
REPEAT the network test with the scan tool. time. The concern may have been caused
Can the scan tool communicate with the RCM? by a loose or corroded connector.
No
GO to H6.
H6 CHECK FOR CORRECT RCM OPERATION
Check for: INSTALL a new RCM. REACTIVATE the
corrosion SRS. REFER to Section 501-20B. CLEAR
damaged pins the DTCs. REPEAT the network test with
pushed-out pins the scan tool.
No
correctly.
Possible Causes
Pinpoint Test I: No Medium Speed Controller
Area Network (MS-CAN) Communication, All
Circuit 1847 (WH/OG) open, short to ground or
Modules Are Not Responding
voltage (MS-CAN +)
Circuit 1848 (PK/OG) open, short to ground or
voltage (MS-CAN -)
Circuit 1847 (WH/OG) (MS-CAN +) and circuit
Normal Operation
1848 (PK/OG) (MS-CAN -) shorted together
The MS-CAN uses an unshielded twisted pair cable,
SJB
circuits 1847 (WH/OG) and 1848 (PK/OG). The
Instrument cluster
smart junction box (SJB) and the instrument cluster
communicate with the scan tool using the MS-CAN
network.
PINPOINT TEST I: NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION,
ALL MODULES ARE NOT RESPONDING
I1 CHECK DATA LINK CONNECTOR (DLC) PINS FOR DAMAGE
(Continued)
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ALL MODULES ARE NOT RESPONDING (Continued)
I1 CHECK DATA LINK CONNECTOR (DLC) PINS FOR DAMAGE
(Continued)
Inspect DLC pins 3 and 11 for damage.
Yes
GO to I2.
No
Are DLC pins 3 and 11 OK? the scan tool.
I2 CHECK THE MS-CAN TERMINATION RESISTANCE
(WH/OG), harness side and the DLC C251-11, circuit 1848
Yes
GO to I5.
No
Is the resistance between 54 and 66 ohms? GO to I3.
(Continued)
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I3 CHECK THE MS-CAN TERMINATION RESISTOR
Yes
GO to I7.
No
Is the resistance between 108 and 132 ohms? GO to I4.
I4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A
SHORT TOGETHER
Yes
GO to I8.
No
Is the resistance less than 5 ohms? GO to I7.
(Continued)
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SHORT TO GROUND
(WH/OG), harness side and ground; and between the DLC
C251-11, circuit 1848 (PK/OG), harness side and ground.
Yes
GO to I6.
No
Are the resistances greater than 5,000 ohms? GO to I10.
SHORT TO VOLTAGE
Key in ON position.
Yes
tool.
No
VERIFY all module fuses are OK. If OK,
Is the voltage greater than 6 volts? tool.
I7 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC AND THE
SJB FOR AN OPEN
(Continued)
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I7 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC AND THE
SJB FOR AN OPEN (Continued)
(WH/OG), harness side; and between the SJB C2280b-51,
circuit 1848 (PK/OG), harness side and the DLC C251-11, circuit
1848 (PK/OG), harness side.
Yes
VERIFY all module fuses are OK. If OK,
CONNECT all modules. CONNECT the
battery ground cable. REPEAT the
No
REPAIR the circuit in question. CONNECT
the battery ground cable. CLEAR the
SHORT TOGETHER WITH THE SJB DISCONNECTED
Yes
GO to I9.
No
DISCONNECTED
(Continued)
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Yes
modules. CONNECT the battery ground
cable. CLEAR the DTCs. REPEAT the
No
SHORT TO GROUND WITH THE SJB DISCONNECTED
Yes
GO to I12.
No
Are the resistances greater than 5,000 ohms? GO to I11.
DISCONNECTED
(Continued)
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Yes
GO to I13.
No
modules. CONNECT the battery ground
cable. CLEAR the DTCs. REPEAT the
Are the resistances greater than 5,000 ohms? network test with the scan tool.
corrosion 419-10. CONNECT the battery ground
damaged pins cable. CLEAR the DTCs. REPEAT the
pushed-out pins network test with the scan tool.
No
correctly.
corrosion REFER to Section 413-01. CONNECT the
damaged pins battery ground cable. CLEAR the DTCs.
pushed-out pins REPEAT the network test with the scan
Connect the instrument cluster connector and make sure it seats tool.
correctly.
No
Pinpoint Test J: No Power To The Scan Tool Normal Operation
The scan tool is connected to the data link
connector (DLC) to communicate with the high
speed controller area network (HS-CAN), medium
speed controller area network (MS-CAN), and
International Standards Organization (ISO) 9141
communications network. Voltage for the scan tool
is provided by circuit 1047 (LG/RD). Ground is
provided by circuits 570 (BK/WH) and 1205 (BK).
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Possible Causes
Fuse Circuit 1205 (BK) open
Circuit 570 (BK/WH) open Scan tool
PINPOINT TEST J: NO POWER TO THE SCAN TOOL
J1 CHECK THE DLC PINS FOR DAMAGE
Inspect DLC pins 4, 5 and 16 for damage.
Yes
GO to J2.
No
Are DLC pins 4, 5 and 16 OK? the scan tool.
J2 CHECK CIRCUIT 1047 (LG/RD) FOR AN OPEN
(LG/RD), harness side and ground.
Yes
GO to J3.
No
Is the voltage greater than 10 volts? tool.
(Continued)
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PINPOINT TEST J: NO POWER TO THE SCAN TOOL (Continued)
J3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN
(BK), harness side and ground; and between the DLC C251-5,
circuit 570 (BK/WH), harness side and ground.
Yes
REPAIR the scan tool. REPEAT the
No
REPAIR the circuit in question. REPEAT
Are the resistances less than 5 ohms? the network test with the scan tool.
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418-01-1 418-01-1 Module Configuration
Programmable Module Installation (PMI)
Module Configuration
PMI is a scan tool process which configures settings
Special Tool(s) in a new module. Data used for the PMI process is
automatically downloaded from the original module
and stored when a scan tool session is started. If
this data cannot be retrieved from the module being Diagnostic System (IDS)
software with appropriate replaced, the scan tool may prompt for As-Built
data entry or display a list of parameter values that
tool
need to be manually selected. Some modules are
reprogrammed during PMI when a
strategy/calibration update is available.
NOTE: A module must be able to communicate
Configurable modules accommodate a variety of with the scan tool in order to carry out PMI. It is
vehicle options, eliminating the need for many important that the scan tool identifies the vehicle
unique modules for one vehicle line. These modules and obtains configuration data prior to removing
must be configured when replaced as part of a any modules.
repair procedure.
To carry out PMI, refer to Programmable Module
Configurable modules should not be exchanged Installation in this section.
between vehicles since the settings are unique to
Module Reprogramming
each vehicle. Failure to configure a new module
Module reprogramming (also referred to as
may result in improper operation and/or any of the
flashing) is a scan tool process which updates
following DTCs setting:
the strategy/calibration in a module. Module
B2477 and/or B2141 sets when a body/chassis reprogramming is automatically carried out during
module is not configured or is configured PMI when a later strategy/calibration is available.
incorrectly.
Reprogramming a module with the same level of
B2900 sets when there is a VIN mismatch software will not improve module operation or
between the module with the B2900 and the repair a hardware failure.
PCM. Either the PCM or the body module stored
NOTE: Module reprogramming should be limited
VIN may be incorrect.
to circumstances where a published Technical
P0602, P0605 and/or P1639 sets when the Service Bulletin (TSB) procedure recommends
powertrain control module (PCM) vehicle doing so.
identification (VID) block is not configured or is
NOTE: A module cannot communicate with other
configured incorrectly.
modules on the communication network while being
U0300 and/or U0301 sets when the reprogrammed. Clear any network communication
configuration between 2 or more modules do not DTCs which may have been set in other modules
match. during reprogramming.
U2050 and/or U2051 sets when a valid
Programmable Parameters
strategy/calibration is not present.
Programmable parameters are customer preference
items that may be modified by the dealer via scan
The following are the 3 different methods of
tool or in some cases modified by the customer
configuration:
following a procedure listed in the vehicle Owners
Programmable module installation (PMI)
Literature. While many configuration options may
Module reprogramming (flashing)
exist for a module, only a few of these options are
programmable parameters.
Programmable parameters
Some modules do not support all 3 methods.
Definition of Terms
The following are definitions of configuration terms:
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Adaptive Learning and Calibration
NOTE: It is not necessary to obtain As-Built data
Some modules require a separate learning procedure
unless directed to do so by the scan tool. This data
be carried out if replaced as part of a repair
may be accessed from the technician service
procedure. For adaptive learning and calibration
publication website.
instructions, refer to the specific module removal
The following chart lists body/chassis module
and installation procedures.
As-Built data addresses:
Vehicle Identification (VID) Block
Body/Chassis Module Addresses for As-Built
Some PCMs contain a memory area called a vehicle
Entry
identification (VID) block. The PCM VID block
Module
commonly stores powertrain configuration items
Module Name Address
such as VIN, tire size, axle ratio, and whether or
Audio control module 727
not the vehicle is equipped with speed control.
Instrument cluster 720
As-Built Data
Satellite radio receiver 782
As-Built data is a VIN specific module
configuration record. During vehicle build, the Smart junction box (SJB) 58
configuration from all modules is downloaded and
stored in the As-Built database. As Built data will
The following chart describes specific module
not reflect customer preference items that have been
programming information:
changed from the default state. These items will
need to be changed using programmable parameters
after the module is configured.
Module Configuration and Parameter Index
Requires Available
Reprogram/ Adaptive Requires Programmable
Module Name Flash Capable Requires PMI Learning Calibration Parameters
Anti-lock brake No No No No None
system (ABS)
module
Audio control Yes Yes No No None
module
Instrument Yes Yes No No None
cluster
Powertrain Yes Yes Yes No Speed control
control module enable/disable
(PCM)
Restraints control No No No Seat weight None
module (RCM) sensor
re-zero
Satellite radio Yes Yes No No None
receiver
Smart junction Yes Yes No No None
box (SJB)
This section provides step-by-step module
configuration procedures. Carry out the
programmable module installation (PMI) procedure
in this section when another workshop manual
section directs to carry out configuration or when
DTCs from the below list are present:
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Diagnostic Trouble Code (DTC) Index
B2477 Module Configuration Failure Audio control module CARRY OUT PMI. REFER to
Instrument cluster Programmable Module Installation
Restraints control module in this section.
(RCM)
P0602 Powertrain Control Module Powertrain control module CARRY OUT PMI. REFER to
Programming Error (PCM) Programmable Module Installation
in this section.
P0605 Internal Control Module Read PCM CARRY OUT PMI. REFER to
Only Memory (ROM) Error Programmable Module Installation
in this section.
P1639 Vehicle ID Block Corrupted, Not PCM CARRY OUT PMI. REFER to
Programmed Programmable Module Installation
in this section.
U0300 Internal Control Module Software PCM CARRY OUT PMI. REFER to
Incompatibility Programmable Module Installation
in this section.
U2050 No Application Present Audio control module CARRY OUT PMI. REFER to
Anti-lock brake system (ABS) Programmable Module Installation
module in this section.
Instrument cluster
PCM
SJB
U2051 One or More Calibration Files ABS module CARRY OUT PMI. REFER to
Missing / Corrupt Audio control module Programmable Module Installation
PCM in this section.
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GENERAL PROCEDURES
9. Test module for correct operation.
Programmable Module Installation
Special Tool(s)
Using the Integrated Diagnostic System
(IDS) When the Original Module is NOT
Available
NOTE: Following module installation, some
modules require a separate learning procedure be
tool
carried out. For adaptive learning and calibration
and Installation procedures.
Using the Integrated Diagnostic System
1. Install the new module.
(IDS) When the Original Module is
Available
2. Connect the IDS and identify the vehicle as
normal.
NOTE: Following module installation, some
modules require a separate learning procedure be 3. From the Toolbox icon, select Module
carried out. For adaptive learning and calibration Programming and press the check mark.
4. Select Programmable Module Installation. and installation procedures.
5. Select the module that was replaced. 1. Connect the IDS and identify the vehicle as
normal.
6. Follow the on-screen instructions, turn the
ignition key to the OFF position, and press the 2. From the Toolbox icon, select Module
check mark. Programming and press the check mark.
7. Follow the on-screen instructions, turn the 3. Select Programmable Module Installation.
ignition key to the ON position, and press the
4. Select the module that is being replaced. check mark.
5. Follow the on-screen instructions, turn the 8. If the data is not available, the IDS displays a
ignition key to the OFF position, and press the screen stating to contact the As-Built Data
check mark. Center. Retrieve the data from the technician
service publication website at this time and
6. Install the new module and press the check
press the check mark.
mark.
9. Enter the module data and press the check
7. Follow the on-screen instructions, turn the
mark.
ignition key to the ON position, and press the
check mark. 10. The IDS downloads the data into the new
module and displays Module Configuration
8. The IDS downloads the data into the new
Complete.
module and displays Module Configuration
Complete. 11. Test module for correct operation.
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419-01A-1 419-01A-1 Anti-Theft Perimeter
Anti-Theft Alarm Horn
1 Anti-theft alarm horn
1. Disconnect the battery. For additional electrical connector (part of
14A464) information, refer to Section 414-01.
2 Anti-theft alarm horn screw
2. Remove the RH rear quarter trim panel. For
3 3A803 Anti-theft alarm horn
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3. Disconnect the anti-theft alarm horn electrical 5. To install, reverse the removal procedure.
connector.
4. Remove the screw and the anti-theft alarm
horn.
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419-01B-1 419-01B-1 Anti-Theft PATS
GENERAL PROCEDURES
1. From the scan tool, enter TOOLBOX. Select:
Anti-Theft Security Access
BODY SECURITY PATS Functions, and
follow the on-screen instructions to ENTER
Special Tool(s)
SECURITY ACCESS. This procedure takes
approximately 10 minutes to carry out, during
which time the ignition switch must be in the
ON position and the scan tool must be
connected to the vehicle.
tool
2. After the 10-minute security access procedure is
completed, click on the tick mark and a new
menu is displayed with command options.
NOTE: The anti-theft security access procedure is
Select only those functions required before
used to obtain passive anti-theft system (PATS)
exiting out of this menu. Do not select more
security access. PATS security access must be
functions than the procedure calls for. Once
granted to erase ignition key codes, program
exited out of this menu, the security access
ignition key codes, enable/disable unlimited key
procedure must be repeated again to carry out
mode, set unlimited transponder key ID and
additional commands.
enable/disable the spare key programming switch
(PID SPAREKEY). The anti-theft security access
procedure invokes a 10-minute time delay prior to
granting security access during which the scan tool
must remain connected to the vehicle. Once
security access is granted, a security access
command menu is displayed which offers various
command options.
NOTE: Once security access has been granted,
multiple security access commands should be
executed (if necessary) prior to exiting the
command menu. This avoids an additional security
access procedure and the associated 10 minute time
delay.
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The interior motion detection and vehicle inclination
Anti-Theft
sensing systems operate only when the vehicle is
The perimeter alarm system consists of:
locked using the RKE transmitter or when using the
Anti-theft alarm horn door lock control switch with the accompanying
door open and all the doors are then closed. For
Anti-theft hood switch
vehicles with a convertible top, the top must be in
Convertible top ajar switch (if equipped)
the fully closed and latched position for the interior
Door ajar switches
motion sensing system to arm. If the vehicle is
locked using the key in the driver door lock
Door arm/disarm switch
cylinder, the system monitors the doors, the
Door lock control switch
luggage compartment lid and the hood, but the
Intrusion/inclination sensor
interior motion and the vehicle inclination sensing
does not arm. Do not arm the interior motion
detection system if movement within the vehicle is
Luggage compartment lid disarm switch
likely to occur. Do not arm the vehicle inclination
Remote keyless entry (RKE) transmitter
sensing system when the vehicle is in transport. For
correct operation of the interior motion detection
Traffic horn(s)
system, make sure all the windows are closed prior
to arming the system. This helps prevent accidental
alarm activation due to external influences and Perimeter Alarm System
makes sure that correct interior motion detection
NOTE: The convertible top (if equipped), the
occurs. The interior motion sensing system does not
luggage compartment lid, and all doors must be
arm if either door is ajar.
closed for the interior motion sensing feature to
activate.
Arming the System
NOTE: The perimeter alarm system includes a
When armed, the perimeter alarm system is
motion detection system that monitors the vehicle
designed to notify the driver of an unauthorized
interior and a vehicle inclination sensor that detects
entry. When unauthorized entry or towing occurs,
changes in vehicle inclination.
the system flashes the turn signal lamps and interior
NOTE: The inclination sensing feature must be lamps and sounds the anti-theft alarm horn and the
disarmed before raising the vehicle on a hoist to traffic horns. The system is ready to arm whenever
prevent false alarms. the key is out of the ignition. Any of the following
actions arm the alarm system:
The anti-theft perimeter alarm feature is controlled
by the SJB. The perimeter alarm system is designed
Pressing the RKE transmitter lock control 1 time
to warn the driver in the event of an unauthorized
to arm the system.
entry to the vehicle and is also designed to help
Locking all the doors using the door lock control
prevent the unwanted towing of the vehicle. When
switch while the driver or passenger door is open
the vehicle is locked and armed, the perimeter alarm
and then closed.
system monitors the following:
Locking the driver door with the key in the driver
Doors
door lock cylinder (this does not arm the interior
Hood motion or vehicle inclination sensing systems).
Luggage compartment lid
Movement inside the vehicle
Change in vehicle inclination/tilt
If unauthorized activation of the above inputs
occurs, the system flashes the turn signals and
sounds the anti-theft alarm horn and the traffic
horns.
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Disarming the System
NOTE: Deactivating an activated alarm by pressing
the PANIC button on the RKE transmitter returns
The perimeter alarm system can be disarmed by:
the system to an armed state.
Unlocking the doors using the RKE transmitter.
NOTE: Unlocking the luggage compartment inhibits
Unlocking the driver door with the key in the
the interior motion and inclination sensing systems,
driver door lock cylinder.
but the perimeter alarm system continues to monitor
the doors and hood. Once the luggage compartment
Turning the ignition switch to the ON position
lid is closed, the interior motion sensing systems
with a programmed ignition key.
are again monitored.
If all the closures (doors, luggage compartment lid
and hood) are closed, the turn signal lamps flash
once. If the vehicle is locked again within 3
seconds, the vehicle locks again, the turn signal
lamps flash and the horn chirps. If any closure is
not properly closed, the turn signal lamps do not
flash and the horn chirps twice. The system waits
20 seconds after locking before arming the
perimeter alarm. After the 20 second pre-arm phase,
the door lock control switch is disabled (if door
lock inhibit function is configured on) to further
protect the vehicle.
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The system arms when the driver door is locked
Anti-Theft
with the key (no intrusion or inclination protection),
Special Tool(s)
the doors are locked with the remote keyless entry
(RKE) transmitter, or the doors are locked with the
door lock control switch (with the door open) and
105-R0057
then the accompanying door is closed. The SJB
monitors the status of all entry points. If any entry
point is open, the alarm arms everything except for
the open entry point. The SJB adds the entry point
to the protected status when the closure of the open
entry point is detected. Note that only when the
system is armed by locking the door using the key
in the door lock cylinder is there no Diagnostic System (IDS)
software with appropriate intrusion/inclination protection. Arming the system
(locking the doors) using the RKE transmitter or
tool
using the door lock control switch allows the
intrusion/inclination protection to also arm.
NOTE: The intrusion sensing feature is not
Flex Probe Kit
105-R025C or equivalent activated if either door or the convertible top (if
equipped) is open when the vehicle is armed.
The SJB inhibits the intrusion/inclination sensor and
the luggage compartment lid ajar inputs if the
luggage compartment lid is opened with a key or
the RKE transmitter. Once the luggage compartment
lid is closed, the intrusion/inclination sensor and
the luggage compartment lid ajar switch are
The smart junction box (SJB) monitors the door ajar
monitored by the SJB.
switches, the anti-theft hood switch, the luggage
Perimeter Alarm Arming
compartment lid ajar switch, and the
intrusion/inclination sensor.
To arm the system:
If any intrusion is detected without the alarm being
Press the door lock control switch to the LOCK
deactivated, the SJB energizes the anti-theft alarm
position with the accompanying door open, then
horn, the traffic horn, and causes the turn signal
close it (then wait 20 seconds for the pre-arm
lamps to flash in regular intervals.
phase to expire).
Press the LOCK button on the RKE transmitter
(then wait 20 seconds for the pre-arm phase to
expire).
Turn the key in the door lock cylinder to the
LOCK position (then wait 20 seconds for the
pre-arm phase to expire). This is the only way to
arm the perimeter alarm system without also
arming the inclination/intrusion feature.
Perimeter Alarm Disarming
To disarm the system (these steps will also
deactivate an activated alarm):
Press the UNLOCK button on the RKE
transmitter.
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Turn the key in the door lock cylinder to the 4. NOTE: Make sure to use the latest scan tool
UNLOCK position. software release.
Turn a programmed PATS key in the ignition If the cause is not visually evident, connect the
lock cylinder to the ON position. scan tool to the data link connector (DLC).
Perimeter Alarm Deactivation
To deactivate an activated alarm (this step will not
disarm the alarm), press the PANIC button on the
VCM.
RKE transmitter.
VCM:
Perimeter Alarm Inhibit
To inhibit (stop/prevent) an armed system from
activating the alarm (the perimeter alarm will
continue to be armed), open the luggage
compartment lid using the key in the luggage
compartment lid lock cylinder.
with the scan tool.
vehicle:
position.
good vehicle.
Anti-theft hood switch Smart junction box response from the powertrain control module
Door arm/disarm switch (SJB) fuse 10 (5A)
(PCM).
Anti-theft alarm horn Circuitry
Door ajar switches Intrusion/inclination
Luggage compartment sensor
lid ajar switch SJB
Luggage compartment
lid anti-theft inhibit
switch
Convertible top ajar
switch
Remote keyless entry 8. Clear the continuous DTCs and carry out the
(RKE) transmitter
3. If an obvious cause for an observed or reported go to the Smart Junction Box (SJB) Diagnostic
concern is found, correct the cause (if possible) Trouble Code (DTC) Index. For all other DTCs,
before proceeding to the next step. refer to Section 419-10.
B1519 Hood Switch Circuit Failure GO to Pinpoint Test E.
B1833 Door Unlock Disarm Switch Circuit Short To GO to Pinpoint Test A.
Ground
B2569 Liftgate Disarm Switch Circuit Short to Ground GO to Pinpoint Test F.
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Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index (Continued)
B200A VSM Inclination Failure GO to Pinpoint Test G.
B200B VSM Ultrasonic Failure GO to Pinpoint Test G.
B200C VSM Module Failure GO to Pinpoint Test G.
U2033 VSM Communication Link Failure GO to Pinpoint Test G.
Symptom Chart
Symptom Chart
SJB
The anti-theft system does not Circuitry GO to Pinpoint Test A.
arm/disarm using the door SJB
arm/disarm switch Door arm/disarm switch
The anti-theft system does not RKE transmitter GO to Pinpoint Test B.
arm/disarm using the SJB
remote keyless entry (RKE)
transmitter
The anti-theft system does not Circuitry REFER to Section 419-01B
disarm using the ignition Controller area network to continue diagnosis of the
lock cylinder (CAN) error PATS.
Inoperative/unprogrammed
key
Passive anti-theft system
(PATS) transceiver
(PCM)
SJB
The anti-theft system does not Circuitry GO to Pinpoint Test C.
operate correctly no Traffic horn
anti-theft alarm horn or traffic Anti-theft alarm horn
horn SJB
The anti-theft system does not Circuitry GO to Pinpoint Test D.
operate correctly anti-theft SJB
alarm horn and traffic horn
are continuously on
The anti-theft system does not Circuitry GO to Pinpoint Test E.
operate correctly turn Anti-theft hood switch
signals do not flash when Door ajar switch(es)
arming Luggage compartment lid ajar
switch
SJB
The alarm system does not Circuitry GO to Pinpoint Test F.
operate correctly the alarm Luggage compartment lid
activates when the luggage anti-theft inhibit switch
compartment is opened with SJB
the key
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The alarm system does not Fuse GO to Pinpoint Test G.
operate correctly intrusion Circuitry
and inclination sensing Intrusion/inclination sensor
module
SJB
Pinpoint Tests DTC B1833 sets when there is a short to ground
on circuit 1313 (LB/BK) or if the door arm/disarm
Pinpoint Test A: The Anti-Theft System Does
switch is shorted internally.
Not Arm/Disarm Using The Door
Possible Causes
Arm/Disarm Switch
Refer to Wiring Diagrams Cell 117, Remote Circuit 1205 (BK) open
Keyless Entry and Alarm for schematic and
Circuit 1313 (LB/BK) open or short to ground
Circuit 1315 (LB/PK) open or short to ground
NOTE: The intrusion and inclination protection
Door arm/disarm switch
features cannot be activated with the door
SJB arm/disarm switch. This allows raising the vehicle
on a hoist, transporting or towing the vehicle, or
when authorized motion inside the vehicle is likely.
Normal Operation
The door arm/disarm switch is located in the driver
door lock cylinder and grounds circuit 1315
(LB/PK) or circuit 1313 (LB/BK) to the smart
junction box (SJB), which arms or disarms the
system. The ajar switches are monitored for a
ground signal by the SJB. Ground is supplied to
the door arm/disarm switch by circuit 1205 (BK).
When an arm request is received by the SJB, the
ajar switch positions are queried. If any door, hood,
or luggage compartment lid is ajar, the turn signal
lamps do not flash and the horn will chirp twice.
Only the closed doors will begin the pre-arm phase,
and as soon as the open body closure is closed, it
will begin its pre-arm phase. If the doors, hood and
luggage compartment lid are closed when the
remote keyless entry (RKE) transmitter LOCK
button is pressed, the perimeter alarm will begin its
pre-arm phase of 20 seconds. After the pre-arm
phase, the system will be armed.
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PINPOINT TEST A: THE ANTI-THEFT SYSTEM DOES NOT ARM/DISARM USING THE DOOR
ARM/DISARM SWITCH
A1 RETRIEVE THE RECORDED SJB DTCs FROM BOTH
CONTINUOUS AND ON-DEMAND SELF-TESTS
Retrieve the recorded SJB DTCs from the continuous and Yes
on-demand self-tests. For DTC B1833, GO to A3.
Are any DTCs recorded?
For all other DTCs, REFER to Section
419-10.
No
GO to A2.
A2 CHECK THAT THE DRIVER DOOR LOCK AND UNLOCK PIDS
READ CORRECTLY
Enter the following diagnostic mode on the scan tool: SJB PIDs.
Yes
Monitor the SJB PID DD UNLOCK while turning the key in the
GO to A7.
driver door lock cylinder to the LOCK and UNLOCK positions.
Do the SJB PID values agree with the door lock cylinder No
positions? GO to A3.
A3 CHECK THE DOOR DISARM SWITCH
Disconnect: Door Disarm Switch C509.
Monitor the SJB PIDs DD UNLOCK while connecting a fused
(5A) jumper wire between the door disarm switch C509-1, circuit
1313 (LB/BK) harness side and ground; and between the door
disarm switch C509-2, circuit 1315 (LB/PK) harness side and
ground.
Yes
Do the SJB PID values agree with the door lock cylinder No
positions? REMOVE the jumper wire. GO to A5.
Measure the resistance between the door disarm switch C509-3,
Yes
INSTALL a new door disarm switch.
REFER to Door Disarm Switch in this
section.
No
(Continued)
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PINPOINT TEST A: THE ANTI-THEFT SYSTEM DOES NOT ARM/DISARM USING THE DOOR
ARM/DISARM SWITCH (Continued)
A5 CHECK CIRCUITS 1313 (LB/BK) AND 1315 (LB/PK) FOR A
SHORT TO GROUND
Measure the resistance between the SJB C2280e-9, circuit 1313
(LB/BK), harness side and ground; and between the SJB
C2280e-18, circuit 1315 (LB/PK), harness side and ground.
Yes
GO to A6.
No
A6 CHECK CIRCUITS 1313 (LB/BK) AND 1315 (LB/PK) FOR AN
OPEN
Measure the resistance between the door arm/disarm switch
C509-1, circuit 1313 (LB/BK), harness side and the SJB
C2280e-9, circuit 1313 (LB/BK), harness side; and between the
door disarm switch C509-2, circuit 1315 (LB/PK), harness side
and the SJB C2280e-18, circuit 1315 (LB/PK), harness side.
Yes
GO to A7.
No
Are the resistances less than 5 ohms? system for normal operation
corrosion 419-10. TEST the system for correct
pushed-out pins
No
correctly.
the system for correct operation.
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Possible Causes
Pinpoint Test B: The Anti-Theft System Does
Not Arm/Disarm Using The Remote
RKE transmitter
Keyless Entry (RKE) Transmitter
SJB
Normal Operation
The smart junction box (SJB) receives lock/unlock
commands from the RKE transmitter. The SJB then
arms/disarms the perimeter alarm system.
PINPOINT TEST B: THE ANTI-THEFT SYSTEM DOES NOT ARM/DISARM USING THE REMOTE
KEYLESS ENTRY (RKE) TRANSMITTER
B1 CHECK THE RKE TRANSMITTER FOR CORRECT DOOR LOCK
OPERATION
Lock and unlock the door locks using the RKE transmitter. Yes
Do the door locks operate correctly? GO to B2.
No
B2 CHECK THE INTERIOR LAMP OPERATION
Lock the doors with the RKE transmitter. Yes
Press the UNLOCK button on the RKE transmitter. GO to B3.
Do the interior lamps turn off when the doors are locked
No
and illuminate when the doors are unlocked?
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test C: The Anti-Theft System Does
Not Operate Correctly No Anti-Theft
Alarm Horn or Traffic Horn
Circuit 1324 (BK/LG) open or short to ground
Refer to Wiring Diagrams Cell 117, Remote
Anti-theft alarm horn
Traffic horn
SJB
Normal Operation
When the system is armed, the door ajar, the
anti-theft hood, and the luggage compartment lid
ajar switches are monitored by the smart junction
box (SJB). If the SJB detects an opening of any of
these entry points without a disarm command, or if
the ignition switch is cycled to the ON position
without the powertrain control module (PCM)
sensing a valid passive anti-theft system (PATS)
key, the SJB supplies voltage to the anti-theft alarm
horn on circuit 1324 (BK/LG) and grounds the horn
relay control circuit for the traffic horn. The
anti-theft alarm horn is grounded on circuit 1205
(BK).
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PINPOINT TEST C: THE ANTI-THEFT SYSTEM DOES NOT OPERATE CORRECTLY NO ANTI-THEFT
ALARM HORN OR TRAFFIC HORN
C1 TEST THE TRAFFIC HORN OPERATION
Press the horn button. Yes
Does the traffic horn sound? GO to C2.
No
C2 CHECK THE ANTI-THEFT ALARM HORN OPERATION
Key in ON position.
Yes
GO to C6.
Commands.
Using the active commands, activate the anti-theft alarm horn. No
Does the anti-theft alarm horn sound? GO to C3.
C3 CHECK CIRCUIT 1324 (BK/LG) FOR A SHORT TO GROUND
Disconnect: Anti-Theft Alarm Horn C3069.
Measure the resistance between the SJB C2280d-12, circuit
1324 (BK/LG), harness side and ground.
Yes
GO to C4.
No
C4 CHECK CIRCUIT 1324 (BK/LG) FOR AN OPEN
Measure the resistance between the SJB C2280d-12, circuit
1324 (BK/LG), harness side and the anti-theft alarm horn
C3069-2, circuit 1324 (BK/LG), harness side.
Yes
GO to C5.
No
(Continued)
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PINPOINT TEST C: THE ANTI-THEFT SYSTEM DOES NOT OPERATE CORRECTLY NO ANTI-THEFT
ALARM HORN OR TRAFFIC HORN (Continued)
Measure the resistance between the anti-theft alarm horn
Yes
INSTALL a new anti-theft alarm horn.
REFER to Anti-Theft Alarm Horn in this
operation.
No
pushed-out pins
No
correctly.
Possible Causes
Pinpoint Test D: The Anti-Theft System Does
Not Operate Correctly Anti-Theft Alarm
Circuit 1324 (BK/LG) short to voltage
Horn and Traffic Horn Continuously On
SJB
Normal Operation
When the system is armed, the door ajar, the
anti-theft hood, and the luggage compartment lid
ajar switches are monitored by the smart junction
box (SJB). If the SJB detects any unauthorized
entry of these entry points without a disarm
command, or if the ignition switch is cycled to the
ON position without the powertrain control module
(PCM) sensing a valid passive anti-theft system
(PATS) key, the SJB supplies voltage to the
anti-theft alarm horn on circuit 1324 (BK/LG) and
grounds the horn relay control circuit for the traffic
horn. The anti-theft alarm horn is grounded on
circuit 1205 (BK).
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PINPOINT TEST D: THE ANTI-THEFT SYSTEM DOES NOT OPERATE CORRECTLY ANTI-THEFT
ALARM HORN AND TRAFFIC HORN CONTINUOUSLY ON
D1 CHECK THE HORN OPERATION
Verify the operation of the anti-theft horn and traffic horn. Yes
Are both the anti-theft alarm horn and the traffic horn on? GO to D3.
No
If only the traffic horn is on, REFER to
Section 413-06.
If only the anti-theft alarm horn is on, GO
to D2.
D2 CHECK THE ANTI-THEFT ALARM HORN OPERATION
Verify the anti-theft alarm horn operation. REPAIR the circuit. TEST the system for
Is the anti-theft alarm horn on? normal operation.
No
GO to D3.
pushed-out pins
No
correctly.
Pinpoint Test E: The Anti-Theft System Does
DTC B1519 sets when there is an open, a short
Not Operate Correctly Turn Signals Do
to ground or voltage on circuit 1711 (VT/OG) or if
Not Flash When Arming
the hood switch is shorted internally or the smart
junction box (SJB) may be damaged.
Possible Causes
Normal Operation
Circuit 1711 (VT/OG) open, short to ground or
When the system is armed, the turn signal lamps
voltage
flash once if all the ajar switches indicate a closed
Anti-theft hood switch
position. If any of them indicate an open position
and the system is commanded to arm, the turn
Door ajar switch(es)
signal lamps will not flash.
SJB
PINPOINT TEST E: THE ANTI-THEFT SYSTEM DOES NOT OPERATE CORRECTLY TURN SIGNALS
DO NOT FLASH WHEN ARMING
E1 RETRIEVE THE RECORDED SJB DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND SELF-TESTS
on-demand self-tests. GO to E3.
Is DTC B1519 recorded?
No
GO to E2.
E2 CHECK THE AJAR SWITCH STATUS TO THE SJB
Close the hood, luggage compartment lid and the doors.
Key in ON position.
(Continued)
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DO NOT FLASH WHEN ARMING (Continued)
E2 CHECK THE AJAR SWITCH STATUS TO THE SJB (Continued)
Monitor the SJB PIDs D DR SW, P DR SW, HOOD SW,
Yes
DECKLID for the door ajar switches, the hood switch and the
GO to E8.
luggage compartment lid ajar switch.
Do the PIDs indicate the doors, hood and the luggage No
compartment lid are closed? REFER to Section 417-02..
E3 CHECK THE ANTI-THEFT HOOD SWITCH FOR CORRECT
OPERATION
Disconnect: Anti-Theft Hood Switch C127.
Measure the resistance between the anti-theft hood switch C127
pin 1, component side and the anti-theft hood switch C127 pin 2,
component side while pressing and releasing the switch.
Yes
GO to E4.
Is the resistance less than 5 ohms with the anti-theft hood No
switch pressed, and greater than 10,000 ohms with the INSTALL a new anti-theft hood switch.
anti-theft hood switch released? CLEAR the DTCs. REPEAT the self-test.
Measure the resistance between the anti-theft hood switch
Yes
GO to E7.
No
Is the resistance less than 5 ohms? GO to E5.
(Continued)
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E5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN BETWEEN THE
HOOD SWITCH AND THE BUSSED ELECTRICAL CENTER
(BEC)
C1035C-D11, harness side.
Yes
GO to E6.
No
E6 CHECK CIRCUIT 1205 (BK) FOR AN OPEN BETWEEN THE BEC
AND GROUND
Measure the resistance between the BEC C1035C-E11, harness
side and ground.
Yes
No
E7 CHECK CIRCUIT 1711 (VT/OG) FOR VOLTAGE
Key in ON position.
(Continued)
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E7 CHECK CIRCUIT 1711 (VT/OG) FOR VOLTAGE (Continued)
Measure the voltage between the anti-theft hood switch C127-1,
Yes
GO to E9.
No
Is any voltage indicated? GO to E8.
E8 CHECK CIRCUIT 1711 (VT/OG) FOR AN OPEN
C127-1, circuit 1711 (VT/OG), harness side and the SJB
C2280c-15, circuit 1711 (VT/OG), harness side.
Yes
GO to E10.
No
E9 CHECK CIRCUIT 1711 (VT/OG) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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E9 CHECK CIRCUIT 1711 (VT/OG) FOR A SHORT TO VOLTAGE
(Continued)
(VT/OG), harness side and ground.
Yes
No
pushed-out pins
No
correctly.
Pinpoint Test F: The Alarm System Does Not Normal Operation
Operate Correctly The Alarm Activates
The smart junction box (SJB) monitors the luggage
When The Luggage Compartment Lid Is
compartment lid anti-theft inhibit switch status. The
Opened With The Key
luggage compartment lid anti-theft inhibit switch
grounds circuit 1350 (WH/PK) when the luggage
compartment lid lock cylinder is turned to open
with the key, completing the ground circuit to
circuit 1205 (BK). The SJB receives this ground
signal and inhibits (stops) the alarm from activating
due to the luggage compartment lid. The
intrusion/inclination sensor does not arm, but the
alarm is still armed for the doors and the hood.
When the luggage compartment lid is closed, the
luggage compartment lid and the
intrusion/inclination sensor are again monitored by
the SJB. After the 20 second pre-arm phase, the
luggage compartment lid and the
intrusion/inclination sensor also become armed
again.
DTC B2569 sets when either the luggage
compartment lid anti-theft inhibit switch is
internally shorted, circuit 1350 (WH/PK) is shorted
to ground, or the SJB is damaged.
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Possible Causes
Circuit 1350 (WH/PK) open or short to ground
Luggage compartment lid anti-theft inhibit switch
SJB
PINPOINT TEST F: THE ALARM SYSTEM DOES NOT OPERATE CORRECTLY THE ALARM
ACTIVATES WHEN THE LUGGAGE COMPARTMENT LID IS OPENED WITH THE KEY
Disconnect: Luggage Compartment Lid Anti-Theft Inhibit Switch
C483.
anti-theft inhibit switch C483-1, circuit 1205 (BK), harness side
and ground.
Yes
GO to F2.
No
F2 CHECK THE LUGGAGE COMPARTMENT LID ANTI-THEFT
INHIBIT SWITCH
anti-theft inhibit switch C483 pin 1 and pin 2, component side
while turning and releasing the key in the luggage compartment
lock cylinder.
Yes
GO to F3.
No
anti-theft inhibit switch (part of the luggage
Is the resistance less than 5 ohms with the key unlocking compartment lid lock cylinder). REFER to
the luggage compartment lid lock cylinder and greater than Section 501-14. CLEAR the DTCs.
10,000 ohms otherwise? REPEAT the self-test.
F3 CHECK CIRCUIT 1350 (WH/PK) FOR AN OPEN OR SHORT TO
GROUND
(Continued)
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PINPOINT TEST F: THE ALARM SYSTEM DOES NOT OPERATE CORRECTLY THE ALARM
ACTIVATES WHEN THE LUGGAGE COMPARTMENT LID IS OPENED WITH THE KEY (Continued)
F3 CHECK CIRCUIT 1350 (WH/PK) FOR AN OPEN OR SHORT TO
GROUND (Continued)
anti-theft inhibit switch C483-2, circuit 1350 (WH/PK), harness
side and the SJB C2280c-21, circuit 1350 (WH/PK), harness
side; and between the luggage compartment lid anti-theft inhibit
switch C483-2, circuit 1350 (WH/PK), harness side and ground.
Yes
GO to F4.
Is the resistance less than 5 ohms between the luggage
compartment lid anti-theft inhibit switch and the SJB; and No
greater than 10,000 ohms between the luggage REPAIR the circuit. CLEAR the DTCs.
compartment lid anti-theft inhibit switch and ground? REPEAT the self-test.
pushed-out pins
No
correctly.
Pinpoint Test G: The Alarm System Does
NOTE: The inclination sensing feature must be
Not Operate Correctly Intrusion and
disarmed before raising the vehicle on a hoist to
Inclination Sensing
prevent false alarms.
Normal Operation
The intrusion and inclination sensor receives voltage
on circuit 645 (WH/LB) and ground on circuit 1205
NOTE: Arming the system by using the door lock
(BK). The sensor begins monitoring the interior
cylinder (door disarm switch) inhibits the intrusion
volume and senses an intrusion through a change in
and inclination sensing features. The intrusion and
interior volume or a change in vehicle inclination.
inclination sensing features can be activated with
When the intrusion and inclination sensor senses a
the remote keyless entry (RKE) transmitter or the
change in state, the change is communicated to the
door lock control switch. The convertible top, the
smart junction box (SJB) through circuit 340
luggage compartment, and all the doors must be
(RD/LB). The SJB then sounds the horns and
closed for the intrusion and inclination sensing
flashes the turn signal lamps.
feature to activate.
DTC B200A sets when there is a failure in the
NOTE: All the windows must be closed for correct
inclination sensor.
intrusion sensing operation.
DTC B200B sets when there is a failure in the
intrusion sensor.
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Possible Causes
DTC B200C sets when there is a failure in the
intrusion/inclination sensor module.
Circuit 340 (RD/LB) open or short to ground
DTC U2033 sets when there is a failure in the
Circuit 645 (WH/LB) open or short to ground
intrusion/inclination sensor module communication
link between the module and the SJB.
Intrusion and inclination sensor
SJB
PINPOINT TEST G: THE ALARM SYSTEM DOES NOT OPERATE CORRECTLY INTRUSION AND
INCLINATION SENSING
G1 CHECK CIRCUIT 645 (WH/LB) FOR VOLTAGE
Close all the doors, the hood, the luggage compartment, and the
convertible top (if equipped).
Disconnect: Intrusion and Inclination Sensor Connector.
Measure the voltage between the intrusion and inclination
sensor connector in the overhead console pin 6, circuit 645
(WH/LB), harness side and ground.
Yes
GO to G2.
No
Is the voltage greater than 10 volts? REPEAT the self-test.
Measure the resistance between the intrusion and inclination
Yes
GO to G3.
No
(Continued)
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INCLINATION SENSING (Continued)
G3 CHECK THE COMMUNICATION LINK CIRCUIT 340 (RD/LB) FOR
VOLTAGE
Measure the voltage between the intrusion and inclination
(RD/LB), harness side and ground.
Yes
GO to G5.
No
Is the voltage greater than 10 volts? GO to G4.
G4 CHECK THE COMMUNICATION LINK CIRCUIT 340 (RD/LB) FOR
AN OPEN
Measure the resistance between the intrusion and inclination
(RD/LB), harness side and the SJB C2280f-14, circuit 340
(RD/LB), harness side.
Yes
No
Is the resistance less than 10,000 ohms? GO to G6.
G5 CHECK FOR AN INTRUSION SENSOR ACTIVE SIGNAL
Connect: Intrusion and Inclination Sensor Connector.
Command.
Trigger the SJB active command ISM ACTIVE ON.
(Continued)
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INCLINATION SENSING (Continued)
G5 CHECK FOR AN INTRUSION SENSOR ACTIVE SIGNAL
(Continued)
While backprobing, measure the voltage between the intrusion
and inclination sensor connector in the overhead console pin 3,
circuit 340 (RD/LB), harness side and ground while triggering the
active command ON.
Yes
INSTALL a new intrusion and inclination
sensor. REFER to Intrusion and Inclination
Sensor in this section.
No
Does the voltage momentarily drop to less than 10 volts? GO to G6.
pushed-out pins
No
correctly.
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PATS is not compatible with aftermarket remote
Anti-Theft
start systems, which allow the vehicle to be started
The passive anti-theft system (PATS) consists of the
from the exterior of the vehicle. These systems may
reduce the security of the vehicle, and also may be
Anti-theft indicator the cause of no-start concerns. Remote start
systems must be removed from the vehicle before
Encoded ignition key(s) (the key contains a
any PATS-related no-start concerns are investigated.
transponder)
PATS will disable the vehicle from starting if there
PATS transceiver
is:
a damaged PATS key.
PATS uses radio frequency identification technology
an unprogrammed PATS key.
to deter a drive-away theft. Passive means that it
does not require any activity by the user.
a non-encoded key (a conventional key or one
that does not have any electronics).
PATS Function
damaged wiring.
The PATS function is controlled by the PCM.
a damaged transceiver.
PATS uses the PCM to carry out all of the PATS
functions such as receiving the identification code
a damaged PCM.
from the PATS key, controlling the starter and fuel
Unlimited Key Mode
injectors enable, and initiates the key interrogation
sequence when the ignition key is turned to the ON
PATS contains a feature called unlimited key mode.
or START position. All elements of PATS must be
This feature allows a customer to program more
functional before the vehicle will start. If any of the
than 8 vehicle keys, if requested. Each vehicle in
components are not working correctly, the vehicle
unlimited key mode is set up with a special
will not start. If the PCM must be replaced for any
unlimited transponder security key code. This
reason (PATS concerns or driveability concerns),
allows all the customer vehicles to share the same
the PATS keys must be programmed into the new
mechanically cut keys. For an individual customer,
PCM. For additional information, refer to Key
any randomly selected security key is acceptable.
Programming Using Diagnostic Equipment in this
For additional information, refer to Spare Key
section.
Programming Unlimited Key Mode in this
section.
PATS is active only for a few seconds when the
vehicle is starting. It is not a PATS concern if the
vehicle stalls after it has been running for a
minimum of 3 seconds. PATS will not disable a
running vehicle.
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Encoded PATS Keys
Anti-Theft
PATS uses a special ignition key that is larger than
Special Tool(s)
a conventional ignition key because it contains a
permanently installed electronic device called a 73III Automotive Meter
105-R0057 or equivalent transponder. Each transponder contains a unique
encrypted identification code which is one of a
very large number of combinations. The addition of
this transponder to the key makes it an encoded
key. The PATS key does not require batteries and
should last the lifetime of the vehicle. Each PATS
key must be programmed into the PCM before it
(VCM) and Integrated can be used to start the vehicle. There are special
general procedures described in this section that
must be carried out if a new PATS key is
necessary. Refer to Key Programming Using
tool
Diagnostic Equipment or Key Programming Using
Two Programmed Keys in this section.
Flex Probe Kit
PATS Transceiver
The PATS transceiver is located under the steering
column shroud and communicates with the encoded
ignition key. During each vehicle start sequence, the
PATS transceiver reads the encoded ignition key
identification code and sends data to the PCM. The
PCM validates the code, and if it is the correct
code, will ground the starter relay solenoid coil and
will also allow the fuel injectors to operate. Refer to
Anti-Theft Indicator
Passive Anti-Theft System (PATS) Transceiver in
NOTE: Replacement of the passive anti-theft
this section.
system (PATS) transceiver does not require the
PATS keys to be programmed into the powertrain
control module (PCM) again.
NOTE: A minimum of 2 PATS keys must be
programmed into the PCM before the vehicle will
start.
NOTE: Make sure any aftermarket remote start
systems have been removed from the vehicle before
any PATS-related no-start concerns are investigated.
PATS uses a visual anti-theft indicator located in
the instrument cluster. The indicator proves out for
3 seconds when the ignition key is in the ON or
START position under normal operation. If there is
a PATS concern, this indicator either flashes
rapidly or glows steadily when the ignition key is
turned to the ON or START position. PATS also
flashes the anti-theft indicator every 2 seconds when
the ignition key is in the OFF position to act as a
visual theft deterrent.
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PATS Operation PATS Parameter Identification (PIDs)
The PATS function is controlled by the PCM. Monitoring the PATS PIDs can be very useful in
When the ignition switch is turned to the ON or determining which diagnostic steps to follow.
START position, the PCM initiates the key Viewing the MASTERKEY PID (with both keys)
interrogation sequence by sending a voltage signal will determine if the key is a programmed key and
to the PATS transceiver. The transceiver then uses will also prove out the transceiver, circuitry and the
its antenna to communicate with the transponder in PCM. A master key is any key that is programmed
the PATS key. This process reads the PATS key into the PCM. Viewing the MIN KEY (minimum
identification code and sends the key identification number of keys) PID (this PID does not change)
code back to the PCM, which interprets it and determines the minimum number of keys that must
determines if it matches one of the stored key be programmed into the PCM. There must be at
codes. If it does match one of the stored key codes, least 2 keys programmed into the PCM in this
the PCM grounds the starter relay solenoid coil and system. Viewing the N KEYCODE (number of
allows fuel injector operation. If it does not match keys programmed) PID will determine if the
one of the stored key codes, or it is only a partial minimum number of keys have been programmed
key read or no key read, the PCM will not ground into the PCM. If the N KEYCODE PID reads 0 or
the starter relay solenoid coil and will not allow fuel 1, additional key(s) will need to be programmed
injector operation. The anti-theft indicator in the into the PCM in order to meet the minimum of 2
instrument cluster will flash (or may glow steadily) keys. If the N KEYCODE PID reads 0 or 1, and
and the PCM will store one or more DTCs. All the MASTERKEY PID reads NOTPREST, that
elements of PATS must be functional before the particular key must be programmed into the PCM.
vehicle will start. If any of the components are not If the N KEYCODE PID reads 1, and the
working correctly, the vehicle will not start. If the MASTERKEY PID reads PRESNT, that particular
PCM must be replaced for any reason (PATS key is already programmed into the PCM. The
concerns or driveability concerns), the PATS keys SPAREKEY PID is defaulted to ENABLE. With the
must be programmed into the new PCM. Refer to SPAREKEY PID displaying ENABLE, the PCM
Key Programming Using Diagnostic Equipment in will accept more than 2 keys (up to a maximum of
this section. 8) being programmed into the PCM. It can be
toggled to DISABLE if the customer does not want
The PATS disables the vehicle from starting if there
any more than 2 keys programmed into the PCM
is:
using the Key Programming Using Two
a damaged PATS key.
Programmed Keys procedure. Refer to Key
Programming Switch State Control in this section.
a non-programmed PATS key.
a non-PATS key (key has no electronics).
Unlimited Key Mode
damaged wiring.
This system contains a feature named unlimited key
mode (PID of UNL KEY). This feature allows a
a damaged transceiver.
customer to program more than 8 keys to their
a damaged PCM.
vehicle if they request it. Each vehicle in unlimited
key mode is set up with a special unlimited
transponder security key code. This allows all the
customer vehicles to share the same keys, but no
other keys from outside can be used to operate the
vehicle(s). Any randomly selected security key code
is acceptable. Refer to Spare Key Programming
Unlimited Key Mode in this section.
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Mechanical Electrical Refer to Section 418-00, No Power To The
Large metallic objects Smart junction box
or electronic devices on (SJB) fuse 19 (5A) with the scan tool.
the key ring that can be Bussed electrical center
used to purchase (BEC) fuse 68 (20A)
vehicle:
gasoline or similar items Circuitry
Ignition lock cylinder Ignition switch
Passive anti-theft system PATS transceiver
position.
(PATS) key Powertrain control
Use of a non-PATS key module (PCM) Verify the scan tool operation with a known
or incorrect PATS key
good vehicle.
More than one PATS
key on key ring
response from the powertrain control module Remote start system
installed
(PCM).
software release.
self-test diagnostics for the PCM.
go to the Powertrain Control Module (PCM)
VCM.
other DTCs, refer to the Powertrain
If the scan tool does not communicate with the Control/Emissions Diagnosis (PC/ED) manual.
VCM:
Check the VCM connection to the vehicle. GO to Symptom Chart.
B1213 Anti-Theft Number of Programmed Keys is If DTCs B1232, B1600, B1601, B1602, B1681
Below Minimum or B2103 are present, they must be addressed
first. If DTC B1213 is the only DTC present,
PROGRAM additional keys. REFER to Key
Programming Using Diagnostic Equipment in
this section. CLEAR the DTCs. CYCLE the
ignition. REPEAT the self-test.
B1232 Transceiver Failure There has been a PATS transceiver antenna
failure. GO to Pinpoint Test A.
DTC B1342 is retrieved again, INSTALL a new
PCM. REFER to Section 303-14. CYCLE the
B1600 PATS Ignition Key Transponder Signal Is Not No PATS key has been read by the PCM. GO
Received to Pinpoint Test B.
B1601 PATS Received Incorrect Key-Code From There is an unprogrammed PATS key. GO to
Ignition Key Transponder Pinpoint Test C.
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Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index (Continued)
B1602 PATS Received Invalid Format of Key-Code Only a partial PATS key was read. GO to
From Ignition Key Transponder Pinpoint Test D.
B1681 PATS Transceiver Module Signal Is Not The PCM did not receive the PATS transceiver
Received signal. GO to Pinpoint Test E.
B2103 Antenna Not Connected There has been a PATS transceiver antenna
failure. GO to Pinpoint Test A.
B2431 Transponder Programming Failed The ignition key was not programmed.
PROGRAM the key. REFER to Spare Key
Programming Using Diagnostic Equipment in
this section. CLEAR the DTCs. CYCLE the
P1260 Theft Detected, Vehicle Immobilized If there are any PATS DTCs present,
ADDRESS them first. If DTC P1260 is the only
DTC present, there may be a power or ground
concern with the PCM. REFER to the
Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
Symptom Chart
Symptom Chart
powertrain control module Circuitry
(PCM) PCM
The anti-theft indicator is Instrument cluster INSTALL a new instrument
always/never on cluster. REFER to Section
normal operation.
The vehicle does not start Circuitry CYCLE the ignition. CARRY
Starter relay OUT the PCM self-test. If
PCM PATS DTCs are present, GO
to the Powertrain Control
Module (PCM) Diagnostic
Trouble Code (DTC) Index in
this section. If no PATS
DTCs are present, REFER to
the Powertrain
(PC/ED) manual.
Pinpoint Tests DTC B1232 or B2103 sets when the powertrain
control module (PCM) detects a PATS transceiver
Pinpoint Test A: DTC B2103 Antenna Not
antenna failure. The PATS transceiver may need to
Connected
be replaced.
Normal Operation
Possible Causes
The passive anti-theft system (PATS) transceiver
PATS transceiver
reads the PATS key when the key is turned to the
START or ON position. PCM
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PINPOINT TEST A: DTC B2103 ANTENNA NOT CONNECTED
A1 INSPECT THE PATS TRANSCEIVER FOR CORRECT
INSTALLATION
NOTE: Replacement of the PATS transceiver does not require the
PATS keys to be programmed into the PCM again.
Verify the PATS transceiver is correctly installed. Refer to
Yes
Passive Anti-Theft System (PATS) Transceiver in this section.
INSTALL a new PATS transceiver. REFER
Key in ON position.
to Passive Anti-Theft System (PATS)
Enter the following diagnostic mode on the scan tool: Clear the
Transceiver in this section. CLEAR the
DTCs.
DTCs. CYCLE the ignition. REPEAT the
self-test. If the concern is still present, GO
Key in ON position.
to A2.
Enter the following diagnostic mode on the scan tool: Retrieve
the DTCs. No
Is DTC B2103 or B1232 retrieved? The system is OK.
NOTE: When a new PCM is installed, the PATS keys must be Yes
programmed into the PCM. INSTALL a new PCM. REFER to Section
303-14. PROGRAM the PATS keys into
the PCM. REFER to Key Programming
Check for:
Using Diagnostic Equipment in this
corrosion
section. REPEAT the self-test.
damaged pins
pushed-out pins
No
correctly.
the DTCs. CYCLE the ignition. REPEAT
the self-test.
Pinpoint Test B: DTC B1600 PATS
DTC B1600 sets when no PATS key has been
Ignition Key Transponder Signal Is Not
read by the PCM.
Received
Possible Causes
Normal Operation
PATS key
During each vehicle start sequence, the passive
PATS transceiver
anti-theft system (PATS) transceiver reads the PATS
key identification code and sends the data to the
PCM
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PINPOINT TEST B: DTC B1600 PATS IGNITION KEY TRANSPONDER SIGNAL IS NOT RECEIVED
NOTE: Large metallic objects, electronic devices on the key ring that can be used to purchase
gasoline or similar items, or a second key on the same key ring as the PATS key may cause
vehicle starting concerns and record DTCs under certain conditions. If a fault cannot be
identified, examine the customer key ring for such objects or devices. If present, inform the
customer that they need to keep these objects from touching the PATS key while starting the
engine. These objects and devices cannot damage the PATS key, but can cause a momentary
concern if they are too close to the key during engine start. If a concern occurs, turn the key
off and restart the engine with all other objects on the key ring held away from the ignition
key. Check to make sure the PATS key used by the customer is an approved Ford PATS key.
(PATS keys from Ford, Rotunda, Strattec, or HUF are approved Ford PATS keys.)
B1 RETRIEVE THE DTCs
Enter the following diagnostic mode on the scan tool: Clear the GO to B2.
DTCs.
No
If DTCs other than PATS PCM DTCs are
Key in ON position.
retrieved, REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
the DTCs.
manual.
Is DTC B1600 retrieved?
If no PATS DTCs are retrieved, the
system is OK. The concern may have
been caused by interference from another
object.
B2 CHECK BOTH PATS KEYS
NOTE: Check to make sure the new PATS keys are approved Ford
encoded PATS keys. Unapproved PATS keys do not always
Yes
operate correctly over various temperature ranges. (PATS keys
If DTC B1600 was present for both
from Ford, Rotunda, Strattec, or HUF are approved Ford PATS
existing keys and the new key, GO to B3.
keys.)
If DTC B1600 was not present with the
Obtain both PATS keys from the customer and follow the
new key, the original key may be
procedure using one PATS key, then the other. If the customer
damaged and should be replaced. CUT a
only has one PATS key, it will be necessary to cut a new PATS
new key to replace the damaged key.
key.
PROGRAM the new PATS key. REFER to
If it is necessary to cut a new PATS key, program the new
Key Programming Using Diagnostic
PATS key. Refer to Key Programming Using Diagnostic
Equipment in this section. CLEAR the
Equipment in this section.
Key in ON position.
Enter the following diagnostic mode on the scan tool: Clear the No
DTCs. If DTCs other than PATS PCM DTCs are
Key in OFF position. retrieved, REFER to the Powertrain
Enter the following diagnostic mode on the scan tool: Retrieve manual. If no PATS DTCs are retrieved,
the DTCs. the system is OK. The concern may have
Using either existing key or the new key, is DTC B1600 been caused by interference from another
present? object.
B3 INSTALL A NEW PATS TRANSCEIVER
NOTE: Do not use the PATS key that may have been programmed
in Step B2.
Install a new PATS transceiver. Refer to Passive Anti-Theft
System (PATS) Transceiver in this section.
Key in ON position.
DTCs.
Key in ON position.
Turn the key to the ON position using an existing customer
Yes
PATS key.
GO to B4.
the DTCs. No
Is DTC B1600 retrieved? The system is OK.
(Continued)
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PINPOINT TEST B: DTC B1600 PATS IGNITION KEY TRANSPONDER SIGNAL IS NOT RECEIVED
(Continued)
Check for:
corrosion
damaged pins
pushed-out pins
No
correctly.
the self-test.
Possible Causes
Pinpoint Test C: DTC B1601 PATS
Received Incorrect Key-Code From Ignition
PATS key
Key Transponder
PCM
Normal Operation
DTC B1601 sets when there is an
unprogrammed PATS key. There is no issue with
the PATS key itself, but the key must be
programmed into the PATS memory (unless the
maximum number of keys are already programmed).
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PINPOINT TEST C: DTC B1601 PATS RECEIVED INCORRECT KEY-CODE FROM IGNITION KEY
TRANSPONDER
vehicle starting concerns and record DTCs under certain conditions. If a fault cannot be
identified, examine the customer key ring for such objects or devices. If present, inform the
customer that they need to keep these objects from touching the PATS key while starting the
engine. These objects and devices cannot damage the PATS key, but can cause a momentary
concern if they are too close to the key during engine start. If a concern occurs, turn the
ignition switch off and restart the engine with all other objects on the key ring held away from
the ignition key. Check to make sure the PATS key used by the customer is an approved Ford
PATS key. (PATS keys from Ford, Rotunda, Strattec, or HUF are approved Ford PATS keys.)
NOTE: Only 8 PATS keys can be programmed into the PCM using the Key Programming
Using Diagnostic Equipment procedure unless the unlimited key mode is active. If the
N KEYCODE PID reads more than 2, the concern may be the PATS key being used is an
unprogrammed key. Verify this by also viewing the MASTERKEY PID. It must read PRESNT
for the key to be valid.
C1 RETRIEVE THE DTCs
NOTE: Follow this procedure using both PATS keys (using one
Yes
at a time).
If DTC B1601 is retrieved for one PATS
If only one key is available, cut a new key and program the
key, REPLACE that key and PROGRAM
keys. Refer to Key Programming Using Diagnostic Equipment in
all the keys. REFER to Key Programming
this section.
If both keys are available, program the keys. Refer to Key
section. CLEAR the DTCs. CYCLE the
Programming Using Diagnostic Equipment in this section.
Key in ON position.
If DTC B1601 is retrieved for both PATS
keys, GO to C2.
DTCs.
Key in ON position. The system is OK. CHECK all the
Enter the following diagnostic mode on the scan tool: Retrieve customer PATS keys by attempting to start
the DTCs. the vehicle with each key to VERIFY all
Is DTC B1601 retrieved for one or both PATS keys? the other PATS keys are programmed.
Check for:
corrosion
damaged pins
pushed-out pins
No
correctly.
the self-test.
Possible Causes
Pinpoint Test D: DTC B1602 PATS
Received Invalid Format Of Key-Code From
PATS key
Ignition Key Transponder
PATS transceiver
Normal Operation
PCM
DTC B1602 sets when only a partial PATS key
was read. Remote starter equipment can also cause
this DTC.
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PINPOINT TEST D: DTC B1602 PATS RECEIVED INVALID FORMAT OF KEY-CODE FROM IGNITION
KEY TRANSPONDER
vehicle starting concern and record diagnostic trouble codes (DTC) under certain conditions. If
a fault cannot be identified, examine the customer key ring for such objects or devices. If
present, inform the customer that they need to keep these objects from touching the PATS key
while starting the engine. These objects and devices cannot damage the PATS key, but can
cause a momentary concern if they are too close to the key during engine start. If a concern
occurs, turn the ignition off and restart the engine with all other objects on the key ring held
away from the ignition key. Check to make sure the PATS key used by the customer is an
approved Ford PATS key. (PATS keys from Ford, Rotunda, Strattec, or HUF are approved
Ford PATS keys.)
NOTE: Only 8 PATS keys can be programmed into the PCM using the Key Programming
Using Diagnostic Equipment procedure unless the unlimited key mode is active. If the
N KEYCODE PID reads more than 2, the concern may be the PATS key being used is an
unprogrammed key. Verify this by also viewing the MASTERKEY PID. It must read PRESNT
for the key to be valid.
D1 RETRIEVE THE DTCs
NOTE: Follow this procedure using both PATS keys (using one Yes
at a time). If DTC B1602 is retrieved for one key,
REPLACE that key and PROGRAM the
If only one key is available, cut a new key and program the
new key. REFER to Spare Key
keys. Refer to Key Programming Using Diagnostic Equipment in
Programming Using Diagnostic
this section.
Equipment in this section. CLEAR the
Key in ON position.
self-test.
DTCs.
Key in OFF position. If DTC B1602 is retrieved for both PATS
Key in ON position. keys, GO to D2.
No
the DTCs.
The system is OK. CHECK all the
Is DTC B1602 retrieved for one or both PATS keys?
customer PATS keys by attempting to start
the vehicle with each key to VERIFY all
the other PATS keys are programmed.
The concern may have been caused by
interference from another object.
D2 INSTALL A NEW PATS TRANSCEIVER
Install a new PATS transceiver. Refer to Passive Anti-Theft
System (PATS) Transceiver in this section.
Key in ON position.
Yes
GO to D3.
DTCs.
Key in ON position. The system is OK. CHECK all the
Enter the following diagnostic mode on the scan tool: Retrieve customer PATS keys by attempting to start
the DTCs.. the vehicle with each key to VERIFY all
Are any PATS DTCs retrieved? the other PATS keys are programmed.
D3 CHECK FOR CORRECT PCM OPERATION
Check for:
corrosion
damaged pins
pushed-out pins
No
correctly.
the self-test.
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Pinpoint Test E: DTC B1681 PATS
DTC B1681 sets when the PATS transceiver
Transceiver Module Signal Is Not Received
signal is not received by the PCM. This DTC can
be caused by circuits to the PATS transceiver,
Refer to Wiring Diagrams Cell 112, Passive
circuits between the PATS transceiver and the PCM,
Anti-Theft System for schematic and connector
the PATS transceiver or the PCM. This can also be
information.
caused by using the incorrect PATS transceiver part
Normal Operation
number.
The passive anti-theft system (PATS) transceiver
Possible Causes
receives voltage from the smart junction box (SJB)
fuse 19 (5A) on circuit 1266 (RD/YE) and is
Fuse
grounded on circuit 1205 (BK). The PATS
transceiver and the powertrain control module
(PCM) communicate on circuits 1215 (WH/LG)
voltage
and 1216 (GY/OG). The PCM compares the key
code stored in memory and enables the starter if the Circuit 1216 (GY/OG) open, short to ground
key code is correct.
PATS transceiver
PCM
PINPOINT TEST E: DTC B1681 PATS TRANSCEIVER MODULE SIGNAL IS NOT RECEIVED
E1 CHECK THE PATS TRANSCEIVER POWER CIRCUIT 1266
(RD/YE) FOR VOLTAGE
Disconnect: PATS Transceiver C2007.
Key in ON position.
Measure the voltage between the PATS transceiver C2007-1,
circuit 1266 (RD/YE), harness side and ground.
Yes
GO to E2.
No
OK, REPAIR the circuit. CLEAR the DTCs.
Is the voltage greater than 10 volts? CYCLE the ignition. REPEAT the self-test.
E2 CHECK THE PATS TRANSCEIVER GROUND CIRCUIT 1205 (BK)
FOR AN OPEN
(Continued)
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PINPOINT TEST E: DTC B1681 PATS TRANSCEIVER MODULE SIGNAL IS NOT RECEIVED (Continued)
E2 CHECK THE PATS TRANSCEIVER GROUND CIRCUIT 1205 (BK)
FOR AN OPEN (Continued)
Measure the resistance between the PATS transceiver C2007-2,
Yes
GO to E3.
No
Is the resistance less than 5 ohms? CYCLE the ignition. REPEAT the self-test.
E3 CHECK THE PATS TRANSCEIVER RECEIVE CIRCUIT 1216
(GY/OG) FOR VOLTAGE
Connect: PATS Transceiver C2007.
Key in ON position.
Measure the voltage by backprobing between the PATS
transceiver C2007-4, circuit 1216 (GY/OG), harness side and
ground.
Yes
GO to E6.
No
Is the voltage greater than 8 volts? GO to E4.
(GY/OG) FOR A SHORT TO GROUND
(Continued)
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(GY/OG) FOR A SHORT TO GROUND (Continued)
Measure the resistance between the PATS transceiver C2007-4,
circuit 1216 (GY/OG), harness side and ground.
Yes
GO to E5.
No
CYCLE the ignition. REPEAT the self-test.
If DTC B1681 is retrieved again, GO to
Is the resistance greater than 10,000 ohms? E12.
(GY/OG) FOR AN OPEN
Measure the resistance between the PCM C175B-42, circuit
1216 (GY/OG), harness side, and the PATS transceiver
C2007-4, circuit 1216 (GY/OG), harness side.
Yes
GO to E12.
No
E6 CHECK THE PATS TRANSCEIVER TRANSMIT CIRCUIT 1215
(WH/LG) FOR VOLTAGE
(Continued)
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(WH/LG) FOR VOLTAGE (Continued)
transceiver C2007-3, circuit 1215 (WH/LG), harness side and
ground.
Yes
self-test.
If DTC B1681 is retrieved again, GO to
E12.
No
(WH/LG) FOR A SHORT TO GROUND WITH THE PATS
TRANSCEIVER CONNECTED
1215 (WH/LG), harness side and ground.
Yes
GO to E9.
No
Is the resistance greater than 10,000 ohms? GO to E8.
TRANSCEIVER DISCONNECTED
(Continued)
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TRANSCEIVER DISCONNECTED (Continued)
1215 (WH/LG), harness side and ground.
Yes
self-test.
No
Is the resistance greater than 10,000 ohms? CYCLE the ignition. REPEAT the self-test.
(WH/LG) FOR AN OPEN
1215 (WH/LG), harness side and the PATS transceiver C2007-3,
circuit 1215 (WH/LG), harness side.
Yes
GO to E10.
No
(WH/LG) FOR VOLTAGE
Connect: PATS Transceiver C2007.
Connect: PCM C175B.
Key in ON position.
Active Commands.
Trigger the active command TRANSMIT to ON.
(Continued)
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(WH/LG) FOR VOLTAGE (Continued)
transceiver C2007-3, circuit 1215 (WH/LG), harness side and
ground.
Yes
INSTALL a new PATS transceiver module.
REFER to Passive Anti-Theft System
(PATS) Transceiver in this section. CLEAR
the self-test.
No
Is the voltage less than 5 volts? GO to E11.
(WH/LG) FOR A SHORT TO VOLTAGE
Key in ON position.
Measure the voltage between the PATS transceiver C2007-3,
circuit 1215 (WH/LG), harness side and ground.
Yes
CYCLE the ignition. REPEAT the self-test.
No
Check for:
corrosion
damaged pins
pushed-out pins
No
correctly.
the self-test.
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419-11-1 419-11-1 Electronic Compass
GENERAL PROCEDURES
3. NOTE: If the CAL indicator does not turn off
Compass Calibration
after the vehicle is driven in a circle no more
than 5 times, repeat the procedure.
1. NOTE: For optimum calibration, drive to an
Drive the vehicle slowly at less than 5 km/h (3
open, level location away from large metallic
mph) in a continuous circle until the C or CAL
objects or structures. Switch off all
disappears from the display and the compass
non-essential electrical accessories (heated rear
heading is shown.
window, heater fan, A/C, map lamps, and
wipers) and make sure all doors are closed.
4. If the C or CAL message does not turn off
Start the vehicle.
within 5 circles (and the procedure has been
repeated at least once), install a new interior
2. NOTE: To exit CAL mode before carrying out
rear view mirror with electronic compass. For
a compass adjustment, turn the key to the OFF
position.
Press and hold (for approximately 6 seconds)
the button until C or CAL appears in the
display, then release the button.
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GENERAL PROCEDURES
Compass Zone Adjustment
1. Refer to the compass calibration zone map to
select the correct compass zone setting for the
geographic location of the vehicle.
3. Momentarily press and release the switch to
increase the zone increment by one. Set the
zone display number to match the vehicle
location on the compass calibration zone map.
4. Release the switch for 10 seconds to exit the
zone setting mode.
2. With the compass display turned on, press and
hold the switch (for 3 seconds) until the display
shows the current zone setting.
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419-10-1 419-10-1 Multifunction Electronic Modules
Diagnostic Trouble Code Chart
B1031 SDARS Satellite Antenna Open Satellite REFER to Section 415-00.
Radio
Receiver
B1032 SDARS Satellite Antenna Short Satellite REFER to Section 415-00.
Radio
Receiver
B106A TPMS Sensor Pressure Range Bit Smart REFER to Section 204-04.
Incorrect State Junction Box
(SJB)
B106B Tire Pressure Sensor Low Battery SJB REFER to Section 204-04.
B1084 Trunk Lamp Circuit Failure SJB REFER to Section 417-02.
B1117 Audio Steering Wheel Button Stuck Audio Unit DISREGARD the DTC. The vehicle does
not have audio steering wheel audio
control buttons. CLEAR the DTCs.
B1119 Audio Disc DVD Player Thermal Audio Unit REFER to Section 419-07.
Shutdown
B1136 Audio Steering Wheel Switch #2 Circuit Audio Unit DISREGARD the DTC. The vehicle does
Failure not have audio steering wheel audio
control buttons. CLEAR the DTCs.
B1140 Map Disk Invalid Audio Unit REFER to Section 419-07.
