Ford Fiesta Workshop Manual 2011 PDF

Ford Fiesta 2011
Workshop Manual & Wiring Diagrams
2004,2005,2006,2007,2008,2009,2010,2011,2012 Free Software Foundation,Inc.

SECTION 100-00: Service Information 2011 Fiesta Workshop Manual
DESCRIPTION AND OPERATION Procedure revision date: 08/09/2011
Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component
movements can be rotational or 1-3 dimensional movements.
Item Description
1 Minor component movement clockwise or counterclockwise
2 Major component movement clockwise or counterclockwise
3 Component movement to the left, right, up, or down
4 Component movement towards or away
5 3 dimensional component movement
6 2 dimensional component movement
7 3 dimensional component rotation
8 3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
Item Description
1 Turn the component clockwise through 45°
2 Turn the component counterclockwise through 45°
7 Turn the component clockwise through 2 complete turns
8 Turn the component counterclockwise through 2 complete turns
Steering Wheel Symbols
Steering wheel symbols are used to provide further information to a required steering wheel position or steering
column lock status.
Item Description
1 Steering wheel in straight ahead position
2 Steering column locked
3 Steering column unlocked
4 Rotate steering wheel 90° left from center
5 Rotate steering wheel 90° right from center
6 Turn steering wheel fully counterclockwise to stop
7 Turn steering wheel fully clockwise to stop
Body Types
Body type symbols are used to identify different body configurations.
Item Description
1 3, 4, 5-door body style
2 Wagon body style
3 Sport Utility Vehicle (SUV) body style
4 Coupe body style
5 Convertible body style
6 Van body style
7 3, 4, 5-door body style - Top View
8 Wagon body style - Top View
9 Underbody view
10 Right-hand drive (RHD) vehicle
11 Left-hand drive (LHD) vehicle
Gearshift Lever Position Symbols
Gearshift lever position symbols are used to show the gear position required for the procedure.
Item Description
1 Set the selector lever to the park (P) position
2 Set the selector lever to the reverse (R) position
3 Set the selector lever to the neutral (N) position
4 Set the selector lever to the drive (D) position
5 Set the selector lever with manual shift option to the drive (D) position
6 Set the selector lever with manual shift option to the manual (M) position
7 Set the selector lever with manual shift option to the shift down (-) position
8 Set the selector lever with manual shift option to the shift up (+) position
9 Set the manual shift lever to the neutral (N) position
10 Set the manual shift lever to indicated gear position (all possible gears shown here)
Screwdriver Symbols
The screwdriver symbols are used to indicate which screwdriver bit is required for the procedure step.
Item Description
1 Screwdriver
2 Phillips or cross-bladed screwdriver
3 Flat-bladed screwdriver
4 Hexagonal or Allen screwdriver
5 TORX screwdriver
Plier Symbols
The plier symbols are used to indicate which plier is required for the procedure step.
Item Description
1 Combination pliers
2 Side cutter pliers
3 Internal snap-ring pliers
4 External snap-ring pliers
5 Hose clamping pliers
6 Locking pliers
7 Long or Needle-nosed pliers
Drilling and Threading Tool Symbols
The drilling or threading tool symbols are used to indicate which type and size drill, thread-cutting device, or file
is required for the procedure.
Item Description
1 Drill bit with a specified diameter
2 Hole saw with a specified diameter
3 Stepped drill bit using a specified step diameter
4 Tap with a specified diameter
5 Die with a specified diameter
6 File or de-burring tool for circular holes
7 File or de-burring tool
Cutting Tool Symbols
The cutting tool symbols are used to indicate which type of cutting tool is used for the procedure.
Item Description
1 Box-cutter or cutting knife
2 Pneumatic body saw
3 Scissors
4 Grinder
5 Jig saw
6 Plasma cutter
7 Sanding block or paper
8 Drill through the indicated number of body layers with the specified diameter drill bit
9 Drill through the indicated number of body layers with an appropriate size drill bit
10 Drill through first body layer with the specified diameter drill bit
11 Drill through first body layer with an appropriate size drill bit
12 Wire brush
Apply Chemicals, Lubricants, or Clamping Load Symbols
The apply chemicals, lubricants or clamping load symbols are used to direct the application of chemicals,
lubricants, or loads for the procedure.
Item Description
1 Apply a bead from the specified tube
2 Apply a bead from the specified cartridge
3 Apply the specified chemical with a brush
4 Apply the specified clamping load to the specified component
5 Apply the specified diameter bead from the specified tube
6 Apply the specified diameter bead from the specified cartridge
7 Apply the specified chemical with a roller
8 Apply hot glue to the specified component
9 Apply the specified amount of fluid
10 Apply the fluid
11 Clean the specified component with the specified material
12 Apply a broken bead of the specified diameter
13 Apply the specified chemical with a spray can
14 Apply the specified lubricant to the specified component
15 Spot weld the specified component
16 Apply a continuous line of weld to the specified component
17 Apply the fluid with a syringe
18 Extract the fluid with a syringe
Measurement Symbols
The measurement symbols are used to show which measurement will be made at a specified point.
Item Description
1 Measure the amperage using a digital multimeter
2 Measure the voltage using a digital multimeter
3 Measure the resistance using a digital multimeter
4 Measure the length or distance
5 Check that the specified pressure is available using a suitable pressure gauge
6 Measure the pressure at the specified port using a suitable pressure gauge
7 Measure the time with a stopwatch
8 Wait for the indicating amount of time
9 The minimum temperature for the specified task
10 The maximum temperature for the specified task
11 The allowable temperature range for the specified task
12 The required temperature for the task
13 Measure for the specified movement
14 Measure for movement not to exceed specified amount
15 Measure for the miniumum-specified movement
General Equipment Symbols
The general equipment symbols specify which general equipment is used to carry out the procedure.
Item Description
1 Hot air gun
2 Soldering iron
3 Putty knife or scraper
4 Awl or scriber
5 Hold-down or securing strap
6 File with specified size
7 Center punch
8 Marker
9 Metal Inert Gas (MIG) welder
10 Hose clamp
11 Trim tool
12 Shop vacuum
13 Strap wrench
14 Wedge
15 Pin punch
Material Symbols
The material symbols are used to indicate where to use the specified material.
Item Description
1 Remove or install a pop-rivet
2 Apply tape to specified area
3 Remove or install a cable tie
Miscellaneous Symbols
These symbols provide miscellaneous information required for the procedure.

Item Description
1 Turn Ignition off
2 Turn Ignition on (run position)
3 This procedure requires the specified number of technicians
4 Respirator or self-contained breathing apparatus
5 Prohibited action used in combination with another symbol
6 Do not use power tools
7 Visual inspection
8 Noise check
9 Dispose the specified component
10 Dispose the specified component
11 Set engine speed to the specified RPM
12 Firmly apply the parking brake
13 Fully release the parking brake
14 Special disposal required
15 Visually inspect using a mirror
16 Area or component must be dry
Mandatory Protective Equipment
The protective equipment symbols indicate required safety equipment to avoid or reduce health and safety
risks.
Item Description
1 Wear protective gloves
2 Wear face shield
3 Wear safety goggles
4 Wear ear protection
5 Wear safety goggles and ear protection
6 Wear a respirator
Prohibition Symbols — Health, Safety, and Component Care
The prohibition symbols are used to prohibit specified actions to avoid safety hazards or component damage.
Item Description
1 Prohibited action used in combination with another symbol
2 No open flames
3 No smoking
4 No water
5 Do not touch
6 Do not switch
7 No grinding
Warning Symbols — Health and Safety Warnings or Component Care
The warning symbols are used to avoid hazardous conditions and to avoid component damage.
Item Description
1 Hazardous voltage or Electrical shock or Electrocution danger
2 Fire hazard or highly flammable
3 Burn hazard or hot surface
4 Device has automatic start-up
5 Toxic
6 Explosive material
7 Battery hazard
8 Corrosive material
9 Lifting hazard
10 Hand crush or force from above hazard
11 Cutting of fingers or hand hazard
12 Pressure hazard
13 Invisible laser radiation. Do not view directly with optical instruments (magnifiers). Class 1M laser
product.
System Diagram Symbols
The symbols provide Information about networks or wiring.

Item Description
1 Medium Speed Controller Area Network
2 High Speed Controller Area Network
3 Local Interconnect Network
4 Wires cross but are not connected
Using This Manual
Introduction
This manual describes and directs repair procedures for this vehicle model year. It includes diagnostics
for all vehicle systems except driveability and emission control. Refer to the separate Powertrain
Control/Emissions Diagnosis (PC/ED) manual for driveability and emission control diagnostics.
Information is organized into groups, with sections that have subsections dividing them.
Warnings, Notices, and Notes in This Manual
Warnings provide information to avoid personal injury and to make sure service actions on critical safety
systems are performed correctly.
Notices provide information to avoid damage to the vehicle or a component.
Notes provide information critical for a complete and effective repair.
Warnings that apply to an entire system or workshop manual section are located in section 100-00
Description and Operation Safety Warnings .
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the
procedure.
Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step. Those
that apply to a group of steps will be placed at the first step requiring it.
Vehicle and Engine Orientation Identifiers
LH and RH vehicle designations are oriented from the driver's seat position looking forward. LH and RH
engine designations are oriented from the flywheel position looking towards the crankshaft pulley.
How to Use Diagnostic Information
DTC and Symptom Charts
Module DTC Charts are used to begin and direct the diagnosis of a DTC. Symptom Charts contain
concern symptoms and direct solutions either in the chart or in a linked Diagnostic Routine. Both DTC
and Symptom Charts may provide the solution within the chart, or provide a link to the appropriate
Diagnostic Routine.
In some sections, the Symptom Chart is preceded by a Preliminary Inspection which must be followed
prior to using the Symptom Chart
Using Module DTC Charts
This Workshop Manual contains diagnostics for DTCs set by vehicle modules. Driveability and emission
DTCs are covered in the separate Powertrain Control/Emissions Diagnosis (PC/ED) manual. If a PCM-
set DTC is not listed in the Workshop Manual, it is serviced in the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
DTC diagnostics are found in both on-line and printed publications and are used as follows:
On-line publications: Using the left side menu, click on the Master DTC Chart link to view the
vehicle module DTC charts. Each module has a chart with links or in-chart solutions for all DTCs
diagnosed in the Workshop Manual.
Printed publications: Use the DTC index in the rear of the book.
Diagnostic Methods
Diagnostic Methods provides information to support diagnosing Ford vehicles. Diagnostic strategies,
diagnostic tool support information, and advanced circuit testing methods are included. REFER to
Diagnostic Methods .
Diagnostic Routines
Diagnostic Routines provide information to determine the root cause of concerns addressed in either a
DTC Chart or Symptom Chart. Each Diagnostic Routine contains:
Diagnostic Overview
Wiring Diagram References (as applicable)
Normal Operation and Fault Conditions
Visual Inspection and Diagnostic Pre-checks
Tool Table (as applicable)
Material Table (as applicable)
Pinpoint Test Steps
Component Tests
Component Tests are used to separately analyze a single common component in a system. The test will
determine if the part is functioning correctly.
Mechanical Procedures Such As Removal and Installation
Reuse Of Fasteners, Seals, Or Gaskets
The following is a list of assumptions made in the reuse of fasteners, seals, or gaskets.
Seals and gaskets must be replaced unless otherwise specified.

Standard fasteners are reused unless otherwise specified.
Fasteners with self-locking features must be replaced unless otherwise noted. Reminder text may
or may not be included with the procedure step. Examples of fastener coatings or fasteners with
mechanical locking (with the locking features highlighted yellow) are shown in illustration 1.
Torque to yield bolts (bolts with more than one stage of tightening torque and a final torque angle
specification) must be discarded and new torque to yield bolts installed unless otherwise stated
within the procedure.
Illustration 1 - self-locking coatings or locking feature are highlighted yellow

Graphics
Illustrations in this manual may be used to replace written step instructions. Color-coding (see color
scheme in this document) is used to communicate the required step action or actions. Service action
icons (see Symbols Glossary ) are used to add additional information regarding the required action.
The color scheme in a step graphic (an illustration used in removal or installation steps) indicates
servicing information as follows:
Fasteners (including panel retainers) or electrical connectors — Magenta (Purple)
Target component that is to be removed — Blue
Components that must be removed prior to the target component shown in blue — Brown
or Green
Components placed aside for access, but not removed; highlighted areas such as
inspection areas, adjustments or measurements — Yellow
Essential Special Service Tools (ESSTs) and other tools — Pale Blue
Chemical or Sealer apply areas — Alternating blue and white dashes (see illustration 4)
Sectioned or cut-away areas — Red
Remaining components — Grey
Callouts in graphics indicate removal (or tightening) order, or identify individual instructions in substeps
of the same number (such as different torque values).
Arrows containing x numbers (Illustration 2) indicate the number of identical fasteners or connectors to
be removed or installed in the graphic.
In Illustration 2, two identical fasteners are indicated by the x2 arrow, with another arrow illustrating a
third fastener of a different type. Because the different fasteners require different torques, callouts are
used to identify those two torque values in the associated step text. The hose clamp is another fastener
to be removed. The yellow coloring of the hose indicates it is to be moved aside (not removed).
The following written steps would be necessary if the illustration did not have color coding:
1. Remove the engine oil pipe fastener at the engine connection.
2. Remove the two engine oil pipe fasteners from the turbocharger and remove the pipe.
3. Remove the air inlet hose from the turbocharger and position aside.
Illustration 2
Hidden fasteners, such as panel retainers, are identified in the illustration by a magenta disc. An inset
detail view illustrating the fastener type may be included (Illustration 3).
Illustration 3 — Note motion arrow at panel bottom; it indicates to lift panel up, then move inward
to remove
Symbols
Symbols may be used inside graphics or in the text area to communicate service actions. The following
examples demonstrate the use of some of these symbols. REFER to Symbols Glossary for a complete
symbols list with explanations.
In the Illustration 4 example, service action symbols are shown as used to direct the application of
sealer, lubricant, weight, tape or cleaning detergent to a component. In this example a bead diameter of
“xx” millimeters is prescribed. The blue and white dashes indicate where the material is applied.
Illustration 4
Illustration 5 is an example of location symbols used to show the location of a component or system
within the vehicle.
Illustration 5
Illustration 6 shows how gearshift lever or selector lever position symbols may be used to indicate the
gearshift lever or selector lever position required. The required Essential Special Service Tool to align
the shift mechanism is shown in pale blue and identified by ESST number.
Illustration 6
Callouts or arrows may be used to identify components for supporting special information, such as a
required sequence or to indicate a number of identical components. Illustration 7 shows a removal order
in the top graphic and the bottom graphic indicates 12 identical bolts.
Illustration 7
Standard tool symbols direct the use of standard tools to perform a service action, such as the cutting of
carpet shown in Illustration 8. Tool symbols may include dimensional values (for example, a drill with a
specified diameter).
Illustration 8
Safety Warnings
Heating, Ventilation and Air Conditioning Safety Warnings
WARNING: Take the following precautions when repairing an air conditioning system
containing R-134a:
Always wear safety goggles.

Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°
F) under atmospheric pressure and will freeze skin tissue.
Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will
displace the oxygen needed to support life.
Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all
normal conditions, but it decomposes when exposed to high temperatures such as a torch
flame. During decomposition it releases irritating and toxic gasses (as described in the
MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid,
carbon dioxide and water.
Failure to follow these instructions may result in serious personal injury.
WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait
until engine is fully cool. Failure to comply with this warning may result in serious injury or burns
from hot liquid escaping from the engine cooling system.
WARNING: Use extreme care and observe all safety and service precautions related to the
use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment.
Battery System Service Warnings
WARNING: Always disconnect the battery ground cable at the battery before disconnecting
the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal,
the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may
result in serious personal injury.
WARNING: Before carrying out maintenance on the starting system, disconnect the battery
ground cable from the frame to completely isolate the starter from the dual frame-mounted
batteries. Failure to follow this instruction may result in serious personal injury.
WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-
ventilated area. Do not allow the battery to come in contact with flames, sparks or burning
substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery
to protect against possible splashing of acid solution. In case of acid contact with skin or eyes,
flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If
acid is swallowed, call a physician immediately. Failure to follow these instructions may result in
serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on
opposite corners. Excessive pressure on the battery end walls may cause acid to flow through
the vent caps, resulting in personal injury and/or damage to the vehicle or battery.
WARNING: Do not get underneath the frame-mounted battery when disconnecting or

connecting the auxiliary battery safety straps. The battery is heavy and could fall. Failure to
follow this instruction may result in serious personal injury.
WARNING: Battery posts, terminals and related accessories contain lead and lead
components. Wash hands after handling. Failure to follow these instructions may result in
Brake System Service Warnings
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's
specification. Additionally, do not use brake fluid that has been previously drained. Following
these instructions will help prevent system contamination, brake component damage and the
risk of serious personal injury.
WARNING: Do not use any brake fluid other than DOT 3 for Hydro-Boost® and DOT 4 for
Hydro-Max®. Incorrect fluid may result in permanent damage to brake components and an
inoperative brake system. Failure to follow these instructions may result in serious injury to
vehicle occupant(s).
WARNING: Do not breathe dust or use compressed air to blow dust from storage
containers or friction components. Remove dust using government-approved techniques.
Friction component dust may be a cancer and lung disease hazard. Exposure to potentially
hazardous components may occur if dusts are created during repair of friction components,
such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and
respiratory tract, and may cause allergic reactions and/or may lead to other chronic health
effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions
may result in serious personal injury.
WARNING: Remove air pressure from the air brake system prior to servicing the system.
Attempting to service the air brake system while it is under pneumatic pressure may result in
serious injury from unexpected hose whip, component movement or component propulsion.
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
Body and Frame Service Warnings
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and
wear protective equipment as directed. Examples may include but are not limited to respirators
and chemically resistant gloves. Failure to follow these instructions may result in serious
personal injury.
WARNING: Always wear protective equipment including eye protection with side shields,
and a dust mask when sanding or grinding. Failure to follow these instructions may result in
WARNING: On vehicles equipped with Safety Canopy® options, prior to carrying out any
sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety
Canopy® module and related components. Failure to comply may result in accidental
deployment or damage to the Safety Canopy®. Refer to Section 501-20B . Failure to follow these
instructions may result in serious injury to technician or vehicle occupant(s).
WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in
incorrect operation of restraint devices. For additional restraints anchoring location information,
refer to Section 501-20A and Section 501-20B . Failure to follow these instructions may result in
serious injury to vehicle occupant(s).
WARNING: Do not carry out body side sectioning repairs in areas of laser welds. Factory
laser welds cannot be duplicated with conventional welding equipment and structural integrity
may be compromised. Failure to follow this instruction may result in serious injury to vehicle
occupant(s).
WARNING: Do not carry out body side sectioning repairs in areas of door hinge or striker
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may
compromise structural integrity during a collision. Failure to follow these instructions may result
in serious injury to vehicle occupant(s).
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected
eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of
the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses
of the deepest shade providing adequate visibility are recommended. It is strongly recommended
that persons working in the weld area wear flash safety goggles. Also wear protective clothing.
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and
the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the
mounting areas to the original production configuration. A new RCM and sensors must be
installed whether or not the air bags have deployed. Failure to follow these instructions may
result in serious personal injury or death in a crash.
WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part
of the vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer.
Failure to follow this instruction may compromise vehicle crash integrity and increase the risk of
personal injury in a rear end collision.
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned,
salvaged or damaged vehicles. The use of such parts could lead to serious injury.
Never use non-Ford parts or accessories for completing repairs.
Ford Motor Company does not approve or recognize body and structural repair procedures,
tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety,
quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to
serious personal injury as they may contain damage which is not visible.
Ford does not approve use of the following:
Salvaged or used parts