B1141 Convertible Top Full Down Position SJB If the self-test was run with the
Switch Circuit Failure convertible top in the full up position,
DTCs B1141 or B1142 may be set.
OPERATE the convertible top to the full
down position. CLEAR the DTCs.
If DTC B1141 or B1142 is retrieved
again, REFER to Section 501-18.
B1142 Convertible Top Full Up Position Switch SJB If the self-test was run with the
Circuit Failure convertible top in the full up position,
DTCs B1141 or B1142 may be set.
OPERATE the convertible top to the full
down position. CLEAR the DTCs.
If DTC B1141 or B1142 is retrieved
again, REFER to Section 501-18.
B1201 Fuel Sender Circuit Failure SJB REFER to Section 413-01.
B1202 Fuel Sender Circuit Open Instrument REFER to Section 413-01.
Cluster
B1202 Fuel Sender Circuit Open SJB REFER to Section 413-01.
B1204 Fuel Sender Circuit Short to Ground Instrument REFER to Section 413-01.
Cluster
B1205 EIC Switch-1 Assembly Circuit Failure Instrument REFER to Section 413-01.
Cluster
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B1213 Anti-Theft Number of Programmed Keys Powertrain REFER to Section 419-01B.
is Below Minimum Control
Module
(PCM)
B1217 Horn Relay Coil Circuit Failure SJB REFER to Section 413-06.
B1231 Event Threshold Exceeded Restraints REFER to Section 501-20B.
Control
Module
(RCM)
B1247 Panel Dim Switch Circuit Open SJB REFER to Section 413-00.
B1300 Power Door Lock Circuit Failure SJB REFER to Section 501-14.
B1301 Power Door Lock Circuit Open SJB REFER to Section 501-14.
B1309 Power Door Lock Circuit Short to SJB REFER to Section 501-14.
Ground
B1310 Power Door Unlock Circuit Failure SJB REFER to Section 501-14.
B1317 Battery Voltage High Anti-Lock REFER to Section 206-09.
Brake System
(ABS)
Module
B1317 Battery Voltage High Instrument REFER to Section 413-01.
Cluster
B1317 Battery Voltage High RCM REFER to Section 414-00.
B1318 Battery Voltage Low ABS Module REFER to Section 206-09.
B1318 Battery Voltage Low Audio Unit REFER to Section 414-00.
B1318 Battery Voltage Low Instrument REFER to Section 413-01.
Cluster
B1318 Battery Voltage Low RCM REFER to Section 414-00.
B1318 Battery Voltage Low Satellite REFER to Section 415-00.
Radio
Receiver
B1319 Driver Door Ajar Circuit Failure SJB If the self-test was run with the driver
door open, DTC B1319 may be set.
CLOSE the door. CLEAR the DTCs.
If DTC B1319 is retrieved again, REFER
to Section 417-02.
B1327 Passenger Door Ajar Circuit Failure SJB If the self-test was run with the
passenger door open, DTC B1327 may
be set. CLOSE the door. CLEAR the
If DTC B1327 is retrieved again, REFER
to Section 417-02.
B1341 Power Door Unlock Circuit Short To SJB REFER to Section 501-14.
Ground
B1342 ECU is Faulted ABS Module CLEAR the DTCs. RETRIEVE the
INSTALL a new ABS module. REFER
to Section 206-09. CLEAR the DTCs.
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B1342 ECU is Faulted Audio Unit CLEAR the DTCs. RETRIEVE the
INSTALL a new audio unit. REFER to
B1342 ECU is Faulted Instrument CLEAR the DTCs. RETRIEVE the
Cluster DTCs. If DTC B1342 is retrieved again,
B1342 ECU is Faulted RCM CLEAR the DTCs. RETRIEVE the
INSTALL a new RCM. REFER to
Section 501-20B. CLEAR the DTCs.
B1342 ECU is Faulted Satellite CLEAR the DTCs. RETRIEVE the
Radio DTCs. If DTC B1342 is retrieved again,
Receiver INSTALL a new satellite radio receiver.
B1342 ECU is Faulted SJB CLEAR the DTCs. RETRIEVE the
INSTALL a new SJB. REFER to Smart
Junction Box (SJB) in this section.
CLEAR the DTCs. REPEAT the
self-test.
B1345 Heated Backlite Input Circuit Short To SJB REFER to Section 501-11.
Ground
B1348 Heated Backlite Relay Circuit Open SJB REFER to Section 501-11.
B1349 Heated Backlite Relay Short To Battery SJB REFER to Section 501-11.
B1353 Ignition Key-In Circuit Open Instrument REFER to Section 413-09.
Cluster
B1356 Ignition Run Circuit Open SJB REFER to Section 211-05.
B1360 Ignition Run/Acc Circuit Open SJB REFER to Section 211-05.
B1365 Ignition Start Circuit Short To Battery SJB REFER to Section 211-05.
B1402 Driver Power Window Down Switch SJB REFER to Section 501-18.
Circuit Failure
B1470 Lamp Headlamp Input Circuit Failure SJB REFER to Section 417-01.
B1475 Accessory Delay Relay Short To Battery SJB REFER to Section 501-11.
B1485 Brake Pedal Input Short to Battery SJB REFER to Section 417-01.
B1499 Lamp Turn Signal Left Circuit Failure SJB REFER to Section 417-01.
B1502 Lamp Turn Signal Left Circuit Short To SJB REFER to Section 417-01.
Ground
B1503 Lamp Turn Signal Right Circuit Failure SJB REFER to Section 417-01.
B1506 Lamp Turn Signal Right Circuit Short To SJB REFER to Section 417-01.
Ground
B1519 Hood Switch Circuit Failure SJB REFER to Section 419-01A.
B1551 Latch/Deck Lid Release Circuit Failure SJB REFER to Section 501-14.
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B1556 Ignition Run/Start Circuit Open Instrument REFER to Section 413-01.
Cluster
B1557 Ignition Run/Start Circuit Short To Instrument REFER to Section 413-01.
Battery Cluster
B1600 PATS Ignition Key Transponder Signal PCM REFER to Section 419-01B.
Is Not Received
B1601 PATS Received Incorrect Key-Code PCM REFER to Section 419-01B.
From Ignition Key Transponder
B1602 PATS Received Invalid Format Of PCM REFER to Section 419-01B.
Key-Code From Ignition Key
Transponder
B1676 Battery Pack Voltage Out Of Range SJB REFER to Section 414-00.
B1681 PATS Transceiver Module Signal Is Not PCM REFER to Section 419-01B.
Received
B1833 Door Unlock Disarm Switch Circuit SJB REFER to Section 419-01A.
Short To Ground
B1869 Lamp Air Bag Warning Indicator Circuit RCM REFER to Section 501-20B.
Open
B1870 Lamp Air Bag Warning Indicator Circuit RCM REFER to Section 501-20B.
Short To Battery
B1884 PAD Warning Lamp Circuit Failure RCM REFER to Section 501-20B.
B1890 PAD Warning Lamp Circuit Short to RCM REFER to Section 501-20B.
Battery
B1891 Air Bag Tone Warning Indicator Circuit RCM REFER to Section 501-20B.
Short to Battery
B1892 Air Bag Tone Warning Indicator Circuit RCM REFER to Section 501-20B.
Failure
B1897 Horn Switch Circuit Failure SJB REFER to Section 413-06.
B1921 Air Bag Diagnostic Monitor Ground RCM REFER to Section 501-20B.
Circuit Open
B1982 Drivers Door Unlock Relay Circuit SJB REFER to Section 501-14.
Failure
B200A VSM Inclination Failure SJB REFER to Section 419-01A.
B200B VSM Ultrasonic Failure SJB REFER to Section 419-01A.
B200C VSM Module Failure SJB REFER to Section 419-01A.
B2021 Dome Lamp Output Return Circuit SJB REFER to Section 417-02.
Failure
B2027 LED Backlighting Output Circuit Failure SJB REFER to Section 413-00.
B2030 Front Fog Lamp Relay Ckt Failure SJB REFER to Section 417-01.
B2044 Left Rear Stop Lamp Circuit Short to SJB REFER to Section 417-01.
Ground
B2046 Right Rear Stop Lamp Circuit Short to SJB REFER to Section 417-01.
Ground
B2047 Right Rear Stop Lamp Circuit Open SJB REFER to Section 417-01.
B2048 Left Rear Turn Lamp Circuit Short to SJB REFER to Section 417-01.
Ground
B2049 Left Rear Turn Lamp Circuit Open SJB REFER to Section 417-01.
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B2050 Right Rear Turn Lamp Circuit Short to SJB REFER to Section 417-01.
Ground
B2051 Right Rear Turn Lamp Circuit Open SJB REFER to Section 417-01.
B2052 Accessory Delay Relay Output Failure SJB REFER to Section 501-11.
B2060 Heated Backlite Indicator Circuit Failure SJB REFER to Section 501-11.
B2061 Heated Backlite Indicator Circuit Shorted SJB REFER to Section 501-11.
to Ground
B2068 Convertible Top Up Output Circuit SJB REFER to Section 501-18.
Failure
B2069 Convertible Top Down Output Circuit SJB REFER to Section 501-18.
Failure
B2071 Hazard Switch Signal Short to Ground SJB REFER to Section 417-01.
B2078 Driver Airbag Deactivation Indicator RCM REFER to Section 501-20B.
Lamp Fault
B2103 Antenna Not Connected Audio Unit REFER to Section 415-00.
B2103 Antenna Not Connected PCM REFER to Section 419-01B.
B2132 Dimmer Switch Circuit Short to Gnd SJB REFER to Section 413-00.
B2143 NVM Memory Failure Instrument REFER to Section 413-01.
Cluster
B2175 A/C Request Signal Circuit Short to SJB REFER to Section 412-00.
Ground
B2204 GPS Antenna Connection Open or Short Audio Unit REFER to Section 419-07.
B2254 Front Fog Lamp Switch Failure SJB REFER to Section 417-01.
B2274 Phone Transceiver Active Circuit Failure Audio Unit DISREGARD the DTC. The vehicle does
not have cellular phone. CLEAR the
B2276 Less Than 2 Transmitters Programmed SJB REFER to Section 501-14.
B2281 Right Turn Switch Short to Ground SJB REFER to Section 417-01.
B2282 Left Turn Switch Short to Ground SJB REFER to Section 417-01.
B2290 Occupant Classification System Fault RCM REFER to Section 501-20B.
B2291 Occupant Position System Fault RCM REFER to Section 501-20B.
B2293 Restraint System - Airbag Fault RCM REFER to Section 501-20B.
B2295 Restraint System - Side Airbag Fault RCM REFER to Section 501-20B.
B2296 Restraint System - Impact Sensor Fault RCM REFER to Section 501-20B.
B2360 Window Motor Control Output Circuit SJB REFER to Section 501-11.
Failure
B236A Chime Output Circuit Open Instrument REFER to Section 413-09.
Cluster
B2384 Audio Reverse Aid Mute Input Ckt. Audio Unit DISREGARD the DTC. The vehicle does
Failure not have parking aid. CLEAR the DTCs.
B2404 Audio Steering Wheel Switch Circuit Audio Unit DISREGARD the DTC. The vehicle does
Fault not have steering wheel audio control
buttons. CLEAR the DTCs. REPEAT the
self-test.
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B2405 Audio Disc CD Player Thermal Audio Unit REFER to Section 415-00.
Shutdown Fault
B2406 Audio Disc CD Player Internal Fault Audio Unit REFER to Section 415-00.
B2425 Remote Keyless Entry Out of SJB REFER to Section 501-14.
Synchronization
B2431 Transponder Programming Failed PCM REFER to Section 419-01B.
B2434 Drivers Seat Belt Buckle Switch Circuit RCM REFER to Section 501-20B.
Short to Ground
B2435 Drivers Seat Belt Buckle Switch RCM REFER to Section 501-20B.
Resistance Out of Range
B2438 Passengers Seat Belt Buckle Switch RCM REFER to Section 501-20B.
Circuit Short to Ground
B2439 Passengers Seat Belt Buckle Switch RCM REFER to Section 501-20B.
Resistance out of Range
B2474 Passenger Door Lock Switch Ckt Short SJB REFER to Section 501-14.
to Ground
B2475 Passenger Door Unlock Switch Circuit SJB REFER to Section 501-14.
Short to Ground
B2477 Module Configuration Failure Audio Unit REFER to Section 418-01.
B2477 Module Configuration Failure Instrument REFER to Section 418-01.
Cluster
B2477 Module Configuration Failure RCM REFER to Section 418-01.
B2477 Module Configuration Failure Satellite REFER to Section 418-01.
Radio
Receiver
B2477 Module Configuration Failure SJB REFER to Section 418-01.
B2479 Park Brake Switch Circuit Short to SJB REFER to Section 413-01.
Ground
B2481 Convertible Top Up/Down Switch Fault SJB REFER to Section 501-18.
B2491 RF Park Lamp Output Circuit Short to SJB REFER to Section 417-01.
Battery
B2493 LF Park Lamp Output Circuit Short to SJB REFER to Section 417-01.
Battery
B2501 LF Lamp Low Beam Circuit Failure SJB REFER to Section 417-01.
B2503 RF Lamp Low Beam Circuit Failure SJB REFER to Section 417-01.
B2519 High Mount Stop Lamp Circuit Failure SJB REFER to Section 417-01.
B2523 License Lamp Circuit Failure SJB REFER to Section 417-01.
B2525 Left Rear Backup Lamp Circuit Failure SJB REFER to Section 417-01.
B2527 Left Rear Stop Lamp Circuit Failure SJB REFER to Section 417-01.
B2528 Left Rear Stop Lamp Circuit Short to SJB REFER to Section 417-01.
Battery
B2529 Left Rear Turn Lamp Circuit Failure SJB REFER to Section 417-01.
B2532 Right Rear Backup Lamp Circuit Short SJB REFER to Section 417-01.
to Battery
B2533 Right Rear Stop Lamp Circuit Failure SJB REFER to Section 417-01.
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B2534 Right Rear Stop Lamp Circuit Short to SJB REFER to Section 417-01.
Battery
B2550 Dome Lamp Output Circuit Short to SJB REFER to Section 417-02.
Ground
B2554 Dome Lamp Output Circuit Failure SJB REFER to Section 417-02.
B2567 Reverse Mirror Output Circuit Failure SJB REFER to Section 501-09.
B2568 Reverse Mirror Output Circuit Short to SJB REFER to Section 501-09.
Ground
B2569 Liftgate Disarm Switch Circuit Short to SJB REFER to Section 419-01A.
Ground
B2572 Brake Shift Interlock Output Circuit SJB REFER to Section 307-05.
Failure
B2578 Passenger Power Window Down Switch SJB REFER to Section 501-18.
Circuit Failure
B2586 Headlamp Mode Select Circuit Failure SJB REFER to Section 417-01.
B2598 Headlamp Relay Circuit Failure SJB REFER to Section 417-01.
B2627 Fuel Sender Circuit Open #2 Instrument REFER to Section 413-01.
Cluster
B2627 Fuel Sender Circuit Open #2 SJB REFER to Section 413-01.
B2628 Fuel Sender Circuit Short to Ground #2 Instrument REFER to Section 413-01.
Cluster
B2628 Fuel Sender Circuit Short to Ground #2 SJB REFER to Section 413-01.
B2633 Driver-Front Microphone Circuit Failure Audio Unit DISREGARD the DTC. The vehicle does
not have voice-activated navigation.
CLEAR the DTCs. REPEAT the
self-test.
B2656 DVD (Digital Versatile Disk) Error Audio Unit REFER to Section 419-07.
B2691 Seat Belt Buckle Switch Circuit Fault, RCM REFER to Section 501-20B.
Front Drivers Side
B2692 Front Passengers Seat Belt Buckle RCM REFER to Section 501-20B.
Switch Circuit Fault
B2868 Left Front Tire Pressure Sensor Fault SJB This DTC is only present when a new
SJB is installed, or the SJB is
re-configured. REFER to Section 204-04
to carry out the tire pressure monitoring
system (TPMS) sensor training in order
to clear this DTC.
B2869 Right Front Tire Pressure Sensor Fault SJB This DTC is only present when a new
to carry out the TPMS sensor training in
order to clear this DTC.
B2870 Right Rear Tire Pressure Sensor Fault SJB This DTC is only present when a new
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B2871 Left Rear Tire Pressure Sensor Fault SJB This DTC is only present when a new
B2872 Tire Pressure Sensor Fault SJB REFER to Section 204-04.
B2879 Fuel Tank Jet Pump Fault Instrument REFER to Section 413-01.
Cluster
B2885 Spare Tire Pressure Sensor Fault SJB DISREGARD the DTC. It is not
applicable to this vehicle.
B2903 Chime Output Circuit Short to Battery Instrument REFER to Section 413-09.
Cluster
B2909 Belt Tension Sensor Fault RCM REFER to Section 501-20B.
B2924 Audio Button Stuck Audio Unit REFER to Section 415-00.
B2940 Chime Output Circuit Short to Ground Instrument REFER to Section 413-09.
Cluster
B2965 Audio System Speaker Circuit Fault Audio Unit REFER to Section 415-00.
B2984 Deployable Steering Column Circuit RCM REFER to Section 501-20B.
Open
Short to Battery
Short to Ground
Resistance Low on Squib
C1093 Traction Control Disable Switch Circuit Instrument REFER to Section 206-09.
Failure Cluster
C1095 ABS Hydraulic Pump Motor Circuit ABS Module REFER to Section 206-09.
Failure
C1096 ABS Hydraulic Pump Motor Circuit ABS Module REFER to Section 206-09.
Open
C1103 ABS Hydraulic Brake Switch Circuit ABS Module REFER to Section 206-09.
Failure
C1115 ABS Power Relay Output Short Circuit ABS Module REFER to Section 206-09.
To Battery
C1145 Speed Wheel Sensor RF Input Circuit ABS Module REFER to Section 206-09.
Failure
C1155 Speed Wheel Sensor LF Input Circuit ABS Module REFER to Section 206-09.
Failure
C1165 Speed Wheel Sensor RR Input Circuit ABS Module REFER to Section 206-09.
Failure
C1175 Speed Wheel Sensor LR Input Circuit ABS Module REFER to Section 206-09.
Failure
C1185 ABS Power Relay Output Circuit Failure ABS Module REFER to Section 206-09.
C1189 Brake Fluid Level Sensor Input Short SJB REFER to Section 413-01.
Circuit To Ground
C1194 ABS Outlet Valve Coil LF Circuit ABS Module REFER to Section 206-09.
Failure
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C1198 ABS Inlet Valve Coil LF Circuit Failure ABS Module REFER to Section 206-09.
C1210 ABS Outlet Valve Coil RF Circuit ABS Module REFER to Section 206-09.
Failure
C1214 ABS Inlet Valve Coil RF Circuit Failure ABS Module REFER to Section 206-09.
C1222 Speed Wheel Mismatch ABS Module REFER to Section 206-09.
C1233 Speed Wheel LF Input Signal Missing ABS Module REFER to Section 206-09.
C1234 Speed Wheel RF Input Signal Missing ABS Module REFER to Section 206-09.
C1235 Speed Wheel RR Input Signal Missing ABS Module REFER to Section 206-09.
C1236 Speed Wheel LR Input Signal Missing ABS Module REFER to Section 206-09.
C1242 ABS Outlet Valve Coil LR Circuit ABS Module REFER to Section 206-09.
Failure
C1246 ABS Outlet Valve Coil RR Circuit ABS Module REFER to Section 206-09.
Failure
C1250 ABS Inlet Valve Coil LR Circuit Failure ABS Module REFER to Section 206-09.
C1254 ABS Inlet Valve Coil RR Circuit Failure ABS Module REFER to Section 206-09.
C1329 ABS Outlet Valve Coil RF Circuit ABS Module REFER to Section 206-09.
Excessive Temperature
C1330 ABS Outlet Valve Coil LR Circuit ABS Module REFER to Section 206-09.
C1331 ABS Outlet Valve Coil RR Circuit ABS Module REFER to Section 206-09.
C1332 ABS Outlet Valve Coil LF Circuit ABS Module REFER to Section 206-09.
C1333 ABS Inlet Valve Coil LR Circuit ABS Module REFER to Section 206-09.
C1334 ABS Inlet Valve Coil LF Circuit ABS Module REFER to Section 206-09.
C1335 ABS Inlet Valve Coil RF Circuit ABS Module REFER to Section 206-09.
C1336 ABS Inlet Valve Coil RR Circuit ABS Module REFER to Section 206-09.
C1404 Traction Control Valve Rear Circuit ABS Module REFER to Section 206-09.
Failure
C1414 Incorrect Module Design Level RCM INSTALL a new correct design level
RCM. REFER to Section 501-20B.
C1446 Brake Switch Circuit Failure ABS Module REFER to Section 206-09.
C1527 Traction Control Rear Valve Circuit ABS Module REFER to Section 206-09.
C1531 Dynamic Stability Control LF Valve ABS Module REFER to Section 206-09.
Circuit Excessive Temperature
C1730 Reference Voltage Out of Range (+5 v) ABS Module REFER to Section 206-09.
C1947 Front Drivers Seat Track Position RCM REFER to Section 501-20B.
Switch Circuit Short to Ground
Switch Circuit Resistance Out of Range
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C1958 Dynamic Stability Control Valve LF ABS REFER to Section 206-09.
Circuit Failure
C1992 Vehicle Speed Circuit Failure Audio Unit VERIFY the audio unit is configured to
receive the vehicle speed signal through
the medium speed controller area
network (MS-CAN). REFER to Section
418-01.
C2200 Front Passengers Seat Track Position RCM REFER to Section 501-20B.
Switch Circuit Short to Ground
Switch Circuit Resistance Out of Range
NOTE: If DTC B2477 is also present, C2780 ECU in Manufacturer Sub-State SJB
REFER to the Action for DTC B2477 in
this DTC Index.
This DTC is only present when a new
to carry out the TPMS sensor training,
then CARRY OUT the SJB self-test in
P0812 Reverse Input Circuit Audio Unit VERIFY the audio unit is configured to
receive the vehicle reverse input signal
through the MS-CAN. REFER to Section
418-01.
P1260 Theft Detected, Vehicle Immobilized PCM REFER to Section 419-01B.
U0073 Control Module Communication Bus A ABS Module REFER to Section 418-00.
Off
U0073 Control Module Communication Bus A Instrument REFER to Section 418-00.
Off Cluster
U0073 Control Module Communication Bus A SJB REFER to Section 418-00.
Off
U0140 Lost Communication With Body Control Audio Unit REFER to Section 415-00.
Module (GEM)
U0155 Lost Communication With Instrument Audio Unit REFER to Section 415-00.
Panel Cluster (IC) Control Module
U0159 Lost Communication With Parking Assist Audio Unit The vehicle does not have parking aid.
Control Module (PAM) CLEAR the DTCs. REPEAT the
self-test.
U0184 Lost Communication With Radio (ACM) Satellite REFER to Section 415-00.
Radio
Receiver
U0193 Lost Communication With Digital Audio Audio Unit REFER to Section 415-00.
U0196 Lost Communication With Entertainment Audio Unit The vehicle does not have rear
Control Module - Rear (AUX) entertainment controls. CLEAR the
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U0196 Lost Communication With Entertainment Satellite The vehicle does not have rear
Control Module - Rear (AUX) Radio entertainment controls. CLEAR the
Receiver DTCs. REPEAT the self-test.
U0197 Lost Communication With Telephone Audio Unit The vehicle does not have cellular
Control Module telephone. CLEAR the DTCs. REPEAT
the self-test.
U0197 Lost Communication With Telephone Satellite The vehicle does not have cellular
Control Module Radio telephone. CLEAR the DTCs. REPEAT
Receiver the self-test.
U0238 Lost Communication With Digital Audio Audio Unit The vehicle does not have THX
Control Module D (DSP) amplifier. CLEAR the DTCs. REPEAT
the self-test.
U0249 Lost Communication With Entertainment Audio Unit The vehicle does not have rear
Control Module - Rear B (RCU) entertainment controls. CLEAR the
U0249 Lost Communication With Entertainment Satellite The vehicle does not have rear
Control Module - Rear B (RCU) Radio entertainment controls. CLEAR the
Receiver DTCs. REPEAT the self-test.
U1900 CAN Communication Bus Fault - ABS Module REFER to Section 418-00.
Receive Error
U1900 CAN Communication Bus Fault - Audio Unit REFER to Section 418-00.
Receive Error
U1900 CAN Communication Bus Fault - Instrument REFER to Section 418-00.
Receive Error Cluster
U1900 CAN Communication Bus Fault - SJB REFER to Section 418-00.
Receive Error
U2011 Module Transmitted Invalid Data (Non ABS REFER to Section 418-01.
SCP)
U2023 Fault Received From External Node Instrument DISREGARD this DTC. CHECK for
Cluster other DTCs and FOLLOW diagnostics
for other modules.
U2033 VSM Communication Link Failure SJB REFER to Section 419-01A.
U2050 No Application Present ABS Module REFER to Section 418-01.
U2050 No Application Present Audio Unit REFER to Section 415-00.
U2050 No Application Present Instrument REFER to Section 418-01.
Cluster
U2050 No Application Present Satellite REFER to Section 415-00.
Radio
Receiver
U2050 No Application Present SJB REFER to Section 418-01.
U2051 One or More Calibration Files Missing / ABS Module REFER to Section 418-01.
Corrupt
U2051 One or More Calibration Files Missing / Audio Unit REFER to Section 415-00.
Corrupt
U2473 Unexpected Vehicle Speed (VSS) Audio Unit REFER to the Powertrain
manual.
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Door Disarm Switch
2. Position the watershield aside.
1 Door disarm switch electrical
3. Disconnect the door disarm switch electrical
connector.
2 Door disarm switch wiring
retainer (part of 220A40)
4. Separate the door disarm switch wiring harness
3 E-clip
retainer from the post on the LH door latch.
4 21970 Lock cylinder actuator pawl
5 19A434A Door disarm switch 5. Remove the E-clip.
Removal and Installation 6. Remove the lock cylinder actuator pawl.
7. Remove the door disarm switch.
1. Remove the LH front door trim panel. For
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The door disarm switch mark must be
positioned towards the harness side of the
switch prior to installation.
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Compass Accuracy
Electronic Compass
Driving near power lines, or driving in the area of
The compass display and module are an integral
large iron or steel structures can temporarily change
part of the interior rear view mirror. A 1 or 2
the compass heading. If the compass remains
character display located in the upper right hand
inaccurate after driving near such objects, calibrate
side of the mirror indicates the current direction of
the compass. For additional information, refer to
the vehicle (N, NE, E, SE, S, SW, W, NW). The
Compass Calibration in this section.
compass continuously recalibrates due to changes in
the magnetic field and remains accurate during most
Most geographic areas (zones) have a magnetic
driving conditions. The compass display can be
north compass point that varies slightly from the
turned off and on by pressing the switch on the
northerly direction on maps. This variation is 4
mirror.
degrees between the adjacent zones and becomes
noticeable as the vehicle crosses multiple zones. A
correct zone setting eliminates the error. For
additional information, refer to Compass Zone
Adjustment in this section.
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Excessive magnetism in or near the vehicle may
Electronic Compass
cause the compass to display ALL SEGMENTS. In
Special Tool(s)
order to distinguish between vehicle magnetics and
surrounding magnetics, drive the vehicle to an area
that is free from large metal objects. Cycling the
key ON and OFF resets the compass. A display of
ALL SEGMENTS within 20 seconds indicates
excessive vehicle magnetism and the mirror should
be replaced. Refer to Section 501-09.
The compass is self-calibrating. This eliminates the
need to manually set the compass. If the compass is
displaying a heading and not displaying C or CAL,
the compass is in auto-calibration mode. In this
mode, the compass automatically calibrates for
changes in vehicle magnetics over the life of the
Interior rear view mirror Smart junction box
vehicle. This auto-calibration mode assures the
(SJB) fuse 7 (10A)
compass heading is always accurate.
Circuitry
Compass sensor
A display of C or CAL indicates the compass
(integral to the interior
requires calibration. The compass may temporarily
rear view mirror)
display C or CAL if the vehicle characteristics have
changed (car wash, collision or other factors).
Compass adjustment is controlled by the switch on
the mirror, which provides access to the calibration
and zone adjustment procedures.
symptom. GO to Symptom Chart.
Symptom Chart
Symptom Chart
The compass is inoperative Fuse GO to Pinpoint Test A.
Circuitry
Interior rear view mirror
Compass switch (part of the
interior rear view mirror)
The compass is inaccurate Incorrect compass zone GO to Pinpoint Test B.
setting
Compass calibration
The compass display and module are integrated into
Pinpoint Test A: The Compass Is Inoperative
the interior rear view mirror. The interior rear view
Refer to Wiring Diagrams Cell 124, Power Mirrors mirror receives switched B+ voltage through circuit
for schematic and connector information. 46 (VT). Circuit 1205 (BK) provides the mirror
ground.
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Possible Causes
Fuse Compass switch (part of the interior rear view
mirror)
Circuit 46 (VT) open or short to ground
PINPOINT TEST A: THE COMPASS IS INOPERATIVE
NOTE: Make sure the compass is turned on by pressing the switch before carrying out this
pinpoint test.
A1 CHECK CIRCUIT 46 (VT) FOR VOLTAGE
Disconnect: Interior Rear View Mirror C911.
Key in ON position.
Measure the voltage between the interior rear view mirror
C911-1, circuit 46 (VT), harness side and ground.
Yes
GO to A2.
No
Measure the resistance between the interior rear view mirror
Yes
INSTALL a new interior rear view mirror.
No
Possible Causes
Pinpoint Test B: The Compass Is Inaccurate
Incorrect compass zone setting
Normal Operation
The compass display and module are integrated into
Compass calibration
the interior rear view mirror. The compass
adjustment and zone variation are controlled by the
switch on the mirror.
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PINPOINT TEST B: THE COMPASS IS INACCURATE
B1 CHECK THE COMPASS ZONE ADJUSTMENT
Carry out the compass zone adjustment procedure. Refer to Yes
Compass Zone Adjustment in this section. GO to B2.
Does the compass zone set correctly?
No
B2 CALIBRATE THE COMPASS
Carry out the compass calibration adjustment procedure. Refer Yes
to Compass Calibration in this section. GO to B3.
Does the compass calibrate correctly?
No
B3 CHECK THE VEHICLE ACCURACY
Position the vehicle and observe the compass display as follows:
Direction Compass Display
North N
Northeast NE
East E
Southeast SE
South S
Southwest SW
Yes
The compass is operating correctly.
West W
No
Northwest NW
Does the compass calibrate correctly? system for normal operation.
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419-07-1 419-07-1 Navigation System
Global Positioning System (GPS)
Antenna
1 GPS antenna-to-audio unit
3. Release the antenna cable locators and remove
10E893)
the GPS antenna.
2 10E893 GPS antenna
1. Remove the audio unit. For additional
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Intrusion and Inclination Sensor
1 Intrusion and inclination
1. Remove the overhead console. sensor screws (2 required)
2 Overhead console jumper
2. Remove the 2 screws and position the intrusion
harness electrical connector
(part of 10503) and inclination sensor aside.
3 15K609 Intrusion and inclination
3. Disconnect the overhead console jumper harness sensor
4 76519A58 Intrusion and inclination
sensor gaskets (2 required)
4. Remove the intrusion and inclination sensor.
5. Remove the foam gaskets from the old intrusion
and inclination sensor and install them on the
new sensor.
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GENERAL PROCEDURES
NOTE: If the SPAREKEY PID reads ENABLE, up
Key Programming Switch State
to 8 keys total can be programmed into the PCM
Control
using the Key Programming Using Two
Programmed Keys procedure in this section. If the
Special Tool(s)
SPAREKEY PID reads DISABLED, the key
Vehicle Communication Module programming using two programmed keys
procedure will not function. This switch is set to
ENABLE when the vehicle is built. This PID does
not affect the Key Programming Using Diagnostic
Equipment procedure or the Spare Key
tool
Programming Unlimited Key Mode procedure.
1. From the scan tool, follow the on-screen
NOTE: The spare key programming switch is a
instructions to ENTER SECURITY ACCESS.
programmable switch which provides the capability
For additional information, refer to Anti-Theft
to enable/disable the normal customer spare key
Security Access in this section.
programming procedure detailed in the Owners
Literature. For additional information, refer to Key
2. NOTE: The default setting on delivery of all
Programming Using Two Programmed Keys in this
new vehicles is ENABLE.
section. This programmable switch is provided as a
From the scan tool menu select: Customer
convenience for rental company fleets or other fleet
Spare Key Programming Enable or Customer
purchasers who may not want the Spare Key
Spare Key Programming Disable and press the
Programming procedure available to the vehicle
tick mark.
driver.
Customer Spare Key Programming
NOTE: The spare key programming switch state
Enable spare key programming
can be viewed with the PCM PID SPAREKEY.
procedure is accessible.
Customer Spare Key Programming
Disable spare key programming
procedure is not accessible.
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GENERAL PROCEDURES
NOTE: If additional keys are to be programmed,
Key Programming Using Diagnostic
and the remaining keys are with the customer, or
Equipment
are not available, instruct the customer to refer to
the Owners Literature for instructions on
Special Tool(s)
programming the remaining keys. In this case, the
Vehicle Communication Module PID SPAREKEY must be enabled.
NOTE: This procedure is not necessary if only the
PATS transceiver was replaced. Replacement of the
transceiver does not erase the PATS key codes in
tool
the PCM.
NOTE: This procedure is used when a customer
needs keys programmed into the system and does
not have 2 programmed ignition keys available. This
procedure is also useful when a programmed
ignition key(s) is lost or the ignition lock cylinder is 2. From the scan tool menu select: Ignition Key
replaced, and it is desired to erase key code(s) from Code Erase and press the tick mark.
the passive anti-theft system (PATS) memory.
3. Turn the key to the OFF position and
NOTE: This procedure erases all programmed
disconnect the scan tool.
ignition keys from the vehicle memory. The vehicle
will not start until a minimum of 2 keys are
4. Insert the first PATS key into the ignition lock
programmed to the vehicle.
cylinder and turn the key to the ON position for
3 seconds.
5. Remove the first PATS key from the ignition
start.
lock cylinder.
NOTE: Two PATS encoded (contains a
6. Insert the next PATS key into the ignition lock
transponder) keys with the correct mechanical cut
must be available to carry out this procedure. One
3 seconds.
or both of them may be the customers original
keys.
7. If it is desired to program additional key(s)
(only up to 8 keys total can be programmed
into the PCM), refer to Key Programming
Using Two Programmed Keys in this section.
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GENERAL PROCEDURES
NOTE: Ignition keys must have a correct
Key Programming Using Two
mechanical key cut for the vehicle and must be
Programmed Keys
PATS encoded keys (contain a transponder).
NOTE: This procedure works only if 2 or more
NOTE: This procedure is not necessary if only the
programmed ignition keys are available. If 2
PATS transceiver was replaced. Replacement of the
programmed keys are not available, refer to Key
transceiver does not erase the PATS key codes in
Programming Using Diagnostic Equipment in this
the PCM.
section.
1. Insert the first programmed key into the ignition
NOTE: The PID SPAREKEY must be enabled for
lock cylinder and turn the key from the OFF
this procedure to operate. If this PID is not enabled,
position to the ON position (maintain the key in
refer to Key Programming Switch State Control in
the ON position for a minimum of 3 seconds
this section, then select SPAREKEY programming
and less than 10 seconds).
switch; ENABLED. The PID SPAREKEY is set to
ENABLE when the vehicle is built.
2. Turn the key to the OFF position and remove
the first key from the ignition lock cylinder.
NOTE: If the programming procedure is successful,
the new key(s) will start the vehicle and the
3. Within 5 seconds of turning the key to the OFF
anti-theft indicator will prove-out for approximately
position, insert the second programmed key into
3 seconds. If the programming procedure is not
the ignition lock cylinder and turn the key from
successful and the new key(s) does not start the
the OFF position to the ON position (maintain
engine, leave the key in the ON position for at least
the key in the ON position for a minimum of 3
3 seconds, then turn the key off. Repeat the key
seconds and less than 10 seconds).
programming procedure from Step 1. If the failure
repeats, refer to Anti-Theft in the Diagnosis and
4. Turn the key to the OFF position and remove
Testing portion of this section to review the DTCs
the key from the ignition lock cylinder.
and carry out the appropriate pinpoint tests.
5. Within 10 seconds of turning the key to the
NOTE: A maximum of 8 passive anti-theft system
OFF position, insert the unprogrammed key (the
(PATS) keys can be programmed into the
new key) into the ignition lock cylinder and
powertrain control module (PCM) during this
turn the key from the OFF position to the ON
programming procedure, but only if the PID
position (maintain the key in the ON position
SPAREKEY is ENABLED.
for a minimum of 3 seconds and less than 10
seconds).
start.
NOTE: If the vehicle is in unlimited key mode, this
spare key programming procedure still functions.
Any 2 keys that can start the vehicle can be used to
program an additional unlimited key.
NOTE: If additional keys are to be programmed,
and the remaining keys are with the customer, or
are not available, instruct the customer to refer to
the Owners Literature for instructions on
programming the remaining keys. In this case, the
PID SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined,
the programming procedure will end.
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6. If it is desired to program additional key(s) 7. Start the vehicle with the new key(s).
(only up to 8 keys total can be programmed
into the PCM), repeat Steps 1 - 5 for each
additional key that needs to be programmed.
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The SJB is located behind the RH A-pillar lower
Module Controlled Functions
trim panel.
The smart junction box (SJB) is the only
For removal information, refer to Smart Junction
multifunction electronic module on this vehicle. The
Box (SJB) in this section.
SJB is a combination of a multifunction electronic
module and an interior fuse panel. SJB functions
For additional information on perimeter anti-theft,
control multiple vehicle systems which include:
refer to Section 419-01A.
For additional information on the battery saver,
Battery saver
heated rear window, and power windows, refer to
Convertible top (if equipped)
Section 501-11.
Convertible top drop window function (if
For additional information on the convertible top,
equipped)
Exterior lighting
For additional information on the exterior lighting,
Heated rear window
Interior lighting
For additional information on the interior lamps and
Perimeter anti-theft (if equipped) illuminated entry, refer to Section 417-02.
Power locks For additional information on the power door locks,
and the RKE system, refer to Section 501-14.
Remote keyless entry (RKE)
For additional information on the TPMS, refer to
Tire pressure monitoring system (TPMS)
Section 204-04.
Interface with the instrument cluster for TPMS
For additional information on the warning chimes,
warning lamp
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Navigation System
The navigation system is integral to the audio unit.
The audio unit controls the operation of the
navigation system and the audio system. The system
uses a global positioning system (GPS) antenna, a
vehicle speed input, and other sensor information
to accurately establish the vehicle position. The
audio unit provides the visual and audible
instructions of the maneuvers required to arrive at
the pre-entered destination. An audible switch
feedback is provided to confirm if an audio unit
button or a screen button is pressed. The audible
switch feedback can be set to ALL, TOUCH
SCREEN, or NONE, depending on user preference.
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Navigation System
Special Tool(s)
Navigation map DVD Circuitry
Vehicle Communication Module Global positioning
(VCM) and Integrated system (GPS) antenna
Diagnostic System (IDS) Audio unit
3. If an obvious cause for an observed or reported tool
software release.
The navigation module is integrated in the audio
unit and controls the operation and the interface
between the user, the vehicle subsystems, and the
external components. The navigation module
communicates with other vehicle systems via the
medium speed controller area network (MS-CAN)
and can be diagnosed with a scan tool. When
VCM.
installing a new audio unit, programmable module
installation (PMI) is required.
VCM:
The vehicle navigation system guides the user to a
pre-entered destination. A navigation map digital
versatile disc (DVD) stored in the navigation
module sends route calculation data to the audio
unit. The audio unit audibly and visually instructs
the user of the maneuvers required to arrive at the
with the scan tool.
destination entered.
In order to calculate the initial vehicle position, the
vehicle:
global positioning system (GPS) antenna is used to
track several available satellites simultaneously. The
position.
GPS antenna only receives data and does not
communicate with the satellites. A gyroscope,
good vehicle.
integral to the navigation module, monitors the pitch
and yaw of the vehicle created during cornering or Refer to Section 418-00 to diagnose no
turning. Vehicle speed and reverse signals received response from the powertrain control module
through the CAN are also used to detect vehicle (PCM).
speed and direction changes.
If the scan tool responds with no Inspection and Verification
self-test diagnostics for the audio unit.
go to the Audio Unit Diagnostic Trouble Code
(DTC) Index.
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go to the Audio Unit Self-Diagnostic Mode.
Audio Unit Self Diagnostic Mode
The navigation system provides internal self
diagnostics to assist with diagnosing vehicle
concerns.
Press and hold preset buttons 4 and 6 for 3 seconds.
Press the End Test button on the screen to exit the
speaker walk test.
ON DEMAND SELF TEST provides internal
self-test diagnostics and displays all the DTCs
resulting from the self-test.
VIEW DTCs provides a list of all the diagnostic
trouble codes (DTCs) currently stored in memory.
CONFIGURATION STATUS displays the current
unit configuration.
SYSTEM INFO provides the navigation module
part number and software information.
GPS INFO provides satellite information and
vehicle current information.
The following diagnostics are available using the
on-screen buttons as follows:
SPEAKER WALK TEST performs a speaker
walk-around test.
MULTI-DISC TEST performs a test of the
compact disc (CD) player mechanism.
HARDKEY TEST checks any of the buttons
operation.
RADIO SIGNAL STRENGTH performs a test of
the antenna signal.
Audio Unit Diagnostic Trouble Code (DTC) Index
B1117 Audio Steering Wheel Button Stuck DTC is not applicable. The vehicle is not
B1119 Audio Disc DVD Player Thermal Shutdown ALLOW the audio unit to cool. REPEAT the
self-test. If DTC B1119 is retrieved again,
B1136 Audio Steering Wheel Switch #2 Circuit Failure DTC is not applicable. The vehicle is not
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B1140 Map Disk Invalid INSERT a good known navigation map DVD.
after the repair.
Section 414-00.
repair.
B2103 Antenna Not Connected REFER to Section 415-00 to diagnose no
reception.
B2204 GPS Antenna Connection Open or Short GO to Pinpoint Test A.
B2274 Phone Transceiver Active Circuit Failure DTC is not applicable. The vehicle is not
equipped with cellular phone functionality.
B2384 Audio Reverse Aid Mute Input Ckt Failure DTC is not applicable. The vehicle is not
equipped with parking aid. DISREGARD the
B2404 Audio Steering Wheel Switch Circuit Fault DTC is not applicable. The vehicle is not
B2405 Audio Disc CD Player Thermal Shutdown Fault ALLOW the unit to cool. DISREGARD the
B2406 Audio Disc CD Player Internal Fault CLEAR the DTCs. REPEAT the self-test. If
repair.
B2633 Driver-Front Microphone Circuit Failure DTC is not applicable. The vehicle is not
equipped with voice-activated navigation.
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B2656 DVD (Digital Versatile Disc) Error REMOVE the navigation map DVD. With a soft
cloth, WIPE the DVD in an outward direction
starting from the center. MAKE SURE there are
no fingerprints or scratches on the DVD surface.
INSERT the DVD. CLEAR the DTCs. REPEAT
the self-test. If DTC B2656 is retrieved again,
INSERT a good known navigation map DVD.
after the repair.
B2924 Audio Button Stuck CLEAR the DTCs. REPEAT the self-test. If
DTC B2924 is retrieved again, GO to Pinpoint
Test D.
B2965 Audio System Speaker Circuit Fault REFER to Section 415-00 to diagnose the
inoperative speaker(s).
C1992 Vehicle Speed Circuit Failure VERIFY the audio unit is configured to receive
the vehicle speed signal through the medium
speed controller area network (MS-CAN).
P0812 Reverse Input Circuit VERIFY the audio unit is configured to receive
the reverse signal through the MS-CAN. REFER
to Section 418-01.
NOTE: Diagnose DTC B1318 (if present) U0140 Lost Communication With Body Control
Module (GEM)
VERIFY the operation of the vehicle
illumination and the accessory delay.
If the vehicle illumination or accessory delay
does not operate correctly, REFER to
Section 413-00 (illumination) or Section
501-11 (accessory delay).
If the vehicle illumination and accessory
delay operate correctly, REMOVE the audio
unit and SEND it to an authorized audio
NOTE: Diagnose DTC B1318 (if present) U0155 Lost Communication With Instrument Panel
Cluster (IC) Control Module
VERIFY the operation of the speedometer.
If the speedometer operates correctly,
REFER to Section 415-01. TEST the system
for normal operation after the repair.
If the speedometer does not operate
correctly, REFER to Section 413-01.
U0159 Lost Communication With Parking Assist DTC is not applicable. The vehicle is not
Control Module (PAM) equipped with parking aid. DISREGARD the
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NOTE: Diagnose DTC U1900 (if present) U0193 Lost Communication With Digital Audio
self-test.
U0238 Lost Communication With Digital Audio DTC is not applicable. The vehicle is not
Control Module D (DSP) equipped with a DSP module. DISREGARD the
self-test.
U1900 CAN Communication Bus Fault - Receive Error REFER to Section 418-00 to diagnose the
MS-CAN.
U2050 No Application Present CONFIGURE the audio unit. REFER to Section
418-01 to carry out programmable module
installation (PMI). REPEAT the self-test. If
DTC U2050 is retrieved again, REMOVE the
repair.
U2051 One or More Calibration Files Missing/Corrupt CONFIGURE the audio unit. REFER to Section
418-01 to carry out PMI. REPEAT the self-test.
If DTC U2051 is retrieved again, REMOVE the
repair.
U2473 Unexpected Vehicle Speed (VSS) REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual to diagnose the
vehicle speed signal.
Symptom Chart
Symptom Chart
audio unit Circuitry
Audio unit
Navigation system does not GPS antenna GO to Pinpoint Test A.
operate correctly no global Audio unit
positioning system (GPS)
antenna signal
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Navigation system does not Audio unit CHECK the anti-lock brake
operate correctly the system (ABS) module for
position cursor is inoperative diagnostic trouble codes
(DTCs).
If ABS module DTCs
are present, REFER to
Section 206-09.
If no ABS module
DTCs are present,
diagnose any audio unit
DTCs. If the symptom is
present after all audio
unit DTCs are
addressed, REMOVE the
audio unit and SEND it
to an authorized audio
system repair facility.
REFER to Section
415-01. TEST the
system for normal
operation after the
repair.
Navigation system does not Audio unit GO to Pinpoint Test B.
operate correctly the
audible switch feedback is
inoperative
Navigation system does not Audio unit GO to Pinpoint Test C.
operate correctly the voice
guidance is inoperative/does
not operate correctly
Navigation system does not Audio unit REMOVE the audio unit and
operate correctly the SEND it to an authorized
display screen is inoperative audio system repair facility.
TEST the system for normal
Navigation system does not Audio unit REMOVE the audio unit and
operate correctly unable to SEND it to an authorized
insert or eject map disc audio system repair facility.
Pinpoint Tests
DTC B2204 sets when an open or short to
ground is detected in the GPS antenna circuit.
Pinpoint Test A: Navigation System Does
Possible Causes
Not Operate Correctly No Global
Positioning System (GPS) Antenna Signal
GPS antenna
Normal Operation
Audio unit
The GPS antenna provides information from the
GPS satellite system to the GPS receiver in the
navigation module. This information is used to
calculate vehicle position and direction of travel.
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PINPOINT TEST A: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY NO GLOBAL
POSITIONING SYSTEM (GPS) ANTENNA SIGNAL
NOTE: The vehicle must be driven outside of any enclosed structure to an area that is
unobstructed by trees, tall buildings, and bridges.
A1 CHECK THE OPERATION OF THE GPS ICON
Move the vehicle outside of any enclosed structure to an area
that is unobstructed by trees, tall buildings, and bridges.
Press the MAP button.
Yes
time.
No
Does the GPS icon disappear? GO to A2.
A2 CHECK THE RECORDED DTCs FROM THE NAVIGATION
MODULE
Check the recorded results from the navigation module self-test. Yes
Are any DTCs recorded? If DTC B2204 is present, GO to A4.
For all other DTCs, REFER to the Audio
Unit Diagnostic Trouble Code (DTC) Index
in this section.
No
GO to A3.
A3 CHECK THE GPS ANTENNA MOUNTING
Verify the GPS antenna is installed properly and no aftermarket Yes
equipment is obstructing it. GO to A4.
Is the GPS antenna mounted properly?
No
Correctly INSTALL the GPS antenna.
REFER to Global Positioning System
(GPS) Antenna in this section. TEST the
A4 SUBSTITUTE THE GPS ANTENNA
Install a good known GPS antenna. Refer to Global Positioning
System (GPS) Antenna in this section.
Move the vehicle outside of any enclosed structure to an area
that is unobstructed by trees, tall buildings, and bridges.
(Continued)
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PINPOINT TEST A: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY NO GLOBAL
POSITIONING SYSTEM (GPS) ANTENNA SIGNAL (Continued)
A4 SUBSTITUTE THE GPS ANTENNA (Continued)
Press the MAP button.
Yes
INSTALL a new GPS antenna. REFER to
Global Positioning System (GPS) Antenna
in this section. CLEAR the DTCs.
No
INSTALL the original GPS antenna. GO to
Does the GPS icon disappear? A5.
A5 CHECK FOR CORRECT AUDIO UNIT OPERATION
Connect all the audio unit connectors and make sure they seat repair.
correctly.
No
Possible Causes
Pinpoint Test B: Navigation System Does
Not Operate Correctly The Audible Switch
Audio unit
Feedback Is Inoperative
Normal Operation
The audible switch feedback settings are controlled
by the audio unit. The audible switch feedback can
be set to ALL, TOUCH SCREEN, or NONE,
depending on user preference.
PINPOINT TEST B: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY THE AUDIBLE SWITCH
FEEDBACK IS INOPERATIVE
B1 CHECK THE SWITCH DISPLAY
Key in ON position.
Press the MENU button.
(Continued)
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PINPOINT TEST B: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY THE AUDIBLE SWITCH
FEEDBACK IS INOPERATIVE (Continued)
B1 CHECK THE SWITCH DISPLAY (Continued)
Select the FEEDBACK tab.
Yes
SELECT ALL BUTTONS. TEST the
No
Is NONE highlighted on the audible feedback settings? GO to B2.
B2 CHECK FOR CORRECT AUDIO UNIT OPERATION
correctly.
No
Possible Causes
Pinpoint Test C: Navigation System Does
Not Operate Correctly The Voice
Audio unit
Guidance Is Inoperative/Does Not Operate
Correctly
Normal Operation
The voice guidance settings are controlled by the
audio unit. The voice guidance volume can be
adjusted or turned off depending on user preference.
PINPOINT TEST C: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY THE VOICE
GUIDANCE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
C1 CHECK THE VOICE GUIDANCE SETTINGS
Key in ON position.
Press the MENU button.
(Continued)
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PINPOINT TEST C: NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY THE VOICE
GUIDANCE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY (Continued)
C1 CHECK THE VOICE GUIDANCE SETTINGS (Continued)
Select the FEEDBACK tab.
Yes
time.
Select DEFAULT SETTING.
Verify the voice guidance operation. No
Does the voice guidance operate correctly? GO to C2.
C2 CHECK FOR CORRECT AUDIO UNIT OPERATION
correctly.
No
Possible Causes
Pinpoint Test D: DTC B2924 Audio Button
Stuck
Audio unit
Normal Operation
DTC B2924 sets as a continuous DTC when an
audio unit button is detected as active for greater
than 120 seconds, or sets if a button is detected as
active for greater than 3 seconds during the self-test.
PINPOINT TEST D: DTC B2924 AUDIO BUTTON STUCK
D1 CHECK FOR STUCK AUDIO UNIT BUTTONS
Key in ON position.
Enter the self-diagnostic menu and select the HARDKEY TEST
function.
(Continued)
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PINPOINT TEST D: DTC B2924 AUDIO BUTTON STUCK (Continued)
D1 CHECK FOR STUCK AUDIO UNIT BUTTONS (Continued)
NOTE: If any button is pushed, the corresponding button on the
screen appears highlighted.
Observe the buttons on the screen.
Yes
GO to D2.
No
Does the hardkey test indicate a stuck button? time.
D2 CHECK FOR CORRECT AUDIO UNIT OPERATION
correctly.
No
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Passive Anti-Theft System (PATS)
Transceiver
3 1153 Ignition lock cylinder 1 55929 Steering column shroud
screws (3 required)
4 PATS transceiver electrical
connector (part of 14401) 2 3K512 Lower steering column
shroud
5 15607 PATS transceiver
(Continued)
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4. NOTE: Replacement of the PATS transceiver
does not require the PATS keys to be
programmed into the powertrain control module
1. Remove the ignition lock cylinder. For
(PCM) again.
2. Disconnect the PATS transceiver electrical
connector.
3. Release the clips and remove the PATS
transceiver.
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The SJB is connected to the medium speed
Smart Junction Box (SJB)
controller area network (MS-CAN) communication
Special Tool(s)
network. The SJB controls both interior and exterior
lighting, body functions, active anti-theft functions
(perimeter alarm), RKE functions, and the TPMS.
105-R0057
The SJB receives wireless signals from both the
RKE transmitters and the TPMS sensors via an
external coaxial antenna.
Some SJB parameters are programmable and the
programmable parameter that is available is vehicle
configuration. Refer to Section 418-01 for Vehicle Communication Module
information concerning the programmable
parameters in the SJB.
tool
Flex Probe Kit
Electrical
Bussed electrical center (BEC) fuse(s):
44 (10A)
59 (30A)
62 (20A)
63 (30A)
67 (30A) The SJB is a combination of a multifunction control
68 (20A)
module and an interior power junction box. SJB
Circuitry
functions control multiple vehicle systems which
include:
Battery saver
Convertible top (if equipped)
Convertible top drop window function (if
equipped)
software release.
Exterior lighting
Interior lighting
Heated rear window
Perimeter anti-theft (if equipped)
Power locks
VCM.
Remote keyless entry (RKE)
Tire pressure monitoring system (TPMS)
VCM:
Interfaces with the instrument cluster TPMS
warning lamp
with the scan tool.
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6. If the scan tool does not communicate with the 9. NOTE: In order to properly run the self-test,
vehicle: the convertible top (if equipped) must be in the
full down position and the doors must be
closed. If these conditions are not met, DTCs
position.
B1141, B1142, B1319 and/or B1327 may be
set. In this case, they would be product
good vehicle.
characteristic and diagnostics should not be
followed for these DTCs at this time. Clear the
DTCs. Repeat the self-test with the convertible
(PCM).
top (if equipped) in the full down position and
both doors closed.
If the DTCs retrieved are related to the concern,
go to the Diagnostic Trouble Code Chart in this
section.
Symptom Chart
Symptom Chart
SJB
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Smart Junction Box (SJB)
4 Coaxial antenna 1 Front SJB electrical
connectors (2 required) (part
5 14A067 SJB
of 14401)
2 W702751 SJB nut
3 Rear SJB electrical
of 14A005)
(Continued)
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Removal
7. NOTE: To remove the coaxial antenna from
the SJB, lift the red lock tab outward and press
the black lever to release the connector.
sensitive to static electrical charges. If exposed to Disconnect the 6 rear SJB electrical connectors,
these charges, damage may result. the coaxial antenna and remove the SJB.
Installation NOTE: Prior to the removal of the module, it is
necessary to upload the module configuration
information to a scan tool. This information must be
1. CAUTION: Make sure the wiring
downloaded into the new SJB after installation. For
harnesses are correctly routed. Pinching the
additional information, refer to Section 418-01, to
wiring harnesses between the SJB and the
carry out programmable module installation (PMI).
mounting surface may cause damage to the
wiring harness.
1. NOTE: The tire pressure monitoring system
NOTE: Do not remove the watershield from
(TPMS) functionality is integral to the SJB.
the new SJB.
NOTE: A new SJB is delivered in a
Connect the 6 rear SJB electrical connectors,
manufacturing mode with 6 pre-set DTCs.
the coaxial antenna and install the SJB.
These DTCs require that successful
configuration of the SJB occurs, then successful
2. Install the SJB nut.
TPMS sensor training occurs, then a successful
self-test occurs, including clearing of DTCs.
These are required in order to clear the 6
3. Connect the 2 front SJB electrical connectors.
manufacturing mode DTCs. They are as
follows:
4. Install the RH A-pillar lower trim panel. For
B2477 (Module Configuration Failure)
B2868 (Left Front Tire Pressure Sensor Fault)
5. Connect the battery. For additional information,
B2869 (Right Front Tire Pressure Sensor
Fault)
B2870 (Right Rear Tire Pressure Sensor 6. NOTE: When successful, this step provides the
Fault) calibration necessary for the SJB operation and
clears the DTC B2477. The clearing of this
B2871 (Left Rear Tire Pressure Sensor Fault)
DTC indicates the calibration data has been
C2780 (ECU in Manufacturer Sub-state)
successfully downloaded to the new SJB.
Upload the module configuration information
Download the SJB configuration information
from the SJB into the scan tool. For additional
from the scan tool to the new SJB. For
information, refer to Section 418-01, to carry
additional information, refer to Section 418-01,
out PMI.
to carry out PMI.
7. NOTE: When successful, this step clears DTCs
B2868, B2869, B2870, and B2871. The clearing
of these DTCs indicates the SJB has recognized
3. Remove the RH A-pillar lower trim panel. For
the tire pressure sensors during the tire pressure
sensor training procedure.
Train the tire pressure sensors. For additional
4. Disconnect the 2 front SJB electrical
connectors.
5. Remove the SJB nut.
6. Slide the SJB downward and position the SJB
forward to access the rear electrical connectors.
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8. NOTE: DTC C2780 will not clear if any of the
5 manufacturing mode DTCs are present in the
SJB.
NOTE: This step is required to clear DTC
C2780, allow the SJB to exit the manufacturing
mode, and to be sure there are no other
concerns with the newly programmed SJB.
Carry out the SJB on-demand self-test. Clear
the DTCs and then retrieve the DTCs to
confirm all DTCs have been cleared.
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GENERAL PROCEDURES
4. Once in security access, if the unlimited
Spare Key Programming Unlimited
transponder security key PID is 00000000 or
Key Mode
00000001, select: program unlimited key
code and press the tick mark. Enter the 8-digit
Special Tool(s)
code chosen by the customer in Step 1 of this
Vehicle Communication Module procedure and press the tick mark.
5. Select: unlimited key mode ON and press
the tick mark.
tool
6. Select: Ignition Key Code Erase and press
the tick mark.
Enabling Unlimited Key Mode
7. Disconnect the scan tool and turn the ignition
switch to OFF.
NOTE: Unlimited key mode is intended for use by
those customers who need more than 8 keys for
8. Insert the first PATS key into the ignition lock
their vehicle.
3 seconds.
NOTE: Before programming, the new key(s) must
have the correct mechanical cut for the ignition lock
cylinder.
lock cylinder.
NOTE: The unlimited key mode is set up by
creating a special, unique unlimited transponder
security key code and programming this key code
3 seconds.
into all of the vehicle keys so they contain the same
key code.
11. If it is desired to program an additional key(s),
refer to Key Programming Using Two
1. The customer must choose an 8-digit number
Programmed Keys in this section for each
(except for 00000000 or 00000001) to be
programmed to all of their vehicles. All
customer vehicles need to use the same number. Disabling Unlimited Key Mode
Valid digits are 0-9 and the letters A-F.
NOTE: By disabling the unlimited key mode, the
2. NOTE: If the PID UNL KEY is not
previous access code no longer operates the vehicle.
available, unlimited key mode is turned on, and
must be turned off before viewing the stored
code. At this time, unlimited keys may be
programmed to the vehicle. To view/change the
stored code, follow the procedure for disabling
the unlimited key mode below.
2. Select: unlimited key mode OFF and press
Monitor the PID UNL KEY and compare its
the tick mark.
value against the code chosen in Step 1. It
should not be the same key code.
3. Select: Ignition Key Code Erase and press
the tick mark.
4. Disconnect the scan tool and turn the ignition
switch to OFF.
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5. Insert the first PATS key into the ignition lock 8. NOTE: With the unlimited key mode turned
cylinder and turn the key to the ON position for off, a maximum of 8 keys can be programmed
3 seconds. into the PCM. For additional information, refer
to Key Programming Using Two Programmed
Keys in this section. The PID SPAREKEY
lock cylinder.
must be enabled.
If it is desired to program an additional key(s),
refer to Key Programming Using Two
Programmed Keys in this section for each
3 seconds.
The PID SPAREKEY must be enabled.
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GENERAL PROCEDURES
NOTE: If 8 keys are already programmed, this
Spare Key Programming Using
procedure does not allow any more ignition keys to
Diagnostic Equipment
be programmed. The number of keys that are
programmed into the PATS can be determined by
Special Tool(s)
viewing the N KEYCODE PID.
1. Turn the key from the OFF position to the ON
position.
tool
NOTE: This procedure is used when a customer
needs to have an additional key programmed into
3. NOTE: Make sure the selection made is
the vehicle without erasing stored key codes, but
PROGRAM. If ERASE selection is
does not have 2 programmed keys available. This
made, all of the keys will be erased from the
procedure is also useful when attempting to
system.
determine if an ignition key is defective, as a new
From the scan tool menu select: Program
key can be installed without erasing keys or without
additional ignition key.
having 2 programmed keys available.
4. Turn the key to the OFF position and
NOTE: Before programming, the new key must
disconnect the scan tool.
have the correct mechanical cut for the ignition lock
cylinder.
5. Start the vehicle with the new PATS key. The
vehicle will now start with the new PATS key
and also with the original PATS keys.
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SPECIFICATIONS
Smart junction box (SJB) nut 6 53
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501-35-1 501-35-1 Body Repairs
Seam Sealer Heavy-bodied, non-sag
Adhesives
adhesive/sealer for use on: standing cosmetic
Material
seams, truck bed seams, tooled door skin seams
and floor pans.
Item Specification
Trim and Weatherstrip Adhesive For use on
body side moulding, emblems, trim, bumper TA-32
impact strips and carpeting.
Trim and Weatherstrip
Adhesive TA-14
Clear Silicone Rubber Used for sealing water
leaks, noise concerns, remounting trim and Plastic Bonding Adhesive
TA-9 repairing torn weatherstripping.
Metal Bonding Adhesive
Structural Adhesive
TA-1
Metal Patch Panel CAUTION: Observe the prescribed
Adhesive TA-3
welding procedures when carrying out sheet
metal repairs. For additional information, refer Motorcraft Metal Surface WSE-M5B392-A
Cleaner ZC-21 to Weld-Bonding in this section.
NOTE: Corrosion protection needs to be restored
Prep ZC-31
whenever it is necessary to sand or grind through
Seam Sealer TA-2 painted surfaces or E-coat, or when bare metal
repairs are made.
NOTE: Factory spot welds may be substituted with
Adhesives are used in a variety of applications.
either resistance spot welds or MIG plug welds.
Typical uses for adhesives include roof panels, door
Spot/plug welds should equal factory welds in both
skins and quarter panels. Trim applications include
location and quantity. Do not place a new spot weld
body side mouldings, emblems, stationary glass and
directly over an original weld location. Plug weld
weatherstripping. Combination sealer/adhesives are
hole should equal 8 mm (0.31 in) diameter.
also used. Surface preparation is critical to a high
quality repair. Following the label instructions for
NOTE: Remove the outer body sheet metal from
the product is essential.
the affected area prior to carrying out any
reinforcing panel replacement. Refer to Sectioning
Work in a well-ventilated area and protect adjacent
Guidelines in this section.
surfaces when working with adhesives. The use of
eye protection and protective clothing is also
NOTE: The following illustrations identify
recommended when working with adhesives. Carry
structural adhesive locations.
out a trial fit, mark and align the surfaces before
bonding the materials together.
Seam sealers and corrosion protection may be
necessary once the adhesive(s) has cured, depending
on the application. The following is a list of
adhesives recommended for certain types of
applications:
Metal Bonding Adhesive For bonding
cold-rolled steel, galvanized steel, aluminum and
correctly prepared E-coat. It is used for door skin
and roof panel replacement and OEM structural
adhesive replacement.
Plastic Bonding Adhesive For bonding a
variety of plastics to plastics and plastics to
primed, painted or E-coated metals. Also for
general purpose bonding of trim components.
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501-35-2 501-35-2 Body Repairs
Frame Rails
A-Pillar Reinforcement
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501-35-3 501-35-3 Body Repairs
A-Pillar
NOTE: Right side shown, left side similar.
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501-35-4 501-35-4 Body Repairs
Upper A-Pillar Reinforcement
A-Pillar/Inner Fender Reinforcement
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501-35-5 501-35-5 Body Repairs
Floor Side Member
Rocker Reinforcement Coupe
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501-35-6 501-35-6 Body Repairs
Rocker Reinforcement Convertible
NOTE: Right side shown, viewed from inner edge.
Rear Underbody Wheelhouse
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501-35-7 501-35-7 Body Repairs
Rear Underbody Rear Flange
Rear Floor Pan Reinforcements
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501-35-8 501-35-8 Body Repairs
Windshield Header Convertible
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501-35-9 501-35-9 Body Repairs
Windshield Header/Rear Window Frame Coupe
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501-20B-1 501-20B-1 Supplemental Restraint System
Restraint System Diagnostic Tool
Air Bag and Safety Belt Pretensioner
Warning
Supplemental Restraint System (SRS)
WARNING: Restraint system diagnostic
Special Tool(s)
tools are for service only. Tools must be removed
prior to operating the vehicle over the road. FLUKE 73III Automotive Meter
105-R0057 or equivalent Failure to remove restraint system diagnostic
tools could result in injury and possible violation
of vehicle safety standards.
Air Bag Module 2nd Stage Deployment
Check
Because the driver and passenger front air bags each
have 2 deployment stages, it is possible that Stage 1 (VCM) and Integrated
Diagnostic System (IDS) has deployed and Stage 2 has not.
If a front air bag module has deployed, it is
mandatory that the front air bag module be
tool
remotely deployed using the appropriate air bag
disposal procedure.
Diagnostic Tool, Restraint
For additional information on driver air bag
System (2 Required)
module and/or passenger air bag module remote
418-133
deployment, refer to Pyrotechnic Device Disposal
in this section.
Diagnosing Customer Concerns With
Continuous Memory Diagnostic Trouble
Diagnostic Tool, Restraint Codes (DTCs)
System (3 Required)
If an air bag indicator lamp ON is reported by the
418-F395
customer but is not present when the vehicle comes
in for service, follow the Diagnostic Instruction
procedures in this section to identify the intermittent
DTC.
Once the DTC is known, read the Normal Operation
section of the pinpoint test for the DTC involved.
System (1 Required)
418-F403
Follow the deactivation or depowering procedure
as directed in this section.
Determine the location of components involved in
creating the DTC.
Carry out a thorough visual inspection of:
components.
connectors.
splices and wiring harnesses.
insulation on conductors.
Refer to the Possible Causes section of the pinpoint
test for the DTC involved, which lists the common
concerns that relate to the DTC. Concerns are listed
according to priority.
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Diagnosing Customer Concerns with Air Bag/Pretensioner Restraint System
Diagnostic Tools On-Demand Diagnostic Trouble Codes
(DTCs)
Air bag/pretensioner restraint system diagnostic
Most supplemental restraint system (SRS) diagnostic tools are used to simulate the equivalent resistance
procedures will require deactivation and reactivation of an air bag module or safety belt pretensioner
or depowering and repowering of the system. during certain diagnostic procedures.
Deactivation and reactivation requires the
Disconnect the Component
disconnection of most SRS components and the
installation of restraint system diagnostic tools. Disconnect the component means to disconnect the
Depowering and repowering requires disconnecting component vehicle harness connector, not to remove
of the battery and removal of the restraints control the component. Do not reconnect a disconnected
module (RCM) fuse. This reduces the risk of component unless instructed to do so.
inadvertent deployment of SRS components while
Deactivate the System
diagnostic procedures are being carried out.
Deactivate the system means to carry out a
Restraint system diagnostic tools are required for
deactivation procedure. Refer to Supplemental
the diagnosis and testing of the SRS. It is not
Restraint System (SRS) Deactivation and
acceptable to short-circuit the air bag module
Reactivation in this section.
connections with a jumper wire. If a jumper wire is
used to short-circuit the air bag module
Depower the System
connections, a fault code (DTC) will be displayed.
Depower the system means to disconnect the battery
Prove Out Procedure and remove the RCM fuse. Refer to Supplemental
Restraint System (SRS) Depowering and
Turn the ignition switch from the OFF to the ON
Repowering in this section.
position and visually monitor the air bag indicator
with all SRS components connected or restraint
Prove Out the System
system diagnostic tools installed. The air bag
Prove out the system means to turn the ignition
indicator will light continuously for approximately
switch from the OFF to the ON position, and to
6 seconds and then turn off. If an SRS fault is
visually monitor the air bag indicator with the air
present, the air bag indicator will:
bag modules and safety belt pretensioners or
fail to light.
restraint system diagnostic tools installed. Refer to
Prove Out Procedure in this section.
remain lit continuously.
flash.
Reactivate the System
The flashing might not occur until approximately 30
Reactivate the system means to carry out the
seconds after the ignition switch has been turned
reactivation procedure. Refer to Supplemental
from the OFF to the ON position. This is the time
Restraint System (SRS) Deactivation and
required for the RCM to complete the testing of the
Reactivation in this section.
SRS. If the air bag indicator is inoperative and an
Repower the System
SRS fault exists, a chime will sound in a pattern of
5 sets of 5 beeps. If this occurs, the air bag
Repower the system means to remove any restraint
indicator will need to be repaired before diagnosis
system diagnostic tools that may have been
can continue.
installed, turn the ignition ON, install the RCM fuse
and connect the battery ground cable. Refer to
Glossary
Supplemental Restraint System (SRS) Depowering
and Repowering in this section.
Secondary Air Bag Warning
The secondary air bag warning is an audible fault
Reconnect the System
format that consists of 5 sets of 5 tone bursts, with
Reconnect the system means to reconnect all system
each set of 5 tone bursts separated by a 5-second
components. Refer to Air Bag System Reconnect
quiet period. One tone burst cycle will consist of
Checklist in this section.
1-second ON and 1-second OFF. This series of 5
activations is repeated every 30 minutes.
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Install a New Component
Occupant classification sensor (OCS) system
connected?
Install a new component means to remove the
existing component and install a new authorized
All air bag modules connected?
part obtained from Ford Customer Service Division.
Safety belt pretensioner connectors connected?
Verify the System Restraints control module (RCM) connected?
Verify the system means to prove out the system All sensors (front and side impact, seat position
with restraint system diagnostic tools installed in and safety belt tension) connected?
place of the SRS components.
All bridge resistors connected?
RCM fuse installed? Air Bag Reconnect Checklist
Battery connected?
The checklist below should be completed following
diagnosis or repair of any air bag system concern:
Clockspring connectors connected?
All in-seat harness connectors connected?
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Air Bag and Safety Belt Pretensioner
The air bag supplemental restraint system (SRS) is
designed to provide increased collision protection
for front seat occupants, in addition to that provided
by the 3-point safety belt system. The SRS will also
provide increased collision protection for the rear
occupants when equipped with optional safety
canopy modules. Safety belt use is necessary to
obtain the best occupant protection and to receive
the full advantage of the SRS.
This vehicle line contains dual-stage deployment
(advanced restraint system) driver and front
passenger air bag modules.
This vehicle line can also be equipped with seat
side air bag modules. Seat side air bag modules
deploy from the outboard front seat backrest upon a
side impact.
Before servicing the SRS, the system must be
depowered. Refer to Supplemental Restraint System
(SRS) Depowering and Repowering.
The air bag and safety belt pretensioner SRS
components are shown in the following illustration.
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Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (Illustration 1 of 2)
5 042B13 Driver air bag module 1 044A74 Passenger air bag module
6 611D11 Driver seat side air bag 2 Belt tension sensor (BTS)
module (if equipped) (part of 611B08)
7 611B09 Driver safety belt retractor 3 611D10 Passenger seat side air bag
and pretensioner module (if equipped)
8 14A664 Clockspring 4 611B08 Passenger safety belt retractor
and pretensioner
(Continued)
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Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components (Illustration 2 of 2)
6 61202 Passenger safety belt buckle 1 14B321 Restraints control module
(includes safety belt switch) (RCM)
7 61203 Driver safety belt buckle 2 14B022 Passenger seat side air bag
(includes safety belt switch) bridge resistor (if equipped)
8 14B345 Driver side impact sensor (if 3 14B345 Passenger side impact sensor
equipped) (if equipped)
9 14B022 Driver seat side air bag 4 Passenger air bag deactivation
bridge resistor (if equipped) (PAD) indicator
10 14B416 Seat position sensor 5 603B02 Occupant classification sensor
(OCS)
11 14B006 Front impact severity sensor
(Continued)
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Bridge Resistors
The driver seat side air bag module:
NOTE: Do not deactivate the seat side air bag
will deploy upon receiving a flow of current from
module circuit by removing the bridge resistor from
the RCM, initiated by the driver seat side impact
the electrical connector.
sensor and internal RCM circuitry.