Major body clips or assemblies from salvage vehicles
Aftermarket structural or body components
Salvaged or reconditioned wheels
Used supplemental restraint system (SRS) components
air bags
restraint system modules
safety belts, buckles or retractors
crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are
carried out by skilled technicians using new genuine Ford parts and Ford-approved methods.
Structural component repair procedures approved by Ford, using genuine Ford parts, have been
validated by Ford Motor Company engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations
regarding structural repairs (frames, rails, aprons and body panels) carried out using non-
genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no
representations that the vehicle will meet any crash safety or anti-corrosion performance
requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's
requirements for safety, performance, strength, quality, durability and corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed
using alternative structural component repair procedures and/or parts.
Engine Cooling System Service Warnings
WARNING: Always allow the engine to cool before opening the cooling system. Do not
unscrew the coolant pressure relief cap when the engine is operating or the cooling system is
hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when
the cap is loosened slightly. Failure to follow these instructions may result in serious personal
injury.
Fuel System Service Warnings
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the
fuel system remains under high pressure, even when the engine is not running. Failure to follow
this instruction may result in serious personal injury.
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when
working on or near any fuel-related component. Highly flammable mixtures are always present
and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue
may ignite when the engine is returned to operation. Failure to follow this instruction may result
in serious personal injury.
WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric
shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring
supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared
in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other
ignition sources. Failure to follow these instructions may result in serious personal injury.
WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the
fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely
removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions
WARNING: Do not work on the fuel system until the pressure has been released and the
engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure.
High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow
these instructions may result in serious personal injury.
WARNING: Avoid contact with fuel during a visual inspection for fuel leaks with the engine
running. Do not work on the fuel system until the pressure has been released and the engine has
cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure
fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these
instructions may result in serious personal injury.
General Service Warnings
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock
absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this
WARNING: Carefully read cautionary 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 these instructions may result in serious personal
injury.
WARNING: Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly
when removing fasteners. Failure to follow this instruction may result in injured fingers.
WARNING: Keep solvents away from ignition sources. Solvents may be flammable and can
ignite or explode if not handled correctly. Failure to follow this instruction may result in serious
personal injury.
WARNING: Place a shop towel between the hands and the exterior mirror glass for
protection in case of glass breakage during mirror service. Failure to follow this instruction may
WARNING: Use only a type-D fire extinguisher to extinguish magnesium fires. Never
attempt to use a type-A, -B, -C extinguisher, or water, as these items are ineffective and may
accelerate a magnesium fire. Failure to follow these instructions may result in serious personal
injury.
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to
raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the
jack or jackstand. Failure to follow this instruction may result in serious personal injury.
WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-
body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle
shifting or falling. Failure to follow this instruction may result in serious personal injury.
WARNING: Install only FCC-approved radio transmitting equipment. See your authorized
radio dealer for the correct transmitter. Use of incorrect transmitting equipment may cause the
vehicle to malfunction or stall, resulting in loss of power brake and power steering assist. Failure
to follow these instructions may result in serious personal injury to vehicle occupant(s).
WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the
driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground
could cause unexpected vehicle movement. Failure to follow this instruction may result in
WARNING: Do not operate the engine with the hood open until the fan blade has been
examined for possible cracks and separation. A damaged fan can separate during operation.
Failure to follow this instruction may result in serious personal injury.
WARNING: Do not stand in line with or near the engine cooling fan blade when revving the
engine. A damaged fan can separate during operation. Failure to follow this instruction may
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground.
Set the parking brake if the rear wheels will remain on the ground. These actions help prevent
unintended vehicle movement. Failure to follow these instructions may result in serious personal
injury.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing high-
voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage
traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in
serious personal injury or death.
WARNING: Vehicles with engine auto start-stop technology may start automatically with the
ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating
engine parts. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear high-voltage insulated safety gloves and a face shield when working with
high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the
appropriate safety and protection rating. Inspect the gloves before use and always wear them
with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for
high-voltage. Failure to follow these instructions may result in serious personal injury or death.
WARNING: Depower the high-voltage traction battery (HVTB) before carrying out any
removal or installation procedures affecting the high-voltage battery system. Failure to follow
this instruction may result in serious personal injury or death.
WARNING: Secure the torque converter in the transmission during removal or installation.
The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to
follow this instruction may result in serious personal injury.
WARNING: When using compressed air, never let air pressure exceed 172 kPa (25 psi) and
always wear safety glasses. Compressed air may cause foreign material or parts to become
airborne. Failure to follow this instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed
or sharp edges. Failure to follow this instruction may result in serious personal injury.
WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting
or placing any object under the vehicle.
Never place your hand between the power running board and the vehicle. Extended power
running boards will retract when doors are closed.
WARNING: Disconnect the window regulator motor connector before working inside the
vehicle doors. Service actions inside the door (such as door latch, handle or lock cylinder
service) or operating the remote keyless entry (RKE) fob may activate the windows on vehicles
equipped with global open/close. Serious injury to hands or arms may occur if a window motor is
activated during service. Failure to follow these instructions may result in serious personal
injury.
Safety Restraints Service Warnings
WARNING: Anytime the Safety Canopy® or side air curtain module has deployed, a new
headliner and new A-, B- and C-pillar upper trim panels and attaching hardware must be
installed. Remove any other damaged components and hardware and install new components
and hardware as needed. Failure to follow these instructions may result in the Safety Canopy® or
side air curtain module deploying incorrectly and increases the risk of serious personal injury or
death in a crash.
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags,
pretensioners, load limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away
to make sure of personal safety. Due to the loud report which occurs when an SRS device is
deployed, hearing protection is required. Failure to follow these instructions may result in
WARNING: The fire suppression system backup power supply must be depleted before
lifting the vehicle or when repairing or replacing any of the following:
Fire suppression system components

Components located near the fire suppression manual switch
Fuel tank and components located near the fuel tank
Rear axle and components located near the rear axle
To deplete the backup power supply, disconnect the battery and wait at least 1 minute. Be sure
to disconnect all auxiliary batteries and power supplies (if equipped). Failure to follow these
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and
the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the
mounting areas to the original production configuration. A new RCM and sensors must be
installed whether or not the air bags have deployed. Failure to follow these instructions may
result in serious personal injury or death in a crash.
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners,

adaptive load limiting retractors, safety belt inflators, or probe the electrical connectors. Failure
to follow this instruction may result in the accidental deployment of the safety belt
pretensioners, adaptive load limiting retractors, or safety belt inflators, which increases the risk
of serious personal injury or death.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy® or side air
curtain modules. Failure to follow this instruction may result in the accidental deployment of
these modules, which increases the risk of serious personal injury or death.
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy®
module, side air curtain module or interior trim panel. This will prevent the Safety Canopy® or
side air curtain module from deploying correctly. Failure to follow this instruction may increase
the risk of serious personal injury or death in a crash.
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint
system operation, which increases the risk of personal injury or death in a crash.
WARNING: Always carry or place a live Safety Canopy®, or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result
in serious personal injury or death in the event of an accidental deployment.
WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag supplemental restraint system (SRS) component and before servicing,
removing, installing, adjusting or striking components near the front or side impact sensors or
the restraints control module (RCM). Nearby components include doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Refer to the Description and Operation portion of Section 501-20B for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of
an accidental deployment.
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
WARNING: Do not paint any air bag module trim covers or deployment doors. Paint may
cause the air bag to deploy incorrectly. Failure to follow this instruction may increase the risk of
serious personal injury or death in a crash.
Tire and Wheel Service Warnings
WARNING: Tires degrade over time depending on many factors such as weather, storage
conditions, and conditions of use (load, speed, inflation pressure, etc.) the tires experience
throughout their lives. In general, new tires should be installed after 6 years regardless of tread
wear. However, heat caused by hot climates or frequent high loading conditions may accelerate
the aging process and may require new tires to be installed more frequently. You should install a
new spare tire when you install new road tires or after six years even if it has not been used.
WARNING: Replacement wheels must be equivalent to the original equipment wheels in:
load carrying capacity.

diameter, width and offset.
pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or
greater than that axle's gross axle weight rating (GAWR) identified on the vehicle's Safety
Compliance Certification label. All other specifications should be evaluated by measurement of
both the original wheel and the replacement wheel. If specifications are not equivalent, the safety
and handling of the vehicle may be degraded, which may result in serious injury to the vehicle
occupant(s).
WARNING: Never inflate a tire that has been run flat without first removing the tire from the
wheel to inspect for damage. A damaged tire can fail during inflation. Failure to follow this
WARNING: Do not hit the wheel or tire with a metallic hammer. This action may damage the
wheel or tire, resulting in tire or wheel failure. Failure to follow this instruction may result in
serious personal injury to the technician or vehicle occupant(s).
WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surface of the wheel and the mounting surface of the wheel hub, brake
drum or brake disc. Make sure that any fasteners that attach the rotor to the hub are secured so
they do not interfere with the mounting surfaces of the wheel. Failure to follow these instructions
when installing wheels may result in the wheel nuts loosening and the wheel coming off while
the vehicle is in motion, which could result in loss of control, leading to serious injury or death to
WARNING: Inflating tires to pressures that exceed maximum tire inflation rating on tire
sidewall may result in tire failure and serious personal injury to the technician or vehicle
occupant(s).
WARNING: Only use replacement tires that are the same size, load index, speed rating and
type (such as P-metric versus LT-metric or all-season versus all-terrain) as those originally
provided by Ford. The recommended tire and wheel size may be found on either the Safety
Compliance Certification Label or the Tire Label, which is located on the B-pillar or edge of the
driver's door. If the information is not found on these labels, consult a Ford dealer. Use of any
tire or wheel not recommended by Ford can affect the safety and performance of the vehicle,
which could result in an increased risk of loss of vehicle control, vehicle rollover, personal injury
and death. Additionally, the use of non-recommended tires and wheels could cause steering,
suspension, axle or transfer case/power transfer unit failure.
WARNING: Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type
wheels. Incorrect combinations could result in tire separation from wheel and may result in
serious injury to vehicle occupant(s).
WARNING: Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to
removal of wheels from the vehicle. Failure to follow this instruction may result in serious
personal injury.
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. Wheels
can loosen after initial tightening. Failure to follow this instruction may result in serious injury to
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual
rear wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can
loosen after initial tightening. Failure to follow this instruction may result in serious injury to
WARNING: Always match the tire size to the wheel size during assembly. Incorrect
matching can result in tire bead damage or tire separation from the wheel. Failure to follow this
instruction may result in serious personal injury to technician or vehicle occupant(s).
WARNING: Keep eyes away from valve stem when deflating tires. Reduce air pressure in
tire as much as possible by pushing in valve core plunger prior to removing the core. Escaping
air can carry particles that can injure the eyes. Failure to follow these instructions may result in
WARNING: Never use wheels different than the original equipment. Additionally, never use
wheel nuts different than the original equipment. Failure to follow these instructions may result
in damage to the wheel or mounting system. This damage could cause the wheel to come off
while the vehicle is being driven, which could result in serious personal injury or death to vehicle
occupant(s).
WARNING: Do not weld or peen wheels. A wheel needing such repairs must have a new
wheel installed. Failure to follow these instructions may result in wheel failure and serious
personal injury.
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release
hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the
skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical
attention. If any part of the battery is swallowed, contact a physician immediately. When
disposing of TPMS sensors, follow the correct procedures for hazardous material disposal.
Diagnostic Methods
Effective Diagnostic Techniques
The following diagnostic process is critical for consistently successful diagnoses. Random methods work
inconsistently and often lead to multiple repairs and the accompanying frustration.
Understand and verify the symptom .

Understanding a symptom requires understanding normal operation.
Duplicate the concern. Re-create the same conditions that demonstrated the original
concern (road testing may be necessary).
Determine the responsible system .
Gather data, such as a visual inspection and an OASIS report.
Perform system tests, such as pressure tests or DTC retrieval.
Identify the responsible component .
Test the suspect component and related parts.
Determine the root cause
Examine related components (wiring faults, misalignments, incorrect adjustments) that
may be the actual cause or may have caused the component failure.
Repair all related faults to avoid repeat failures.
Verify the repair has corrected the concern (and not created any new ones) using the
identical conditions that demonstrated the original concern.
Diagnostic Scan Tool Testing
Network Test
Performing a network test is always recommended for analysis of electronic system concerns. Always
solve network issues before addressing individual symptoms or DTCs.
Recommended Practice: REFER to Symptom Chart in Section 418-00 to diagnose a network outage
or no response from an individual module (or modules).
DTC Retrieval
Generally, a good diagnostic strategy is to resolve all on-demand codes related to the system concern.
Retrieving all continuous DTCs can also be beneficial to understand historic issues or issues outside of
the suspect system that may be affecting your concern. On-demand testing should be done to ensure
the fault represented by a continuous DTC is still present.
Continuous Memory Diagnostic Trouble Codes (CMDTCs)
Modules that produce diagnostic trouble codes have a program that evaluates system conditions,
normally while the vehicle or system is in use. Module inputs can be checked for values indicating an
electrical fault with the monitoring circuit or component. Module outputs can be monitored for correct
function. Codes are stored when predefined limits are exceeded and retained even if the ignition is
turned off (generally DTC-retention is for 40+ ignition cycles). Not all continuous codes have a matching
on-demand code - and vice versa; this varies with different modules. For example, some network
communication codes are continuous only. It is important to note that the presence of a continuous DTC
does not guarantee that the fault currently exists.
Ford On-Demand DTCs

Ford Motor Company modules have a unique feature that performs a special diagnostic program at the
request of the technician (using a scan tool). This "On-demand" diagnostic program can exercise system
outputs not normally running when the car is parked and record observed faults. These diagnostic codes
are communicated to the scan tool; they are not recorded in module memory. An on-demand test is an
effective tool for evaluating real input and output conditions during module activity – activity that might
not normally be occurring during service bay conditions. For example, an air suspension module on-
demand test can run the compressor, vent the system, and observe the report from the height sensor
even when the car is already at correct trim height and not requiring height adjustment.
Network Communication DTCs
Network DTCs (U-prefix codes) are often a result of intermittent concerns such as damaged wiring or
low battery voltage occurrences. Additionally, vehicle repair procedures (such as module reprogramming
or diagnostics with modules disconnected) often set network DTCs. Replacing a module to resolve a
network DTC is unlikely to resolve the concern. To prevent recurrence of intermittent network concerns,
inspect all network wiring, especially in-line and module connectors; test the vehicle battery.
Recommended practice: Clear the DTC and retest. If the DTC repeats, test the vehicle communication
network.
DTC Nomenclature (SAE J2012 and ISO 14229)
Many modules use 5-character DTCs followed by a 2-character failure-type code. The failure-type
(sometimes called "fault byte") digits provide information about specific fault conditions such as opens or
shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to
assist in determining DTC history.
Integrated Diagnostic System (IDS) Scan Tool Usage
If The IDS Scan Tool Does Not Communicate With The VCM
1. Check the VCM power; examine the connection to the vehicle.

The VCM LED illumination prove-out confirms power and ground from the DLC are
provided to the VCM .
Recommended Practice: REFER to Section 418-00 , No Power to the Scan Tool, to
diagnose no power to the VCM .
2. Check the scan tool connection to the VCM .
3. Follow scan tool instructions to retry.
If The IDS Scan Tool Does Not Communicate With The Vehicle
The IDS scan tool first attempts to communicate with the PCM. After establishing communication with
the PCM, the scan tool then attempts to communicate with all other modules on the vehicle.
1. Verify the scan tool operation with a known good vehicle.
2. Verify the ignition is ON.
3. If an IDS session cannot be established with the vehicle ( IDS may state "No communication can
be established with the PCM"):
Choose "NO" when the scan tool prompts to retry communication.
Enter either a PCM part number, tear tag, or calibration number to identify the vehicle and
start a session.
The PCM part number can be determined from OASIS -- choose “HVBoM” from the
OASIS page and search for the PCM part number
The PCM part number and 4-character tear tag are printed on the PCM label.
Establish a session based on the PCM information (above).
4. Using the tool box menu, run the network test.
Determine if all modules on the network are unresponsive or if only the PCM does not
communicate.
Recommended practice: REFER to Symptom Chart in Section 418-00 to diagnose the
network outage or no response from the PCM.
Measuring Automotive Circuits
Wiring Pin (Terminal) Fit And The Use Of Rotunda Flex Probes
To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D must be used to
connect test equipment or jumper wires to pins (terminals).
Male to female pin (terminal) fit is critical for connection reliability.
Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal
separation force (a damaged pin or terminal will have very low separation force from the
mating pin or terminal)
Correctly checking the separation force of small pins (terminals) may require removal of
the connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or
removal
Replace damaged connectors or pins (terminals).
Use the Wiring Diagram connector view (cell 150) to identify the correct replacement
connector with pigtail.
Use the Wire Harness Terminal Repair Guide to identify and order the correct replacement
pin and pigtail. Available through Ford Dealers, REFER to FMC dealer website, or REFER
to www.fcs.dealersonnection.com/wire .
Checking Power-Providing Circuits
Measuring a power wire with the intended load disconnected using a DMM will only find open
circuits (open fuse or wire).
Recommended practice: Circuits carrying approximately 200-1000 mA* may be loaded with the
specified test light SGT27000. Measure circuit voltage with a DMM while the test light is
connected and illuminated. A reduction in the voltage present during test-light-loading indicates
excessive circuit resistance.
Recommended practice: Circuits carrying more than one ampere* should be loaded with a
device requiring similar current (e.g., a headlamp bulb may be effective). A reduction in the
voltage present during loading indicates excessive resistance.
*Circuit current is matched to wire gauge/size; Examples:
Conductor sizes of 24 gauge (.5 mm) or smaller are generally used to carry approximately
1 ampere (1000 mA) or less. Use of the test light to load these circuits is appropriate.
Conductor sizes of 20 gauge (.8 mm) or larger are generally used to carry approximately 5
amperes (5000 mA) or more. Match the substitute load (measure substitute load current
first as necessary) to this current level.
Checking Ground-Providing Circuits
The best method of checking ground circuits is to measure the circuit voltage drop during
component operation (or attempted operation).
An ohmmeter may be accurately used if the battery has been disconnected.
Recommended practice: Expect less than 2 ohms for most small diameter (18 gauge and
smaller) wires.
Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less
than approximately 5 amperes (this is due to the fact that very small resistances, undetectable by
a DMM , cause significant voltage loss in higher current circuits).
DMM ohmmeter readings are easily corrupted by the normal voltage present (battery connected)
in many ground circuits.
Recommended practice: Reverse the leads and check for changes in the measurement.
Reversing the DMM lead connections should never change the resistance measurement
(unless the circuit contains a semi-conductor). Measurement (non-semi-conductor)
differences when leads are interchanged at the test points indicate invalid test results. The
presence of voltage corrupts the reading, and causes the meter reading to change when
the leads are reversed.
Checking Circuit Continuity
Recommended practice: Expect less than 2 ohms of resistance for most wires.
Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less
than approximately 5 amperes. This is due to the fact that very small resistances, below the
resolution of a DMM , cause significant voltage loss in higher current circuits.
The DMM applies a small amount of voltage to the circuit or component to calculate resistance.
As a result, DMM ohmmeters are very sensitive to any level of voltage present. Voltage present in
the circuit will corrupt the DMM reading.
Checking For Unintended Continuity (Shorts) To Other Circuits
A DMM ohmmeter may be used to detect undesired circuit connections to:

Ground
Other unpowered circuits
Recommended practice: Expect greater than 10,000 ohms of resistance between two separate
circuits; the best result is an open circuit DMM indication (no detected resistance).
Shorts to voltage are checked with a DMM voltmeter
Recommended practice: Turn ignition on (with battery connected) and measure the circuit for
any voltage present (none should be present)
Checking Circuits By Back-Probing A Connector
Back-probing should be a testing method of last resort. It should only be employed where a
diagnostic step requires a circuit to be tested under actual operating conditions. Back-probing is a
risky testing method due to the uncertainty of the probe connection and the possibility of
damaging terminals.
Do not force test leads or other probes into connectors. Adequate care must be exercised to
avoid connector terminal damage while ensuring that good electrical contact is made with the
circuit or terminal. Failure to follow these instructions may cause damage to wiring, terminals, or
connectors and subsequent electrical faults.
Use Rotunda Back-Probe Pins POMA6411 to assist in making a good test connection and
to prevent connector or terminal damage during back-probing.
Do not test for the presence of voltage at a single point where zero volts is a possible result (you
cannot tell the difference between a bad probe contact and a zero volt result).
Do not test for continuity/opens (using a DMM ohmmeter) between two points (you cannot tell the
difference between bad probe contacts and an open circuit).
Back-probing may be used where the circuit must be analyzed with the voltage-drop method (if
the circuit carries greater than 5 amperes and no other means of testing will definitively eliminate
circuit resistance as a possible fault). A zero-volt result indicates incorrect test conditions (no
current flow) or bad back-probe connections.
Occasionally, module failure mode behavior will change the operation of a circuit when it is
opened for testing. Back-probing is an acceptable remedy for these testing dilemmas.
Circuit Analysis Using Jumper Wires (Creating Substitute Circuits)
Jumper wires may be employed for circuit analysis.

Cautions:
Always use fused jumper wires — the recommended universal-testing jumper wire fuse is
2-5 amperes; larger fuse ratings should be used only in special circumstances.
Use flex probes or equivalent to prevent connector terminal damage (flex probes are not
intended to carry higher currents necessary to operate motors such as a cooling fan or
blower motor).
Follow workshop manual testing directions when using jumper wires to avoid component or
harness damage due to incorrect jumper connections.
Never repair a circuit by adding a new wire in parallel to the old one (overlaying the circuit)
without fully understanding what caused the circuit to fail. Always find, examine, and repair
the fault to correct the root cause and to repair any adjacent wiring that has been
damaged.
Checking Modules
Generally, module failure rate is very low and therefore replacement modules usually do not
resolve the root cause. Incorrect replacement of a module is often the result of inadequate
testing.
Understand the correct module function.
Make sure programmable parameters are set correctly for the function in question (see the
list in Section 418-01 ).
Resolve DTCs first — as directed by Diagnostic Routines.
Test all inputs, both hard-wired and networked.
Test outputs (see "Checking module switching circuits" below).
Check applicable TSBs for module software changes (flash programming).
Checking module switching circuits.
Using the scan tool module-output command function (e.g., IDS Output State Control) to
activate components is a fast way to confirm an output is capable of being switched on by
the module. Testing that reveals normal module-output function confirms the need to
analyze the module inputs.
Don't apply ground or power directly to module-switched components with jumper wires
(unless directed by a workshop manual procedure), as the component can be damaged by
a direct connection to ground/power.
SECTION 100-01: Identification Codes 2011 Fiesta Workshop Manual
Identification Codes
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN) Locator
The Vehicle Identification Number (VIN) is a 17-digit combination of letters and numbers. The VIN is stamped
on a metal tab riveted to the instrument panel, top upper left of the dash. The VIN is also found on the Vehicle
Certification (VC) label.
If the VIN plate requires replacement, authorized dealers must contact their respective regional office.
Item Description
1 World Manufacturer Identifier (WMI)
2 Restraint-type code
3 Vehicle line, series, body-type code
4 Engine-type code
5 Computer-generated check digit
6 Model year code
7 Assembly plant code
8 Production sequence number
World Manufacturer Identifier (WMI)
The first 3 VIN positions are the World Manufacturer Identifier (WMI).
3FA — Ford Motor Company, Cuatitlian, Mexico, passenger car
Restraint Type
The fourth VIN position is the vehicle restraint type code.
D — Active safety belts — all positions, driver and front passenger air bags with driver and front
passenger side impact air bags
K — Active safety belts — all positions, no air bags (Mexico only)
Vehicle Line, Series and Body Type
Positions 5 through 7 indicate vehicle line, series and body type.
P4A — 4-door sedan — S

P4B — 4-door sedan — SE
P4C — 4-door sedan — SEL
P4E — 5-door hatchback — SE
P4F — 5-door hatchback — SES
Engine Type
The eighth VIN position identifies the engine displacement and number of cylinders.
J — 1.6L, in-line 4-cylinder, SIGMA

K — 1.6L, in-line 4-cylinder, SIGMA (flex-fuel)
Additional engine information can be obtained from the engine tag. Refer to Section 303-01 .
Check Digit
The ninth VIN position is a government-assigned, computer-generated check digit.
Model Year
The tenth VIN position is the model year code.
B — 2011
Assembly Plant
The eleventh VIN position is the assembly plant code.

M — Cuautitlan Assembly, Cuautitlan, Mexico
Production Sequence Number
The last 6 VIN positions are a numeric code for the vehicle build sequence. This is also the vehicle serial and
warranty number.
The serial number can also be found on the engine block, transmission and frame.
100001-999999 — Ford Motor Company vehicle
Vehicle Certification (VC) Label
Vehicle Certification (VC) Label Locator
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
Rating (GVWR) and tire information.
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit
the VIN to their respective regional office. The regional office will submit a web form to the assembly plant for
the replacement label. Once the label has been printed, a representative from the regional office will deliver the
label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and requires a
replacement label, the dealer must submit a request to the Department of Motor Vehicles.
Item Description
1 Exterior paint code
2 Region code
3 Domestic special order code
4 Interior trim code
5 Tape/paint stripe code
6 Radio code
7 Axle code
8 Transmission code
9 Spring code
10 Powertrain calibration code
Paint Code
Paint codes may be listed as a 2-part code. The first set of paint code numbers/letters indicate the vehicle
primary body color. The second set of letters/numbers (if applicable) indicate a 2-tone or accent body color. All
paint codes are a base coat/clear coat finish.
L7 — Bright Magenta
NQ — Yellow Blaze (tri-coat)
SQ — Lime Squeeze Metallic
SZ — Blue Flame Metallic
T9 — Monterrey Gray
U6 — Red Candy Tint
UH — Tuxedo Black Metallic
UX — Ingot Silver Metallic
YZ — Oxford White
Interior Trim Codes
The interior trim codes are listed as a 2-part code. The first digit listed indicates the seat and fabric style. The
second digit listed indicates the interior trim color.
Trim Codes
C — Greenwich cloth
D — Crossroad cloth
L — Soho leather
Interior Trim Color Codes

B — Black/Black
C — Black/Cashmere Tan
L — Charcoal Black/Light Stone
R — Ebony/Red
U — Black/Blue
Tape/Paint Stripe Codes
Tape and paint stripe codes do not apply.
Radio Codes
Available radio codes are as follows.
A — AM/FM stereo with CD player and MP3 enabled

D — Electronic AM/FM stereo
Axle Codes
Available axle ratios are as follows.
GG — 4.07 ratio (automatic transmission)

MM — 4.07 ratio (manual transmission)
Additional axle information can be obtained from the axle tag. Refer to Section 205-00 .
Transmission Codes
Available transmission type codes are as follows.
A — 6-speed automatic
C — 5-speed manual
Additional transmission information can be obtained from the transmission tag. Refer to Section 307-11 or
Section 308-00 .
Spring Codes
Spring codes are listed as a 2-part code. The first set of characters identify the front springs. The second set of
characters identify the rear springs.
Front Springs
Base part number — 5310
Rear Springs
Base part number — 5560
Powertrain Calibration Information
NOTE: Powertrain calibration information is limited to a maximum of 5 characters per line on the 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 VC label. Only the base calibration
information is printed. Revision levels will not appear, however, they can be obtained through a scan tool using
the most current software revision.
Item Description
1 Model year (year in which the calibration strategy was first introduced).
2 Vehicle code
3 Transmission code
4 Unique calibrations (designates different hardware to similar vehicles), example: tires or drive ratios
5 Fleet code (describes fleet to which the vehicle belongs), example: 6 — Evaporative Emission (EVAP)
6 Certification region (lead region where multiple regions are included in one calibration), example: A —
US federal
7 Revision level (will advance as revisions occur), obtained through scan tool
Model Year
B — 2011
Vehicle Code
CH — Fiesta
Transmission Code
A — Automatic transmission
C — Manual transmission
Unique Calibration
The Emission/Corporate Average Fuel Economy/CO2 Compliance Department is responsible for assigning
these calibration numbers. Unique identifications are assigned to cover similar vehicles to differentiate between
tires, drive configurations, final drive ratios and other calibration-significant factors.
These 2 characters are chosen by the analyst to provide identifiable information unique to each calibration. For
example, using the number 2 to denote a 2-valve engine versus using the number 4 to denote a 4-valve engine
provides an easily identifiable difference.
Fleet Coding
0 — Certification (US 4K, final sale in export markets)
1 — Heavy duty gas engine/Dyno
2 — Fast Automobile Manufacturers' Association, US
3 — Alternative durability protocol, US
4 — Not assigned
5 — Not assigned
6 — Evaporative Emission (EVAP)
7 — Mileage accumulation aging endurance durability
8 — On-Board Diagnostic (OBD)
9 — Not assigned
Certification Region
5 — US 50 states
A — US federal, including altitude, may include Canada and/or Mexico
B — US California standard, includes US green states
C — Canada
D — China
E — European Community (Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland,
Italy, Luxembourg, Netherlands, Portugal, Spain, Sweden and United Kingdom)
F — European Extended Community (E-plus Croatia, Czech Republic, Estonia, Hungary, Norway,
Poland, Romania, Russian Federation, Slovakia, Slovenia, Switzerland and Yugoslavia)
G — Gulf Cooperative Council (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and United Arab Emirates)
H — Hong Kong
J — Japan
K — Korea
L — Malaysia
M — Mexico
N — New Zealand
P — Australia
Q — South America (Brazil)
S — Singapore
T — Taiwan
U — South America (unleaded fuel regions)
V — Vietnam
X — Rest Of World (ROW)
Y — Military
Z — Israel
Revision Level (not printed on label)

91-99 — Hardware and certification levels
01-04 — Preliminary levels
00 — Job 1 production (initial certification)
05-09 — Pre-job 1 revisions to calibrations
10-89 — Post-job 1 revisions to calibrations
0B — Durability test level
BD — OBD intermediate level (pre-05)
SECTION 100-02: Jacking and Lifting 2011 Fiesta Workshop Manual
Jacking and Lifting
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand.
WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could
result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious
personal injury.
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the
parking brake if the rear wheels will remain on the ground. These actions help prevent unintended
vehicle movement. Failure to follow these instructions may result in serious personal injury.
NOTICE: It is not recommended that the vehicle is jacked or lifted on the rear suspension
crossmember. If the vehicle must be lifted on the crossmember, make sure that the jack or lift is
positioned centrally. Failure to follow these instructions will result in deformation of the closing plate
which will weaken the crossmember.
NOTICE: Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Jacking and Lifting Locations

SECTION 100-03: Maintenance Schedule 2011 Fiesta Workshop Manual
Maintenance Schedules — Gasoline Engines
For Maintenance Schedule information, refer to the Scheduled Maintenance Guide chapter in the
Owner's Guide.
Also available at:
www.motorcraftservice.com and select Owner Guides.

SECTION 100-04: Noise, Vibration and Harshness 2011 Fiesta Workshop Manual
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a
ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness
normally describes a firmer than usual response from the suspension system. NVH is a term used to
describe these conditions, which result in varying degrees of dissatisfaction. Although a certain level of
NVH caused by road and environmental conditions is normal, this section is designed to aid in the
diagnosis, testing and repair of NVH symptoms.
Acceptable NVH
All internal combustion engines and drivelines produce some noise and vibration; operating in a real
world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers
reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds
are abnormal when actually the sounds are normal for the vehicle type. As a technician, it is very
important to be familiar with vehicle features and know how they relate to NVH symptoms and their
diagnosis. For example, if the vehicle has automatic overdrive, it is important to test drive the vehicle
both in and out of overdrive mode.
Glossary of Terms
Amplitude
The quantity or amount of energy produced by a vibrating component (G-force). An extreme vibration
has a high amplitude. A mild vibration has a low amplitude. See Intensity.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Buffet/Buffeting
Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side
glass.
Buzz
A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also
describes a high-frequency vibration. Vibration feels similar to an electric razor.
Chatter
A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp
A short-duration, high-pitched noise associated with a slipping drive belt.
Chuckle
A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.
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.
Conductor
The components that carry (transmit) a vibration frequency from the originator to the reactor.
Cycles Per Second
Cycles per second. Same as hertz (Hz).
Cracks
A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak
A metallic squeak.
Cycle
The process of a vibrating component going through a complete range of motion and returning to the
starting point.
Decibel (dB)
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drone
A low-frequency, steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency, rhythmic noise often accompanied by a sensation of pressure on the ear
drums. Also described as a low rumble, boom or rolling thunder.
Flutter
Mid to high intermittent sound due to air flow. Similar to a flag flapping in the wind.
Frequency
The rate at which a cycle occurs within a given time.

G-force
The additional load or weight produced in an object during acceleration. When measuring the level or
amplitude of a vibration without sound, the unit G is added to associate the force of the vibration to
gravity. This is similar to measuring the weight of an object, which is also a function of gravity.
Gravelly Feel
A grinding or growl in a component, similar to the feel experienced when driving on gravel.
Grind
An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hertz (Hz)
A unit of measure used to describe noise and vibration concerns expressed in cycles per second.
Hiss
Steady, high-frequency noise. Vacuum leak sound.
Hoot
A steady, low-frequency tone, sounds like blowing over a long neck bottle.
Howl
A mid-range frequency noise between drumming and whine. Also described as a hum.
Hum
Mid-frequency steady sound, like a small fan motor. Also described as a howl.
Intensity
The physical quality of sound that relates to the strength of the vibration (measured in decibels). The
higher the sound's amplitude, the higher the intensity and vice versa. See Amplitude.
Knock
A heavy, loud, repetitious sound, like a knock on the door.
Moan
A constant, low-frequency tone. Also described as a hum.
Ping
A short-duration, high-frequency sound, which has a slight echo.
Pitch
The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and
vice versa.
Pumping Feel
A slow, pulsing movement.
Rattle
A random and momentary or short-duration noise.
Reactor
The component, or part, that receives a vibration from an originator and conductor and reacts to the
vibration by moving.
Roughness
A medium-frequency vibration. A slightly higher frequency than a shake. This type of vibration is usually
related to drivetrain components.
Rustling
Intermittent sound of varying frequency, sounds similar to shuffling through leaves.
Shake
A low-frequency vibration, usually with visible component movement. Usually relates to tires, wheels,
brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also
referred to as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low-frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Squeak
A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long-duration, high-pitched noise.
Tap
A light, rhythmic or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by 2 items striking together.
Tick
A rhythmic tap, similar to a clock noise.

Tip-In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).
Transient
A noise or vibration that is momentary, a short duration.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up
and down.
Whine
A constant, high-pitched noise. Also described as a screech.
Whistle
High-pitched noise with a very narrow frequency band. Examples of whistle noises are a turbocharger or
air flow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle.
SECTION 100-04: Noise, Vibration and Harshness 2011 Fiesta Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 05/13/2010
Noise, Vibration and Harshness (NVH)
Special Tool(s)
Electronic Vibration Analyzer (EVA)
100-F027 (014-00344) or
equivalent
EngineEAR
107-R2100 or equivalent
EngineEAR/ChassisEAR
Mastertech® Series MTS 4000

Driveline Balance and NVH
Analyzer (Vetronix)
257-00018 or equivalent
Squeak and Rattle Repair Kit

164-R4900
Ultrasonic Leak Detector

Diagnostic Theory
The shortest route to an accurate diagnosis results from:
system knowledge, including comparison with a known good system.

system history, including repair history and usage patterns.
condition history, especially any relationship to repairs or sudden change.
knowledge of possible sources.
using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of NVH symptoms requires:

a road or system test to determine the exact nature of the symptom.
an analysis of the possible causes.
testing to verify the cause.
repairing any symptoms found.
a road test or system test to make sure the cause has been corrected or brought back to within an
acceptable range.
Diagnostic Procedure Overview
Qualifying the symptom by the particular sensation present can help narrow down the cause. Always use the
"symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the
problem into related areas to correct the customer concern.
Verify the "symptom".

Determine which "system(s)" can cause the "symptom" using the diagnostic tools described in this
section.
After determining the possible "system(s)", refer to the appropriate section in this manual to identify the
worn or damaged "components".
After identifying the "components", identify the "cause" of the failure.
Tools and Techniques
The diagnostic tools allow for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. Remember that the vibrating source component (originator) may only generate a
small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving
component (reactor), due to contact with other components (transfer path). For the best results, carry out the
test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
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.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity and if it
tends to diminish above/below a certain speed.
If a vibration symptom is vehicle speed related, the tire and wheel rpm/frequency and driveshaft
frequency should be calculated.
If a vibration symptom is engine speed related, the engine, engine accessory and engine firing
frequencies should be calculated.
Frequencies with an amplitude reading of 0.06 Gs or less are barely perceptible NVH levels. No
corrective action is necessary.
d. Place the vibration sensor on or near the suspect area outside the vehicle.
e. Continue the road test, driving the vehicle at the speed the symptom occurs and take another reading.
f. Compare the readings.
A match in frequency indicates the problem component or area.
An unmatched test could indicate the symptom is caused by the engine, torque converter or
engine accessory. Use the diagnostic tools in the rpm mode and check if symptom is rpm related.
The following diagnostic tools and techniques can be used separately or in conjunction with each other to aid in
the diagnosis of NVH symptoms. They are listed in order of preference for ease in their use for locating these
symptoms.
NVH Analyzer (Vetronix)
The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100 NVH
analyzers are tools to aid in the identification and isolation of a noise, vibration or harshness symptom in a
vehicle. They measure noise and vibration data and compare it with data obtained from the vehicle's PCM as
well as vehicle variants that were entered by the user such as pulley size, axle ratio and tire size in order to
provide possible sources. The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix)
and the MTS 4100 have the following characteristics:
Interface with the vehicle's computer system

Support and store vibration data input from 1 or 2 accelerometers
Support and store noise data input from 2 microphones
Provide a photo-tachometer for operation of the driveshaft balancing function
Provide a strobe output capable of driving a standard timing light
Contain a real-time clock circuit that provides time and date information which is used for tagging test
data
Have the capability to print to an external printer and interface with a PC
Can be powered from a variety of power sources: cigarette lighter, AC power or the internal battery pack
The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100 NVH
analyzers have 4 main operating modes. The first is for vibration diagnosis. This mode measures data from 1 or
2 accelerometers simultaneously while obtaining data from the vehicle. Then it carries out a frequency analysis
on the accelerometer information and compares the vibration frequencies with the frequencies associated with
various rotating components within the vehicle. The data can be presented in 4 different display modes:
principle component, bar chart, frequency spectrum or waterfall. All display mode formats contain the same
common elements, such as amplitude.
The second is for noise diagnosis. This mode measures noise from 1 or 2 microphones simultaneously. All
noise measurements are in decibels (dBs). All frequency bands used for noise measurements are the same as
for the vibration measurements, up to 1,000 Hz.
The third is driveshaft balancing. Driveshaft balancing is done using 1 or 2 accelerometers and a photo-
tachometer. The accelerometers measure the vibration at both ends of the driveshaft, while the photo-
tachometer measures the rotation speed and position reference. Refer to Section 205-00 .
The fourth is the strobe. A strobe or standard timing light can be connected to an analyzer, to provide a means
for measuring rotation speed. The strobe function is used for isolating the source of a vibration.
Electronic Vibration Analyzer (EVA)
The Electronic Vibration Analyzer (EVA) is a hand-held electronic scan tool which will assist in locating the
source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the 3 most common vibration frequencies and their corresponding
amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of
each vibration being displayed and its relative G-force. The keypad is arranged to make the EVA simple to
program and use. Some of the functions include the ability to average readings as well as record, play back and
freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating
components such as a driveshaft or engine accessories.
Item Description
1 Electronic Vibration Analyzer (EVA) screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G-force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration
Record the readings taken with the diagnostic tool.
Frequencies should be read in the "average" mode.

Frequencies have a range of plus or minus 2 Hz. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
Vibrate Software®
Vibrate Software® (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the
source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration diagnosis.
Every rotating component will have an angular velocity that is faster, slower or the same as the engine's
crankshaft. Vibrate Software® calculates the angular velocity of each component and graphically represents
these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how
Vibrate Software® helps diagnose a vibration symptom:
Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency
rpm and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency
rpm reading and the engine rpm reading intersect indicates the specific component group causing the
symptom.
A frequency measurement tool capable of measuring vibration frequency and engine rpm will be
needed.
Provides graphics of diagnostic procedures to aid in testing components.
Reed Tachometer
The Reed tachometer is a hand-held vibration sensor which will assist in locating the source of unacceptable
vibrations. The vibration sensor can be placed anywhere in the vehicle for testing purposes. The Reed
tachometer contains several reeds that are tuned to vibrate or resonate at different frequencies ranging from 10
to 80 Hz or 600 to 4,800 rpm. Though the Reed tachometer is able to measure multiple frequencies, it does not
measure amplitude.
Sirometer
The Sirometer measures frequency in hertz and rpm. To use the Sirometer, place it on any vibrating component
and slowly scroll the wire out by turning the knob. As the length of wire changes, so does its natural frequency.
Find the length of wire that vibrates with the highest amplitude. This frequency will match that of the vibrating
component. Read the frequency for that length of wire.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle
is being road tested. The ChassisEARs can identify the noise and location of damaged/worn wheel bearings,
CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of
damaged/worn bearings in generators, coolant pumps, A/C compressors and power steering pumps. They are
also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The
EngineEAR has a sensing tip, amplifier and headphones. The directional sensing tip is used to listen to the
various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier.
Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by
or passing through, the component. Various volume levels can reveal different sounds.
Mechanic's Stethoscope
A mechanic's stethoscope is an inexpensive tool for locating noises in engines and other moving parts. It can
be used to help diagnose piston slap, worn gears, faulty valves, coolant pump failure, damaged gaskets,
defective bearings and body squeaks.
Squeak and Rattle Repair Kit
The Squeak and Rattle Repair Kit (Rotunda tool number 164-R4900) contains lubricants and self-adhesive
materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following
materials:
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
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is
weatherstripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative
emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the
ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the
vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is
approached, a beeping sound is produced which increases in both speed and frequency.
Write-Up Job Aid
To assist the service advisor and the technician, a Write-Up Job Aid used during the interview process is
included with this material. The Write-Up Job Aid serves as a place to record all important symptom
information.
1: Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much information
as possible about the symptom and take a test drive with the customer. There are many ways a customer will
describe NVH symptoms and this will help minimize confusion arising from descriptive language differences. It
is important that the symptom is correctly interpreted and the customer descriptions are recorded. During the
interview, complete the write-up job aid and ask the following questions:
When was it first noticed?

Did it appear suddenly or gradually?
Did any abnormal occurrence coincide with or precede its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2: Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle
is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that
will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on
the road.
3: Preparing for the Road Test
Observe the following when preparing for the road test:
Review the information recorded on the write-up job aid. It is important to know the specific symptom the
customer has with the vehicle.
Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing
route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the
condition occurs.
While observing that they are not related to the symptom, eliminate the following:
If possible, lower the radio antenna in order to minimize turbulence.
Identify anything that could potentially make noise or be a source of wind noise.
Inspect the vehicle for add-on items that create vibration/noise.
Turn off the radio and the heating and cooling system blower.
The engine speed is an important factor in arriving at a final conclusion. Therefore, connect a diagnostic
tool, Vetronix, or an accurate tachometer to the engine, even if the vehicle has a tachometer. This will
make sure of an exact engine speed reading.
4: Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test or both.
The decision to carry out a road test, an engine run-up test or both depends on the type of NVH symptom. A
road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A Drive
Engine Run-Up (DERU) or a Neutral Engine Run-Up (NERU) test identifies noises and vibrations relating to
engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests,
however, they will eliminate many possibilities if carried out correctly.
5: Road Test
NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the symptom.
During the road test, take into consideration the customer's driving habits and the driving conditions. The
customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this information helps
to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this
information, select and carry out the appropriate test(s), proceeding to the next step of this process.
The Slow Acceleration Test is normally the first test to carry out when identifying an NVH symptom,
especially when a road test with the customer is not possible.
The Heavy Acceleration Test helps to determine if the symptom is torque-related.
The Neutral Coast Down Speed Test helps to determine if the symptom is vehicle speed-related.
The Downshift Speed Test helps to determine if the symptom is engine speed-related.
The Steering Input Test helps to determine how the wheel bearings and other suspension components
contribute to a vehicle speed-related symptom.
The Brake Test helps to identify vibrations or noise that are brake related.
The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy
surface.
The Engine Run-Up Tests consist of the Neutral Engine Run-Up (NERU) Test and the Drive Engine
Run-Up (DERU) Load Test. These tests help to determine if the symptom is engine speed-related.
The Neutral Engine Run-Up (NERU) Test is used as a follow-up test to the Downshift Speed Test when
the symptom occurs at idle.
The Drive Engine Run-Up (DERU) Load Test helps to identify vibration/noise sensitive to engine load or
torque. It also helps to reproduce engine speed-related symptoms that cannot be duplicated when
carrying out the Neutral Engine Run-Up (NERU) Test or the Neutral Coast Down Test.
The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related
symptoms.
The Vehicle Cold Soak Procedure helps to identify symptoms occurring during initial start-up and when
an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
Slowly accelerate to the speed where the reported symptom occurs. Note the vehicle speed, the engine
rpm and, if possible, determine the vibration frequency.
Attempt to identify from what part of the vehicle the symptom is coming.
Attempt to identify the source of the symptom.
If the source of the symptom has been identified as a result of this test, proceed to the appropriate
section for further diagnosis and repair. If the source has not been identified, continue with the road test.
Heavy Acceleration Test
Accelerate hard from 0-64 km/h (0-40 mph).