If the seat side air bag bridge resistor is removed,
an open circuit fault will be generated by the RCM.
is mounted in the driver seat back.
If a restraint system diagnostic tool is installed at
the seat side air bag electrical connector, a Passenger Air Bag Module
low-resistance fault will be generated.
NOTE: References to the passenger air bag module
The seat side air bag bridge resistor: must not be confused with the side (seat-mounted)
air bag components of the SRS.
is equipped on vehicles without seat side air bag
The passenger air bag module:
modules.
must not be removed in the deactivation is a dual-stage air bag, deploying at 1 of 2
procedure. different rates depending upon impact severity and
safety belt usage.
is mounted under the driver and passenger seat to
the seat pan. will deploy upon receiving a flow of current from
the RCM.
Clockspring
The clockspring:
is mounted in the right side of the instrument
is mounted on the steering column, behind the
panel.
steering wheel.
Passenger Seat Side Air Bag Module
allows continuous electrical contact between the
NOTE: References to side air bag modules refer to
RCM and the driver air bag module when the
the seat-mounted and not to the steering wheel or
steering wheel is turned.
instrument panel-mounted air bag components of the
Driver Air Bag Module
SRS.
NOTE: References to the driver air bag module
NOTE: For additional information, when servicing
must not be confused with the side (seat-mounted)
a seat equipped with a side air bag module, refer to
air bag components of the SRS.
Section 501-10.
The driver air bag module:
The passenger seat side air bag module:
is steering wheel mounted.
the RCM, initiated by the passenger seat side
is a dual-stage air bag, deploying at 1 of 2
impact sensor and internal RCM circuitry.
different rates depending upon impact severity,
safety belt usage and driver seat position.
is mounted in the passenger seat back.
the RCM.
Safety Belt Buckle Switch
has no subassemblies.
As part of the SRS, the driver and passenger safety
Driver Seat Side Air Bag Module
belt buckles are equipped with a Hall-effect switch.
The safety belt buckle switches indicate to the RCM
NOTE: References to side air bag modules refer to
whether the safety belt buckles are buckled or
the seat-mounted and not to the steering wheel or
unbuckled.
instrument panel-mounted air bag components of the
SRS.
The RCM uses this information in determining the
deployment rate of the dual-stage driver and
NOTE: For additional information, when servicing
passenger air bag modules.
a seat equipped with a seat side air bag module,
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The safety belt buckle switches are also used for the When an OCS system fault is present, the air bag
driver safety belt warning system and the driver and indicator lamp will illuminate or the air bag warning
passenger Belt Minder. Refer to Section 501-20A. chime will be activated (if an air bag indicator fault
is present). The SRS then defaults the passenger air
Safety Belt Pretensioners
bag module to ON (activated) regardless of the size
As part of the SRS the safety belt retractors are of the occupant in the front outboard passenger seat.
equipped with pretensioners. The pretensioners
The OCS system components (seat cushion foam
remove excess slack from the safety belt webbing.
pad, bladder with pressure sensor and electronic
The pretensioners are activated by the RCM when
control unit) are calibrated to each other and are
the module detects an impact event force exceeding
serviced as an assembly. OCS system components
a programmed limit. Refer to Section 501-20A.
are not to be installed separately. If installing a
new OCS system, OCS system component or seat
Occupant Classification Sensor
cushion foam pad, a new OCS system service kit
CAUTION: It is necessary carry out the
(seat cushion foam pad, bladder with pressure
OCS system reset when a front passenger seat
sensor, electronic control unit and seat wiring
cushion is disassembled, a new trim cover
harness) must be installed as an assembly.
installed or an OCS service kit is installed. A
The OCS system also interprets a variable voltage
scan tool is used to trigger the active command
signal provided by the safety belt tension sensor to
to carry out the OCS system reset.
identify the presence of a properly fastened child
NOTE: To identify between a production OCS
safety seat in the front outboard passenger seat. The
system and a service OCS system (OCS service
OCS system then communicates with the RCM,
kit), inspect the electronic control unit (ECU)
automatically deactivating the passenger air bag
electrical connector. A production OCS system
module. Refer to Safety Belt Tension Sensor in this
allows the disconnection of the ECU electrical
section.
connector. A service OCS system (OCS service kit)
Passenger Air Bag Deactivation (PAD)
has the ECU electrical connector glued to the ECU,
Indicator
it cannot and should not be disconnected or altered.
CAUTION: The passenger air bag
The seat occupant classification sensor (OCS)
deactivation (PAD) indicator is part of the
system is found only on the front passenger seat.
hazard/traction control switch assembly and
The front passenger seat OCS system is comprised
cannot be separately serviced.
of a silicone gel-filled bladder mounted in the seat
cushion, a pressure sensor that is mounted to the
The passenger air bag deactivation (PAD) indicator
seat frame and an ECU which is also mounted to
is a visual indicator used to inform the front seat
the seat frame. Pressure is applied to the OCS
occupants of the passenger air bag deactivation
system bladder when the weight of any occupant or
state. The PAD indicator is located in a position
object in the front passenger seat is sensed. The
visible to each front seat occupant.
pressure is then transferred through a tube, is
The RCM controls the state of the PAD indicator
sensed by the OCS system pressure sensor, then
through a direct hardwire connection, based on
electronically communicated to the OCS system
information provided by the OCS system. The PAD
ECU. Based on preprogrammed set points, the OCS
indicator is lit to indicate the passenger air bag
system ECU will inform the RCM, via a high-speed
module is deactivated (OFF). An exception to this
controller area network (HS-CAN), of the necessary
is when the front passenger seat is determined to be
information. The RCM uses this information in
empty, and therefore indication of a deactivated
determining if the passenger air bag module is to be
passenger air bag module is not necessary. In all
deployed in the event of a deployable collision. The
other cases the PAD indicator is unlit when the
RCM may also use this information to
passenger air bag module is enabled.
illuminate/not illuminate the passenger air bag
deactivation (PAD) indicator. For additional
information regarding PAD indicator operation, refer
to Passenger Air Bag Deactivation (PAD) Indicator
in this section.
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When the ignition switch is in the RUN position, The safety belt tension sensor is used by the OCS
the PAD indicator prove-out period is initiated by system to identify the presence of a child safety seat
the RCM. The RCM briefly activates the PAD on the front outboard passenger seat. The safety belt
indicator to prove-out the indicator function and tension sensor senses the tension on the safety belt
verify to the front occupants correct functional assembly then provides an output to the OCS
operation of the PAD indicator. system ECU, indicating that the safety belt assembly
is cinched. After sensing the weight applied to the
The PAD indicator will illuminate/not illuminate
seat by the occupant and using the safety belt
within 1.0 0.5 seconds of a change of state from
tension sensor input, the OCS system determines
the OCS system.
how the occupant should be classified and
When an OCS system fault is present the SRS
communicates this information to the RCM. If the
defaults the passenger air bag module to enabled
occupant is classified to be a child, the RCM will
regardless of the size of the occupant in the front
then automatically deactivate the passenger air bag
outboard passenger seat. The PAD indicator will be
module.
unlit.
Seat Track Position Sensor
The following table indicate the passenger air bag
status and the PAD indicator status based the size of
The seat track position sensor is a Hall-effect sensor
the front outboard passenger occupant.
located on the driver seat track. The seat track
position sensor informs the RCM of the driver seat
Passenger Air Bag and PAD Indicator Status
position. The RCM uses this information in
determining the deployment rate of the dual-stage Passenger
Safety driver air bag module.
Belt Passenger PAD
Occupant Buckle Air Bag Indicator Restraints Control Module (RCM)
Size Status Status Status
WARNING: The RCM orientation is
None Unbuckled Disabled Unlit
critical for correct system operation. If a vehicle
None Buckled Disabled Lit
equipped with an air bag supplemental restraint
Small Buckled/ Disabled Lit system (SRS) has been involved in a collision in
Unbuckled
which the center tunnel area has been damaged,
Large Buckled/ Enabled Unlit inspect the mounting and bracket for
Unbuckled
deformation. If damaged, a new RCM must be
installed whether or not the air bags have
deployed. In addition, make sure the area of the
Safety Belt Tension Sensor
RCM mounting is restored to its original
The safety belt tension sensor: condition.
NOTE: When installing a new restraints control
is part of the front outboard passenger safety belt
module (RCM), always make sure the correct RCM
and retractor assembly.
is being installed. If an incorrect RCM is installed,
is located at the safety belt anchor point.
erroneous DTCs will result.
is used in conjunction with the OCS system.
The RCM is mounted on the center tunnel under the
is a 3-wire Hall-effect sensor that is part of the
instrument panel. The RCM:
front passenger safety belt and retractor assembly.
deploys the air bags in the event of a deployable
impact.
activates the safety belt retractor pretensioners to
remove slack from the safety belt webbing.
monitors the SRS for faults.
illuminates the air bag warning indicator if a fault
is detected.
illuminates the PAD indicator when conditions
warrant illumination.
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flashes the air bag warning indicator to indicate LFCs are prioritized. If 2 or more faults occur at the
the lamp fault code (LFC) detected. same time, the fault having the highest priority will
be displayed first. After that fault has been
communicates through the data link connector
corrected, the next highest priority fault will be
(DLC) the current or historical DTCs.
displayed.
signals the instrument cluster module to activate a
The RCM includes a backup power supply. This
chime if the air bag warning indicator is not
feature provides sufficient power to deploy the front
available and another SRS fault exists.
air bags, seat side air bags (if equipped) and the
records deployable and non-deployable impact
safety belt pretensioners in the event that the
data.
ignition circuit is damaged in a collision before the
The RCM monitors the SRS for possible faults. If a
air bags are deployed. The backup power supply
fault is detected while the ignition switch is in the
will deplete its stored energy reserve in
RUN position, the RCM will illuminate the
approximately 1 minute after the battery ground
restraints indicator lamp located in the instrument
cable is disconnected.
cluster.
Electrical System
When the ignition is cycled (turned off and then
The electrical system that supports the air bag SRS:
on), the air bag warning indicator will remain lit for
6 seconds and then go out. If an SRS fault exists,
is powered from the battery through the ignition
the air bag warning indicator will then flash the
circuit.
2-digit LFC associated with that fault. The air bag
provides the electrical path from the RCM to the
warning indicator will flash the LFC 5 times, then
SRS components.
remain illuminated for the rest of the key cycle. The
RCM will communicate current and history DTCs
air bag warning indicator.
through the DLC using a scan tool. If the air bag
warning indicator does not function, and the RCM
detects a fault condition, the RCM will signal the
DLC.
instrument cluster module to activate an audible
chime. The chime is a series of 5 sets of 5 tone
instrument cluster module.
bursts. If the chime is heard, the SRS and the air
bag warning indicator require repair.
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Impact Sensors
The impact sensors provide data to the RCM for use
in calculating impact severity. This is accomplished
WARNING: Mounting orientation of the
using various electrical sensors located throughout
impact sensors and the RCM is critical for
the vehicle. A front impact severity sensor is
correct system operation. If a vehicle has been
located in the front-center of the vehicle, behind
involved in a collision in which the center tunnel
the grille. In addition, on vehicles equipped with
area has been damaged, inspect the RCM
seat side air bags, there are side impact sensors
mounting area for deformation. Inspect the
located near the base of each B-pillar.
impact sensor mounting area for damage. If
damaged, a new RCM and sensors must be
installed whether or not the air bags have
deployed. In addition, make sure the mounting
area of the RCM and impact sensors are
restored to the original production
configuration.
WARNING: Vehicle sensor orientation is
critical for correct system operation. If a vehicle
system (SRS) is involved in a collision, inspect
the sensor mounting bracket and wiring pigtail
for deformation. Install and correctly position a
new sensor or any other damaged supplemental
restraint system (SRS) components whether or
not the air bag is deployed.
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501-05-1 501-05-1 Interior Trim and Ornamentation
A-Pillar Trim Panel
4 519A58 Overhead console 1 N806664 Sun visor screws/sun visor
arm clip screws (6 required)
5 Overhead console electrical
connector (part of 14A464) 2 04132 Sun visor arm clips (2
required)
6 030A64 A-pillar trim panel (2
required) (RH/LH) 3 4104/4105 Sun visors (2 required)
(RH/LH)
7 51916 Header trim panel
(Continued)
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3. If necessary, remove the overhead console.
NOTE: If removing the header trim panel, remove
the 2 A-pillar trim panels.
4. If necessary, remove the 2 screws and the 2 sun
visor arm clips.
1. Remove the 2 sun visor srews and the sun
visor.
5. If necessary, remove the header trim panel.
2. Remove the A-pillar trim panel.
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501-14-1 501-14-1 Handles, Locks, Latches and Entry Systems
GENERAL PROCEDURES
8. Turn the key from OFF to ON.
Autolock and Horn Chirp
Programming
9. Verify that the horn chirps. This indicates the
system is in the enable/disable mode and is
1. Electronically unlock the vehicle using the
ready to accept program changes.
remote keyless entry (RKE) transmitter or the
power lock control switch.
10. Press the door lock control switch UNLOCK
then LOCK button once to toggle the
2. Close all doors.
autolock/relock feature OFF.
3. Confirm the key is in the OFF position.
11. Verify that the horn chirps 1 time. There should
be only 1 chirp indicating that autolock/relock
4. Turn the key from OFF to ON.
feature is disabled. If 1 chirp is heard, followed
by a longer sound of the horn, the
5. NOTE: Steps 4 through 8 must be carried out
autolock/relock feature is enabled. Return to
within 30 seconds.
Step 9.
Press the door lock control switch UNLOCK
button 3 times. 12. Turn the key to the OFF position to exit the
enable/disable mode.
6. Turn the key from ON to OFF.
13. Verify that the horn chirps once to indicate that
7. Press the door lock control switch UNLOCK
a feature has been changed.
button 3 times.
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501-03-1 501-03-1 Body Closures
hood hinges
Body Closures
luggage compartment lid
The body closures consist of the following
components:
luggage compartment lid hinges
luggage compartment lid hydraulic lifts
door check arms
luggage compartment lid latch striker
front doors
front door latch striker plates
front door hinges
hood
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501-00-1 501-00-1 Body System General Information
Silicone Spray Lubricant
Body Sealer Types And Applications
Silicone Spray Lubricant XL-6 meeting Ford
Clear Silicone Rubber TA-32
specification ESR-M13P4-A:
Clear Silicone Rubber TA-32 or equivalent meeting
is used to keep the door and the window
Ford specification ESB-M4G92-A is used for
weatherstrip pliable and soft.
sealing water leaks, noise concerns, remounting
should be applied to the weatherstrip at every
trim, and repairing torn weatherstripping.
lubrication period.
Caulking Cord
makes the door easier to close.
3M Strip Caulk-Black 051135-08578 or equivalent
retards weatherstrip squeaks.
meeting Ford specification WSB-M4G32-C:
retards weatherstrip wear.
is a heavy-bodied, plastic base with a filler.
helps retain door window alignment by reducing
is commonly known as perma-gum.
friction between the glass frame and the rubber
is used on spot-welds holes, around moulding weatherstrip.
clips, and between surfaces not sealed with a
should not be used prior to painting.
gasket.
Weatherstrip Adhesive
Trim and Weatherstrip Adhesive TA-14 is a quick
drying, strong adhesive designed to hold
weatherstripping onto all body panels and
surrounding metal.
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4. Some leaks can be located by placing bright
Body System
light under the vehicle, removing any necessary
Material
trim or carpet, and inspecting the interior of the
body at joints and weld lines.
Item Specification
Noise
Sealant
Wind noise, rattles, and their sources are detected
TA-30
by driving the vehicle at highway speeds. The
vehicle should be driven in 4 different directions
with all of the windows closed, the radio off, the
Leaks
blower motor off, and all of the ventilation ducts
NOTE: Trim reveals the location of most leaks.
open.
1. Remove any trim or carpet in the general area
Most wind noise leaks occur at the door and
of the leak.
window seals or at the sheet metal joints in the door
or the door opening.
2. Road test or water test the vehicle.
3. Inspect for a dust pattern around the area in
question. Inspect for water paths near and
above the area in question.
Symptom Chart
Symptom Chart
Dust and water leaks Body sealer missing REMOVE the trim panel.
Opening in the weldings or CHECK for leaks and SEAL
body joints with the appropriate sealer.
Components not fully ROAD TEST or WATER
installed TEST for leaks. RECHECK
Components missing for leaks; use light under the
Components damaged vehicle with the trim
removed. CHECK the interior
of the body at the joints and
weld lines.
Dust/water leaks at the floor Missing or damaged plugs CHECK the plugs for proper
pan and grommets and/or grommets installation. REPLACE if
necessary.
Door drain holes collecting Holes clogged with mud or CLEAN the drain holes of
water road tar dirt and foreign material.
CHECK the drain holes
regularly. TEST the system
Wind noise, air entering the Leaks at the door and SEAL leaks with Silicone
vehicle through small holes in window seals or sheet metal Gasket and Sealant. ROAD
the body joints in the doors or door TEST.
openings
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Rattles Loose objects in the wells, CHECK the doors by
pillars, and quarter panels carefully STRIKING the
Misalignment (if tightening underside of the door with a
bolts does not eliminate rubber mallet. LISTEN for
rattle) loose objects in the door.
Weatherstripping and/or REPAIR. TIGHTEN the body
anti-squeak material bolts and screws.
ADJUST the alignment of the
doors or panels. REFER to
Section 501-03.
APPLY additional sealer.
INSTALL in the proper
location to eliminate rattle.
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Body
Body and Sheet Metal
The body:
is a unibody open cowl structure.
is constructed of a lightweight, all-steel material
with a removable, bolted hood, front fenders,
doors, and luggage compartment lid.
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501-35-1 501-35-1 Body Repairs
Steel doors
Body
Steel luggage compartment lid
The body consists of the following:
High-strength roll-formed bolt-on front and rear
Unibody construction
bumper beams
Two door coupe
Rear underbody bracing on convertible models
Two door convertible
provides additional structural support
Lightweight steel material
Structural adhesive used in body side, rocker
Steel radiator support assembly reinforcements, A-pillar and underbody
HSLA (high-strength low alloy), high-strength and Vehicles built prior to 01/2007 contain dual-phase
mild steels steel in the rocker panel reinforcement and
underbody cross braces, vehicles built after
Aluminum hood
01/2007 will contain high-strength steel in
Bolted, removable front fenders, hinged doors and
components that were constructed of dual-phase
hood
steel
Front subframe assembly which houses steering
For dimensional information, refer to the following
and suspension components and provides
illustrations:
structural support
Steel fenders
Body Margins
NOTE: Dimensions apply to right and left side.
NOTE: Coupe body style shown, convertible similar.
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501-35-2 501-35-2 Body Repairs
Item Description Specification
1 Grille to fascia 1.0 mm (0.03
in) 1.0 mm
(0.03 in)
2 Fender to fascia 1.0 mm (0.03
in) 1.0 mm
(0.03 in)
3 Hood to fender 4.0 mm (0.15
in) 2.0 mm
(0.07 in)
4 Door to fender 4.0 mm (0.15
in) 2.0 mm
(0.07 in)
Body Margins
Item Description Specification Item Description Specification
5 Door to quarter 4.0 mm (0.15 9 Lamp assembly 4.0 mm (0.15
panel in) 2.0 mm to luggage in) 2.0 mm
(0.07 in) compartment (0.07 in)
6 Luggage 4.0 mm (0.15 10 Luggage 7.0 mm (0.27
compartment lid in) 2.0 mm compartment lid in) 3.0 mm
to quarter panel (0.07 in) to fascia (0.11 in)
7 Lamp assembly 3.0 mm (0.11 11 Luggage 4.0 mm (0.15
to quarter panel in) 2.0 mm compartment lid in) 2.0 mm
(0.07 in) to lamp (0.07 in)
assembly
8 Lamp assembly 4.0 mm (0.15
to fascia in) 2.0 mm
(0.07 in)
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501-35-3 501-35-3 Body Repairs
Underhood Dimensions
NOTE: Measurements are obtained on center, unless otherwise indicated.
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501-35-4 501-35-4 Body Repairs
Bodyside Closure Dimensions
Coupe
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501-35-5 501-35-5 Body Repairs
Convertible
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501-35-6 501-35-6 Body Repairs
Rear Opening Dimensions
NOTE: Dimensions apply to coupe and convertible.
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501-35-7 501-35-7 Body Repairs
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501-35-8 501-35-8 Body Repairs
Underbody Dimensions
Frame Datum Height Convertible
CAUTION: A structural frame rail or unibody service kit may be available for this vehicle. If a
kit is available, refer to the included instruction sheet for installation guidelines. If no instruction sheet
is included with the service part, it is mandatory that the replacement section be installed as delivered
at the original factory seam locations.
NOTE: Datum height determined measuring from holes and slots on center, unless otherwise indicated.
NOTE: Inset views indicated from left side of vehicle.
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501-35-9 501-35-9 Body Repairs
Frame Datum Height Coupe
NOTE: Datum height determined measuring from holes and slots on center, unless otherwise indicated.
NOTE: Inset views indicated from left side of vehicle.
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501-35-10 501-35-10 Body Repairs
Underbody Dimensions
NOTE: Coupe shown, convertible similar.
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501-19-1 501-19-1 Bumpers
6. Position the front splash shield aside and
Bumper Cover Front
remove the 4 front bumper cover-to-
reinforcement nuts.
Base vehicle and GT
Shelby GT 500
All vehicles
3. Remove the 2 upper front bumper cover bolts.
7. If equipped, disconnect the 2 fog lamp
4. Remove the 6 front fender splash shield-to-front
bumper cover screws.
8. Disconnect the 4 side marker lamp electrical
5. If equipped, remove the 4 lower air deflector
connectors and remove the front bumper cover.
screws.
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501-19-1 501-19-1 Bumpers
5. Disconnect the electrical connector from inside
Bumper Cover Rear
the luggage compartment and remove the rear
bumper cover.
Feed the rear bumper electrical harness
through the rear of the vehicle.
luggage compartment trim panel.
2. Remove the 4 rear bumper cover-to-bumper
Transfer components as needed.
cover bracket screws.
3. NOTE: GT vehicles are equipped with 3
pin-type retainers.
If equipped, remove the 3 rear bumper cover
pin-type retainers.
4. From inside the luggage compartment, remove
the 4 rear bumper cover nuts.
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501-19-1 501-19-1 Bumpers
Bumper Exploded View, Front
Base Vehicle and GT
4 W706805 Front fender splash 1 W705436 Upper radiator sight shield
shield-to-front bumper cover pin-type retainer (6 required)
screws (6 required)
2 8C291 Upper radiator sight shield
5 W711059 Front bumper
3 W712277 Front bumper cover bolt
cover-to-reinforcement nut (4
(upper) (2 required)
required)
(Continued)
(Continued)
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501-19-2 501-19-2 Bumpers
6 Side marker light electrical 11 17C882B Front bumper upper center
connector (part of 14A464) inner isolator
7 N801169 Lower air deflector screw (4 12 W711097 Front bumper bolt (8
required) required)
8 17D957 Front bumper cover 13 17757 Front bumper
9 310D12 Front bumper isolator 14 17B814 Lower radiator grille
pin-type retainer (4 required)
10 17C882A Front bumper lower outer
isolator
(Continued)
Shelby GT 500
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501-19-3 501-19-3 Bumpers
9 17D957 Front bumper cover 1 W705436 Upper radiator sight shield
pin-type retainer (8 required)
10 310D12 Front bumper isolator
pin-type retainer (4 required) 2 8C291 Upper radiator sight shield
11 17C882A Front bumper lower outer 3 W712277 Front bumper cover bolt
isolator (upper) (2 required)
12 W711097 Front bumper bolt (outboard) 4 W706805 Front fender splash
(4 required) shield-to-front bumper cover
screws (6 required)
13 W711457 Front bumper bolt (inboard)
(3 required) 5 W711059 Front bumper
cover-to-reinforcement nuts (4
14 17757 Front bumper
required)
15 17B814 Lower radiator grille
6 Side marker light electrical
connector
7 Fog lamp electrical connector
8 N801169 Lower air deflector screw (4
required)
(Continued)
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501-19-1 501-19-1 Bumpers
Bumper Exploded View, Rear
NOTE: Base vehicle and GT shown, Shelby GT 500 similar.
3 W712919 Rear bumper cover-to-bumper 1 58403D24 Luggage compartment trim
cover bracket screws (4 panel pin-type retainer (4
required) required)
4 13A457 Rear bumper cover pin-type 2 63424A82 Luggage compartment trim
retainer (3 required) (if panel
equipped)
(Continued)
(Continued)
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501-19-2 501-19-2 Bumpers
5 N621927 Rear bumper cover nut (4 10 W711097 Rear bumper bolt (6 required)
required)
11 17906 Rear bumper
6 17K835 Rear bumper cover
12 W611103 Rear bumper cover bracket
7 Rear bumper cover electrical bolt (12 required)
13 17D942 Rear bumper cover bracket
8 310D12 Rear bumper isolator pin-type
retainers (2 required)
9 17C882 Rear bumper isolators
(Continued)
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501-19-1 501-19-1 Bumpers
3. Drill out the 6 front bumper spot welds.
Bumper Front
4. Remove the front bumper bolts and the front
bumper.
Eight required (Base vehicle and GT).
information, refer to Bumper Cover Front in Seven required (Shelby GT 500).
this section.
2. Remove the 4 front bumper isolator pin-type
5. NOTE: Spot welding the bumper is not
retainers and the front bumper lower outer and
required for installation.
upper center inner isolators.
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501-19-1 501-19-1 Bumpers
2. Remove the 2 pin-type retainers and the 2 rear
Bumper Rear
bumper isolators.
3. Remove the 6 rear bumper bolts and the rear
bumper.
1. Remove the rear bumper cover. For additional
information, refer to Bumper Cover Rear in
this section.
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501-19-1 501-19-1 Bumpers
Bumpers
CAUTION: Never apply excessive heat to
the bumper cover surface. Heat could cause
distortion of the bumper cover.
The bumper systems consist of the following
components:
Front bumper
Front bumper cover
Front bumper isolator
Rear bumper
Rear bumper cover
Rear bumper isolator
Rear bumper bracket
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501-20A-1 501-20A-1 Safety Belt System
Child Safety Seat Tether Anchor
LATCH
2. Remove the Lower Anchors and Tethers for
CHildren (LATCH) attachment fasteners.
1 W700833- Lower Anchors and Tethers
S437MXD for CHildren (LATCH) bolt To install, tighten to 40 Nm (30 lb-ft).
(2 required)
2 601B28 LATCH 3. Remove the LATCH attachment.
3 W700833- LATCH bolt (2 required)
When installing, make sure the LATCH is
S437MXD
positioned with the locator pin going
4 601B28 LATCH
through the hole provided in the LATCH
attachment.
When installing the seat cushion, make sure
the safety belt buckles are accessible to the
occupants after installation.
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Clockspring
NOTE: The air bag warning lamp illuminates when
the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate
2 Clockspring screws (4
a supplemental restraint system (SRS) fault.
required) (part of 14A644)
3 14A644 Clockspring
NOTE: The SRS must be fully operational and free
4 Clockspring electrical of faults before releasing the vehicle to the
customer.
5 3K512 Lower steering column
shroud NOTE: Repair is made by installing a new part
only. If the new part does not correct the condition,
shroud screws (2 required) install the original part and carry out the diagnostic
procedure again.
Removal
1. Depower the system. For additional
information, refer to Supplemental Restraint
WARNING: Always wear safety glasses
System (SRS) Depowering and Repowering in
when repairing an air bag supplemental restraint
the General Procedures portion of this section.
system (SRS) vehicle and when handling an air
bag module. This will reduce the risk of injury in
2. Make sure the road wheels are in the
the event of an accidental deployment.
straight-ahead position.
WARNING: To reduce the risk of personal
injury, do not use any memory saver devices.
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3. Tilt the steering wheel in the DOWNWARD 9. NOTE: The tilt steering column mechanism is
position and LOCK the tilt handle. spring loaded, carefully release the tilt handle
while repositioning.
Carefully position the steering column up and
additional information, refer to Driver Air Bag
leave the tilt handle in the unlocked position.
Module in this section.
10. Position the lower steering column shroud
5. Remove the steering wheel. For additional
downward.
11. Disconnect the clockspring electrical connector.
6. Remove the lower steering column shroud 2
screws.
12. Remove the 4 clockspring screws and remove
the clockspring.
7. Remove the upper steering column shroud.
8. NOTE: If the clockspring is to be reinstalled,
do not allow the clockspring to turn from its
removal position.
If reusing the clockspring, tape the clockspring
center rotor to the outer housing to keep it from
rotating.
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Installation
Vehicles needing clockspring recentering
1. WARNING: Incorrect centralization
may result in premature component failure.
If in doubt when centralizing the clockspring,
repeat the centralizing procedure. Failure to
follow this instruction may result in personal
injury.
CAUTION: Make sure the road wheels
are in the straight-ahead position.
If the vehicles clockspring has rotated out of
center, follow these steps to center the
clockspring.
1 Hold the clockspring outer housing
stationary.
2 CAUTION: Overturning will
destroy the clockspring. The internal
ribbon wire acts as the stop and can be
broken from its internal connection.
While turning the rotor counterclockwise,
carefully feel for the ribbon wire to run out
of length and for a slight resistance. Stop
turning at this point.
3 Turn the clockspring clockwise
(approximately 3 turns) until the ribbon
wire shows anywhere across the window
(window will be near the 2 oclock
position) and the arrow on the rotor lines up
with the arrow on the bottom left of the
housing. Clockspring is now centered.
X Do not allow the rotor to turn from this
position.
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All vehicles
2. Install the clockspring and the 4 screws. 4. Position the lower steering column shroud
upward.
5. Carefully position the steering column down
and place the tilt handle in the LOCKED
position.
Vehicle repairs reusing the same
clockspring
6. NOTE: When the tape is removed, do not
allow the clockspring to turn.
Remove the tape applied during clockspring
removal.
3. Connect the clockspring electrical connector.
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Vehicles installing a new clockspring
10. CAUTION: If the vehicle is left
unattended by the technician between
centralizing the clockspring and installing the
7. CAUTION: Do not rotate the new
steering wheel, the centralizing procedure
clockspring between removing the sealing
must be repeated.
key and installing the steering wheel. If the
vehicle is left unattended by the technician
Install the steering wheel. For additional
between removing the sealing key and
installing the steering wheel, carry out the
centralizing procedure. 11. Install the driver air bag module. For additional
information, refer to Driver Air Bag Module in
Remove the sealing key.
this section.
All vehicles
12. Repower the system. For additional information,
refer to Supplemental Restraint System (SRS)
8. Install the upper steering column shroud.
Depowering and Repowering in the General
Procedures portion of this section.
9. Install the 2 lower steering column shroud
screws.
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501-12-1 501-12-1 Instrument Panel and Console
Console Floor
3. Apply the parking brake and remove the floor
console finish panel.
1 F7E391 Shift lever bezel (if equipped)
2 W505004 Floor console finish panel
4. Disconnect the electrical connector to the
screws (2 required)
powerpoint and audio input jack.
3 63044F06 Floor console finish panel
4 04608/04609 Center stack wings (2
5. Remove the 2 center stack wings.
required)
5 W707628 Floor console screws (2 6. Remove the 2 front floor console screws.
required)
6 466K48 Floor console mat 7. Remove the mat, the 2 floor console nuts and
the floor console.
7 W711098 Floor console nuts (2
required)
8 045A06 Floor console
1. If equipped, remove the shift lever bezel.
2. Remove the 2 floor console finish panel screws.
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Console glove compartment door
Console Floor
Beverage holder
The floor console consists of the following
components:
Power point
Console finish panel
Audio input jack
Coin holder
Console glove compartment
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501-18-1 501-18-1 Convertible Top
3. Remove the screw and the convertible top ajar
Convertible Top Ajar Switch
switch.
1. Remove the RH rear quarter trim panel. For
2. Remove the RH rear window inner belt
moulding.
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6. Remove the inner quarter window belt line
Convertible Top Assembly
seals.
Removal
7. Disconnect the convertible top ajar switch
CAUTION: Removal, installation and
handling of the convertible top requires an
8. Momentarily place the convertible top switch in
assistant or damage to the convertible top may
the raise position to release the tension on the
occur.
convertible top frame.
CAUTION: Use care when working around
9. Remove the 2 bolts (1 each side) and the 2
or handling the convertible top material to avoid
hydraulic lift cylinder brackets (1 each side).
scratching or creasing the material.
10. Remove the 2 clevis-to-hydraulic-lift cylinder
CAUTION: Use care when handling the
rod bolts (1 each side).
convertible top material to avoid damaging the
rear glass. If damaged or broken, the rear glass 11. Position the hydraulic lift cylinders aside.
cannot be replaced and will require replacement
12. Remove the 6 bolts (3 each side) attaching the
of the convertible top material.
L-brackets to the quarter panel.
NOTE: Light scratches in the convertible top
material can be removed using isopropyl alcohol
13. Loosen the 2 rear bolts (1 each side) and
and 600-grit sandpaper or steel wool. Use light
remove the 4 front bolts (2 each side) attaching
pressure, polishing in a circular motion. Use care
the pivot bracket to the quarter panel.
not to use excessive pressure. Do not use power
tools, as these permanently damage the convertible 14. Remove the 2 convertible top frame number 5
top material. Heavy scratches require replacement of bow pivot bolts (1 each side).
the convertible top material.
NOTE: Light creases in the convertible top material
convertible top frame number 5 bow more
can be removed by applying water to the creased
than necessary to remove it from the vehicle.
area, and pulling the creased area flat, while
Excessive compression can damage the
applying mild heat from a heat gun. Use care not to
convertible top frame number 5 bow.
apply excessive heat, as this permanently damages
Place a cargo strap or other suitable device
the convertible top material. Heavy creases may
around the convertible top frame number 5
require replacement of the convertible top material.
bow, near the ends, and compress the
convertible top frame number 5 bow
1. Remove the well sling channel and the 4
approximately 80 cm (3.14 inches), while lifting
pin-type retainers from the rear seat backrest.
on the convertible top.
2. Remove the rear seat backrest. For additional
16. With an assistant, remove the convertible top
assembly from the vehicle.
3. Disconnect the heated rear window electrical
If necessary, release the tension of the
connector from the body harness.
4. Lower the convertible top.
5. Remove the 2 rear quarter trim panels. For
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Installation 7. Install the 6 bolts (3 each side) attaching the
1. CAUTION: Use care when cutting the
tie straps or damage to the convertible top
8. Operate the convertible top by hand, to make
material may occur.
sure the top operates freely, without binding.
Cut and remove the number 5 bow and side rail
tie straps.
9. Position the hydraulic lift cylinders.
10. Install the 2 clevis-to-hydraulic lift cylinder rod
convertible top frame number 5 bow more
bolts (1 each side).
than necessary to install it to the vehicle.
Excessive compression can damage the
11. Install the 2 hydraulic lift cylinder brackets (1
With an assistant, position the convertible top
each side) and the 2 bolts (1 each side).
assembly into the vehicle.
If necessary, compress the convertible top
frame number 5 bow approximately 80 cm
12. Connect the convertible top ajar switch
(3.14 inches).
3. Slowly release the convertible top frame
13. Install the 2 rear quarter trim panels. For
number 5 bow, while aligning the guide pins on
the convertible top frame with the holes in the
rear quarter panels.
14. CAUTION: Use care when cutting the
tie straps or damage to the convertible top
4. Install the 2 convertible top frame number 5
material may occur.
bow pivot bolts (1 each side).
Cut and remove the well sling tie strap.
15. Raise the convertible top.
5. Position the water diverters as shown, making
sure the edges overlap completely, and the
16. Recheck the position of the water diverters, and
diverters are not caught between the brackets
adjust as necessary for correct placement.
and the body.
17. Connect the heated rear window electrical
connector to the body harness.
18. Install the rear seat backrest. For additional
19. Position the well sling channel and install the 4
pin-type retainers to the rear seat backrest.
20. Make sure the door glass and quarter glass
correctly seal against the convertible top side
rail. If adjustment is necessary, refer to Section
501-11.
6. Install the bolts for the pivot brackets.
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2. Remove the screws and the appropriate
Convertible Top Bows
convertible top frame bow(s).
3. NOTE: Manually operate the convertible top
frame before installing the headliner, to be sure
1. Remove the convertible top headliner. For
the frame operates smoothly, without binding.
additional information, refer to Convertible Top
Headliner in this section.
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Convertible Top Exploded View
Convertible Top Assembly (View 1 of 3)
5 W711393 Pivot bracket front bolts (4 1 W709053 Hydraulic lift cylinder bracket
required) bolt (2 required)
6 W506413 Convertible top frame number 2 N808519 Clevis-to-hydraulic lift
5 bow pivot bolt (2 required) cylinder rod bolt (2 required)
3 W711423 L-bracket bolts (6 required)
4 W711772 Pivot bracket rear bolt (2
required)
(Continued)
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12 7651542 RH front weatherstrip retainer 7 14018 Convertible top ajar switch
channel
8 Convertible top ajar switch
13 7651560 RH center weatherstrip screw
retainer channel
9 7651555 LH rear weatherstrip retainer
14 7651554 RH rear weatherstrip retainer channel
channel
10 7651561 LH center weatherstrip
15 76514A34 Compression panel retainer channel
16 Header form panel (part of 11 7651543 LH front weatherstrip retainer
7653038) channel
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17 Double-sided tape 21 7651916 Convertible top headliner
18 7652700 Top cover assembly 22 7652806 RH/ Convertible top tension cable
7652807 LH
19 7654212 LH stay pad
20 7654213 RH stay pad
(Continued)
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29 7652188 Convertible top frame number 23 7653105 Convertible top frame LH
5 bow side rail
30 7650508-B LH convertible top latch 24 7653104 Convertible top frame RH
side rail
31 7650508-A RH convertible top latch
25 7653024 Convertible top frame number
32 Convertible top latch screws
1 bow
(4 required)
33 76514A38 Dowel pins (2 required)
2 bow
3 bow
4 bow
(Continued)
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6. Remove the 3 headliner fasteners from the
Convertible Top Headliner
7. Remove the 6 fasteners attaching the headliner
tracks to the convertible top frame number 2
1. Remove the convertible top stay pad. For
and number 3 bows (3 each bow).
additional information, refer to Stay Pad in this
section.
8. Remove the 2 listing strap fasteners (1 each
side) from the convertible top frame between
2. Remove the sail panel clips from the
the convertible top frame number 2 and number
convertible top frame.
3 bows.
3. Remove the 2 sail panel fasteners (1 each side)
9. Remove the 6 headliner fasteners from front
from the convertible top frame number 5 bow.
corners of the convertible top frame.
4. Remove the 2 listing strap rivets (1 each side)
10. Remove the headliner from the convertible top
from the rear rail.
frame.
5. Remove the 2 headliner mounting brackets (1
each side) from the rear rail.
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2. Partially open the convertible top.
Convertible Top Latch
3. Remove the caps and the 2 convertible top latch
screws.
CAUTION: Make sure to hand-start the
screws for the convertible top latches to avoid
4. Remove the convertible top latch.
damaging the convertible top frame.
1. Release the convertible top latches.
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4. Remove the 11 screws and the compression
Convertible Top Material
panel.
Removal
5. Remove the staples which secure the LH and
RH front corners of the convertible top material
CAUTION: Be sure to mark the location of
to the frame.
the weatherstrip retaining channels prior to
removal. If the weatherstrip retaining channels
6. Remove the front retaining track securing the
are not replaced in their original locations, the
front of the convertible top material from the
weatherstrips may not seal properly, resulting in
front of the convertible top frame number 1
water leaks and interior damage. Failure to
bow.
replace the retaining channels correctly may
require replacement of the convertible top
7. Remove the foam tape and the rivets attaching
assembly.
the front corners of the convertible top material
to the convertible top frame.
CAUTION: Use care when working around
or handling the convertible top material to avoid
8. Pull the top material from the header form
scratching or creasing the material.
panel.
CAUTION: Use care when handling the 9. Remove the 6 screws and the header form
convertible top material to avoid damaging the panel.
rear glass. If damaged or broken, the rear glass
10. Using chalk, mark the positioning of the old top
cannot be replaced, and will require replacement
cover at the top of the convertible top frame
of the convertible top material.
number 5 bow.
NOTE: Light scratches in the convertible top
material can be removed using isopropyl alcohol
11. Remove the staples attaching the convertible
and 600-grit sandpaper or steel wool. Use light
top material to the convertible top frame
pressure, polishing in a circular motion. Use care
number 5 bow.
not to use excessive pressure. Do not use power
tools, as these permanently damage the convertible 12. Disconnect the heated rear window electrical
top material. Heavy scratches require replacement of connectors from the rear window glass.
the convertible top material.
13. Remove the convertible top cover elastic listing
NOTE: Light creases in the convertible top material
strap from the front side rails.
can be removed by applying water to the creased
area, and pulling the creased area flat, while
14. Remove the convertible top cover elastic listing
applying mild heat from a heat gun. Use care not to
straps (one on each side) from the front side
apply excessive heat, as this permanently damages
rails.
the convertible top material. Heavy creases may
require replacement of the convertible top material. 15. Remove the convertible top cover elastic listing
strap from the convertible top cover.
1. Remove the convertible top assembly. For
additional information, refer to Convertible Top 16. Remove the convertible top cover elastic listing
Assembly in this section. straps (one on each side) from the rear side
rails.
2. Place the convertible top assembly on a flat
surface and open fully. 17. Position the water diverters aside to gain access
to the tensioner cables.
3. Remove the screws and the LH and RH side
front and rear weatherstrips and retainer 18. Remove the tensioner cable guides from the
channels. convertible top frame number 5 bow.
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19. Remove the tensioner cables from the tensioner 11. Install the convertible top listing straps under
cable springs. the header form panel.
20. Remove the 2 pin-type retainers (1 each side) 12. Install the header form panel and 6 screws.
securing the convertible top material to the
1 Tighten to 5 Nm (44 lb-in).
weatherstrip retainer channels.
2 Apply 3 pieces of double-sided tape to the
header form panel.
21. Remove the convertible top channels from the
convertible top frame number 2 and number 3
13. Apply a light mist of water to the double-sided
bows.
tape, and the underside of the convertible top
Remove the convertible top material.
material where it will contact the tape.
Installation
14. Install the rivets attaching the front corners of
the convertible top material to the frame (2
NOTE: Using chalk, make sure to mark the
each side) and cover the rivets with a short
position of the convertible top frame number 5 bow
piece of foam tape.
on the new top cover.
15. Install the front retaining channel into place on
1. Snap the convertible top channels into the
the front of the frame and, starting in the center
guides on the convertible top frame number 3
and working out towards the edges, clamp the
bow, then the number 2 bow, and center the
convertible top material in place.
convertible top on the frame.
16. NOTE: Prior to stapling, make sure there are
2. Using heavy wire or other suitable material,
no wrinkles in the convertible top material
pull the convertible top listing strap through the
along the front edge.
channel on the underside of the top cover.
Staple the front corners of the convertible top
material to the frame.
3. Using heavy wire or other suitable material,
pull the convertible top tensioner cables through
17. Install the compression panel and 11 screws.
the channels to the rear of the convertible top.
4. Connect the heated rear window electrical
connectors.
18. Using an assistant, pull the convertible top
material rearward around the convertible top
5. Install the convertible top tensioner cables to
frame number 5 bow, to the same position as
the tensioner cable springs.
the old top cover.
6. Install the tensioner cable guides to the
19. After all wrinkles are removed, remove the tape
cover strip and press the convertible top
material firmly against the front header panel to
7. Position the convertible top material, and secure
seat it against the double-sided tape.
to the weatherstrip retainer channels with
pin-type retainers.
20. NOTE: Make sure there are no wrinkles on the
top of the convertible top material.
8. Attach the convertible top listing straps (one on
Staple the convertible top material to the
each side) to the rear side rails.
9. Install the convertible top listing strap to the
21. Remove the extra material from the convertible
front side rails.
top below the convertible top frame number 5
bow.
10. Install the convertible top listing straps (one on
each side) to the front side rails.
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23. Install the left and right side weatherstrips.
22. CAUTION: Make sure the
weatherstrip retaining channels are replaced
24. Install the convertible top assembly in the
in their original locations. Failure to replace
vehicle. For additional information, refer to
the retaining channels in their correct
Convertible Top Assembly in this section.
positions may cause water leaks, resulting in
interior damage.
Install the LH and RH side front and rear
weatherstrip retainer channels and screws.
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3. NOTE: Manually operate the convertible top
Convertible Top Side Rail
frame before installing the headliner, to be sure
the frame operates smoothly, without binding.
1. Remove the convertible top headliner. For
Make sure the door glass and quarter glass
correctly seal against the convertible top
Headliner in this section.
side rail. If adjustment is necessary, refer to
Section 501-11.
2. Remove the screws and the side rail(s) from the
convertible top frame bows.
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2. Disconnect the convertible top switch electrical
Convertible Top Switch
connector.
3. Release the locking tabs, and remove the
convertible top switch.
1. Remove the overhead console.
Disconnect the overhead console electrical 4. To install, reverse the removal procedure.
connector.
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Convertible Top Tension Cable
Removal
1. Remove the upper quarter trim panel cap and
upper quarter trim panel. For additional
2. Open the convertible top approximately
half-way.
6. Using side cutters, cut the cable from the cable
3. Remove pushpins and the front weatherstrip.
flag (cut as close to the flag as possible).
4. Remove the 2 Torx screws and the front
7. Tie the old cable to the spring end of the new
weatherstrip retainer channel.
tension cable (make sure it is secure).
8. Close the convertible top until it is
approximately 15.25 cm (6 in) from the top of
the windshield frame.
9. From inside vehicle, carefully pull the tension
cable out to feed the new tension cable through
the convertible top. You may need to open the
convertible to get the spring of the new cable
passed through the body.
5. Drill out the rivet attaching the cable flag to the
convertible top frame No. 1 bow. Once the
cable flag is loose, use a small punch to knock
out the rivet slug and clear the hole.
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10. Drill out the rivet attaching the old cable to the
convertible top frame No. 5 bow. Use a small
punch to knock out the rivet slug and clear the
hole.
4. Install the 2 Torx screws and the front
weatherstrip retainer channel.
Installation
1. Open the convertible top as necessary to rivet
new cable flag to convertible top frame No. 1
bow.
5. Install the front weatherstrip.
Install the 2 pushpins.
2. NOTE: Save the sound isolation webbing from
the old cable so it can be transferred to the new
cable.
Pull the old cable through the cable guide and
route the new cable through the cable guide.
3. Put the sound isolation material on the new
cable spring and rivet new cable to convertible
top frame No. 5 bow. 6. Close the convertible top completely.
Check the outside appearance of the
convertible top.
From inside the vehicle, make sure the cable
is routed through guide and cable is under
tension. Repair as necessary.
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7. Install the upper quarter trim panel cap and
upper quarter trim panel. For additional
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Convertible Top Latches
Convertible Top
The convertible top latches secure the convertible
The convertible top consists of the following
top assembly to the windshield header when the
components:
convertible top assembly is in the raised position.
Convertible top cover assembly
The convertible top latches must be manually
released before lowering the convertible top
Convertible top frame bows (1-5)
assembly.
Convertible top frame side rails
Convertible top latches Header Form Panel
Header form panel The header form panel supports the forward portion
of the convertible top assembly. The convertible top
Headliner
latches secure the header form panel to the
Hydraulic pump and motor assembly
windshield header.
Hydraulic lift cylinders with hydraulic lines
Headliner
Stay pads
The headliner is attached to the convertible top
Weatherstrips
frame bows and must be installed after the
convertible top cover assembly and the stay pads
Convertible Top Assembly
are removed.
The convertible top is not adjustable, and is
removed from the vehicle as an assembly. Once
Hydraulic Pump and Motor Assembly
removed, the convertible top components can be
The hydraulic pump and motor assembly provide
disassembled, replaced, and installed as necessary.
pressurized hydraulic fluid to the hydraulic lines and
the hydraulic lift cylinders.
Convertible Top Cover Assembly
The convertible top hydraulic system is comprised
The convertible top cover assembly includes the
of the hydraulic lift cylinders, the motor, the
rear window glass. The rear window glass is not
hydraulic lines and a convertible top switch. The
removable, and the convertible top material and rear
hydraulic system, except for the convertible top
glass must be installed as an assembly.
switch, is removed as an assembly, but the
Convertible Top Frame Bows components may be installed separately.
The convertible top frame bows provide support for
Hydraulic Lift Cylinders and Hydraulic
the convertible top cover assembly. The convertible
Lines
top frame bows are the attachment points for the
The hydraulic lines receive the pressurized hydraulic
convertible top cover assembly.
fluid from the hydraulic motor and pump assembly.
Convertible Top Frame Side Rails The hydraulic lines carry the pressurized hydraulic
fluid to the hydraulic lift cylinders which then raise
The convertible top frame side rails form the LH
or lower the convertible top assembly.
and RH side structure of the convertible top
assembly. The convertible top frame side rails
Stay Pads
support the convertible top frame bows and provide
The stay pads are attached to the convertible top
the attachment points for the LH and RH side
frame bows and are installed as an assembly.
convertible top cover assembly.
Weatherstrips
The weatherstrips seal the convertible top assembly
to the vehicle to provide a weather-tight seal.
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The convertible top assembly is a floating frame,
Convertible Top
Z-fold design. The main pivot brackets are attached
Special Tool(s)
to the body, and the convertible top frame side rails
expand or fold when the convertible top is raised or
lowered. The LH and RH stay pads are attached to
Diagnostic System (IDS) the convertible top frame bows, and provide the
main source of tension for the convertible top
material. When the convertible top is in the full
tool
down position, it stores in the compartment behind
the rear seat backrest. When the convertible top is
in the full up position, the body provides a stop
which the convertible top frame number 5 bow
contacts to provide a weather seal for the
convertible top against the body.
The convertible top hydraulic system uses a 12-volt
reversible pump and motor assembly. When active,
the pump uses hydraulic pressure to extend the
hydraulic lift cylinders to raise the convertible top,
Flex Probe Kit
105-R025B or equivalent or retract the hydraulic lift cylinders to lower the
convertible top. The convertible top motor/pump
assembly is equipped with a thermal circuit breaker.
The circuit breaker typically resets after 5 minutes
depending on the ambient temperature. The thermal
circuit breaker cannot be repaired and must be
installed as a unit with the motor/pump assembly. In
the event of a hydraulic system failure, the
convertible top cannot be operated manually.
Convertible top operation is controlled by the smart
junction box (SJB). When the convertible top
raise/lower switch is operated, the SJB commands
the front and rear windows to the full down
position. Window operation is disabled while the
convertible top raise/lower switch is being operated.
When the SJB receives a full down input for both
rear windows, it commands the appropriate relay
closed to raise or lower the convertible top. If the
SJB does not receive a full down input signal for
both rear windows, the convertible top operation is
disabled.
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Mechanical Electrical refer to Section 418-00, no power to the
Convertible top brackets Bussed electrical center
and frame (BEC) fuse(s): with the scan tool.
Convertible top latches 13 (40A)
Convertible top pump 51 (10A)
vehicle:
and motor assembly Circuitry
Hydraulic lift cylinders Convertible top pump
Hydraulic lines and motor assembly
Convertible top ajar
switch good vehicle.
Convertible top switch
Connector(s)
response from the smart junction box (SJB).
Convertible top raise
relay
Convertible top lower
relay
LH or RH rear power communication from one or more modules,
window motor
Smart junction box
(SJB)
record the continuous memory diagnostic BEC
9. If the DTCs retrieved are releated to the
concern, go to the Smart Junction Box (SJB)
software release.
(VCM) light emitting diode (LED) prove out
confirms power and ground from the DLC are
provided to the VCM.
If the scan tool still does not communicate with
the VCM:
B1141 Convertible Top Full Down Position Switch SJB GO to Pinpoint Test E.
Circuit Failure
B1142 Convertible Top Full Up Position Switch SJB GO to Pinpoint Test E.
Circuit Failure
B1402 Driver Power Window Down Switch Circuit SJB GO to Pinpoint Test A.
Failure
B2068 Convertible Top Up Output Circuit Failure SJB GO to Pinpoint Test A.
B2069 Convertible Top Down Output Circuit Failure SJB GO to Pinpoint Test A.
B2481 Convertible Top Up/Down Switch Fault SJB GO to Pinpoint Test A.
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B2578 Passenger Power Window Down Switch Circuit SJB GO to Pinpoint Test A.
Failure
All Other SJB REFER to Section 419-10.
DTCs
Symptom Chart
Symptom Chart
The convertible top does not Fuse(s) GO to Pinpoint Test A.
raise/lower Circuitry
Convertible top raise relay
Convertible top lower relay
Convertible top switch
(BEC)
LH rear window motor
RH rear window motor
The convertible top Convertible top assembly GO to Pinpoint Test B.
hesitates/comes down uneven Hydraulic lift cylinders
Hydraulic system
The convertible top does not Convertible top assembly GO to Pinpoint Test C.
raise or does not go up all the Hydraulic lift cylinders
way Hydraulic system
The convertible top hydraulic Convertible top assembly GO to Pinpoint Test D.
system is inoperative/does Hydraulic lift cylinders
not operate correctly Hydraulic motor/pump
assembly
Pinpoint Tests Refer to Wiring Diagrams Cell 100, Power
Windows for schematic and connector information.
Pinpoint Test A: The Convertible Top Does
Not Raise/Lower
Refer to Wiring Diagrams Cell 103, Convertible
Top for schematic and connector information.
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Possible Causes
Normal Operation
The convertible top switch supplies a ground signal
Fuse(s)
for the smart junction box (SJB) on circuits 2038
Circuit 588 (VT) open, short to ground or short to
(LB/OG) when the switch is in the lower position,
voltage
and 2052 (VT/OG) when the switch is in the raise
Circuit 902 (YE) open position. If vehicle speed is less than 5 km/h (3
mph), the SJB grounds the appropriate relay (using
either circuit 1174 [WH/RD] or circuit 588 [VT]) to
Circuit 1174 (WH/RD) open, short to ground or
direct voltage through the convertible top motor to
short to voltage
raise or lower the convertible top. When the raise or
lower relay is operating, the other relay remains in
its normal state and supplies the motor/pump
Circuit 2012 (RD/BK) open
ground. When the SJB receives a request to operate
Circuit 2014 (YE/LB) open
the convertible top, the front and rear windows open
Circuit 2038 (LB/OG) open or short to ground
to the full down position. The SJB monitors the
status of the rear windows on circuit 2012
Circuit 2052 (VT/OG) open or short to ground
(RD/BK) for the right rear window, and circuit
Convertible top raise relay
2014 (YE/LB) for the left rear window. When the
Convertible top lower relay
SJB receives a full down input for both rear
windows, the convertible top operation is enabled. If Convertible top switch
the SJB does not receive a full down input for both
rear windows, the convertible top operation is
SJB
disabled. Window operation is disabled when the
LH or RH rear window motor convertible top raise/lower switch is active.
The convertible top motor/pump assembly is
equipped with a thermal circuit breaker. The circuit
breaker typically resets after 5 minutes depending
on the ambient temperature. The thermal circuit
breaker cannot be repaired and must be installed as
a unit with the motor/pump assembly.
PINPOINT TEST A: THE CONVERTIBLE TOP DOES NOT RAISE/LOWER
to us the correct probe adapter(s) may damage the connector.
NOTE: Vehicle speed must be less than 5 km/h (3 mph) for the convertible top to operate.
A1 RETRIEVE THE RECORDED SJB DTCS FROM BOTH THE
CONTINUOUS AND ON-DEMAND SELF TESTS
on-demand self tests. For DTC B2481, GO to A9.
Are any SJB DTCs recorded?
For DTC B1402 or B2578, GO to A27.
For DTC B1141 or B1142, GO to Pinpoint
Test E.
No
GO to A2.
A2 CHECK THE VEHICLE SPEED INPUT
Enter the following diagnostic mode on the scan tool: SJB PIDs. GO to A3.
Monitor the powertrain control module (PCM) vehicle speed
No
sensor PID.
Does the PID display less than 5 km/h (3 mph)?
instrument cluster.
(Continued)
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PINPOINT TEST A: THE CONVERTIBLE TOP DOES NOT RAISE/LOWER (Continued)
A3 CHECK THE SJB CONVERTIBLE TOP SWITCH INPUT
Enter the following diagnostic mode on the scan tool: Monitor
SJB PIDs.
Monitor the SJB convertible top switch status PID for convertible
top up switch and convertible top down switch status while
Yes
operating the convertible top switch in the raise and lower
GO to A4.
positions.
Do the PIDs change from inactive to active when the No
convertible top switch is operated, for both positions? GO to A8.
A4 CHECK THE WINDOW OPERATION
Make sure all the windows are fully up.
Yes
Operate the convertible top switch in the lower position.
GO to A5.
If necessary, return all windows to the full up position.
Operate the convertible top switch in the raise position. No
Do all the windows open fully when the convertible top REFER to Section 501-11 to diagnose the
switch is operated in the raise and lower positions? convertible top drop feature.
A5 CHECK THE SJB CONVERTIBLE TOP OUTPUT PIDS
Monitor the SJB convertible top output PID for the convertible
Yes
top up and the convertible top down status, while operating the
GO to A7.
convertible top switch in the raise and lower positions.
Does the convertible top up and convertible top down No
status match the convertible top switch position? GO to A6.
A6 CHECK THE REAR WINDOW FULL DOWN INPUTS TO THE SJB
Yes
Make sure the rear windows are all the way down.
GO to A7.
Observe the window down position status PID for left rear
window full down and right rear window full down. No
Does the status for each position read Yes? GO to A27.
A7 CHECK FOR CONVERTIBLE TOP MOTOR OPERATION
Commands.
Yes
Operate the SJB active command for the convertible top down
relay output and convertible top up relay output while listening
for convertible top motor operation. No
Does the convertible top motor operate in both directions? GO to A16.
A8 CHECK CIRCUIT 1205 (BK) AT THE CONVERTIBLE TOP
SWITCH FOR AN OPEN
Disconnect: Convertible Top Switch C9013.
Measure the resistance between convertible top switch C9013-3,
Yes
GO to A9.
No
A9 CHECK CIRCUIT 2052 (VT/OG) FOR A SHORT TO GROUND
(Continued)
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A9 CHECK CIRCUIT 2052 (VT/OG) FOR A SHORT TO GROUND
(Continued)
Yes
GO to A10.
No
A10 CHECK CIRCUIT 2038 (LB/OG) FOR A SHORT TO GROUND
circuit 2038 (LB/OG), harness side and ground.
Yes
GO to A11.
No
A11 CHECK CIRCUIT 2052 (VT/OG) FOR AN OPEN
circuit 2052 (VT/OG), harness side and SJB C2280f-15, circuit
2052 (VT/OG), harness side.
Yes
GO to A12.
No
(Continued)
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A12 CHECK CIRCUIT 2038 (LB/OG) FOR AN OPEN
circuit 2038 (LB/OG), harness side and SJB C2280f-16, circuit
2038 (LB/OG), harness side.
Yes
GO to A13.
No
A13 CHECK THE CONVERTIBLE TOP SWITCH JUMPER HARNESS
FOR AN OPEN
Disconnect the convertible top switch jumper harness from the
Yes
convertible top switch.
GO to A14.
Measure the resistances of the convertible top switch jumper
harness C9013, component side, and the convertible top switch, No
harness side. REPAIR the circuit. CLEAR the DTCs.
Are the resistances less than 5 ohms? REPEAT the self-test.
A14 CHECK THE CONVERTIBLE TOP SWITCH JUMPER HARNESS
Connect: Convertible Top Switch C9013. Yes
Measure the resistances between the convertible top switch GO to A15.
jumper harness, harness side and ground.
No
Are the resistances greater than 10,000 ohms?
A15 CHECK THE CONVERTIBLE TOP SWITCH
Measure the resistance between the convertible top switch pin 7,
component side and the convertible top switch pin 3, component
Yes
side; and between the convertible top switch pin 6, component
GO to A31.
side and the convertible top switch pin 3, component side, while
operating the convertible top switch in the raise and lower No
positions. INSTALL a new convertible top switch.
Are the resistances less than 5 ohms when the switch is REFER to Convertible Top Switch in this
operated, and greater than 10,000 ohms when the switch is section. CLEAR the DTCs. REPEAT the
in the off position? self-test.
A16 CHECK THE OPERATION OF THE CONVERTIBLE TOP LOWER
OUTPUT CIRCUIT
Remove the convertible top lower relay.
Commands.
(Continued)
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A16 CHECK THE OPERATION OF THE CONVERTIBLE TOP LOWER
OUTPUT CIRCUIT (Continued)
Measure the resistance between the BEC convertible top lower
relay, C1502-30 and ground, while operating the SJB active
command for the convertible top lower relay output.
Yes
GO to A17.
Is the resistance less than 5 ohms when the command is
activated, and greater than 10,000 ohms when the command No
is deactivated? GO to A18.
A17 CHECK THE OPERATION OF THE CONVERTIBLE TOP RAISE
OUTPUT CIRCUIT
Remove the convertible top raise relay.
Commands.
(Continued)
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A17 CHECK THE OPERATION OF THE CONVERTIBLE TOP RAISE
OUTPUT CIRCUIT (Continued)
Measure the resistance between BEC convertible top raise relay
C1501-30 and ground, while operating the SJB active command
for the convertible top raise relay output.
Yes
GO to A22.
Is the resistance less than 5 ohms when the command is
activated, and greater than 10,000 ohms when the command No
is deactivated? GO to A20.
A18 CHECK CIRCUIT 1174 (WH/RD) FOR A SHORT TO GROUND OR
AN OPEN
(Continued)
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A18 CHECK CIRCUIT 1174 (WH/RD) FOR A SHORT TO GROUND OR
AN OPEN (Continued)
Measure the resistance between SJB C2280c-26, circuit 1174
(WH/RD), harness side and BEC convertible top lower relay
C1502-85; and between SJB C2280c-26, circuit 1174 (WH/RD),
Yes
GO to A19.
BEC, and greater than 10,000 ohms between the SJB and REPAIR the circuit. CLEAR the DTCs.
ground? REPEAT the self-test.
(Continued)
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A19 CHECK CIRCUIT 1174 (WH/RD) FOR A SHORT TO VOLTAGE
Measure the voltage between BEC convertible top lower relay
C1502-85 and ground.
Yes
No
A20 CHECK CIRCUIT 588 (VT) FOR A SHORT TO GROUND OR AN
OPEN
(Continued)
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A20 CHECK CIRCUIT 588 (VT) FOR A SHORT TO GROUND OR AN
OPEN (Continued)
(VT), harness side and BEC convertible top raise relay
C1501-85; and between SJB C2280c-11, circuit 588 (VT),
Yes
GO to A21.
BEC, and greater than 10,000 ohms between the SJB and REPAIR the circuit. CLEAR the DTCs.
(Continued)
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A21 CHECK CIRCUIT 588 (VT) FOR A SHORT TO VOLTAGE
C1502-85 and ground.
Yes
No
A22 CHECK CIRCUIT 902 (YE) FOR VOLTAGE
Install the convertible top raise and lower relays.
Disconnect: Convertible Top Motor C4062.
Commands.
Measure the voltage between convertible top motor C4062-2,
circuit 902 (YE), harness side and ground while operating the
SJB active command for the convertible top lower relay output.
Yes
GO to A23.
No
(Continued)
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A23 CHECK CIRCUIT 903 (RD) FOR VOLTAGE
Commands.
Measure the voltage between convertible top motor C4062-1,
circuit 903 (RD), harness side and ground while operating the
SJB active command for the convertible top raise relay output.
Yes
GO to A26.
No
A24 CHECK CIRCUIT 902 (YE) FOR AN OPEN OR A SHORT TO
GROUND
Remove the convertible top lower relay.
(Continued)
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GROUND (Continued)
Measure the resistance between convertible top motor C4062-2,
circuit 902 (YE), harness side and BEC convertible top down
relay, C1502-30; and between the convertible top motor
connector C4062-2, circuit 902 (YE), harness side and ground.
Yes
GO to A29.
Is the resistance less than 5 ohms between the convertible No
top motor and the BEC, and greater than 10,000 ohms REPAIR the circuit. CLEAR the DTCs.
between the convertible top motor and ground? REPEAT the self-test.
A25 CHECK CIRCUIT 903 (RD) FOR AN OPEN OR A SHORT TO
GROUND
Remove the convertible top raise relay.
(Continued)
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A25 CHECK CIRCUIT 903 (RD) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
Measure the resistance between convertible top motor C4062-1,
circuit 903 (RD), harness side and BEC convertible top raise
relay, C1501-30; and between convertible top motor C4062-1,
circuit 903 (RD), harness side and ground.
Yes
GO to A29.
Is the resistance less than 5 ohms between the convertible No
top motor and the BEC, and greater than 10,000 ohms REPAIR the circuit. CLEAR the DTCs.
between the convertible top motor and ground? REPEAT the self-test.
Remove the convertible top raise and lower relays.
(Continued)
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A26 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between BEC convertible top raise relay
C1501-87a and ground; and between BEC convertible top lower
relay C1502-87a and ground.
Yes
GO to A29.
No
A27 CHECK THE OPERATION OF CIRCUITS 2012 (RD/BK) AND
2014 (YE/LB)
Make sure both rear windows are completely down.
(RD/BK), harness side and ground; or between SJB C2280c-52,
circuit 2014 (YE/LB), harness side and ground.
Yes
GO to A31.
No
Are the resistances less than 5 ohms? GO to A28.
(Continued)
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A28 CHECK CIRCUIT 2012 (RD/BK) AND CIRCUIT 2014 (YE/LB) FOR
AN OPEN
Disconnect: RH Rear Window Motor C3118.
Disconnect: LH Rear Window Motor C3119.
Measure the resistance between RH rear window motor
C3119-5, circuit 2012 (RD/BK), harness side and SJB
C2280c-20, circuit 2012 (RD/BK), harness side; and between LH
rear window motor C3118-5, circuit 2014 (YE/LB), harness side
and SJB C2280c-52, circuit 2014 (YE/LB), harness side.
Yes
INSTALL a new rear window motor as
No
(Continued)
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A29 CHECK FOR VOLTAGE TO THE CONVERTIBLE TOP RELAYS
C1502-87 and ground; between BEC convertible top lower relay
C1502-86 and ground; between BEC convertible top raise relay
C1501-87 and ground; and between BEC convertible top raise
relay C1501-86 and ground.
Yes
GO to A30.
No
VERIFY the BEC fuses 13 (40A) and 51
(10A) are OK. If OK, REPAIR or INSTALL
a new BEC as necessary. CLEAR the
Are all the voltages greater than 10 volts? DTCs. REPEAT the self-test.
A30 CHECK THE CONVERTIBLE TOP RAISE AND LOWER RELAYS
Carry out the relay component test for the convertible top raise Yes
and lower relays. Refer to Wiring Diagrams Cell 149 for INSTALL a new motor/pump assembly.
component testing. REFER to Hydraulic System, Lift Cylinder
Do both relays pass the component test? and Motor in this section. CLEAR the
No
INSTALL a new convertible top relay as
necessary. CLEAR the DTCs. REPEAT
the self-test.
No
correctly.
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Possible Causes
Pinpoint Test B: The Convertible Top
Hesitates/Comes Down Uneven
Convertible top assembly
Normal Operation
Hydraulic lift cylinders
Hydraulic system
or retract the hydraulic lift cylinders to lower the
convertible top. The convertible top assembly is a
floating frame, Z-fold design. The main pivot
brackets are attached to the body, and the
convertible top frame side rails expand or fold when
the convertible top is raised or lowered. The LH
and RH stay pads are attached to the convertible top
frame bows, and provide the main source of tension
for the convertible top material.
PINPOINT TEST B: THE CONVERTIBLE TOP HESITATES/COMES DOWN UNEVEN
NOTE: The convertible top is not adjustable. If the convertible top frame is damaged, or
requires adjustment, the damaged components must be replaced.
B1 CHECK THE MOTOR OPERATION
Gain access to the convertible top motor/pump assembly. Yes
Operate the convertible top to the lower and raise positions GO to Pinpoint Test A.
while listening to the motor.
No
Does the motor stop and then continue at any time?
GO to B2.
B2 CHECK THE CONVERTIBLE TOP LINKAGE
Operate the convertible top to the lower and raise positions Yes
while observing the convertible top linkage. The condition is not present at this time.
Does the linkage operate smoothly without binding? RETURN the vehicle to the customer.
No
GO to B3.
B3 CHECK THE CONVERTIBLE TOP
Remove the hydraulic system from the vehicle. Refer to Yes
Hydraulic System, Lift Cylinder and Motor in this section. INSTALL new components as necessary.
Operate the convertible top assembly up and down manually. REFER to Convertible Top Bows or
Does the convertible top bind? Convertible Top Side Rail in this section.
No
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Possible Causes
Pinpoint Test C: The Convertible Top Does
Not Raise Or Does Not Go Up All the Way
Convertible top assembly
Normal Operation
Hydraulic system
the convertible top is raised or lowered. The LH
and RH stay pads are attached to the convertible top
frame bows, and provide the main source of tension
for the convertible top material.
PINPOINT TEST C: THE CONVERTIBLE TOP DOES NOT RAISE OR DOES NOT GO UP ALL THE WAY
NOTE: The convertible top is not adjustable. If the convertible top frame is damaged, or
requires adjustment, the damaged components must be replaced.
C1 CHECK THE CONVERTIBLE TOP OPERATION
Operate the convertible top switch to the raise and lower GO to C2.
positions.
No
Does the motor operate for both positions?
C2 CHECK THE CONVERTIBLE TOP LINKAGE
Operate the convertible top to the lower and raise positions Yes
while observing the convertible top linkage. GO to C3.
Does the linkage bind and prevent the convertible top from
No
raising?
The concern is not present at this time.
RETURN the vehicle to the customer.
C3 CHECK THE CONVERTIBLE TOP
Hydraulic System, Lift Cylinder and Motor in this section. INSTALL new components as necessary.
Operate the convertible top assembly up and down manually. REFER to Convertible Top Bows or
Does the convertible top bind? Convertible Top Side Rail in this section.
No
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Possible Causes
Pinpoint Test D: The Convertible Top
Hydraulic System Is Inoperative/Does Not
Convertible top frame bows
Operate Correctly
Convertible top frame side rails
Normal Operation
Hydraulic motor/pump assembly
the convertible top is raised or lowered. The
convertible top frame bows attach to the convertible
top frame side rails and provide tension for the
convertible top material.
PINPOINT TEST D: THE CONVERTIBLE TOP HYDRAULIC SYSTEM IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
D1 CHECK THE FLUID LEVEL
NOTE: The fluid level should be even with the bottom of the filler
plug hole, with the hydraulic lift cylinders fully extended.
Yes
NOTE: Place an absorbent cloth below the filler plug when
GO to D3.
checking the fluid level.
Remove the filler plug and check the fluid level. No
Is the fluid level OK? GO to D2.
D2 CHECK THE HYDRAULIC SYSTEM FOR LEAKS
Inspect all fittings and hoses for leaks. Yes
Are any leaks noticed? REPAIR the leaking fittings or INSTALL
new hoses as necessary. TEST the
No
GO to D3.
D3 BLEED THE HYDRAULIC SYSTEM
Bleed the hydraulic system. Refer to System Bleeding in this Yes
section. OPERATE the convertible top up and
Does the system operate correctly after bleeding? down 3 times. INSPECT the hydraulic
system for leaks or loss of fluid. REPAIR
as necessary if leaks are detected.
No
GO to D4.
D4 CHECK THE CONVERTIBLE TOP
Hydraulic System, Lift Cylinder and Motor in this section. REPLACE the damaged components as
Operate the convertible top assembly up and down manually. necessary. REFER to Convertible Top
Does the convertible top bind? Bows or Convertible Top Side Rail in this
operation.
No
GO to D5.