Decelerate in a lower gear.
The symptom is torque-related if duplicated while carrying out this test.
Neutral Coast Down Speed Test
Drive at a higher rate of speed than where the symptom occurred when carrying out the Slow
Acceleration Test.
Place the transmission in NEUTRAL and coast down past the speed where the symptom occurs.
The symptom is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
If the symptom was not duplicated while carrying out this test, carry out the Downshift Speed Test to
verify if the symptom is engine speed related.
Downshift Speed Test
Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
Drive at the engine rpm where the symptom occurs.
The symptom is engine speed related if duplicated while carrying out this test. This eliminates the tires,
wheels, brakes and the suspension components as sources.
If necessary, repeat this test using other gears and NEUTRAL to verify the results.
Steering Input Test
Drive at the speed where the symptom occurs, while making sweeping turns in both directions.
If the symptom 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.
Brake Test
With the brake released, accelerate the vehicle. While coasting (brake pedal released) to a stop in
NEUTRAL, note any abnormal rate of deceleration. Abnormal deceleration could indicate a parking
brake or service brake that is not fully releasing.
Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking
applications.
Accelerate to 89-97 km/h (55-60 mph). Moderately apply the brakes and slow the vehicle to a stop.
A brake vibration can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon
brake application and should diminish when the brake is released. For vehicles with separate park brake
shoes, noise or vibration from the parking brake system will not be affected by applying the hydraulic
brakes. On these systems, the parking brake system requires inspection if a parking brake concern is
suspected.
If the source of the symptom has been identified as a result of this test, proceed to the appropriate brake
section(s) for further diagnosis and repair. If the source has not been identified, continue with the road
test.
Road Test Over Bumps
Drive the vehicle over a bump or rough surface 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.
Neutral Engine Run-Up (NERU) Test
Install a tachometer.
Place the vehicle in PARK on Front Wheel Drive (FWD) vehicles with automatic transmissions, or in
NEUTRAL for all other vehicles.
Slowly increase the engine rpm from idle to fuel cutoff or redline. When the symptom occurs, note the
engine rpm and, if possible, determine the vibration frequency.
Attempt to identify what part of the vehicle the symptom is coming from.
Attempt to identify the source of the symptom.
Drive Engine Run-Up (DERU) Load Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Do not carry out the Engine Load Test for more than 5 seconds or damage to the transmission
or transaxle may result.
Block the front and rear wheels.

Apply the parking brake and the service brake.
Install a tachometer.
Shift the transmission into DRIVE, and slowly increase and decrease the engine rpm between an idle to
approximately 2,000 rpm. When the symptom occurs, note the engine rpm and, if possible, determine
the vibration frequency.
Repeat the test in REVERSE.
If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or
transaxle mounts.
If the symptom is definitely engine speed-related, carry out the Engine Accessory Test to narrow down
the source.
Engine Accessory Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Limit engine running time to one minute or less with belts removed or serious engine damage
will result.
NOTE: Use a frequency measurement tool to pinpoint accessory vibrations. A listening device, such as an
EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belt(s).

Slowly increase the engine rpm to where the symptom occurs.
If the vibration/noise is duplicated when carrying out this test, the belt(s) and accessories are not
sources.
If the vibration/noise was not duplicated when carrying out this test, install the accessory belt(s), one at a
time, to locate the source.
Vehicle Cold Soak Procedure

To carry out this procedure, proceed as follows:
Test preparations include matching customer conditions (if known). If not known, document the test
conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to 3
minutes.
Park the vehicle where testing will occur. The vehicle must remain at or below the symptom temperature
(if known) for 6-8 hours.
Before starting the engine, conduct a visual inspection under the hood.
Turn the key on, but do not start the engine. Listen for the fuel pump, ABS and air suspension system
noises.
Start the engine.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a stethoscope
or EngineEAR.
Classify NVH Symptom
For NVH concerns, it is necessary to classify the customer's concern into one of the 3 categories: noise,
vibration or harshness. The reason for this is that a customer concern may consist of a combination of
symptoms involving noise and vibration, or vibration and harshness. In cases where there are combination
symptoms, determine which diagnostic path to follow: noise, vibration or harshness. For example, if a customer
has a concern involving a noise and a vibration, and it is determined that it is vehicle speed-related, follow the
vibration diagnostic path.
Noise Symptoms
Once a symptom is classified as a noise, the particular conditions under which the noise occurs need to be
identified. These conditions are identified and verified during the road test. For example, a noise may only occur
while turning. The next step is to determine which systems on the vehicle are related to that condition. In this
case, the steering system and wheel/tire system may be suspect. After identifying possible systems, a
preliminary inspection of these systems should be done. If the source of noise is still unidentified, use a
listening device (such as the ChassisEAR) to pinpoint the source. Once the source has been identified,
determine if this source is related to the suspected system previously identified. If it is related, then complete
the repair to resolve the customer concern. If it is unrelated, then it is possible that the source of the noise is a
reactor to a noise being transmitted through a transfer path. If this is the case, repairing the reactor will not
resolve the customer concern. The transfer path must be identified and a determination made if the noise is
normal, but accentuated by the transfer path (conductor), or if the originator is the fault causing excessive noise
to transfer to another component through a conductor. There is a relationship between systems identified as
related to conditions and the noise transfer path. In some cases, the condition under which the noise occurs
has nothing to do with the identified source. This relationship is important in the diagnosis of noise concerns. It
is the first clue that the identified source of noise might be a reactor and that further investigation is needed to
diagnose a possible noise transfer path concern. Based on the results from the road test, make a determination
of which action in the symptom chart to take first.
Vibration Symptoms
Most vibrations consist of movements back and forth or up and down that repeat. Every time the vibrating
component goes through its complete range of motion and returns to the starting point is called a cycle. The
rate at which these cycles occur within a given time is called the frequency. Frequency is measured in cycles
per second or Hertz (Hz). One cycle per second equals one Hz. Once the frequency of a vibration is known,
calculations can be done to determine the system that is the source of the concern.
Order of Vibration
The order of a vibration refers to how often the vibration is present in one revolution of the component. For
example, a vibration that is present once each revolution of a component would be a first order vibration. A
vibration present twice each revolution of the component would be a second order vibration. Vibration orders do
not have to be whole numbers, they can have decimal values such as 1.5 order vibration or 3.08 order
vibration.
The concept of order of vibration is important to remember when the measured frequency of a vibration does
not seem to match the frequency calculations of any of the likely systems or components. As the order
increases, the frequency of the vibration will also increase by a multiple of that number.
For example, vibration may be present where the frequency is measured at 14 Hz. After doing the necessary
calculations it is determined the first order tire and wheel frequency is 7 Hz and the first order driveshaft
frequency is 22 Hz. Based on this information it can be determined the vibration is most likely a second order
tire and wheel vibration: 7 Hz (first order tire and wheel frequency) multiplied by 2 (second order) equals 14 Hz
(second order tire and wheel frequency).
Relationship of Vibration Frequency to Order of Vibration
After carrying out the road test as described in this section, the vibration was determined to be either vehicle-
speed related or engine-speed related. That determination will identify the vibration frequency calculations that
should be done.
Vibration Type Calculate

Vehicle-speed related Tire-speed vibration frequency
Driveshaft-speed vibration frequency

Engine-speed related Engine vibration frequency
Engine accessory vibration frequency
Engine firing vibration frequency
In calculating and using frequency readings, it is important to remember the direct relationship between Hz and
rpm. One Hz is equal to 60 rpm. This is easy to remember; think of Hz as cycles per second. There are 60
seconds in a minute, therefore multiply Hz reading by 60 to get rpm. Conversely, divide rpm by 60 to get Hz.
Use the Frequency and RPM Calculations Worksheet to calculate system/component frequencies. The
worksheet provides the necessary steps to determine each system/component group frequency.
Frequency Calculations
Calculating Tire and Wheel Frequency
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and
wheel rpm and frequency by carrying out the following:
Measure the diameter of the tire.

Record the speed at which the vibration occurs.
Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart.
If the vehicle speed is not listed, calculate the tire and wheel frequency as follows:
Divide the vehicle speed at which the vibration occurs by 16 km/h (10 mph). Multiply that number
by the 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number
by 60.
For example, if calculating the frequency based on vehicle speed in km/h for a 64 km/h vibration
with 835 mm tires, divide 64 km/h by 16 km/h = 4. Multiply 4 by 105 rpm = 420. Divide 420 by 60
seconds = 7 Hz at 64 km/h.
If calculating the frequency based on vehicle speed in mph for a 40 mph vibration with 33 inch
tires, divide 40 mph by 10 mph = 4. Multiply 4 by 105 rpm = 420. Divide 420 by 60 seconds = 7 Hz
at 40 mph.
The calculated frequency of 7 Hz is the first order tire and wheel vibration; the second order tire
and wheel vibration would be twice this number at 14 Hz; the third order tire and wheel vibration
would be 21 Hz; and so on.
Tire Speed and Frequency Chart

Tire Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (in) @ 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 1,092/18 1,274/21
508 (20) 173 865/14 1,038/17 1,211/20
533 (21) 165 825/14 990/16 1,155/19
560 (22) 158 790/13 948/16 1,106/18
585 (23) 151 755/13 906/15 1,057/18
610 (24) 145 725/12 870/14 1,015/17
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
Calculating Driveshaft Frequency
Knowing the tire and wheel frequency allows for easy calculation of driveshaft frequency. The driveshaft drives
the tires through the rear axle. Therefore, to determine driveshaft frequency, multiply tire and wheel frequency
by the ratio of the rear axle. Calculate driveshaft frequency by performing the following steps:
Obtain the axle ratio of the vehicle. Suppose the vehicle has a vibration problem at 64 km/h (40 mph)
and a rear axle ratio of 2.93:1.
Multiply the tire and wheel frequency of 7 Hz (calculated previously) with the rear axle ratio of 2.93:1.
This results in a driveshaft frequency of 21 Hz at a vehicle speed of 64 km/h (40 mph).
The calculated frequency of 21 Hz is the first order driveshaft frequency; the second order frequency of the
driveshaft is twice this number, or 42 Hz; and so on.
Calculating Engine Frequency
Use the engine rpm where the vibration symptom occurs to determine engine frequency. Calculate engine
frequency by dividing the engine rpm by 60 (the number of seconds in a minute). For example, if the
corresponding engine rpm of a vibration concern on a vehicle is 2,400 rpm, the resulting engine frequency is 40
Hz. Therefore, a 40 Hz vibration is a first order engine vibration. For purposes of vibration diagnosis, the engine
also includes the torque converter and exhaust system.
Calculating Engine Accessory Frequency
Belt-driven engine accessories often produce vibrations at different frequencies than the engine itself. This is
because the drive ratio created by the different size pulleys causes them to rotate at different speeds.
Determining engine accessory frequency is comparable to calculating driveshaft frequency.
Calculate engine accessory frequency by performing the following steps:
Determine the size ratio factor between the accessory pulley and the crankshaft pulley. For example, if
the diameter of the crankshaft pulley is 6 inches and the accessory pulley diameter is 2 inches, the
accessory pulley rotates 3 times for every crankshaft rotation (6 divided by 2).
Multiply the engine rpm where the vibration condition occurs by the number of times the accessory pulley
is rotating per crankshaft revolution. For example, if the engine rpm is 2,400 rpm, the accessory is
rotating at 7,200 rpm (2,400 rpm multiplied by 3).
Divide the accessory rpm by 60 (the number of seconds in a minute). In this example, the engine
accessory frequency is 120 Hz (7,200 divided by 60).
Calculating Engine Firing Frequency
Engine firing frequency is a term used to describe the pulses an engine creates from the firing of the cylinders.
Engine firing frequency depends on how many cylinders an engine has. The number of times an engine fires a
cylinder with each crankshaft revolution is equal to one-half the number of cylinders. A 4-cylinder engine fires 2
cylinders with each crankshaft revolution. Two revolutions of the crankshaft fire all 4 cylinders. A 6-cylinder
engine fires 3 cylinders with each crankshaft revolution. An 8-cylinder engine fires 4 cylinders for each
crankshaft revolution.
Calculate engine firing frequency by performing the following steps:
Multiply the engine rpm where the vibration symptom occurs by the number of cylinders fired with each
crankshaft revolution. For example, a vehicle with a 6-cylinder engine experiences a vibration concern at
2,400 rpm. The engine is firing the cylinders at 7,200 times per minute (3 multiplied by 2,400).
Divide this number by 60 (the number of seconds in a minute) to obtain the engine firing frequency. In
this example, the engine firing frequency is 120 Hz (7,200 divided by 60) at 2,400 rpm.
Frequency and RPM Calculations Worksheet

Harshness Symptoms
Harshness is customer perception which gives the impression of no isolation from the tire/wheel and
suspension system. Harshness may be caused by road conditions, temperature changes, component damage
and/or incorrect customer modifications on original components/specifications. Customers usually experience
harshness when the vehicle is driving over bumps or potholes and in cold weather conditions. Harshness can
also be experienced with excessive tire pressure, sporty tires, heavy-duty springs and shocks, or other vehicle
modifications. Some aftermarket tires, even with the correct size, may change vehicle behavior and produce
customer concerns. The first step in diagnosing a harshness concern is to determine if the concern was
experienced only in certain specific operating conditions, such as large potholes or extremely cold weather. In
these cases, harshness should be considered normal. A known good vehicle can be driven under the same
conditions and the rides can be compared to determine whether the concern is normal or vehicle specific. The
second step is to check tire pressure and make sure it was set within vehicle specifications. The third step is to
inspect for aftermarket or modified components and determine if they are the cause of the harshness complaint.
If the harshness concern persists after the above steps, it is possible that some components are damaged.
Based on the results from the road test, make a determination of which action in the symptom chart to take first.
NVH Symptom Chart Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. Use
the symptom and possible system categories as follows:
Identify the operating condition that the vehicle is exhibiting.

Match the operating condition to the symptom.
Verify the symptom.
Calculate the frequency and order of the symptom.
Identify which category or system(s) could cause the symptom.
Refer to the section indicated to identify and diagnose the symptom or confirm that the system is not the
source of the condition.
Use the diagnostic instructions in this section along with the necessary listed tools to identify the vibration order
and to isolate the symptom and the possible systems associated with that symptom. Then based on the results
from the road test, make a determination of which action in the symptom chart to take first. Since it is possible
any one of multiple systems may be the cause of the symptom, it may be necessary to use a process of
elimination type diagnostic approach to pinpoint the concern. Refer to the section(s) indicated to identify and
isolate the cause or rule that system out as being the causal system for the symptom.
Vehicle-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not cause a higher order
vibration.
When a vehicle-speed related vibration is present, both tire-speed related vibration and driveshaft-speed
related vibration calculations should be carried out.
Symptom Chart — Tire-Speed Related Vibrations
Symptom Chart — Tire-Speed Related Vibrations

Condition Possible Sources Action
First order tire vibration Tire or wheel REFER to Section 204-04 .
Wheel bearings REFER to Section 204-00 .
Drive axle REFER to Section 205-00 .
Halfshaft REFER to Section 205-00 .
Brake rotor or drum REFER to Section 206-00 .
Second order tire vibration Tire or wheel REFER to Section 204-04 .
Third order tire vibration Tire or wheel REFER to Section 204-04 .
Drive axle REFER to Section 205-00 .
Driveshaft REFER to Section 205-00 .
Halfshaft REFER to Section 205-00 .
Symptom Chart — Driveshaft-Speed Related Vibrations

Symptom Chart — Driveshaft-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not
cause a higher order vibration.
First order Driveshaft REFER to Section 205-00 .
driveshaft
vibration
Rear drive REFER to Section 205-00 .
axle/differential
Second U-joint REFER to Section 205-00 .
order
driveshaft
vibration
Output shaft bushing in Refer to the appropriate section in
transmission/transaxle Group 307 for the procedure. Refer
to the appropriate section in Group
308 for the procedure. GO to the
Symptom Chart in the appropriate
section.
Third order Rear drive REFER to Section 205-00 .
driveshaft axle/differential
vibration
Symptom Chart — Engine-Speed Related Vibrations
Symptom Chart — Engine-Speed Related Vibrations
NOTE: When an engine-speed related vibration is present, engine, engine accessory and
engine firing calculations should be carried out.
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not
cause a higher order vibration.
NOTE: Some engine-speed related vibrations are normal though they should not be felt in
the passenger compartment.
0.5 order Engine REFER to Section 303-00 .
engine
vibration
First through Engine REFER to Section 303-00 .
sixth order
engine
vibration
Transmission/transaxle Refer to the appropriate section in
Group 307 for the procedure. Refer
section.
Engine mounts REFER to Section 303-00 .
mounts Group 307 for the procedure. Refer
section.
Exhaust system REFER to Section 309-00 .
Belt driven Engine pulley REFER to Section 303-00 .
accessory
speed
vibration
Coolant pump REFER to Section 303-00 .
Generator REFER to Section 414-00 .
A/C compressor REFER to Section 412-00 .
Power steering pump REFER to Section 211-00 .
Vacuum pump REFER to Section 303-00 .
Accessory drive belt REFER to Section 303-00 .
Symptom Chart — Noise, Air Leaks or Water Leaks
Symptom Chart — Noise, Air Leaks or Water Leaks

Wind noise, air Body REFER to the Symptom Chart in
or water leaks Section 501-00 .
Roof opening panel REFER to the Symptom Chart in
Section 501-00 .
Belt driven Accessory drive belt REFER to Section 303-05 .
accessory Pulleys
noise/squeal or
chirping
Front end noise Front suspension REFER to Section 204-00 .
while driving
vehicle
Drive axle or REFER to Section 205-00 .
differential
Brake system REFER to Section 206-00 .
Steering linkage or REFER to Section 211-00 .
gear
Group 307 for the procedure.
Refer to the appropriate section in
Group 308 for the procedure. GO
to the Symptom Chart in the
appropriate section.
Engine REFER to Section 303-00 .
Body REFER to the Symptom Chart in
Section 501-00 .
Rear end noise Rear suspension REFER to Section 204-00 .
while driving
vehicle
Drive axle or REFER to Section 205-00 .
differential
Brake system REFER to Section 206-00 .
Section 501-00 .
Noise with Engine REFER to Section 303-00 .
vehicle stopped
Power steering pump REFER to Section 211-00 .
Generator REFER to Section 414-00 .
A/C compressor REFER to Section 412-00 .
Section 501-00 .
Symptom Chart — Harshness
Symptom Chart — Harshness

Harsh vehicle ride Front suspension REFER to Section 204-00 .
Rear suspension REFER to Section 204-00 .
SECTION 501-00: Body System — General Information 2011 Fiesta Workshop Manual
SPECIFICATIONS Procedure revision date: 05/13/2010
Material
Item Specification Fill
Capacity
3M™ Strip Caulk - Black WSB-M4G32-C —
051135-08578
Seam Sealer — —
TA-2
Clear Silicone Rubber ESB-M4G92-A —
TA-32
Silicone Gasket and Sealant WSE-M4G323- —
A4
TA-30
Silicone Spray Lubricant ESR-M13P4-A —
XL-6
Trim and Weatherstrip — —
Adhesive
TA-14-A
Insulation
Body insulation is comprised of urethane, Polyvinyl Chloride (PVC), foam and recycled felt. Insulation is
used as a sound deadener to reduce exterior road and powertrain noises from the interior of the vehicle.
Baffles are located in the bottom of the A-, B- and C-pillars. Mastic insulators are also used as insulation.
For information on the location of the mastic insulators, refer to Section 501-35 . Insulation is installed:
above and below the instrument panel.

at the cowl side panels.
over the front and rear floor pan areas.
over the luggage compartment floor.
Body Sealer Types And Applications
Seam Sealer
Seam Sealer TA-2 or equivalent:
is a heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed
seams, tooled door skin seams and floor pans.
can be used on water leaks and noise concerns.
Clear Silicone Rubber
Clear Silicone Rubber TA-32 or equivalent meeting Ford Specification ESB-M4G92-A:
does not run.

is fast drying.
remains semi-elastic.
can be used for sealing water leaks, noise concerns, remounting trim and repairing torn
weatherstripping.
Silicone Gasket and Sealant
Silicone Gasket and Sealant TA-30 or equivalent meeting Ford specification WSE-M4G323-A4:
is a form-in-place gasket and multi-purpose adhesive/sealant.

is a room temperature curing silicone rubber.
Caulking Cord
3M™ Strip Caulk-Black 051135-08578 or equivalent meeting Ford specification WSB-M4G32-C:
is a heavy-bodied, plastic base with a filler.

is commonly known as perma-gum.
is used on spot-weld holes and between surfaces not sealed with a gasket.
Weatherstrip Adhesive
Trim and Weatherstrip Adhesive TA-14-A or equivalent:
is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Spray Lubricant XL-6 or equivalent meeting Ford specification ESR-M13P4-A:
is used to keep the door and the window weatherstrip pliable and soft.
makes the door easier to close.
retards weatherstrip squeaks.
retards weatherstrip wear.
helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
should not be used prior to painting.
Body System
Material
Item Specification
Seam Sealer —
TA-2
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Inspection and Verification
Dust and Water Leaks
Most dust and water leaks occur due to missing or incorrectly installed body sealer or components. The
source of the leak is detected by:
pressurizing the vehicle and testing with soapy water.