(Continued)
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PINPOINT TEST D: THE CONVERTIBLE TOP HYDRAULIC SYSTEM IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY (Continued)
D5 CHECK THE HYDRAULIC SYSTEM OUT OF THE VEHICLE
Bleed the hydraulic system. Refer to System Bleeding in this Yes
section. CHECK all fittings and hoses for leaks.
Does the system operate correctly after bleeding? REPAIR as necessary if leaks are
detected. TEST the system for normal
operation.
No
GO to D6.
D6 CHECK THE HYDRAULIC LIFT CYLINDERS
Operate the hydraulic system using a 12-volt power source. Yes
Do the hydraulic lift cylinders extend and retract fully and INSTALL a new motor/pump assembly.
evenly? REFER to Hydraulic System, Lift Cylinder
and Motor in this section. TEST the
No
INSTALL a new hydraulic lift cylinder.
REFER to Hydraulic System, Lift Cylinder
and Motor in this section. TEST the
Possible Causes
Pinpoint Test E: DTCs B1141 and B1142
Convertible Top Full Down/Up Position
Circuit 700 (WH/VT) short to voltage, short to
Switch Circuit Failure
ground or open
Refer to Wiring Diagrams Cell 103, Convertible
Top for schematic and connector information.
Circuit 1558 (TN/BK) short to voltage, short to
ground or open
Convertible top ajar switch
Normal Operation
SJB
The smart junction box (SJB) monitors the status of
the convertible top through circuits 1558 (TN/BK)
and 700 (WH/VT). When the convertible top is in
the full up position, the convertible top ajar switch
closes to ground circuit 1558 (TN/BK). When the
convertible top is in the full down position, the
convertible top ajar switch closes to ground circuit
700 (WH/VT). Ground is provided through circuit
1205 (BK). DTC B1141 sets if the convertible top
ajar switch on-demand self test is run with the
convertible top not in the full down position. DTC
B1142 sets if the convertible top ajar switch
on-demand self test is run with the convertible top
in the full up position.
PINPOINT TEST E: DTCs B1141 AND B1142 CONVERTIBLE TOP FULL DOWN/UP POSITION SWITCH
CIRCUIT FAILURE
to us the correct probe adapter(s) may damage the connector.
E1 CARRY OUT THE ON-DEMAND SELF TEST FOR THE
CONVERTIBLE TOP AJAR SWITCH
NOTE: Make sure the convertible top is in the full down position
before carrying out this test.
(Continued)
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CIRCUIT FAILURE (Continued)
E1 CARRY OUT THE ON-DEMAND SELF TEST FOR THE
CONVERTIBLE TOP AJAR SWITCH (Continued)
Yes
Key in ON position.
GO to E2.
With the convertible top and the rear windows in the full down
position, carry out the on-demand self test for the convertible top No
ajar switch. The concern is not present at this time.
Does DTC B1141 or DTC B1142 set as current? RETURN the vehicle to the customer.
E2 CHECK FOR CONVERTIBLE TOP AJAR SWITCH OPERATION
Disconnect: Convertible Top Ajar Switch C3266.
Measure the resistance between convertible top ajar switch
C3266-1, circuit 1558 (TN/BK), component side and convertible
top ajar switch C3266-3, circuit 1205 (BK), component side,
with the convertible top in the full up position; and between
convertible top ajar switch C3266-2, circuit 700 (WH/VT),
component side and between convertible top ajar switch 3266-3,
circuit 1205 (BK), component side, with the convertible top in the
full down position.
Yes
GO to E3.
No
INSTALL a new convertible top ajar
switch. REFER to Convertible Top Ajar
Switch in this section. CLEAR the DTCs.
Yes
GO to E4.
No
E4 CHECK CIRCUIT 700 (WH/VT) AND 1558 (TN/BK) FOR A SHORT
TO GROUND
(Continued)
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E4 CHECK CIRCUIT 700 (WH/VT) AND 1558 (TN/BK) FOR A SHORT
TO GROUND (Continued)
C3266-1, circuit 1558 (TN/BK), harness side and ground; and
between convertible top ajar switch C3266-2, circuit 700
(WH/VT), harness side and ground.
Yes
GO to E5.
No
Are the resistances greater than 10,000 ohms? REPEAT the self-test.
E5 CHECK CIRCUITS 700 (WH/VT) AND 1558 (TN/BK) FOR AN
OPEN
(WH/VT), harness side and convertible top ajar switch C3266-2,
circuit 700 (WH/VT), harness side; and between SJB
C2280c-18, circuit 1558 (TN/BK), harness side and convertible
top ajar switch C3266-1, circuit 1558 (TN/BK), harness side.
Yes
GO to E6.
No
(Continued)
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E6 CHECK CIRCUIT 700 (WH/VT) FOR A SHORT TO VOLTAGE
Measure the voltage between convertible top ajar switch
C3266-2, circuit 700 (WH/VT), harness side and ground; and
between convertible top ajar switch C3266-1, circuit 1558
(TN/BK), harness side and ground.
Yes
No
corrosion. 419-10. TEST the system for normal
pushed-out pins. operation.
No
correctly.
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501-02-1 501-02-1 Front End Body Panels
Cowl Vent Screen
1. Remove the 2 wiper pivot arms. For additional
1 17D515 Wiper pivot arm nut covers
(2 required)
2. Remove the 4 cowl vent screen pin-type
2 W706109 Wiper pivot arm nuts (2
retainers.
required)
3 175261/17527 Wiper pivot arms
3. NOTE: The RH cowl vent screen overlaps the
4 N804837 Cowl vent screen pin-type
LH cowl vent screen and must be removed
first.
5 G046000094 RH cowl vent screen
Remove the RH and LH cowl vent screens.
6 G046000093 LH cowl vent screen
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Door Ajar Switch
1. Remove the door latch. For additional
information, refer to Door Latch in this section.
2. Remove the door ajar switch.
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501-03-1 501-03-1 Body Closures
GENERAL PROCEDURES
Door Alignment
NOTE: The door should be adjusted for even and
parallel fit with the body opening and surrounding
panels as well as making sure the anti-chuck pin is
not binding on convertible models.
1. Mark the position of the front door hinges to
the front door to use as reference points.
2. Loosen the 4 front door hinge-to-front door
bolts enough to permit movement.
4. NOTE: After aligning the door, verify the door
can be closed easily and fits tightly.
Tighten the 4 front door hinge-to-front door
bolts.
3. Adjust the front door alignment to specification.
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501-03-1 501-03-1 Body Closures
Door Check Arm
2. Remove the door check arm bolts.
To install, tighten to 9 Nm (80 lb-in). 1 56912 Door check arm bolts (2
required)
3. Remove the nuts and the door check arm.
2 W705436 Door check arm nuts (2
required)
3 23500 Door check arm
1. Remove the front door trim panel. For
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Door Latch
Material
Item Specification
Multi-Purpose Grease ESB-M1C93B
Spray
XL-5
1. NOTE: The LH side is shown, the RH side is
similar.
Remove the door trim panel. For additional
6. If equipped, disconnect the door lock cylinder
actuating rod.
3. NOTE: Push upward on the exterior door
handle actuating rod when installing the rod
into the retaining clip.
Disconnect the exterior door handle actuating
rod.
7. Disconnect the 2 wiring harness electrical
connectors.
4. Remove the 3 door latch bolts.
5. Disconnect the manual lock rod.
8. Remove the cable cover.
Release the clip.
Remove the pin-type retainer.
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10. Remove the door latch.
9. CAUTION: Make sure the interior
door handle actuating cable does not kink or
damage to the cable may occur.
Disconnect the interior door handle actuating
cable.
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Door Lock Actuator
1. Remove the door latch. For additional
information, refer to Door Latch in this section.
2. Remove the door lock actuator.
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Door Lock Control Switch
1. Remove the interior door handle. For additional
information, refer to Interior Door Handle in
this section.
2. Remove the door lock control switch from the
interior door handle.
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Door Lock Cylinder
Material
Item Specification
Lubricant
XL-1
Lubricate the door lock cylinder after
installation.
3. Disconnect the door lock cylinder actuating rod.
4. If equipped, disconnect the door disarm switch
wiring harness electrical connector.
5. Remove the bolt and the door lock cylinder.
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Door Trim Panel
1 17D698/17D699 Sail panel (RH/LH)
1. Remove the sail panel.
2 21999 Door lock control knob bezel
(RH/LH) If equipped, disconnect the exterior mirror
control switch electrical connector. 3 22620/22621 Interior door handle cover
(RH/LH)
2. Remove the interior door handle cover and the
4 N807780 Door trim panel bolt
door trim panel bolt.
5 14527/14528 Window control switch
housing (RH/LH)
3. Remove the window control switch housing.
6 Window control switch
electrical connector Disconnect the electrical connector.
7 W709996 Door trim panel screw
4. Remove the door trim panel center screw.
8 6320456/ Door trim panel handle cover
6320457 (RH/LH)
5. Remove the door trim panel handle cover and
9 N807780 Door trim panel bolt
the door trim panel bolt.
10 W709996 Door trim panel screws (8
required)
11 23942/23943 Door trim panel (RH/LH)
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6. Remove the 8 outer door trim panel screws and 7. To install, reverse the removal procedure.
the door trim panel.
Disconnect the interior door handle actuating
cable.
If equipped, disconnect the subwoofer
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Driver Air Bag Module
Item Part Number Description WARNING: Do not set a live air bag
module down with the trim cover face down.
1 3L518 Driver air bag module bolt
caps This will reduce the risk of injury in the event of
an accidental deployment.
2 W506411 Driver air bag module bolts
3 Driver air bag module
WARNING: After deployment, the air bag
electrical connectors (part of
14A664) surface can contain deposits of sodium
hydroxide, a product of the gas generant 4 043B13 Driver air bag module
combustion that is irritating to the skin. Wash
your hands with soap and water afterwards. Removal
WARNING: Never probe the connectors on
the air bag module. Doing so can result in air
bag deployment, which can result in personal
injury.
WARNING: Carry a live air bag module
with the air bag and trim cover pointed away
from your body. This will reduce the risk of
injury in the event of an accidental deployment.
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NOTE: The SRS must be fully operational and free 4. Disconnect the 2 driver air bag module
of faults before releasing the vehicle to the electrical connectors.
customer.
NOTE: Repair is made by installing a new part
install the original part and carry out the diagnostic
procedure again.
2. Remove the 2 driver air bag module bolt caps
from the steering wheel (1 shown).
5. Remove the drivers air bag module.
6. CAUTION: The clockspring electrical
connectors are unique and cannot be
reversed when connected to the driver air
bag module. Match the electrical connector
key to the keyway in the driver air bag
module. Do not force the electrical
connectors into the driver air bag module.
3. Remove the 2 driver air bag module bolts (1
shown).
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501-08-1 501-08-1 Exterior Trim and Ornamentation
Engine Cover Vent
Installation
1 16C928 Engine cover vent
1. Clean the hood surface with a mixture of 50%
2 Double-sided tape
alcohol and 50% water.
Removal
2. Install the engine cover vent.
1 Insert the engine cover vent rear tabs into
NOTE: If the engine cover vent is removed from
the hood.
the vehicle, it must be installed new.
2 Press down on the engine cover vent and
1. Remove the hood insulator.
secure the engine cover vent clips to the
hood.
2. Lift up on the front of the engine cover vent
and then pull towards the front of the vehicle.
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Exterior Door Handle
1. Raise the door window glass to the full-up
position.
3. If equipped, remove the door lock cylinder. For
additional information, refer to Door Lock
Cylinder in this section.
6. Slide the exterior door handle rearward and
remove.
4. NOTE: Push upward on the exterior door
handle actuating rod when installing the rod
into the retaining clip.
Extend the handle away from the door lock
Open the exterior door handle actuating clip
cylinder cover to allow clearance for the
and disconnect the actuating rod.
exterior door handle bellcrank through the
door panel.
5. NOTE: Two exterior door handle studs must be
removed on the RH side.
Remove the exterior door handle studs.
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501-09-1 501-09-1 Rear View Mirrors
Exterior Mirror Control Switch
2. Remove the exterior mirror control switch from
the sail panel.
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Exterior Mirror Glass
Removal
1. Position the inner edge of the exterior mirror
glass to its maximum travel.
Installation
1. WARNING: Place a shop towel
between the exterior mirror glass and the
hand to avoid personal injury in the instance
of glass breakage. Failure to follow these
NOTE: An audible click will be heard during
2. WARNING: Place a shop towel
installation.
between the exterior mirror glass and the
hand to avoid personal injury in the instance
Install the exterior mirror glass by pressing
of glass breakage. Failure to follow these
firmly in the center of the exterior glass until it
snaps onto the exterior mirror motor.
Grasp the outer edge of the exterior mirror
glass and pull outward to remove the exterior
mirror glass.
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2. Remove the 3 exterior mirror motor screws.
Exterior Mirror Motor
3. Disconnect the exterior mirror motor electrical
connector.
1. Remove the exterior mirror glass. For additional
information, refer to Exterior Mirror Glass in
4. Remove the exterior mirror motor.
this section.
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Exterior Mirror
If equipped, disconnect the exterior mirror
control switch electrical connector.
2. Remove the 3 nuts and the exterior mirror.
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Exterior Mirrors Exploded View
6 N621907 Exterior mirror mounting nuts 1 17K707 Exterior mirror glass
(3 per side required)
2 Exterior mirror motor screws
7 17682/17683 Exterior mirror (RH/LH) (3 per side required)
3 17D696 Exterior mirror motor
4 17K709 Sail panel
5 17B676 Exterior mirror control switch
(Continued)
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Exterior Trim
The exterior trim and ornamentation consists of the
Engine cover vent
Radiator grille
Rear spoiler
Rocker panel mouldings
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Fender Splash Shield
1 W706805 Fender splash shield screws
1. Remove the 3 front fender splash shield screws. (3 required)
2 16K194 Fender splash shield pin-type
2. Remove the 5 pin-type retainers and the front
retainer (front) (5 required)
fender splash shield.
3 16B568 Fender splash shield (front)
4 W709176 Rocker panel pin-type
3. Remove the 2 pin-type retainers and position
the rocker panel aside.
5 16K194 Fender splash shield pin-type
retainers (rear) (2 required)
4. Remove the 2 pin-type retainers and the rear
6 16B568 Fender splash shield (rear)
fender splash shield.
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Fender
2. Remove the fender splash shield. For additional
information, refer to Fender Splash Shield in
1 39001B Rocker panel pin-type
this section.
2 6310155 Rocker panel
3. Remove the 4 front rocker panel pin-type
3 W505421 Fender bolts (lower) (2
retainers and position the rocker panel aside.
required)
4 W505421 Fender bolt
4. Remove the 2 lower fender bolts.
5 W505421 Fender support nut
6 W505421 Fender bolts (top) (4
required)
5. Remove the fender bolt.
7 16015 Fender
Both fenders
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Right fender
6. Remove the fender support nut through the door
opening.
7. Disconnect the antenna lead-in cable. For
8. Disconnect the hood ajar switch.
Both fenders
9. Remove the 4 top fender bolts and the fender.
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501-35-1 501-35-1 Body Repairs
Material
Frame Members
Item Specification
Special Tool(s) Low Temperature
Anti-Corrosion Coating
Pro 230 Mig Welder
PM-12-A
208-00030
Cleaner
ZC-21
Prep
ZC-31
Front Frame Rail
NOTE: Left side shown, right side similar.
NOTE: Cut line shown in illustration is approximate, refer to the following procedure for specific cut
locations.
1 16055 LH/ Frame rail sectioning kit
16054 RH
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501-35-2 501-35-2 Body Repairs
2. Remove the engine. For additional information,
CAUTION: This sectioning procedure is
only recommended when collision damage does
not extend into the front shock tower area. For
3. Remove the suspension components. For
more severe collision damage, repairs must be
made at the original factory seam and joint
locations.
4. CAUTION: The frame rail sectioning
NOTE: The following repair procedure illustrates
instruction kit provides the specific service
the sectioning of the front side member and fender
procedure instructions for replacement of the
reinforcement components. In situations where
frame rail sectioning kit. It is mandatory
collision damage is less severe, the sectioning
that the replacement section be installed per
procedure to repair only those damaged components
the installation guidelines. The frame rail
may be determined from these procedures.
service component must be located to
maintain the original factory dimensions. For
additional information, refer to Body in this
section for correct underbody dimensional
painted surfaces or E-coat, or when bare metal
information.
repairs are made. Refer to Restoring Corrosion
Remove the radiator support assembly.
Protection Following Repair in this section.
5. Cut off the front apron from the main part of
NOTE: Observe prescribed welding procedures
the apron, 80.5 mm (3.16 in) forward of the 14
when carrying out any repair to unibody/frame
mm (0.55 in) x 20 mm (0.78 in) slot, and
structure. For additional information, refer to
remove the remainder of the apron.
Welding Precautions Steel in this section.
1. Position the vehicle on a frame repair rack
following the manufacturers recommendations.
Measure the vehicle to determine if the body
requires straightening and alignment. Refer to
Body in this section for dimensional
information.
Remove the front bumper. For additional
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501-35-3 501-35-3 Body Repairs
6. NOTE: Factory spot welds may be substituted 7. Drill out the spot welds attaching the shock
with either resistance spot welds or MIG plug tower to the apron panel, and the apron to the
welds. Spot/plug welds should equal factory lower rail.
welds in both location and quantity. Do not
Dress all spot weld surfaces.
place a new spot weld directly over an original
weld location. Plug weld hole should equal 8
8. Chamfer inner and outer side member cutline
mm (0.31 in) diameter.
surfaces to improve butt weld surfaces.
Drill out the spot welds in the front fender
9. Measure 12.5 mm (0.49 in) rearward from the
apron reinforcement.
lower rail cutline. Drill seven 8 mm (0.31 in)
holes in the insert overlap area flange.
10. Transcribe the inner front side member cutline
to the new lower side member, cut to length
and chamfer the butt end to improve the weld
surface.
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501-35-4 501-35-4 Body Repairs
11. Construct an insert from the unused inner side
member material.
12. Measure 12.5 mm (0.49 in) forward from the
lower rail cutline. Drill nine 8 mm (0.31 in)
holes in the new lower side member for
attachment of the insert.
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501-35-5 501-35-5 Body Repairs
13. Apply corrosion protection to the repair areas 14. Position the insert to new lower side member,
on the vehicle and service parts. clamp and MIG plug weld 9 holes.
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501-35-6 501-35-6 Body Repairs
15. Position the new radiator support assembly,
apron panel, rail assembly, front fender lower
reinforcement and front fender upper
reinforcement.
MIG plug weld all holes.
16. Fusion weld the front fender upper and lower
reinforcements to the front fender apron, front
fender apron to the radiator support and the
seam between the old and the new side
members.
Dress all welds.
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Front Door Handles, Locks and
Latches Exploded View
5 14630/14631 Wiring harness (RH/LH) 1 22152/22153 Exterior door handle actuating
rod (RH/LH)
6 6322600/ Interior door handle (RH/LH)
6322601 2 W707400 Door latch bolts (3 required)
7 21812/21813 Front door latch (RH/LH) 3 63218A01 Manual lock rod
8 218A42/ Door lock actuator (RH/LH) 4 6322135 Door lock cylinder actuating
218A423 rod (if equipped)
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9 10B997 Door ajar switch 14 7821991 Door lock cylinder (if
equipped)
10 Door lock cylinder actuating
pawl 15 W709892 Exterior door handle studs (2
required RH)
11 632191 Door lock cylinder bolt (LH
only) 16 22404/22405 Exterior door handle (RH/LH)
12 6321991 Door disarm switch (if
equipped)
13 422405 Door lock cylinder cover (if procedures in this section.
equipped)
(Continued)
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Front End Body Panels
The front end body panel components consist of the
following:
Air deflectors
Cowl vent screens
Fenders
Fender splash shields
Hood
Hood hinges
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Front Impact Severity Sensor
Item Part Number Description WARNING: To reduce the risk of personal
1 14B345 Front impact severity sensor
2 W520111 Front impact severity sensor
nut
3 Front impact severity sensor
14290)
of faults before releasing the vehicle to the
customer.
when repairing an air bag supplemental restraint NOTE: Repair is made by installing a new part
system (SRS) vehicle and when handling an air only. If the new part does not correct the condition,
bag module. This will reduce the risk of injury in install the original part and carry out the diagnostic
the event of an accidental deployment. procedure again.
1. Depower the system. For additional WARNING: Vehicle sensor orientation is
critical for proper system operation. If a vehicle
for deformation. Replace and properly position
the sensor or any other damaged supplemental
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2. Remove the retainers and the radiator upper air
4. WARNING: The tightening torque of
deflector.
the air bag front impact severity sensor
retaining bolt is critical for correct system
operation.
NOTE: Make sure the radiator support and
front impact severity sensor mating surfaces are
clean and free of foreign material.
NOTE: Note position of locator tabs on sensor
for installation.
Remove the bolt and the front impact severity
sensor.
3. Disconnect the front impact severity sensor
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501-11-1 501-11-1 Glass, Frames and Mechanisms
Window Glass, Door
Glass, Frames and Mechanisms
The bottom of the door window glass is mounted in
Windshield Glass
2 window glass clamps which are part of the front
The windshield exterior mouldings are installed with
door window regulator. Door window glass bolts
the windshield glass. The windshield exterior and spacers provide attachment points for the door
mouldings cannot be replaced without removal of window glass and prevent direct contact between
the windshield. the door window glass bolts and the door window
glass.
Window Control Switch
Window Glass, Quarter
Power windows are standard. The window control
switches are available only to the front seat The coupe rear quarter window glasses are set in
passengers. There are no window control switches urethane. The convertible rear quarter window
glasses are powered and have a full down sensor for the rear seat passengers. The rear quarter
incorporated to indicate when the convertible top windows are operated by a single switch, located in
may operate. the drivers door. The rear window switch operates
the rear quarter windows in proportional up/down
Window Glass, Rear
only. The front window control switches use
The coupe rear window is mounted in urethane and
double-detent switches. The first detent is for
contains the heated rear window grid (if equipped).
proportional up/down and the second detent is for
The convertible rear window is sewn into the
one-touch up/down.
convertible top and contains the heated rear window
Window, One-Touch Up/Down
grid (if equipped). The convertible rear window is
replaced with a convertible top material. Refer to
The window one-touch up/down feature is activated
Section 501-18.
by pulling/pressing the window control switch to the
up/down position (second detent). This allows the
Convertible Top Drop Window Function
front door window glass to move upward/downward
When the convertible top switch is operated (to
until it is fully closed/open. A momentary
raise or lower the convertible top), the smart
activation of the window control switch, while the
junction box (SJB) sends a signal on a shared
window glass is moving upward or downward, stops
circuit to the 4 window motors to activate a full
the front door window glass. The bounce-back
down operation of all 4 windows. When the rear
feature is incorporated into the one-touch up feature.
quarter windows reach the full down position, the
Bounce-back occurs if the window motor detects an
full down sensor in each rear quarter window motor
obstruction/debris in the window channel. It also
sends a signal to the SJB that the windows are in
occurs if a door window motor initialization is not
the full down position. At this time, the SJB allows
carried out after repairs or if lubrication needs to be
the convertible top to operate (up or down). If the
carried out on the door window glass. The rear
SJB does not see the full down signal from both
quarter windows (convertible only) do not have the
rear quarter window motors, the convertible top
one-touch up/down feature.
does not operate. Conversely, all 4 windows operate
Window, Short Drop in any convertible top position. This function is to
prevent an accidental opening of the convertible
The window motors monitor their respective door
top with the windows in the up position causing
ajar switches. When the window motor senses a
contact between the windows and convertible top
door has been opened (by monitoring its door ajar
which may result in damage to the convertible top
switch) the window motor opens the window
or windows.
slightly to clear the grooved channel weatherstrip.
After the door is closed, the window motor senses
the closed door (by monitoring its door ajar switch)
and the window motor fully closes and seats the
window glass into the grooved channel weatherstrip.
This function is on both the coupe and the
convertible.
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Global Open
The SJB sends a signal on the global open circuit,
to the window motors to open the windows based
on a signal received from the remote keyless entry
(RKE) transmitter. If the accessory delay relay is
active, the global open feature will not operate.
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The window motor maintains operation until:
Glass, Frames and Mechanisms
the voltage at the window motor drops below 9
Special Tool(s)
volts.
a motor stall is detected by monitoring the current
draw.
A momentary activation of the window control
switch stops the one-touch up/down operation.
Pulling or pressing the window control switches to
the first detent operates the windows in a
proportional mode. Each window motor has a
dedicated auto circuit which provides ground to the (VCM) and Integrated
Diagnostic System (IDS) window motor(s) for one-touch up/down operation.
The SJB sends a signal on the global open circuit,
to the window motors to open the windows based
tool
on a signal received from the remote keyless entry
(RKE) transmitter. If the accessory delay relay is
Flex Probe Kit active, the global open feature will not operate.
105-R025B or equivalent
Power Window Control
Power window regulator Bussed electrical center
Window run (BEC) fuses: NOTE: Battery voltage and ground must be
weatherstrip 5 (30A)
removed before disconnecting the smart junction
Door window glass 7 (30A)
box (SJB) connectors to avoid setting false
11 (30A)
diagnostic trouble codes (DTCs).
12 (30A)
52 (30A)
The power window one-touch up or down
Smart junction box
operations (front windows only) are controlled by
(SJB) fuse 6 (5A)
the window motors. These features function only
SJB
when the key is in the ON or ACC positions. The
Window control switch
one-touch up or down operations are requested by Window motor
Heated rear window pulling or pressing the window control switch up
relay
or down to the second detent. When the second
Heated rear window
detent of the window control switch is
switch
pulled/pressed, the auto circuit is grounded through
Heated rear window
the switch and the commanded up or down circuit is
grid
also grounded through the switch. Depending on Circuitry
which (up or down) circuit carries voltage, the
window motor operates the window to the
commanded one-touch up or down direction.
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4. NOTE: Make sure to use the latest scan tool refer to Section 418-00 to diagnose no
software release. response from the SJB.
If the cause is not visually evident, connect the 7. Carry out the network test.
5. NOTE: The vehicle communication module communication from one or more modules,
(VCM) LED prove out confirms power and refer to Section 418-00.
VCM.
If the scan tool does not communicate with the trouble codes (DTCs).
VCM:
check the VCM connection to the vehicle. self-test diagnostics for the SJB.
check the scan tool connection to the VCM. 9. If the DTCs retrieved are related to the concern,
Trouble Code (DTC) Chart. For all other DTCs,
with the scan tool.
vehicle:
good vehicle.
B1342 ECU is Defective CLEAR the DTCs. RETRIEVE the
DTCs. If DTC B1342 is retrieved,
INSTALL a new SJB. REFER to
normal operation.
B1345 Heated Backlite Input Circuit Short to GO to Pinpoint Test D.
Ground
B1348 Heated Backlite Relay Circuit Open GO to Pinpoint Test D.
B1349 Heated Backlite Relay Short to GO to Pinpoint Test D.
Battery
B1475 Accessory Delay Relay Short to GO to Pinpoint Test E.
Battery
B2052 Accessory Delay Relay Output GO to Pinpoint Test C.
Failure
B2060 Heated Backlite Indicator Circuit GO to Pinpoint Test D.
Failure
B2061 Heated Backlite Indicator Circuit GO to Pinpoint Test E.
Shorted to Ground
B2360 Window Motor Control Output GO to Pinpoint Test H.
Circuit Failure
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Symptom Chart
Symptom Chart
No communication with the Circuitry REFER to Section 419-10 to
smart junction box (SJB) SJB continue diagnosis of the
module communication network.
A single power window is Fuse GO to Pinpoint Test A.
inoperative driver front Circuitry
Window control switch
Ignition switch
Window motor
(BEC)
A single power window is Fuse(s) GO to Pinpoint Test B.
inoperative passenger front Circuitry
Passenger window control
switch
Window motor
All power windows are Smart junction box (SJB) INSTALL a new SJB.
inoperative Bussed electrical center REFER to Section 419-10.
(BEC)
A single power window is Fuse GO to Pinpoint Test C.
inoperative rear quarter Circuitry
Rear window control switch
Rear window motor(s)
The one-touch up/down Fuse If driver window, GO to
feature is inoperative Circuitry Pinpoint Test A. If passenger
Window control switch window, GO to Pinpoint Test
Ignition switch B.
Window motor
The defrost system is Fuse GO to Pinpoint Test D.
Heated rear window relay
Heated rear window switch
Heated rear window grid
The defrost system will not Circuitry GO to Pinpoint Test E.
shut off automatically Heated rear window relay
The short drop windows do Circuitry GO to Pinpoint Test F.
not operate correctly Driver window motor
Passenger window motor
Door ajar switch
Window motor not initialized
The global open function is Remove keyless entry (RKE) GO to Pinpoint Test H.
inoperative/does not operate transmitters
correctly. Circuitry
Door window motors not
initialized
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Bounce-back occurring Door window glass out of ADJUST the door window
adjustment glass.
Door window glass INSTALL a new door
weatherstrip worn window glass weatherstrip.
Obstruction in the window REMOVE the obstruction
channel from the window channel.
DE-INITIALIZE the door
window motor by
disconnecting the battery with
the door window motor in
operation, then INITIALIZE
the door window motor.
REFER to Window Motor
Initialization in this section.
The one-touch up feature is Door window motor not DE-INITIALIZE the door
inoperative initialized window motor by
Window control switch disconnecting the battery with
the door window motor in
operation, then INITIALIZE
the door window motor.
REFER to Window Motor
Initialization in this section. If
the one-touch up feature is
still inoperative, INSTALL a
new power window control
switch.
The convertible top drop Window motor GO to Pinpoint Test G.
function is inoperative/does Circuitry
not operate correctly Smart junction box (SJB)
Fuse
Pinpoint Test A: A Single Power Window is
Inoperative Driver Front Circuit 226 (WH/BK) open
Refer to Wiring Diagrams Cell 100, Power Circuit 227 (YE) open
Circuit 400 (LB/BK) open
Normal Operation
Circuit 404 (VT/LG) open
With the key in the ON position (or with the
Circuit 985 (RD/LB) open
delayed accessory function active), pulling the
window control switch up provides voltage on
circuit 226 (WH/BK) to the window motor. Pressing Circuit 2034 (VT/YE) open
the window control switch down provides voltage
Ignition switch
on circuit 227 (YE) to the window motor.
Window motor
Depending on which circuit has voltage supplied
Window control switch determines which direction the window motor
operates. The window motor operates in the
commanded direction to move the window up or
down.
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PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE DRIVER FRONT
A1 CHECK THE POWER SUPPLY TO THE DRIVER WINDOW
CONTROL SWITCH
Disconnect: Driver Window Control Switch C504.
Key in ON position.
Measure the voltage between driver window control switch
C504-3, circuit 985 (RD/LB), harness side and ground.
Yes
GO to A2.
No
VERIFY the SJB fuse 6 (5A) is OK. If OK,
A2 CHECK THE DRIVER WINDOW CONTROL SWITCH CIRCUIT
1205 (BK) FOR AN OPEN
Measure the resistance between driver window control switch
Yes
GO to A3.
No
A3 CHECK THE DRIVER WINDOW CONTROL SWITCH FOR AN
OPEN
Carry out the window control switch component test. Refer to Yes
Wiring Diagrams Cell 149 for component testing. GO to A4.
Is the driver window control switch OK?
No
INSTALL a new driver window control
switch. REFER to Window Control Switch
normal operation.
A4 CHECK CIRCUIT 227 (YE) FOR AN OPEN
Connect: Driver Window Control Switch C504.
Disconnect: Driver Window Motor C518.
Key in ON position.
(Continued)
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PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE DRIVER FRONT (Continued)
A4 CHECK CIRCUIT 227 (YE) FOR AN OPEN (Continued)
Measure the voltage between driver window motor C518-4,
circuit 227 (YE), harness side and ground while rocking the
driver window control switch to the DOWN position.
Yes
GO to A5.
No
Is the voltage greater than 10 volts with the switch in the REPAIR the circuit. TEST the system for
DOWN position? normal operation.
A5 CHECK CIRCUIT 226 (WH/BK) FOR AN OPEN
circuit 226 (WH/BK), harness side and ground while rocking the
driver window control switch to the UP position.
Yes
GO to A6.
No
UP position? normal operation.
(Continued)
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A6 CHECK CIRCUIT 404 (VT/LG) FOR AN OPEN
Measure the resistance between driver window motor C518-1,
circuit 404 (VT/LG), harness side and ground while rocking the
driver window control switch to the UP and DOWN positions.
Yes
GO to A7.
No
Is the resistance less than 5 ohms with the switch in the UP REPAIR the circuit. TEST the system for
and DOWN positions? normal operation.
A7 CHECK CIRCUIT 2034 (VT/YE) FOR AN OPEN
circuit 2034 (VT/YE), harness side and ground.
Yes
GO to A8.
No
(BEC) fuse 5 (30A) is OK. If OK, REPAIR
the circuit. TEST the system for normal
Is the voltage greater than 10 volts? operation.
A8 CHECK CIRCUIT 400 (LB/BK) FOR AN OPEN
circuit 400 (LB/BK), harness side and ground.
Yes
GO to A9.
No
(Continued)
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A9 CHECK THE DRIVER WINDOW MOTOR CIRCUIT 1205 (BK) FOR
AN OPEN
Yes
INSTALL a new driver window motor.
REFER to Window Regulator and Motor
Front Door in this section. TEST the
No
A10 CHECK CIRCUIT 985 (RD/LB) FOR AN OPEN
Measure the resistance between driver window control switch
C504-3, circuit 985 (RD/LB), harness side and SJB C2280e-26,
circuit 985 (RD/LB), harness side.
Yes
GO to A11.
No
A11 CHECK THE SJB FOR CORRECT OPERATION
Disconnect all of the SJB connectors. Yes
corrosion.
pushed-out pins.
Pinpoint Test B: A Single Power Window is
Inoperative Passenger Front
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Normal Operation
Circuit 314 (TN/LB) open
Circuit 405 (VT/LB) open
window control switch up provides voltage on
circuit 313 (WH/YE) to the window motor. Pressing Circuit 984 (YE/LB) open
the window control switch down provides voltage
on circuit 314 (TN/LB) to the window motor.
Circuit 2033 (BN/LB) open
Passenger window control switch
determines which direction the window motor
Window motor
down.
Possible Causes
Fuse(s)
Circuit 170 (RD/LB) open
PINPOINT TEST B: A SINGLE POWER WINDOW IS INOPERATIVE PASSENGER FRONT
B1 CHECK THE OPERATION FROM THE DRIVER WINDOW
CONTROL SWITCH
Key in ON position.
Yes
Operate the passenger window from the driver window control
GO to B2.
switch.
Does the passenger window operate correctly from the No
driver window control switch? GO to B5.
Disconnect: Passenger Window Motor C623.
Measure the resistance between passenger window motor
Yes
GO to B3.
No
B3 CHECK CIRCUIT 2033 (BN/LB) FOR AN OPEN
Key in ON position.
(Continued)
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PINPOINT TEST B: A SINGLE POWER WINDOW IS INOPERATIVE PASSENGER FRONT (Continued)
B3 CHECK CIRCUIT 2033 (BN/LB) FOR AN OPEN (Continued)
Measure the voltage between passenger window motor C623-7,
circuit 2033 (BN/LB), harness side and ground.
Yes
GO to B4.
No
(BEC) fuse 7 (30A) is OK. If OK, REPAIR
the circuit. CLEAR the DTCs. TEST the
Is the voltage greater than 10 volts? system for normal operation.
B4 CHECK CIRCUIT 170 (RD/LB) FOR AN OPEN
circuit 170 (RD/LB), harness side and ground.
Yes
GO to B9.
No
B5 CHECK THE PASSENGER WINDOW CONTROL SWITCH FOR
AN OPEN
Disconnect: Suspect Window Control Switch. Yes
Carry out the window control switch component test. Refer to GO to B6.
Wiring Diagrams Cell 149 for component testing.
No
Is the window control switch OK?
INSTALL a new window control switch.
REFER to Window Control Switch in this
operation.
Measure the resistance between passenger window control Yes
switch C604-1, circuit 1205 (BK), harness side and ground. GO to B7.
Is the resistance less than 5 ohms?
No
normal operation.
B7 CHECK CIRCUIT 984 (YE/LB) FOR VOLTAGE
Key in ON position.
(Continued)
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B7 CHECK CIRCUIT 984 (YE/LB) FOR VOLTAGE (Continued)
Measure the voltage between passenger window control switch
C604-5, circuit 984 (YE/LB), harness side and ground.
Yes
GO to B9.
No
Is the voltage greater than 10 volts? 6 (5A) is OK. If OK, GO to B8.
B8 CHECK CIRCUIT 984 (YE/LB) FOR AN OPEN
Measure the resistance between passenger window control
switch C604-5, circuit 984 (YE/LB), harness side and SJB
C2280e-25, circuit 984 (YE/LB), harness side.
Yes
GO to B12.
No
B9 CHECK CIRCUIT 314 (TN/LB) FOR AN OPEN
Connect: Window Control Switch.
Key in ON position.
(Continued)
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B9 CHECK CIRCUIT 314 (TN/LB) FOR AN OPEN (Continued)
circuit 314 (TN/LB), harness side and ground while rocking the
passenger and driver window control switches to the DOWN
position.
Yes
GO to B10.
No
B10 CHECK CIRCUIT 313 (WH/YE) FOR AN OPEN
circuit 313 (WH/YE), harness side and ground while rocking the
passenger and driver window control switches to the UP
position.
Yes
GO to B11.
No
(Continued)
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B11 CHECK CIRCUIT 405 (VT/LB) FOR AN OPEN
C623-1, circuit 405 (VT/LB), harness side and ground while
rocking the passenger window control switch to the UP and
DOWN positions.
Yes
INSTALL a new passenger window motor.
No
UP and DOWN positions? normal operation.
B12 CHECK THE SJB FOR CORRECT OPERATION
corrosion.
pushed-out pins.
Pinpoint Test C: A Single Power Window is
Circuit 333 (YE/RD) open
Inoperative Rear Quarter
Circuit 882 (BN/YE) open
Circuit 884 (YE/BK) open
Circuit 885 (YE/LB) open
Normal Operation
Circuit 1670 (BN/YE) open
window control switch up or pressing the switch
Rear window control switch
down supplies voltage to the window motor.
Window motor
determines which direction the window motor
down.
Possible Causes
Fuse(s)
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PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE REAR QUARTER
C1 CHECK THE OPERATION OF THE REAR WINDOWS
Operate the rear windows with the driver rear window control Yes
switch. GO to C2.
Are both rear windows inoperative?
No
GO to C5.
C2 CHECK THE REAR WINDOW CONTROL SWITCH FOR AN
OPEN
Carry out the window control switch component test. Refer to Yes
Wiring Diagrams Cell 149 for component testing. GO to C3.
Is the window control switch OK?
No
INSTALL a new window control switch.
REFER to Window Control Switch in this
operation.
C3 CHECK CIRCUIT 333 (YE/RD) FOR VOLTAGE
Key in ON position.
Measure the voltage between rear window control switch
C566-5, circuit 333 (YE/RD), harness side and ground.
Yes
GO to C5.
No
C4 CHECK CIRCUIT 333 (YE/RD) FOR AN OPEN
Measure the resistance between rear window control switch
C566-5, circuit 333 (YE/RD), harness side and SJB C2280e-23,
circuit 333 (YE/RD), harness side.
Yes
GO to C11.
No
(Continued)
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PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE REAR QUARTER (Continued)
C5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Disconnect: Suspect Window Motor.
Measure the resistance between LH rear window motor
C3118-8, or RH rear window motor C3119-8, circuit 1205 (BK),
Yes
GO to C6.
No
C6 CHECK THE VBATT CIRCUIT FOR AN OPEN
Key in ON position.
Measure the voltage between LH rear window motor, C3118-7,
or RH rear window motor C3119-7, circuit 1670 (BN/YE),
Yes
GO to C7.
No
(Continued)
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C7 CHECK CIRCUIT 885 (YE/LB) FOR AN OPEN
While rocking the rear window control switch to the down
position, measure the voltage between LH rear window motor
C3118-4, or RH rear window motor C3119-4, circuit 885
(YE/LB), harness side and ground.
Yes
GO to C8.
No
C8 CHECK CIRCUIT 884 (YE/BK) FOR AN OPEN
While rocking the passenger window control switch to the UP
position, measure the voltage between LH rear window motor
C3118-3, or RH rear window motor C3119-3, circuit 884
(YE/BK), harness side and ground.
Yes
GO to C9.
No
(Continued)
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C9 CHECK CIRCUIT 882 (BN/YE) FOR VOLTAGE
Measure the voltage between LH rear window motor C3118-2,
or RH rear window motor C3119-2, circuit 882 (BN/YE), harness
side and ground.
Yes
INSTALL a new rear quarter window
regulator and motor. REFER to Window
Regulator Motor Rear Quarter in this
operation.
No
C10 CHECK CIRCUITS 193 (YE/LG) OR 882 (BN/YE) FOR AN OPEN
Measure the resistance between LH rear window motor
C3118-2, circuit 882 (BN/YE), harness side and SJB C2280e-17,
circuit 193 (YE/LG), harness side; or between RH rear window
motor C3119-2, circuit 882 (BN/YE), harness side and SJB
C2280e-16, circuit 882 (BN/YE), harness side.
Yes
GO to C11.
No
C11 CHECK THE SJB FOR CORRECT OPERATION
corrosion.
operation.
pushed-out pins.
Pinpoint Test D: The Defrost System is
Inoperative
Refer to Wiring Diagrams Cell 56, Heated Window
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Normal Operation
Circuit 298 (VT/OG) open
When the rear defrost switch on the climate control
assembly is pressed, a ground signal is sent to the
Circuit 1389 (WH) open or short to voltage
smart junction box (SJB) on circuit 1426 (PK). The
SJB then grounds circuit 1389 (WH). This energizes Circuit 1426 (PK) open or short to ground
the heated rear window relay, allowing voltage to
Circuit 1427 (TN/LB) open, short to ground or
be supplied to the heated rear window grid through
short to voltage
circuit 186 (BN/LB). The heated rear window grid
is grounded by circuit 1205 (BK).
Possible Causes
Heated rear window grid
Fuse(s)
Circuit 186 (BN/LB) open
PINPOINT TEST D: THE DEFROST SYSTEM IS INOPERATIVE
D1 CHECK FOR RECORDED SJB DIAGNOSTIC TROUBLE CODES
(DTCs)
Check the recorded results from the SJB self-test. If DTC B1348 or B1349, GO to D9. If DTC
Are any DTCs retrieved? B1345, GO to D13. If DTC B2060 or
B2061, GO to D15.
No
GO to D2.
D2 CHECK CIRCUIT 1389 (WH) FOR GROUND
Disconnect: Heated Rear Window Relay.
Key in ON position.
Press the heated rear window switch to ON.
(Continued)
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PINPOINT TEST D: THE DEFROST SYSTEM IS INOPERATIVE (Continued)
D2 CHECK CIRCUIT 1389 (WH) FOR GROUND (Continued)
Measure the resistance between heated rear window relay
C1099-86, circuit 1389 (WH), harness side and ground.
Yes
GO to D3.
No
D3 CHECK CIRCUIT 298 (VT/OG) FOR AN OPEN
(Continued)
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D3 CHECK CIRCUIT 298 (VT/OG) FOR AN OPEN (Continued)
Measure the voltage between heated rear window relay
C1099-30 and C1099-85, circuit 298 (VT/OG), harness side and
ground.
Yes
GO to D4.
No
D4 CHECK THE HEATED REAR WINDOW RELAY FOR AN OPEN
OR INTERNAL SHORT (NO DTCs)
Carry out the heated rear window relay component test. Refer to Yes
Wiring Diagrams Cell 149 for component testing. GO to D5.
Is the heated rear window relay OK?
No
INSTALL a new heated rear window relay.
D5 CHECK CIRCUIT 186 (BN/LB) FOR AN OPEN
Disconnect: Heated Rear Window.
Key in ON position.
(Continued)
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D5 CHECK CIRCUIT 186 (BN/LB) FOR AN OPEN (Continued)
Connect a fused (5A) jumper wire between heated rear window
relay C1099-30, circuit 298 (VT/OG), harness side and heated
rear window relay C1099-87, circuit 186 (BN/LB), harness side.
Measure the voltage between heated rear window C402a-1
(coupe), circuit 186 (BN/LB), harness side and ground; or
between heated rear window C402-1 (convertible), circuit 186
(BN/LB), harness side and ground.
Yes
REMOVE the jumper wire. GO to D6.
No
(Continued)
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D6 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between heated rear window C402b-1
(coupe), circuit 1205 (BK), harness side and ground; or between
heated rear window C402-2 (convertible), circuit 1205 (BK),
Yes
REPAIR the heated rear window grid.
REFER to Window Grid Wire Repair in
operation.
No
D7 CHECK THE HEATED REAR WINDOW SWITCH FOR CORRECT
OPERATION
NOTE: The use of an analog ohmmeter may be necessary for this
step due to the momentary ground signal of the heated rear window
switch.
While pressing the heated rear window switch to ON, measure
the resistance between SJB C2280b-18, circuit 1426 (PK),
Yes
GO to D18.
No
D8 CHECK CIRCUIT 1426 (PK) FOR AN OPEN
Disconnect: Climate Control Assembly C294a.
(Continued)
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D8 CHECK CIRCUIT 1426 (PK) FOR AN OPEN (Continued)
(PK), harness side and climate control assembly C294a-10,
circuit 1426 (PK), harness side.
Yes
INSTALL a new climate control assembly.
No
D9 CHECK CIRCUIT 298 (VT/OG) FOR VOLTAGE
C1099-85, circuit 298 (VT/OG), harness side and ground.
Yes
GO to D10.
No
(Continued)
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D10 CHECK THE HEATED REAR WINDOW RELAY FOR AN OPEN
OR AN INTERNAL SHORT (DTC B1348, B1349)
Carry out the heated rear window relay component test. Refer to Yes
Wiring Diagrams Cell 149 for component testing. GO to D11.
Is the heated rear window relay OK?
No
INSTALL a new heated rear window relay.
D11 CHECK CIRCUIT 1389 (WH) FOR AN OPEN
Measure the resistance between heated rear window relay
C1099-86, circuit 1389 (WH), harness side and SJB C2280c-12,
circuit 1389 (WH), harness side.
Yes
GO to D12.
No
D12 CHECK CIRCUIT 1389 (WH) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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D12 CHECK CIRCUIT 1389 (WH) FOR A SHORT TO VOLTAGE
(Continued)
C1099-86 circuit 1389 (WH), harness side and ground.
Yes
normal operation.
No
D13 VERIFY DTC B1345
Key in ON position.
(PK), harness side and ground.
Yes
GO to D18.
No
Is the resistance greater than 10,000 ohms? GO to D14.
D14 CHECK CIRCUIT 1426 (PK) FOR A SHORT TO GROUND
(Continued)
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D14 CHECK CIRCUIT 1426 (PK) FOR A SHORT TO GROUND
(Continued)
(PK), harness side and ground.
Yes
INSTALL a new climate control assembly.
No
D15 CHECK CIRCUIT 1427 (TN/LB) FOR AN OPEN OR SHORT TO
GROUND
(TN/LB), harness side and climate control assembly C294a-4,
circuit 1427 (TN/LB), harness side; and between SJB
C2280b-7, circuit 1427 (TN/LB), harness side and ground.
Yes
GO to D16.
climate control assembly and greater than 10,000 ohms REPAIR the circuit. TEST the system for
between the SJB and ground? normal operation.
D16 CHECK CIRCUIT 1427 (TN/LB) FOR A SHORT TO VOLTAGE
Key in ON position.
(Continued)
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D16 CHECK CIRCUIT 1427 (TN/LB) FOR A SHORT TO VOLTAGE
(Continued)
Measure the voltage between SJB C2280b-7, circuit 1427
(TN/LB), harness side and ground.
Yes
normal operation.
No
D17 CHECK THE CLIMATE CONTROL ASSEMBLY FOR AN OPEN
OR INTERNAL SHORT
Install a known good climate control assembly. Yes
Operate the heated rear window. INSTALL a new climate control assembly.
Does the indicator illuminate? REFER to Section 412-01. TEST the
No
GO to D18.
D18 CHECK THE SJB FOR CORRECT OPERATION
corrosion.
pushed-out pins.
Possible Causes
Pinpoint Test E: The Defrost System Will Not
Shut Off Automatically
Circuit 186 (BN/LB) short to voltage
Refer to Wiring Diagrams Cell 56, Heated Window
Circuit 1389 (WH) short to ground
Normal Operation
When the rear defrost switch on the climate control
assembly is pressed, a signal is sent to the smart
junction box (SJB) to ground circuit 1389 (WH).
This closes the heated rear window relay, allowing
voltage to be supplied to the heated rear window
grid through circuit 186 (BN/LB). The heated rear
window grid is grounded by circuit 1205 (BK).
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PINPOINT TEST E: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY
E1 CHECK THE HEATED REAR WINDOW RELAY FOR AN OPEN
OR INTERNAL SHORT
Key in ON position.
Yes
GO to E2.
Carry out the heated rear window relay component test. Refer to
Wiring Diagrams Cell 149 for component testing. No
Does the heated rear window relay pass the component INSTALL a new heated rear window relay.
test? CLEAR the DTCs. REPEAT the self-test.
E2 CHECK CIRCUIT 186 (BN/LB) FOR A SHORT TO VOLTAGE
Disconnect: Heated Rear Window C402a (coupe), C402
(convertible).
Measure the voltage between heated rear window C402a-1
(coupe), C402-1 (convertible), circuit 186 (BN/LB), harness side
and ground.
Yes
No
E3 CHECK CIRCUIT 1389 (WH) FOR A SHORT TO GROUND
(Continued)
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PINPOINT TEST E: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY (Continued)
E3 CHECK CIRCUIT 1389 (WH) FOR A SHORT TO GROUND
(Continued)
Measure the resistance between the heated rear window relay
C1099-86, circuit 1389 (WH), harness side and ground.
Yes
GO to E4.
No
E4 CHECK THE SJB FOR CORRECT OPERATION
corrosion.
pushed-out pins.
Pinpoint Test F: The Short Drop Windows
Do Not Operate Correctly
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Possible Causes
Normal Operation
The short drop window feature is activated when
Circuit 1312 (LG/BK) open
one (or both) of the doors are opened, which opens
a door ajar switch. When the driver door is opened
Driver window motor (opening the driver door ajar switch), a signal on
circuit 1312 (LG/BK) is interpreted by the driver
window motor that the driver door is open. The
Door ajar switch
driver window motor then carries out the short drop
Window motor not initialized
function on the driver window. When the passenger
door is opened (opening the passenger door ajar
switch), a signal on circuit 1314 (YE/LG) is
interpreted by the passenger window motor that the
passenger door is open. The passenger window
motor then carries out the short drop function on the
passenger window. This feature is on both the
coupe and the convertible.
PINPOINT TEST F: THE SHORT DROP WINDOWS DO NOT OPERATE CORRECTLY
F1 VERIFY THE INTERIOR LAMP OPERATION
Open and close the driver door and view the interior lamps Yes
operation. GO to F2.
Open and close the passenger door and view the interior lamps
No
operation.
REFER to Section 417-02 to continue the
diagnosis of the interior lamps.
F2 CARRY OUT THE SHORT DROP CALIBRATION
Carry out the Window Motor Initialization in this section. The system is operating correctly at this
Does the short drop window feature operate correctly? time. INFORM the customer of the short
drop window feature. REFER to the
Owners Literature.
No
For the driver window, GO to F3.
For the passenger window, GO to F4.
F3 CHECK CIRCUIT 1312 (LG/BK) FOR AN OPEN
Disconnect: Driver Door Ajar Switch C526.
circuit 1312 (LG/BK), harness side and driver door ajar switch
C526-2, circuit 1312 (LG/BK), harness side.
Yes
INSTALL a new driver window motor.
No
F4 CHECK CIRCUIT 1314 (YE/LG) FOR AN OPEN
(Continued)
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PINPOINT TEST F: THE SHORT DROP WINDOWS DO NOT OPERATE CORRECTLY (Continued)
F4 CHECK CIRCUIT 1314 (YE/LG) FOR AN OPEN (Continued)
Disconnect: Passenger Door Ajar Switch C602.
C623-5, circuit 1314 (YE/LG), harness side and passenger door
ajar switch C602-2, circuit 1314 (YE/LG), harness side.
Yes
INSTALL a new passenger window motor.
No
Possible Causes
Pinpoint Test G: The Convertible Top Drop
Function is Inoperative/Does Not Operate
Circuit 2020 (GY/YE) open or short to ground
Correctly
Circuit 2031 (GY/PK) open or short to ground
Circuit 2032 (LB) open or short to ground
Normal Operation
Driver window motor
The convertible top drop function is activated when
the convertible top switch is operated. When the
smart junction box (SJB) sees the voltage drop on
RH rear window motor
circuit 2038 (LB/OG) (lower) or circuit 2052
LH rear window motor
(VT/OG) (raise), the SJB first sends a signal to all
4 window motors on circuits 2032 (LB) (driver),
SJB
2031 (GY/PK) (passenger), 2020 (GY/YE) (LH
rear) and 2021 (WH/YE) (RH rear). At this time, all
4 window motors operate to the fully down
position. The rear window motors have a fully
down sensor the SJB monitors. When the SJB sees
that the LH and RH rear windows are fully down, it
then grounds circuit 1174 (WH/RD) (lower relay) or
588 (VT) (raise relay) to close the desired relay and
operate the convertible top in the requested
direction. If the SJB does not see the correct signal
from the LH rear and RH rear window full down
sensors, the SJB does not allow the convertible top
to operate.
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PINPOINT TEST G: THE CONVERTIBLE TOP DROP FUNCTION IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
G1 VERIFY THE WINDOW OPERATION
Open and close all of the windows using the driver window GO to G2.
control switches.
No
Do all of the windows operate correctly?
If the driver window does not operate
correctly, GO to Pinpoint Test A. If the
passenger window does not operate
correctly, GO to Pinpoint Test B. If one or
both of the rear windows do not operate
correctly, GO to Pinpoint Test C.
G2 OPERATE THE CONVERTIBLE TOP
Attempt to operate the convertible top. Yes
Do the windows drop fully before the convertible top starts The system is operating correctly at this
to operate? time. INFORM the customer of the
convertible top drop function. REFER to
the owners literature.
No
For the driver window, GO to G3. For the
passenger window, GO to G4. For both,
operation.
For the LH rear window, GO to G5. For
the RH rear window, GO to G6. For both
rear windows, INSTALL a new SJB.
G3 CHECK CIRCUIT 2032 (LB) FOR AN OPEN OR SHORT TO
GROUND
circuit 2032 (LB), harness side and SJB C2280d-5, circuit 2032
(LB), harness side; and between driver window motor C518-6,
circuit 2032 (LB), harness side and ground.
Yes
INSTALL a new driver door window
Regulator and Motor Front Door in this
operation.
Is the resistance less than 5 ohms between the window No
motor and the SJB and greater than 10,000 ohms between REPAIR the circuit. TEST the system for
the window motor and ground? normal operation.
G4 CHECK CIRCUIT 2031 (GY/PK) FOR AN OPEN OR SHORT TO
GROUND
(Continued)
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G4 CHECK CIRCUIT 2031 (GY/PK) FOR AN OPEN OR SHORT TO
GROUND (Continued)
C623-6, circuit 2031 (GY/PK), harness side and SJB C2280d-6,
circuit 2031 (GY/PK), harness side; and between passenger
window motor C623-6, circuit 2031 (GY/PK), harness side and
ground.
Yes
INSTALL a new passenger door window
Regulator and Motor Front Door in this
operation.
motor and the SJB, and greater than 10,000 ohms between REPAIR the circuit. TEST the system for
G5 CHECK CIRCUITS 2031 (GY/PK) AND 2020 (GY/YE) FOR AN
Disconnect: LH Rear Window Motor C3118.
Measure the resistance between LH rear quarter window motor
C3118-6, circuit 2031 (GY/PK), harness side and SJB
C2280d-19, circuit 2020 (GY/YE), harness side; and between LH
rear quarter window motor C3118-6, circuit 2031 (GY/PK),
Yes
INSTALL a new LH rear quarter window
operation.
G6 CHECK CIRCUITS 2031 (GY/PK) AND 2021 (WH/YE) FOR AN
Disconnect: RH Rear Window Motor C3119.
(Continued)
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G6 CHECK CIRCUITS 2031 (GY/PK) AND 2021 (WH/YE) FOR AN
OPEN OR SHORT TO GROUND (Continued)
Measure the resistance between RH rear quarter window motor
C3119-6, circuit 2031 (GY/PK), harness side and SJB
C2280d-20, circuit 2021 (WH/YE), harness side; and between
RH rear quarter window motor C3119-6, circuit 2031 (GY/PK),
Yes
INSTALL a new RH rear quarter window
operation.
Possible Causes
Pinpoint Test H: The Global Open Function
Is Inoperative/Does Not Operate Correctly
RKE transmitters
Open, short to ground or voltage in circuits 2032
(LB), 2031 (GY/RD), 2021 (WH/YE) or 2020
(GY/YE)
Normal Operation
When the unlock button of the remote keyless entry
SJB
(RKE) transmitter is held for 2 seconds the global
Window motor
open function activates. The smart junction box
Window motors not initialized
(SJB) sends a signal on circuit 2032 (LB), 2031
(GY/RD), 2021 (WH/YE) and 2020 (GY/YE) to
activate the one-touch down operation of all the
windows.
PINPOINT TEST H: THE GLOBAL OPEN FUNCTION IS INOPERATIVE/ DOES NOT OPERATE
CORRECTLY
NOTE: One-touch up/down must be operational for the global open function to operate
correctly. Make sure one-touch up/down is operational before proceeding with this diagnostic.
H1 CHECK THE REMOTE KEYLESS ENTRY (RKE) TRANSMITTER
Check for correct operation of the RKE transmitter. Yes
Does the RKE transmitter unlock and lock the doors? GO to H2.
No
inoperative RKE transmitter.
H2 CHECK CIRCUITS 2032 (LB), 2031 (GY/RD), 2021 (WH/YE) AND
2020 (GY/YE) FOR A SHORT TO VOLTAGE
Disconnect: Smart Junction Box (SJB) C2280D.
Key in ON position.
(Continued)
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2020 (GY/YE) FOR A SHORT TO VOLTAGE (Continued)
Measure the voltage between SJB inoperative window
C2280D-5, circuit 2032 ([LB] LF), C2280D-6, circuit 2031
([GY/RD] RF), C2280D-20, circuit 2021 ([WH/YE] RR),
C2280D-19, circuit 2020 ([GY/YE] LR), harness side and ground.
Yes
GO to H3.
No
Is the voltage greater than 10 volts? GO to H4.
H3 CHECK WINDOW MOTORS FOR A SHORT TO VOLTAGE
Disconnect: Inoperative Window Motors C518, C623, C3118,
C3119.
Measure the voltage between SJB inoperative window
Yes
REPAIR the circuit. INITIALIZE the
window motors. REFER to Window Motor
Initialization in this section. CLEAR the
DTCs. REPEAT the self-test. TEST the
No
INSTALL a new window motor. CLEAR
2020 (GY/YE) FOR A SHORT TO GROUND
Connect: Inoperative Window Motors C518, C623, C3118,
C3119.
(Continued)
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2020 (GY/YE) FOR A SHORT TO GROUND (Continued)
Measure the resistance between SJB inoperative window
Yes
GO to H6.
No
Is the resistance greater than 10,000 ohms? GO to H5.
H5 CHECK WINDOW MOTORS FOR A SHORT TO GROUND
C3119.
Yes
INSTALL a new window motor. CLEAR
No
H6 CHECK FOR AN OPEN IN CIRCUITS 2032 (LB), 2031 (GY/RD),
2021 (WH/YE) AND 2020 (GY/YE)
Disconnect: Smart Junction Box (SJB) C2280D.
C3119.
(Continued)
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H6 CHECK FOR AN OPEN IN CIRCUITS 2032 (LB), 2031 (GY/RD),
2021 (WH/YE) AND 2020 (GY/YE) (Continued)
C2280D-19, circuit 2020 ([GY/YE] LR), harness side and
inoperative window motor C518-6, circuit 2032 ([LB] LF),
C623-6, circuit 2031 ([GY/RD] RF), C3119-6, circuit 2021
([WH/YE] RR), C3118-6, circuit 2020 ([GY/YE] LR), harness
side.
Yes
GO to H7.
No
H7 CHECK THE SJB FOR CORRECT OPERATION
Connect all SJB connectors and make sure they seat correctly.
No
time. Concern may have been caused by
a loose or corroded connector. CLEAR the
Component Tests 4. Contact a good ground point with the negative
lead of the meter. The voltage reading should
Grid Wire Test
not differ.
1. Using a bright lamp inside the vehicle, inspect
5. With the negative lead of the meter grounded,
the wire grid from the exterior. A broken grid
touch each grid line of the heated rear window
wire appears as a brown spot.
at its midpoint with the positive lead. A reading
2. Run the engine at idle. Set the heated rear
of approximately 6 volts indicates the line is
window switch to ON. The heated rear window
good. A reading of zero volts indicates the line
indicator should come on.
is broken between the midpoint and the B+
side of the grid line. A reading of 12 volts
3. Working from the interior of the vehicle with a
indicates the circuit is broken between the
voltmeter, contact the broad red-brown stripes
midpoint of the grid line and ground.
of the heated rear window positive lead to
battery side and the negative lead to ground
side. The meter should read 10-13 volts. A
lower voltage reading indicates a loose ground
connection.
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Handles, Locks, Latches and Entry
Systems
Lock Cylinders
Individual lock cylinders are repaired by discarding
the inoperative lock cylinder and building a new
lock cylinder using the appropriate lock repair
package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to
the current key code of the vehicle.
Latch System
The door latch system consists of: The RKE transmitter initiates the following
electronic system functions:
Interior door handle (front)
Unlocks the driver door.
Interior door handle (front) actuating cable
Unlocks both doors.
Front door latch
Locks both doors and flashes the turn signal
Manual lock rod
lamps if all doors (hood and luggage compartment
Exterior door handle
if equipped with alarm) are closed.
Exterior door handle actuating rod
Activates/deactivates the panic alarm.
Door latch striker plate
Commands the interior lamps on when unlocking
Door lock cylinder
and off when locking.
Door lock cylinder actuating rod
Sounds the horn once when LOCK is pressed
twice within 3 seconds, and the doors (hood and
Door lock control switch
luggage compartment if equipped with alarm) are
Door lock actuator
closed.
Luggage compartment lid latch with mechanical
Sounds the horn twice when LOCK is pressed
interior release handle and cable
within 3 seconds if any door (hood and luggage
Luggage compartment lid lock cylinder
compartment if equipped with alarm) is ajar.
Arms/disarms the alarm system (if equipped).
Remote Keyless Entry (RKE) System
The RKE transmitter has a maximum operating
The electronic door lock system has 3 main
range of 10 m (33 ft).
components:
Locking From The Driver Door Key Cylinder
NOTE: Locking the driver door with the key does
RKE transmitter
not lock the passenger door. Use the door lock
control switch or manually lock the passenger door
to make sure that the vehicle is properly secured.
The vehicle keys are designed to lock or unlock the
driver door or to open the luggage compartment lid.
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Headliner
2. Remove the 6 sun visor screws, the 2 sun
visors, and the 2 sun visor arm clips.
1 N806664 Sun visor screws/sun visor
arm clip screws (6 required)
2 6304104/ Sun visors (2 required)
6304105 (RH/LH) Disconnect the electrical connector.
3 6304132 Sun visor arm clips (2
4. Remove the 2 headliner pin-type retainers. required)
4 519A58 Overhead console
5. Disconnect the headliner electrical connector
5 Overhead console electrical
and remove the headliner.
6 Headliner electrical connector
(part of 14484)
7 W709950 Headliner pin-type retainers
(2 required)
8 6351916 Headliner
1. Remove the quarter window trim panel. For
additional information, refer to Quarter Window
Trim Panel in this section.
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6. NOTE: A new headliner will need to be
installed if the headliner is folded during
removal or installation.
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501-03-1 501-03-1 Body Closures
GENERAL PROCEDURES
4. Adjust the front door to specification.
Hinge Adjustment
1. Remove the fender. For additional information,
2. Mark the position of the upper and lower front
door hinges to the body to use as reference
points.
5. NOTE: After adjusting the door hinge, verify
the door can be closed easily and fits tightly.
Tighten the 4 front door hinge-to-body bolts.
6. Install the fender. For additional information,
3. Loosen the 2 upper and 2 lower front door
hinge-to-body bolts enough to permit
movement.
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Hood Latch and Components
Exploded View
4 N808727 Hood latch release handle 1 W611103 Hood latch bolts (2 required)
screws (2 required)
2 Hood latch release cable (part
5 16916 Hood latch release handle of 16916)
3 16700 Hood latch
(Continued)
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4. Remove the LH A-pillar lower trim panel.
Hood Latch Release Handle
5. Remove the 2 hood latch release handle screws.
6. Remove the hood release latch handle and
1. Remove the hood latch. For additional
cable.
information, refer to Hood Latch in this section.
Release the grommet from the dash panel.
2. Disconnect the hood latch release cable guides.
3. Remove the LH scuff plate.
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3. NOTE: Mark the location of the hood latch to
Hood Latch
aid installation.
Material Remove the 2 hood latch bolts.
Item Specification
4. Disconnect the hood latch release cable.
Spray
XL-5
5. Remove the hood latch.
Adjust the hood latch for correct
engagement after installation.
Lubricate the hood latch after installation.
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Hydraulic System, Lift Cylinder and
Motor
Material
Item Specification
TA-25
7 7653392 Upper hydraulic line 1 W709053 Hydraulic lift cylinder bracket
bolts (2 required)
8 7653390 Lower hydraulic line
2 7650668 Hydraulic lift cylinder
brackets (2 required)
Removal
3 N808519 Clevis-to-hydraulic lift
cylinder rod bolts (2 required)
NOTE: The convertible top hydraulic components
4 7650600 Hydraulic lift cylinders (2
are removed from the vehicle as an assembly. The
required)
hydraulic components are individually repaired and
5 W704723 Convertible top pump and
the system must be bled before being installed into
motor assembly nuts (2
the vehicle.
required)
6 76533A00 Convertible top pump and Hydraulic system
motor assembly
(Continued)
1. Lower the convertible top.
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Installation
2. Remove the rear seat backrests. For additional
Motor assembly
3. Remove the 2 rear quarter trim panels. For
1. NOTE: Make sure each fitting is installed in
the correct position on the folding top hydraulic
4. Momentarily place the convertible top switch in
component.
the raise position to release the tension on the
NOTE: Make sure the tetra seal is installed in
convertible top system.
the bottom of each of the folding top hydraulic
motor ports before attaching the hose fittings.
5. Remove the 2 bolts (1 each side) and the 2
hydraulic lift cylinder brackets (1 each side).
NOTE: Apply thread locker to the fitting
threads.
6. Remove the 2 clevis-to-hydraulic lift cylinder
Install the hydraulic lines onto the motor
rod bolts.
assembly fittings.
Tighten to 4 Nm (35 lb-in). 7. Fully lower the hydraulic lift cylinders.
Hydraulic lift cylinder
8. Release the hydraulic line locators on each side.
9. Disconnect the convertible top pump motor
2. NOTE: Make sure each fitting is installed in
the correct position on the folding top hydraulic
component.
10. Remove the 6 bolts (3 each side) attaching the
NOTE: Make sure the tetra seal is installed in
the bottom of each of the folding top hydraulic
lift cylinder ports before attaching the upper
11. NOTE: Remove the convertible top motor and
and lower hose fittings.
hydraulic lift cylinders as an assembly.
NOTE: Apply thread locker to the fitting
Remove the 2 nuts and the convertible top
threads.
pump and motor assembly.
Install the hydraulic lines onto the hydraulic lift
Hydraulic lift cylinder
cylinder fittings.
12. NOTE: Prior to removal, mark the upper and
Hydraulic system lower hydraulic lines to make sure the hydraulic
lift cylinders are positioned correctly.
Remove the hydraulic lines from the lift 3. Bleed the hydraulic system. For additional
cylinder. information, refer to System Bleeding in this
section.
Motor assembly
4. Install the 6 bolts (3 each side) attaching the
13. NOTE: Prior to removal, mark the hydraulic
lines to make sure the motor is positioned
correctly.
5. NOTE: Install the convertible top motor and
Remove the hydraulic lines from the convertible
hydraulic lift cylinders as an assembly.
top motor assembly.
Position the convertible top motor and hydraulic
lift cylinders and install the convertible top
motor nuts.
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6. Connect the convertible top motor electrical 9. Position the hydraulic lift cylinders and install
connector. the 2 brackets and the 2 bolts.
7. Engage the hydraulic line locators on each side.
10. Install the 2 rear quarter trim panels. For
8. Install the 2 clevis-to-hydraulic lift cylinder rod
bolts.
Tighten to 20 Nm (15 lb-ft). 11. Install the rear seat backrest. For additional
12. Raise the convertible top.
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Ignition Lock Cylinder
Material
Item Specification
Penetrating and Lock -
Lubricant
XL-1
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shroud screw
shroud
4 11582 Ignition lock cylinder
1. Remove the steering column cover.
Lubricate the ignition lock cylinder after
column shroud.
installation.
3. Turn the key to the RUN position.
4. Insert a small punch into the hole and remove
the ignition lock cylinder.
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501-35-1 501-35-1 Body Repairs
Inner Body Reinforcing Panels
Special Tool(s)
Pro 230 Mig Welder
208-00030
Heat Treatment Induction
Resistance Spot Welder
254-00001
Material
Item Specification
Low Temperature
PM-12-A
TA-1
Cleaner
ZC-21
Seam Sealer
TA-2
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501-35-2 501-35-2 Body Repairs
Coupe
CAUTION: Body side section repairs should not be carried out in areas of laser welds, door
hinge or striker anchoring points or near restraints anchoring points. Do not cut or grind body side
components within 50 mm (1.96 in) of restraint anchoring points. For additional restraints anchoring
location information, refer to Section 501-20A. Cut points shown in illustrations are approximate.
NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug
welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over
an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
NOTE: Observe prescribed welding procedures when carrying out any body side section repair. For additional
information, refer toWeld-Bonding in this section.
NOTE: Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring
Corrosion Protection Following Repair in this section.
5 24301 LH/ B-pillar inner 1 02501 LH/ A-pillar assembly
24300 RH high-strength steel (part of 02500 RH high-strength steel
27791/27790)
2 02039B LH/ Cowl side panel
6 27791 LH/ Quarter panel inner mild 02038B RH high-strength steel
27790 RH steel
3 02509 LH/ A-pillar reinforcement
7 28061 LH/ Quarter panel upper rear 02508 RH high-strength steel
28060 RH extension mild steel
4 02505 LH/ A-pillar inner
8 28059 LH/ Quarter panel lower extension 02504 RH high-strength steel
28058 RH mild steel
(Continued)
(Continued)
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501-35-3 501-35-3 Body Repairs
9 Wheelhouse inner panel 10 02B67 LH/ Rocker panel reinforcement
mild steel (part of 02B66 RH (vehicles built prior to
27791/27790) 01/2007) dual-phase
steel/(vehicles built after
(Continued)
01/2007) high-strength steel
11 02733 LH/ Gusset high-strength steel
02732 RH
Convertible
7 280C99 LH/ C-pillar reinforcement 1 02501 LH/ A-pillar assembly
280C98 RH mild steel 02500 RH high-strength steel
8 28059 LH/ Quarter panel lower rear 2 02509 LH/ A-pillar reinforcement
28058 RH extension mild steel 02508 RH high-strength steel
9 27791 LH/ Quarter panel inner mild 3 02505 LH/ A-pillar inner panel
27790 RH steel 02504 RH high-strength steel
10 28061 LH/ Quarter panel upper rear 4 02039B LH/ Cowl side panel
28060 RH extension mild steel 02038B RH high-strength steel
11 28153 Quarter panel upper outer 5 025B33 LH/ Bracket high-strength steel
LH/28152 RH panel mild steel 025B32 RH
12 Wheelhouse inner panel 6 24301 LH/ B-pillar reinforcement
mild steel (part of 24300 RH high-strength steel (part of
27791/27790) 27791/27790)
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501-35-4 501-35-4 Body Repairs
1. Remove the outer body sheet metal from the
affected area prior to carrying out any
13 02B67 LH/ Rocker panel reinforcement
reinforcing panel replacement. For additional
02B66 RH (vehicles built prior to
01/2007) dual-phase information, refer to Sectioning Guidelines in
steel/(vehicles built after
this section.