Locate and tape off the body vents.
Turn the blower motor to HIGH.
Turn the air recirculation to OFF.
Close the windows and doors.
Open the hood and spray soapy water along body seams and grommets. Make sure to test
the areas around the A-pillar at the fender and hood hinge area.
Check for bubbles.
inspecting for a dust pattern or water path near and above the area in question.
removing any trim or carpet in the general area of the leak.
road testing or water hose testing the vehicle.
placing a bright light under the vehicle, removing any necessary trim or carpet and inspecting the
interior of the body at joints and weld lines.
Wind Noise
Most wind noise leaks occur at the corners of the windows or in the doors. Wind noise is detected by
driving the vehicle at highway speeds or at speeds as specified by the customer. Drive the vehicle in 4
different directions, with all of the windows closed, the radio off and the A/C blower motor off.
Squeak and Rattle
Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2
surfaces or loose wires and connectors. Detect the source of the noise by stopping movement of the
suspect part by hand or using dampening or low friction materials.
Symptom Chart — NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are
available. For a list of these tools, an explanation of their uses and a glossary of
common terms, refer to Section 100-04 . Since it is possible that any one of multiple
systems may be the cause of a symptom, it may be necessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is
not the causal system for the symptom, refer back to Section 100-04 for the next likely
system and continue diagnosis.
Draft/wind noise Loose fit seal PINCH seal carrier to
and water leak improve retention on seal
around door flange.
perimeter
Seal installed REINSTALL the seal.
incorrectly
Door misaligned REALIGN the door. CHECK
door gaps and fit in door
opening and ADJUST as
necessary. REFER to
Section 501-03 .
Scuff plate trim panel REINSTALL the scuff plate
installed incorrectly trim panel.
Seal or seal pushpins INSTALL a new
damaged seal/pushpins.
Sheet metal joints in SEAL leaks with sealant.
door or door opening
Draft/wind noise Door glass misaligned ADJUST door glass.
and water leak
around glass run
Glass run installed REINSTALL glass run.
incorrectly
Leak path behind INSTALL foam rope behind
glass run glass run.
Glass run channel PINCH glass run channel to
spread wide reduce size of opening.
Glass run damaged INSTALL a new glass run.
Draft/wind noise Belt line seal installed ADJUST seal (do not bend
and water leak at incorrectly on flange the flange).
inner belt line
No contact with side ADJUST door glass.
glass
No contact with glass ADJUST belt line seal or
runs at both ends of ADD foam at seal ends.
belt line seal
Belt line seal damaged INSTALL a new seal.
Draft/wind noise Belt line seal installed ADJUST seal.
and water leak at incorrectly on flange
outer belt line (no glass contact)
Belt line seal does not ADJUST door glass.
contact the glass
No contact with glass ADJUST belt line seal or
runs at both ends of ADD foam at seal ends.
belt line seal
Belt line seal damaged INSTALL a new seal.
Draft/wind noise Hole in weathershield SEAL hole with suitable
at inner door tape.
handle/speaker
opening
Weathershield REALIGN weathershield.
misaligned INSTALL a new
weathershield if pressure
sensitive adhesive fails.
Exterior door handle REALIGN or INSTALL a
seal new seal as necessary.
misaligned/damaged REFER to Section 501-14 .
Speaker or speaker INSTALL a new door
seal missing or speaker.
damaged
Draft/wind noise Missing or damaged CHECK plugs/grommets for
and water leaks plugs/grommets correct installation or
at floor pan and damage. INSTALL new
grommets plugs/grommets if
necessary.
Road noise Missing mastic CHECK for missing mastic
insulators insulators. REFER to
Section 501-35 .
Missing body CHECK for missing body
insulators insulators.
Rattles in Loose wires/cables CHECK that all wires/cables
body/doors and are correctly routed and
instrument panel inserted in correct retainers.
Loose CHECK doors by carefully
objects/components in striking underside of doors
door wells, pillars with a rubber mallet while
quarter trim panels listening for rattles in doors
and pillars. REMOVE or
TIGHTEN loose
objects/components.
Buzz from instrument IDENTIFY which
panel components components of the
instrument panel are
buzzing. SECURE/FASTEN
components as necessary,
ADD foam or felt as needed
if rattle persists.
Door drain holes Holes clogged with CLEAN drain holes of
collecting water mud or road tar foreign material with a
punch or screwdriver.
CHECK drain holes
regularly.
Wind noise from Exterior mirror housing REALIGN with edges
exterior rear view misaligned shingled to airflow, with no
mirror gaps.
Mirror sail gasket REINSTALL with gasket
folded/misaligned unfolded and aligned
correctly.
Mirror housing trim REINSTALL with edges
cap installed shingled to airflow.
incorrectly
Air leak through mirror Fully ENGAGE mirror into
housing hinge its operating position. USE
foam to block air path
through hinge.
Inner sail trim installed REINSTALL sail trim.
incorrectly ADJUST door trim.
Inner sail REINSTALL trim cover with
gasket/barrier installed gasket/barrier aligned
incorrectly correctly.
Air path through wiring BLOCK air path(s) with
bundle/fastener foam/tape.
access holes
Exposed fastener INSTALL a new cap if
access hole on mirror missing.
housing/sail
Rattle/vibration Mirror glass REMOVE mirror glass and
from exterior rear adjustment screws TIGHTEN mirror glass
view mirror loose adjustment motor screws.
REFER to Section 501-09 .
Mirror mounting nuts TIGHTEN mirror mounting
loose nuts. REFER to Section
501-09 .
Aftermarket air If possible, REMOVE
deflector/stone shields aftermarket air
deflector/stone shield, then
ROAD TEST vehicle. If
concern is no longer
present, ADVISE customer
that aftermarket component
was causing concern.
Draft/wind noise Gaps in the sealant APPLY approved sealant.
and water leak bead
around perimeter
of all fixed glass
Air traveling up INSTALL foam rope full
windshield molding length of the A-pillar.
along A-pillar
Gaps in sealant bead RESEAL windshield/rear
of windshield/rear glass. REFER to Section
glass 501-11 .
Windshield/rear glass REINSTALL windshield/rear
misaligned or not glass. REFER to Section
installed correctly 501-11 .
Rear hood seal at REALIGN or INSTALL a
base of windshield new seal as necessary.
misaligned/damaged
Draft noise at Cowl seal REALIGN or INSTALL a
cowl misaligned/damaged new seal as necessary.
Draft/water leak Roof opening REFER to Section 501-17
or noise from roof panel/components for diagnosis.
opening panel
Wind noise Fender splash shield REALIGN fender splash
created by airflow misaligned shield.
over or behind
body panels
Body panel misaligned REALIGN appropriate body
(exposed edge) panel.
Hood misaligned (front CHECK hood gaps and fit.
margin) ADJUST hood as
necessary.
Front grille edge noise APPLY foam in hollow
areas behind louvers.
Wind noise Grille relationship to If possible, ADJUST grille
created by grille leading edge on hood opening panel forward to
opening panel eliminate wind noise.
Sharp edges due to REMOVE sharp edges (no
material imperfections damage to visible surface).
Wind noise from Air extractor housing REINSTALL air extractor
air extractor seated incorrectly housing.
(body vent)
Air extractor housing INSTALL a new air
or flaps damaged extractor.
Wind noise from Turbulence created by DETERMINE if an OEM part
bug location and shape or aftermarket. If
shield/exterior aftermarket ADVISE
windshield sun customer accordingly. If
visor OEM, VERIFY correctly
installed. If noise is
abnormal, REPAIR or
INSTALL new as required.
Draft/wind noise Loose fit seal PINCH seal carrier to
and water leak improve retention on seal
around liftgate flange or INSERT foam in
perimeter carrier.
Seal misaligned or REINSTALL seal.
installed incorrectly
Seal misaligned or REINSTALL seal.
installed incorrectly
Liftgate misaligned REALIGN liftgate. CHECK
liftgate fit in body opening
and ADJUST as necessary.
Scuff plate misaligned REINSTALL scuff plate.
Seal or seal pushpins INSTALL a new seal.
damaged
SECTION 501-02: Front End Body Panels 2011 Fiesta Workshop Manual
Torque Specifications
Description Nm lb-ft lb-in
Fender bolts 6 — 53
Hood hinge-to-body bolts 25 18 —
Hood hinge-to-hood nuts 11 — 97
Front bumper-to-radiator support bolts 9 — 80
Radiator support front bracket-to-front bumper bolt 9 — 80
Radiator support upper bolts 25 18 —
Radiator support rear bracket bolts 9 — 80
GENERAL PROCEDURES Procedure revision date: 05/13/2010
Hood Alignment
1. NOTE: To adjust the hood, the hood latch must be removed.
Remove the hood latch. For additional information, refer to Section 501-14 .
2. NOTE: It is not possible to adjust the rear of the hood to the height of the fender.
Loosen the 4 hood hinge-to-hood nuts and the 4 hood hinge-to-body bolts until the hood will
slightly move.
3. Adjust the hood to align the hood-to-fender gaps. For additional information on body margins,
refer to Section 501-35 .
4. Tighten the 4 hood hinge-to-body bolts.

Tighten to 25 Nm (18 lb-ft).
5. Tighten the 4 hood hinge-to-hood nuts.

Tighten to 11Nm (97 lb-in).
6. NOTE: NOTE: The clearances and edge alignment must be correct before the hood latch is
installed.
Install the hood latch. For additional information, refer to Section 501-14 .
The hood latch must be installed so that the hood engages without stress and the
clearances on the LH and RH sides are not changed.
REMOVAL AND INSTALLATION Procedure revision date: 05/13/2010
Front End Body Panels — Exploded View
Item Part Number Description

1 W702704 Front fender lower bolts (2 required)
2 W702704 Front fender inner rear bolt
3 W702704 Front fender front middle bolt
4 W702704 Front fender front outer bolts (2 required)
5 W702704 Front fender front middle nut
6 W702704 Front fender upper front bolt
7 W702704 Front fender upper rear bolt
8 16005/ 16606 Front fender (RH/LH)
9 W715537 Front fender splash shield pin-type retainer (7 required)
10 W706169 Front fender splash shield retainers
1. For additional information, refer to the procedures in this section.

Fender Splash Shield
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
2. Remove the wheel and tire. For additional information, refer to Section 204-04 .
3. If equipped, remove the front mudflaps.
4. Remove the 8 front fender splash shield retainers and the front fender splash shield.
5. To install reverse the removal procedure.

Fender
Removal
1. With the vehicle in NEUTRAL, position it on the hoist. For additional information, refer to Section
100-02 .
2. Remove the headlamp assembly. For additional information, refer to Section 417-01 .
3. Remove the front fender upper bolt.

To install, tighten to 6 Nm (53 lb-in).
4. Gently pry out on the fixed front corner glass to gain access to the front fender upper rear bolt.
5. Loosen the front fender upper rear bolt.
Calculate the correct torque wrench setting for the following torque. Refer to the Torque
Wrench Adapter Formulas in the Appendix.
6. Remove the front fender splash shield. For additional information, refer to Fender Splash Shield
in this section.
7. Remove the front fender inner rear bolt and the 2 front fender lower bolts.
8. Remove the 3 front bumper cover-to-front bumper cover bracket upper bolts and disconnect the
front bumper cover from the front fender.
9. Remove the 3 front fender bracket bolts.
10. Slide the front fender towards the front of the vehicle and remove.
11. To install, reverse the removal procedure.
Air Deflector — Lower, Radiator
Part
Item Number Description
1 W710763 Front stone deflector extension bolts (4 required)
2 16184/ Front stone deflector extension (RH/LH)
16185
3 W704277 Front stone deflector extension nut (2 required)
4 W712196 Front stone deflector-to-lower radiator air deflector pin-
type retainer (6 required)
5 17808 Front stone deflector
6 W712196 Front stone deflector-to-lower radiator air deflector pin-
type retainer
7 W500214 Lower radiator air deflector bolt (5 required)
8 8327 Lower radiator air deflector
9 — Front fender splash shield retainer (2 required and
serviced as part of the front fender splash shield)
10 W701054 Front fender splash shield pin-type retainer (2 required)
1. Remove the front bumper cover. For additional information, refer to Section 501-19 .
2. If equipped, remove the 2 scrivet retainers and both front lower side radiator air deflectors.
3. Remove the 5 lower radiator air deflector bolts and the lower radiator air deflector.

Transfer parts as necessary.
Radiator Grille Opening Panel Reinforcement
Part
1 W701121 Front bumper-to-radiator grille opening panel
reinforcement (4 required)
2 — Radiator grille opening panel reinforcement nut (part of
16138)
3 W702928 Radiator grille opening panel reinforcement support-to-
front bumper bolt
4 W713533 Radiator grille opening panel reinforcement upper bolt (2
required)
5 54101A02 Radiator grille opening panel reinforcement rear support
bracket
6 W500213 Radiator grille opening panel reinforcement rear support
bracket bolt (2 required)
7 16138 Radiator grille opening panel reinforcement
1. Remove the radiator lower air deflector. For addition information, refer to Air Deflector — Lower,
Radiator in this section.
2. Drain the cooling system. For additional information, refer to Section 303-03 .
3. Remove both headlamp assemblies.

1. Remove the 3 headlamp assembly bolts.
2. Disconnect and remove both headlamp assemblies.
4. Disconnect the hood release cable at the hood latch and position aside.
5. Release the degas bottle hose from the upper right side of the radiator grille opening panel
reinforcement.
6. Recover the refrigerant. For additional information, refer to Section 412-00 .
7. Remove the A/C condenser inlet and outlet line nuts and disconnect both lines.
8. Disconnect the A/C pressure transducer electrical connector and disconnect the wiring harness from the
radiator grille opening panel reinforcement.
9. If equipped, remove the 2 scrivets and both side radiator air deflectors.
10. Remove the air cleaner housing-to-radiator grille opening panel reinforcement retainer.
11. Remove the 4 front bumper-to-radiator grille opening panel reinforcement bolts.
12. Remove the radiator grille opening panel reinforcement support-to-front bumper bolt.
13. Remove the 2 radiator grille opening panel reinforcement upper bolts.
To install, tighten to 25 Nm (18 lb-ft).
14. Remove the radiator grille opening panel reinforcement.

Cowl Panel Grille

1 018A16 Upper cowl panel
2 14197 Upper cowl panel-to-lower cowl panel clip (6 required)
3 W700133 Lower cowl panel bolt (4 required)
4 016B26 Lower cowl panel
Upper Cowl Panel and Lower Cowl Panel
1. Remove the wiper blade arms. For additional information, refer to Section 501-16 .
2. Remove the 6 upper cowl panel-to-lower cowl panel clips.
3. Remove the upper cowl panel.
Lower Cowl Panel
4. Remove the headlamp assemblies. For additional information, refer to Section 417-01 .
5. Remove the 4 lower cowl panel bolts.
6. Release the brake booster vacuum hose from the clip on the lower cowl panel.
7. Remove the lower cowl panel.
All
SECTION 501-03: Body Closures 2011 Fiesta Workshop Manual
Material
Capacity
Multi-Purpose Grease ESB-M1C93- —
XG-4 and/or XL-5, or B
equivalents
Door check arm-to-body bolts 25 18 —
Door check arm-to-door nuts 10 — 89
Door hinge-to-body bolts 24 18 —
Door hinge-to-door bolts 24 18 —
Lifgate hinge bolts 11 — 97
Luggage compartment hinge-to-luggage compartment lid bolts 11 — 97
Luggage Compartment Lid Alignment
1. Loosen the 4 luggage compartment lid bolts.
2. Adjust the luggage compartment lid as necessary. For additional information on body margins,
3. Tighten the 4 luggage compartment lid hinge bolts.

Tighten to 11Nm (97 lb-in).
Liftgate Alignment
1. Loosen the 4 liftgate hinge-to-liftgate bolts just enough to permit movement of the liftgate.
2. NOTE: The liftgate should be adjusted for even and parallel fit with the liftgate opening and the
surrounding panels.
Adjust the liftgate as necessary. For additional information on body margins, refer to Section 501-
35 .
3. Tighten the 4 liftgate hinge-to-liftgate bolts.

Tighten to 11 Nm (97 lb-in).
Striker Adjustment
Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5, or equivalents
NOTE: Before adjusting the door latch striker plate, verify that the door can be closed easily and fits
tightly.
1. Loosen the door latch striker bolts.
2. Reposition the door latch striker plate from side to side or up and down as necessary.
3. Tighten the door striker plate bolts.

4. Check the adjustment of the door. For additional information on body margins, refer to Section
501-35 .
Repeat the procedure as necessary.
Lubricate the door latch using the specified lubricant.
Door Alignment — Front
Material
Item Specification
All alignments
1. Remove the door latch striker plate.
Front door in and out, up and down alignment
2. Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door
alignment.
Front door fore, aft and tilt alignment
3. Loosen, but do not remove, the front door hinge-to-body fasteners enough to allow door
alignment.
All alignments
4. Adjust the door. For additional information on body margins, refer to Section 501-35 .
5. Tighten the door fasteners.

Tighten the front door hinge-to-front door fasteners to 24 Nm (18 lb-ft).
Tighten the front door hinge-to-body fasteners to 25 Nm (18 lb-ft).
6. Install and adjust the door striker as necessary. For additional information, refer to Striker
Adjustment in this section.
Door Alignment — Rear
Material
Item Specification
All alignments
1. Remove the door latch striker plate.
Rear door in and out, up and down alignment
2. Loosen, but do not remove, the rear door hinge-to-door fasteners enough to allow door alignment.
Front door fore, aft and tilt alignment
3. Loosen, but do not remove, the rear door hinge-to-body fasteners enough to allow door alignment.
All alignments
4. Adjust the door. For additional information on body margins, refer to Section 501-35 .
5. Tighten the door fasteners.

Tighten the rear door hinge-to-door fasteners to 24Nm (18 lb-ft).
Tighten the rear door hinge-to-body fasteners 25 Nm (18 lb-ft).
6. Install and adjust the door striker as necessary. For additional information, refer to Striker Adjustment in
this section.
Door
Front Door

1 W713332 Front door lower hing-to-door bolt (4 required)
2 W711806 Front door lower hinge-to-body bolt (2 required)
3 W520101 Front door check nut (4 required)
4 W713778 Front door check bolt (2 required)
5 23504 Front door check
6 22810/ 22811 Front door lower hinge (RH/LH)
7 W713332 Front door upper hinge-to-door bolt (4 required)
8 22810/ 22811 Front door upper hinge (RH/LH)
9 W711806 Front door upper hinge-to-body bolt (2 required)
10 W709923 Front door upper hinge nut (2 required)
11 W709923 Front door lower hing nut (2 required)
Rear Door
1 W713332 Rear door lower hinge-to-door bolt (4 required)
2 26810/ 26811 Rear door lower hinge (RH/LH)
3 W702368 Rear door lower hinge-to-body bolt (2 required)
4 W520101 Rear door check nut (4 required)
5 27204 Rear door check
6 W713778 Rear door check bolt (2 required)
7 W713332 Rear door upper hinge-to-door bolt (4 required)
8 W702368 Rear door upper hinge-to-body bolt (2 required)
9 26800/ 26801 Rear door upper hinge (RH/LH)
10 W709923 Rear door upper hinge nut (2 required)
11 W709923 Rear door lower hinge nut (2 required)
1. Disconnect the door bulk head connector at the body.

1. Carefully pull the rubber grommet around the bulk head connector back away from the body to
gain access to the 3 clips on the bulk head connector.
2. Release the upper clip and the 2 lower clips and pull the door bulk head connector from the body.
3. Disconnect the electrical connectors from the door bulk head connector.
2. Remove the door check arm-to-body bolt.

3. Remove the 2 upper hinge-to-door bolts.

4. NOTE: The aid of an assistant is required to hold the door up while removing the lower hinge-to-door
bolts.
Remove the 2 lower hinge-to-door bolts.


If necessary, adjust the door. For additional information, refer to Door Alignment — Front or Door
Alignment — Rear in this section.
Door Check Arm
NOTE: Front and rear door check arms are removed in the same manner. For additional information on
location, refer to the exploded view in Door in this section.
1. Remove the door check arm-to-body bolt.

2. Remove the 2 door check arm-to-door nuts.

3. Remove the door speaker. For additional information, refer to Section 415-00 .
4. Remove the front door check arm.

Liftgate

1 406A10 Rear liftgate shock (RH/LH)
2 40110 Rear liftgate
3 42900 Rear liftgate hinge (RH/LH)
4 W702434 Rear liftgate hinge bolt (4 required)
5 — Liftgate electrical connector (part of 14B562A)
1. Remove both upper B-pillar trim panels. For additional information, refer to Section 501-05 .
2. Remove both upper C-pillar trim panels. For additional information, refer to Section 501-05 .
3. Gently drop down the headliner in the rear to access the liftgate bulkhead electrical connector and the
rear washer hose.
1. Remove the 2 rear headliner pin-type retainers.
2. Release the headliner from the liftgate weather strip and gently let drop down.
4. Disconnect the liftgate bulkhead connector located under LH rear of headliner.

5. Release the wiring harness locator and position the harness outside of the vehicle.
6. NOTICE: Plug washer hose after disconnecting. Failure to do so will result in damage to
headliner due to fluid leakage.
Disconnect the rear washer hose located under the right rear of headliner.
7. Release the washer hose grommet and position outside of the vehicle.
8. With the help of an assistant, disconnect both liftgate shocks at the liftgate.
9. NOTICE: To minimize the possibility of the cross threading, hand-start all fasteners during the
installation.
With the help of an assistant, mark the position of each hinge with a wax pencil or suitable non staining
marker and remove the 4 liftgate hinge-to-liftgate bolts.