01/2007) high-strength steel
14 02733 LH/ Bracket high-strength steel
02732 RH
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GENERAL PROCEDURES
1. NOTE: Refer to the correct removal and
Inspection and Repair After a
installation procedure for all SRS components
being installed.
Deployment
When any deployable device or combination of
devices are deployed and/or the restraints
WARNING: The restraint system
control module (RCM) has the diagnostic
diagnostic tool is for restraint system service
trouble code (DTC) B1231 (Crash Data
only. Remove from vehicle prior to road use.
Memory Full) in memory, the repair of the
Failure to remove could result in injury and
vehicles SRS is to include the removal of all
possible violation of vehicle safety standards.
deployed devices and the installation of new
deployable devices, the removal and installation
NOTE: After diagnosing or repairing an SRS, the
of new impact sensors, and the removal and
restraint system diagnostic tools must be
installation of a new RCM.
removed before operating the vehicle over the
road.
2. When any damage to the impact sensor
mounting points or mounting hardware has
NOTE: After diagnosing or repairing a seat system,
occurred, repair or install new mounting points
the restraint system diagnostic tools must be
and mounting hardware as needed.
road.
3. When the driver air bag module has deployed, a
new clockspring must be installed.
NOTE: Deployable devices (such as air bag
modules, pretensioners) may deploy alone or in
4. Inspect the entire vehicle for damage, including
various combinations depending on the impact
the following components:
event.
Steering column
NOTE: Always refer to the appropriate workshop
Instrument panel knee bolsters and mounting
manual procedures prior to carrying out vehicle
points
repairs affecting the supplemental restraint system
(SRS) and safety belt system. Instrument panel braces and brackets
Instrument panel and mounting points
Seats and seat mounting points
customer.
Safety belts, safety belt buckles and safety
belt retractors. For additional information,
refer to Section 501-20A
SRS wiring, wiring harnesses and
connectors
5. After carrying out the review and inspection of
the entire vehicle for damage, repair or install
new components as needed.
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Instrument Panel Center Finish Panel
2. Remove the 6 screws and remove the
instrument panel center finish panel.
1 W705314 Instrument panel center finish
panel screw (6 required) Disconnect the electrical connectors.
2 Instrument panel center finish
panel electrical connectors (5 3. NOTE: Be sure that all climate control
assembly electrical connectors are securely
3 6304302 Instrument panel center finish fastened before installing the center instrument
panel
panel finish panel.
information, refer to Console Floor in this
section.
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Power point
Instrument Panel
Passenger air bag module
The instrument panel consists of the following
components:
Glove compartment
Instrument panel steering column cover
Instrument cluster
Instrument panel reinforcement
Instrument panel finish panels
Audio unit
A/C control unit
Center stack wings
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Instrument Panel
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information, refer to Console Floor in this
section.
reinforcement cover screws (2
required)
3. Remove the 2 scuff plates.
2 6304459 Steering column
reinforcement cover
4. Remove the 2 A-pillar lower trim panels.
3 Headlamp switch electrical
5. NOTE: On the coupe, install the front locating
of 14401)
hook, then snap the A-pillar trim panel in place
4 Bulkhead electrical connector
working rearward.
(part of 14401)
5 W711097 Instrument panel support bolt Remove the 2 A-pillar trim panels.
6 W704980 Steering column shaft bolt
7 19A136 Antenna connector
8 Defrost mode actuator
7. CAUTION: Do not allow the steering 14401)
column to rotate while the steering column
9 Bulkhead electrical connector
shaft is disconnected or damage to the (part of 14401)
clockspring can result. If there is evidence
10 Smart junction box (SJB)
that the steering column shaft has rotated, electrical connector (part of
14401) the clockspring must be removed and
recentered. For additional information, refer 11 SJB electrical connector (part
of 14401) to Section 501-20B.
12 W711564 Instrument panel center
Secure the steering wheel, remove and discard
support screws (2 required)
the bolt, and separate the steering column shaft
13 W711097 Instrument panel center
from the steering column.
support bolts (3 required)
14 18C298 Instrument panel lower
8. Remove the 2 screws and the steering column
15 6304481/ Instrument panel end panels
reinforcement cover.
6304480 (2 required)
Disconnect the 2 electrical connectors
16 W711097 Instrument panel upper
9. On the LH side disconnect the instrument panel
17 N811309 Instrument panel cowl top
bulkhead electrical connector and remove the
bracket nut
instrument panel support bolt.
18 Restraints control module
(RCM) small connector (part
of 14401)
19 6304304 Instrument panel 10. On the RH side disconnect the antenna in-line
connector and the 4 instrument panel harness
11. Remove the 2 instrument panel center support
screws.
sensitive to static electrical charges. If exposed to
these charges, damage may result.
12. Remove the 3 instrument panel center support
bolts.
(SRS). For additional information, refer to To install, tighten to 20 Nm (15 lb-ft).
Section 501-20B.
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13. Through the instrument cluster opening, loosen 16. Remove the 4 instrument panel upper support
the instrument panel cowl top bracket nut. bolts.
Tighten to 9 Nm (80 lb-in). To install, tighten to 40 Nm (30 lb-ft).
14. Remove the 2 instrument panel lower support 17. Disconnect the RCM small connector.
bolts.
18. NOTE: Two technicians are necessary to carry
out this step.
15. Remove the 2 instrument panel end panels. Remove the instrument panel.
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Insulation
Insulation is comprised of urethane, PVC, and
recycled felt. Insulation is installed:
under the roof panel.
above and below the instrument panel.
on the cowl sides.
over the front and rear floor areas.
on a coupe, in the B and C-pillar sections.
under the hood.
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Interior Door Handle
2. Remove the interior door handle from the door
trim panel.
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Interior Rear View Mirror
Special Tool(s)
Installer, Rear View Mirror
501-025 (T94P-17700-AH)
2. Insert a suitable tool between the bottom of the
mirror mount and bracket. Push upward on the
1 17700 Interior rear view mirror
tool until the mirror mount is released from the
bracket.
Removal
Installation
CAUTION: The interior rear view mirror
is of the break-away design. Excessive force in
1. Place the interior rear view mirror on the
any direction may cause damage to the mirror or
windshield bracket.
the windshield.
1. Position the interior rear view mirror in the full
up position.
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2. Using the special tool, press the interior rear
view mirror in place until fully seated.
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Interior Trim Exploded View
NOTE: The coupe is shown, the convertible is similar.
9 6311B08 Front safety belt assembly 1 03598/03599 A-pillar trim panel (RH/LH)
10 W505956 Coat hook bolt 2 13208/13209 Door scuff plate (RH/LH)
11 29024 Coat hook 3 390018 A-pillar lower trim panel
pin-type retainer
12 51986/51987 Quarter window trim panel
(RH/LH) 4 02344/02345 A-pillar lower trim panel
(RH/LH)
13 W706544 Quarter trim panel pin-type
retainer (3 required) 5 Lower front safety belt
anchor bolt cover (part of
14 31012/31013 Quarter trim panel (RH/LH)
6311B08-A)
15 54403 Parcel shelf pin-type retainers
6 Lower front safety belt
(4 required)
anchor bolt (part of
16 6346668 Parcel shelf
6311B08-A)
7 Upper front safety belt anchor
1. For additional information, refer to the bolt cover (part of
6311B08-A) procedures in this section.
8 Upper front safety belt anchor
bolt (part of 6311B08-A)
(Continued)
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upper quarter trim panels (convertible)
Interior Trim
lower quarter trim panels (convertible)
The interior trim consists of:
upper quarter trim panel caps (convertible)
A-pillar trim panels
quarter trim panels
A-pillar lower trim panels
parcel shelf trim panel
door trim panels
quarter window trim panels
coat hooks
door scuff plates
headliner
sun visors
header trim panel (convertible)
tether anchor covers (coupe)
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GENERAL PROCEDURES
Lead Terminal Repair 2. CAUTION: Do not use any type of
flame torch or flame heated soldering gun
for this procedure. Testing indicates Material
inadequate heat generation at the tip and the
Item Specification
exhaust heat can cause damage to plastic
Terminal Kit - Back Glass
trim parts in the area. Use only an electric
4F1Z-14421-AA
soldering gun with 100 watts or more of
Ultra-Clear Spray Glass ESR-M14P5-A
power. Before using the soldering gun, be
Cleaner
sure to melt a small amount of rosin core
ZC-23
solder to the tip. The solder assists in
achieving better heat transfer from the
1. NOTE: The rear window glass must be at least
soldering gun tip to the new terminal.
16C (61F) (room temperature) at the time of
the repair. NOTE: The new terminal has pre-applied
solder, flux and temperature-sensitive paint. The
NOTE: The new terminal covers the original
paint provides a visual indication when the
terminal location, but it must be placed so that
terminal has reached the correct temperature to
the terminal conductive areas are placed on a
melt solder on the terminal. When the correct
good conductive base.
temperature is achieved the temperature paint
Clean the bus bar in the area to be repaired
liquefies and changes color.
with steel wool (3.0 to 4.0 grade), and then
NOTE: Depending on the original terminal
with window cleaner to remove all dirt, wax,
location, and whether the terminal is covered by
grease, oil or other foreign matter.
pillar trim, determines where to locate the new
terminal. Some grid line bus-bars may only
allow the placement of the terminal above or
below the original tab location due to space
limitations. For most vehicle applications the
replacement tab location covers the original tab
location but still allows the replacement tab to
attach to the bus-bar on good conductive
material.
Place the replacement terminal type A over the
original tab location, making sure the
conductive areas of the terminal are on a good
conductive area. Do not place the terminal tab
foot on the original location which does not
have conductive material.
3. Hold the terminal in place with an item such as
a regular lead pencil at a 90 degree angle from
the terminal. (Holding at other than a 90 degree
angle may allow the terminal to slip when the
solder liquefies.)
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4. Place the soldering gun tip on the top of the 5. Remove the soldering gun and pencil from the
terminal but not on the painted areas of the tab. terminal. The terminal should be allowed to
Energize the soldering gun and watch for the cool for another 2 minutes before the wiring
painted area of the terminal to liquefy and lead is attached to the terminal.
change color. The paint should liquefy in
6. Attach the electrical lead connection to this
approximately 25-45 seconds after heating. As
terminal, turn on the heated rear window, and
soon as the paint color completely changes on
verify the operation.
either side of the terminal, de-energize the
soldering gun and continue to hold the terminal
in place with the soldering gun and pencil for
an additional 30 seconds.
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Autolock occurs when both doors are closed, the
Locks, Latches and Entry Systems
brake pedal is applied while the speed is less than 8
Special Tool(s)
km/h (5 mph), and then the speed increases to 8
km/h (5 mph) or greater.
Relock is dependent on an autolock event happening
first.
Relock occurs after a door is opened, the brake hardware, or equivalent scan
tool pedal is applied while the speed is less than 8 km/h
(5 mph), all the doors are closed again, and the
speed increases to 8 km/h (5 mph) or greater.
105-R0057 or equivalent Smart Unlock
NOTE: It is possible to lock the vehicle with the
key in the ignition lock cylinder if the doors are
locked with the RKE transmitter or manually locked
with the manual push buttons.
The smart unlock feature prevents the driver door
Flex Probe Kit
from locking with the key in the ignition lock
cylinder. When the SJB receives a LOCK command
from a door lock control switch, and the key is in
the ignition lock cylinder with the driver door
open, the SJB commands the driver door to unlock.
Remote Keyless Entry (RKE) Transmitter
The RKE transmitter can be programmed using the
ignition lock cylinder method. Refer to Remote
Power Locks
Keyless Entry Transmitter Programming in this
section.
The power lock/unlock feature commands both of
the vehicle doors to lock or unlock upon a
Remote Keyless Entry (RKE) Transmitter
command from the door lock control switch or
Lock/Unlock Control Unlock
remote keyless entry (RKE) transmitter. Power
The RKE transmitter feature provides lock/unlock
locking and unlocking of the doors functions
functions independently of key position, vehicle
independently of the key position, vehicle speed, or
speed, or transmission position. The RKE
transmission position. The smart junction box (SJB)
transmitter feature provides a 2-step process for
activates the power door lock relays to supply the
unlocking the doors. Upon receipt of the first
correct power and grounds for the door lock
request for unlocking the doors, the SJB unlocks
actuators.
the driver door only. If another unlock command is
Autolock
received within 3 seconds of the first, the SJB
unlocks both the doors.
If the vehicle is equipped with the autolock feature,
there are 2 methods to enable/disable the feature,
either using the driver door lock control switch or
the dealer may enable/disable the feature using a
scan tool.
The autolock feature automatically and conditionally
locks both doors as a convenience to the customer.
This feature operates only when the key is in the
ON position.
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Remote Keyless Entry (RKE) Transmitter Central Locking/Unlocking
Lock/Unlock Control Lock
The central locking/unlocking function is
The RKE transmitter feature requests that both the
independent of the ignition switch and transmission
doors be locked when the lock button on the RKE
range selector lever position. Central unlocking of
transmitter is pressed. On any press of the LOCK
both the doors is accomplished with the:
button with both the doors closed, the RKE
driver door lock control switches (unless the
transmitter feature commands 1 flash of the turn
unlock inhibit feature is enabled).
signal lamps. If any door (luggage compartment lid
two unlock commands from the RKE transmitter
or hood if equipped with perimeter alarm) is ajar,
within 3 seconds.
no flash occurs, indicating that both the doors were
locked, but one or more closures are ajar. As soon
Central locking of both doors is accomplished with
as the last closure is closed, the turn signal lamps
the:
flash once. If 2 presses of the LOCK button are
door lock control switches
received within 3 seconds, the horn chirps once and
the turn signal lamps flash to indicate that all the
lock command from the RKE transmitter
closures are closed and locked. If any door (luggage
When the vehicle is in an armed or full-alarm
compartment or hood if equipped with perimeter
security state, any unlock command from the door
alarm) is ajar when the second lock command is
lock control switches is ignored if the unlock inhibit
received within 3 seconds of the first, the RKE
feature is enabled. The door lock control switches
transmitter feature commands the horn chirp twice
are enabled if a valid unlock command is received
without flashing the turn signal lamps to indicate
from the RKE transmitter or the key is cycled to
that both the doors were locked, but 1 or more
ON.
closures are ajar. When the key is in the ON or
START position, no turn signal lamp flashes or
Unlock Inhibit Programming
horn chirp confirmations occur.
NOTE: Both of the doors must be closed during the
unlock inhibit programming procedure.
Panic Alarm
1. Turn the key to ON.
The panic alarm feature provides audible and visual
alarms that are evident from the exterior of the 2. Press the UNLOCK button 3 times.
vehicle. The panic alarm feature commands the turn
3. Turn the key to OFF.
signal lamps to flash and the horn to sound until
4. Press the UNLOCK button 3 times.
deactivation. These outputs occur simultaneously.
5. Turn the key to ON.
Activation of the panic alarm is accomplished by
pressing the PANIC button on the RKE transmitter
6. Press the LOCK button, then press the LOCK
whenever the key is in the OFF or ACC positions.
button again. The horn chirps once if the
At all other times this feature is disabled.
unlock inhibit feature was just deactivated or it
Deactivation of an active panic alarm is
chirps twice (1 short chirp and 1 long chirp) if
accomplished by: 1) a second press of the RKE
the unlock inhibit feature was just activated.
transmitter PANIC button, 2) switching the key out
7. Turn the key to OFF. The horn chirps to
of the OFF or ACC position or, 3) a period of 2
confirm the procedure is complete.
minutes and 45 seconds has elapsed since the initial
activation.
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with the scan tool.
Latches Bussed electrical center
(BEC) fuse(s): 5. If the scan tool does not communicate with the
57 (20A)
vehicle:
62 (20A)
Circuitry
position. Connector(s)
Smart junction box
(SJB) external antenna
good vehicle.
Remote keyless entry
(RKE) transmitter
Door lock control
switch(es)
(PCM).
SJB
software release.
self-test diagnostics for the smart junction box
(SJB).
VCM.
VCM:
B1300 Power Door Lock Circuit Failure If both door locks are inoperative, GO to
Pinpoint Test B.
If a single door lock is inoperative, GO to
Pinpoint Test C.
B1301 Power Door Lock Circuit Open GO to Pinpoint Test B.
B1309 Power Door Lock Circuit Short to Ground GO to Pinpoint Test A.
B1310 Power Door Unlock Circuit Failure If both door locks are inoperative, GO to
Pinpoint Test B.
Pinpoint Test C.
B1341 Power Door Unlock Circuit Short To Ground GO to Pinpoint Test A.
B1551 Latch/Decklid Release Circuit Failure GO to Pinpoint Test I.
B1982 Drivers Door Unlock Relay Circuit Failure If both door locks are inoperative, GO to
Pinpoint Test B.
Pinpoint Test C.
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B2276 Less Than 2 Transmitters Programmed PROGRAM the remote keyless entry (RKE)
transmitters. REFER to Remote Keyless Entry
Transmitter Programming in this section.
B2425 Remote Keyless Entry Out of Synchronization GO to Pinpoint Test E.
B2474 Passenger Door Lock Switch Circuit Short to GO to Pinpoint Test A.
Ground
B2475 Passenger Door Unlock Switch Circuit Short to GO to Pinpoint Test A.
Ground
Symptom Chart
Symptom Chart
smart junction box Circuitry
All door locks are inoperative Circuitry GO to Pinpoint Test A.
from one switch Door lock control switch(es)
SJB
All door locks are inoperative Fuse GO to Pinpoint Test B.
Circuitry
Door lock actuator(s)
SJB
A single door lock is Circuitry GO to Pinpoint Test C.
inoperative Door lock actuator(s)
SJB
The doors do not lock/unlock SJB external antenna GO to Pinpoint Test D.
using the remote keyless RKE transmitter battery
entry (RKE) transmitter RKE transmitter
RKE transmitter programming
Aftermarket systems
High power devices
TV/radio transmission towers
SJB
The remote keyless entry RKE transmitter button GO to Pinpoint Test E.
(RKE) transmitter is out of pressed a substantial amount
synchronization of times while outside the
range of the vehicle
RKE transmitter
SJB
The remote keyless entry SJB external antenna GO to Pinpoint Test F.
(RKE) transmitter has poor Aftermarket systems
range performance High power devices
RKE transmitter
SJB
Panic feature is inoperative or RKE transmitter GO to Pinpoint Test G.
does not operate correctly SJB
The smart lock does not SJB GO to Pinpoint Test H.
operate correctly
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The luggage compartment lid Fuse GO to Pinpoint Test I.
is inoperative using the Circuitry
remote keyless entry (RKE) RKE transmitter
transmitter Luggage compartment lid
release relay
Luggage compartment lid
release solenoid
(BEC)
SJB
The autolock does not operate SJB GO to Pinpoint Test J.
correctly
The door locks operate only Unlock inhibit activated DEACTIVATE unlock
one way SJB inhibit. CARRY OUT the
Unlock Inhibit Programming
procedure in this section. If
the concern is still present,
INSTALL a new SJB.
operation.
The power door unlock Unlock inhibit deactivated ACTIVATE unlock inhibit.
inhibit feature is inoperative SJB CARRY OUT the Unlock
Inhibit Programming
procedure in this section. If
the concern is still present,
INSTALL a new SJB.
operation.
Pinpoint Tests When the SJB receives a door lock control switch
lock command, the door lock relay is energized,
Pinpoint Test A: All Door Locks Are
supplying voltage to the door lock actuators through
Inoperative From One Switch
circuits 1328 (RD/OG) and 1383 (RD). The
Refer to Wiring Diagrams Cell 110, Power Door
actuators are grounded through circuits 1329 (YE)
Locks for schematic and connector information.
and 1384 (LB), the SJB and circuit 1205 (BK).
When the SJB receives a door lock control switch
unlock command, the driver door unlock and the
door unlock relays are energized, supplying voltage
to the door lock actuators through circuits 1329
Normal Operation
(YE) and 1384 (LB). The actuators are grounded
The door lock control switches are grounded
through circuits 1328 (RD/OG) and 1383 (RD), the
through circuit 1205 (BK). The door lock control
SJB and circuit 1205 (BK).
switches supply a ground signal to the smart
DTC B1309 is an on-demand DTC that sets if
junction box (SJB) for the lock command through
the SJB detects a short to ground on the driver door
circuit 1316 (WH/VT) from the driver door lock
lock switch circuit 1316 (WH/VT).
control switch, or circuit 1296 (OG/BK) from the
passenger door lock control switch. The door lock
DTC B1341 is an on-demand DTC that sets if
control switches supply a ground signal to the SJB the SJB detects a short to ground on the driver door
for the unlock command through circuit 1317 unlock switch circuit 1317 (DB/LG).
(DB/LG) from the driver door lock control switch,
or circuit 1297 (YE/RD) from the passenger door
lock control switch.
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DTC B2474 is an on-demand DTC that sets if Circuit 1297 (YE/RD) open, short to ground or
the SJB detects a short to ground on the passenger voltage
door lock switch circuit 1296 (OG/BK).
Circuit 1316 (WH/VT) open, short to ground or
DTC B2475 is an on-demand DTC that sets if voltage
the SJB detects a short to ground on the passenger
Circuit 1317 (DB/LG) open, short to ground or
door unlock switch circuit 1297 (YE/RD).
voltage
Possible Causes
Door lock control switch(es)
SJB
Circuit 1296 (OG/BK) open, short to ground or
voltage
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH
A1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
on-demand self-tests. For DTC B1309 or B1341, GO to A7.
For DTC B2474 or B2475, GO to A8.
For all other SJB DTCs, REFER to Smart
Code (DTC) Index in this section.
No
GO to A2.
Disconnect: Suspect Door Lock Control Switch.
Measure the resistance between the driver door lock control
switch C505-1, circuit 1205 (BK), harness side and ground; or
between the passenger door lock control switch C605-1, circuit
Yes
If the door locks are inoperative from the
driver door lock control switch, GO to A3.
If the door locks are inoperative from the
passenger door lock control switch, GO to
A4.
No
A3 CHECK THE DRIVER DOOR LOCK CONTROL CIRCUITS FOR
AN OPEN
(Continued)
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PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH (Continued)
A3 CHECK THE DRIVER DOOR LOCK CONTROL CIRCUITS FOR
AN OPEN (Continued)
(WH/VT), harness side and the driver door lock control switch
C505-4, circuit 1316 (WH/VT), harness side; and between the
SJB C2280e-1, circuit 1317 (DB/LG), harness side and the
driver door lock control switch C505-2, circuit 1317 (DB/LG),
harness side.
Yes
GO to A5.
No
A4 CHECK THE PASSENGER DOOR LOCK CONTROL CIRCUITS
FOR AN OPEN
(OG/BK), harness side and the passenger door lock control
switch C605-4, circuit 1296 (OG/BK), harness side; and between
the SJB C2280e-5, circuit 1297 (YE/RD), harness side and the
passenger door lock control switch C605-2, circuit 1297
(YE/RD), harness side.
Yes
GO to A6.
No
A5 CHECK THE DRIVER DOOR LOCK CONTROL CIRCUITS FOR A
SHORT TO VOLTAGE
Key in ON position.
(Continued)
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Measure the voltage between the SJB C2280e-3, circuit 1316
(WH/VT), harness side and ground; and between the SJB
C2280e-1, circuit 1317 (DB/LG), harness side and ground.
Yes
No
Key in ON position.
Measure the voltage between the SJB C2280e-8, circuit 1296
(OG/BK), harness side and ground and between the SJB
C2280e-5, circuit 1297 (YE/RD), harness side and ground.
Yes
No
SHORT TO GROUND
Disconnect: Driver Door Lock Control Switch C505.
(Continued)
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(WH/VT), harness side and ground; and between the SJB
C2280e-1, circuit 1317 (DB/LG), harness side and ground.
Yes
GO to A9.
No
Disconnect: Driver Door Lock Control Switch C605.
(OG/BK), harness side and ground; and between the SJB
C2280e-5, circuit 1297 (YE/RD), harness side and ground.
Yes
GO to A9.
No
A9 CHECK THE DOOR LOCK CONTROL SWITCH
Carry out the driver or passenger door lock control switch Yes
component test. Refer to Wiring Diagrams Cell 149 for GO to A10.
component testing.
No
Is the door lock control switch OK?
INSTALL a new door lock control switch.
REFER to Door Lock Control Switch in
the self-test.
(Continued)
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corrosion 419-10. PROGRAM all the RKE
damaged pins transmitters. REFER to Remote Keyless
pushed-out pins Entry Transmitter Programming in this
Connect all the SJB connectors and make sure they seat section. INFORM the customer that any
correctly. RKE transmitters not present need to be
Operate the system and verify the concern is still present. programmed. TEST the system for normal
Is the concern still present? operation.
No
Pinpoint Test B: All Door Locks are
DTC B1300 is a continuous or on-demand DTC
Inoperative
that sets if the SJB detects a short to ground on
either of the door lock circuits 1328 (RD/OG) or
1383 (RD).
that sets if the SJB detects an open on ground
circuit 1205 (BK).
Normal Operation
that sets if the SJB detects a short to ground on the
door unlock circuit 1384 (LB).
that sets if the SJB detects a short to ground on the
driver door unlock circuit 1329 (YE).
Possible Causes
Fuse
control switches supply a ground signal to the SJB
for the unlock command through circuit 1317 Circuit 1205 (BK) open
Circuit 1328 (RD/OG) short to ground
Circuit 1329 (YE) short to ground
Circuit 1383 (RD) short to ground
Circuit 1384 (LB) short to ground lock command, the door lock relay is energized,
SJB
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PINPOINT TEST B: ALL DOOR LOCKS ARE INOPERATIVE
on-demand self-tests. For DTC B1301, GO to B4.
For DTC B1300, B1310 or B1982, GO to
B2.
No
GO to B3.
B2 RERUN THE SJB CONTINUOUS AND ON-DEMAND SELF-TESTS
Disconnect the suspect door lock actuator. Yes
Rerun the SJB continuous and on-demand self-tests. For DTC B1300, GO to B5.
Check for recorded SJB DTCs from the continuous and
For DTC B1310, GO to B6.
on-demand self-tests.
For DTC B1982, GO to B7.
No
INSTALL a new door lock actuator.
REFER to Door Lock Actuator in this
self-test.
B3 CHECK CIRCUIT 1679 (WH/YE) FOR AN OPEN
Key in ON position.
Yes
GO to B8.
No
Disconnect: SJB C2280a.
(Continued)
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PINPOINT TEST B: ALL DOOR LOCKS ARE INOPERATIVE (Continued)
B4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between the SJB C2280a-1, circuit 1205
Yes
GO to B8.
No
B5 CHECK CIRCUITS 1328 (RD/OG) AND 1383 (RD) FOR A SHORT
TO GROUND
Disconnect: SJB C2280g and C2280h.
Disconnect: Driver Door Lock Actuator C525 and Passenger
Door Lock Actuator C603.
Measure the resistance between the SJB C2280g-3, circuit 1328
(RD/OG), harness side and ground; and between the SJB
C2208h-27, circuit 1383 (RD), harness side and ground.
Yes
GO to B8.
No
REPAIR the circuit in question. VERIFY
the BEC fuse 62 (20A) is OK. If OK,
Are the resistances greater than 10,000 ohms? CLEAR the DTCs. REPEAT the self-test.
B6 CHECK CIRCUIT 1384 (LB) FOR A SHORT TO GROUND
Disconnect: Passenger Door Lock Actuator C603.
(Continued)
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PINPOINT TEST B: ALL DOOR LOCKS ARE INOPERATIVE (Continued)
B6 CHECK CIRCUIT 1384 (LB) FOR A SHORT TO GROUND
(Continued)
1384 (LB), harness side and ground.
Yes
GO to B8.
No
REPAIR the circuit. VERIFY the BEC fuse
62 (20A) is OK. If OK, CLEAR the DTCs.
B7 CHECK CIRCUIT 1329 (YE) FOR A SHORT TO GROUND
Disconnect: SJB C2280g.
Disconnect: Driver Door Lock Actuator C525.
(YE), harness side and ground.
Yes
GO to B8.
No
REPAIR the circuit. VERIFY the BEC fuse
62 (20A) is OK. If OK, CLEAR the DTCs.
No
Pinpoint Test C: A Single Door Lock is
Inoperative
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Normal Operation
that sets if the SJB detects an open on either of the
door lock circuits 1328 (RD/OG) or 1383 (RD).
that sets if the SJB detects an open on the door
unlock circuit 1384 (LB).
that sets if the SJB detects an open on the driver
control switches supply a ground signal to the SJB
door unlock circuit 1329 (YE).
for the unlock command through circuit 1317
Possible Causes
Circuit 1328 (RD/OG) open
Circuit 1329 (YE) open
lock command, the door lock relay is energized,
Circuit 1384 (LB) open
SJB
PINPOINT TEST C: A SINGLE DOOR LOCK IS INOPERATIVE
C1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
on-demand self-tests. For DTC B1300, GO to C2.
For DTC B1310, GO to C3.
For DTC B1982, GO to C4.
No
GO to C6.
C2 CHECK CIRCUITS 1328 (RD/OG) AND 1383 (RD) FOR AN OPEN
Disconnect: SJB C2280g and C2280h.
Disconnect: Driver Door Lock Actuator C525 and Passenger
Door Lock Actuator C603.
(Continued)
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PINPOINT TEST C: A SINGLE DOOR LOCK IS INOPERATIVE (Continued)
C2 CHECK CIRCUITS 1328 (RD/OG) AND 1383 (RD) FOR AN OPEN
(Continued)
(RD/OG), harness side and the driver door lock actuator C525-1,
circuit 1328 (RD/OG), harness side.
1383 (RD), harness side and the passenger door lock actuator
C603-1, circuit 1383 (RD), harness side.
Yes
GO to C5.
No
C3 CHECK CIRCUIT 1384 (LB) FOR AN OPEN
Disconnect: Passenger Door Lock Actuator C603.
1384 (LB), harness side and the passenger door lock actuator
C603-2, circuit 1384 (LB), harness side.
Yes
GO to C5.
No
(Continued)
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PINPOINT TEST C: A SINGLE DOOR LOCK IS INOPERATIVE (Continued)
C4 CHECK CIRCUIT 1329 (YE) FOR AN OPEN
Disconnect: SJB C2280g.
Disconnect: Driver Door Lock Actuator C525.
(YE), harness side and the driver door lock actuator C525-2,
circuit 1329 (YE), harness side.
Yes
GO to C5.
No
C5 CHECK THE SUSPECT DOOR LOCK ACTUATOR
Connect a fused (10A) jumper wire between the suspect door
lock actuator connector pin 1, component side and the positive
Yes
battery terminal; and momentarily connect the suspect door lock
REMOVE the jumper wire. GO to C6.
actuator connector pin 2, component side and ground.
Connect a fused (10A) jumper wire between the suspect door No
lock actuator connector pin 2, component side and the positive INSTALL a new door lock actuator.
battery terminal; and momentarily connect the suspect door lock REFER to Door Lock Actuator in this
actuator connector pin 1, component side and ground. section. CLEAR the DTCs. REPEAT the
Does the door lock actuator operate correctly? self-test.
No
Possible Causes
Pinpoint Test D: The Doors Do Not
Lock/Unlock Using the Remote Keyless
SJB external antenna
RKE transmitter battery
Normal Operation
RKE transmitter programming
Remote locking and unlocking of the doors is
RKE transmitter
accomplished by the smart junction box (SJB)
receiving a command message from the RKE
Aftermarket systems
transmitter through the SJB external antenna. The
High power devices
SJB processes the command and provides voltage
and ground to the door lock actuators.
SJB
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PINPOINT TEST D: THE DOORS DO NOT LOCK/UNLOCK USING THE REMOTE KEYLESS ENTRY (RKE)
TRANSMITTER
NOTE: All RKE transmitters must be present to begin diagnosis of the RKE system.
NOTE: Aftermarket or dealer-installed systems may adversely effect the RKE system
operation. These systems should be disconnected before diagnosing any RKE concerns.
D1 CHECK FOR THE CORRECT RKE TRANSMITTERS
NOTE: Make sure the RKE transmitters are those provided with the Yes
original equipment manufacturer (OEM) system and not from an GO to D2.
aftermarket or a dealer-installed system that may have been
No
installed on the vehicle.
The system cannot be tested without the
Check that the correct RKE transmitters are used with the
correct RKE transmitters. INFORM the
vehicle.
customer that all the correct RKE
Are all the correct RKE transmitters present?
transmitters must to be present to proceed
with diagnosis of the system.
D2 CHECK THE OPERATION OF THE RKE TRANSMITTER WITH
THE KEY IN THE OFF POSITION
Check the operation of the RKE transmitter. The system is operating correctly.
Does the system operate correctly? INFORM the customer of the correct
vehicle behavior.
No
GO to D3.
D3 CHECK THE POWER DOOR LOCK SYSTEM FOR CORRECT
OPERATION
Verify the door lock/unlock operation by actuating the driver door Yes
lock control switch. GO to D4.
Do all the doors lock and unlock correctly?
No
D4 CHECK IF THE EXTERNAL SJB ANTENNA IS CONNECTED
Verify that the SJB external antenna is connected. Yes
Is the external antenna connected? GO to D5.
No
CONNECT the SJB external antenna
correctly. TEST the system for normal
operation.
D5 CHECK FOR COMPLETE FUNCTIONALITY OF THE RKE
TRANSMITTER(S)
Check all the RKE transmitter buttons for correct operation. Yes
Does the PANIC button operate correctly? REPLACE the RKE transmitter.
PROGRAM all the RKE transmitters.
REFER to Remote Keyless Entry
INFORM the customer that any RKE
transmitters not present need to be
programmed. TEST the system for normal
operation.
No
GO to D6.
D6 MAKE SURE THE RKE TRANSMITTER SIGNAL IS BEING
RECEIVED
function tests, RKE transmitter test or program transmitter.
Monitor the RKE transmitter identification code (TIC) through the
scan tool menus.
NOTE: The vehicle must be electronically unlocked prior to
using any scan tools (through the RKE transmitter or the door
lock control switch).
Verify the RKE transmitter signal is being received. Using a scan
Yes
tool, press a button on the RKE transmitter while observing the
GO to D7.
scan tool.
Does the TIC show up on the scan tool screen when a No
button is pressed? GO to D8.
(Continued)
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PINPOINT TEST D: THE DOORS DO NOT LOCK/UNLOCK USING THE REMOTE KEYLESS ENTRY (RKE)
TRANSMITTER (Continued)
D7 DETERMINE IF THE RKE TRANSMITTERS ARE PROGRAMMED
Function Tests, Transmitter Test or Program Transmitter. GO to D9.
Monitor the RKE transmitter TIC/DATA through the scan tool
No
menus.
Verify the RKE transmitters are programmed to the vehicle.
Does the TIC displayed under RKE transmitter match any of
the TICs stored in memory?
operation.
D8 CHECK THE RKE TRANSMITTER BATTERY
Using a thin coin, open the RKE transmitter. Yes
Do not clean off any grease from the battery terminal on the GO to D10.
back surface of the circuit board.
No
Verify the correct battery is being used (CR2032).
INSTALL a new battery. Do not program
Remove the RKE transmitter battery and measure the voltage.
the RKE transmitters (damaged or dead
Is the voltage greater than 2.5 volts?
batteries do not erase TICs from memory).
D9 CHECK IF THE RKE TRANSMITTER IS OUT OF
SYNCHRONIZATION WITH THE SJB
NOTE: The vehicle must be electronically unlocked prior to
Yes
using any scan tools (through the RKE transmitter or the door
lock control switch).
Retrieve continuous DTCs with the scan tool. No
Is continuous DTC B2425 stored in the SJB? GO to D10.
D10 CHECK FOR NORMAL OPERATION WITH A KNOWN GOOD
RKE TRANSMITTER
function tests, RKE transmitter test or program transmitter. REPLACE the inoperative RKE
Monitor the RKE transmitter TIC/DATA through the scan tool transmitter. PROGRAM all the RKE
menus. transmitter(s). REFER to Remote Keyless
Using the customers second RKE transmitter or a known good Entry Transmitter Programming in this
RKE transmitter that is correct for the vehicle (and programmed section. INFORM the customer that any
to the vehicle), verify the RKE transmitter signal is being RKE transmitters not present need to be
received. programmed. CLEAR the DTCs. REPEAT
Does the TIC show up on the scan tool when a button is the self-test.
pressed on the RKE transmitter?
No
GO to D11.
D11 CHECK THE SJB FOR CORRECT OPERATION
damaged pins transmitter(s). REFER to Remote Keyless
No
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Possible Causes
Pinpoint Test E: The Remote Keyless Entry
(RKE) Transmitter is Out of Synchronization
RKE transmitter button pressed a substantial
amount of times while outside the range of the
Normal Operation
vehicle
The RKE transmitters and the smart junction box
(SJB) use a rolling code to prevent the codes from
RKE transmitter
being captured by a code grabber. The system
advances the counter in the RKE transmitter and in
the SJB every time an RKE transmitter button is
pressed.
DTC B2425 is a continuous DTC that sets when
the SJB detects the rolling counter received from an
RKE transmitter is 1024 times greater than the
rolling counter stored in the module.
PINPOINT TEST E: THE REMOTE KEYLESS ENTRY (RKE) TRANSMITTER IS OUT OF
SYNCHRONIZATION
E1 SYNCHRONIZE THE INOPERATIVE RKE TRANSMITTER
Press any button on the inoperative RKE transmitter 4 times The system is OK. CLEAR the DTCs.
consecutively within 30 seconds. REPEAT the self-test.
Does the RKE transmitter operate correctly now?
No
GO to E2.
E2 CHECK FOR A SECOND RKE TRANSMITTER
Check for another RKE transmitter that operates with the Yes
vehicle. GO to E3.
Is there another RKE transmitter that operates with the
No
vehicle?
GO to E4.
E3 SYNCHRONIZE THE INOPERATIVE RKE TRANSMITTER USING
THE SECOND RKE TRANSMITTER
Yes
Press any button on the operational RKE transmitter.
The system is OK. CLEAR the DTCs.
Within 30 seconds, press a button on the inoperative RKE
transmitter.
Check the inoperative RKE transmitter for correct operation. No
Does the inoperative RKE transmitter operate now? GO to E4.
E4 PROGRAM THE INOPERATIVE RKE TRANSMITTER OR ALL
THE RKE TRANSMITTERS
Program the inoperative RKE transmitter individually using a Yes
scan tool or program all the RKE transmitters using the manual The system is OK. INFORM the customer
key cycle method. Refer to Remote Keyless Entry Transmitter that any RKE transmitters not present
Programming in this section. need to be programmed. CLEAR the
Does the inoperative RKE transmitter operate now? DTCs. REPEAT the self-test.
No
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Possible Causes
Pinpoint Test F: The Remote Keyless Entry
(RKE) Transmitter Has Poor Range
RKE transmitter
Performance
SJB external antenna
Normal Operation
Aftermarket systems
Remote locking and unlocking of the doors is
High power devices
accomplished by the smart junction box (SJB)
receiving a command message from the RKE
transmitter through the SJB external antenna. The
SJB
SJB processes the command and provides voltage
and ground to the door lock actuators. The RKE
transmitter has a maximum operating range of 10 m
(33 ft).
PINPOINT TEST F: THE REMOTE KEYLESS ENTRY (RKE) TRANSMITTER HAS POOR RANGE
PERFORMANCE
NOTE: Aftermarket or dealer-installed systems may adversely effect the RKE system
operation. These systems should be disconnected before diagnosing any RKE concerns.
F1 CHECK FOR THE CORRECT RKE TRANSMITTERS
NOTE: Make sure the RKE transmitters are those provided with Yes
the original equipment manufacturer (OEM) system and not from GO to F2.
an aftermarket or a dealer installed system that may have been
No
installed on the vehicle.
The system cannot be tested without the
Check that the correct RKE transmitters are used with the
correct RKE transmitters. INFORM the
vehicle.
customer that all the correct RKE
Are all the correct RKE transmitters present?
transmitters must to be present to proceed
with diagnosis of the system.
F2 CHECK ALL RKE TRANSMITTERS FOR POOR RANGE
PERFORMANCE
NOTE: The 3 m (10 ft) measurement of range is not the Yes
standard but is a guideline that clearly indicates a vehicle is GO to F3.
experiencing poor range performance.
No
Check all RKE transmitters for poor range performance (less
REPLACE the inoperative RKE transmitter
than 3 m [10 ft]).
and PROGRAM all the RKE transmitters.
Do all RKE transmitters experience poor range?
operation.
F3 CHECK THE LOCATION OF THE VEHICLE AND THE
APPROACH ANGLES AROUND THE VEHICLE
Make sure the poor performance is consistent in nature and is
not from one approaching angle.
Yes
The RKE transmitter range performance may be degraded in
GO to F4.
certain locations. For example, if the vehicle is within 0.8 km
(0.5 mile) of high power devices or radio/TV towers, the No
operating distance of the RKE transmitters may be reduced. The system is operating correctly at this
Is the poor range performance consistent around the time. TEST the system for normal
vehicle? operation.
F4 CHECK IF THE SJB EXTERNAL ANTENNA IS CONNECTED
Verify that the SJB external antenna is connected. Yes
Is the external antenna connected? GO to F5.
No
CONNECT the SJB external antenna
correctly. TEST the system for normal
operation.
(Continued)
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PINPOINT TEST F: THE REMOTE KEYLESS ENTRY (RKE) TRANSMITTER HAS POOR RANGE
PERFORMANCE (Continued)
F5 CHECK THE SJB FOR CORRECT OPERATION
No
Possible Causes
Pinpoint Test G: Panic Feature is Inoperative
or Does Not Operate Correctly
RKE transmitter
Normal Operation
SJB
When the remote keyless entry (RKE) transmitter
PANIC button is pressed, the smart junction box
(SJB) grounds the horn relay which supplies voltage
to activate the horn. The SJB also provides voltage
to the turn signal lamps to activate them.
PINPOINT TEST G: PANIC FEATURE IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY
G1 VERIFY OPERATION OF THE HORN
Operate the horn through the steering wheel switch. Yes
Does the horn operate correctly? GO to G2.
No
G2 VERIFY THE TURN SIGNAL LAMP OPERATION
Turn on the hazard lamps. Yes
Do the hazard lamps operate correctly? GO to G3.
No
G3 CARRY OUT THE SJB HORN ACTIVE COMMAND USING THE
SCAN TOOL
Yes
Enter the following diagnostic mode on the scan tool: SJB active
GO to G4.
commands.
Activate the HORN active command for 1 second. No
Does the horn operate? GO to G7.
G4 CARRY OUT THE SJB PARKING LAMP ACTIVE COMMANDS
USING THE SCAN TOOL
Activate the parking lamps LF_PARK and RF_PARK active Yes
commands for 5 seconds. GO to G5.
Do the parking lamps operate?
No
GO to G7.
G5 CHECK THE REMOTE TRANSMITTER OPERATION
Lock and unlock the doors using the RKE transmitter buttons. Yes
Do the doors lock and unlock correctly? GO to G6.
No
(Continued)
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PINPOINT TEST G: PANIC FEATURE IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY
(Continued)
G6 CHECK THE RKE TRANSMITTER SIGNAL TO THE SJB
Enter the following diagnostic mode on the scan tool: SJB PIDs. Yes
Read the SJB REMOTE TRANSMITTER SIGNAL PID while GO to G7.
pressing the PANIC button on the RKE transmitter.
No
Do the PID values agree with the button presses?
REPLACE the RKE transmitter.
Connect all SJB connectors and make sure they seat correctly. section. INFORM the customer that any
Operate the system and verify the concern is still present. RKE transmitters not present need to be
Is the concern still present? programmed. TEST the system for normal
operation.
No
Possible Causes
Pinpoint Test H: The Smart Lock Does Not
Operate Correctly
NOTE: It is possible to lock the vehicle with the
keys in the ignition lock cylinder if the doors are
locked with the remote keyless entry (RKE)
transmitter or manually locked with the manual
push buttons.
Normal Operation
The smart unlock feature unlocks the driver door if
the key is in the ignition lock cylinder and the
driver door is open when the vehicle is locked with
the door lock control switch. The smart unlock
feature requests the driver door be unlocked 1
second after these conditions occur. The smart
unlock feature unlocks the driver door only if the
keycode programming and transmitter identification
code (TIC) programming modes are not active.
PINPOINT TEST H: THE SMART LOCK DOES NOT OPERATE CORRECTLY
H1 CHECK THE COURTESY LAMP OPERATION
Open and close the driver door. Yes
Do the courtesy lamps operate correctly? GO to H2.
No
H2 CHECK THE SJB IGNITION STATUS
Enter the following diagnostic mode on the scan tool: SJB PID. Yes
Monitor the SJB ignition switch status PID GO to H3.
Are the correct values received?
No
(Continued)
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PINPOINT TEST H: THE SMART LOCK DOES NOT OPERATE CORRECTLY (Continued)
H3 CHECK FOR CORRECT SJB OPERATION
Connect all SJB connectors and make sure they seat correctly. section. INFORM the customer that any
Operate the system and verify the concern is still present. RKE transmitters not present need to be
Is the concern still present? programmed. TEST the system for normal
operation.
No
Possible Causes
Pinpoint Test I: The Luggage Compartment
Lid is Inoperative Using the Remote Keyless
Fuse
Circuit 26 (WH/VT) open or short to ground
Refer to Wiring Diagrams Cell 113, Luggage
Circuit 1092 (PK/OG) open
Compartment for schematic and connector
information.
RKE transmitter
Normal Operation
The luggage compartment lid release solenoid is
Luggage compartment lid release relay
grounded on circuit 1205 (BK). When the smart
Luggage compartment lid release solenoid (part of
junction box (SJB) receives an open command from
the luggage compartment lid latch)
the RKE transmitter the SJB grounds the luggage
compartment lid release relay control circuit 26
(WH/VT). The relay closes and supplies voltage to
SJB
circuit 1092 (PK/OG) which closes the luggage
compartment lid release solenoid, releasing the
luggage compartment lid.
that sets if the SJB detects an open or short to
ground on the door lock circuit 26 (WH/VT).
PINPOINT TEST I: THE LUGGAGE COMPARTMENT LID IS INOPERATIVE USING THE REMOTE
KEYLESS ENTRY (RKE) TRANSMITTER
I1 RETRIEVE THE RECORDED DTCs FROM BOTH THE
on-demand self-tests. For DTC B1551, GO to I9.
No
GO to I2.
I2 CARRY OUT THE SJB TRUNK RELEASE ACTIVE COMMAND
USING THE SCAN TOOL
Key in ON position.
(Continued)
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KEYLESS ENTRY (RKE) TRANSMITTER (Continued)
I2 CARRY OUT THE SJB TRUNK RELEASE ACTIVE COMMAND
USING THE SCAN TOOL (Continued)
Yes
Command.
Select the SJB TRUNK REL active command and command
the luggage compartment lid release relay ON. No
Does the luggage compartment lid release operate? GO to I3.
I3 CHECK THE LUGGAGE COMPARTMENT LID RELEASE
CIRCUITRY
Connect a fused (5A) jumper wire between the SJB C2280c-13,
circuit 26 (WH/VT), harness side and ground.
Yes
REMOVE the jumper wire. GO to I10.
No
Does the luggage compartment lid release operate? REMOVE the jumper wire. GO to I4.
I4 CHECK CIRCUIT 1092 (PK/OG) FOR VOLTAGE
Disconnect: Luggage Compartment Lid Release Solenoid C430.
Connect a fused (5A) jumper wire between the SJB C2280c-13,
(Continued)
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I4 CHECK CIRCUIT 1092 (PK/OG) FOR VOLTAGE (Continued)
Measure the voltage between the luggage compartment lid
release solenoid C430-2, circuit 1092 (PK/OG), harness side
and ground.
Yes
GO to I5.
No
Is the voltage greater than 10 volts? GO to I6.
I5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
release solenoid C430-3, circuit 1205 (BK), harness side and
ground.
Yes
latch. REFER to Luggage Compartment
Lid Latch in this section. TEST the system
for normal operation
No
I6 CHECK THE LUGGAGE COMPARTMENT LID RELEASE RELAY
Carry out the luggage compartment lid release relay component Yes
test. Refer to Wiring Diagrams Cell 149 for component testing. GO to I7.
Does the relay pass the component test?
No
release relay. TEST the system for normal
operation.
(Continued)
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I7 CHECK THE LUGGAGE COMPARTMENT LID RELEASE RELAY
INPUT CIRCUITS FOR VOLTAGE
Measure the voltage between the luggage compartment lid
release relay input circuits in the BEC and ground.
Yes
GO to I8.
No
VERIFY the BEC fuse 57 is OK. If OK,
Are the voltages greater than 10 volts? INSTALL a new BEC.
I8 CHECK CIRCUIT 1092 (PK/OG) FOR AN OPEN
Measure the resistance between the BEC C1035a-E7, circuit
1092 (PK/OG), harness side and the luggage compartment lid
release solenoid C430-2, circuit 1092 (PK/OG), harness side.
Yes
GO to I10.
No
I9 CHECK CIRCUIT 26 (WH/VT) FOR AN OPEN OR SHORT TO
GROUND
Disconnect: Luggage Compartment Lid Release Solenoid C430.
(Continued)
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I9 CHECK CIRCUIT 26 (WH/VT) FOR AN OPEN OR SHORT TO
GROUND (Continued)
Measure the resistance between the BEC C1035a-F7, circuit 26
(WH/VT), harness side and the SJB C2280c-13, circuit 26
(WH/VT), harness side; and between the BEC C1035a-F7,
Yes
GO to I10.
Is the resistance less than 5 ohms between the BEC and the No
SJB, and greater than 10,000 ohms between the BEC and REPAIR the circuit. CLEAR the DTCs.
No
Pinpoint Test J: The Autolock Does Not
Brake pedal is applied and vehicle speed is less
Operate Correctly
than 5 km/h (3 mph)
Vehicle speed exceeds 5 km/h (3 mph)
Normal Operation
The autolocking function causes the vehicle to
Relock occurs after a door is opened, the brake
automatically lock all the doors when the following
pedal is applied while the vehicle speed is less than
conditions are all concurrently met during the
5 km/h (3 mph), all the doors are closed again, and
current key cycle:
the vehicle speed increases to 5 km/h (3 mph) or
greater.
All doors are closed
Possible Causes
Autolocking function is active
Key in ON position
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PINPOINT TEST J: THE AUTOLOCK DOES NOT OPERATE CORRECTLY
J1 VERIFY THE AUTOLOCK FEATURE IS ENABLED
Verify the autolock feature is enabled. Yes
Is the autolock feature enabled? GO to J2.
No
ENABLE the autolock feature on with any
method.
J2 CHECK COURTESY LAMPS
Open the driver door. Yes
Do the courtesy lamps illuminate? GO to J3.
No
J3 CHECK THE SJB VEHICLE SPEED, IGNITION SWITCH STATUS
AND BRAKE PEDAL POSITION (BPP) PIDs
Key in ON position. GO to J4.
No
Monitor the SJB vehicle speed PID, ignition switch status PID
REFER to the Powertrain
and brake ON/OFF PID.
Are the correct PID values received?
manual to continue diagnosis of the
vehicle speed.
diagnosis of the ignition switch status.
diagnosis of the stoplamp switch.
J4 CHECK FOR CORRECT SJB OPERATION
No
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Luggage Compartment Lid Latch
Material
Item Specification
Spray
XL-5
6 W500614 Luggage compartment lid 1 Luggage compartment lid
lock cylinder bolts (2 latch electrical connector (part
required) of 19B516)
7 Luggage compartment lid 2 N807260 Luggage compartment lid
release cable (part of 43200) latch nuts (3 required)
8 43262 Luggage compartment lid 3 19A434 Luggage compartment lid ajar
lock cylinder switch
4 43200 Luggage compartment lid
Removal and Installation latch
5 Luggage compartment lid
anti-theft inhibit switch
1. Remove the luggage compartment lid trim
electrical harness (if
panel.
equipped) (part of 6343262)
(Continued)
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2. Disconnect the luggage compartment lid latch
actuator cable from the luggage compartment
lid lock cylinder.
4. NOTE: Mark the location of the luggage
compartment lid latch to aid installation.
Remove the 3 luggage compartment lid latch
nuts.
5. Position the luggage compartment lid ajar
switch aside.
6. Remove the luggage compartment lid latch.
Lubricate the luggage compartment lid latch
after installation.
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4. Remove the 2 bolts and the luggage
Luggage Compartment Lid Lock
compartment lid lock cylinder.
Cylinder
Material
Item Specification
Lubricant
XL-1
1. Remove the luggage compartment lid trim
panel.
actuator cable from the luggage compartment
lid lock cylinder.
Lubricate the luggage compartment lid lock
3. If equipped, disconnect the luggage
cylinder after installation.
compartment lid lock cylinder electrical
connector.
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501-10-1 501-10-1 Seating
5. NOTE: : The plastic rivets attaching the
Lumbar Assembly
backrest trim cover to the inboard and outboard
recliners are one-time use rivets and must be
installed new when the front seat backrest cover
is removed or a new cover installed.
Remove the plastic rivets attaching the backrest
trim cover to the inboard and outboard
system (SRS) vehicle and when handling an
recliners.
airbag module. This will reduce the risk of
NOTE: If a seat equipped with a supplemental
restraint system (SRS) component is being serviced,
the supplemental restraint system (SRS) must be
depowered.
the restraints control module (RCM) fuse is
removed and the ignition switch is ON. This is
normal operation and does not indicate a
supplemental restraint system (SRS) fault. 6. Release the J-strip at the back of the backrest
trim cover.
customer.
All seats
1. Position the seat to gain access to the seat
track-to-floor nuts and bolts.
2. Depower the SRS. For additional information,
Procedures portion of Section 501-20B.
3. Remove the seat. For additional information,
refer to Seat Front in this section.
4. Remove the front seat backrest. For additional
information, refer to Seat Backrest Front in
this section.
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501-10-2 501-10-2 Seating
7. Release the inner J-strip at the bottom of the
backrest trim cover and remove all electrical
connectors.
Seats with manual lumbar
10. Remove the 2 side springs. Release the 2
pin-type retainers at the bottom, slide the rods
8. Invert the backrest trim cover to expose the
out of the backrest frame at the top and remove
lumbar/backrest support assembly rods going
the lumbar assembly.
into the backrest frame.
Seats with power lumbar
12. Install the front seat backrest. For additional
9. Disconnect the electrical connector, release the information, refer to Seat Backrest Front in
4 retainers (2 shown) and slide the rods out of this section.
the backrest frame and remove the lumbar
13. Install the seat. For additional information, refer
assembly.
to Seat Front in this section.
14. Repower the SRS. For additional information,
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501-10-1 501-10-1 Seating
Lumbar Control Switch
2. Remove the clip and the recline handle.
3. Remove the screw at the rear of the cushion
side shield. Pull out on the side of the cushion
side shield, release the retaining clips and
pin-type retainer and separate the side shield.
4. Disconnect the lumbar control switch.
5. Release the retainers and remove the lumbar
control switch from the cushion side shield.
depowered.
6. CAUTION: Inspect the cushion side
shield retaining clips for damage. Install new
retainers if damage is present.
removed and the ignition switch is ON. This is To install, reverse the removal procedure.
supplemental restraint system (SRS) fault.
customer.
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Seat with a Service Kit Occupant Classification
Occupant Classification Sensor
Sensor
Special Tool(s)
tool
Seat with OEM Occupant Classification Sensor
1 62900 Seat cushion trim cover
2 603B02 OCS service kit (foam pad,
bladder, hose with pressure
sensor, electronic control unit
(ECU) and wiring harness)
3 63100 Seat cushion frame assembly
Removal
1 62900 Seat cushion trim cover
2 Seat cushion foam pad
3 Pin-type retainers the event of an accidental deployment.
4 Occupant classification sensor
(OCS) (bladder, hose with WARNING: To reduce the risk of personal
pressure sensor, electronic
control unit (ECU) and wiring
harness)
WARNING: Do not separate the occupant
5 63100 Seat cushion frame assembly
classification sensor (OCS) system components.
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CAUTION: There are 3 OCS system
service kits available for this vehicle (base seat,
install the original part and perform the diagnostic
heated seat and power heated seat). Always make
procedure again.
sure the correct OCS service kit is installed.
All seats
CAUTION: It is necessary to carry out the
OCS system reset when a front passenger seat
1. Position the seat to access all the seat
cushion is disassembled, a new trim cover
track-to-floor pan bolts.
installed or an OCS service kit is installed. A
scan tool is used to trigger the active command
to carry out the OCS system reset.
NOTE: The heated seat element on the front Supplemental Restraint System (SRS)
passenger seat cushion is not serviceable separately. Depowering and Repowering in the General
If a new heated seat element is needed on the front Procedures portion of this section.
passenger seat cushion, a new OCS service kit
3. Remove the passenger seat. For additional equipped with a heated seat element must be
information, refer to Section 501-10. installed.
NOTE: If a seat equipped with a SRS component is
4. Remove the seat backrest. For additional
being serviced, the SRS must be depowered.
NOTE: OCS system components (seat cushion
5. Remove the seat track. For additional
foam pad, bladder with pressure sensor and
electronic control unit) are calibrated to each other
and are serviced as an assembly. The OCS system
6. Release the seat trim cover and foam pad.
components are not to be installed separately. If a
Release all the seat cushion trim cover
J-clips and the pin-type retainer from the
cushion foam pad are needed, a new OCS system
seat cushion frame assembly.
service kit (seat cushion foam pad, bladder with
pressure sensor, electronic control unit and seat
7. CAUTION: Use care when separating
wiring harness) must be installed as an assembly.
the seat upholstery from the hook and loop
strip, or the hook and loop strip can be torn
from the seat cushion foam pad.
kit) inspect the electronic control unit (ECU)
Separate the trim cover from the foam pad.
Release the hook and loop fasteners and
allows the disconnect of the ECU electrical
remove the hog rings.
has the ECU electrical connector glued to the ECU.
It cannot and should not be disconnected or altered.
a SRS fault.
customer.
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All seats
8. NOTE: Production pressure sensor shown,
service kit pressure sensor similar.
12. Remove the rivets and separate the ECU from
Bend to release the retaining tab and remove
the seat cushion frame bracket.
the pressure sensor from the bracket.
13. NOTE: Note position of hose routing for
installation.
Remove the OCS from the seat cushion frame
assembly.
Feed the hose, pressure sensor, wire harness,
electrical connector and ECU through the
opening in the seat cushion frame assembly.
Seats with power
9. Disconnect the seat control switch electrical
connector from the side trim cover.
All seats
10. NOTE: Note position of wire routing for
installation.
Release all the seat wire harness routing clips
and electrical connector retainers from the seat
cushion frame assembly.
Seats with a production occupant
classification sensor (OCS)
11. Release the 2 OCS bladder pin-type retainers
and separate it from the seat cushion frame
assembly.
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Installation
2. NOTE: Make sure the ECU is properly secured
to the bracket.
All seats
Position the ECU onto the seat cushion frame
bracket and install new rivets.
1. WARNING: Do not separate the OCS
3. Bend the retaining tab back on the pressure
system components.
sensor bracket.
CAUTION: Inspect the occupant
classification sensor assembly, seat cushion
frame and support assembly for any foreign
objects, before installing the occupant
classification sensor assembly to the seat
cushion frame. If any foreign objects are
found, remove them. Failure to do so may
result in personal injury, in the event of an
air bag deployment.
CAUTION: Failure to route the seat
occupant sensor components through the
correct seat cushion support opening can
cause component failure.
Seats with a service kit OCS
CAUTION: While positioning the seat
cushion frame and occupant classification
sensor assembly, be careful not to damage
4. Position the OCS service kit foam pad and
any of the components. Failure to do so can
attach the 2 pin-type retainers to the seat
result in component failure.
cushion frame assembly.
NOTE: If the original equipment OCS is not
Seats with a production OCS
being installed, install a service kit OCS using
all parts in the kit.
5. Attach the 2 OCS bladder pin-type retainers to
Position the OCS to the seat cushion frame.
the seat cushion frame assembly.
electrical connector and the ECU through All seats
the seat cushion frame assembly.
6. Attach all the seat wire harness routing clips
and electrical connector retainers to the cushion
frame assembly.
Seats with power
7. Connect the seat control switch electrical
connector to the side trim cover.
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All seats
8. Install the pressure sensor onto the seat cushion
frame bracket, making sure the retaining tab is
completely engaged.
When installed correctly, an audible click
will be heard and the pressure sensor will
not be able to be removed from its bracket
without disengaging the retaining tab.
10. Attach the seat cushion trim cover J-clips and
the pin-type retainer to the seat cushion frame
assembly.
11. Install the seat track. For additional information,
12. Install the seat backrest. For additional
13. Install the passenger seat into the vehicle. For
9. CAUTION: Inspect the seat cushion
foam pad and seat cushion trim cover for
any foreign objects, before installing the seat 14. Repower the SRS. Do not prove out the SRS
cushion trim cover and the seat cushion foam at this time. For additional information, refer to
pad. If any foreign objects are found, remove Supplemental Restraint System (SRS)
them. Failure to do so may result in Depowering and Repowering in the General
personal injury, in the event of an air bag Procedures portion of this section.
deployment.
Align the seat cushion trim cover to the seat
cushion foam pad and attach the hog rings and
hook and loop fasteners.
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16. NOTE: The ignition switch must be cycled
15. WARNING: Do not separate the OCS
after the OCS system reset.
system components.
Cycle the ignition switch from ON to OFF.
CAUTION: It is necessary to carry out
the OCS system reset when a front passenger
17. Prove out the SRS as follows:
seat cushion is disassembled, a new trim
Turn the ignition key from ON to OFF. Wait
cover installed or an OCS service kit is
10 seconds, then turn the key back to ON and
installed. A scan tool is used to trigger the
visually monitor the air bag indicator with the
active command to carry out the OCS system
air bag modules installed. The air bag indicator
reset.
will light continuously for approximately 6
CAUTION: Make sure the seat is
seconds and then turn off. If an air bag SRS
completely assembled before carrying out the
fault is present, the air bag indicator will:
OCS system reset.
- fail to light.
CAUTION: The following precautions
- remain lit continuously.
must be taken before carrying out the OCS
- flash.
system reset.
The flashing might not occur until
Make sure the OCS system components
approximately 30 seconds after the ignition
are connected and no faults are present.
switch has been turned from the OFF to the ON
Make sure the OCS system is not at a
position. This is the time required for the
temperature below 0C (32F) or above
restraints control module (RCM) to complete
45C (113F) when initiating the OCS
the testing of the SRS. If the air bag indicator
system reset process. If the vehicle has
is inoperative and a SRS fault exists, a chime
been exposed to extreme cold or hot
will sound in a pattern of 5 sets of 5 beeps. If
temperatures, the vehicle must be
this occurs, the air bag indicator and any SRS
exposed and kept at a temperature within
fault discovered must be diagnosed and
the limits, 0C to 45C (32F to 113F)
repaired.
for a minimum of 30 minutes.
Clear all continuous DTCs from the RCM using
Make sure nothing is present on the
a scan tool.
passenger seat before carrying out the
OCS system reset and nothing is placed
on the seat during the process.
Make sure a minimum 8-second time
period has passed after cycling the
ignition switch ON before the OCS
system reset process.
NOTE: For best results, the OCS system should be
at or near room temperature, 10C to 29C (50F to
85F).
NOTE: If the first attempt to carry out the OCS
system reset is unsuccessful, a second attempt must
be made.
Carry out the OCS system reset active
command using the scan tool.
With the front passenger seat empty, use a
scan tool to trigger the active command.
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18. NOTE: When installing a new OCS, a prepaid
return postcard is provided with the new OCS.
The serial number for the new part and the
vehicle identification number (VIN) must be
recorded and sent to Ford Motor Company.
If a new OCS was installed, fill out the
necessary information on the OCS traceability
card and return it along with the complete
inoperative occupant classification sensor to
Ford Motor Company.
When returning the inoperative OCS
include: seat cushion foam pad, bladder,
electronic control unit, pressure sensor
(transducer), hose, electrical connectors and
wire harness (service part OCS only).
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501-35-1 501-35-1 Body Repairs
Paint Codes
Vehicle Paint Code Locator
Primary Color Codes
D3 Colorado Red
G2 Redfire
G5 Alloy Gray
G9 Vista Blue
HP High Performance White
P3 Windveil Blue
T8 Tungsten Gray
TL Satin Silver
U3 Valencia
Paint codes are listed as a 2-part code. The first set
UA Ebony
of characters listed identifies the vehicle primary
paint color. The second set of characters listed (if
applicable) identifies the vehicle accent or 2-tone
color. All colors are base coat/clear coat.
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Parcel Shelf
additional information, refer to Quarter Window
Trim Panel in this section.
2. Remove the 4 parcel shelf pin-type retainers.
3. Position the 2 rear seat belts aside and remove
the parcel shelf.
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Passenger Air Bag Deactivation (PAD)
Indicator
1 Center instrument panel finish
panel screws
2 13D734 Passenger airbag deactivation
indicator
3 Passenger airbag deactivation
indicator electrical connector
(part of 14401)
procedure again.
customer.
NOTE: The passenger air bag deactivation indicator
is part of the hazard switch/traction control switch
assembly.
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2. Remove the console shifter bezel.
5. Remove the 6 screws and position out the
center instrument panel finish panel.
finish panel. 6. Disconnect the passenger airbag deactivation
indicator electrical connector.
7. Release the 4 tabs (2 upper and 2 lower) on the
passenger airbag deactivation indicator and
remove it from the center instrument panel
finish panel.
kick panels.
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Passenger Air Bag Module
1 044A74 Passenger air bag module
2 Passenger air bag module
deployment door clips (part
of 044A74) system (SRS) vehicle and when handling an air
3 Glove compartment door
4 Passenger air bag module
14401) WARNING: Carry a live air bag module
with the air bag and deployment door pointed
5 W505252 Passenger air bag module
bolts (2 required) away from your body. This will reduce the risk
of injury in the event of an accidental
deployment.
WARNING: Do not set a live air bag
module down with the deployment door face
down. This will reduce the risk of injury in the
event of an accidental deployment.
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surface can contain deposits of sodium
hydroxide, a product of the gas generant
your hands with soap and water afterwards.
2. Open and lower glove compartment door.
3. Disconnect the passenger air bag module
injury.
4. Remove the 2 air bag module bolts.
To install, tighten to 11 Nm (8 lb-ft)
WARNING: Air bag modules with
discolored or damaged deployment doors must
be replaced, not repainted. 5. CAUTION: Do not handle the
passenger air bag module by grabbing the
WARNING: To reduce the risk of personal edges of the deployment door.
Through the glove box opening, release the
deployment door clips (6 upper, 6 lower and 2
on each side) from the instrument panel (I/P)
and then remove the passenger air bag module
out of the I/P.
6. NOTE: During air bag module installation,
make sure all the deployment door clips are
fully seated into the I/P.
customer.
procedure again.
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GENERAL PROCEDURES
3. NOTE: If a dual stage driver or passenger air
Pyrotechnic Device Disposal
bag module has deployed due to a crash event,
the air bag module requires manual deployment
Disposal of Deployable Devices and
to make sure both stages have deployed before
Pyrotechnic Devices That Are
scrapping the vehicle or disposing of the air bag
Undeployed/Inoperative
module. To determine if a vehicle is equipped
with dual stage driver or passenger air bag
NOTE: All inoperative air bag modules and safety
modules, refer to the Description and Operation
belt pretensioners have been placed on the
Mandatory Return List. All discolored or damaged
air bag modules must be treated the same as any
Dispose of the deployed device in the same
inoperative live air bag being returned.
manner as any other part to be scrapped.
Pyrotechnic Devices That Require
Manual Deployment
1. Safety and environmental concerns require
2. Remove the undeployed/inoperative device. For consideration and treatment of restraints system
additional information, refer to the appropriate deployable and pyrotechnic devices when
procedure in this section or Section 501-20A. disposing of vehicles, deployable devices or
pyrotechnic devices. Deploying deployable and
3. NOTE: When installing a new air bag module,
pyrotechnic devices before scrapping a vehicle
a prepaid return postcard is provided with the
or the device eliminates the potential for
replacement air bag module. The serial number
hazardous exposures or reactions during
for the new part and the vehicle identification
processing. If special handling procedures are
number (VIN) must be recorded and sent to
followed, deployable and pyrotechnic devices
Ford Motor Company.
can be deployed safely and recycled with the
vehicle, shipped separately to a recycling
If installing a new air bag module record the
facility or disposed of safely.
necessary information and return the inoperative
air bag module to Ford Motor Company.
NOTE: To determine the deployable devices a
vehicle is equipped with, refer to the Description
and Operation portion of this section.
Pyrotechnic Devices That Are Deployed
A vehicle equipped with any of the following
deployable devices requires manual deployment
of the devices before scrapping the vehicle or
component. For additional information, refer to
the appropriate portion of this procedure.
Driver air bag module
2. Remove the deployed device. For additional
Passenger air bag module
information, refer to the appropriate procedure
Seat side air bag modules
in this section or Section 501-20A.
Safety canopy modules
Side air curtain modules
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2. NOTE: To determine the pyrotechnic devices a
WARNING: Do not set a live air bag
vehicle is equipped with, refer to the
module down with the trim cover face down.
Description and Operation portion of this
This will reduce the risk of injury in the event of
section.
an accidental deployment.
A vehicle equipped with any of the following
WARNING: Carry a live seat side air bag
pyrotechnic devices requires manual deployment
module with the air bag and tear seam pointed
of the devices before scrapping the vehicle or
away from your body. This will reduce the risk
component. For additional information, refer to
the appropriate portion of this procedure.
deployment.
Safety belt buckle pretensioners
Safety belt retractor pretensioners
WARNING: Deployment is to be carried
Adaptive load limiting retractors out outdoors with all personnel at least 9.14
meters (30 feet) away to make sure of personal
Deployable steering column
safety. Due to the loud report which occurs when
the air bag is deployed, hearing protection is
3. NOTE: To determine if a vehicle is equipped
required.
with dual stage driver or passenger air bag
modules, refer to the Description and Operation
If a dual stage driver or passenger air bag
module has deployed due to a crash event, the
air bag module requires manual deployment to
make sure both stages have deployed before
scrapping the vehicle or disposing of the air bag
NOTE: For air bag modules with multiple squibs,
module. For additional information, refer to
all the squibs on the air bag module must be
Driver Air Bag Module, Passenger Air Bag
deployed.
Module and Seat Side Air Bag Modules
Remote Deployment in this procedure. NOTE: Some driver and passenger front air bags
have 2 deployment stages. After a crash event it is
Driver Air Bag Module, Passenger Air
possible that Stage 1 has deployed and Stage 2 has
Bag Module and Seat Side Air Bag
not.
Modules Remote Deployment
If a front air bag module has deployed, it is
mandatory that the front air bag module be
remotely deployed using the appropriate air bag
disposal procedure.
NOTE: A typical air bag disposal is shown that is
similar for all vehicles.
injury.
WARNING: Carry a live air bag module
with the air bag and trim cover pointed away
from your body. This will reduce the risk of
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All driver, passenger and seat side air bag
3. Remove the air bag module. For additional
modules
in this section.
1. Make a container to house the air bag module
4. NOTE: If the air bag module does not have a
for deployment.
hard-wired pigtail, it will be necessary to cut
NOTE: The tires must be of sufficient size
the wires and connector(s) from the vehicle
to accommodate the air bag module.
wire harness and reconnect to the air bag
Obtain a tire and wheel assembly and an
module.
additional 4 tires (without wheels) of the
Cut each of the air bag module wires near the
same size.
electrical connector that connects to the vehicle
With the tire and wheel assembly on the
wire harness.
bottom, stack the tires.
5. Remove any sheathing (if present) and strip the
Securely tie all of the tires together.
insulation from the ends of the cut wires.
6. NOTE: Typical driver air bag module with 2
squibs shown, other air bag modules with
multiple squibs similar.
For air bag modules with multiple squibs, twist
together a wire from each squib then repeat for
the remaining wires from each squib.
7. Make a jumper harness to deploy the air bag
module.
Obtain 2 wires (20 gauge minimum) at least
9.14 meters (30 feet) long and strip both
ends of each wire.
At one end of the jumper harness, connect
the wires together.
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8. Using the end of the jumper harness that the
wires are not connected together, attach each
wire of the jumper harness to each wire of the
air bag module or to the twisted-together wires
if multiple squibs. Use tape or other insulating
material to make sure that the leads do not
make contact with each other.
Driver air bag modules
9. NOTE: Make sure to maintain the connections
to the air bag module.
With the stack of tires upright and the wheel on
Passenger and seat side air bag modules
the bottom, carefully place the driver air bag
module, with the trim cover facing up, on the
wheel.
10. NOTE: Make sure to maintain the connections
to the air bag module.
Tip the stack of tires on its side and place the
air bag module inside the center tire, making
sure that there are 2 tires beneath the tire
containing the air bag module and 2 tires
(including the tire and wheel assembly) above
the tire containing the air bag module.
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11. Place the tire stack upright, with the wheel on 14. Deploy the air bag module by touching the ends
top. of the 2 wires of the jumper harness to the
terminals of a 12-volt battery.
15. To allow for cooling, wait at least 10 minutes
before approaching the deployed air bag
module.
16. Dispose of the deployed air bag module in the
same manner as any other part to be scrapped.
Safety Belt Buckle Pretensioners, Safety Belt
Retractor Pretensioners and Adaptive Load
Limiting Safety Belt Retractors Remote
Deployment
WARNING: The safety belt pretensioner is
a pyrotechnic device. Always wear safety glasses
when repairing an air bag equipped vehicle and
when handling a safety belt buckle pretensioner
or safety belt retractor pretensioner. Never probe
a pretensioner electrical connector. Doing so
could result in pretensioner or air bag
deployment and could result in personal injury.
out outdoors with all personnel at least 9.14
the pretensioner or adaptive load limiting
All driver, passenger and seat side air bag
retractor is deployed, hearing protection is
modules
required.
12. Remain at least 9.14 meters (30 feet) away
NOTE: A typical safety belt buckle and retractor
from the air bag module.
disposal is shown that is similar for all vehicles.
13. From the end of the jumper harness that is not
connected to the air bag module, disconnect the
2 wires of the jumper harness from each other.
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1. Make a container to house the safety belt 4. NOTE: If the safety belt buckle or retractor
buckle or retractor for deployment. does not have a hard-wired pigtail, it will be
necessary to cut the wires and connector(s)
NOTE: The tires must be of sufficient size
from the vehicle wire harness and reconnect to
to accommodate the safety belt buckle or
the safety belt buckle or retractor.
retractor.
Cut each of the safety belt buckle or retractor
Obtain a tire and wheel assembly and an
wires near the electrical connector that connects
additional 4 tires (without wheels) of the
to the vehicle wire harness.
same size.
With the tire and wheel assembly on the
bottom, stack the tires.
Securely tie all of the tires together.
6. Make a jumper harness to deploy the safety belt
buckle or retractor.
ends of each wire.
the wires together.
7. NOTE: Typical safety belt retractor
pretensioner shown, other safety belt buckle
pretensioners and load limiting retractors
similar.
Using the end of the jumper harness that the
safety belt buckle or retractor. Use tape or other
insulating material to make sure that the leads
do not make contact with each other.
3. Remove the safety belt buckle or retractor. For
additional information, refer to the appropriate
procedure in Section 501-20A.
When deploying a safety belt buckle
pretensioner, install a nut and bolt of
sufficient length and of the same diameter
as was used to retain it to the seat.
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8. NOTE: Make sure to maintain the connections 13. To allow for cooling, wait at least 10 minutes
to the safety belt buckle or retractor. before approaching the deployed safety belt
Tip the stack of tires on its side and place the
safety belt buckle or retractor inside the center
14. Dispose of the deployed safety belt buckle or
tire, making sure that there are 2 tires beneath
retractor in the same manner as any other part
the tire containing the safety belt buckle or
to be scrapped.
retractor and 2 tires (including the tire and
wheel assembly) above the tire containing the
Safety Belt Buckle Pretensioners, Safety Belt
safety belt buckle or retractor.
Retractor Pretensioners and Load Limiting
Safety Belt Retractors In-Vehicle
9. Place the tire stack upright, with the wheel on
Deployment
top.
the pretensioner or adaptive load limiting
retractor is deployed, hearing protection is
required.
NOTE: A typical safety belt buckle and retractor
disposal is shown that is similar for all vehicles.
2. Access the safety belt buckle or retractor
electrical connectors. For additional information,
refer to Section 501-20A.
from the safety belt buckle or retractor.
3. Cut each of the safety belt buckle or retractor
wires, leaving at least 4 inches to work with.
connected to the safety belt buckle or retractor,
disconnect the 2 wires of the jumper harness
from each other.
12. Deploy the safety belt buckle or retractor by
touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
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Safety Canopy Modules and Side Air Curtain
5. Make a jumper harness to deploy the safety belt
Modules In-Vehicle Deployment
ends of each wire.
the wires together.
6. NOTE: Typical safety belt retractor
pretensioner shown, other safety belt buckle
pretensioners and load limiting retractors are
similar.
Using the end of the jumper harness that the
safety belt buckle or retractor. Use tape or other
do not make contact with each other.
the safety canopy or side air curtain is deployed,
hearing protection is required.
NOTE: The safety canopy module deployment for a
scrapped vehicle will occur in its installed position
in the vehicle.
NOTE: A typical safety canopy module disposal is
shown that is similar for all vehicles.
2. Access the safety canopy/side air curtain
from the safety belt buckle or retractor.
module electrical connectors. For additional
in this section.
connected to the safety belt buckle or retractor,
3. Cut each of the safety canopy/side air curtain
from each other.
module wires leaving at least 4 inches to work
with.
9. Deploy the safety belt buckle or retractor by
before approaching the deployed safety belt
11. Dispose of the deployed safety belt buckle or
retractor in the same manner as any other part
to be scrapped.
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5. NOTE: Typical safety canopy/side air curtain 8. From the end of the jumper harness that is not
module with 2 squibs shown, other safety connected to the safety canopy/side air curtain
canopy/side air curtain modules with 2 squibs module, disconnect the 2 wires of the jumper
are similar. harness from each other.
For safety canopy/side air curtain modules with
9. Deploy the safety canopy/side air curtain
multiple squibs, twist together a wire from each
module by touching the ends of the 2 wires of
squib then repeat for the remaining wires from
the jumper harness to the terminals of a 12-volt
each squib.
battery.
before approaching the deployed safety
canopy/side air curtain module.
11. Dispose of the deployed safety canopy/side air
curtain module in the same manner as any other
part to be scrapped.
Deployable Steering Column In-Vehicle
Deployment
6. Make a jumper harness to deploy the safety
canopy/side air curtain module.
ends of each wire.
the wires together.
7. Using the end of the jumper harness that the the deployable steering column is deployed,
wires are not connected together, attach each hearing protection is required.
safety canopy/side air curtain module or to the
twisted-together wires if multiple squibs. Use
tape or other insulating material to make sure
that the leads do not make contact with each
other.
2. NOTE: It may be necessary to lower or remove
the deployable steering column from the
instrument panel to access the deployable
steering column electrical connector.
Access the deployable steering column electrical
connector.
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3. NOTE: If the deployable steering column does
not have a hard-wired pigtail, it will be
necessary to cut the wires and connector(s)
from the vehicle wire harness and reconnect to
the deployable steering column.
Cut each of the deployable steering column
wires, leaving at least 4 inches to work with.
5. Make a jumper harness to deploy the
deployable steering column.
from the deployable steering column.
ends of each wire.
connected to the deployable steering column,
the wires together.
from each other.
6. Using the end of the jumper harness that the
9. Deploy the deployable steering column by
deployable steering column. Use tape or other
do not make contact with each other. 10. To allow for cooling, wait at least 10 minutes
before approaching the deployed steering
column.
11. Dispose of the deployed steering column in the
same manner as any other part to be scrapped.
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Quarter Trim Panel Convertible
5 31012/31013 Lower quarter trim panel 1 13208/13209 Door scuff plate (RH/LH)
(RH/LH)
2 31004/31005 Upper quarter trim panel cap
(RH/LH)
3 390018 Quarter trim panel pin-type
1. Remove the door scuff plate.
4 31112/31113 Upper quarter trim panel
(RH/LH)
2. Remove the upper quarter trim panel cap. (Continued)
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3. Remove the rear seat cushion. For additional 5. Remove the 2 pin-type retainers and the lower
information, refer to Section 501-10. quarter trim panel.
4. Remove the pin-type retainer and the upper 6. To install, reverse the removal procedure.
quarter trim panel.
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Quarter Trim Panel Coupe
1. Remove the door scuff plate.
2. Remove the quarter trim panel lower pin-type
retainer.
3. Fold the rear seat forward, remove the 2
pin-type retainers, and the rear quarter trim
panel.
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3. Open the coat hook cover. Remove the bolt and
Quarter Window Trim Panel
coat hook.
4. Remove the upper front safety belt anchor bolt
cover and bolt.
1. NOTE: On the coupe, install the front locating
hook, then snap the A-pillar trim panel in place
working rearward.
5. Remove the quarter window trim panel.
Remove the 2 A-pillar trim panels.
2. Remove the rear quarter trim panel. For
additional information, refer to Quarter Trim
Panel Coupe in this section.
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Radiator Grille
1 8200 Radiator grille
2. Release the radiator grille retaining clips from
the front bumper cover and remove the radiator
grille.
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Rear View Mirrors
The rear view mirror system consists of the
exterior mirror
exterior mirror control switch
exterior mirror glass
exterior mirror motor
interior rear view mirror
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The exterior mirrors are electrically controlled by
Rear View Mirrors
the exterior mirror control switch for both vertical
Special Tool(s)
and horizontal movement. The exterior mirror
control switch is hardwired to the exterior mirrors.
When the LH or RH exterior mirror is selected,
adjustment is carried out by moving the control to
the desired position.
2. Visually inspect for obvious signs of Flex Probe Kit
105-R025B or equivalent mechanical or electrical damage.
Exterior mirrors Circuitry
Exterior mirror control
switch
Principles Of Operation
Exterior mirror motor
Smart junction box
The rear view mirror system consists of 2 exterior
(SJB) fuse 4 (5A)
mirrors (each mirror includes 2 mirror motors)
mounted on the exterior doors, an exterior mirror
control switch and an interior rear view mirror.
Symptom Chart
Symptom Chart
The mirrors are inoperative Fuse GO to Pinpoint Test A.
Circuitry
Exterior mirror control switch
A single mirror is inoperative Circuitry GO to Pinpoint Test B.
Exterior mirror control switch
A single mirror does not Circuitry GO to Pinpoint Test C.
function with switch logic Exterior mirror control switch
Pinpoint Tests
Pinpoint Test A: The Mirrors Are Inoperative
Refer to Wiring Diagrams Cell 124, Power Mirrors
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Possible Causes
Normal Operation
The exterior mirror control switch is supplied
fuse
voltage from the smart junction box through circuit
circuit 542 (YE) open, short to voltage, or short
956 (OG/LG) and grounds through circuit 1205
to ground
(BK). The exterior mirror control switch activates
circuit 956 (OG/LG) open or short to ground the LH exterior mirror by switching voltage and
ground to circuits 541 (DB), 540 (RD), and 542
circuit 1205 (BK) open
(YE). The switch activates the RH exterior mirror
by switching voltage and ground to circuits 544
(VT), 543 (DG), and 542 (YE). The exterior mirror
control switch must be in the appropriate (left or
right) position for the desired mirror to operate.
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE
A1 CHECK CIRCUIT 956 (OG/LG) FOR VOLTAGE
Disconnect: Exterior Mirror Control Switch C527.
Measure the voltage between the exterior mirror control switch
C527-3, circuit 956 (OG/LG), harness side and ground.
Yes
GO to A2.
No
Measure the resistance between the exterior mirror control
switch C527-1, circuit 1205 (BK), harness side and ground.
Yes
GO to A3.
No
A3 CHECK CIRCUIT 542 (YE) FOR VOLTAGE
Disconnect: Exterior Mirror C622.
(Continued)
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PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE (Continued)
A3 CHECK CIRCUIT 542 (YE) FOR VOLTAGE (Continued)
Measure the voltage between the exterior mirror control switch
C527-6, circuit 542 (YE), harness side and ground.
Yes
normal operation.
No
GROUND
switch C527-6, circuit 542 (YE), harness side and the RH
exterior mirror C622-2, circuit 542 (YE), harness side; and
between the exterior mirror control switch C527-6, circuit 542
(YE), harness side and ground.
Yes
INSTALL a new exterior mirror control
switch. REFER to Exterior Mirror Control
Switch in this section. TEST the system
Is the resistance less than 5 ohms between the exterior
mirror control switch connector and the exterior mirror No
connector, and greater than 10,000 ohms between the REPAIR the circuit. TEST the system for
exterior mirror control switch connector and ground? normal operation.
A5 CHECK CIRCUIT 956 (OG/LG) FOR AN OPEN OR A SHORT TO
GROUND
(Continued)
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PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE (Continued)
A5 CHECK CIRCUIT 956 (OG/LG) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
(OG/LG), harness side and the exterior mirror control switch
C527-3, circuit 956 (OG/LG), harness side; and between the
SJB C2280e-19, circuit 956 (OG/LG), harness side and ground.
Yes
GO to A6.
Is the resistance less than 5 ohms between the SJB
connector and the exterior mirror control switch connector, No
and greater than 10,000 ohms between the SJB connector REPAIR the circuit. TEST the system for
and ground? normal operation.
corrosion
operation.
pushed-out pins
Possible Causes
Pinpoint Test B: A Single Mirror Is
Inoperative
circuit 540 (RD) open, short to voltage, or short
to ground
circuit 541 (DB) open, short to voltage, or short
to ground
Normal Operation
voltage through circuit 956 (OG/LG) and grounded
to ground
through circuit 1205 (BK). The exterior mirror
circuit 543 (DG) open, short to voltage, or short
control switch activates the LH exterior mirror by
to ground
switching voltage and ground to circuits 541 (DB),
circuit 544 (VT) open, short to voltage, or short
540 (RD) and 542 (YE). The switch activates the
to ground
RH exterior mirror by switching voltage and ground
to circuits 544 (VT), 543 (DG), and 542 (YE). The
exterior mirror control switch must be in the
appropriate (left or right) position for the desired
mirror to operate.
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE
B1 CHECK THE COMMON FEED INPUT
Disconnect: Exterior Mirror Connector C516 or C622.
(Continued)
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PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE (Continued)
B1 CHECK THE COMMON FEED INPUT (Continued)
Measure the voltage between the LH exterior mirror C516-2,
circuit 542 (YE), harness side and ground; or between the RH
exterior mirror C622-2, circuit 542 (YE), harness side and
ground.
Yes
GO to B3.
Select the inoperative side and actuate the exterior mirror control
switch to the down position, then the right position. No
B2 CHECK CIRCUIT 542 (YE) FOR AN OPEN
switch C527-6, circuit 542 (YE), harness side and the LH
exterior mirror C516-2, circuit 542 (YE), harness side; or
between the exterior mirror control switch C527-6, circuit 542
(YE), harness side and the RH exterior mirror C622-2, circuit
542 (YE), harness side.
Yes
No
(Continued)
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B3 CHECK THE UP/DOWN INPUT
circuit 541 (DB), harness side and ground; or between the RH
exterior mirror C622-1, circuit 544 (VT), harness side and
ground.
Yes
GO to B6.
No
For LH inoperative, GO to B4.
Actuate the exterior mirror control switch to the up position.
Is the voltage greater than 10 volts? For RH inoperative, GO to B5.
B4 CHECK CIRCUIT 541 (DB) FOR AN OPEN
switch C527-5, circuit 541 (DB), harness side and the LH
exterior mirror C516-1, circuit 541 (DB), harness side.
Yes
No
B5 CHECK CIRCUIT 544 (VT) FOR AN OPEN
(Continued)
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B5 CHECK CIRCUIT 544 (VT) FOR AN OPEN (Continued)
switch C527-2, circuit 544 (VT), harness side and the RH
exterior mirror C622-1, circuit 544 (VT), harness side.
Yes
No
B6 CHECK THE LEFT/RIGHT INPUT
circuit 540 (RD), harness side and ground; or between the RH
exterior mirror C622-3, circuit 543 (DG), harness side and
ground.
Yes
CHECK the exterior mirror jumper harness
of the mirror in question for open or short
circuits, and damaged or pushed out pins.
If the jumper harness is OK, INSTALL a
new exterior mirror motor. REFER to
Exterior Mirror Motor in this section. TEST
the system for normal operation. If the
jumper harness is not OK, INSTALL a new
exterior mirror. REFER to Exterior Mirror in
operation.
No
For LH inoperative, GO to B7.
Actuate the exterior mirror control switch to the left position.
Is the voltage greater than 10 volts? For RH inoperative, GO to B8.
(Continued)
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B7 CHECK CIRCUIT 540 (RD) FOR AN OPEN
switch C527-8, circuit 540 (RD), harness side and the LH
exterior mirror C516-3, circuit 540 (RD), harness side.
Yes
No
B8 CHECK CIRCUIT 543 (DG) FOR AN OPEN
switch C527-7, circuit 543 (DG), harness side and the RH
exterior mirror C622-3, circuit 543 (DG), harness side.
Yes
No
Possible Causes
Pinpoint Test C: A Single Mirror Does Not
Function With Switch Logic
circuit 540 (RD) open, short to voltage, or short
to ground
circuit 541 (DB) open, short to voltage, or short
to ground
Normal Operation
voltage through circuit 956 (OG/LG) and grounded
to ground
through circuit 1205 (BK). The exterior mirror
circuit 543 (DG) open, short to voltage, or short
control switch activates the LH exterior mirror by
to ground
switching voltage and ground to circuits 541 (DB),
circuit 544 (VT) open, short to voltage, or short
540 (RD), and 542 (YE). The switch activates the
to ground
RH exterior mirror by switching voltage and ground
to circuits 544 (VT), 543 (DG), and 542 (YE). The
exterior mirror control switch must be in the
appropriate (left or right) position for the desired
mirror to operate.
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PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
C1 CHECK THE EXTERIOR MIRROR CONNECTOR LOGIC
Disconnect: Exterior Mirror C516 (LH), or C622 (RH).
Measure for voltage at the suspect exterior mirror connector
harness side, while actuating the exterior mirror control switch
according to the following chart.
Exterior
mirror control
switch Measure for
Connector-Pin Circuit position voltage
LH side selected
C516-3 540 (RD) Left Greater than 10
volts
C516-1 541 (DB) Up Greater than 10
volts
C516-2 542 (YE) Right Greater than 10
volts
C516-2 542 (YE) Down Greater than 10
volts
Exterior
mirror control
switch Measure for
RH side selected
Yes
C622-3 543 (DG) Left Greater than 10 CHECK the exterior mirror jumper harness
volts
C622-1 544 (VT) Up Greater than 10 If the jumper harness is OK, INSTALL a
volts
C622-2 542 (YE) Right Greater than 10 the system for normal operation. If the
volts
C622-1 542 (YE) Down Greater than 10 this section. TEST the system for normal
operation.
volts
No
Is the circuit logic OK? GO to C2.
C2 CHECK THE EXTERIOR MIRROR CONNECTOR
Disconnect: Exterior Mirror C516 (LH) or C622 (RH).
Measure the resistance at the suspect exterior mirror connector
harness side, while actuating the exterior mirror control switch
according to the following chart.
(Continued)
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PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC (Continued)
C2 CHECK THE EXTERIOR MIRROR CONNECTOR (Continued)
Exterior
mirror control
switch Measure for
Connector-Pin Circuit position resistance
LH side selected
C516-3 540 (RD) Right Less than 5
ohms to ground
C516-1 541 (DB) Down Less than 5
ohms to ground
C516-2 542 (YE) Left Less than 5
ohms to ground
C516-2 542 (YE) Up Less than 5
ohms to ground
Exterior
mirror control
switch Measure for
RH side selected
Yes
C622-3 543 (DG) Right Less than 5 CHECK the exterior mirror jumper harness
ohms to ground
C622-1 544 (VT) Down Less than 5 If the jumper harness is OK, INSTALL a
ohms to ground
C622-2 542 (YE) Left Less than 5 the system for normal operation. If the
ohms to ground
C622-2 542 (YE) Up Less than 5 this section. TEST the system for normal
operation.
ohms to ground
No
Is the circuit logic OK? GO to C3.
C3 CHECK THE EXTERIOR MIRROR CONTROL SWITCH
Remove the exterior mirror control switch. Leave the harness
connected.
Measure for voltage at the exterior mirror control switch while
actuating the exterior mirror control switch according to the
following chart.
(Continued)
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(Continued)
Exterior
mirror control
switch Measure for
C527-6 542 (YE) Right Greater than 10
volts
C527-6 542 (YE) Down Greater than 10
volts
LH side selected
C527-8 540 (RD) Left Greater than 10
volts
C527-5 541 (DB) Up Greater than 10
volts
RH side selected
C527-7 543 (DG) Left Greater than 10 Yes
GO to C4.
volts
No
C527-2 544 (VT) Up Greater than 10
volts
Is the circuit logic OK? for normal operation.
Remove the exterior mirror control switch. Leave the harness
connected.
Measure for resistance at the exterior mirror control switch while
actuating the exterior mirror control switch according to the
following chart.
(Continued)
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(Continued)
Exterior
mirror control
switch Measure for
C527-6 542 (YE) Left Less than 5
ohms to ground
C527-6 542 (YE) Up Less than 5
ohms to ground
LH side selected
C527-8 540 (RD) Right Less than 5
ohms to ground
C527-5 541 (DB) Down Less than 5
ohms to ground
RH side selected
Yes
C527-7 543 (DG) Right Less than 5 REPAIR the circuits in question. TEST the
ohms to ground
No
C527-2 544 (VT) Down Less than 5
ohms to ground
Is the circuit logic OK? for normal operation.
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501-35-1 501-35-1 Body Repairs
GENERAL PROCEDURES
5. Dry only the horizontal surfaces of the vehicle,
Refinishing Environmental Damage
do not dry the glass at this time.
Material
6. CAUTION: Do not apply the alkaline
Item Specification
neutralizer directly to the vehicle plastic
Motorcraft Detail Wash
trim.
ZC-3-A
NOTE: Use a separate wash mitt for each
Motorcraft Acid
product applied to the vehicle.
Neutralizer
ZC-1-A
NOTE: Alkaline neutralizer is a ready to use
Motorcraft Alkaline product. Do not mix with water.
Neutralizer
Pour the alkaline neutralizer into a squirt bottle
ZC-2-A
and apply the solution to a clean wash mitt.
Iron Oxide (Rail Dust) or Acid Rain
Decontamination
7. CAUTION: Do not allow the alkaline
neutralizer to dry on the vehicle.
NOTE: Iron oxide contamination appears as tiny
Apply the product to the vehicle keeping the
rust spots on horizontal surfaces and in severe cases
solution wet and lightly agitate for 5 to 7
can be felt. This damage is typically caused from
minutes. For severe conditions, work the
rail shipment, storage near railroad tracks or fallout
product for up to 8 minutes.
from industrial manufacturing facilities.
8. Rinse the vehicle completely with cold water to
NOTE: Acid rain contamination can be identified
remove the product.
as water spotting and in severe cases staining within
the water spots.
9. Prepare the detail wash by mixing 29.5 ml (1
ounce) with 3.78L (1 gallon) of water.
1. CAUTION: Never paint over iron
particles. Use only the recommended
10. Using a clean wash mitt, shampoo the entire
decontamination procedure detailed below.
vehicle and rinse with cold water. Dry the
vehicle completely.
Rinse any dust, dirt and foreign material from
the vehicle body with cold water. Flush
11. Visually inspect the paint surface for any
liberally.
remaining evidence of ferrous metal particles.
Repeat procedure as necessary.
2. Prepare the acid neutralizer by mixing 8 parts
of water to 1 part neutralizer in a bucket.
3. CAUTION: Do not allow the product
to dry on the vehicle.
NOTE: Use a separate wash mitt for each
product applied to the vehicle.
Working quickly and beginning at the top of
the vehicle and working to the sides, apply the
acid neutralizer mix to the entire vehicle. Keep
the vehicle wet with the solution and lightly
agitate for 5 to 7 minutes. Continue around the
vehicle 4 to 5 times. For severe conditions,
work the product for up to 8 minutes.
4. Rinse the vehicle completely with cold water to
remove the product.
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501-35-2 501-35-2 Body Repairs
Surface Finishing Following 2. Apply machine glaze to the vehicle surface as
Decontamination
recommended by the product manufacturer.
3. Use an alcohol and water mixture (1 to 1) to
1. CAUTION: When attempting to affect
clean the buffed and polished areas. Verify
a repair by buffing, polishing or color
removal of scratches and swirls before the
sanding, do not remove an excess of 0.3 MIL
application of the final polish.
of paint film or refinishing will be required.
NOTE: Acid rain discoloring or etching may
4. Apply a final polish material by hand, with a
require color sanding in addition to buffing and
dual-action sander and foam pad, or with an
polishing. In extreme cases, refinishing may be
orbital polisher and appropriate polishing
required if the following procedure does not
bonnet.
restore the vehicle finish.
5. Wash and dry the vehicle.
NOTE: Do not intermix buffing products. Use
only one manufacturers product.
NOTE: Always follow the manufacturers
product usage sequence. Use the appropriate
buffing or polishing pad at the recommended
buffing speed as specified by the product
manufacturer.
Apply rubbing compound to the vehicle surface
as recommended by the product manufacturer.
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501-35-1 501-35-1 Body Repairs
GENERAL PROCEDURES
1. Wash the repair area with pH-neutral soap and
Refinishing Manufacturing Damage
water.
Material
2. Remove any trim, emblems and hardware from
Item Specification
the area to be repaired.
Low Temperature
Anti-Corrosion Coating 3. NOTE: All delamination must be removed.
PM-12-A
Sand or media blast the damaged surface,
Motorcraft Detail Wash
keeping the repair area as minimal as possible.
ZC-3-A
4. Treat any bare metal surface to prevent flash
WARNING: The correct protective
corrosion, and prime and block sand as
equipment and clothing must be worn when
necessary prior to refinishing.
using paints, solvents, sanding or grinding.
Proper ventilation must also be provided to avoid
5. Mask the adjacent panels to protect from
harmful fumes in the work area.
overspray.
CAUTION: Protect adjacent
6. Spot repair the base coat as necessary,
areas/substrates when preparing for and during
following the paint manufacturers prescribed
refinishing.
procedures.
NOTE: Peeling/delamination concerns can be
7. Following the paint manufacturers prescribed
described as lack of adhesion, either between the
procedure, apply clear coat to the entire panel.
substrate and topcoats or between individual coats
of paint.
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GENERAL PROCEDURES
4. If the door locks do not respond for any RKE
Remote Keyless Entry Transmitter
transmitter, wait several seconds and press the
Programming
button again. If the door locks still fail to
respond, refer to Inspection and Verification.
CAUTION: All remote keyless entry (RKE)
Make sure that no more than the maximum
transmitters must be programmed at the same
number of RKE transmitters are attempted to
time.
be programmed.
1. The vehicle must be electronically unlocked
5. Exiting the programming mode is accomplished
before entering program mode, via the RKE
if one of the following occurs:
transmitter or the door lock control switch
Turning the key to the OFF position.
while the driver door is open.
20 seconds have passed since entering
programming mode or since the last RKE
2. Turn the key from the OFF to the RUN
transmitter was programmed.
position 8 times within 10 seconds, with the
eighth turn ending in the RUN position. If the
The maximum number of RKE transmitters
module has successfully entered program mode,
have been programmed.
it locks and then unlocks all the doors.
3. Within 20 seconds, press any button on an RKE
transmitter, and the doors lock and then unlock
to confirm that the RKE transmitter has been
programmed. Repeat this step for each RKE
transmitter.
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501-35-1 501-35-1 Body Repairs
GENERAL PROCEDURES
1. The surfaces must be free of oil, dirt and other
Restoring Corrosion Protection
foreign material.
Following Repair
1 Thoroughly clean and degrease metal
surfaces using a good wax and grease
Material
remover.
Item Specification
2 Adhesion will be improved by lightly
Low Temperature
abrading the surface.
PM-12-A
3 Apply anti-corrosion coating with a brush
Motorcraft Metal Surface WSE-M5B392-A (natural hair brush only) or roller.
Cleaner
4 The material may also be applied through
ZC-21
spraying.
X Shake the product until all particles are Prep
ZC-31 suspended.
Roof Ditch Sealer
X Filter the material into a spray gun cup
TA-15
and dilute up to 10% with water.
X Apply the material using a
TA-1
basecoat/clearcoat spray gun equipped
Metal Patch Panel
with a 1.4 mm (0.05 in) tip.
Adhesive
TA-3
X Allow the material to flash dry to remove
water and let air dry, or bake at 60C
(140F) for 45 minutes.
5 Apply at 2.5 MIL film thickness.
repairs are made. 6 Anti-corrosion products will reach full-bond
strength within 48 hours at 21C (70F) and
NOTE: Avoid applying corrosion protection to
60% relative humidity.
mechanical and electrical parts, electric motors,
speakers, door locks and drain holes.
2. NOTE: Make sure the corrosion protection
material is fully cured before attempting to
prime or paint the surface(s).
When welding overlapping surfaces or
substrates, apply corrosion protection between
the surfaces prior to welding. When the
surfaces have been welded, apply corrosion
protection to the exterior surfaces or substrates.
3. When treating exposed seams, apply the
appropriate seam sealer, following product
guidelines. Prime and paint as required.
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Restraints Control Module (RCM)
Removal
1 W520111 Restraints control module
(RCM) nuts WARNING: Always wear safety glasses
2 RCM small connector (part of
14401) system (SRS) vehicle and when handling an air
3 RCM large connector (part of
14A005) the event of an accidental deployment.
4 14B321 RCM
WARNING: The restraints control module
(RCM) orientation is critical for correct air bag
supplemental restraint system (SRS) operation. If
a vehicle equipped with an SRS system has been
involved in a collision in which the center tunnel
area has been damaged, inspect the mounting
and bracket for deformation. If damaged, the
RCM must be replaced whether or not the air
bags have deployed. In addition, make sure the
area of the RCM is restored to its original
condition.
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finish panel.
sensitive to static electrical charges. If exposed to
these charges, damage can result.
NOTE: When installing a new restraints control
module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed,
erroneous DTCs will result.
customer.
kick panels.
procedure again.
NOTE: Radio is removed for clarity.
2. Remove the console shifter bezel.
5. Remove the 6 screws and position out the
center instrument panel finish panel.
6. Disconnect the electrical connectors and remove
the center instrument panel finish panel.
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7. NOTE: A similar RCM and connectors are 8. Disconnect the small RCM electrical connector.
shown.
9. Remove the 3 nuts and the RCM.
Disconnect the large restraint control module
(RCM) electrical connector.
Installation
1 Pinch the thumb tab and pivot the connector
position assurance lever all the way back
until it stops.
the air bag restraints control module (RCM)
2 Pull out and disconnect the large RCM
retaining nuts is critical for correct system
operation.
Position the RCM and install the nuts.
2. Connect the small RCM electrical connector.
3. Make sure the large RCM connector position
assurance lever is in the full RELEASE position
before attempting to connect the connector.
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5. Connect the electrical connectors and install the
4. CAUTION: Putting the large RCM
center instrument panel finish panel and the 6
electrical wiring connector into the RCM on
screws.
an angle can cause bad electrical connections
and damage components.
6. Install the driver and passenger center console
CAUTION: Do not push the connector
kick panels.
to where the lever pivots and seats itself.
Light pressure is needed to get the connector
7. Install the center console top finish panel and
into position on the RCM before using the
the 2 screws.
lever to fully seat the connector.
NOTE: A similar RCM and connectors are
shown.
Connect the large RCM electrical wiring
connector.
Using the connector position assurance
lever, pivot it toward the RCM, drawing the
connector into the RCM.
X Make sure the thumb tab is engaged to
the retainer on the RCM and locked in
place.
8. Install the console shifter bezel.
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Rocker Panel Moulding
1 W709176-S Front rocker panel-to-fender
1. Remove the 2 front rocker panel pin-type retainers (2 required
each side) moulding-to-fender pin-type retainers.
2 W710532-S Rocker panel moulding
pin-type retainers (8 required 2. Remove the 8 rocker panel pin-type retainers.
each side)
3. Using a suitable tool, release the 8 hidden 3 6310176 RH/ Rocker panel moulding
6310177 LH GT pin-type retainers and remove the rocker panel
moulding. 3 6310154 RH/ Rocker panel moulding
6310155 LH base vehicle
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Safety Belt Buckle Front
1 Safety belt buckle switch
electrical connector WARNING: All safety belt assemblies
(including retractors, belt tension sensor [BTS] if
2 Safety belt buckle bolt
equipped, buckles, shoulder belt height adjuster
3 61202/61203 Safety belt buckle assembly
[if equipped], child safety seat tether attachments
(RH/LH)
and attaching hardware) should be inspected
after any collision. All new belt assemblies
should be installed new unless a qualified
technician finds the assemblies show no damage
and operate correctly. Belt assemblies not in use
during a collision should also be inspected and
new assemblies installed if either damage or
incorrect operation is noted. Failure to follow
these instructions could increase the risk of
injury in collisions.
the (SRS) must be depowered.
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NOTE: The air bag warning lamp illuminates when 4. Disconnect the safety belt buckle switch
the restraints control module (RCM) fuse is electrical connector.
5. Remove the bolt and the safety belt buckle.
When installing the safety belt buckle,
position the safety belt buckle to the seat
and align the locator tabs.
customer.
7. Install the front seat. For additional information,
procedure again.
8. Repower the SRS. Refer to Supplemental
1. Position the seat to gain access to the
seat-to-floor fasteners on the side with the
Repowering in the General Procedures portion
affected safety belt buckle.
of Section 501-20B.
2. Depower the SRS. Refer to Supplemental
9. Check the active restraint system for correct
operation. For additional information, refer to
Safety Belt System in this section.
of Section 501-20B.
3. Remove the front seat with the affected safety
belt buckle. For additional information, refer to
Section 501-10.
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Safety Belt Buckle Rear
1 W520113-S424 Safety belt buckle nut
WARNING: All safety belt assemblies
2 60044/60045 Safety belt buckle (RH/LH)
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2. Remove the nut and the safety belt buckle. 3. To install, reverse the removal procedure.
When installing the safety belt buckle, align When installing the seat cushion, make sure
the locator tab between the dimples in the the safety belt buckles are accessible to the
floor pan as shown for correct installation. occupants after installation.
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GENERAL PROCEDURES
Safety Belt Cleaning
1. WARNING: Do not bleach or re-dye
the webbing, as the webbing may weaken.
Clean the safety belt webbing only with a mild
soap solution recommended for cleaning
upholstery or carpets. Follow the instructions
provided with the soap.
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GENERAL PROCEDURES
Safety Belt Maintenance
1. The safety belt assemblies should be
periodically inspected to make sure that they
have not become damaged and that they remain
in correct operating condition, particularly if
they have been subjected to severe stress.
2. Before installing the new safety belt assembly,
the safety belt retaining areas must be inspected
for damage and distortion. If the retaining
points are damaged and distorted, the sheet
metal must be reworked back to its original
shape and structural integrity.
3. Install the new safety belt(s) using the
appropriate instructions. Carry-out the
Functional Test Procedure. For additional
information, refer to Safety Belt System in this
section.
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GENERAL PROCEDURES
Safety Belt Procedure After a
Collision
1. Before installing a new safety belt assembly,
the safety belt attaching areas must be inspected
for damage and distortion. If the attaching
points are damaged and distorted, the sheet
metal must be worked back to its original shape
and structural integrity.
2. Install the new safety belt(s); refer to the
procedure in this section. Carry-out the
Functional Test. For additional information,
refer to Safety Belt System in this section.
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Safety Belt Retractor and
Pretensioner
3 Secondary safety belt guide 1 Safety belt anchor bolt (part
(part of 611B08 RH/611B09 of 611B08 RH/611B09 LH)
LH)
2 Belt tension sensor (BTS)
4 D-ring (part of 611B08 electrical connector (part of
RH/611B09 LH) 611B08)
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5 D-ring bolt (part of 611B08
customer.
RH/611B09 LH)
6 60262 D-ring cover
7 611B08/611B09 Safety belt retractor and
pretensioner (RH/LH)
8 Safety belt retractor and
procedure again.
pretensioner bolt (part of
611B08 RH/611B09 LH)
All retractors
9 Safety belt retractor and
pretensioner electrical
1. Move the seat to the most forward position on
the side with the affected safety belt retractor.
Removal
2. Depower the SRS. Refer to Supplemental
of Section 501-20B.
3. Remove the safety belt anchor bolt.
4. Remove the lower quarter trim panel. For
Passenger retractor
5. Disconnect the belt tension sensor (BTS)
Separate the BTS wire harness and retainers
from the body.
All retractors
6. Disconnect the safety belt retractor and
pretensioner electrical connector.
7. Remove the D-ring cover.
8. Remove the D-ring bolt.
9. Remove the secondary safety belt guide from
the B-pillar.
10. Remove the bolt and the safety belt retractor
and pretensioner.
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Passenger retractor
Installation
6. Connect the BTS electrical connector. CAUTION: The shipping clip on a new
retractor must remain attached prior to the
Install the BTS wire harness and retainers to
installation of the retractor into the vehicle. The
the body.
clip must be removed after the retractor is
installed. All retractors
NOTE: Make sure the safety belt is not twisted.
7. Install the lower quarter trim panel. For
All retractors
8. Install the safety belt anchor bolt.
1. Position the safety belt retractor and
pretensioner and install the bolt.
9. Repower the SRS. Refer to Supplemental
2. Install the secondary safety belt guide into the
B-pillar.
of Section 501-20B.
3. Install the D-ring bolt.
4. Install the D-ring cover.
5. Connect the safety belt retractor and
pretensioner electrical connector.
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Safety Belt Retractor Rear
1 Safety belt anchor bolt (part
of 611B68 RH/611B69 LH)
2 Safety belt retractor bolt (part
of 611B68 RH/611B69 LH)
3 611B68/611B69 Safety belt retractor (RH/LH)
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Removal Installation
WARNING: All safety belt assemblies CAUTION: The shipping clip on a new
(including retractors, belt tension sensor [BTS] if retractor must remain attached prior to the
equipped, buckles, shoulder belt height adjuster installation of the retractor into the vehicle. The
[if equipped], child safety seat tether attachments clip must be removed after the retractor is
and attaching hardware) should be inspected installed.
NOTE: Make sure the safety belt is not twisted
when inserting it in the package tray trim panel.
1. Position the safety belt retractor and install the
bolt.
incorrect operation is noted. Failure to follow To install, tighten to 40 Nm (30 lb-ft).
2. Install the package trim panel. For additional
3. NOTE: The anti-rotation tab must be correctly
aligned for correct installation.
2. Remove the safety belt anchor bolt.
Install the safety belt anchor and bolt.
3. Fold the rear seat backrests down.
4. Fold the rear seat backrests up.
4. Remove the package tray trim panel. For
5. Remove the bolt and the safety belt retractor.
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Safety Belt System
Safety belt webbing Open fuse
integrity Bare, broken or
active restraint system to duplicate the Safety belt buckle and disconnected wire
tongue assembly Connector not tightly
condition.
Safety belt retractor engaged
Safety belt warning
mechanical or electrical concerns apply: indicator burned out or
broken
3. If the inspection reveals an obvious concern(s)
that can be readily identified, repair as required.
With the exception of removing a twist from
the safety belt webbing, do not attempt to repair
a component of the safety belt system; new
components must be installed.
determine the symptom. GO to Symptom Chart.
Symptom Chart
Symptom Chart
The safety belt warning Circuitry REFER to Section 413-09.
chime does not operate, the Instrument cluster module
safety belt warning indicator
is OK
The safety belt warning Circuitry REFER to Section 413-09.
indicator does not operate, the Instrument cluster module
safety belt warning chime is
OK
Neither the safety belt Circuitry REFER to Section 413-09.
warning chime nor the safety Safety belt buckle switch
belt warning indicator Instrument cluster module
operates
Excessive pressure on the Front safety belt retractor and CARRY OUT the Functional
occupant during normal wear, tongue Test. REFER to Component
the webbing cannot be Rear safety belt retractor and Test. INSTALL components
extracted, excessive slack in tongue necessary.
webbing does not retract
Component Test 1. Verify the following during the latching
sequence:
Carry out the appropriate Functional Test(s) as
determined in Inspection and Verification.
Tongue insertion is not hindered by
excessive effort.
Functional Test Buckle and Tongue
A click is heard when the buckle latches the
The safety belt buckle and tongue assembly must
tongue.
operate freely during the latching and unlatching
2. Verify the system integrity by forcefully pulling
function. Fasten the safety belt by inserting the
on the belt webbing.
tongue (male portion) into the buckle (female
portion).
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3. Unlatch the belt by fully depressing the buckle
2 WARNING: The maximum brake
release button and allowing the belt to release
application should be on dry concrete or
and retract.
equivalent hard surface, NEVER on wet
pavement or gravel.
4. Verify the following during the unlatching
process:
WARNING: The driver and
Push-button depression does not require
passenger must be prepared to brace
excessive effort.
themselves in the event the retractor does
not lock.
Tongue can be removed easily from the
buckle.
Make a maximum brake application without
a skid.
5. Repeat the above steps 3 times.
3 NOTE: Do not jerk on the safety belt
6. If the inspection reveals an obvious concern(s)
webbing when carrying out this test.
that can be readily identified, service as
required. Do not attempt to carry out any repair
Lean forward slightly when the brake
on the buckle and tongue assembly. If a
application is made.
concern exists with either component, a new
4. The safety belts should lock up with minimum
safety belt buckle and/or safety belt and
webbing extension.
retractor assembly must be installed.
5. If there is a lockup of both shoulder straps, the
Functional Test Retractor
safety belt assemblies are functioning correctly.
Should either or both retractors fail to lock up
The safety belt and retractor assembly must be
at the 8 km/h (5 mph) speed, repeat the test at
freely operational for extraction and retraction of the
a constant 24 km/h (15 mph) speed. (This test
safety belt webbing between full extension and
must be carried out with the assistance of a RH
in-vehicle stowed positions.
front or rear passenger if the RH front or rear
1. Extract and retract the safety belt between the
safety belts are to be tested.)
full extension and stowed positions.
6. CAUTION: Before installing a new
2. Verify the retractor operates without excessive
safety belt assembly, inspect the mounting
effort or binding.
area for damage and distortion. If the
3. Install a new safety belt buckle retractor and
retractor of a new safety belt assembly has
tongue assembly if no obvious concerns are
been bolted into a damaged or distorted
noticed and the complaint has been verified.
mounting area, the retractor could be
warped and may not function. If this is the
Functional Test System Road Test
case, remove the retractor and return the
Inspection
sheet metal to the original configuration and
1. NOTE: If the RH or the rear safety belts are to
install another complete safety belt assembly.
be tested, the assistance of a passenger is
If a retractor does not lock up at the 24 km/h
required.
(15 mph) test, return the vehicle for service of
Fasten the safety belts and proceed to a safe
malfunctioning safety belts.
area.
2. Attain a speed of 8 km/h (5 mph).
3. WARNING: The driver and passenger
must be prepared to brace themselves if the
retractor does not lock.
Test the safety belts.
1 Grasp the shoulder harness and prepare to
lean forward.
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Functional Test Automatic Locking
3. Latch the seat belt buckle and tongue assembly.
Retractor
4. Pull the shoulder belt out until the automatic
locking retractor (ALR) feature is activated.
WARNING: After any vehicle collision, the
safety belt system at all outboard seating
5. Release the shoulder belt and allow it to retract
positions (except driver, which has no automatic
until it stops.
locking retractor [ALR] feature) must be checked
6. Pull on the shoulder belt to check that the belt
by a qualified technician to verify that the ALR
has remained in the ALR mode. If the belt is
feature for child safety seats is still functioning
not locked, install a new safety belt and
correctly, in addition to other checks for correct
retractor assembly.
safety belt system function. A new safety belt and
7. Unlatch the safety belt tongue from the buckle
retractor assembly must be installed if the safety
and allow the safety belt to retract to its stowed
belt assemblys ALR feature, or any other safety
position.
belt function, is not operating correctly when
checked according to the procedures in the
8. Pull the shoulder belt to verify the retractor
workshop manual. Failure to install a new safety
assembly has converted automatically out of the
belt and retractor assembly could increase the
ALR mode. If the shoulder belt remains locked
risk of injury in collisions.
in the stowed position, install a new safety belt
and retractor assembly.
1. Position the seat back (if adjustable) into the
full up position.
2. Position the height adjuster (if equipped) in the
full down or up position.
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Safety Belt System WARNING: A forward-facing child safety
seat should only be placed in the front seat when
it is unavoidable. If you must place a
(including retractors, belt tension sensor [BTS], if
forward-facing child seat in the front, always
equipped, buckles, front seat belt buckle support
move the seat as far back as possible, because
assemblies [slide bar], if equipped, shoulder belt
the force of the deploying front passenger air
height adjusters, if equipped, child safety seat
bag could cause death or serious injury to the
tether bracket assemblies, if equipped and
infant. If the vehicle is equipped with a
attaching hardware) should be inspected after
passenger airbag deactivation switch, the
any collision. Ford recommends new safety belt
passenger airbag must be deactivated.
assemblies be installed unless a qualified
When any new active occupant restraint components
are installed, use only the replacement parts
and operate correctly. Safety belt assemblies not
specified in the Ford Customer Service Division
in use during a collision should also be inspected
Master Parts Catalog.
and new assemblies installed if either damage or
incorrect operation is noted.
The active restraint system consists of the
following:
The Automatic Locking Retractor (ALR) feature
of the safety belt retractor must be checked by a
Front safety belt buckles, attached to the inboard
qualified technician to verify that the ALR
side of the seats
feature for a child seat is functioning correctly,
Front safety belt retractors and pretensioners,
in addition to other checks for correct safety belt
located behind the lower B-pillar trim panels
system function. A new belt and retractor
assembly must be installed if the safety belt Belt tension sensor (BTS), located at the
assemblys automatic locking retractor passenger front safety belt anchor point
feature, or any other safety belt function, is not
Rear safety belt retractors, mounted to the rear
operating correctly when inspected according to
package tray (coupe only)
the functional inspection procedures in the
Rear safety belt retractors, mounted to a stanchion
workshop manual. Failure to install a new belt
behind the rear seat backrest (convertible only)
and retractor assembly could increase the risk of
Rear safety belt buckle assemblies, attached to the
floor pan
WARNING: Each seating position in the
Rear child safety seat tether anchors, at both
vehicle has a specific safety belt assembly which
seating positions, welded to the underside of the
consists of one buckle and one tongue. The safety
package tray (coupe only)
belt assembly is designed to be used as a pair
and is not to be used across seating positions. Rear lower anchors and tethers for children
(LATCH) at both seating positions, attached to
WARNING: Never put a rear-facing child
the floor pan
seat on the front seat of a vehicle with a
passenger airbag. If the airbag deploys, it can hit
Safety Belt Retractor and Pretensioner
the back of the child seat with enough force to
The front outboard safety belt retractors use a safety
cause severe personal injury or death to the
belt pretensioner system. This works in conjunction
infant.
with the front air bag system and, if equipped, side
air bag system. The pretensioner is a pyrotechnic
device that removes excess webbing slack from the
safety belt. When activated by the restraints control
module (RCM), the pretensioner deploys in the
retractor, removing excess slack from the lap and
shoulder safety belt. The pretensioners are activated
when the RCM detects an impact force exceeding a
programmed limit.
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If the vehicle is involved in a collision that results The emergency locking retractor (ELR) mode will
in deployment of the safety belt pretensioners, a allow the occupant freedom of movement, locking
new driver and passenger seat belt system tight only on hard braking, hard cornering or an
(including safety belt buckle and pretensioners or impact of approximately 8 km/h (5 mph). The ELR
safety belt retractor and pretensioners, safety belt mode helps to reduce the forward movement of the
retractors, safety belts, buckles and height adjusters) driver and passengers. The ELR mode is
must be installed. continuously in operation at all seating positions.
For safety belt retractor pretensioner diagnostic The ALR portion of this system does not allow the
information, refer to Section 501-20B. occupant freedom of movement. The ALR mode is
used when locking a child seat in an outboard
For safety belt retractor and pretensioner disposal
seating position or when a tight belt fit is desired.
The ALR mode is automatically engaged when the
Belt Tension Sensor (BTS) webbing is fully extracted from the retractor and
then allowed to retract. As the webbing is retracted
The safety belt tension sensor is part of the
back onto the spool, an audible clicking sound is
passenger front outboard safety belt and retractor
made indicating the retractor is in ALR mode and
assembly and is not serviced separately. The safety
the webbing will not pull back out of the retractor.
belt tension sensor is located at the safety belt
To disengage the ALR mode, let the webbing
anchor point and is used in conjunction with the
retract back onto the spool. The ALR mode is
occupant classification sensor (OCS) system. For
disengaged when the webbing is free to move out
additional information, refer to Section 501-20B.
and back into the retractor.
Dual Locking Mode Retractors
The automatic locking mode must be used when
installing a child safety seat in the front or rear
WARNING: After any vehicle collision, the
passenger seating positions where dual locking
safety belt system at all outboard seating
mode retractors are provided.
positions (except driver, which has no automatic
locking retractor feature) must be checked by a
Energy Management Retractor
qualified technician to verify that the automatic
This vehicle has a safety belt system with an energy
locking retractor feature for child seats is still
management feature at the front seating positions to
functioning correctly, in addition to other checks
help further reduce the risk of injury in the event of
for correct safety belt system function. A new
a head-on collision.
belt and retractor assembly must be installed if
the safety belt assemblys automatic locking
The energy management retractor feature is
retractor feature or any other safety belt
designed to pay out webbing in a controlled
function is not operating correctly when checked
manner. This feature is designed to help reduce the
according to the procedures in the workshop
belt force acting on an occupants chest.
manual. Failure to install a new belt and
Safety Belt Warning System
retractor assembly could increase the risk of
The driver safety belt warning indicator illuminates
and a chime sounds to remind the occupants to
NOTE: When replacing a dual locking mode
fasten their safety belts.
retractor, the retractor should be checked to make
sure it is not in the automatic locking retractor
The conditions of operation for the driver safety belt
(ALR) mode after installation in the stowed
warning indicator and chime are as follows:
position.
If the driver safety belt is not buckled before the
All outboard continuous-loop, 3-point retractor
ignition switch is turned to ON, then the safety
systems, except the driver position, are equipped
belt warning indicator illuminates for 1 to 2
with the dual locking mode system.
minutes and the warning chime sounds for 4- to
8-seconds.
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If... Then...
If the driver safety belt is buckled while the
warning indicator is illuminated and the warning The driver and/or The Belt Minder feature
passenger safety belt is will not activate. chime is sounding, then the safety belt warning
buckled before the
indicator and warning chime turn off.
ignition switch is turned
If the driver safety belt is buckled before the
to the ON position or less
ignition switch is turned to ON, the safety belt than 1-2 minutes have
elapsed since the ignition
warning indicator and warning chime will remain
switch has been turned
off.
ON...
Belt Minder The driver and/or The Belt Minder feature is
passenger safety belt is activated the safety
The Belt Minder feature is a supplemental warning
not buckled before the belt warning indicator
to the safety belt warning function. This feature
vehicle has reached at illuminates and the
provides an additional reminder to the driver that
least 5 km/h (3 mph) and warning chime sounds for
the driver and/or passenger safety belt is unbuckled 1-2 minutes have elapsed 6 seconds every 30
since the ignition switch seconds, repeating for
by intermittently sounding a chime and illuminating
has been turn to ON... approximately 5 minutes
the safety belt warning indicator in the instrument
or until the safety belt(s)
cluster.
is buckled.
The passenger safety Belt Minder feature is
The drivers or front The Belt Minder feature is
activated only when the occupant classification
passengers safety belt activated the safety
sensor (OCS) system detects a passenger in the right becomes unbuckled for belt warning indicator
approximately 1 minute illuminates and the
front seat and the passenger weight exceeds a
while the vehicle is warning chime sounds for
programmed limit. For additional information on the
traveling at least 3 mph (5 6 seconds every 30
OCS system, refer to Section 501-20B.
km/h) and more than 1-2 seconds, repeating for
minutes have elapsed approximately 5 minutes To activate or deactivate the Belt Minder feature,
since the ignition switch or until safety belt(s) is
has been turned to ON... buckled.
Safety Belt Extension
A safety belt that is too short even when fully
extended can be lengthened. The safety belt
extension (611C22) is available. This assembly will
add approximately 20 cm (8 inches) to the length of
the safety belt. Use the safety belt extension only if
the safety belt is too short when fully extended. Do
not use the safety belt extension to alter the fit of
the shoulder belt across the torso. Safety belt
extensions are available at no cost from any
authorized Ford or Lincoln-Mercury dealer.
Lower Anchors and Tethers for Children
(LATCH)
The lower anchors and tethers for children
(LATCH) system is a standardized and uniform
attachment system for installing child safety seats in
passenger vehicles. LATCH-equipped child safety
seats have 2 lower attachments that connect to the
vehicle portion of the LATCH system.
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The vehicle portion of the system consists of 2 If the child safety seat tether anchors were in use
attachment points (6-mm wires) bolted to the floor during a collision, inspect and return the vehicle
pan at both rear seating positions. The attachment structure to its original production configuration.
points protrude from the bight-line between the seat
Attaching Safety Seats with Tether
cushion and seat backrest.
Straps
If a child safety seat was in use during a collision,
Some manufacturers make child safety seats that
inspect the vehicle portion of the system for
include a tether strap that goes over the back of the
damage. If any of the attachment points (6-mm
vehicle seat and attaches to an anchoring point.
wires) are damaged, a new one must be installed.
Other manufacturers offer the tether strap as an
For additional information, refer to Child Safety
accessory. Contact the manufacturer of the child
Seat Tether Anchor LATCH in this section.
safety seat for information about ordering a tether
strap. Child Safety Seat Tether Anchors
Instructions for installing the child safety belt The child safety seat tether anchors on the coupe
are located in the rear at both seating locations and anchor tether kit are included in the kit with the
are welded to the underside of the package tray. tether attachment.
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GENERAL PROCEDURES
Safety Belt Tongue Rotated on Belt
1. Grasp the belt tongue and pull the belt webbing
down to form a loop through the upper (longer
and narrower) slot in the tongue.
6. Pull the excess belt webbing through the slot.
7. NOTE: Dual slot tongue shown; single slot
tongue is similar.
The safety belt tongue should face inward when
completed.
2. Rotate and fold the belt webbing over itself
within the slot to remove the twist.
3. Pull the excess belt webbing back through the
upper slot in the belt tongue.
4. Grasp the belt tongue and pull the belt webbing
up to form a loop through the low slot in the
tongue.
5. Rotate and fold the belt webbing over itself
within the slot to remove the twist.
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501-35-1 501-35-1 Body Repairs
Sealers
Material
Item Specification
TA-32
Roof Ditch Sealer TA-15
Seam Sealer TA-2
The correct sealing of joints is essential to repairing
the vehicle correctly. Sealers are used to prevent
wind noise, water leaks, exhaust fumes and dust
from entering the vehicle. They also provide
anti-corrosion barriers. Sealers are applied to areas
such as door and rear compartment hem flanges,
wheelhouse, quarter outer, floor, cowl, roof and
other panel-to-panel attaching points. The following
joint sealers are recommended for use depending
upon the application:
Brushable Seam Sealer A sealer intended to
restore the original brushed seam appearance. It is
used to seal lap joints in sheet metal that are spot
welded (for example, floorpans and cowls).
Roof Ditch Sealer A self-leveling sealer used
for drip rails, roof seams, quarter panels to rear
deck and for water leaks.
Seam Sealer A fast curing, non-sag, paintable,
permanently flexible sealer typically used for
cosmetic seams, truck bed seams, floor pans and
door skin seams.
Clear Silicone Rubber Used for sealing water
leaks, noise concerns, remounting trim and
repairing torn weatherstripping.
Sealers should remain flexible after curing and must
be paintable. Follow the manufacturers directions
for correct application of these materials.
Any damage to originally sealed joints should be
repaired by resealing. Along with attaching points of
new panels, open joints that require bridging of
sealer to close a gap should be sealed using a
heavy-bodied sealer.
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501-10-1 501-10-1 Seating
5. Remove the head restraint.
Seat Backrest Cover Front
1 Position the head restraint as high as it will
Removal and Installation go.
2 Using an appropriate tool, push through the
WARNING: Always wear safety glasses hole on the inboard side of the head
when repairing an air bag supplemental restraint restraint guide and release the head restraint.
X Hold the head restraint up so it does not
engage back into the head restraint guide.
3 Release the head restraint guide on the other
side and remove the head restraint.
WARNING: Front seat back trim covers
installed on seats equipped with side air bags
cannot be repaired; they are to be replaced
(cleaning is permissible).
depowered.
customer.
3. Remove the front seat. For additional
information, refer to Seat Front in this
section.
this section.
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501-10-2 501-10-2 Seating
6. Remove the plastic rivets attaching the backrest 9. Release the inner J-strip at the bottom of the
trim cover to the inboard and outboard backrest trim cover and remove the harness
recliners. wires from the backrest cover.
7. Remove the backrest recliner release bezel 10. Release the pin-type retainer and backrest trim
screw. Slide down, pull and remove the from the backrest frame.
backrest recliner release bezel and backrest
recliner release handle.
8. Release the outer J-strip at the bottom of the
backrest trim cover.
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501-10-3 501-10-3 Seating
11. WARNING: Front seat back trim 12. WARNING: To correctly retain the
covers installed on seats equipped with side backrest trim cover and allow correct
air bags cannot be repaired, they are to be deployment of the seat side air bag module,
installed new. Cleaning is permissible. make sure to install 2 hog rings to attach the
backrest trim cover wire to the listing wire
WARNING: To correctly retain the
in each foam pad window. Failure to follow
backrest trim cover and allow correct
this instruction may result in personal injury
deployment of the seat side air bag module,
in the event of a seat side air bag module
make sure to install 2 hog rings to attach the
deployment.
Invert the backrest trim cover up and remove
the second row of hog rings.
1 Place a hand between the backrest trim
deployment.
cover and backrest foam pad and carefully
separate the hook-and-loop strips.
CAUTION: Use care when separating
2 Remove the 2 hog rings per window.
the seat cushion trim cover from the
hook-and-loop strip. The hook-and-loop strip
can be torn from the seat cushion foam.
Invert the backrest trim cover up and remove
the first row of hog rings.
cover and backrest foam pad and carefully
13. Invert the backrest trim cover to the top of the
backrest.
14. NOTE: The head restraint guides are not
interchangeable.
Release and remove the 2 head restraint guides.
15. Remove the backrest trim cover.
16. NOTE: A backrest trim cover for a seat with
a side air bag module is different than a
backrest trim cover for a seat without a side
air bag module. Make sure the correct backrest
trim cover is being installed.
this section.
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501-10-4 501-10-4 Seating
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501-10-1 501-10-1 Seating
Seat Backrest Front
Special Tool(s)
customer.
tool
NOTE: If a driver or passenger seat backrest
heated seat element is faulty, a new seat backrest
foam pad must be installed with the heated seat
element. Do not reuse the original seat backrest
foam pad. WARNING: Always wear safety glasses
All seats
injury in the event of an accidental deployment. 1. Position the seat to gain access to the seat
2. Depower the SRS. For additional information, injury, do not use any memory saver devices.
Depowering and Repowering in the General WARNING: After deployment, the air bag
Procedures portion of Section 501-20B. surface can contain deposits of sodium
section.
Driver seat with manual height adjust
injury.
5. Remove the manual height adjust handle center CAUTION: It is necessary to carry out the
cover. occupant classification sensor (OCS) system reset
when a front passenger seat backrest is separated
6. Remove the 2 screws and the manual height
from the seat cushion, the seat cushion is
adjust handle.
disassembled, a new trim cover is installed or an
OCS service kit is installed. A scan tool is used
All seats
to trigger the active command to carry out the
OCS system reset.
Remove the screw at the rear of the cushion
depowered.
Vehicles with a manual seat, remove the
cushion side shield.
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501-10-2 501-10-2 Seating
Seats with side air bags Passenger heated seat
8. Separate the side air bag module electrical 11. NOTE: Note the harness routing for
connector and the wire harness pin-type installation.
retainers from the seat track bracket and
Release the cushion cover rear J-clip and
cushion frame.
disconnect the backrest heated seat electrical
connector and detach the connector from the
Driver seat with power lumbar and heated
seat cushion frame.
seats
9. NOTE: Note the harness routing for
installation.
Release the cushion trim cover rear lower J-clip
and disconnect the power lumbar and heated
seat cushion electrical connector and separate
the connectors from the seat cushion frame.
All seats
12. Remove the 2 outboard recliner-to-cushion
frame bolts.
13. At the rear inboard side of the seat, release the
cushion trim cover flap from the cushion frame
10. NOTE: Note the harness routing for
bracket.
installation.
Disconnect the backrest heated seat electrical
14. Remove the 2 inboard recliner-to-cushion frame
connector and separate it from the bottom of
bolts and remove the backrest.
the seat cushion frame.
17. Repower the SRS. If the passenger seat has
been serviced, do not prove out the SRS at
this time. For additional information, refer to
http://vnx.su
501-10-3 501-10-3 Seating
Passenger seat
85F).
18. WARNING: Do not separate the
occupant classification sensor (OCS) system
components. Failure to follow these
be made.
instructions could increase the risk of injury
in a collision.
With the front passenger seat empty, use a the occupant classification sensor (OCS)
scan tool to trigger the active command. system reset when a front passenger seat
backrest is separated from the seat cushion,
the seat cushion is disassembled, a new trim
cover is installed or an OCS service kit is
All seats reset.
system reset.
system reset.
Make sure the OCS system components seconds and then turn off. If an air bag SRS
are connected and no faults are present. fault is present, the air bag indicator will:
Make sure the OCS system is not at a - fail to light.
- flash.
repaired.
a scan tool.
http://vnx.su
501-10-4 501-10-4 Seating
http://vnx.su
501-10-1 501-10-1 Seating
Seat Backrest Front
5 63226 Static lumbar 1 64417 Backrest trim cover
6 W500633 Recliner-to-cushion frame 2 14D696 Heated seat element (if
bolts (4 required) equipped)
7 056552 Plastic rivets 3 64810 Backrest foam pad
8 611A08 Head restraint assembly 4 65500 Power lumbar assembly
(driver only) (if equipped)
9 022537 Inboard head restraint guide
(Continued)
(Continued)
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501-10-2 501-10-2 Seating
Item Part Number Description WARNING: Front seat back trim covers
installed on seats equipped with side air bags 10 020617 Outboard head restraint guide
cannot be repaired; they are to be installed new
11 61018 Backrest frame
(cleaning is permissible).
12 62672 Backrest recliner release bezel
13 W506943 Backrest recliner release bezel
screw
14 62762 Backrest recliner release
handle
NOTE: If a side air bag deployment took place,
15 N605892 Side air bag module bolts
new backrest foam pad, trim cover, side air bag
16 611D79 Side air bag module bracket module, bracket and nuts, and U-nuts and bolts
must be installed. A new seat back frame should be 17 611D11 Side air bag module
installed new if necessary.
18 W520822 U-nuts
19 051811 Side air bag
NOTE: : The plastic rivets attaching the backrest
module-to-bracket nuts (part
trim cover to the inboard and outboard recliners are
of 611D10)
one-time use rivets and must be installed new when
the front seat backrest cover is removed or installed
21 Rivets
new.
Disassembly
depowered.
WARNING: Carry a live side air bag
NOTE: If a driver or passenger seat backrest
heated seat element is faulty, a new seat backrest
deployment.
element. Do not reuse the original seat backrest
WARNING: Do not set a live side air bag
foam pad.
module down on the cover tear seam. This will
reduce the risk of injury in the event of an
accidental deployment.
customer.
All seats
injury.
WARNING: Side air bag modules with
damaged covers must be installed new.
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501-10-3 501-10-3 Seating
3. Remove the front seat. For additional 6. NOTE: : The plastic rivets attaching the
information, refer to Seat Front in this backrest trim cover to the inboard and outboard
section. recliners are one-time use rivets and must be
installed new when the front seat backrest cover
is removed or a new cover is installed.
Remove the plastic rivets attaching the backrest
this section.
recliners.
5. Remove the head restraint.
1 Position the head restraint as high as it will
7. Remove the backrest recliner release bezel
go.
screw. Slide down, pull and remove the
backrest recliner release bezel and backrest
2 Using an appropriate tool, push through the
recliner release handle.
hole on the inboard side of the head
restraint guide and release the head restraint.
8. Release the outer J-strip at the bottom of the
X Hold the head restraint up so it does not
engage back into the head restraint guide.
3 Release the head restraint guide on the other
side and remove the head restraint.
9. Release the inner J-strip at the bottom of the
http://vnx.su
501-10-4 501-10-4 Seating
10. WARNING: Front seat back trim
covers installed on seats equipped with side
air bags cannot be repaired, new trim covers
are to be installed. Cleaning is permissible.
WARNING: To correctly retain the
deployment.
12. Invert the backrest trim cover to the top of the
backrest.
the seat cushion trim cover from the
hook-and-loop strip. The hook-and-loop strip
interchangeable.
can be torn from the seat cushion foam.
Release and remove the 2 head restraint guides.
Invert the backrest trim cover upward and
remove the first row of hog rings.
14. Remove the backrest trim cover.
cover and backrest foam pad, and carefully
15. Remove the backrest foam pad from the
backrest frame.
Seats with side air bags
16. Remove the side air bag module.
Release the side air bag module wire
harness pin-type retainers from the backrest
frame.
X Note wire harness routing for assembly.
Remove the side air bag module
bracket-to-backrest frame bolts.
Remove the side air bag module with wire
harness.
11. Invert the backrest trim cover upward and
remove the second row of hog rings.
cover and backrest foam pad, and carefully
http://vnx.su
501-10-5 501-10-5 Seating
All seats
Assembly
17. NOTE: Make note of the cable routing for
assembly.
1. Slide the power lumbar assembly rods into the
Remove the recliner cable and casing from the
backrest frame and connect the electrical
outboard recliner.
connector.
18. Remove 2 rivets, pull out at the bottom and
Seats with static lumbar
remove the backrest recliner release with cable.
If necessary, remove the tie strap holding
2. Slide the static lumbar assembly rods into the
the cable to the backrest frame.
backrest frame, install the 2 pin-type retainers
and install the 2 side springs.
All seats
3. Position the backrest recliner release with cable
and install the 2 rivets.
If necessary, install a tie strap holding the
cable to the backrest frame.
19. Disconnect the electrical connector, release the
4 retainers (2 shown) and slide the rods out of
the backrest frame.
4. Route the backrest recliner release cable as
noted during disassembly and install the cable
and casing to the outboard recliner.
Seats with static lumbar
20. Remove the 2 side springs. Release the 2
pin-type retainers at the bottom, slide the rods
out of the backrest frame at the top and remove
the static lumbar assembly.
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501-10-6 501-10-6 Seating
Seats with a new side air bag module
5. NOTE: When installing a new side air bag
module after deployment, install a new module,
module bracket, module-to-bracket nuts,
U-nuts-to-backrest frame, module and
Install the side air bag module bracket on the
side air bag module and tighten the 2 nuts.
Tighten the nuts to 6 Nm (53 lb-in).
http://vnx.su
501-10-7 501-10-7 Seating
6. WARNING: Inspect the mounting
surfaces of the side air bag module and the
seat back frame mounting bracket for any
foreign material before installing the side air
bag module. If any foreign material is found,
remove it. Failure to do so may result in
personal injury, in the event of an air bag
deployment.
WARNING: Before installing the side
air bag module, check it for damage and
All seats
foreign material. If the air bag module is
damaged, install a new one. If any foreign
material is found, remove it. Failure to do so
7. Position the backrest frame into the backrest
may result in personal injury, in the event
foam pad.
of an air bag deployment.
8. Position the backrest trim cover to the top of
WARNING: Inspect the side air bag
the backrest.
cavity in the seat back pad for any foreign
material. If any foreign material is found,
9. WARNING: To correctly retain the
remove it. Failure to do so may result in
personal injury in the event of an air bag
deployment.
WARNING: If the air bag cover has
separated or the air bag material has been
exposed, install a new side air bag module.
Do not attempt to repair the air bag module.
Failure to do so may result in personal
deployment.
injury in the event of an air bag deployment.
Roll the backrest trim cover down and install
the second row of hog rings. CAUTION: Make sure the side air bag
module wiring harness is not pinched
1 Install the 2 hog rings per window as
between the side air bag module and the
shown.
mounting bracket.
2 Attach the hook-and-loop strips.
Position the side air bag module bracket to the
backrest frame, install the bolts and install the
wire harness pin-type retainers to the backrest
frame.
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501-10-8 501-10-8 Seating
13. Slide the backrest recliner release bezel upward
10. WARNING: To correctly retain the
to engage the clip, install the screw.
14. Install the backrest recliner release handle.
15. NOTE: The plastic rivets attaching the backrest
trim cover to the inboard and outboard recliners
are one-time use rivets and must be installed
new when the front seat backrest cover is
deployment.
removed or a new cover is installed.
Roll the backrest trim cover down and install
Fold the backrest trim cover over on each side
the first row of hog rings.
of the inboard and outboard recliner. Install the
plastic rivets attaching the backrest trim cover
shown.
to the inboard and outboard recliners.
2 Attach the hook-and-loop strips.
interchangeable.
Install the 2 head restraint guides.
17. Install the head restraint.
this section.
11. Attach the backrest trim cover inner J-strip.
12. Attach the J-strip at the bottom of the backrest
trim cover.
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501-10-1 501-10-1 Seating
Seat Backrest Rear, Coupe
2. Remove the rear seat backrest. For additional
information, refer to Seat Backrest Rear in
1 Rivets (2 required)
this section.
3 Inboard pivot bracket
3. Release the backrest trim cover J-strip and
4 60515 Outboard pivot bracket remove the staples.
4. Pull the backrest panel out from the backrest
6 Backrest latch assembly
foam pad and backrest trim cover.
7 60509 Backrest panel
Upon assembly, the latch release strap must
8 Backrest foam pad
come through the trim cover.
9 66601 Backrest trim cover
5. Remove the 4 rivets and the pivot brackets.
Disassembly
6. Remove the rivets, separate the pin-type retainer
from the cable end and remove the backrest
information, refer to Seat Cushion Rear in
latch assembly.
this section.
http://vnx.su
501-10-2 501-10-2 Seating
the seat backrest trim cover from the hook
and loop strip. The hook and loop strip can
be torn from the seat backrest foam.
Release the hook and loop strips and separate
the backrest trim cover from the backrest foam
pad.
http://vnx.su
501-10-1 501-10-1 Seating
Seat Backrest Rear
Coupe Backrest
4 W505433 Backrest pivot bracket bolt 1 62452 Backrest striker
5 60615 Backrest pivot bracket 2 W505260 Backrest striker bolts (2
required)
6 W505433 Backrest-to-floor bolt
3 Backrest assembly
(Continued)
http://vnx.su
501-10-2 501-10-2 Seating
Convertible Backrest
1 W505433 Backrest-to-floor bolts (2
NOTE: Coupe LH 50 percent backrest shown, RH
required)
similar.
2 Backrest assembly
All vehicles
information, refer to Seat Cushion Rear.
http://vnx.su
501-10-3 501-10-3 Seating
Coupe vehicles Vehicles with a convertible top
2. Remove the bolt, pull the strap to pivot the 3. Remove the backrest bolts at the bottom, slide
backrest down, slide the backrest out of the the backrest up, disengaging the hooks and
backrest pivot bracket and remove the L/H remove the backrest.
backrest.
All vehicles
Make sure the safety belts and buckles are
accessible to the occupants after installation.
http://vnx.su
501-10-1 501-10-1 Seating
Seat Control Switch
2. Remove the clip and the recline handle
3. Remove the seat control switch knob.
5. Disconnect the seat control switch.
6. Release the retainers and remove the seat
depowered.
customer.
http://vnx.su
501-10-1 501-10-1 Seating
NOTE: When installing an OCS service kit
Seat Cushion Cover Front
equipped with heated seats, a new seat cushion
heated seat element must be installed. Do not reuse
Special Tool(s)
the original equipment manufacture (OEM) OCS
seat cushion heated seat element. The OCS service
kit does not come with a new seat cushion heated
seat element.
tool
customer.
All seats
CAUTION: It is necessary to carry out the information, refer to Seat Front in this
occupant classification sensor (OCS) system reset section.