If necessary, adjust the liftgate. For additional information, refer to Liftgate Alignment in this
section.
SECTION 501-05: Interior Trim and Ornamentation 2011 Fiesta Workshop Manual
Front safety belt D-ring bolt 40 30 —
Rear door pull handle screw 3 — 27
Rear safety belt lower anchor bolt 48 35 —
Upper B-pillar trim panel screw 6 — 53
Upper C-pillar trim panel screw - 4 door sedan 6 — 53
Interior Trim — Exploded View
4 Door Sedan
NOTE: RH side shown, LH side similar.

1 W713688 A-pillar trim panel retaining clip
2 W715667 A-pillar trim panel 2-stage high-retention
retaining clip
3 03598 (RH)/ 03599 A-pillar trim panel
(LH)
4 W713688 B-pillar upper trim panel retaining clip (2
required)
5 24356(RH)/ 24357 B-pillar upper trim panel
(LH)
6 W712518 B-pillar upper trim panel bolt
7 W715667 C-pillar upper trim panel 2-stage high-retention
retaining clip
8 W713688 C-pillar upper trim panel retaining clip (4
required)
9 — C-pillar upper trim panel cover (part of 31004
(RH)/ 31005 (LH))
10 31004 (RH)/ 31005 C-pillar upper trim panel
(LH)
11 W712518 C-pillar upper trim panel bolt
12 46808 (RH) / 46809 Parcel shelf upper trim panel
(LH)
13 W710338 Retaining clip (5 required) (2 required)
14 31012 (RH) / 31013 C-pillar lower trim panel
(LH)
15 W703198 Pushpin
16 W710338 C-pillar lower trim panel retaining clip (4
required)
17 13288 (RH) / 13289 Rear scuff plate
(LH)
18 W714848 Pushpin with foam seal (6 required)
19 24346 (RH) / 24347 B-pillar lower trim panel
(LH)
20 W713688 B-pillar lower trim panel retaining clip (2
required)
21 — Cowl side trim panel retainer pin (part of 02344
(RH) / 02345 (LH))
22 02344 (RH) / 02345 Cowl side trim panel
(LH)
23 13208 (RH) / 13209 Front scuff plate
(LH)
5 Door Hatchback
NOTE: LH side shown, RH side similar.

1 03598 (RH)/ 03599 A-pillar trim panel
(LH)
2 W713688 A-pillar trim panel retaining clip
3 W715667 A-pillar trim panel 2-stage high-retention
retaining clip
4 W713688 B-pillar upper trim panel retaining clip (2
required)
5 24356(RH)/ 24357 B-pillar upper trim panel
(LH)
6 W712518 B-pillar upper trim panel bolt
7 W715667 C-pillar upper trim panel 2-stage high-retention
retaining clip
required)
9 31010 (RH) / 31011 C-pillar upper trim panel
(LH)
10 46808 (RH) / 46809 Cargo cover support panel
(LH)
11 W701303 Cargo cover support panel screw
12 W713688 Cargo cover support panel retaining clip
13 31148 (RH) / 31149 Quarter trim panel
(LH)
14 W701380 Pushpin
15 31012 (RH) / 31013 C-pillar lower trim panel
(LH)
16 W703198 Pushpin
17 W710338 C-pillar lower trim panel retaining clip (4
required)
18 13228 (RH) / 13229 Rear scuff plate
(LH)
19 W714848 Pushpin with foam seal (6 required)
(LH)
21 W713688 B-pillar lower trim panel retaining clip (2
required)
22 — Cowl side trim panel retainer pin (part of 02344
(RH) / 02345 (LH))
23 02344 (RH) / 02345 Cowl side trim panel
(LH)
24 13208 (RH) / 13209 Front scuff plate
(LH)

A-Pillar Trim Panel
NOTICE: To avoid damage to the A-pillar trim panel, remove any retaining clips from the body
and attach them to the A-pillar trim panel before installing.
1. Position the door opening weatherstrip aside.
2. Gently pull the upper A-pillar trim panel toward the center of the vehicle to release the A-pillar trim
panel retaining clips.

B-Pillar Trim Panel
Lower and upper
1. Position the front and rear weatherstrips aside.
2. Remove the front scuff plate trim panel. For additional information, refer to Scuff Plate Trim Panel
— Front in this section.
3. Remove the rear scuff plate trim panel. For additional information, refer to Scuff Plate Trim Panel
— Rear in this section.
4. Position the seats in the full forward position.
5. Gently pull the B-pillar lower trim panel toward the center of the vehicle to release the 2 B-pillar
lower trim panel retaining clips.
6. NOTICE: To avoid damage to the B-pillar lower trim panel, remove any retaining clips from
the body and attach them to the B-pillar lower trim panel before installing.
Remove the B-pillar lower trim panel.
Upper
7. NOTE: Inspect the safety belt D-ring cover for damage and replace D-ring cover if damaged.
Remove the bolt cover and safety belt D-ring bolt and position the safety belt aside.
1. To install, tighten to 40 Nm (30 lb-ft).
8. Remove the B-pillar upper trim panel bolt.
9. Remove the B-pillar upper trim panel.

Pull the B-pillar upper trim panel toward the center of the vehicle to release the 2 B-pillar
upper trim panel retaining clips.
10. NOTICE: To avoid damage to the B-pillar upper trim panel, remove any retaining clips from
the body and attach them to the B-pillar upper trim panel before installing.
To install, reverse the removal procedure.

To install, align the trim panel retaining clips to the retaining clip holes in the body.
C-Pillar Trim Panel — 4-Door Sedan
Upper
1. Position the rear seat backrest down.
Lower and upper
2. Position the rear door opening weatherstrip aside.
3. Gently pull the parcel shelf upper trim panel toward the center of the vehicle to release the 4
parcel shelf upper trim panel retaining clips and position the parcel shelf upper trim panel aside.
Upper
4. Gently pull the C-pillar upper trim panel cover toward the center of the vehicle to release the 4 C-
pillar upper trim panel cover retaining clips.
Remove the C-pillar upper trim panel cover.
5. Gently pull the C-pillar lower trim panel toward the center of the vehicle to release the 3 C-pillar
upper retaining clips.
6. Remove the C-pillar upper trim panel screw.

To install, tighten the screw to 6 Nm (53 lb-In).
7. Remove the C-pillar upper trim panel.

Pull the C-pillar upper trim panel toward the center of the vehicle to release the 4 C-pillar
Lower
8. Remove the rear seat cushion. For additional information, refer to Section 501-10 .
9. Remove the rear door scuff plate.
10. Remove the C-pillar lower trim panel pushpin.

Lower the rear seat back as necessary for access to pushpin.
upper retaining clips and remove the C-pillar lower trim panel.
Lower and upper
12. NOTICE: To avoid damage to the trim panels, remove any retaining clips from the body
and attach them to the trim panels before installing.

C-Pillar Trim Panel — 5-Door Hatchback
Upper and lower
1. Position the rear door opening weatherstrip aside.
3. Remove the C-pillar lower trim panel pushpin.

Lower the rear seat back as necessary for access to pushpin.
4. Remove the rear door scuff plate.
lower retaining clips.
6. NOTICE: To avoid damage to the C-pillar lower trim panel, remove any retaining clips from
the body and attach them to the C-pillar lower trim panel before installing.
Remove the C-pillar lower trim panel.
Upper
NOTE: The rear seat is removed for clarity.
7. Remove the safety belt anchor bolt.

8. Remove the C-pillar upper trim panel.
Pull the C-pillar upper trim panel toward the center of the vehicle to release the 5 C-pillar
Route the shoulder safety belt through the C-pillar upper trim panel.
Upper and lower
9. NOTICE: To avoid damage to the C-pillar lower trim panel, remove any retaining clips from
the body and attach them to the C-pillar lower trim panel before installing.

Quarter Trim Panel — 5-Door Hatchback
1. Remove the C-pillar upper and lower trim panel. For additional information, refer to C-Pillar Trim Panel —
5-Door Hatchback in this section.
2. NOTICE: To avoid damage to the rear hatch scuff plate trim panel, remove any retaining clips from
the body and attach them to the rear hatch scuff plate trim panel before installing.
Remove the rear hatch scuff plate trim panel.

Remove the 2 pushpin retainers.
Pull the rear hatch scuff plate trim panel upwards to release the retaining clips.
To install, align the rear hatch scuff plate trim panel retaining clips to the holes in the body.
3. Position the rear hatch weatherstrip aside.
4. Remove the rear package tray trim panel.
5. Remove the cargo cover support panel screw.
6. Gently pull the cargo cover support panel toward the center of the vehicle to release the 3 cargo center
support panel retaining clips.
7. Remove the cargo cover support panel.

Disconnect the cargo panel light.
8. Remove the pushpin retainer.
9. Remove the quarter trim panel.

Liftgate Trim Panel

1 W712474 Upper liftgate trim panel retaining clip (4
required)
2 42906 (RH) / 42907 Upper liftgate trim panel
(LH)
3 W700426 Upper liftgate trim panel screw (2 required)
4 W700426 Lower liftgate trim panel screw
5 46404 Lower liftgate trim panel
6 W712474 Lower liftgate trim panel retaining clip (10
required)
Upper liftgate trim panel
1. Remove the upper liftgate trim panel retaining screw.
2. Remove the upper liftgate trim panel.

Pull the upper liftgate trim panel toward the center of the vehicle and release the 2 upper liftgate
trim panel retaining clips.
3. NOTICE: To avoid damage to the upper liftgate trim panel, remove any retaining clips from the
body and attach them to the upper liftgate trim panel before installing.

To install, align the upper liftgate trim panel retaining clips to the retaining clip holes in the body
Lower liftgate trim panel

4. Remove the lower liftgate trim panel.
Remove the lower liftgate trim panel retaining screw.
Pull the lower liftgate trim panel toward the front of the vehicle and release the 10 lower liftgate
trim panel retaining clips.
5. NOTICE: To avoid damage to the lower liftgate trim panel, remove any retaining clips from the
body and attach them to the lower liftgate trim panel before installing.

To install, align the lower liftgate trim panel retaining clips to the retaining clip holes in the body
Scuff Plate Trim Panel — Front
NOTICE: To avoid damage to the front scuff plate trim panel, remove any pushpins from the body
and attach them to the front scuff plate trim panel before installing.
1. Pull the front scuff plate trim panel upwards to release the pushpins. For additional information on
the pushpin location, refer to Interior Trim — Exploded View in this section.
To install, align the trim panel pushpins to the pushpin holes in the body.
Scuff Plate Trim Panel — Rear
NOTICE: To avoid damage to the rear scuff plate trim panel, remove any pushpins from the body
and attach them to the rear scuff plate trim panel before installing.
1. Pull the rear scuff plate trim panel upwards to release the pushpins. For additional information on
the pushpin location, refer to Interior Trim — Exploded View in this section.
To install, align the trim panel pushpins to the pushpin holes in the body.
Door Trim Panel — Front

1 23834 RH/ 23835 LH Front door panel bracket
2 W707291 Front door panel bracket nut (3 required)
3 W709931 Front door module bolt (3 required)
4 W790227 Front door panel clip
5 — Pushpin (8 required)
6 219B00 Grommet (3 required)
7 23942 RH/23943 LH Front door trim panel
8 22600 (RH)/22601 (LH) Front door latch inside handle assembly
9 4605B01 Front door latch inside handle assembly
screw
10 W10A02 Door latch inside handle assembly screw
cover
11 14529 (RH)/14A132 Window switch assembly
(LH)
12 24184 (RH) / 24185 Grab handle cover
(LH)
13 — Grab handle cover S-clips (4 required)
14 W719311 Door pull handle screw (2 required)
15 W710836 Front door trim panel screw (3 required)
16 23834 RH/ 23835 LH Front door panel bracket (2 required)

All vehicles
1. NOTICE: To avoid damage to the grab handle cover, remove any grab handle cover S-clips from
the front door trim panel and attach them to the grab handle cover before installing.
Using a suitable tool, pry from the lower corner and remove the grab handle cover.
2. Remove the 2 door pull handle screws.
3. Remove the screw cover, screw and remove the front door latch inside handle assembly.
Disconnect the door latch cable.
Manual windows
4. Using a suitable tool, pry the window regulator handle and remove the window regulator handle.
All vehicles
5. Remove the 3 front door trim panel screws.
6. NOTICE: To avoid damage to the front door trim panel, remove any pushpins from the front door
module and attach them to the front door trim panel before installing.
Working from the bottom of the front door trim panel, Disengage the 8 pushpins from the door.
Using a pushpin removal tool, pull the front door trim panel outward to release the retaining
pushpins.
7. Lift the front door trim panel and remove the front door trim panel.
Power Windows
8. Disconnect the power window switch.
All Vehicles
9. If required, remove the front door panel clip from the front door trim panel.

Door Trim Panel — Rear
NOTE: Click here or refer to the on-line Workshop Manual to view this illustration as an interactive exploded
view, requires Adobe® Acrobat® 8.0 or higher.

1 W713651 Pushpin
2 W709011 Pushpin
3 254K06 RH/ 254K07 Rear door sail panel (5 door hatchback)
LH
3 254K05 RH/ 254K06 Rear door sail panel (4 door sedan)
LH
4 22600 RH/ 22601 LH Rear door latch inside handle assembly
5 05B01 Rear door latch inside handle assembly
screw
6 W10A02 Screw cover
7 14529 Rear window control switch
8 W713911 Rear door trim panel screw (2 required)
9 27406 RH/ 27407 LH Rear door trim panel
10 — Pushpin (6 required)
All vehicles
1. NOTICE: To avoid damage to the rear door sail panel, remove the pushpin from the rear door and
attach them to the rear door sail panel before installing.
Remove the rear door sail panel.
2. Remove the door handle screw cover and screw.
3. Remove the 2 rear door trim panel screws.
Manual windows
4. Use a suitable tool to pry the window regulator handle to remove the window regulator handle.
Power windows
5. Remove the window control switch. For additional information, refer to Section 501-11 .
All vehicles
6. NOTICE: To avoid damage to the rear door trim panel, remove any pushpins from the rear door
module and attach them to the rear door trim panel before installing.
Working from the bottom of the rear door trim panel, disengage the 7 pushpins from the door.
7. Pull the rear door trim panel away from the door to release the rear door trim panel retaining clips and
rear door trim panel.
Disconnect the door latch cable.

To install, align the trim panel pushpins to the pushpin holes in the rear door module.
Parcel Shelf — 4-Door Sedan

1 F46668 Retaining clip (4 required)
2 46808 (RH) / 46809 (LH) Parcel shelf upper trim panel
3 W710338 Parcel shelf side clip (4 required)
4 611B90 Center safety belt bezel
5 W700673 Pin-type retainers (4 required)
6 46668A Parcel shelf trim panel
7 W703708 Safety belt anchor bolt (3 required)
2. Remove the 3 safety belt anchor bolts.

3. Remove the RH and LH parcel shelf upper trim panels.

Gently pull the parcel shelf upper trim panel toward the center of the vehicle to release the 4
parcel shelf upper trim panel retaining clips.
Pull the RH and LH safety belts through the parcel shelf upper trim panel openings.
Remove the parcel shelf upper trim panel.
4. Remove the RH and LH C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel — 4-
Door Sedan in this section.
5. Remove the safety belt retractor bezel.

Pull the safety belt retractor bezel toward the front of the vehicle.
Remove the safety belt retractor bezel from the safety belt.
6. Remove the 4 parcel shelf pin-type retainers.
7. Remove the parcel shelf.

Pull the parcel shelf toward the front of the vehicle.
Pull the center safety belt rearward through the center retractor opening.
8. NOTICE: To avoid damage to the parcel shelf upper trim panel, remove any retaining clips from
the body and attach them to the parcel shelf upper trim panel before installing.

Headliner — 4-Door Sedan
NOTE: Headliner with roof opening panel shown, all others similar.

1 W711521 Trim pin (2 required)
2 51916 Headliner
3 W712427 Retaining clip (4 required)
4 040A06 Center high mounted stop lamp (CHIMSL)
cover
5 52124 Headliner retainer (if equipped)
6 W502660 Screw (6 required)
7 04104 (RH)/04104 Sun visor assembly
(LH)
8 04132 Sun visor clip (2 required)
9 519A70 Overhead console assembly (if equipped)
1. Remove the front passenger seat. For additional information, refer to Section 501-10 .
2. Remove the LH and RH sun visors.

Remove the 4 sun visor screws.
3. Remove the LH and RH sun visor clips.

Remove the 2 sun visor clip screws.
4. Remove the LH and RH A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel in this
section.
5. Remove the LH and RH B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel in this
section.
6. Remove the LH and RH C-pillar upper trim panels. For additional information, refer to C-Pillar Trim Panel
— 4-Door Sedan in this section.
7. Remove the CHIMSL cover.
8. Remove 2 screws and the CHIMSL retainer plate.
9. NOTE: RH A-pillar shown, LH A-pillar similar.
Disconnect the 2 electrical connectors located at the A-pillars.

Detach the 8 wire harness pin-type retainers.
10. If equipped, release the 2 wiring harness guides from the roof opening panel drain tubes.
11. If equipped, remove the roof opening panel headliner retainer.
12. Disconnect the rear view mirror electrical connector.
13. If equipped, disconnect the roof opening panel motor electrical connector.
14. NOTICE: An assistant is required when removing the headliner from the vehicle to avoid damage
to the headliner.
Remove the headliner.

Remove the headliner through the RH front door opening.

Headliner — 5-Door Hatchback
NOTE: Headliner with roof opening panel shown, all others similar.

2 51916 Headliner
4 52124 Headliner retainer (if equipped)
5 W502660 Screw (6 required)
6 04104 (RH) / 04105 (LH) Sun visor assembly
7 04132 Sun visor clip (2 required)
8 519A70 Overhead console assembly (if equipped)

Remove the 4 sun visor screws.
2. Remove the LH and RH sun visor clips.

Remove the 2 sun visor clip screws.
3. Remove the LH and RH A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel in this
section.
4. Remove the LH and RH B-pillar upper and lower trim panels. For additional information, refer to B-Pillar
Trim Panel in this section.
5. Position aside the LH and RH C-pillar upper trim panels.
6. NOTE: RH A-pillar shown, LH A-pillar similar.
Disconnect the 2 electrical connectors located at the A-pillars.

Detach the 8 wire harness pin-type retainers.
Disconnect the rear glass washer hose at the LH A-pillar.
7. If equipped, release the 2 wiring harness guides from the roof opening panel drain tubes.
8. If equipped, remove the roof opening panel headliner retainer.
9. Disconnect the rear view mirror electrical connector.
10. If equipped, disconnect the roof opening panel motor electrical connector.
11. Disconnect the rear glass washer hose at the RH C-pillar.
12. Lower the rear seat backs.
13. NOTICE: An assistant is required when removing the headliner from the vehicle to avoid damage
to the headliner.
Remove the headliner.

Remove the 2 pushpins.
Remove the headliner through the rear hatch opening.

SECTION 501-08: Exterior Trim and Ornamentation 2011 Fiesta Workshop Manual
Description Nm lb-in
Roof-mounted spoiler bolts 8 71
Applique — Decklid

1 5442512 Decklid lower applique
2 W713090 Decklid upper applique retainers (4 required)
3 5443400 Decklid upper applique
4 W707977 Decklid upper applique nut (4 required)
NOTE: A new decklid lower applique must be installed.
1. Remove the 10 pin-type retainers and the decklid trim panel.
2. NOTICE: Use care not to damage the paint when prying on the decklid applique.
NOTE: A new decklid lower applique must be installed.

Use a non-marring tool, and pry the decklid lower applique off.
3. Remove the decklid upper applique.

1. Remove the 4 decklid upper applique screws.
2. Disconnect the decklid latch electrical connector and remove the decklid upper applique.

Applique — Liftgate

1 V425A52 Rear liftgate emblem
2 5825510 Lower liftgate applique
3 5843400 Upper liftgate applique
4 W520201 Liftgate applique nut (6 required)
1. Remove the liftgate trim panel. For additional information, refer to Section 501-05 .
2. Remove the 6 liftgate applique nuts.
3. Remove the liftgate applique.

Remove the license plate lamp bulbs.
Disconnect the luggage compartment lid/liftgate latch switch and disconnect the wiring harness
from the liftgate applique.

Radiator Grille
Part
1 8200 Lower radiator grille
2 8200 Lower radiator grille outer frame
3 8213 Emblem
4 8200 Upper radiator grille
5 N807389 Upper radiator grille pin-type retainer (4 required)
6 8A284 Upper radiator grille reinforcement
7 W520822 Emblem nut (2 required)
8 8A284 Upper radiator grille lower reinforcement bracket
9 W706737 Upper radiator grille lower reinforcement bracket rivet (4
required)
Upper Radiator Grille and Lower Radiator Grille
Upper Radiator Grille
2. Remove the 4 upper radiator grille pin-type retainers.
3. Disconnect the upper radiator grille reinforcement from the front bumper cover and remove the upper
radiator grille and reinforcement.
4. Disconnect the upper radiator grille from the reinforcement and remove.
Lower Radiator Grille
5. From the back side of the front bumper cover disconnect the lower radiator grille and remove.
6. Disconnect the outer frame from the bumper cover and remove.
Upper Radiator Grille and Lower Radiator Grille

Spoiler — Decklid

1 5444210 Spoiler
2 — Foam tape (part of 5444210)
2. NOTE: Use an 11mm, 12 point socket or wrench to compress the 2 locking tabs on the clips.
Release the 7 clips and remove the decklid spoiler.

Installation
1. Clean the rear spoiler mounting surfaces.
2. Install the decklid spoiler and connect the 7 clips.
3. Install the decklid trim panel and the 10 pin-type retainers.

Spoiler — Roof

1 W702351 Roof-mounted spoiler bolt cover (2 required)
2 W500213 Roof-mounted spoiler bolt (2 required)
3 W706169 Roof-mounted spoiler screw (4 required)
4 W713489 Roof-mounted spoiler clip (3 required)
5 W714205 Roof-mounted spoiler nut (4 required)
6 44210 Roof-mounted spoiler
7 13A613 High mounted stop lamp
8 46058 High mounted stop lamp screws (2 required)
1. Remove the high mounted stoplamp. For additional information, refer to Section 417-01 .
2. Remove the roof mounted spoiler.

1. Remove the roof mounted spoiler bolt covers.
2. Remove the 2 roof mounted spoiler bolts.
3. Remove the 4 roof mounted spoiler screws.
4. Remove the 2 roof mounted spoiler screws behind the high mounted stoplamp.
5. Disconnect the 3 roof mounted spoiler clips and remove the roof mounted spoiler.
Press down slightly on the front corner of the roof mounted spoiler to cause the rear corner to
raise up slightly.
With your fingers behind the raised corner release the pressure on the front corner and pull gently
out towards the rear of the vehicle to disconnect the clips and remove the spoiler.
SECTION 501-09: Rear View Mirrors 2011 Fiesta Workshop Manual
Exterior mirror nuts 14 124
Rear View Mirrors
Exterior Mirror
The exterior mirror consists of the following serviceable components:
Exterior mirror glass (heated glass optional)

Exterior mirror cover
Exterior mirror housing
Exterior mirror control switch
Exterior mirror motor
Turn signal (if equipped)
Exterior Heated Mirror (If equipped)
The exterior heated mirrors self actuate when the ambient air temperature is less than 5° C (41° F) and
engine coolant temperature is less than 60° C (140° F). The rear window defroster LED indicator does
not illuminate when the exterior heated mirrors self actuate.
Interior Mirror
This vehicle is equipped with either a non-dimming or auto-dimming interior rear view mirror.
Rear View Mirrors — Exterior
Special Tool(s)
Fluke 77-IV Digital Multimeter
FLU77-4 or equivalent
Flex Probe Kit

NUD105-R025D or equivalent
Principles of Operation
LH and RH exterior rear view mirror glass movement is controlled by the exterior rear view mirror switch
and the LH and RH exterior rear view mirror motors. Adjusting the exterior rear view mirror switch to the
LH or RH position determines which exterior rear view mirror motor to control.
Heated Exterior Mirror
The rear window defrost switch controls the operation of the heated exterior rear view mirrors. The
heated exterior rear view mirrors only operate when the rear window defrost system is operating. The
heated exterior rear view mirror voltage is supplied by the rear defrost relay output from the Body
Control Module (BCM) and Central Junction Box (CJB) fuse 25 (7.5A), which isolates the heated exterior
rear view mirrors from the rear window defrost system in the event of a fault.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart

Mechanical Electrical
Exterior rear view mirror Battery Junction Box (BJB) fuse 26 (7.5A) (vehicles built up
Exterior rear view mirror to 1/14/2011)
switch Central Junction Box (CJB) fuse 16 (7.5A) (vehicles build
Exterior rear view mirror after 1/14/2011)
glass CJB fuse 25 (7.5A)
Exterior rear view mirror switch
Exterior rear view mirror motor
Exterior rear view mirror
Heated exterior rear view mirror glass
Loose or corroded connections
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Exterior
Mirrors or GO to Symptom Chart - NVH .
Symptom Chart — Exterior Mirrors
Symptom Chart — Exterior Mirrors

The exterior rear view mirrors are Fuse GO to
inoperative Wiring, terminals Pinpoint Test
or connectors A.
Exterior rear view
mirror switch
A single exterior rear view mirror is Wiring, terminals GO to
inoperative or connectors Pinpoint Test
Exterior rear view B.
mirror switch
Exterior rear view
mirror motor
Exterior rear view
mirror
A single exterior rear view mirror Wiring, terminals GO to
does not operate correctly with or connectors Pinpoint Test
switch logic Exterior rear view C.
mirror switch
Exterior rear view
mirror motor
Exterior rear view
mirror
The heated exterior rear view mirror Fuse GO to
is inoperative Wiring, terminals Pinpoint Test
or connectors D.
Exterior rear view
mirror glass
common terms, refer to Section 100-04 . Since it is possible any one of multiple
Exterior rear Exterior rear view TIGHTEN the exterior rear view
view mirror mirror mounting mirror fasteners to the specified
vibrates/loose nuts loose value located in the Specifications
table.
Exterior rear view PRESS the center of the exterior
mirror glass loose rear view mirror glass up, down,
left and right to make sure the
glass is seated correctly. If the
glass is still loose, REMOVE the
glass and INSPECT the exterior
rear view mirror backing plate for
damage. If the backing plate is
damaged, INSTALL a new exterior
rear view mirror glass. REFER to
Exterior Mirror Glass in this
section.
Aftermarket air If possible, REMOVE aftermarket
deflector/stone air deflector/stone shield, then
shields ROAD TEST the vehicle. If
concern is no longer present,
ADVISE customer that aftermarket
components were causing
undesired vibration.
Wind noise Foam gasket VERIFY the foam gasket is
between the present and in good condition. If
exterior rear view necessary, REPOSITION the
mirror and door foam gasket between the exterior
frame is missing or rear view mirror and door frame.
damaged
Exterior rear view VERIFY there are no gaps
mirror is not between the exterior rear view
correctly fitted to mirror and the door frame . If
the door necessary, LOOSEN the exterior
rear view mirror nuts and
REPOSITION the mirror.
Exterior rear view VERIFY the exterior rear view
mirror cover mirror cover is not loose or
broken. If necessary, INSTALL a
new exterior rear view mirror
cover. REFER to Exterior Mirror
Cover in this section.
Pinpoint Tests
Pinpoint Test A: The Exterior Rear View Mirrors are Inoperative
Refer to Wiring Diagrams Cell 124 , Power Mirrors for schematic and connector information.
Normal Operation
The exterior rear view mirror switch receives voltage at all times from the Battery Junction Box (BJB)
(vehicles built up to 1/14/2011) or CJB (vehicles built after 1/14/2011). The exterior rear view mirror
switch has only one ground circuit. The exterior rear view mirrors share a common circuit for both
up/down and right/left movements.
This pinpoint test is intended to diagnose the following:

Fuse
Wiring, terminals or connectors
PINPOINT TEST A: THE EXTERIOR REAR VIEW MIRRORS ARE INOPERATIVE
Test Step Result / Action to Take

A1 CHECK FOR VOLTAGE TO THE EXTERIOR REAR VIEW
MIRROR SWITCH
Disconnect: Exterior Rear View Mirror Switch C527. Yes
Measure the voltage between exterior rear view mirror switch GO to A2 .
C527-6, circuit SBB26 (YE/RD) (vehicles built up to 1/14/2011)
or SBP16 (VT/RD) (vehicles built after 1/14/2011), harness side No
and ground. VERIFY that BJB fuse 26
(7.5A) (vehicles built up to
1/14/2011) or CJB fuse 16
(7.5A) (vehicles built after
1/14/2011) is OK. If OK,
REPAIR the circuit. If not
OK, REFER to the Wiring
Diagrams manual to
identify the possible
causes of the circuit short.
TEST the system for
normal operation.
Is the voltage greater than 10 volts?

A2 CHECK FOR GROUND TO THE EXTERIOR REAR VIEW
MIRROR SWITCH
Measure the resistance between exterior rear view mirror Yes
switch C527-4, circuit GD143 (BK/VT), harness side and GO to A3 .
ground.
No
REPAIR the circuit for an
open. TEST the system for
normal operation.
Is the resistance less than 5 ohms?

A3 CHECK THE EXTERIOR REAR VIEW MIRRORS COMMON
CIRCUIT FOR AN OPEN
Disconnect: LH Exterior Rear View Mirror Switch C521. Yes
Measure the resistance between exterior rear view mirror INSTALL a new exterior
switch C527-3, circuit CPM18 (GN/BN), harness side and LH rear view mirror switch.
exterior rear view mirror C521-6, circuit CPM18 (GN/BN) REFER to Exterior Mirror
harness side. Control Switch in this
section. TEST the system
for normal operation.
No
open. TEST system for
normal operation.
Pinpoint Test B: A Single Exterior Rear View Mirror is Inoperative
Normal Operation
Under normal operation, the exterior rear view mirror switch uses a common circuit to control the
up/down and right/left movements of both exterior rear view mirrors.

PINPOINT TEST B: A SINGLE EXTERIOR REAR VIEW MIRROR IS INOPERATIVE
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when making measurements.
Failure to use the correct probe adapter(s) may damage the connector.
Result / Action to
Test Step
Take
B1 CHECK THE LH EXTERIOR REAR VIEW MIRROR OPERATION
Operate the LH exterior rear view mirror using the exterior rear view Yes
mirror switch. GO to B2 .
Does the LH exterior rear view mirror operate?
No
GO to B4 .
B2 CHECK THE EXTERIOR REAR VIEW MIRROR SWITCH
Ignition OFF. Yes
Disconnect: Exterior Rear View Mirror Switch C527. GO to B3 .
Carry out the exterior rear view mirror switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new
exterior rear view
mirror switch. REFER
Did the exterior mirror control switch pass the component to Exterior Mirror
test? Control Switch in this
section. TEST the
system for normal
operation.
B3 CHECK THE EXTERIOR REAR VIEW MIRRORS COMMON
CIRCUIT FOR AN OPEN
Disconnect: RH Exterior Rear View Mirror C601. Yes
Measure the resistance between exterior rear view mirror switch INSTALL a new
C527-3, circuit CPM18 (GN/BN), harness side and RH exterior rear exterior rear view
view mirror C601-6, circuit CPM18 (GN/BN), harness side. mirror motor. REFER
to Exterior Mirror
Motor in this section.
TEST the system for
normal operation.
No
REPAIR the circuit for
an open. TEST the
system for normal
operation.

B4 CHECK THE EXTERIOR REAR VIEW MIRROR SWITCH
Ignition OFF. Yes
Disconnect: Exterior Rear View Mirror Switch C527. GO to B5 .
Carry out the Exterior Rear View Mirror Switch component test.
No
exterior rear view
mirror switch. REFER
Did the exterior mirror control switch pass the component to Exterior Mirror
test? Control Switch in this
section. TEST the
system for normal
operation.
B5 CHECK THE EXTERIOR REAR VIEW MIRRORS COMMON
CIRCUIT FOR AN OPEN
Disconnect: LH Exterior Rear View Mirror Switch C521. Yes
Measure the resistance between exterior rear view mirror switch INSTALL a new
C527-3, circuit CPM18 (GN/BN), harness side and LH exterior rear exterior rear view
view mirror C521-6, circuit CPM18 (GN/BN), harness side. mirror motor. REFER
to Exterior Mirror
TEST the system for
normal operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
Pinpoint Test C: A Single Exterior Rear View Mirror Does Not Operate Correctly with Switch
Logic
Normal Operation
Under normal operation, the exterior rear view mirror switch supplies voltage and ground to the LH and
RH exterior rear view mirrors to control movement. Each mirror contains a horizontal and a vertical
motor. The exterior rear view mirror switch controls movement by reversing polarity of the voltage and
ground circuits being supplied to each motor.

PINPOINT TEST C: A SINGLE EXTERIOR REAR VIEW MIRROR DOES NOT FUNCTION WITH
SWITCH LOGIC
Result / Action to
Test Step
Take
C1 CHECK THE EXTERIOR REAR VIEW MIRROR MOVEMENT
(LEFT/RIGHT)
Operate the RH and LH exterior rear view mirrors in the right and left Yes
direction using the exterior rear view mirror switch. GO to C2 .
Do the exterior rear view mirrors move left and right?
No
GO to C3 .
C2 CHECK THE EXTERIOR REAR VIEW MIRROR MOVEMENT
(UP/DOWN)
Operate the RH and LH exterior rear view mirrors in the up and Yes
down direction using the exterior rear view mirror switch. The system is
Do the exterior rear view mirrors move up and down? operating correctly at
this time. Concern
may have been
caused by a loose or
corroded connector.
TEST the system for
normal operation.
No
GO to C4 .
C3 CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR REAR
VIEW MIRROR LEFT/ RIGHT CIRCUIT
Disconnect: Inoperative Exterior Rear View Mirror C521 (LH) or Yes
C601 (RH). INSTALL a new
NOTE: Position the exterior rear view mirror switch to the LH or RH exterior rear view
position. mirror motor. REFER
LH exterior rear view mirror: While operating the exterior rear view to Exterior Mirror
mirror switch in the rightward position, measure the voltage between Motor in this section.
the LH exterior rear view mirror C521-5, circuit CPM18 (GN/BN), TEST the system for
harness side and ground. normal operation.
No
GO to C5 .
RH exterior rear view mirror: While operating the exterior rear view
mirror switch in the rightward position, measure the voltage between
the RH exterior rear view mirror C601-7, circuit CPM17 (BU/GN),
harness side and ground.

C4 CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR REAR
VIEW MIRROR UP/DOWN CIRCUIT
Disconnect: Inoperative Exterior Rear View Mirror C521 (LH) or Yes
C601 (RH). INSTALL a new
NOTE: Position the exterior rear view mirror switch to the LH or RH exterior rear view
position. mirror motor. REFER
LH exterior rear view mirror: While operating the exterior rear view to Exterior Mirror
mirror switch in the upward position, measure the voltage between Motor in this section.
the LH exterior rear view mirror C521-7, circuit CPM21 (YE/VT), TEST the system for
harness side and ground. normal operation.
No
GO to C6 .
RH exterior rear view mirror: While operating the exterior rear view
mirror switch in the upward position, measure the voltage between
the RH exterior rear view mirror C601-5, circuit CPM14 (GY/BN),

C5 CHECK THE INOPERATIVE EXTERIOR REAR VIEW MIRROR
LEFT/RIGHT CIRCUIT FOR AN OPEN
LH exterior rear view mirror: Measure the resistance between INSTALL a new
exterior rear view mirror switch C527-7, circuit CPM18 (GN/BN), exterior rear view
harness side and LH exterior rear view mirror C521-5, circuit CPM18 mirror switch. REFER
(GN/BN), harness side. to Exterior Mirror
Control Switch in this
section. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
RH exterior rear view mirror: Measure the resistance between

exterior rear view mirror switch C527-5, circuit CPM17 (BU/GN),
harness side and RH exterior rear view mirror C601-7, circuit
CPM17 (BU/GN), harness side.
C6 CHECK THE INOPERATIVE EXTERIOR REAR VIEW MIRROR
UP/DOWN CIRCUIT FOR AN OPEN
LH exterior rear view mirror: Measure the resistance between INSTALL a new
exterior rear view mirror switch C527-1, circuit CPM21 (YE/VT), exterior rear view
harness side and LH exterior rear view mirror C521-7, circuit CPM21 mirror switch. REFER
(YE/VT), harness side. to Exterior Mirror
section. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
RH exterior rear view mirror: Measure the resistance between

exterior rear view mirror switch C527-2, circuit CPM14 (GY/BN),
harness side and RH exterior rear view mirror C601-5, circuit
CPM14 (GY/BN), harness side.
Pinpoint Test D: The Heated Exterior Rear View Mirror is Inoperative

Refer to Wiring Diagrams Cell 56 , Heated Window for schematic and connector information.
Normal Operation
Under normal operation, when the rear window defrost switch is pressed to the ON position, the rear
window defrost relay closes and voltage is supplied to Central Junction Box (CJB) fuse 25 (7.5A) to
power the LH and RH exterior rear view mirrors. The exterior rear view mirrors do not share a common
ground.

Fuse
Exterior rear view mirror glass
PINPOINT TEST D: THE HEATED EXTERIOR REAR VIEW MIRROR IS INOPERATIVE
Result / Action to
Test Step
Take
D1 CHECK THE OPERATION OF THE REAR WINDOW DEFROST
SYSTEM
With the engine running, activate the rear window defrost switch to Yes
the ON position. GO to D2 .
Using a infrared temperature gun or equivalent measure the
temperature of the rear window glass for approximately 30 No
seconds noting changes in temperature. REFER to Section
Does the temperature of the rear window glass rise? 501-11 to diagnose the
rear window defrost
system.
D2 CHECK THE OPERATION OF THE HEATED EXTERIOR REAR
VIEW MIRRORS
With the rear window defrost switch in the ON position, using a Yes
infrared temperature gun or equivalent measure the temperature of GO to D3 .
the RH and LH exterior rear view mirror glass for approximately 30
seconds noting changes in temperature. No
Does at least one heated mirror glass operate correctly? VERIFY that CJB fuse
25 (7.5A) is OK. If OK,
REPAIR circuit CRD06
(BN/YE) for an open. If
not OK, REPAIR circuit
CBP25 (WH/OG)
harness side for a
short to ground. TEST
the system for normal
operation.
D3 CHECK THE VOLTAGE TO THE INOPERATIVE HEATED
EXTERIOR REAR VIEW MIRROR GLASS
Ignition ON. Yes
Disconnect: Inoperative Heated Exterior Rear View Mirror C521 GO to D4 .
(LH) or C601 (RH).
NOTE: The rear window defrost system activates for 10 minutes. No
With the engine running, press the rear window defrost switch to REPAIR the circuit for
the ON position. an open. TEST the
Measure the voltage between: system for normal
LH exterior rear view mirror C521-1, circuit CBP25 operation.
(WH/OG), harness side and ground.
RH exterior rear view mirror C601-1, circuit CBP25
(WH/OG), harness side and ground.

D4 CHECK THE INOPERATIVE EXTERIOR REAR VIEW MIRROR
GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between: INSTALL a new
LH exterior rear view mirror C521-2, circuit GD143 exterior rear view
(BK/VT), harness side and ground. mirror glass. REFER to
RH exterior rear view mirror C601-2, circuit GD145 Exterior Mirror Glass in
(BK/BU), harness side and ground. this section. TEST the
system for normal
operation.
No
an open. TEST the
system for normal
operation.

Rear View Mirrors — Interior
Special Tool(s)
Interior Auto-Dimming Rear View Mirror
The interior auto-dimming rear view mirror automatically reduces the glare caused by headlamps
reflecting in the interior rear view mirror. Voltage is supplied to the interior auto-dimming mirror when the
ignition is in the RUN or ACC position. The auto-dimming feature is disabled when the vehicle is in
REVERSE.
The interior auto-dimming rear view mirror has 2 photoelectric sensors, a forward facing sensor and a
rearward facing sensor, that detect forward and rearward light conditions. Based on these inputs, the
automatic dimming feature adjusts the reflectance level of the interior rear view mirror glass to eliminate
unwanted glare. The reflectance level of the mirror glass is variable and depends on the amount of rear
glare in relation to ambient light conditions in front of the interior mirror.
When the forward sensor detects daytime conditions, the rearward sensor is inactive and the mirror
stays in a high reflectance mode. When the forward sensor detects nighttime conditions, the rearward
sensor is active and detects glare from the headlights of vehicles approaching from the rear or other
glare-producing light sources. To provide increased visibility when backing up, the interior rear view
mirror automatically returns to a high reflectance mode whenever the vehicle is in REVERSE.
If the forward or rearward sensors are blocked, the interior auto-dimming rear view mirror might not work
correctly.
2. Visually inspect for signs of mechanical and electrical damage.

Interior rear view mirror Central Junction Box (CJB) fuse 2 (10A)
Interior auto-dimming rear view mirror
Wiring harness
4. If the concern is not visually evident, verify the symptom and GO to Symptom Chart - Interior
Mirror or GO to Symptom Chart - NVH .
Symptom Chart — Interior Mirror
Symptom Chart — Interior Mirror

The interior Interior mirror NOTE: Do not clean the housing
mirror is glass/housing is or glass of any mirror with harsh
blemished dirty abrasives, fuel or other
petroleum-based cleaning
products.
CLEAN the affected interior mirror

surface.
The interior mirror INSPECT the interior mirror
is damaged. damage. If needed, INSTALL a
new interior mirror. REFER to
Interior Rear View Mirror in this
section.
The auto- Obstructed If possible, REMOVE the
dimming mirror rearward-facing obstruction. If the obstruction
does not sensor cannot be removed, GO to
operate Stickers, Pinpoint Test E to TEST the
correctly window interior auto-dimming mirror for
decals, correct function.
tags
Non-OEM
window
tinting
Obstructed
forward-facing
sensor
Stickers,
window
decals,
tags
Non-OEM
window
tinting
Light source near None. Any light source the
or inside vehicle rearward-facing sensor is
exposed to can be considered
glare.
Vehicle inside None. Ambient light conditions
garage or tunnel are similar to nighttime conditions.
Fuse GO to Pinpoint Test E .
Interior auto-
dimming mirror
Wiring, terminals
or connectors
Possible
Condition Action
Sources
The interior Interior If the mirror is still on the windshield do
mirror mirror not remove. ATTEMPT to fully seat the
vibrates/loose mounting mirror first. If the mirror is still loose or
loose vibrates, REMOVE and REINSTALL the
mirror. REFER to Interior Rear View
Mirror in this section. If the condition still
exists, INSTALL a new mirror.
Pinpoint Tests
Pinpoint Test E: The Auto-Dimming Mirror Does Not Operate Correctly
Normal Operation
The interior auto-dimming mirror contains 2 photoelectric sensors: one in the front of the interior rear
view mirror and one mounted on the glass side of the mirror. If the sensors are blocked, the auto-
dimming feature may not operate correctly. Always verify both sensors are not physically blocked before
attempting to diagnose auto-dimming mirror concerns. Whenever the gear selector lever is placed in
REVERSE, the interior auto-dimming mirror temporarily disables the auto-dimming feature. The auto-
dimming feature is enabled again when the gear selector lever is moved out of REVERSE.