4. Remove the front seat backrest. For additional from the seat cushion, the seat cushion is
information, refer to Seat Backrest Front in disassembled, a new trim cover is installed or an
this section. OCS service kit is installed. A scan tool is used
All seats
OCS system reset.
5. Release all seat cushion trim cover-to-cushion
frame retainers.
depowered.
the seat upholstery from the hook-and-loop
strip, or the hook-and-loop strip can be torn
from the cushion foam pad.
normal operation and does not indicate a Separate the hook-and-loop strips, remove the
supplemental restraint system (SRS) fault. hog rings and separate the cushion trim cover
NOTE: If a driver or passenger seat cushion
heated seat element is faulty, a new seat cushion
element. Do not reuse the original seat cushion
foam pad.
http://vnx.su
501-10-2 501-10-2 Seating
http://vnx.su
501-10-3 501-10-3 Seating
Passenger seat
85F).
be made.
components.
the occupant classification sensor (OCS)
With the front passenger seat empty, use a system reset when a front passenger seat
scan tool to trigger the active command. backrest is separated from the seat cushion,
after carrying out the OCS system reset.
reset.
All seats
OCS system reset.
system reset.
Make sure the OCS system components will light continuously for approximately 6
are connected and no faults are present. seconds and then turn off. If an air bag SRS
temperature below 0C (32F) or above - fail to light.
- flash.
repaired.
a scan tool.
http://vnx.su
501-10-4 501-10-4 Seating
http://vnx.su
501-10-1 501-10-1 Seating
Seat Cushion Front
Special Tool(s)
tool
http://vnx.su
501-10-2 501-10-2 Seating
Driver Power Seat Cushion with Heated Seat Element Shown
7 Cushion side shield screw 1 62901 Cushion trim cover
8 62187 Cushion side shield 2 14D698 Heated seat element (if
equipped)
9 14A701 Seat control switch
3 Cushion foam pad
10 619A74 Lumbar control switch (if
equipped) 4 Seat control switch knob (if
equipped)
11 W520113 Cushion frame-to-seat-track
nuts (4 required) 5 62622 Recline handle
12 63101 Cushion frame 6 Recline handle clip (part of
62622)
13 61701 Seat track
(Continued)
(Continued)
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501-10-3 501-10-3 Seating
14 61203 Safety belt buckle 16 14A699 Driver seat wire harness
15 Safety belt buckle bolt (part
of 61203)
(Continued)
Driver Manual Front Seat Cushion with Heated Seat Element Shown
3 Cushion foam pad 1 62901 Cushion trim cover
4 62768 Manual height adjust handle 2 14D698 Heated seat element (if
center cover (if equipped) equipped)
http://vnx.su
501-10-4 501-10-4 Seating
5 61753 Manual height adjust handle 10 62187 Cushion side shield
(if equipped)
11 63101 Cushion frame
12 14A699 Driver seat wire harness
nuts (4 required)
13 61701 Seat track
7 62622 Recline handle
14 61203 Safety belt buckle
8 Recline handle clip (part of
62622)
of 61203)
9 Cushion side shield screw
(Continued)
Passenger Manual Front Seat Cushion with Heated Seat Element Shown
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501-10-5 501-10-5 Seating
8 62186 Side shield 1 62900 Cushion trim cover
9 63100 Cushion frame 2 14D698 Heated seat element (if
equipped)
nuts (4 required) 3 Cushion foam pad (part of
original equipment [OE]
occupant classification sensor
[OCS])
62622)
4 Pin-type retainers (2 required)
(part of OE OCS)
5 OE OCS
of 61203)
6 632A22 OCS service kit
15 618B46 Seat track
7 Side shield screw
(Continued)
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501-10-6 501-10-6 Seating
Passenger Power Front Seat Cushion with Heated Seat Element Shown
6 632A22 OCS service kit 1 62900 Cushion trim cover
7 Side shield screw 2 14D698 Heated seat element (if
equipped)
8 62186 Side shield
3 Cushion foam pad (part of
nuts (4 required)
[OCS]
(part of OE OCS) 12 Recline handle clip (part of
62622)
5 OE OCS
(Continued)
(Continued)
http://vnx.su
501-10-7 501-10-7 Seating
kit), inspect the electronic control unit (ECU)
of 61203)
allows the disconnection of the ECU electrical
15 61701 Power seat track
has the ECU electrical connector glued to the ECU.
Disassembly
It cannot and should not be disconnected or altered.
WARNING: Always wear safety glasses NOTE: If a seat equipped with a supplemental
when repairing an air bag supplemental restraint restraint system (SRS) component is being serviced,
system (SRS) vehicle and when handling an air the supplemental restraint system (SRS) must be
bag module. This will reduce the risk of injury in depowered.
WARNING: Do not separate the occupant
classification sensor (OCS) system components.
NOTE: When installing a new occupant
classification sensor (OCS) service kit, refer to
Section 501-20B for the OCS service kit installation
procedure.
injury.
NOTE: If a driver or passenger seat cushion
heated seat element is faulty, a new seat cushion
occupant classification sensor (OCS) system reset
element. Do not reuse the original seat cushion
foam pad.
When installing an OCS service kit equipped with
heated seats, a new cushion heated seat element
must be installed. Do not reuse the original
equipment manufacture (OEM) OCS driver cushion
OCS system reset.
heated seat element. The OCS service kit does not
come with a new cushion heated seat element.
NOTE: OCS system components (seat cushion
foam pad, bladder with pressure sensor and
electronic control unit) are calibrated to each other
and are serviced as an assembly. The OCS system
customer.
components are not to be installed separately. If a
All seats
cushion foam pad are needed, a new OCS system
service kit (seat cushion foam pad, bladder with
pressure sensor, electronic control unit and seat wire
harness) must be installed as an assembly.
http://vnx.su
501-10-8 501-10-8 Seating
Passenger seats with OE OCS or OCS
service kit
section.
14. CAUTION: Do not oversize the seat
cushion frame holes used to rivet the
electronic control unit (ECU) in place.
this section.
NOTE: OE ECU shown, service kit OCS
similar.
5. Remove the seat track. For additional
information, refer to Seat Track Manual or Using a 5 mm (0.19 in) drill, remove the 2
Seat Track Power in this section. rivets and separate the ECU from the cushion
frame.
Power driver seat
6. Disconnect the seat control switch and lumbar
control switch (if equipped) and remove the
cushion side shield.
control switch and the lumbar control (if
equipped) switch from the cushion side shield.
8. Disconnect the heated seat electrical connectors
(if equipped).
Power passenger seat
15. NOTE: OE OCS pressure sensor shown,
service kit OCS pressure sensor similar.
9. Disconnect the seat control switch and remove
the cushion side shield.
Bend to release the tab and remove the pressure
sensor from the bracket.
11. Disconnect the heated seat electrical connectors
(if equipped).
Manual driver and all passenger seats
12. Release the cushion trim cover rear J-strip.
Driver seat and passenger seat with original
equipment (OE) occupant classification
sensor (OCS)
13. Remove the cushion foam pad and cushion trim
16. NOTE: Note wire harness routing for
cover from the cushion frame.
installation.
Release any seat wire harness routing pin-type
retainers from the cushion frame.
Passenger seat with OE OCS
17. Remove the OCS bladder pin-type retainers.
http://vnx.su
501-10-9 501-10-9 Seating
Passenger seats with OE OCS or OCS All seats
service kit
18. NOTE: Note the cushion frame opening that
the seat upholstery from the hook-and-loop
the OCS components and seat wire harness are
strip, or the hook and loop strip can be torn
being routed through for installation.
Remove the OCS and seat wire harness from
Separate the hook-and-loop strips, remove the
the cushion frame.
hog rings and separate the cushion trim cover
electrical connectors and ECU through the
Assembly
opening in the cushion frame.
All seats
1. Position the cushion trim cover to the cushion
foam pad, attach the hook-and-loop strips and
install the hog rings.
Driver seat
2. Route the seat wire harness to the cushion
frame and attach the pin-type retainer(s) as
noted during removal.
Driver seat
installation.
Release any pin-type retainer(s) and remove the
seat wire harness from the cushion frame.
http://vnx.su
501-10-10 501-10-10 Seating
Passenger seats with OE OCS or OCS Passenger seat with OE OCS
service kit
4. Install the OCS bladder pin-type retainers.
3. WARNING: Do not separate
components.
service kit
CAUTION: Inspect the occupant
classification sensor assembly, seat cushion
5. Position the ECU onto the seat cushion pan
frame and support assembly for any foreign
bracket and install the new rivets.
material, before installing the occupant
The ECU must be correctly positioned and
classification sensor assembly to the seat
securely riveted in place. Failure to do so
cushion frame. If any foreign material is
can set a diagnostic trouble code (DTC) in
found, remove it. Failure to do so may
the restraints control module (RCM).
result in personal injury, in the event of an
air bag deployment.
CAUTION: Failure to route the seat
occupant sensor components through the
correct seat cushion support opening can
cause component failure.
CAUTION: While positioning the seat
cushion frame and occupant classification
sensor assembly, be careful not to damage
any of the components. Failure to do so can
result in component failure.
NOTE: If the original equipment occupant
classification sensor (OCS) is not being
installed, install a service kit OCS using all
6. Bend the retaining tab back on the pressure
parts in the kit.
sensor bracket.
Position the OCS components and seat wire
harness through the cushion frame opening as
noted during removal.
electrical connectors and ECU through the
opening in the cushion frame.
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501-10-11 501-10-11 Seating
7. Install the pressure sensor onto the cushion 10. Position the cushion side shield to the cushion
frame bracket, making sure the retaining tab is frame and connect the seat control switch and
completely engaged. lumbar control switch.
When installed correctly, an audible click
All seats
will be heard and the pressure sensor will
not be able to be removed from its bracket
11. Position the cushion foam pad and trim cover to
without disengaging the retaining tab.
the cushion frame.
12. Install the seat track. For additional information,
refer to Seat Track Manual or Seat Track
Power in this section.
13. Install the seat backrest. For additional
this section.
8. Attach any seat wire harness routing pin-type
retainers to the cushion frame as noted during
removal.
Power driver seat
9. Install the seat control switch and the lumbar
control switch into the cushion side shield.
Install the seat control switch knob.
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501-10-12 501-10-12 Seating
service kit
85F).
16. WARNING: Do not separate the system reset is unsuccessful, a second attempt must
occupant classification sensor (OCS) system be made.
components.
the occupant classification sensor (OCS)
With the front passenger seat empty, use a
system reset when a front passenger seat
scan tool to trigger the active command.
the seat cushion is disassembled, a new trim 17. NOTE: The ignition switch must be cycled
cover is installed or an OCS service kit is after carrying out the OCS system reset.
reset.
All seats
OCS system reset.
system reset.
Make sure the OCS system components
are connected and no faults are present.
- fail to light.
- flash.
repaired.
a scan tool.
http://vnx.su
501-10-1 501-10-1 Seating
Seat Cushion Rear
1 Seat cushion assembly
Removal
1. From under the front of the rear cushion
assembly, push each of the 2 seat cushion
release tabs in, lift up at the front and remove
the rear cushion assembly.
http://vnx.su
501-10-2 501-10-2 Seating
Installation
1. Align the cushion assembly and push down,
engaging the retainer tabs.
Make sure the safety belts and buckles are
accessible to the occupants after installation.
http://vnx.su
501-10-1 501-10-1 Seating
Seat Exploded View, Front
Front Seat Backrest
4 65500 Power lumbar assembly 1 64417 Backrest trim cover
(driver side only) (if
2 14D696 Heated seat element (if
equipped)
equipped)
5 63226 Manual lumbar
3 64810 Backrest foam pad
(Continued)
(Continued)
http://vnx.su
501-10-2 501-10-2 Seating
6 W500633 Recliner-to-cushion frame 15 N605892 Side air bag module bolts (2
bolts (4 required) required)
7 056552 Plastic rivets 16 611D79 Side air bag module bracket
8 611A08 Head restraint assembly 17 611D11 Side air bag module
9 022537 Inboard head restraint guide 18 W520822 U-nuts (2 required)
10 020617 Outboard head restraint guide 19 051811 Side air bag
module-to-bracket nuts (2
11 61018 Backrest frame
required) (part of 611D10)
12 62672 Backrest recliner release bezel
13 W506943 Backrest recliner release bezel
21 Backrest recliner release
screw
rivets (2 required)
handle
(Continued)
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501-10-3 501-10-3 Seating
Driver Power Front Seat Cushion
7 Cushion side shield screw 1 62901 Cushion trim cover
8 62187 Cushion side shield 2 14D698 Heated seat element (if
equipped)
9 14A701 Seat control switch
3 Cushion foam pad
10 619A74 Lumbar control switch (if
equipped) 4 Seat control switch knob (if
equipped)
nuts 5 62622 Recliner handle
12 63101 Cushion frame 6 Recliner handle clip (part of
62622)
(Continued)
(Continued)
http://vnx.su
501-10-4 501-10-4 Seating
14 61203 Safety belt buckle 16 14A699 Driver seat wire harness
of 61203)
(Continued)
Driver Manual Front Seat Cushion
3 Cushion foam pad 1 62901 Cushion trim cover
4 62768 Manual height adjust handle 2 14D698 Heated seat element (if
center cover (if equipped) equipped)
http://vnx.su
501-10-5 501-10-5 Seating
5 61753 Manual height adjust handle 10 62187 Cushion side shield
(if equipped)
12 14A699 Driver seat wire harness
nuts (4 required)
13 61701 Seat track
62622)
of 61203)
9 Cushion side shield screw
(Continued)
Passenger Manual Front Seat Cushion
http://vnx.su
501-10-6 501-10-6 Seating
8 62186 Side shield 1 62900 Cushion trim cover
9 63100 Cushion frame 2 14D698 Heated seat element (if
equipped)
nuts (4 required) 3 Cushion foam pad (part of
[OCS])
62622)
(part of OE OCS)
5 OE OCS
of 61203)
6 632A22 OCS service kit
15 618B46 Manual seat track
7 Side shield screw
(Continued)
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501-10-7 501-10-7 Seating
Passenger Power Front Seat Cushion
6 632A22 OCS service kit 1 62900 Cushion trim cover
7 Side shield screw 2 14D698 Heated seat element (if
equipped)
8 62186 Side shield
3 Cushion foam pad (part of
nuts (4 required)
(OCS)
(part of OE OCS) 12 Recline handle clip (part of
62622)
5 OE OCS
(Continued)
(Continued)
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501-10-8 501-10-8 Seating
of 61203)
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501-10-1 501-10-1 Seating
Seat Exploded View, Rear
Hard Top 50 Percent Backrest
7 60509 Backrest panel 1 Rivets (2 required)
8 Backrest foam pad 2 Rivets (2 required)
9 66601 Backrest trim cover 3 Inboard pivot bracket
4 60515 Outboard pivot bracket
6 Backrest latch assembly
(Continued)
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501-10-1 501-10-1 Seating
Seat Front
NOTE: Driver seat shown, passenger seat similar.
4 618C82 Outboard seat track nut cover 1 Seat track-to-floor bolts
5 Seat electrical connectors 2 Front seat
(part of 14A699)
3 618C84 Inboard seat track nut cover
6 N807939 Seat track-to-floor nuts
(Continued)
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501-10-2 501-10-2 Seating
3. Release the safety belt loop magnet at the side
shield and separate the safety belt from the seat.
4. Slide back and remove the 2 seat track nut
covers.
5. Remove the seat track-to-floor nuts.
6. Remove the seat track-to-floor bolts.
injury.
7. Tip the seat, disconnect the side air bag module
(if equipped) and main seat harness electrical
connectors and remove the seat.
depowered.
customer.
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Seat Position Sensor
customer.
procedure again.
NOTE: Power seat track seat position sensor
shown, manual seat track position sensor similar.
1. Position the front seat to the rearmost and
UPWARD position.
1 Seat position sensor bolt System (SRS) Depowering and Repowering in
2 Seat position sensor electrical
3. Disconnect the seat position sensor electrical
3 14B416 Seat position sensor
connector.
the seat position sensor retaining bolt is
critical for correct system operation.
NOTE: Note the position of the seat position
sensor locating tab for installation.
Remove the bolt and the seat position sensor.
To install, tighten to 6 Nm (53 ft-in).
the SRS must be depowered.
a SRS fault.
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501-10-1 501-10-1 Seating
Seat Track Manual
Special Tool(s)
section.
tool
5. Remove the manual height adjust handle center
cover.
adjust handle.
All seats
pin-type retainer and remove the side shield.
installation.
OCS system reset.
Separate the side air bag module electrical
connector and wire harness pin-type retainers NOTE: If a seat equipped with a supplemental
from the manual seat track bracket. restraint system (SRS) component is being serviced,
All seats
depowered.
9. Release all cushion trim cover-to-cushion frame
retainers.
installation.
Disconnect the safety belt buckle switch and
separate the pin-type retainers from the seat
track.
customer.
All seats
installation.
Separate the main seat electrical connector from
the manual seat track.
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501-10-2 501-10-2 Seating
Driver seat
14. Remove the bolt and safety belt buckle.
installation. 15. To install, reverse the removal procedure.
Disconnect the seat position sensor and separate
the pin-type retainer.
All seats
17. Repower the SRS. If a passenger seat has
13. Remove the 4 nuts and the manual seat track.
Lift the cushion foam pad to access the
manual seat track nuts.
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501-10-3 501-10-3 Seating
Passenger seat
85F).
be made.
in a collision.
after carrying out the OCS system reset.
All seats reset.
OCS system reset.
system reset.
- flash.
repaired.
a scan tool.
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501-10-4 501-10-4 Seating
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501-10-1 501-10-1 Seating
Seat Track Power
Special Tool(s)
section.
tool
6. Remove the manual height adjust handle center
cover.
adjust handle.
installation.
Separate the side air bag module electrical
connector and wire harness from the power seat
OCS system reset.
track bracket.
Driver seat
depowered.
installation.
Disconnect the seat position sensor and separate
the pin-type retainer.
All seats
10. Release the cushion trim cover rear J-clip,
disconnect the power lumbar electrical
connector and separate it from the cushion
customer.
frame.
All seats
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501-10-2 501-10-2 Seating
11. NOTE: Note wire harness routing for 15. Remove the bolts and safety belt buckle and
installation. bracket.
Disconnect the power seat track motor electrical To install, tighten to 42 Nm (31 lb-ft).
connector, separate the main seat electrical
connector and wire harness from the power seat
track bracket and position the wire harness
aside.
installation.
Disconnect the safety belt buckle switch and the
seat position sensor (driver seat) and separate
the pin-type retainers from the seat track.
13. Release all cushion trim cover to cushion frame
retainers.
14. Remove the 4 nuts and the power seat track.
Lift the cushion foam pad to access the
power seat track nuts.
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501-10-3 501-10-3 Seating
Passenger seat
85F).
be made.
in a collision.
All seats reset.
OCS system reset.
system reset.
- flash.
repaired.
a scan tool.
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501-10-4 501-10-4 Seating
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501-10-1 501-10-1 Seating
Heated Seats
Seats
The driver and passenger heated seats share a
Special Tool(s)
common battery feed to the heated seat relay
junction box. The ignition circuit powers the logic 73 III Automotive Meter
105-R0057 board and illumination of the heated seat switches
located internal to the electronic manual
temperature control assembly (EMTC). The battery
feed is used to provide voltage to the heater mats.
There are 2 power supplies to the heated seat relay.
One power supply energizes the relay and heated
switch LED when the key is in the RUN position
and the heated seat switch is activated. This closes
the relay and power is provided to the heated seat
elements through the other power circuit. The
heated seat module will remain ON until the heated tool
seat switch button is depressed to cycle the heated
seat module OFF or a 10-minute time-out period
Diagnostic Tool, Restraint occurs. If ignition power is switched OFF, the
System (2 required)
heated seat module will enter an OFF state.
418-133
The driver seat cushion and backrest heater
elements are wired in series as are the passenger
seat cushion and backrest heater elements. The
heated seat system is designed to maintain the
temperature by the opening (no voltage to the
heated seat mats) and closing (voltage supplied to
Restraint System Diagnostic Tool
the heated seat mats) of the bi-metallic thermostat.
Warning
WARNING: This tool is for restraint Inspection and Verification
system service only. Remove from vehicle prior
to road use. Failure to remove could result in
system.
injury and possible violation of vehicle safety
standards.
Power Seats
The 6-way power seat feature moves the seat in 6
possible directions: the base of the seat can be
moved forward or rearward and the front and back
of the seat cushion can be moved up and down
independently. The power seat feature operates
independent of the position of the ignition.
The power seat motors are hardwired to the seat
control switch. The circuits are normally at ground
through the seat control switch. An individual
circuit is switched to power when a specific
adjustment position is selected.
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501-10-2 501-10-2 Seating
symptom. GO to Symptom Chart.
Front seat track Heated seat fuse bussed
Symptom Chart
Seat at limit(s) of travel electrical center (BEC)
Refer to the Wiring Diagram manual for the
Seat tracks obstructed or fuse 66 (25A)
damaged Driver power seat and connector numbers cited in the pinpoint tests.
Power lumbar assembly lumbar (BEC) fuse 14
damaged (30A)
Passenger power seat
(BEC) fuse 15 (30A)
Loose, corroded or
damaged connectors
Seat control switch
Heated seat switch
(internal to EMTC)
Heated seat relays
Lumbar seat control
switch
Heat seat cushion
element
Heat seat backrest
element
SYMPTOM CHART
The power seat is inoperative Fuse GO to Pinpoint Test A.
Driver Circuitry
Seat control switch
The power seat is inoperative Fuse GO to Pinpoint Test B.
Passenger Circuitry
Seat control switch
The power seat moves but is Seat track alignment GO to Pinpoint Test C.
noisy Seat track
The power seat moves but is Fastening hardware GO to Pinpoint Test D.
loose Seat track
The power seat does not Seat track obstructed GO to Pinpoint Test E.
make full travel Seat track
The power seat does not Circuitry GO to Pinpoint Test F.
move horizontally/vertically Seat control switch
Driver Seat track
The power seat does not Circuitry GO to Pinpoint Test G.
move horizontally/vertically Seat control switch
Passenger Seat track
The power lumbar is Fuse GO to Pinpoint Test H.
Lumbar control switch
Lumbar assembly
The heated seat is Fuse GO to Pinpoint Test I.
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501-10-3 501-10-3 Seating
SYMPTOM CHART (Continued)
The heated seat is inoperative Circuitry GO to Pinpoint Test J.
seat does not heat but the Heated seat cushion
heated seat indicator Heated seat backrest
illuminates when Heated seat relay
presseddriver
the heated seat is inoperative Circuitry GO to Pinpoint Test K.
seat does not heat but the Heated seat cushion
heated seat indicator Heated seat backrest
illuminates when Heated seat relay
pressedPassenger
The seat control switch is powered by battery
Refer to Inspection and Verification and the
voltage on circuit 566 (DG) and is supplied ground
Symptom Chart for direction to the appropriate
on circuit 1205 (BK).
Pinpoint Test.
Possible Causes
Pinpoint Test A: The Power Seat Is
An inoperative power seat can be caused by:
Inoperative Driver
a fuse.
Refer to Wiring Diagrams Cell 120, Seating for
wiring, terminals or connectors.
a faulty power seat switch.
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE DRIVER
A1 CHECK VOLTAGE TO SEAT CONTROL SWITCH CIRCUIT 566
(DG)
WARNING: The restraint system diagnostic tool is for
restraint system service only. Remove from vehicle prior to
road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
NOTE: The air bag warning lamp illuminates when the restraints
control module (RCM) fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before
releasing the vehicle to the customer.
WARNING: Be sure that nobody is in the vehicle and
that there is nothing blocking or set in front of any air bag
module when the battery ground cable is connected.
For vehicles equipped with seat side air bags, carry out the
following:
Depower the SRS. Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in the General
Disconnect driver seat side air bag C367.
Connect restraint system diagnostic tool 418-133 to driver
seat side air bag C367.
Disconnect: Driver Seat Control Switch C360.
(Continued)
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501-10-4 501-10-4 Seating
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE DRIVER (Continued)
A1 CHECK VOLTAGE TO SEAT CONTROL SWITCH CIRCUIT 566
(DG) (Continued)
Measure the voltage between driver seat control switch C360-4,
circuit 566 (DG), harness side and ground.
Yes
GO to A2.
No
fuse 14 (30A) is OK. If OK, REPAIR the
circuit. TEST the system for normal
operation.
For vehicles equipped with seat side air
bags, DISCONNECT the battery ground
cable. DISCONNECT the restraint system
diagnostic tool from driver seat side air
bag module C367. CONNECT driver seat
side air bag module C367. REPOWER the
Is the voltage greater than 10 volts? SRS. REFER to Section 501-20B.
A2 CHECK SEAT CONTROL SWITCH CIRCUIT 1205 (BK) FOR AN
OPEN
Measure the resistance between driver seat control switch Yes
C360-2, circuit 1205 (BK), harness side and ground. INSTALL a new seat control switch. TEST
SRS. REFER to Section 501-20B.
No
normal operation.
side air bag module C367. REPOWER the Is the resistance less than 5 ohms?
Pinpoint Test B: The Power Seat Is Possible Causes
Inoperative Passenger
An inoperative power seat can be caused by:
a fuse.
Normal Operation
a faulty power seat switch.
voltage on circuit 1462 (RD/WH) and is supplied
ground on circuit 1205 (BK).
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501-10-5 501-10-5 Seating
PINPOINT TEST B: THE POWER SEAT IS INOPERATIVE PASSENGER
B1 CHECK THE VOLTAGE TO SEAT CONTROL SWITCH CIRCUIT
1462 (RD/WH)
following:
Disconnect passenger seat side air bag C337.
Connect restraint system diagnostic tool 418-133 to
passenger seat side air bag C337.
Disconnect: Passenger Seat Control Switch C3190.
Measure the voltage between passenger seat control switch
Yes
GO to B2.
No
operation.
diagnostic tool from passenger seat side
air bag module C337. CONNECT
passenger seat side air bag module C337.
REPOWER the SRS. REFER to Section
Is the voltage greater than 10 volts? 501-20B.
(Continued)
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501-10-6 501-10-6 Seating
PINPOINT TEST B: THE POWER SEAT IS INOPERATIVE PASSENGER (Continued)
B2 CHECK SEAT CONTROL SWITCH CIRCUIT 1205 (BK) FOR AN
OPEN
Measure the resistance between passenger seat control switch Yes
C3190-2, circuit 1205 (BK), harness side and ground. INSTALL a new seat control switch. TEST
501-20B.
No
normal operation.
air bag module C337. CONNECT Is the resistance less than 5 ohms?
501-20B.
Pinpoint Test C: The Power Seat Moves But
Is Noisy
Normal Operation
The power seat should move quietly during
operation. Some noise is acceptable.
Possible Causes
A noisy power seat can be caused by:
a misaligned seat track.
a faulty seat track component.
an object obstructing seat movement.
PINPOINT TEST C: THE POWER SEAT MOVES BUT IS NOISY
C1 CHECK THE TRACK ALIGNMENT
ON. This is normal operation and does not indicate a supplemental Yes
restraint system (SRS) fault. ALIGN the track to the seat and the floor.
No
Check the alignment of the track to the floor and the track to the IDENTIFY the cause and REPAIR as
seat. necessary. TEST the system for normal
Is the track out of alignment? operation.
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501-10-7 501-10-7 Seating
Pinpoint Test D: The Power Seat Moves But Possible Causes
Is Loose
A loose power seat can be caused by:
Normal Operation
loose fastening hardware.
The power seat movement should be smooth and
the seat cushion should not rock during or after
operation.
PINPOINT TEST D: THE POWER SEAT MOVES BUT IS LOOSE
D1 CHECK THE FASTENING HARDWARE
NOTE: The air bag warning lamp illuminates when the restraints Yes
control module (RCM) fuse is removed and the ignition switch is TIGHTEN all fastening hardware to
ON. This is normal operation and does not indicate a supplemental specification. TEST the system for normal
restraint system (SRS) fault. operation.
No
IDENTIFY the cause and REPAIR as
Inspect the seat fastening hardware. necessary. TEST the system for normal
Is the fastening hardware loose? operation.
Pinpoint Test E: The Power Seat Does Not Possible Causes
Make Full Travel
A power seat that does not make full travel can be
caused by:
Normal Operation
The power seat should travel fully horizontal
an obstruction.
(forward/rearward) and vertical (front up/down and
rear up/down).
PINPOINT TEST E: THE POWER SEAT DOES NOT MAKE FULL TRAVEL
E1 CHECK FOR AN OBSTRUCTION IN THE SEAT TRACK
Yes
REMOVE the obstruction(s) and
LUBRICATE the track(s). TEST the
501-20B.
No
IDENTIFY the cause and REPAIR as
(SRS) Depowering and Repowering in the General Procedures
operation.
portion of Section 501-20B.
Remove the affected seat. Refer to Seat Front in this section. REPOWER the SRS. REFER to Section
Are there any obstructions in the track? 501-20B.
Pinpoint Test F : The Power Seat Does Not
Move Horizontally/Vertically Driver
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501-10-8 501-10-8 Seating
The seat control switch is powered by battery A power seat that does not move horizontally and/or
voltage on circuit 566 (DG) and is supplied ground vertically can be caused by:
on circuit 1205 (BK). When pressed, the seat
control switch supplies that voltage and ground to a
a faulty seat control switch.
power seat track motor to move the seat. When
pressed in the opposite direction, the power seat
a faulty seat track motor.
switch reverses the polarity to the power seat track
motor, which moves the seat in the opposite
direction. There are 3 power seat track motors that
combine to move the seat horizontally
(forward/reverse) and vertically (front up/down and
rear up/down).
PINPOINT TEST F: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY DRIVER
F1 DETERMINE WHICH DIRECTION HAS FAILED
following:
Yes
GO to F2.
Push the driver seat control switch to the front and rear. No
Does the power seat move to the front and rear? GO to F9.
F2 DETERMINE POWER SEAT TILTING FAILURE
Verify the power seat tilting feature. Yes
Can the power seat be tilted forward and rearward? If only the forward tilting operates, GO to
F3.
If only the rearward tilting operates, GO to
F6.
No
INSTALL a new seat control switch. TEST
F3 CHECK VOLTAGE TO THE REAR HEIGHT MOTOR
Disconnect: Driver Power Seat Motor Assembly C353.
(Continued)
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501-10-9 501-10-9 Seating
(Continued)
F3 CHECK VOLTAGE TO THE REAR HEIGHT MOTOR (Continued)
Measure the voltage between driver power seat motor assembly
C353-8, circuit 983 (RD/LG) and C353-2, circuit 982 (YE/LG),
harness side, while pushing the seat control switch rear up and
rear down.
Yes
INSTALL a new driver seat track
assembly. TEST the system for normal
operation.
Is the voltage greater than 10 volts when the seat control
switch is in the rear up position, greater than negative (-) 10
volts in the rear down position and 0 volts in the NEUTRAL No
position? GO to F4.
F4 CHECK CIRCUIT 983 (RD/LG) FOR AN OPEN
Measure the resistance between driver seat control switch
C360-5, circuit 983 (RD/LG), harness side and driver power seat
motor assembly C353-8, circuit 983 (RD/LG), harness side.
Yes
GO to F5.
No
normal operation.
Is the resistance less than 5 ohms? SRS. REFER to Section 501-20B.
(Continued)
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501-10-10 501-10-10 Seating
(Continued)
F5 CHECK CIRCUIT 982 (YE/LG) FOR AN OPEN
Yes
C360-7, circuit 982 (YE/LG), harness side and driver power seat INSTALL a new driver seat control switch.
motor assembly C353-2, circuit 982 (YE/LG), harness side. TEST the system for normal operation.
No
normal operation.
F6 CHECK VOLTAGE TO THE FRONT HEIGHT MOTOR
C353-1, circuit 979 (RD/LB) and C353-7, circuit 990 (YE/LB),
harness side while pushing the driver seat control switch front
up and front down.
Yes
operation.
switch front height adjustment is in the front up position,
greater than negative (-) 10 volts in the front down position No
and 0 volts in the NEUTRAL position? GO to F7.
F7 CHECK CIRCUIT 979 (RD/LB) FOR AN OPEN
(Continued)
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501-10-11 501-10-11 Seating
(Continued)
F7 CHECK CIRCUIT 979 (RD/LB) FOR AN OPEN (Continued)
C360-1, circuit 979 (RD/LB), harness side and driver power seat
motor assembly C353-1, circuit 979 (RD/LB), harness side.
Yes
GO to F8.
No
normal operation.
F8 CHECK CIRCUIT 990 (YE/LB) FOR AN OPEN
Yes
C360-8, circuit 990 (YE/LB), harness side and driver power seat INSTALL a new driver seat control switch.
motor assembly C353-7, circuit 990 (YE/LB), harness side. TEST the system for normal operation.
No
normal operation.
F9 CHECK VOLTAGE TO THE HORIZONTAL MOTOR
(Continued)
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501-10-12 501-10-12 Seating
(Continued)
F9 CHECK VOLTAGE TO THE HORIZONTAL MOTOR (Continued)
C353-3, circuit 981 (RD/WH) and C353-5, circuit 980 (YE/WH),
harness side while pushing the seat control switch forward and
rearward.
Yes
operation.
switch is in the rearward position, greater than negative (-)
10 volts in the forward position and 0 volts in the NEUTRAL No
position? GO to F10.
F10 CHECK CIRCUIT 981 (RD/WH) FOR AN OPEN
C360-6, circuit 981 (RD/WH), harness side, and driver power
seat motor assembly C353-3, circuit 981 (RD/WH), harness side.
Yes
GO to F11.
No
normal operation.
(Continued)
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501-10-13 501-10-13 Seating
(Continued)
F11 CHECK CIRCUIT 980 (YE/WH) FOR AN OPEN
Yes
C360-3, circuit 980 (YE/WH), harness side and driver power INSTALL a new driver seat control switch.
seat motor assembly C353-5, circuit 980 (YE/WH), harness side. TEST the system for normal operation.
No
normal operation.
Pinpoint Test G: The Power Seat Does Not Possible Causes
Move Horizontally/Vertically Passenger
A power seat that does not move horizontally and/or
vertically can be caused by:
Normal Operation
a faulty seat control switch.
a faulty seat track motor.
voltage on circuit 1462 (RD/WH) and is supplied
ground on circuit 1205 (BK). When pressed, the
seat control switch supplies that voltage and ground
to a power seat track motor to move the seat. When
pressed in the opposite direction, the power seat
switch reverses the polarity to the power seat track
motor, which moves the seat in the opposite
direction. There are 3 power seat track motors that
combine to move the seat horizontally
(forward/reverse) and vertically (front up/down and
rear up/down).
PINPOINT TEST G: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY PASSENGER
G1 DETERMINE WHICH DIRECTION HAS FAILED
(Continued)
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501-10-14 501-10-14 Seating
(Continued)
G1 DETERMINE WHICH DIRECTION HAS FAILED (Continued)
following:
Yes
GO to G2.
Push the passenger seat control switch to the front and rear. No
Does the power seat move to the front and rear? GO to G9.
G2 DETERMINE POWER SEAT TILTING FAILURE
Verify the power seat tilting feature. Yes
Can the power seat be tilted forward and rearward? If only the rearward tilting operates, GO to
G3.
If only the forward tilting operates, GO to
G6.
No
INSTALL a new seat control switch. TEST
501-20B.
G3 CHECK VOLTAGE TO THE FRONT HEIGHT MOTOR
Disconnect: Passenger Power Seat Motor Assembly C3015.
Measure the voltage between passenger power seat motor
assembly C3015-8, circuit 984 (YE/LB) and C3015-2, circuit 985
(RD/LB), harness side, while pushing the seat control switch rear
up and rear down.
Yes
INSTALL a new passenger seat track
operation.
501-20B.
switch front height adjustment is in the front up position,
greater than negative (-) 10 volts in the front down position No
and 0 volts in the NEUTRAL position? GO to G4.
G4 CHECK CIRCUIT 984 (YE/LB) FOR AN OPEN
(Continued)
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501-10-15 501-10-15 Seating
(Continued)
G4 CHECK CIRCUIT 984 (YE/LB) FOR AN OPEN (Continued)
Measure the resistance between passenger seat control switch
C3190-7, circuit 984 (YE/LB), harness side and passenger
power seat motor assembly C3015-8, circuit 984 (YE/LB),
harness side.
Yes
GO to G5.
No
normal operation.
Is the resistance less than 5 ohms? 501-20B.
G5 CHECK CIRCUIT 985 (RD/LB) FOR AN OPEN
C3190-5, circuit 985 (RD/LB), harness side and passenger INSTALL a new passenger seat control
power seat motor assembly C3015-2, circuit 985 (RD/LB), switch. TEST the system for normal
harness side. operation.
501-20B.
No
normal operation.
side air bag module C367. REPOWER the Is the resistance less than 5 ohms?
G6 CHECK VOLTAGE TO THE REAR HEIGHT MOTOR
(Continued)
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501-10-16 501-10-16 Seating
(Continued)
G6 CHECK VOLTAGE TO THE REAR HEIGHT MOTOR (Continued)
assembly C3015-1, circuit 988 (YE/LG) and C3015-7, circuit 989
(RD/LG), harness side while pushing the passenger seat control
switch front up and front down.
Yes
operation.
501-20B.
switch is in the rear up position, greater than negative (-) 10
volts in the rear down position and 0 volts in the NEUTRAL No
position? GO to G7.
G7 CHECK CIRCUIT 988 (YE/LG) FOR AN OPEN
C3190-8, circuit 988 (YE/LG), harness side and passenger
power seat motor assembly C3015-1, circuit 988 (YE/LG),
harness side.
Yes
GO to G8.
No
normal operation.
(Continued)
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501-10-17 501-10-17 Seating
(Continued)
G8 CHECK CIRCUIT 989 (RD/LG) FOR AN OPEN
C3190-1, circuit 989 (RD/LG), harness side and passenger INSTALL a new passenger seat control
power seat motor assembly C3015-7, circuit 989 (RD/LG), switch. TEST the system for normal
harness side. operation.
air bag module C337. CONNECT driver
seat side air bag module C337.
501-20B.
No
normal operation.
passenger seat side air bag module C337. Is the resistance less than 5 ohms?
501-20B.
G9 CHECK VOLTAGE TO THE HORIZONTAL MOTOR
assembly C3015-3, circuit 987 (RD/WH) and C3015-5, circuit
986 (YE/WH), harness side while pushing the seat control switch
forward and rearward.
Yes
operation.
501-20B.
switch is in the rearward position, greater than negative (-)
10 volts in the forward position and 0 volts in the NEUTRAL No
position? GO to G10.
G10 CHECK CIRCUIT 987 (RD/WH) FOR AN OPEN
(Continued)
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501-10-18 501-10-18 Seating
(Continued)
G10 CHECK CIRCUIT 987 (RD/WH) FOR AN OPEN (Continued)
C3190-6, circuit 987 (RD/WH), harness side, and driver power
seat motor assembly C3015-3, circuit 987 (RD/WH), harness
side.
Yes
GO to G11.
No
normal operation.
G11 CHECK CIRCUIT 986 (YE/WH) FOR AN OPEN
C3190-3, circuit 986 (YE/WH), harness side and driver power INSTALL a new passenger seat control
seat motor assembly C3015-5, circuit 986 (YE/WH), harness switch. TEST the system for normal
side. operation.
501-20B.
No
normal operation.
passenger seat side air bag module C337. Is the resistance less than 5 ohms?
501-20B.
Pinpoint Test H: The Power Lumbar Is Normal Operation
Inoperative
The lumbar control switch is powered by battery
voltage on circuit 566 (DG) and is supplied ground
on circuit 1205 (BK). When the knob of the lumbar
control switch is pressed, voltage and ground are
supplied to the power lumbar motor. When
pressing the lumbar knob in the opposite direction,
the lumbar control switch reverses the polarity to
the power lumbar motor, which moves the lumbar
mechanism in the opposite direction.
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501-10-19 501-10-19 Seating
Possible Causes
An inoperative power lumbar can be caused by:
a faulty lumbar control switch.
a faulty power lumbar motor assembly.
PINPOINT TEST H: THE POWER LUMBAR IS INOPERATIVE
H1 CHECK CIRCUIT 566 (DG) FOR AN OPEN
following:
Disconnect: Lumbar Control Switch C361.
Measure the voltage between lumbar control switch C361-4,
circuit 566 (DG), harness side and ground.
Yes
GO to H2.
No
operation.
Is the voltage greater than 10 volts? SRS. REFER to Section 501-20B.
(Continued)
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501-10-20 501-10-20 Seating
PINPOINT TEST H: THE POWER LUMBAR IS INOPERATIVE (Continued)
Measure the resistance between lumbar control switch C361-2,
circuit 1205 (BK), harness side and ground; and between lumbar
control switch C361-8, circuit 1205 (BK), harness side and
ground.
Yes
GO to H3.
No
normal operation.
Are the resistances less than 5 ohms? SRS. REFER to Section 501-20B.
H3 CHECK THE LUMBAR MOTOR
Connect: Lumbar Control Switch C361.
Disconnect: Power Lumbar Motor C366.
Measure the voltage between power lumbar motor C366-1,
circuit 1097 (BN), harness side and power lumbar motor C366-2,
circuit 1094 (PK), harness side.
Yes
INSTALL a new power lumbar assembly.
Operate the power lumbar control switch in both directions. No
Is the voltage greater than 10 volts in both directions? GO to H4.
H4 CHECK CIRCUIT 1094 (PK) AND CIRCUIT 1097 (BN) FOR A
SHORT TO GROUND
Disconnect: Lumbar Control Switch C361.
(Continued)
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501-10-21 501-10-21 Seating
PINPOINT TEST H: THE POWER LUMBAR IS INOPERATIVE (Continued)
H4 CHECK CIRCUIT 1094 (PK) AND CIRCUIT 1097 (BN) FOR A
Measure the resistance between lumbar control switch C361-3,
circuit 1097 (BN), harness side and ground; and between lumbar
control switch C361-7, circuit 1094 (PK), harness side and
ground.
Yes
GO to H5.
No
normal operation.
Are the resistances greater than 10,000 ohms. SRS. REFER to Section 501-20B.
H5 CHECK CIRCUIT 1094 (PK) AND CIRCUIT 1097 (BN) FOR AN
OPEN
Measure the resistance between power lumbar control switch
C361-3, circuit 1097 (BN), harness side and power lumbar motor
C366-1, circuit 1097 (BN), harness side; and between lumbar
Yes
control switch C361-7, circuit 1094 (PK), harness side and INSTALL a new lumbar control switch.
power lumbar motor C366-2, circuit 1094 (PK), harness side. TEST the system for normal operation.
No
normal operation.
Are the resistances less than 5 ohms? SRS. REFER to Section 501-20B.
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501-10-22 501-10-22 Seating
Pinpoint Test I: The Heated Seat Is Possible Causes
Inoperative
An inoperative heated seat can be caused by:
Normal Operation
fuse(s).
module includes the heated seat control buttons and
a faulty heated seat switch (EMTC).
indicators. The heated seat system will function
when the EMTC module is ON or OFF. There is a a faulty heated seat relay.
relay box located behind the headlamp switch area
a faulty heated seat element.
containing 2 micro relays for the driver and
passenger heated seats. There are 2 power supplies
to the heated seat relay. One power supply
energizes the relay and heated switch LED when the
key is in the run position and the heated seat switch
is activated. This closes the relay and power is
provided to the heated seat elements through the
other power circuit. If the heated seat switch is ON
when the ignition is turned OFF, the heated seat
switch will be ON when the ignition is turned back
ON.
PINPOINT TEST I: THE HEATED SEAT IS INOPERATIVE
I1 CHECK HEATED SEAT SWITCH OPERATION
Press both heated switches to ON. If both indicators illuminate: For driver
Do one or both heated switch indicators illuminate? seat, GO to Pinpoint Test J. For
passenger seat, GO to Pinpoint Test K.
No
GO to I2.
I2 CHECK THE HEATED SEAT POWER CIRCUITS
Disconnect: Heated Seat Relay Driver or Passenger.
Key in ON position.
Measure the voltage at heated seat relay pin 1, circuit 1048
(LB/WH), harness side and ground; and between pin 3, circuit
1048 (LB/WH), harness side and ground.
Yes
GO to I3.
No
fuse 66 (25A) is OK. If OK, REPAIR circuit
1048 (LB/WH). TEST the system for
Are the voltages greater than 10 volts? normal operation.
I3 CHECK THE EMTC MODULE FOR DTCs
Yes
Connect: Heated Seat Relay Driver or Passenger.
REFER to Section 412-00 to diagnose
Key in ON position.
the EMTC fault.
Enter the following diagnostic mode on the scan tool: Electronic
Manual Temperature Control (EMTC) Module Self -Test / No
Retrieve DTCs. INSTALL a new EMTC module. TEST the
Were any DTCs retrieved? system for normal operation.
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501-10-23 501-10-23 Seating
Pinpoint Test J: The Heated Seat Is Possible Causes
InoperativeSeat Does Not Heat But The
Heated Seat Indicator Illuminates When
PressedDriver
a faulty heated seat switch (EATC module).
Normal Operation
a faulty heated seat relay.
a faulty heated seat mat.
switch LED when the key is in the run position and
the heated seat switch is activated. This closes the
relay and power is provided to the heated seat
elements through the other power circuit. If the
heated seat switch is ON when the ignition is turned
OFF, the heated seat switch will be ON when the
ignition is turned back ON.
PINPOINT TEST J: THE HEATED SEAT IS INOPERATIVESEAT DOES NOT HEAT BUT THE HEATED
SEAT INDICATOR ILLUMINATES WHEN PRESSED DRIVER
J1 CHECK CIRCUIT 1064 (YE/LB) FOR AN OPEN
following:
Disconnect: Driver Seat Connector C311.
Key in ON position.
(Continued)
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501-10-24 501-10-24 Seating
SEAT INDICATOR ILLUMINATES WHEN PRESSED DRIVER (Continued)
J1 CHECK CIRCUIT 1064 (YE/LB) FOR AN OPEN (Continued)
Measure the voltage between driver seat C311-1, circuit 1064
(YE/LB), harness side and ground.
Yes
GO to J3.
No
Is the voltage greater than 10 volts? GO to J2.
J2 CHECK THE HEATED SEAT RELAY
Swap the driver heated seat relay with the passenger heated INSTALL a new heated seat relay. TEST
seat relay. the system for normal operation.
Does the seat heat when the heated seat switch is
depressed?
No
GO to J3.
J3 CHECK CIRCUIT 1064 (YE/LB) FOR AN OPEN
Measure the resistance between driver seat C311-1 circuit 1064
(YE/LB), harness side and driver heated seat relay pin 5, circuit
1064 (YE/LB), harness side.
Yes
GO to J4.
No
REPAIR circuit 1064 (YE/LB). TEST the
(Continued)
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501-10-25 501-10-25 Seating
SEAT INDICATOR ILLUMINATES WHEN PRESSED DRIVER (Continued)
J4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between driver seat C311-9 circuit 1205
Yes
GO to J5.
No
REPAIR circuit 1205 (BK). TEST the
J5 CHECK HEATED SEAT CUSHION ELEMENT FOR AN OPEN
Disconnect: Heated Seat Cushion Element C3300.
Measure the resistance between driver heated seat cushion
element C3300-1 and C3300-2 component side.
Yes
GO to J6.
No
INSTALL a new heated seat cushion
element. REFER to Seat Cushion Cover
Front. TEST the system for normal
operation.
Is the resistance between 0.8 and 1.3 ohms? SRS. REFER to Section 501-20B.
J6 CHECK HEATED SEAT BACKREST ELEMENT FOR AN OPEN
Disconnect: Heated Seat Backrest Element C3310. Yes
Measure the resistance between driver heated seat cushion REPAIR seat harness. TEST the system
element C3310-1 and C3310-2 component side. for normal operation.
No
INSTALL a new heated seat cushion
element. REFER to Seat Cushion Cover
Front. TEST the system for normal
operation.
bag module C367. CONNECT driver seat Is the resistance between 0.8 and 1.3 ohms?
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501-10-26 501-10-26 Seating
Pinpoint Test K: The Heated Seat Is Possible Causes
InoperativeSeat Does Not Heat But The
Heated Seat Indicator Illuminates When
PressedPassenger
a faulty heated seat switch (EMTC module).
Normal Operation
a faulty heated seat relay.
a faulty heated seat element.
switch LED when the key is in the run position and
the heated seat switch is activated. This closes the
relay and power is provided to the heated seat
elements through the other power circuit. If the
heated seat switch is ON when the ignition is turned
OFF, the heated seat switch will be ON when the
ignition is turned back ON.
PINPOINT TEST K: THE HEATED SEAT IS INOPERATIVESEAT DOES NOT HEAT BUT THE HEATED
SEAT INDICATOR ILLUMINATES WHEN PRESSEDPASSENGER
K1 CHECK CIRCUIT 2124 (YE/LB) FOR AN OPEN
following:
Disconnect: Passenger Seat Connector C300.
Key in ON position.
(Continued)
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501-10-27 501-10-27 Seating
SEAT INDICATOR ILLUMINATES WHEN PRESSEDPASSENGER (Continued)
K1 CHECK CIRCUIT 2124 (YE/LB) FOR AN OPEN (Continued)
Measure the voltage between passenger seat C300-1, circuit
2124 (YE/LB), harness side and ground.
Yes
GO to K3.
No
Is the voltage greater than 10 volts? GO to K2.
K2 CHECK THE HEATED SEAT RELAY
Swap the passenger heated seat relay with the driver heated INSTALL a new heated seat relay. Test
seat relay. the system for normal operation.
Does the seat heat when the heated seat switch is
depressed ?
501-20B.
No
GO to K3.
K3 CHECK CIRCUIT 2124 (YE/LB) FOR AN OPEN
Measure the resistance between passenger seat C300-1 circuit
2124 (YE/LB), harness side and passenger heated seat relay pin
5, circuit 2124 (YE/LB), harness side.
Yes
GO to K4.
No
REPAIR circuit 2124 (YE/LB). TEST the
K4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
(Continued)
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501-10-28 501-10-28 Seating
K4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN (Continued)
Measure the resistance between passenger seat C300-9 circuit
Yes
GO to K5.
No
REPAIR circuit 1205 (BK). TEST the
K5 CHECK HEATED SEAT CUSHION ELEMENT FOR AN OPEN
Disconnect: Heated Seat Cushion C334.
Measure the resistance between passenger heated seat cushion
element C334-1 and C334-2 component side.
Yes
GO to K6.
No
INSTALL a new heated seat cushion.
REFER to Seat Cushion Cover Front.
Is the resistance between 0.8 and 1.3 ohms? 501-20B.
(Continued)
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501-10-29 501-10-29 Seating
K6 CHECK HEATED SEAT BACKREST ELEMENT FOR AN OPEN
Disconnect: Heated Seat Backrest C335. Yes
Measure the resistance between driver heated seat backrest REPAIR the seat harness. TEST the
element C335-1 and C335-2 component side. system for normal operation.
501-20B.
No
INSTALL a new heated seat Backrest.
REFER to Seat Backrest Front. TEST
air bag module C337. CONNECT Is the resistance between 0.8 and 1.3 ohms?
501-20B.
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501-10-1 501-10-1 Seating
Power Lumbar
Seats
The driver seat has an electro-mechanical backrest
Front Seats
pad adjuster mounted horizontally to provide more
The front seats can be equipped with the following
lower body displacement. The lumbar switch is
systems:
located on the side of the seat cushion side shield.
Manual seat tracks
Manual Recline
Power seat tracks
The manual recline can be adjusted by a handle
mounted on the outboard side of the cushion side
Manual seat cushion height adjust (driver only)
shield.
Manual backrest adjust (recline)
Power lumbar adjust (driver only) Seat Side Air Bags
Seat side air bags (optional) Driver and passenger seat side air bags are attached
to the seat backrest frame. For diagnostic
Heated seats (optional)
information, or if the seat side air bag has deployed,
Heated Seats refer to Section 501-20B.
This system allows the electrical heating of the front Front seat backrest trim covers installed on seats
seats on passenger demand. with seat side air bags cannot be repaired. Install
new front seat backrest trim covers. Cleaning is
The heated seats system has the following
permissible.
components:
If a seat side air bag deployment took place, new
Heated seat relays
seat back foam pad, trim cover, seat side air bag
Heating elements located in the seat cushion and
module, bracket and nuts, and U-nuts and bolts
backrest
must be installed. Install a new seat backrest frame,
if necessary.
Heated seat control switches, located on the
electronic manual temperature control (EMTC)
Occupant Classification Sensor (OCS)
module
The OCS is standard equipment on all front
Manual Lumbar
passenger seats. For information on diagnosing or
servicing the OCS, refer to Section 501-20B.
The manual front seat lumbar is mounted vertically
to provide more lower body displacement for front
Rear Seats
seat occupants.
The fold-down rear seat backrests (coupe only) are
a split (50/50) design and operate independently of
each other.
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501-35-1 501-35-1 Body Repairs
GENERAL PROCEDURES
Sectioning Guidelines
Special Tool(s)
Pro 230 Mig Welder
208-00030
Heat Treatment Induction
Resistance Spot Welder
254-00001
Material
Item Specification
Low Temperature
PM-12-A
TA-1
Metal Patch Panel
Adhesive
TA-3
Cleaner
ZC-21
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501-35-2 501-35-2 Body Repairs
Coupe
CAUTION: Body side section repairs should not be carried out in areas of laser welds, door
hinge or striker anchoring points or near restraints anchoring points. Do not cut or grind body side
components within 50 mm (1.96 in) of restraint anchoring points. For additional restraints anchoring
location information, refer to Section 501-20A. Cut points shown in illustrations are approximate.
CAUTION: When carrying out repairs to LH quarter panel sheet metal, the factory sealer
between the quarter panel and the fuel filler opening must be removed and sealed using Flexible Foam
TA-4 to provide a correct seal.
NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug
welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over
an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
NOTE: Observe prescribed welding procedures when carrying out any body side section repair. For additional
information, refer to Welding Precautions Steel in this section.
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
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501-35-3 501-35-3 Body Repairs
Convertible
1. Corrosion protection needs to be restored
whenever it is necessary to sand or grind
through painted surfaces or E-coat, or when
bare metal repairs are made. Refer to Restoring
Corrosion Protection Following Repair in this
section.
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Side Air Bag Module
5 N605892 Side air bag module bolts 1 Seat back trim cover J-clip
and pin-type retainers (part of
6 611D79 Side air bag module bracket
64417)
7 611D10 Side air bag module
2 64417 Seat back trim cover
8 Side air bag
3 64810 Seat back foam pad
module-to-bracket nuts (part
of 611D10) 4 Side air bag module electrical
wiring clips (part of 611D10)
9 W520822 U-nuts
(Continued)
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Removal
NOTE: When replacing the side air bag after
deployment, refer to Section 501-10 for additional
information concerning the installation of a new
side air bag.
customer.
WARNING: Carry a live side air bag
NOTE: Driver seat side air bag module shown,
passenger side similar.
deployment.
WARNING: Do not set a live side air bag
procedure again.
module down on the cover tear seam. This will
reduce the risk of injury in the event of an 1. Position the seat to access all of the seat
accidental deployment. track-to-floor pan bolts.
2. Depower the system. For additional WARNING: After deployment, the air bag
injury.
5. Remove the plastic rivets attaching the backrest
WARNING: Side air bag modules with
damaged covers must be replaced.
recliners.
WARNING: Front seat back trim covers
6. Release the front seat backrest trim cover J-clip.
installed on seats equipped with side air bags
cannot be repaired, they are to be replaced.
Cleaning is permissible.
NOTE: If a side air bag deployment took place a
new seat back foam pad, trim cover, side air bag
module, bracket and nuts, U-nuts and bolts must be
installed. The seat back frame should be replaced if
necessary.
7. Remove the seat backrest trim cover inner
J-clip.
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8. WARNING: Front seat back trim 10. WARNING: Note the position of the
covers installed on seats equipped with side wiring harness, to aid installation. An
air bags cannot be repaired; they are to be incorrectly routed wiring harness could
installed new (cleaning is permissible). become damaged when the seat is moved.
Failure to follow this instruction may result
in personal injury.
the seat cushion trim cover from the hook
Detach the wiring pin-type retainers from seat
and loop strips. The hook and loop strips can
backrest frame.
be torn from the seat cushion foam.
Invert the seat backrest trim cover up.
1 Place a hand between the seat backrest trim
cover and foam pad and carefully separate
the hook and loop strips.
2 Remove the hog rings.
11. Remove the bolts and the side air bag module.
9. Position the seat back foam pad aside.
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All seats
Installation
Seats installing a new side air bag module
2. WARNING: Inspect the mounting
surfaces of the side air bag module and the
1. NOTE: When installing a new side air bag
seat back frame mounting bracket for any
module after deployment, install a new module,
foreign objects before installing the side air
module bracket, module-to-bracket nuts,
bag module. If any foreign objects are found,
U-nuts-to-backrest frame and module and
remove them. Failure to do so may result in
personal injury, in the event of an air bag
deployment.
Install the side air bag module bracket on the
side air bag module and tighten the 2 nuts.
WARNING: Before installing the side
Tighten the nuts to 6 Nm (53 lb-in). air bag module, check it for damage and
foreign objects. If the air bag module is
damaged, install a new one. If any foreign
objects are found, remove them. Failure to
do so may result in personal injury, in the
event of an air bag deployment.
WARNING: Inspect the side air bag
cavity in the seat back pad for any foreign
objects. If any foreign objects are found,
remove them. Failure to do so may result in
personal injury in the event of an air bag
deployment.
WARNING: If the air bag cover has
separated or the air bag material has been
exposed, install a new side air bag module.
Do not attempt to repair the air bag module.
Failure to do so may result in personal
injury in the event of an air bag deployment.
CAUTION: Make sure the side air bag
module wiring harness is not pinched
between the side air bag module and the
mounting bracket.
Install the side air bag module and the bolts.
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3. NOTE: Note wire routing from removal.
Attach the wiring pin-type retainers to the seat
backrest frame.
6. Attach the seat backrest trim cover inner J-clip.
7. Attach the front seat backrest trim cover J-clip.
4. Reposition the seat back foam pad to the seat
backrest frame.
8. Fold the backrest trim cover over on each side
of the inboard and outboard recliner. Install the
plastic rivets attaching the backrest trim cover
to the inboard and outboard recliners.
5. WARNING: Make sure to install 2 hog
rings to attach the backrest trim cover wire
to the listing wire in each foam pad window
to correctly retain the backrest trim cover
and allow correct deployment of the seat side
10. Install the front seat. For additional information,
air bag module. Failure to follow this
instruction may result in personal injury in
the event of a seat side air bag module
deployment.
Install the seat backrest trim cover.
shown.
2 Attach the hook and loop strips.
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Side Impact Sensor
1 Side impact sensor bolt (part
of 14B345) WARNING: Always wear safety glasses
2 Side impact sensor electrical
connector (part of 14A005) system (SRS) vehicle and when handling an air
3 14B345 Side impact sensor
WARNING: Vehicle sensor orientation is
critical for proper system operation. If a vehicle
for deformation. Replace and properly position
the sensor or any other damaged supplemental
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NOTE: The air bag warning lamp illuminates when 4. Disconnect the side impact sensor electrical
the RCM fuse is removed and the ignition switch is connector.
the side impact sensor retaining bolt is
critical for correct system operation.
NOTE: Make sure the side impact sensor
customer.
mating surfaces are clean and free of foreign
material.
NOTE: Note the position of the side impact
sensor locating tabs for installation.
procedure again.
Remove the bolt and the side impact sensor.
NOTE: Driver side shown, passenger side similar.
System (SRS) Depowering and Repowering in 7. Repower the system. For additional information,
the General Procedures portion of this section. refer to Supplemental Restraint System (SRS)
2. Remove the door scuff plate. For additional
3. Position back the carpet.
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SPECIFICATIONS
Door latch bolts 12 9
Item Specification
Door lock cylinder bolt 9 80
Lubricants
Exterior door handle 9 80
Multi-Purpose Grease ESB-M1C93B studs
Spray XL-5
Hood latch bolts 12 9
Lubricant XL-1
lid latch nuts
Lock Repair/Replacement Specifications lid lock cylinder bolts
Lock Repair Package
Part Number Name
F85Z-11582-AA Ignition Cylinder
F8ZZ-6321990-AA Door Lock
XR32-6343262-BA Luggage Compartment
Lid
F8DZ-5406082-AA Glove Box
F8DZ-5421970-AA Lock Lever Kit
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501-10-1 501-10-1 Seating
SPECIFICATIONS
Safety belt 42 31
Description Nm lb-ft lb-in buckle-to-safety belt
buckle bracket bolt
Seat track-to-floor bolts 48 35
and nuts Safety belt buckle 36 27
bracket-to-seat track
Seat track-to-cushion 36 27
nuts
frame nuts
Rear seat 23 17
Recliner-to-cushion 55 41
backrest-to-floor bolt
frame bolts
Rear seat backrest 23 17
Recliner-to-backrest 55 41
striker bolt
frame bolts
Rear seat backrest 23 17
Side air bag 6 53
pivot bracket-to-floor
module-to-bracket nuts
bolt
Side air bag module 10 89
bracket-to-backrest
frame bolts
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SPECIFICATIONS
Convertible top frame 9 80
Item Specification number 5 bow pivot
bolts
MERCON MERCON
Multi-Purpose Automatic Convertible top latch 6 53
Transmission Fluid screws
XT-2-QDX (US);
Convertible top pump 4 35
XT-2-LM12 (Canada)
and motor assembly
Threadlock and Sealer WSK-M2G351-A5 nuts
TA-25
Header form panel 5 44
screws
Torque Specifications Hydraulic lift cylinder 20 15
bracket bolts
Hydraulic line-to-lift 4 35
Clevis-to-hydraulic lift 20 15
cylinder fittings
cylinder rod bolts
Hydraulic line-to-motor 4 35
Compression panel 2 18
fittings
screws
L-bracket bolts 27 20
Convertible top ajar 9 80
Pivot bracket bolts 48 35
switch screw
Weatherstrip retaining 6 53
channel screws
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501-03-1 501-03-1 Body Closures
SPECIFICATIONS
Door check arm bolts 9 80
Item Specification
Door check arm nuts 9 80
Door latch striker plate 25 18
Grease XG-1-C or
bolts
(Canada) Front door 30 22
hinge-to-body bolts
XL-6 Front door 30 22
hinge-to-front door
bolts
Spray XG-4 and/or XL-5
Door clearance: bottom of 5.0 - 6.0 mm (0.196 -
lid hinge bolts
the door to the rocker 0.236 in) parallel top to
panel bottom within 1.0 mm Luggage compartment 12 9
(0.04 in) lid hinge nuts
Door clearance: between 4.0 - 5.0 mm (0.157 -
fender and door 0.196 in) parallel top to
bottom within 1.0 mm
(0.04 in)
Door flushness: door to -1.0 - 0.00 mm (-0.04 -
the front fender 0.00 in)
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501-19-1 501-19-1 Bumpers
SPECIFICATIONS
Rear bumper bolts 25 18
Rear bumper cover 5 44
Front bumper bolts 25 18 nuts
Front bumper 5 44
cover-to-reinforcement
nuts
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SPECIFICATIONS
Rear safety belt retractor bolt 40 30
Rear safety belt anchor bolt 40 30
D-ring bolt, Coupe 48 35
Rear safety belt 40 30
D-ring bolt, Convertible 40 30 buckle-to-floorpan nut
Front safety belt retractor and 40 30 Lower Anchors and Tethers 40 30
pretensioner bolt for CHildren (LATCH) bolts
Front safety belt anchor bolt 40 30
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SPECIFICATIONS
Exterior mirror mounting nuts 9 80
Exterior mirror motor screws 7 62
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SPECIFICATIONS
Rear spoiler nuts 5 44
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501-16-1 501-16-1 Wipers and Washers
SPECIFICATIONS
Windshield washer 6 53
Item Specification fluid reservoir bolts
RH wiper blade to top 33-45 mm (1.29-1.77 Windshield washer 6 53
edge of cowl top vent inches) fluid reservoir nut
panel
Windshield wiper 15 11
LH wiper blade to top 39-52 mm (1.53-2.05 motor bolts
edge of cowl top vent inches)
panel
motor output shaft bolt
Fluids/Adhesives
Threadlock 262 WSK-M2G351-A6 mounting arm and
pivot shaft bolts
Premium Windshield WSB-M8B16-A2
Washer Concentrate (US) Windshield wiper pivot 28 21
ZC-32-A or B (US) arm nuts
Premium Windshield
Washer Fluid (Canada)
CXC-37-(A, B, C, D, E,
F, G, H) (Canada)
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SPECIFICATIONS
Upper front safety belt anchor 48 35
Description Nm lb-ft bolt
Lower front safety belt 40 30
anchor bolt
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SPECIFICATIONS
Seat side air bag 6 53
Description Nm lb-ft lb-in module bracket to seat
side air bag module
Driver air bag module 7 62
nuts
bolts
Seat side air bag 10 89
Front impact severity 10 89
module and bracket to
sensor nut
seat backrest bolts
Passenger air bag 11 8
Side impact sensor 11 8
module bolts
severity bolts
Restraints control 12 9
Seat track assembly 36 27
module nuts
nuts
Seat position sensor 6 53
bolts
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SPECIFICATIONS
Item Specification
Item Specification XL-6
Adhesives Sealers
Trim and Weatherstrip 3M Strip Caulk-Black WSB-M4G32-C
Adhesive TA-14 051135-08578
Clear Silicone Rubber ESB-M4G92-A Silicone Gasket and WSE-M4G323-A4
TA-32 Sealant TA-30
Lubricants
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SPECIFICATIONS
Instrument panel 20 15
Description Nm lb-ft lb-in support bolts
Instrument panel cowl 9 80 Instrument panel 40 30
top bracket nut RH/LH support bolts
Instrument panel lower 9 80 Steering column shaft 25 18
support bolts bolt
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SPECIFICATIONS
Item Specification
SIKA 2-HOUR CURE
Item Specification
Sika Urethane Adhesive
Laquer Touch-Up Paint ESR-M2P100-C Sika Tack ASAP
(match color to exterior
Sika Urethane Metal and
grid wire)
Glass Primer Sika 206
PM-19500-XXXXX or
G+P
PMP-19500-XXXXX
Foam Core Butyl WSB-M3G143-B1
E69Z-19562-A Torque Specifications
Polypropylene Film Fine
Line Tape (commercially
Door window glass bolts 9 80
available)
Door window regulator and 10 89
Rear Window Defroster
motor nuts
Repair PM-11 (US);
CPM-11 (Canada)
Rear quarter window glass 10 89
bolts (convertible)
Terminal Kit - Back Glass 4F1Z-14421-AA
Rear quarter window inner 9 80
belt weatherstrip bolts
Cleaner ZC-23
Rear quarter window 10 89
DOW AUTOMOTIVE 2-HOUR CURE
regulator and motor nuts
Dow Urethane Adhesive
(convertible)
BetasealExpress
Dow Urethane One Step
Glass Primer Betaprime
5500 / 5500A / 5500SA
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SPECIFICATIONS
Fender bolts/nuts 11 8
Wiper pivot arm nuts 28 21
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501-35-1 501-35-1 Body Repairs
SPECIFICATIONS
Item Specification
Item Specification Prep ZC-31
Motorcraft Acid Metal Bonding Adhesive
Neutralizer ZC-1-A TA-1
Motorcraft Alkaline Metal Patch Panel
Neutralizer ZC-2-A Adhesive TA-3
Motorcraft Detail Wash Seam Sealer TA-2
ZC-3-A
Motorcraft Custom Clear TA-32
Coat Polish ZC-8-A
Trim and Weatherstrip
Ultra-Clear Spray Glass ESR-M14P5-A Adhesive TA-14
Cleaner ZC-23
Plastic Bonding Adhesive
Motorcraft Adhesion TA-9
Promoter PM-19A316-AA
Flexible Foam Repair
Wax and Grease Remover TA-4
Low Temperature
General Equipment
PM-12-A
Pro 230 Mig Welder 208-00030
Roof Ditch Sealer TA-15
Heat Treatment Induction Resistance Spot Welder
254-00001
Cleaner ZC-21
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Spoiler Rear
NOTE: GT shown, base vehicle and Shelby GT 500 similar.
1 W702147-S Rear spoiler nuts (4 required)
2 6341602 Rear spoiler
Removal
1. Remove the 4 nuts and remove the rear spoiler.
Installation
Base vehicle and Shelby GT 500
All vehicles
1. Clean the surfaces.
2. Apply double-sided tape to the rear spoiler as
3. Install the rear spoiler.
shown.
4. Install the 4 mounting nuts.
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Installation
Stay Pad
1. Install the 4 fasteners (2 each side) attaching
Removal
the stay pads to the convertible top frame
number 3 bow.
1. Remove the convertible top material. For
Material in this section.
number 4 bow.
2. NOTE: Prior to performing this step, be sure to
mark the distance from the convertible top
frame number 4 bow to the convertible top
the stay pads to the front mount brackets.
frame number 5 bow on the new stay pad,
using the original stay pad as a guide.
4. NOTE: Make sure to install the new stay pads
Remove the staples attaching the stay pads to
in the same location as the original stay pads.
the convertible top frame number 5 bow.
Pull the rear of the stay pad tight and staple the
stay pad to the convertible top frame number 5
3. Remove the 6 fasteners (3 each side) attaching
bow, keeping the same distance to the
the stay pads to the front mount brackets.
convertible top frame number 4 bow as the old
stay pad.
5. Install the convertible top material. For
number 4 bow.
Material in this section.
number 3 bow.
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501-03-1 501-03-1 Body Closures
GENERAL PROCEDURES
2. Reposition the door latch striker plate from side
Striker Adjustment
to side or up and down as necessary.
NOTE: After adjusting the door latch striker plate,
3. Tighten the 2 door latch striker plate bolts.
verify the door can be closed easily and fits tightly.
1. Loosen the door latch striker plate bolts.
4. Check the adjustment. Repeat the procedure as
necessary.
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GENERAL PROCEDURES
Supplemental Restraint System (SRS) WARNING: Never probe the connectors on
the air bag module. Doing so can result in air Deactivation and Reactivation
injury.
Special Tool(s)
System
418-F403
System (2 required)
418-133
the SRS must be depowered. Diagnostic Tool, Restraint
System (2 required)
418-F395 NOTE: After diagnosing or repairing an SRS, the
restraint system diagnostic tools must be
road.
NOTE: The SRS must be fully operational and free tool
customer.
Deactivation
All vehicles
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch to OFF.
3. At the smart junction box (SJB), located in the
RH lower kick panel, remove the cover and the
restraints control module (RCM) fuse 17 (10A)
from the SJB. For additional information, refer
to the Wiring Diagram Manual.
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4. Turn the ignition ON and visually monitor the 8. Remove the 2 driver air bag module bolts (1
air bag indicator for at least 30 seconds. The air shown).
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been
removed. If the air bag indicator does not
remain lit continuously, remove the correct
RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental
deployment and possible personal injury, the
backup power supply must be depleted
before repairing or replacing any front or
side air bag supplemental restraint system
(SRS) components and before servicing,
9. NOTE: Label the driver air bag module squib
replacing, adjusting or striking components
number on the driver air bag module electrical
near the front or side air bag sensors, such
connectors before disconnecting.
as doors, instrument panel, console, door
latches, strikers, seats and hood latches.
Disconnect the 2 electrical connectors and
remove the driver air bag module.
The front impact severity sensor is located
on the radiator support bracket.
The first row side impact sensors (if
equipped) are located at or near the base of
the B-pillars.
disconnect the battery ground cable and wait
at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if
equipped).
Disconnect the battery ground cable and wait at
least one minute. For additional information,
10. Attach the restraint system diagnostic tools to
7. Remove the 2 driver air bag module bolt caps
the clockspring electrical connectors at the top
from the steering wheel (1 shown).
of the steering column.
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Vehicles with seat side air bags
11. Fully lower the glove compartment door.
12. Disconnect the passenger air bag module
15. Release the red locking tab and disconnect the
passenger side air bag module electrical
connector.
13. Attach the restraint system diagnostic tool to
the vehicle harness side of the passenger air bag
16. Attach the restraint system diagnostic tool to
module electrical connector.
the vehicle harness side of the passenger side
air bag module electrical connector.
Vehicles without seat side air bags
17. Release the red locking tab and disconnect the
driver side air bag module electrical connector.
14. CAUTION: Do not deactivate the seat
side air bag module circuit by removing the
seat side air bag bridge resistor from the seat
side air bag electrical connector.
If the seat side air bag bridge resistor is
removed, an open circuit fault will be generated
by the RCM.
If a restraint system diagnostic tool is installed
at the seat side air bag electrical connector, a
low resistance fault will be generated by the
RCM.
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18. Attach the restraint system diagnostic tool to 4. Connect the driver side air bag module
the vehicle harness side of the driver side air electrical connector and reset the red locking
bag module electrical connector. tab.
All vehicles
5. Remove the restraint system diagnostic tool
from the vehicle harness side of the passenger
side air bag module electrical connector.
19. Install RCM fuse 17 (10A) to the SJB.
Reactivation
All vehicles
1. Remove RCM fuse 17 (10A) from the SJB.
2. Disconnect the battery ground cable and wait at
least one minute.
Vehicles with seat side air bags
6. Connect the passenger side air bag module
electrical connector and reset the red locking
3. Remove the restraint system diagnostic tool
tab.
from the vehicle harness side of the driver side
air bag module electrical connector.
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All vehicles
11. CAUTION: The clockspring electrical
connectors are unique and cannot be
7. Remove the restraint system diagnostic tool reversed when connected to the driver air
from the vehicle harness side of the passenger bag module. Match the electrical connector
air bag module electrical connector. key to the keyway in the driver air bag
module. Do not force the electrical
connectors into the driver air bag module.
Connect the 2 electrical connectors and position
the driver air bag module.
8. Connect the passenger air bag module electrical
connector.
12. Install the 2 driver air bag module bolts (1
shown).
9. Close the glove compartment door.
10. Remove the restraint system diagnostic tools
from the clockspring electrical connectors at the
top of the steering column.
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13. Install the 2 driver air bag module bolt caps in 18. Prove out the supplemental restraint system
the steering wheel (1 shown). (SRS) as follows:
- fail to light.
- flash.
14. WARNING: The restraint system
position. This is the time required for the RCM
to complete the testing of the SRS. If the air
bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of 5 sets
of 5 beeps. If this occurs, the air bag indicator
Make sure all restraint system diagnostic tool(s)
and any SRS fault discovered must be
that may have been installed during the repair
diagnosed and repaired.
have been removed from the vehicle and all
Clear all continuous DTCs from the restraints
SRS components are connected.
control module using a scan tool.
15. Turn the ignition switch from OFF to ON.
16. Install RCM fuse 17 (10A) to the SJB and
close the cover.
17. WARNING: Be sure that nobody is in
the vehicle and that there is nothing blocking
or set in front of any air bag module when
the battery ground cable is connected.
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GENERAL PROCEDURES
4. Turn the ignition ON and visually monitor the
air bag indicator for at least 30 seconds. The air
Depowering and Repowering
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been
Special Tool(s)
removed. If the air bag indicator does not
Vehicle Communication Module remain lit continuously, remove the correct
RCM fuse before proceeding.
tool
6. WARNING: To avoid accidental
deployment and possible personal injury, the
backup power supply must be depleted
Depowering Procedure
before repairing or replacing any front or
side air bag supplemental restraint system
(SRS) components and before servicing,
replacing, adjusting or striking components
near the front or side air bag sensors, such
as doors, instrument panel, console, door
latches, strikers, seats and hood latches.
The front impact severity sensor is located
on the radiator support bracket.
The first row side impact sensors (if
equipped) are located at or near the base of
injury.
the B-pillars.
disconnect the battery ground cable and wait
at least one minute. Be sure to disconnect
auxiliary batteries and power supplies (if
equipped).
Disconnect the battery ground cable and wait at
least one minute. For additional information,
Repowering Procedure
1. WARNING: The restraint system
customer.
1. Turn all vehicle accessories OFF.
Make sure all restraint system diagnostic tool(s)
that may have been installed during the repair
have been removed from the vehicle and all
3. At the smart junction box (SJB), located in the
SRS components are connected.
RH lower kick panel, remove the cover and the
restraints control module (RCM) fuse 17 (10A)
2. Turn the ignition switch from OFF to ON.
from the SJB. For additional information, refer
to the Wiring Diagram Manual.
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3. Install RCM fuse 17 (10A) to the SJB and 5. Prove out the SRS as follows:
close the cover.
4. WARNING: Be sure that nobody is in
the vehicle and that there is nothing blocking
or set in front of any air bag module when
the battery ground cable is connected.
- fail to light.
- flash.
position. This is the time required for the RCM
to complete the testing of the SRS. If the air
bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of 5 sets
of 5 beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be
diagnosed and repaired.
Clear all continuous DTCs from the restraints
control module using a scan tool.
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GENERAL PROCEDURES
6. NOTE: Make sure the motor/pump is above the
System Bleeding
hydraulic lift cylinders before operating the
motor/pump.
Material
NOTE: Some noise squeal may be noticed due
Item Specification
to the air in the hydraulic system.
With the hydraulic lift cylinder rod eyes up and
Fluid the hydraulic pump bypass button pressed,
XT-2-QDX (US);
connect a 12-volt power source to the motor
XT-2-LM12 (Canada)
connector and operate the motor until the
cylinders are fully extended.
1. Remove the hydraulic system from the vehicle.
For additional information, refer to Hydraulic
7. With the hydraulic lift cylinder rod eyes down
System, Lift Cylinder and Motor in this section.
and the hydraulic pump bypass button pressed,
reverse the 12-volt connection and operate the
2. Remove the fill plug at the end of the hydraulic
motor until the cylinders are fully retracted.
pump.
8. Repeat Steps 5 through 7 three times, ending
3. Elevate the pump and motor assembly above
with the hydraulic lift cylinders retracted.
the hydraulic lift cylinders.
9. Remove the fill plug and check the fluid level.
4. NOTE: The hydraulic pump bypass button
If necessary, add automatic transmission fluid to
needs to be pressed while the bleeding
the bottom of the fill hole.
procedure is carried out.
Locate the hydraulic pump bypass button. 10. Install the fill plug.
11. Install the hydraulic system in the vehicle. For
additional information, refer to Hydraulic
System, Lift Cylinder and Motor in this section.
5. With the hydraulic lift cylinders fully retracted,
fill the pump with automatic transmission fluid
to the bottom of the fill hole and install the fill
plug.
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Washer Pump and Reservoir
Material
Item Specification
Premium Windshield WSB-M8B16-A2
Washer Concentrate (US)
ZC-32-A or B (US)
Premium Quality
Windshield Washer Fluid
(Canada)
CXC-37-(A, B, C, D, E,
F, G, H) (Canada)
Windshield Washer Pump and Fluid Reservoir Exploded View
4 W710381 Windshield washer fluid 1 17664 Windshield washer pump (or
reservoir bolts (2 required) part of 17618)
5 17618 Windshield washer fluid 2 17B610 Windshield washer pump seal
reservoir (includes 17664 and (or part of 17664)
17B618)
3 W623332 Windshield washer fluid
reservoir nut
(Continued)
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Windshield washer fluid reservoir
Windshield washer pump or fluid reservoir
5. Remove the 2 windshield washer fluid reservoir
bolts.
WARNING: Windshield washer solution
contains methanol, which is poisonous and
flammable. Observe all cautions and warnings 6. Remove the nut and the windshield washer
indicated on the label of the washer solution fluid reservoir.
container. Failure to follow these instructions
could result in personal injury.
Windshield washer pump or fluid reservoir
7. CAUTION: Do not operate the
Section 100-02.
windshield washer pump prior to filling the
windshield washer reservoir.
2. Disconnect windshield washer pump hose and
drain the windshield washer solvent.
3. Disconnect the windshield washer pump
Windshield washer pump only
4. Remove the windshield washer pump.
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501-35-1 501-35-1 Body Repairs
GENERAL PROCEDURES
1. Verify the vehicle is dimensionally correct on a
Weld-Bonding
frame machine. Straighten if necessary.
General Equipment
2. Remove damaged panels with an air saw or air
Heat Treatment Induction Resistance Spot Welder
chisel. Remove only large portions of the
254-00001
damaged panel. Avoid cutting into mating
Pro 230 MIG Welder 208-00030
flanges or adjacent parts.
Material
3. Drill out the spot welds using an appropriate
Item Specification spot-weld cutter and remove the remaining
portions of the panel to be replaced.
Low Temperature
PM-12-A 4. Prepare any damaged flanges on the vehicle
using hammer and dolly.
TA-1
5. Grind the mating surface of the original flanges
Seam Sealer
not greater than 25 mm (0.98 in) where the TA-2
metal bonding adhesive will be applied.
Weld-Bonding Squeeze-Type
Be sure to remove galvanizing on metal.
Resistance Spot Welding (STRSW)
Metal should have a shiny appearance.
Method
Be careful not to damage the corners or thin
the metal. The E-coat should also be
removed on the opposite side of the flange
whenever it is necessary to grind through painted
only where the spot welds are to be placed.
surfaces or E-coat, or when bare metal repairs are
made. For additional information, refer to Restoring
6. Bevel any edges to less than 10 degrees on the
new panel where a finished section joint is
section.
needed.
NOTE: Door shells are manufactured with
structural adhesives only, weld bonding door skins 7. Dry-fit and clamp the replacement service parts
is not recommended. Only metal bonding adhesive to verify a correct fit.
should be used.
Remove the service part after verifying
correct fit and alignment.
NOTE: Weld-bonding is a method used to join
metals using squeeze-type resistance spot welding
8. If MIG welding, refer to Weld-Bonding
(STRSW) or metal inert gas welding (MIG) and
MIG Welding Method in this section.
structural adhesive. The steps listed in this
procedure apply to both types of welding. STRSW
9. NOTE: The ends of welding clamps should be
is the preferred method. MIG welding should only
insulated on the ends using tape or similar
be used when areas to be welded cannot be
material when welding is carried out.
accessed using STRSW-type machinery.
Follow manufacturers prescribed welding
procedures and settings. For additional
NOTE: Factory spot welds should be substituted
information, refer to Welding Precautions
with either resistance spot welds or MIG plug
Steel in this section.
welds. Spot/plug welds should equal factory welds
in both location and quantity. Do not place a new
10. Prepare the adhesive. Dispense a small amount
spot weld directly over an original weld location.
of metal bonding adhesive from the cartridge to
Plug weld hole should equal 8 mm (0.31 in)
make sure of an even flow of both components.
diameter.
Attach the mixing tip and dispense a mixing tip
length of adhesive to make sure of a correct
mix ratio.
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501-35-2 501-35-2 Body Repairs
11. NOTE: Working time of the adhesive is 40-50 13. Place the service part(s) in the correct position
minutes at 21C (70F). For every -7C (20F) on the vehicle.
above 21C (70F), decrease the working time
When positioned do not pull the component
by one half. For every -7C (20F) below 21C
away from the vehicle. If repositioning is
(70F), double the working and cure time.
necessary, slide the service part(s). This will
Create a test sample. make sure of correct contact between the
components and adhesive.
1 Prepare the metal and adhesive as described.
Apply a 6-9 mm (0.23-0.35 in) bead of
14. Clamp evenly and tightly. The adhesive
adhesive and weld the sample.
contains glass beads which will prevent
2 Place the welded sample in a vice and
over-clamping the component.
perform destructive weld tests by peeling
the scrap metal apart using large channel
15. NOTE: Welding can be carried out anytime
lock-type pliers. Measure the weld nugget
during the adhesive curing process, or after the
to determine that the nugget meets Ford
adhesive is fully cured. Welder settings will
weld nugget requirements.
vary when welding through wet adhesive versus
welding through fully cured adhesive. Refer to
3 When the correct weld nugget is achieved,
welder manufacturers recommended settings
the service part can be weld-bonded.
for welding through fully cured adhesive. It is
Weld Nugget Chart
recommended to place a shunt weld in an area
with no adhesive to make sure of conductivity,
Test Thickness of
particularly when welding through fully cured Metal (in millimeters) Nugget Size (mm)
adhesive.
0.7 + 0.7 4.30
NOTE: If welding will not be carried out
0.7 + 0.7 + 0.7 4.30
immediately, allow a minimum of 1.5 to 2
0.9 + 0.9 4.70
hours of adhesive cure time at 21C (70F)
0.9 + 0.9 + 0.9 4.70
before removing clamps. Cure time at lower
1.0 + 1.0 5.20 temperatures should be increased. Clamps may
be removed immediately after the component
1.0 + 1.0 + 1.0 5.20
is welded.
2.0 + 2.0 7.10
Wipe excess adhesive from the panel before it
2.0 + 2.0 + 2.0 7.10
cures.
3.0 + 3.0 8.70
3.0 + 3.0 + 3.0 8.70
16. Finish any cosmetic section seams with
fiber-filled body filler. Rough sand the filler, 3.0 + 0.7 4.30
after the adhesive cures, apply conventional
0.7 + 3.0 + 1.0 5.20
body filler and block-sand the area.
2.0 + 2.0 + 0.7 4.30
0.9 + 0.9 + 2.0 4.70
17. Prime any bare metal areas with anti-corrosion
coating. Apply 2-3 coats allowing it to flash dry 2.0 + 0.9 + 1.0 5.20
between coats.
1.0 + 3.0 + 1.0 5.20
3.0 + 1.0 + 2.0 7.10
18. Use seam sealer wherever a cosmetic seam
0.9 + 0.7 + 0.9 4.30
sealer is required.
19. Mix and apply primer surfacer per
12. Apply a 6-9 mm (0.23-0.35 in) bead of metal
manufacturers recommendations.
bonding adhesive to the vehicle prepared flange
surface.
20. Mix and apply basecoat per manufacturers
recommendations.
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501-35-3 501-35-3 Body Repairs
21. Mix and apply clearcoat per manufacturers 3. Using an appropriate grinder, carefully grind
recommendations. Refinishing materials may be around the entire receiving flange area
force-dried following paint manufacturers following the original welds. Be sure to remove
recommendations. all E-coat, paint or galvanized coating from the
mating surfaces of the joint.
Weld-Bonding MIG Welding Method
Do not grind above the mating surface area
to prevent the possibility of corrosion
NOTE: Metal inert gas (MIG) weld-bonding can be
forming later.
substituted as an alternative to squeeze type
resistance spot welding (STRSW). It may only be
4. Repeat the procedure from Step 3 on the mating
used to weld areas that are inaccessible to STRSW
surface of the replacement service part(s).
machinery. However when accessible STRSW is the
preferred method.
5. Prepare the new service panel for plug welds.
Using the original panel as a reference, drill
or punch holes in the exact number as the
whenever it is necessary to grind through painted
original spot welds. The holes should be
surfaces or E-coat, or when bare metal repairs are
positioned as close as possible to the
made. For additional information, refer to Restoring
original spot weld locations, without lining
up exactly on top of an original spot weld
section.
site.
NOTE: Door shells are manufactured with
To make sure of correct weld performance,
structural adhesives only, weld-bonding door skins
grind the immediate perimeter of plug weld
is not recommended. Only metal bonding adhesive
hole. Grind only in the area of the plug
should be used.
weld, this will keep corrosion to a
minimum.
NOTE: Factory spot welds should be substituted
with either resistance spot welds or MIG plug
6. Dry-fit and clamp the replacement service parts
welds. Spot/plug welds should equal factory welds
to verify a correct fit and alignment.
in both location and quantity. Do not place a new
Remove the service part after verifying
correct fit and alignment.
diameter.
7. The vehicle prepared flange areas where plug
welds will be located must be kept free of
1. Remove damaged panels with an air saw or air
adhesive. Apply 25 mm (0.98 in) tape to the
chisel. Remove only large portions of the
plug weld areas to prevent contamination from
damaged panel. Avoid cutting into mating
the adhesive.
flanges or adjacent parts.
Drill out the spot welds using an appropriate
8. Prepare the adhesive. Dispense a small amount
spot-weld cutter and remove the remaining
of metal bonding adhesive from the cartridge to
portions of the panel to be replaced.
make sure of an even flow of both components.
Attach the mixing tip and dispense a mixing tip
2. After removing the damaged sheet metal
length of adhesive to make sure of correct mix
panel(s), repair any damaged flanges on the
ratio.
vehicle using hammer and dolly.
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501-35-4 501-35-4 Body Repairs
9. NOTE: Work time of the adhesive is 40-50 13. Finish any cosmetic section seams with
minutes at 21C (70F). For every -7C (20F) fiber-filled body filler. Rough sand the filler,
above 21C (70F), decrease the working time apply conventional body filler after the adhesive
by one half. For every -7C (20F) below 21C cures and block-sand the area.
(70F), double the working and cure time.
14. Prime any bare metal areas with anti-corrosion
Apply a 6-9 mm (0.23-0.35 in) bead of
coating. Apply 2-3 coats allowing it to flash dry
adhesive to the vehicle prepared flange surface.
between coats.
Remove the tape from the plug weld areas.
15. Use seam sealer wherever a cosmetic seam
10. Place the service part(s) in the correct position
sealer is required.
on the vehicle.
When positioned, do not pull the component
16. Mix and apply primer surfacer per
away from the vehicle. If repositioning is
manufacturers recommendations.
necessary, slide the service part(s). This will
make sure of correct contact between the
17. Mix and apply basecoat per manufacturers
components and adhesive.
recommendations.
11. Clamp evenly and tightly. The adhesive
18. Mix and apply clearcoat per manufacturers
contains glass beads which will prevent
recommendations. Refinishing materials may be
over-clamping the component.
force-dried following paint manufacturers
recommendations.
12. NOTE: Welding can be carried out anytime
during the adhesive curing process, or after the
adhesive is fully cured.
NOTE: If welding will not be carried out
immediately, allow a minimum of 1.5 to 2
hours of adhesive cure time at 21C (70F)
before removing clamps. Cure time at lower
temperatures should be increased. Clamps may
be removed immediately after the component
is welded.
Wipe excess adhesive from the panel before it
cures.
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501-35-1 501-35-1 Body Repairs
A test weld should always be carried out on a test
Welding Precautions Aluminum
sample.
Correct equipment and cleaning procedures must be
Preheating the aluminum workpiece can help
used when welding aluminum.
prevent weld cracking. The preheating temperature
Gas-metal-arc-welding (GMAW) or MIG and
should not exceed 110C (230F).
Gas-tungsten-arc-welding (GTAW) or TIG are used
for welding aluminum and aluminum alloys.
Use a temperature indicator to prevent
overheating.
The correct protective clothing should always be
Attach the ground clamp as close as possible to
worn.
the work area.
Proper ventilation must be provided to avoid the
Types of filler rods to use when TIG welding
accumulation of poisonous gases.
aluminum:
Aluminum-silicon alloy.
battery.
Aluminum-magnesium alloy.
Disconnect on-vehicle modules and protect them
from possible heat damage and electrical currents
Adequate power supply needs to be used to make
when welding.
sure of correct equipment performance.
Use a stainless steel wire brush to remove
Corrosion protection needs to be restored
aluminum oxides.
Make sure the surface is clean and free of foreign
repairs are carried out. Refer to Restoring
materials.
Use degreasers that do not contain hydrocarbons.
section.
Do not use a wire brush that has been used on
stainless or carbon steel.
Follow equipment manufacturers prescribed
procedures as aluminum and aluminum alloys
have a higher thermal conductivity and lower
melting point which can lead to easier burn
through.
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501-35-1 501-35-1 Body Repairs
Factory spot welds may be substituted with either
Welding Precautions Steel
resistance spot welds or MIG plug welds.
Spot/plug welds should equal factory welds in
both location and quantity. Do not place a new
Item Specification
Low Temperature
diameter.
PM-12-A
General Equipment
Pro 230 MIG Welder 208-00030
repairs are made. Refer to Restoring Corrosion
Heat Treatment Induction Resistance Spot Welder Protection Following Repair in this section.
254-00001
Welding Precautions Dual-Phase Steel
The correct equipment and settings must be used
The correct equipment and settings must be used
when welding dual-phase steel. MIG and resistance
when welding mild or high-strength steel. Metal
spot welding are the recommended methods.
inert gas (MIG) and squeeze-type resistance spot
Surfaces must be clean and free of foreign
welding (STRW) are the preferred methods.
materials.
Surfaces must be clean and free of foreign
materials. ER70-S-6 is the recommended wire specification to
use when welding dual-phase steel components.
The correct protective clothing should always be
Recommended gas mixtures are as follows: C02,
worn.
92Ar8C02, 84Ar16C02 and 77Ar23C02.
Correct eye protection must be worn.
Components made of dual-phase steel should not be
Adequate ventilation must be provided to avoid
heated to straighten or repair. New components
accumulation of poisonous gases.
should be installed if severely bent or kinked.
A test weld should always be carried out on a test
Do not use Oxyacetylene equipment to weld
sample.
dual-phase steel.
Correct eye protection must be worn.
procedures and equipment settings for the type of
weld being carried out. The correct protective clothing should always be
worn.
Use grinding discs and wire brushes dedicated to
the type of material being welded. Adequate ventilation must be provided to avoid
the accumulation of poisonous gases.
procedures and equipment settings for the type of A test weld should always be carried out on a test
weld being used. ER70S-2 or ER70S-6 wire are sample.
typically used for MIG welding steel.
Use cleaning and abrasive grinding wheels
Disconnect the battery ground cable from the dedicated to the type of materials being welded.
battery.
Disconnect on-vehicle modules and protect them procedures and equipment settings for the type of
from possible heat damage and electrical currents welder being used.
when welding.
Components made of high-strength steel should
Disconnect on-vehicle modules and protect them
not be heated to straighten or repair. Severely
from possible heat damage and electrical currents
bent or kinked components should be replaced
when welding.
with new ones.
whenever bare metal repairs made.
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501-35-2 501-35-2 Body Repairs
Factory spot welds may be substituted with either Vehicles equipped with optional safety canopy
resistance spot welds or MIG plug welds. require removal of these components prior to any
Spot/plug welds should equal factory welds in welding procedures being carried out in the
both location and quantity. Do not place a new roofline or body side areas of the vehicle. Refer
spot weld directly over an original weld location. to Section 501-20B.
Vehicles built prior to 01/2007 contain dual-phase
diameter.
steel in the rocker reinforcement and underbody
crossbraces. Vehicles built after 01/2007 contain
high-strength steel in the rocker reinforcement and
underbody crossbraces.
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Window Control Switch
NOTE: LH side shown, RH side similar.
NOTE: Coupe shown, convertible similar.
1 241A22 Door panel switch plate
2 Window control switch
14630/14631)
3 14529 Window control switches
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2. Release the tabs and remove the window
control switch.
1. CAUTION: Use a shop towel or
similar material between the tool and the
door trim panel or damage to the door trim
panel may occur.
Release the clip and remove the door panel
switch plate.
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GENERAL PROCEDURES
Window Glass Adjustment Front
Door, Height Stop Adjustment
2. Close the door.
3. Raise the door window glass to the desired
height.
4. NOTE: Door window front height adjustment
shown. Door window rear height adjustment is
5. Adjust the door window front and rear height
similar.
stop adjustments to achieve the desired door
Lower the window to access the door window
window height.
front and rear height stop adjustments.
6. Install the door trim panel. For additional
7. If necessary, carry out the Window Motor
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GENERAL PROCEDURES
3. Check the dimension of the gap between the
Window Glass Adjustment Front
door window glass and the weatherstrip retainer
Door, Stabilizer
in the locations shown. If the dimension is
within the specification, only a final adjustment
Initial Adjustment
may be required.
1 Sheet metal
NOTE: The following procedure must be carried
out after a door window glass, or a door window
2 Weatherstrip retainer
regulator and motor is replaced, or removed and
3 Door window glass
re-installed.
4 10.5 mm (0.41 in) (Convertible)
1. Remove the door opening weatherstrip.
11.5 mm (0.45 in) (Coupe)
2. Close the door.
4. Remove the door trim panel. For additional 6. NOTE: As the door window glass is moved up
information, refer to Section 501-05. and down, the door window glass clamps have
plastic inserts equipped with ramp-style surfaces
5. Remove the water shield.
that tip the glass in or out as the glass
assembly, are slid up or down.
Loosen the 2 (front and rear) door window
glass bolts.
7. Fully close the door.
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8. Adjust the door window glass by physically 17. Operate the window up and down several times
moving the glass to the desired position and to check for smooth operation and adequate
tighten the door window glass bolts. sealing properties (it may be necessary to carry
out a water leak test with a hose).
Final Adjustment
9. From underneath the door, loosen the front
window regulator guide rail lock nut.
1. NOTE: This procedure should be carried out as
a final adjustment to the initial adjustment or
can be used as a minor adjustment for the door
window glass.
NOTE: After the initial adjustment is carried
out (or if only a minor adjustment is required)
the final adjustment, if necessary, can be made.
Use the front and rear window regulator guide
rail adjustments for inboard/outboard movement
of the door window glass.
NOTE: The rear adjustment is a jackscrew that
is exposed by removing the round reflector
located at the bottom of the door trim panel.
NOTE: The front adjustment is a sliding stud
10. Operate the door window glass to the full down
and nut located on the bottom of the door.
position.
From underneath the door, loosen the front
11. Tighten the front window regulator guide rail
window regulator guide rail lock nut.
lock nut.
12. Operate the door window glass to the full up
position and verify the dimensions meet the
specification as outlined in the initial
adjustment graphics. If necessary, re-adjust the
glass as outlined in the previous steps.
13. Install the door opening weatherstrip.
14. Install the water shield.
15. Install the door trim panel. For additional
2. Remove the round reflector located at the
16. Initialize the door window motor. For additional
bottom of the door trim panel.
information, refer to Window Motor
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3. NOTE: The clockwise direction of the 4. From underneath the door, tighten the front
jackscrew moves the window regulator guide window regulator guide rail lock nut.
rail inboard (the door window glass tips
5. Initialize the door window motor. For additional
outboard), resulting in less seal pressure
(maximum of 5 revolutions). The
counterclockwise direction of the jackscrew
moves the window regulator guide rail
6. Operate the window up and down several times
outboard (the door window glass tips inboard),
to check for smooth operation and adequate
resulting in more seal pressure (maximum of 10
sealing properties (it may be necessary to carry
revolutions).
out a water leak test with a hose).
Loosen the lock nut, adjust the jackscrew on
the rear window regulator guide rail as
7. Install the round reflector.
necessary and tighten the lock nut.
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GENERAL PROCEDURES
3. Loosen the 2 rear quarter window glass bolts.
Window Glass Adjustment Rear
Quarter, Convertible
4. Adjust the rear quarter window glass to desired
position.
1. Make sure the door alignment is properly
adjusted. For additional information, refer to
5. Tighten the quarter window glass bolts to 10
Section 501-03.
Nm (89 lb-in).
2. Remove the rear quarter trim panel. For
6. Install the rear quarter trim panel. For
additional information, refer to Section 501-05
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Window Glass Front Door
1 76231A06 Door window glass bolts and
1. Remove the door trim panel. For additional sleeves (2 required)
2 6321410 RH/ Door window glass
6321411 LH
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3. Remove the 2 door window glass bolts and 5. To install, reverse the removal procedure.
sleeves.
Make sure the window glass is correctly
To install, tighten to 9 Nm (80 lb-in). seated into the window glass clamps during
installation.
4. Tip the front of the glass down to clear the
Adjust the door window glass as necessary.
door filler and remove the door window glass.
For additional information, refer to Window
Glass Adjustment Front Door, Height
Stop Adjustment and Window Glass
Adjustment Front Door, Stabilizer in this
section.
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Window Glass Rear Quarter,
Convertible
Removal
1 W711156 Rear quarter window glass
1. Remove the rear quarter trim panel. For bolts (2 required)
2 7629710 RH/ Rear quarter window glass
7629711 LH
2. Remove the 2 bolts and the rear quarter
window glass.
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Installation
2. Adjust the rear quarter window glass to desired
position and tighten the 2 bolts to 10 Nm (89
lb-in).
1. Install the rear quarter window glass and finger
tighten the 2 bolts.
3. Install the rear quarter trim panel. For
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Window Glass Rear Quarter,
Coupe
Special Tool(s)
Interior Auto Glass Cut-Out
Knife Kit (electric)
Interior Auto Glass Cut-Out
Knife Kit (air powered)
Material
Item Specification
DOW AUTOMOTIVE
2-HOUR CURE
Betaseal Express
5500 / 5500A / 5500SA
SIKA 2-HOUR CURE
Sika Tack ASAP
G+P
Cleaner
ZC-23
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Removal
1 Urethane adhesive
2 6329710 RH/ Quarter window glass
632971 LH
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avoid scratching the pinch weld.
Using the special tool and working from the
inside, cut the urethane seal.
3. Remove the quarter window glass.
4. NOTE: Avoid scratching the pinch weld. For
minor scratches or exposed metal on the pinch
weld see manufacturers recommendations.
Trim the urethane with an appropriate tool
3. Remove the quarter window glass.
leaving a 1 mm to 2 mm base of Original
Equipment urethane on the pinchweld.
4. Using a soft brush or vacuum, clean the pinch
weld.
Installation
1. CAUTION: When installing
urethane-installed glass parts, the vehicle
must not be driven until the urethane has
cured. Adequate cure time is specified on the
drive away chart for each urethane product
as the temperatures and humidity vary.
Inadequate or incorrect curing can
adversely affect the retention of the quarter
window glass.
NOTE: For additional material guidelines,
5. If reinstalling the original quarter window glass,
refer to the manufacturers installation
remove the urethane adhesive from the quarter
information.
window glass.
6. If installing a new quarter window glass, clean
2. Dry-fit the quarter window glass by centering it
the inside of the glass surface with glass cleaner
using the locating pins. Make alignment marks
to make sure the ceramic-coated area is clean.
with tape or non-staining grease pencil on both
the glass and the vehicle body.
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7. CAUTION: Be sure to use the same
brand and cure-rate products for the
adhesive and primer. Do not mix different
brands of urethane and primer. Refer to the
Material Chart in this procedure.
NOTE: Sika uses the same black primer for the
glass and pinch weld area.
If installing a new quarter window glass, apply
urethane glass primer according to
manufacturers instructions. Allow at least 6
minutes to dry.
8. Cut the applicator tip to specification.
10. CAUTION: Open a window to prevent
the quarter window glass from being pushed
out by air pressure when the door is closed.
Using the locator pins on the glass, install the
quarter window glass by aligning the locator
pins to the body locator holes.
as the temperature and humidity vary.
9. NOTE: Use either a high-ratio, electric or
adversely affect the retention of the quarter
battery-operated caulk gun that applies the
window glass.
urethane adhesive with less effort and a
After the urethane has cured, check the quarter
continuous bead.
window glass seal for air or water leaks through
Apply a bead of urethane adhesive to the pinch
the urethane adhesive bead and add urethane
weld. Make sure that all gaps in the urethane
adhesive as necessary.
adhesive are smoothed into one continuous
bead, starting at the bottom of the quarter 12. Install the quarter window trim panel. For
window glass near the center. additional information, refer to Section 501-05.
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Window Glass Rear
Material
Item Specification
DOW AUTOMOTIVE
2-HOUR CURE
Betaseal Express
5500 / 5500A / 5500SA
SIKA 2-HOUR CURE
Sika Tack ASAP
G+P
Cleaner
ZC-23
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NOTE: The luggage compartment lid is not shown for clarity.
Removal
1 Heated rear window electrical
connector (part of 14A005) WARNING: To prevent glass splinters
from entering eyes or cutting hands, wear safety
2 Urethane adhesive
glasses and heavy gloves when cutting glass from
3 6342006 Rear window glass
the vehicle. Failure to follow these instructions
1. Disconnect the 2 heated rear window electrical
connectors.
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prevent scratching the pinch weld.
NOTE: Lubricate the existing urethane
adhesive with water to aid the tool while
cutting.
Using an appropriate tool (with the luggage
compartment lid open approximately 45
degrees), starting at the bottom outboard corner
of the rear window glass, cut the urethane
adhesive from the glass.
3. Remove the rear window glass.
4. If reinstalling the original rear window glass,
remove the urethane adhesive from the rear
weld.
window glass.
Installation
5. If installing a new rear window glass, clean the
inside of the glass surface with glass cleaner to
CAUTION: When installing the urethane
make sure the ceramic-coated area is clean.
installed glass parts, the vehicle must not be
driven until the urethane adhesive has cured.
Adequate cure time is specified on the drive
away chart for each urethane product as the
temperature and humidity vary. Inadequate or
incorrect curing can adversely affect the
retention of the rear window glass.
NOTE: For additional material guidelines, refer to
the manufacturers installation information.
If installing a new rear window glass, apply
1. Dry-fit the rear window glass by centering it
side-to-side and by adjusting the setting blocks
minutes to dry.
(if equipped) to get the correct position of the
part top-to-bottom. Make alignment marks with
tape or non-staining grease pencil on both the
glass and the vehicle body.
2. Remove the rear window glass.
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the rear window glass from being pushed out
by air pressure when the door is closed.
continuous bead.
Using the alignment marks install the rear
window glass.
bead, starting at the bottom of the rear window
glass near the center.
adversely affect the retention of the rear
window glass.
After the urethane has cured, check the rear
window glass seal for air or water leaks through
the urethane adhesive bead and add urethane
adhesive as necessary.
11. Connect the 2 heated rear window electrical
connectors.
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GENERAL PROCEDURES
NOTE: The interior side of the grid lines are not
Window Grid Wire Repair
painted, but due to the silver tarnishing tend to
change the grid to a gold or brown color. The repair
Material
area is bright silver and tarnishes over time to
Item Specification
match the rest of the grid.
Cleaner
1. Bring the vehicle up to a room temperature of
ZC-23
at least 16C (61F) or above.
Lacquer Touch-up Paint ESR-M2P100-C
(match color to exterior
2. NOTE: Do not use scrapers, sharp instruments
grid wire)
or abrasive window cleaners on the interior
PM-19500-XXXXX or
surface of the rear window glass as this may
PMP-19500-XXXXX
cause damage to the grid lines.
Rear Window Defroster
Repair
Clean the entire grid line repair area with
PM-11 (US); CPM-11
window cleaner and 0000 steel wool to remove
(Canada)
all dirt, wax, grease, oil or other foreign
Polypropylene Film Fine
material.
Line Tape
(commercially available)
3. Mark the location of the grid break on the
exterior of the rear window glass.
NOTE: If the first layer of the heated rear window
grid (brown) is damaged or missing, it is necessary
to apply touch-up paint on the glass prior to
applying the silver rear window defroster repair.
NOTE: The grid line material is not embedded into
the glass but is baked to the glass surface and
consequently can be scraped off. Inoperative lines
may appear to the eye to be undamaged due to
residue remaining on the glass and require diagnosis
with a voltmeter or 12V test lamp. For additional
information, refer to Diagnosis and Testing in this
section.
NOTE: An undamaged grid line has small ridges
that project above the surface of the glass and can 4. Using a polypropylene film fine line tape, mask
easily be felt when running a fingernail across them. the area directly above and below the grid
Grid lines that have been razor bladed feel break extending the tape 26 mm (1.02 in)
smooth when a fingernail is dragged across the beyond the concern area in both directions. The
affected area. There may be some residue left on
break area should be at the center of the mask.
the glass that appears to be grid material but a
check with a voltmeter or 12V test lamp confirms
an open circuit.
NOTE: If the brown color under the grid line is
damaged or missing (this is very rare), it is
necessary to apply acrylic lacquer touch-up paint for
color match. This paint must meet specification
ESR-M2P100-C and should be applied to the glass
prior to applying the rear window defroster repair
compound.
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5. NOTE: If the brown layer is not broken or
missing, apply only the silver grid repair
compound to the break.
NOTE: If both the brown and silver layers of
the grid are broken or missing, apply a coating
of the acrylic touch-up paint across the break in
the grid line first. Do not overlap the silver grid
line with the paint. Several applications may be
necessary to achieve a color match.
NOTE: Extend the silver repair coating at least
6.35 mm (0.25 in) on both sides of the break
area.
NOTE: Allow at least 5 minutes of drying time 6. After 5 minutes, or after the repair area dries
between applications for the touch-up paint or completely, remove the mask.
the silver repair coating. Applying fewer coats
or not allowing adequate drying time between
7. CAUTION: Be careful not to damage
coats produces repaired resistance that is greater
the grid line with the razor blade. If this
than original equipment manufacture (OEM)
occurs, additional repair may be necessary.
resistance, resulting in poor defrost performance
Remove any excess repair compound above or
and excessive localized heating.
below the grid line with a razor blade.
Apply the repair coating to the grid break area
in several smooth, continuous strokes.
8. NOTE: The repair coating air-dries in
approximately 1 minute and can be energized
Apply a minimum of 6 applications of the grid
after 5 minutes.
repair compound.
NOTE: Optimum adhesion occurs after
approximately 24 hours.
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GENERAL PROCEDURES
NOTE: The door MUST be closed during this
Window Motor Initialization
procedure, in order for the door window motor to
initialize.
CAUTION: Make sure no obstructions are
present in the window system when carrying out
NOTE: The windows must be in the full open
this procedure.
position for this procedure to operate correctly.
NOTE: A battery disconnect does not require this
1. Press and hold the window control switch in the
procedure to be carried out.
UP position at the second detent until the
window glass stalls into the glass top run. Once
NOTE: Excessive bounce-back (bounce-back that
the top run is reached, hold the window control
occurs with no obstructions present) may indicate a
switch in the DOWN position at the second
non-initialized window motor.
detent until the window glass stalls at the
bottom of its travel.
NOTE: The front window motors must be
initialized whenever: a new window regulator and
2. Test for correct window operation by carrying
motor is installed, a new window glass is installed,
out the one-touch down and the one-touch up
a glass top run removal and installation or when
features.
carrying out any operation in which grease or
lubricants are applied to the window system. A
Using the vehicle communication module
new front window motor is in a proportional
(VCM)
up/down mode until initialized.
CAUTION: Make sure there are no NOTE: The convertible rear window motors do
obstructions present in the window system when NOT need to be initialized as they do not have
carrying out this procedure. one-touch up or one-touch down functions.
NOTE: All front window components (window
CAUTION: Bounce-back is disabled during
glass, window regulator, window motor and glass
this procedure.
top run) must be installed and tightened to
NOTE: This procedure terminates without specification before carrying out this procedure.
initialization if a corresponding window switch is
NOTE: If this procedure is only partially
pressed before stall is reached.
completed, the front window motor remains
NOTE: The windows must be in the full open non-initialized and only the proportional up/down
position for this procedure to operate correctly. functions operate. A non-initialized window motor
may allow one-touch down operation, but does NOT
3. Carry out the window calibration (IP learn)
allow one-touch up operation.
using the scan tool.
NOTE: If the one-touch up does not function after
3 attempts using the window control switch 4. After stalling into the header seals, the front
initialization method, especially if false bounce-back windows move to the full open position.
occurs, carry out the Door Window Motor
5. Test for correct window operation by Initialization using the scan tool.
attempting the one-touch down and the
Using the window control switch
one-touch up features using the window control
switch.
CAUTION: Make sure there are no
obstructions present in the window system when
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Window Regulator and Motor Front
Door
3 N621906 Door window regulator nuts 1 Door window motor electrical
(4 required) connector (part of
14630/14631)
4 6323200 RH/ Door window regulator and
6323201 LH motor 2 N621906 Door window motor nuts (3
required)
(Continued)
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5. Remove the door window regulator and motor
through the rear access hole.
1. Remove the door window glass. For additional
information, refer to Window Glass Front
Door in this section
Adjust the door window glass as necessary.
For additional information, refer to Window
2. Disconnect the door window motor electrical
Glass Adjustment Front Door, Stabilizer
connector.
in this section.
Initialize the window motor. For additional
3. Remove the 3 door window motor nuts.
4. NOTE: Make certain not to disturb the jack
screw when removing the lower right window
regulator nut. This may affect the window
adjustment.
Remove the 4 door window regulator nuts.
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Window Regulator Motor Rear
Quarter
3 Rear quarter window motor 1 W505424 Rear quarter window inner
electrical connector (part of belt weatherstrip bolts (2
14A017) required)
4 Rear quarter window 2 76297B06 RH/ Rear quarter window inner
regulator and motor harness 76297B07 LH belt weatherstrip
locator (part of 14A017)
(Continued)
(Continued)
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3. Disconnect the electrical connector from the
rear quarter window motor.
5 N621906 Rear quarter window
regulator and motor nuts (3
4. Remove the harness locator from the rear required)
quarter window regulator and motor assembly.
6 76304306 RH/ Rear quarter window
76304307 LH regulator and motor
5. NOTE: Make certain not to disturb the jack
screws when removing the rear quarter window
regulator and motor assembly nuts.
Remove the 3 nuts and the rear quarter window
1. Remove the rear quarter window glass. For
regulator and motor assembly.
additional information, refer to Window Glass
Rear Quarter, Convertible in this section.
2. Remove the 2 bolts and the rear quarter
window inner belt weatherstrip.
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Windshield Glass
Material
Item Specification
DOW AUTOMOTIVE
2-HOUR CURE
Betaseal Express
5500 / 5500A / 5500SA
SIKA 2-HOUR CURE
Sika Tack ASAP
G+P
Cleaner
ZC-23
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Removal
1 7603110 Windshield glass moulding
WARNING: To prevent glass splinters
2 Urethane adhesive
from entering eyes or cutting hands, wear safety
3 6303100 Windshield glass
glasses and heavy gloves when cutting glass from
the vehicle. Failure to follow these instructions
2. Remove the interior rear view mirror. For
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prevent scratching the pinch weld.
NOTE: Lubricate the existing urethane
adhesive with water to aid the tool while
cutting.
Using an appropriate tool, starting at the bottom
corner of the windshield glass, cut the urethane
adhesive from the glass.
4. Remove the windshield glass.
weld.
4. If reinstalling the original windshield glass,
remove the urethane adhesive from the
Installation
windshield glass.
CAUTION: When installing the urethane
5. NOTE: If a new windshield glass is to be
installed glass parts, the vehicle must not be
installed, attach the new moulding to the edge
driven until the urethane adhesive has cured.
of the glass starting at the top center then work
Adequate cure time is specified on the drive
down the sides and around the corners.
away chart for each urethane product as the
If installing a new windshield glass, clean the
temperature and humidity vary. Inadequate or
inside of the glass surface with glass cleaner to
incorrect curing can adversely affect the
make sure the ceramic-coated area is clean.
retention of the windshield glass.
NOTE: For additional material guidelines, refer to
the manufacturers installation information.
1. Dry-fit the windshield glass by centering it
side-to-side and by adjusting the setting blocks
(if equipped) to get the correct position of the
part top-to-bottom. Make alignment marks with
tape or non-staining grease pencil on both the
If installing a new windshield glass, apply
glass and the vehicle body.
2. Remove the windshield glass.
minutes to dry.
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the windshield glass from being pushed out
by air pressure when the door is closed.
continuous bead.
Using the alignment marks, install the
windshield glass.
adhesive are smoothed into one continuos bead,
starting at the bottom of the windshield glass
near the center.
adversely affect the retention of the
windshield glass.
After the urethane has cured, check the
windshield glass seal for air or water leaks
through the urethane adhesive bead and add
urethane adhesive as necessary.
11. Install the interior rear view mirror. For
12. Install the cowl vent screen. For additional
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GENERAL PROCEDURES
All Vehicle
Windshield Reseal
Material
Item Specification
DOW AUTOMOTIVE
8. Clean the interior and exterior of the windshield
2-HOUR CURE
glass surface with glass cleaner.
Betaseal Express
9. Cut the urethane adhesive applicator tip to
SIKA 2-HOUR CURE
specification.
Sika Tack ASAP
Cleaner
ZC-23
Coupe
1. Remove the RH and LH A-pillar trim panels.
continuous bead.
NOTE: Make sure all gaps in the urethane
bead.
Apply urethane adhesive over top of the
existing urethane adhesive.
Apply the urethane adhesive to the top and
3. Remove the 2 screws and the 2 visor clips.
sides of the windshield from the interior of
the vehicle.
4. Remove the LH and RH sun visors.
Apply the urethane adhesive to the bottom
of the windshield from the exterior of the
5. Lower the front portion of the headliner and
vehicle.
block with a suitable material.
11. After the urethane has cured, check the
Convertible
windshield glass seal for air or water leaks
through the urethane adhesive bead and add
6. Remove the LH and RH A-pillar trim panel and
urethane adhesive as necessary.
the header trim panel. For additional
12. Install the cowl vent screen. For additional
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Convertible
13. Install the header trim panel and the LH and
RH A-pillar trim panels. For additional
Coupe
14. Position the front portion of the headliner.
15. Install the LH and RH sun visors.
16. Install the 2 visor clips and the 2 screws.
All Vehicles
17. Install the overhead console.
19. Adjust the wiper blade and pivot arms as
18. Install the RH and LH A-pillar trim panels.
necessary. For additional information, refer to
Section 501-16.
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Wiper and Washer System
Exploded View
4 N804837 Cowl top vent screen pin-type 1 17C526 Wiper pivot arm nut covers
retainers (4 required) (2 required)
5 63018A16 RH cowl top vent screen 2 W706109 Wiper pivot arm nuts (2
required)
6 63018A17 LH cowl top vent screen
3 17526/17527 Wiper pivot arms (RH/LH) (Continued)
(Continued)
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7 W707532 Windshield wiper mounting 10 Windshield wiper motor bolts
arm and pivot shaft bolts (3 (3 required)
required)
11 17508 Windshield wiper motor
8 17508 Windshield wiper mounting
arm and pivot shaft
9 Windshield wiper motor
output shaft bolt
(Continued)
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GENERAL PROCEDURES
Wiper Blade and Pivot Arm
Adjustment
NOTE: When adjusting the wiper pivot arms, the
wiper blades must not be less than the specified
distance from the cowl weatherstrip.
1. Cycle and park the windshield wipers.
2. Verify that the RH windshield wiper blade is
33-45 mm (1.29-1.77 inches) above the cowl
weatherstrip.
3. Verify that the LH wiper blade is 39-52 mm
(1.53-2.05 inches) above the cowl weatherstrip.
4. If the wiper blades are not properly aligned,
remove and reposition the windshield wiper
pivot arms. For additional information, refer to
Wiper Pivot Arm in this section.
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2. Remove the bolt and disconnect the mounting
Wiper Motor
arm and pivot shaft linkage from the wiper
motor output shaft.
Material
If reusing the old bolt, apply Threadlock to
Item Specification
the bolt before installation.
Threadlock WSK-M2G351-A6
262
Removal and Installation 3. Remove the 3 bolts and the windshield wiper
motor.
CAUTION: The internal permanent
magnets used in the windshield wiper motor are
made of a glass-like material. To avoid damaging 4. To install, reverse the removal procedure.
the magnets, do not handle the windshield wiper
motor roughly, or strike the motor with a
hammer or any other object.
1. Remove the wiper mounting arm and pivot
shaft. For additional information, refer to Wiper
Mounting Arm and Pivot Shaft in this section.
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2. Remove the 3 bolts and the windshield wiper
Wiper Mounting Arm and Pivot Shaft
mounting arm and pivot shaft.
3. Disconnect the windshield wiper motor
1. Remove the RH and LH cowl vent screens. For
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Wiper Pivot Arm
Removal
1. NOTE: New wiper pivot arms need to be
installed as an assembly.
Remove the 2 wiper pivot arm nut covers.
2. Remove the 2 nuts and the 2 wiper pivot arms.
Installation
1. Cycle and park the windshield wipers.
3. Install the 2 wiper pivot arm nuts.
2. Install the wiper blade and pivot arm onto the
If necessary, adjust the wiper pivot arms.
pivot shaft.
For additional information, refer to Wiper
Align the wiper blades to 33-45 mm
Blade and Pivot Arm Adjustment in this
(1.29-1.77 inches) for the RH wiper blade,
section.
and 39-52 mm (1.53-2.05 inches) for the LH
wiper blade.
4. Install the 2 wiper pivot arm nut covers.
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Wiper/Washer Switch
Windshield Wiper/Washer Switch Exploded View
4 3530 Steering column upper shroud 1 W710937 Steering column lower shroud
screws (2 required)
5 Windshield wiper/washer
switch screws (2 required) 2 W706805 Steering column lower shroud
screw
6 17A553 Windshield wiper/washer
switch 3 3530 Steering column lower shroud
(Continued)
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the windshield wiper/washer switch.
1. Remove the 3 screws and the steering column
upper and lower shrouds.
2. Remove the 2 windshield wiper/washer switch
screws.
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High Speed Windshield Wipers
Wipers and Washers
High speed is activated when the windshield
Special Tool(s)
wiper/washer switch supplies a ground to the
windshield wiper motor internal park/run relay and 73III Automotive Meter
105-R0057 or equivalent the internal HI/LO speed relay, through circuit 63
(RD). Voltage is then sent to the high speed side of
the wiper motor, which activates the high-speed
mode. High speed mode is exited by selecting a
different state on the switch. When the switch is
placed in the OFF position, the motor continues to
operate until the motor returns to the park position,
Flex Probe Kit
105-R025B or equivalent and the Hall-effect sensor senses the motor magnet.
The output to the run/park relay deactivates the
relay and disconnects the voltage to the motor.
Low Speed Windshield Wipers
Low speed is activated when the windshield
wiper/washer switch supplies a ground to the
windshield wiper motor inputs through circuits 56 Electrical System Tester
010-00736 or equivalent (DB/OG) and 61 (YE/RD). The module then
supplies ground for the run/park relay, which
activates the relay, sending voltage to the low
speed side of the motor, activating the low speed
mode. Low speed mode is exited by selecting a
different state on the switch. When the switch is
Principles Of Operation
placed in the OFF position, the motor continues to
operate until the motor returns to the park position,
The windshield wiper motor is a smart wiper motor
and the Hall-effect sensor senses the motor magnet.
with an integrated electronics module. The internal
The output to the run/park relay deactivates the
components of the motor are the high/low relay,
relay and disconnects the voltage to the motor.
washer pump relay, and the run/park relay and
associated electronics.
Intermittent Wiper Speed Windshield Wipers
The windshield wiper motor receives its inputs from
The intermittent wiper speeds are activated with
the windshield wiper/washer switch. These signals
grounds. They are controlled by the windshield
are ground reference signals. When the switch is
wiper/washer switch inputs through circuits 56
placed in different positions, various input signals
(DB/OG), 58 (WH), and 61 (YE/RD) to the
are selected and sent through circuits to the motor.
windshield wiper motor. The module activates the
The windshield wiper motor module identifies these
run/park relay coil. The high/low relay remains
selected input signals and activates the motor to the
deactivated, supplying the voltage to the motor low
selected function.
speed input and activating the windshield wiper
motor. When the module receives the grounded
input, the motor continues to operate until the
Hall-effect sensor senses the motor magnet, and the
motor returns to the park position. The output to the
run/park relay deactivates the relay and disconnects
the voltage to the motor. The wipers remain parked
until the module completes a time-out and then
repeats the intermittent wiper cycle.
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Software Safe Mode Inspection and Verification
The windshield wiper motor defaults to software 1. Verify the customer concern.
safe mode when the run/park sensor does not sense
the Hall-effect magnet inside the wiper motor. This
can be caused by an obstruction of the windshield
wipers, a binding linkage, or loss of the Hall Visual Inspection Chart
sensor signal. The motor continues to operate in a
high/low speed condition, and when turned off, the
Windshield washer Bussed electrical center
wipers immediately park on the windshield. If
pump hoses (BEC) fuse 10 (30A)
necessary, the wipers can be turned on and off until
Windshield wiper Smart junction box
they return to the park position.
mounting arm and pivot (SJB) fuse 3 (10A)
shaft Circuitry
Washer System
Windshield wiper motor
Windshield washer
The windshield washer is activated by the
pump
windshield wiper motor when it receives a ground
Windshield
signal from the windshield wiper/washer switch
wiper/washer switch
washer input through circuit 680 (LB/OG). When a
ground input is received on the wash request circuit,
the internal module activates the internal
windshield washer relay by grounding the respective
relay coil. When the relay is activated, it supplies
voltage to the washer pump. When the internal
module activates the internal windshield relay, it
also activates the internal run/park relay to operate
the wiper motor.
Symptom Chart
Symptom Chart
The wipers are inoperative Fuse(s) GO to Pinpoint Test A.
Circuitry
Windshield wiper/washer
switch
The low wiper speed does not Windshield wiper motor GO to Pinpoint Test B.
operate correctly high Circuitry
speed OK
The wipers stay on Circuitry GO to Pinpoint Test C.
continuously Windshield wiper motor
switch
The high/low wiper speeds do Windshield wiper motor GO to Pinpoint Test D.
not operate correctly Windshield wiper/washer
(intermittent wiper mode OK) switch
The intermittent wiper speed Circuitry GO to Pinpoint Test E.
does not operate correctly Windshield wiper/washer
(high/low speeds OK) switch
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The wipers will not park at Pivot arm adjustment ADJUST the pivot arms or
the correct position Linkage INSTALL a new windshield
Windshield wiper motor wiper motor. REFER to
Wiper Blade and Pivot Arm
Adjustment or Wiper Motor
in this section.
The wash and wipe function Circuitry GO to Pinpoint Test F.
is inoperative Windshield wiper motor
switch
The wipers do not operate Circuitry GO to Pinpoint Test G.
correctly in the MIST Windshield wiper motor
position Windshield wiper/washer
switch
The washer pump is Circuitry GO to Pinpoint Test H.
inoperative Windshield wiper motor
Windshield washer pump
Fuse(s)
Pinpoint Test A: The Wipers Are Inoperative
Refer to Wiring Diagrams Cell 81, Front Wipers
Circuit 2025 (RD/YE) open or short to ground and Washers for schematic and connector
information.
Circuit 2026 (RD/OG) open or short to ground
Normal Operation Windshield wiper/washer switch
The windshield wiper motor receives inputs from
the windshield wiper/washer switch circuits 56
(DB/OG), 58 (WH), 61 (YE/RD), and 63 (RD). The
internal wiper motor module controls the internal
wiper run/park relay to control the windshield wiper
motor in conjunction with the internal wiper HI/LO
relay. The windshield wiper motor receives voltage
from circuit 2026 (RD/OG) and is grounded through
circuit 1205 (BK). The windshield wiper motor
internal microprocessor and relays receive voltage
from circuit 2025 (RD/YE) and are grounded
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE
A1 CHECK CIRCUIT 2025 (RD/YE) FOR VOLTAGE
Disconnect: Windshield Wiper Motor C125.
Key in ON position.
(Continued)
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PINPOINT TEST A: THE WIPERS ARE INOPERATIVE (Continued)
A1 CHECK CIRCUIT 2025 (RD/YE) FOR VOLTAGE (Continued)
Measure the voltage between the windshield wiper motor
C125-8, circuit 2025 (RD/YE), harness side and ground.
Yes
GO to A3.
No
Is the voltage greater than 10 volts? 3 (10A) is OK. If OK, GO to A2.
A2 CHECK CIRCUIT 2025 (RD/YE) FOR AN OPEN OR A SHORT TO
GROUND
Measure the resistance between the windshield wiper motor
C125-8, circuit 2025 (RD/YE), harness side and the SJB
C2280h-6, circuit 2025 (RD/YE), harness side; and between the
windshield wiper motor C125-8, circuit 2025 (RD/YE), harness
side and ground.
Yes
REPAIR or INSTALL a new SJB. REFER
to Section 419-10. TEST the system for
normal operation.
Are the resistances less than 5 ohms between the
windshield wiper motor and the SJB, and greater than No
10,000 ohms between the windshield wiper motor and REPAIR the circuit. TEST the system for
(Continued)
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A3 CHECK CIRCUIT 2026 (RD/OG) FOR VOLTAGE
Measure the voltage between the windshield wiper motor
C125-5, circuit 2026 (RD/OG), harness side and ground.
Yes
GO to A5.
No
(BEC) fuse 10 (30A) is OK. If OK, GO to
Is the voltage greater than 10 volts? A4.
A4 CHECK CIRCUIT 2026 (RD/OG) FOR AN OPEN OR A SHORT TO
GROUND
Disconnect: BEC C1035d.
C125-5, circuit 2026 (RD/OG), harness side and the BEC
C1035d-A3, circuit 2026 (RD/OG), harness side; and between
the windshield wiper motor C125-5, circuit 2026 (RD/OG),
Yes
REPAIR or INSTALL a new BEC. TEST
Are the resistances less than 5 ohms between the
windshield wiper motor and the BEC, and greater than No
10,000 ohms between the windshield wiper motor and REPAIR the circuit(s). TEST the system
ground? for normal operation.
(Continued)
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A5 CHECK THE WINDSHIELD WIPER MOTOR GROUND
Measure the resistance between the windshield wiper C125-6,
Yes
GO to A6.
No
Disconnect: Windshield Wiper/Washer Switch C2137.
Measure the resistance between the windshield wiper/washer
switch C2137-2, circuit 1205 (BK), harness side and ground.
Yes
GO to A7.
No
A7 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Carry out the windshield wiper/washer switch component test. Yes
Refer to Wiring Diagrams Cell 149 for component testing. GO to A8.
Does the windshield wiper/washer switch pass the
No
component test?
INSTALL a new windshield wiper/washer
switch. REFER to Wiper/Washer Switch in
this section.
A8 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
Disconnect all the windshield wiper motor connectors. Yes
Check for: INSTALL a new windshield wiper motor.
corrosion. REFER to Wiper Motor in this section.
pushed-out pins. TEST the system for normal operation.
Connect all the windshield wiper motor connectors and make
No
sure they seat correctly.
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Possible Causes
Pinpoint Test B: The Low Wiper Speed Does
Not Operate Correctly High Speed OK
and Washers for schematic and connector
information.
Normal Operation
module (internal) controls the wiper run/park relay
(internal) using internal circuitry to control the
windshield wiper motor in conjunction with the
HI/LO relay (internal).
PINPOINT TEST B: THE LOW WIPER SPEED DOES NOT OPERATE CORRECTLY HIGH SPEED OK
B1 CHECK THE WIPERS FOR HIGH SPEED OPERATION
Place the windshield wiper/washer switch in each position. GO to B2.
Do the wipers only operate when the switch is in the high
No
speed position?
GO to Symptom Chart to continue
diagnosis.
B2 CHECK THE LOGIC GROUND CIRCUIT 1205 (BK) FOR AN
OPEN
Yes
GO to B3.
No
B3 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
No
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Possible Causes
Pinpoint Test C: The Wipers Stay On
Continuously
Circuit 56 (DB/OG) short to ground
Circuit 58 (WH) short to ground
Circuit 61 (YE/RD) short to ground
information.
Circuit 63 (RD) short to ground
Normal Operation
Windshield wiper/washer switch
module (internal) controls the run/park relay
windshield wiper motor in conjunction with the
HI/LO relay (internal).
PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY
C1 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Disconnect: Windshield Wiper/Washer Switch C2137. GO to C2.
Carry out the windshield wiper/washer switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing.
component test?
this section.
C2 CHECK CIRCUITS 56 (DB/OG), 58 (WH), 61 (YE/RD), AND 63
(RD) FOR A SHORT TO GROUND
C125, harness side and ground as follows:
Windshield Wiper Motor C125
Pin Circuit
C125-10 56 (DB/OG)
C125-11 58 (WH)
C125-1 63 (RD)
C125-9 61 (YE/RD)
Yes
GO to C3.
No
REPAIR the circuit(s). TEST the system
Are the resistances greater than 10,000 ohms? for normal operation.
(Continued)
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PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY (Continued)
C3 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
No
Pinpoint Test D: The High/Low Wiper Normal Operation
Speeds Do Not Operate Correctly
(Intermittent Wiper Mode OK)
information.
motor in conjunction with the HI/LO relay
(internal).
Possible Causes
PINPOINT TEST D: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY (INTERMITTENT
WIPER MODE OK)
D1 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Disconnect: Windshield Wiper/Washer Switch C2137. GO to D2.
No
component test?
this section.
D2 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
No
Pinpoint Test E: The Intermittent Wiper Normal Operation
Speed Does Not Operate Correctly
(High/Low Speeds OK)
information.
motor in conjunction with the HI/LO relay
(internal).
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Possible Causes
Circuit 58 (WH) open
PINPOINT TEST E: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY (HIGH/LOW
SPEEDS OK)
E1 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Disconnect: Windshield Wiper/Washer Switch C2137. GO to E2.
No
component test?
this section.
E2 CHECK CIRCUIT 58 (WH) FOR AN OPEN
switch C2137-1, circuit 58 (WH), harness side, and the
windshield wiper motor connector C125-11, circuit 58 (WH),
harness side.
Yes
GO to E3.
No
E3 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
No
Pinpoint Test F: The Wash and Wipe Normal Operation
Function Is Inoperative
The mist function is activated when the module
(internal) receives a reference signal through circuit
680 (LB/OG). When the wash button is pressed for
longer than 0.25 second, the windshield wiper motor
information.
cycles, sending battery voltage through circuit 941
(BK/WH) to the washer pump motor.
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Possible Causes
Circuit 680 (LB/OG) open
PINPOINT TEST F: THE WASH AND WIPE FUNCTION IS INOPERATIVE
F1 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Disconnect: Windshield Wiper/Washer Switch C2137. GO to F2.
No
component test?
this section.
F2 CHECK CIRCUIT 680 (LB/OG) FOR AN OPEN
switch C2137-5, circuit 680 (LB/OG), harness side and the
windshield wiper motor C125-12, circuit 680 (LB/OG), harness
side.
Yes
GO to F3.
No
F3 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
No
Pinpoint Test G: The Wipers Do Not Operate Normal Operation
Correctly in the MIST Position
(DB/OG), 63 (RD), and 680 (LB/OG). The module
(internal) controls the wiper run/park relay (internal)
information.
using internal circuitry to control the motor in
conjunction with the HI/LO relay (internal).
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Possible Causes
Circuit 680 (LB/OG) open
Circuit 56 (DB/OG) open Windshield wiper/washer switch
Circuit 61 (YE/RD) open Windshield wiper motor
PINPOINT TEST G: THE WIPERS DO NOT OPERATE CORRECTLY IN THE MIST POSITION
G1 CHECK THE WIPERS FOR LOW SPEED OPERATION
Place the windshield wiper/washer switch in the low speed GO to G2.
position.
No
Do the wipers operate correctly in the low speed position?
GO to Symptom Chart to continue
diagnosis.
G2 CHECK CIRCUITS 56 (DB/OG), 61 (YE/RD), AND 680 (LB/OG)
FOR AN OPEN
Disconnect: Windshield Wiper/Washer Switch C2137.
C125-10, circuit 56 (DB/OG), harness side and the windshield
wiper/washer switch C2137-12, circuit 56 (DB/OG), harness
side; between the windshield wiper motor C125-9, circuit 61
(YE/RD), harness side and the windshield wiper/washer switch
C2137-6, circuit 61 (YE/RD), harness side; and between the
windshield wiper motor C125-12, circuit 680 (LB/OG), harness
side and the windshield wiper/washer switch C2137-5, circuit
680 (LB/OG), harness side
Yes
GO to G3.
No
REPAIR the circuit(s). TEST the system
Are the resistances less than 5 ohms? for normal operation.
G3 CHECK THE WINDSHIELD WIPER/WASHER SWITCH
Carry out the windshield wiper/washer switch component test. GO to G4.
No
component test?
this section.
G4 CHECK FOR CORRECT WIPER MOTOR OPERATION
No
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Possible Causes
Pinpoint Test H: The Washer Pump Is
Inoperative
Circuit 941 (BK/WH) open or short to ground
information.
Normal Operation
The windshield wiper/washer switch sends a
reference signal through circuit 680 (LB/OG) to the
module (internal). The module then sends battery
voltage through circuit 941 (BK/WH) to the
windshield washer pump motor, which uses circuit
1205 (BK) for a ground to activate the windshield
washer pump.
PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE
H1 CHECK THE WINDSHIELD WASHER PUMP FOR VOLTAGE
Disconnect: Windshield Washer Pump C137.
Key in ON position.
Measure the voltage between the windshield washer pump
C137-1, circuit 941 (BK/WH) harness side and ground while
pressing the windshield wiper/washer switch to the wash
position.
Yes
GO to H4.
No
Is the voltage greater than 10 volts? GO to H2.
H2 CHECK CIRCUIT 941 (BK/WH) FOR AN OPEN OR A SHORT TO
GROUND
(Continued)
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PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE (Continued)
H2 CHECK CIRCUIT 941 (BK/WH) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
connector C125-7, circuit 941 (BK/WH), harness side and the
windshield washer pump connector C137-1, circuit 941 (BK/WH),
harness side.
Yes
GO to H3.
No
Measure the resistance between the windshield washer pump
Yes
REPLACE the windshield washer pump.
REFER to Washer Pump and Reservoir in
this section.
No
H4 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
Disconnect the windshield wiper motor connectors. Yes
No
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Component Test Wiper Motor
CAUTION: Do not handle the windshield
wiper motor roughly when diagnosing the wiper
operation. Failure to follow this caution may
cause damage to the motor magnets, which
results in an inoperative motor. Rough handling
of new windshield wiper motors can also
damage the motor magnets.
NOTE: The windshield wiper motor component test
determines if the windshield wiper motor and
module are functional and not in software safe
mode. Refer to Principles of Operation in this
section for software safe mode parameters.
NOTE: Battery voltage must remain within 10 to
15 volts to carry out the test and keep the
windshield wiper motor from entering its software
safe mode.
NOTE: When connecting the voltage and ground
test leads to the windshield wiper motor terminals,
care must be taken not to short the terminals
between voltage and ground. Make sure the logic
ground, pin 3, is always securely connected to
prevent permanent damage to the windshield wiper
motor.
The following component test checks the motor out Disconnect the windshield wiper motor connector
of the vehicle. C125 from the windshield wiper motor. Connect the
(1) green lead from the (2) SABRE to the battery
Use the SABRE Premium Battery and Electrical
ground (-) post. Connect the red lead (3) from the
System Tester to test the windshield wiper motor.
SABRE to the wiper motor (4) component side
connector, ground and logic ground pins 6 and 3
(3). Connect the battery positive cable (5) to the
windshield wiper motor (4) component side
connector, battery and logic positive pins 5 and 8
(5).
Low Speed
Test the low speed mode by connecting a separate
set of test leads from the battery ground (-) post to
windshield wiper motor (4) component side, pins 9
and 10 (6). When these pins are grounded, the
windshield wiper motor operation is in low speed
mode.
High Speed
Test the high speed mode by connecting a separate
set of test leads from the battery ground (-) post to
the windshield wiper motor (4) component side,
pins 1, 9, and 10 (7). When these pins are
grounded, the windshield wiper motor operation is
in high speed mode.
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Washer Pump Relay (Integral)
If the windshield wiper motor does not pass all of
Test the windshield wiper motor internal washer
the tests, install a new windshield wiper motor.
relay function by measuring the voltage between the
Refer to Wiper Motor in this section. If the
windshield wiper motor (4) component side, pin 7
windshield wiper motor passes all the tests, measure
(8) and ground while grounding the windshield
the resistance of all circuits on the wiper motor
wiper motor (4) component side, pin 12 (9). When
harness and repair as necessary.
wash command input pin 12 is grounded, measured
voltage should read 10 volts or greater.
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Windshield wiper blades
Wipers and Washers
The wiper and washer system consists of the
Windshield wiper mounting arm and pivot shaft
Wiper pivot arms
Windshield washer nozzle and bracket
Windshield washer fluid reservoir
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502-00-1 502-00-1 Uni-Body, Subframe and Mounting System
GENERAL PROCEDURES
Body Misalignment Check
1. CAUTION: Do not attempt to correct
any serious misalignment with one
pulling/pushing operation. Damage to the
structure may occur.
NOTE: All body alignment measurements are
made without trim, and from metal to metal.
To check the body alignment, take 2 opposite
diagonal measurements between the front,
center or rear pillars. Take the measurements
between reference points, such as crease lines
or weld joints which are diagonally opposite
each other on the 2 pillars being measured.
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Crossmember Front
3. Loosen the A/C line bracket nut and release the
A/C line bracket from the front crossmember.
1 W520213 Front stabilizer bar bracket
nuts (4 required) To install, tighten to 7 Nm (62 lb-in).
2 W707246 Front crossmember nuts (4
required) 4. Release the power steering line locator from the
crossmember.
3 5019 Front crossmember
5. Using a suitable tool, support the radiator.
6. Remove the 4 front stabilizer bar bracket nuts.
Section 100-02.
7. NOTE: Two technicians are needed to carry
out this step.
2. Release the brake line from the 2 clips on the
front crossmember.
Remove the 4 nuts and the front crossmember.
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The front crossmember is bolted to the body and is
Frame Assembly
used to:
Underbody misalignment can affect front and rear
wheel alignment, the operation of the suspension
aid in structural support.
parts and drivetrain operation. Window glass cracks,
provide a mounting surface for the front stabilizer
door and window opening concerns, and air or
bar.
water leaks at the doors are often caused by
support the radiator, cooling fan and evaporator.
improperly tightened bolts and body misalignment.
The rear support braces are:
Every structural member and outer panel is designed
to offer the maximum protection in the event of a
used to aid in structural support.
collision.
designed to aid in protection of a collision.
The front subframe is bolted to the body and is
designed to aid stability in handling.
used to:
equipped on convertible models only.
aid in structural support.
provide mounting surfaces for the front
suspension control arms.
provide a mounting point for the engine isolators.
provide a mounting surface for the steering gear.
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SPECIFICATIONS
Description Nm lb-ft lb-in shaft coupling bolt
A/C line bracket nut 7 62 Power steering bracket 47 35
bolt
Engine insulator nuts 55 41
Power steering line 11 8
Front crossmember 115 85
support bracket bolt
nuts
Front stabilizer bar 70 52
bolts (convertible)
bracket nuts
Front subframe bolts 115 85
bolts (upper)
(rear)
(convertible)
Front subframe nuts 115 85
(front)
Lower ball joint nuts 103 76
and bolts
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6. NOTE: Using the taller adapters, support the
Subframe Front, 4.0L
special tool on the shock towers.
Special Tool(s) Install the special tool.
303-F072
Lifting Bracket Set, Engine
303-050 (T70P-6000)
7. Using the special tool, raise and support the
engine.
shaft coupling bolt.
Section 100-02.
9. Separate the lower steering column shaft from
the steering gear.
10. Remove the power steering line support bracket
bolt.
4. Remove the power steering bracket bolt and
11. CAUTION: Support the steering gear
with safety wire or damage to the steering
gear may occur.
Remove the 2 steering gear bolts and position
the steering gear aside.
12. Remove the 2 lower ball joint nuts and bolts.
13. Separate the 2 lower ball joints from the
steering knuckles.
14. With a suitable tool, support the subframe.
15. Remove the 4 front subframe bolts at the torque
5. Remove the 2 engine insulator nuts.
box.
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16. Remove the 4 front subframe nuts. 18. NOTE: Use a suitable alignment tool with a 15
mm (0.59 in) outside diameter shaft that is long
enough to go through the subframe and body.
Align the subframe to the body before
tightening the subframe bolts and nuts to
out this step.
specification.
Lower and remove the front subframe.
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6. NOTE: Using the taller adapters, support the
special tool on the shock towers.
Special Tool(s) Install the special tool.
303-F072
Lifting Bracket Set, Engine
303-050 (T70P-6000)
7. Using the special tool, raise and support the
engine.
shaft coupling bolt.
Section 100-02.
9. Separate the lower steering column shaft from
the steering gear.
bolt.
gear may occur.
12. Remove the 2 lower ball joint nuts and bolts.
13. Separate the 2 lower ball joints from the
steering knuckles.
5. Remove the 2 engine insulator nuts.
14. With a suitable tool, support the subframe.
15. Remove the 4 front subframe bolts at the torque
box.
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16. Remove the 4 front subframe nuts. 18. NOTE: Using a suitable alignment tool with a
15 mm (0.59 in) outside diameter shaft that is
long enough to go through the subframe and
body. Align the subframe to the body before
tightening the subframe bolts and nuts to
out this step.
specification.
Lower and remove the front subframe.
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Special Tool(s)
303-F072
required)
303-D087 (D93P-6001-A1)
6. Remove the LH and RH engine insulator nuts.
303-F070
supercharger (SC) and the 3-bar support and
the vehicle hood.
coupling bolt.
Section 100-02.
bolt.
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15. Remove the 4 front subframe nuts.
gear may occur.
NOTE: The engine must be lifted enough to
allow the LH bolt to be removed.
NOTE: The steering gear must be secured
loosely with safety wire to allow subframe
removal.
To ins

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INTRODUCTION

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