Fuse
Obstructed rearward facing sensor
Obstructed forward facing sensor
Interior auto-dimming mirror
PINPOINT TEST E: THE AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY
NOTE: If the Transmission Range (TR) sensor is malfunctioning and the backup lamps are on all the
time or do not turn on, the interior auto-dimming mirror will not darken or return to normal view.

E1 CHECK THE OPERATION OF THE BACKUP LAMPS
Ignition ON. Yes
Move the selector lever through the entire range. GO to E2 .
Do the backup lamps illuminate and only in REVERSE?
No
REFER to Section 417-01 to
diagnose the backup lamps.
E2 VERIFY THE FORWARD AND REARWARD FACING
SENSORS ARE NOT BLOCKED
Visually verify the forward and rearward facing sensors are Yes
not blocked. Sources of blockage can include: If possible, REMOVE the
stickers, window decals or tags. blockage. TEST the system
non-OEM window tinting. for normal operation. If it is
Were either of the sensors blocked? not possible to remove the
blockage, REVIEW the
operation of the interior
auto-dimming mirror with
the customer.
No
GO to E3 .
E3 CHECK OPERATION OF THE INTERIOR AUTO-DIMMING
MIRROR — DAYLIGHT CONDITIONS
Ignition ON. Yes
Use a bright lamp to illuminate the forward facing sensor. The GO to E4
mirror should adjust to a high reflectance mode (mirror will be
clear). No
INSTALL a new interior
auto-dimming mirror.
REFER to Interior Rear
View Mirror in this section.
TEST the system for normal
operation.
Does the mirror adjust to the high reflectance (clear)

mode?
MIRROR — NIGHTTIME CONDITIONS WITH GLARE
Ignition ON. Yes
NOTE: Covering the sensor with a finger or hand is not GO to E5 .
adequate.
Simulate nighttime conditions with glare: No
cover the forward sensor with black electrical tape or GO to E7 .
other dark material.
illuminate the rearward facing sensor. The mirror
should darken to a lower reflectance mode.
Did the mirror darken to a lower reflectance (darker)
mode?
MIRROR — NIGHTTIME CONDITIONS WITHOUT GLARE
Ignition ON. Yes
NOTE: Covering the sensor with a finger or hand is not GO to E6 .
adequate.
Simulate nighttime conditions without glare: No
cover the rearward facing sensor. The mirror should GO to E7 .
adjust to the high reflectance mode.
Did the mirror adjust to the high reflectance (clear)

mode?
MIRROR — NIGHTTIME CONDITIONS WITH THE VEHICLE IN
REVERSE
Ignition ON. Yes
NOTE: Covering the sensor with a finger or hand is not The system is operating
adequate. normally at this time.
Simulate nighttime conditions with glare: REVIEW operation of the
cover the forward sensor with black electrical tape or interior auto-dimming mirror
other dark material. feature with the customer.
illuminate the rearward facing sensor. (mirror should
darken at this time) No
GO to E7 .
Select REVERSE.
Did the mirror adjust to a high reflectance (clear) mode?
E7 CHECK FOR VOLTAGE TO THE INTERIOR AUTO-DIMMING
MIRROR
Ignition OFF. Yes
Disconnect: Interior Auto-Dimming Mirror C911. GO to E8 .
Ignition ON.
Measure the voltage between interior auto-dimming mirror No
C911-1, circuit CPB02 (GN), harness side and ground. VERIFY that Central
Junction Box (CJB) fuse 2
(10A) is OK. If OK, REPAIR
the circuit. If not OK,
REFER to the Wiring
Diagrams manual to identify
the possible causes of the
circuit short. TEST the
system for normal
operation.

E8 CHECK FOR GROUND TO THE INTERIOR AUTO-DIMMING
MIRROR
Ignition OFF. Yes
Measure the resistance between interior auto-dimming mirror GO to E9 .
C911-4, circuit GD143 (BK/VT), harness side and ground.
No
normal operation.

E9 CHECK FOR VOLTAGE TO THE INTERIOR AUTO-DIMMING
MIRROR REVERSE CIRCUIT
Ignition ON. Yes
Select REVERSE. INSTALL a new interior
Measure the voltage between interior auto-dimming mirror auto-dimming mirror.
C911-9, circuit CET47 (BU), harness side and ground. REFER to Interior Rear
View Mirror in this section.
operation.
No
REPAIR the circuit. TEST
operation.

Exterior Mirrors — Exploded View
NOTE: Click here or refer to the on-line Workshop Manual to learn about using an Interactive Illustration.

1 — Exterior mirror nut cover
2 W520202 Exterior mirror nut
3 17K707 Exterior mirror glass
4 — Exterior mirror motor screw (3 required) (part of
17D696)
5 17D696 Exterior mirror motor
6 17D742 RH/ 17D743 Exterior mirror cover
LH
7 17682 RH/ 17683 LH Exterior mirror

Exterior Mirror
1. Remove the door speaker. For additional information, refer to Section 415-00 .
2. Disconnect the electrical connector.
3. Remove the exterior mirror nut cover.
4. NOTE: When installing the mirror, make sure to align the locating pin to the locating hole.
Remove the exterior mirror nut.

5. Remove the exterior mirror.

Route the electrical wiring harness through the door.

Exterior Mirror Glass
Removal
1. NOTE: Exterior mirror glass and motor removed from the housing and viewed from the back to show location of
clips and placement of screwdriver.
Disengage the exterior mirror glass from the exterior mirror motor in the following sequence:
1. Position the exterior mirror glass to the full upper outboard position.
2. Insert a flat-blade screwdriver between the lower inboard retaining tab and the exterior mirror glass
backing plate.
3. Twist the flat-blade screwdriver to release the retaining tab from the exterior mirror glass backing plate.
4. Position the exterior mirror glass to the full upper inboard position.
5. Insert a flat-blade screwdriver between the upper outboard retaining tab and the exterior mirror glass
backing plate.
6. Twist the flat-blade screwdriver to release the retaining tab from the exterior mirror glass backing plate.
2. WARNING: Place a shop towel between the hands and the exterior mirror glass for protection in
case of glass breakage during mirror service. Failure to follow this instruction may result in serious
personal injury.
Remove the exterior mirror glass from the exterior mirror motor by gently pulling the exterior mirror glass
outward
If equipped, disconnect the electrical connectors.
Installation
1. If equipped, connect the electrical connectors.
2. Position the exterior mirror glass onto the exterior mirror motor.
3. WARNING: Place a shop towel between the hands and the exterior mirror glass for protection in
case of glass breakage during mirror service. Failure to follow this instruction may result in serious
personal injury.
NOTICE: Apply hand pressure directly over the center of the mirror. Failure to follow this instruction
may result in glass breakage.
Install the exterior mirror glass by pressing firmly in the center of the exterior glass until it snaps onto the
exterior mirror motor.
Exterior Mirror Motor
1. Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass In this
section.
2. Remove the 3 exterior mirror motor screws.
3. Disconnect the exterior mirror motor electrical connector.
4. Remove the exterior mirror motor.

Exterior Mirror Cover
Removal
1. Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass In this section.
2. If equipped, remove the exterior mirror cover retainer.
3. Remove the exterior mirror cover.

Using a flat-blade screwdriver, release the 3 retaining tabs while pulling the exterior mirror cover toward
the front of the vehicle.
Installation
1. Align the inner lower corner of the mirror cover with the groove in the mirror frame.
2. Align the 3 mirror cover tabs with the slots on the mirror frame and install the mirror cover.
Press the mirror cover into place and the 3 lock tabs are fully seated.
3. If equipped, install the exterior mirror cover retainer.
4. Install the exterior mirror glass. For additional information, refer to Exterior Mirror Glass In this section.
Exterior Mirror Control Switch
Part
1 17B676 Exterior mirror control switch
2 — Exterior mirror control switch electrical connector (part
of 14631)
1. NOTICE: Make sure to use a non-marring tool when removing the exterior mirror switch.
Otherwise, damage to the door trim panel may occur.
Remove the exterior mirror control switch.

Insert a non-marring tool between the door trim panel and the exterior mirror control switch and
gently pry outward.
Interior Rear View Mirror
Special Tool(s)
Installer, Rear View Mirror
501-025 (T94P-17700-AH)
Mirror Remover
501-D118A
Interior auto-dimming mirror with top access mount
Part
1 — Interior auto-dimming mirror electrical connector (part of
14A005)
2 17700 Interior auto-dimming mirror
Interior auto-dimming mirror with bottom access mount

1 17700 Interior auto-dimming mirror
Removal
Interior mirror with top access mirror mount
NOTICE: This procedure should be used only for an interior rear view mirror with the top access mount.
Otherwise, damage to the windshield glass may occur.
NOTICE: The windshield must be at room temperature. Otherwise, damage to the windshield glass may occur.
NOTE: Use only steps 1 - 4 for the removal of this style of interior rear view mirror.
2. Position the interior rear view mirror to the full downward position.
3. NOTICE: Make sure the Mirror Remover is fully inserted into the interior rear view mirror mount access
hole. Otherwise, damage to the windshield glass may occur.
Insert the Mirror Remover between the interior rear view mirror mount and windshield bracket, located at the
top of the interior rear view mirror mount.
4. NOTICE: Twisting the interior rear view mirror mount from right to left may cause a stress fracture to
the windshield.
NOTICE: Make sure to use the windshield bracket as the pivot point. Otherwise, damage to the
windshield will occur.
Release the interior rear view mirror mount from the windshield bracket by pulling the Mirror Remover
downward and away from the windshield.
Interior mirror with bottom access mirror mount
NOTICE: This procedure should be used only for an interior rear view mirror with the bottom access mount.
Otherwise, damage to the windshield glass may occur.
NOTICE: The windshield must be at room temperature. Otherwise, damage to the windshield glass may occur.
NOTE: Use only steps 5 - 7 for the removal of this style of interior rear view mirror.
6. Insert the Mirror Remover between the interior rear view mirror mount and windshield bracket located at the
bottom of the mirror mount.
7. NOTICE: Twisting the interior rear view mirror mount from right to left may cause a stress fracture to
the windshield.
NOTICE: Make sure to use the windshield bracket as the pivot point. Otherwise, damage to the
windshield will occur.
Release the interior rear view mirror mount from the windshield bracket by pulling the Mirror Remover away
from the windshield.
Installation
Interior mirror with top access mirror mount
NOTE: Use only steps 1 - 4 for the installation of this style of interior rear view mirror.
1. Slide the interior rear view mirror mount over the windshield bracket from the top.
2. Press the interior rear view mirror mount downward along the windshield bracket until a click is felt. The click
indicates that the mirror mount is engaged onto the windshield bracket.
3. Connect the electrical connector.
4. If equipped, check the compass zone and calibration. For additional information, refer to Section 413-01 .
Interior mirror with bottom access mirror mount
NOTE: Use only steps 5 - 8 for the installation of this style of interior rear view mirror.
5. Slide the interior rear view mirror mount over the windshield bracket from the top.
6. Using the Rear View Mirror Installer, press the interior rear view mirror mount downward along the windshield
bracket until the mirror mount is fully seated onto the windshield mounting button.
8. If equipped, check the compass zone and calibration. For additional information, refer to Section 413-01 .
SECTION 501-10: Seating 2011 Fiesta Workshop Manual
Front Seat
Cushion pan screws a — — —
Occupant Classification System Module (OCSM) bracket screws a — — —
Occupant Classification System Module (OCSM) screws a — — —
Recliner-to-seat track bolts a — — —
Seat track-to-floor bolts a — — —
Rear Seat
Backrest hinge bolt 40 30 —
Backrest latch bolt 24 18 —
Backrest striker bolt 25 18 —
Hinge pin bolt 38 28 —
Rear safety belt anchor bolt 48 35 —
Safety belt retractor bolt 48 35 —
a Refer to the procedure in this section.
Seats
Front Seats
The front seats are equipped with the following serviceable systems:
2-way seat track (passenger only)

4-way seat track (driver only)
Manual recliners (serviced with backrest frame)
Heated seats (if equipped)
Occupant Classification System (OCS) (passenger seat only, if equipped)
Seat side air bags (in seat backrests) (if equipped)
Safety belt buckles
Seat track position sensors (if equipped)
Seat Backrests
The recliner mechanism is part of the seat backrest frame and is not serviced separately.
Seat Tracks
Front seats are equipped with a 2-way manual passenger seat track and 4-way manual driver seat track
which includes a height adjust handle that ratchets to raise and lower the seat. Both seat tracks are
serviced as complete assemblies which include the cushion frames and seat mounting feet.
Heated Seats
The heated seat system includes the following serviceable components:
Cushion heater mats (attached to seat cushion foam pads)

Heated seat relays (located in the Central Junction Box (CJB))
Heated seat switches (located on the instrument panel)
Thermostats (serviced only as part of each cushion heater mat)
Body Control Module (BCM)
NOTE: If a new heater mat is needed on a front passenger seat cushion equipped with an Occupant
Classification System (OCS) system, install a new OCS service kit with a heater mat already adhered to
the cushion foam pad.
The cushion heater mats are serviceable separately. A heater mat can be peeled away from a foam pad
and a new one adhered in its place providing excessive foam is not removed from the foam pad. If
excessive foam is removed during removal, a new foam pad must be installed. A heater mat cannot be
reused; the 2-way tape adhesive will no longer hold the heater mat position on the foam pad causing it
to shift or bunch up.
Occupant Classification System (OCS) System
NOTE: OCS system components [seat wiring harness, seat cushion foam pad, bladder with pressure
sensor and Occupant Classification System Module (OCSM)] are calibrated to each other and are
serviced as an assembly. If new OCS system components are needed, an OCS system service kit must
be installed as an assembly.
For information on diagnosing or servicing the OCS system, refer to Section 501-20B .
Seat Side Air Bags
Driver and passenger seat side air bags are attached to the seat backrest frame. For diagnostic
information, or if the seat side air bag has deployed, refer to Section 501-20B .
Rear Seats
The rear seat cushion and 60/40 fold flat backrests are equipped with the following serviceable
components:
Backrest and cushion trim covers and foam pads

Backrest hinges (attached to floor pan)
Backrest latches (attached to backrest frame)
Backrest latch strikers (attached to quarter panel)
Cushion latches (located underneath cushion front edge attached to floor pan)
Head restraints and head restraint guides (attached to the backrests)
Seats
Special Tool(s)
Flex Probe Kit

Vehicle Communication Module

(VCM) and Integrated
Diagnostic System (IDS)
software with appropriate
hardware, or equivalent scan
tool
Principles of Operation — Heated Seats
Heated Seats
The heated seat system only operates when the engine is running. When the heated seat switch(es)
(located on the instrument panel) is activated, it supplies a ground signal to the Body Control Module
(BCM). When the BCM receives the heated seat switch signal, it activates the appropriate (driver or
passenger) heated seat relay, (located in the Central Junction Box (CJB). When the heated seat relay is
activated, voltage is supplied to the cushion heater mat. The cushion heater mats are directly connected
to ground to complete the electrical circuit to heat the seat.
Each cushion heater mat contains a non-serviceable internal thermostatic switch that closes when cold
to complete the heater grid circuit and heat the seat. When hot, the thermostatic switch opens the heater
grid circuit and allows the seat to cool. During normal operation, several minutes may be required before
seat temperature is increased and several more minutes of cooling before the heater mats continue with
heating. The heated seat indicator illuminates continuously while the thermostatic switch cycles between
open and closed.
The seat should be occupied to correctly test for normal operation. Temperature measuring devices do
not provide an accurate method for testing heated seat operation as surface temperatures are subject to
human and environmental characteristics. Correct testing requires heater mat resistance measurements
which have tight tolerances affecting heat cycle time length.
The heated seat system does not time-out. A heated seat remains on until it is turned off by the heated
seat switch or the ignition is switched OFF.
1. Verify the customer concern by operating the heated seat functions.
2. Visually inspect for obvious signs of mechanical and electrical damage.

Seat cushion trim cover damaged (heated Central Junction Box (CJB) fuse 17
seat heater mats) (7.5A)
Wiring harness
Loose or corroded connector(s)
Heated seat switch (located on the
instrument panel)
Heated seat relay
Cushion heater mat
4. NOTE: Make sure to use the latest scan tool software release.
If the concern is with the heated seat and the cause is not visually evident, connect the scan tool
to the Data Link Connector (DLC).
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM .
If the scan tool does not communicate with the VCM :

check the VCM connection to the vehicle.
check the scan tool connection to the VCM .
refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan
tool.
6. If the scan tool does not communicate with the vehicle:

verify the ignition is ON.
verify the scan tool operation with a known good vehicle.
refer to Section 418-00 to diagnose no response from the PCM.
7. Carry out the network test.

If the scan tool responds with no communication for one or more modules, refer to Section
418-00 .
If the network test passes, retrieve and record on-demand and Continuous Memory
Diagnostic Trouble Codes (CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the BCM .
9. If the DTCs retrieved are related to the concern, go to the Body Control Module (BCM) DTC
Chart. For all other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart .

DTC Chart
NOTE: Refer to Description and Operation, Intelligent Access with Push Button Start in Section 419-01B
to review the procedures for achieving the various ignition states on vehicles with this feature.
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure
type code provides information about specific fault conditions such as opens or shorts to ground.
Continuous Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status
code suffix to assist in determining DTC history.
Body Control Module (BCM) DTC Chart

DTC Description Action
B1034:12 Left Front Seat Heater Element: Circuit Short GO to Pinpoint Test B .
To Battery
B1034:14 Left Front Seat Heater Element: Circuit Short If the heated seat is inoperative, GO to
To Ground or Open Pinpoint Test B .
If the heated seat is on all the time, GO

to Pinpoint Test D .
B1036:12 Right Front Seat Heater Element: Circuit GO to Pinpoint Test C .
Short To Battery
B1036:14 Right Front Seat Heater Element: Circuit If the heated seat is inoperative, GO to
Short To Ground or Open Pinpoint Test C .
If the heated seat is on all the time, GO

to Pinpoint Test D .
B115A:23 Front Passenger Seat Heater: Signal Stuck GO to Pinpoint Test C .
Low
B115B:23 Front Driver Seat Heater: Signal Stuck Low GO to Pinpoint Test B .
All Other — REFER to the Master DTC Chart in
DTCs Section 419-10 .
Symptom Chart
Symptom Chart
NOTE: Refer to Description and Operation, Intelligent Access with Push Button Start in
Section 419-01B to review the procedures for achieving the various ignition states on
vehicles with this feature.
The heated seats are Fuse GO to Pinpoint Test A .
inoperative — driver Wiring,
and passenger terminals or
connectors
BCM
The heated seat is Heated seat GO to Pinpoint Test B .
inoperative/does not relay
operate correctly — Heated seat
driver switch
Wiring,
terminals or
connectors
Heater mat
BCM
The heated seat is Heated seat GO to Pinpoint Test C .
inoperative/does not relay
operate correctly — Heated seat
passenger switch
Wiring,
terminals or
connectors
Heater mat
BCM
The heated seat does Heated seat GO to Pinpoint Test D .
not operate correctly relay
— driver or passenger Wiring,
seat heats when the terminals or
system is off connectors
BCM
The heated seat does Heated seat The driver heated seat switch
not operate correctly switch LED is powered from the same
— driver seat does Wiring, circuit providing the voltage for
heat but the heated terminals or the heater mat. CHECK circuit
seat indicator does not connectors CHS11 (VT/GN) for an open
illuminate when between the driver heated seat
pressed relay and the driver heated seat
switch. If the circuit is OK,
INSTALL a new driver heated
seat switch. TEST the system for
normal operation.
The heated seat does Heated seat The passenger heated seat
not operate correctly switch switch LED is powered from the
— passenger seat Wiring, same circuit providing the voltage
does heat but the terminals or for the heater mat. CHECK circuit
heated seat indicator connectors CHS12 (YE/GN) for an open
does not illuminate between the passenger heated
when pressed seat relay and the passenger
heated seat/ambient lighting
switch. If the circuit is OK,
INSTALL a new passenger
heated seat/ambient lighting
switch. TEST the system for
normal operation.
Pinpoint Tests
Refer to Inspection and Verification and the Symptom Chart for direction to the appropriate Pinpoint
Test.
Pinpoint Test A: The Heated Seats are Inoperative — Driver and Passenger Seats
Refer to Wiring Diagrams Cell 119 , Climate Controlled Seats for schematic and connector information.
Normal Operation
The heated seat system only operates when the engine is running. When the driver or passenger heated
seat switch (located on the instrument panel) is activated, it supplies a ground signal to the Body Control
Module (BCM). When the BCM receives the heated seat switch signal, it activates the appropriate
(driver or passenger) heated seat relay (located in the Central Junction Box (CJB). When the heated
seat relay is activated, voltage is supplied to the cushion heater mat. The cushion heater mats are
directly connected to ground to complete the electrical circuit to heat the seat.

Fuse
BCM
PINPOINT TEST A: THE HEATED SEATS ARE INOPERATIVE — DRIVER AND PASSENGER
SEATS

A1 CHECK FOR VOLTAGE TO THE DRIVER HEATED SEAT
RELAY
Disconnect: Driver Heated Seat Relay. Yes
Ignition ON. GO to A2 .
Measure the voltage between driver heated seat relay
socket pin 1, circuit CBP17 (BN/GN), and ground. No
VERIFY Central Junction Box
(CJB) fuse 17 (7.5A) is OK. If
OK, REPAIR the circuit. If not
system for normal operation.

A2 CHECK THE HEATED SEAT SWITCH GROUND CIRCUIT
Ignition OFF. Yes
Disconnect: Driver Heated Seat Switch C2400. GO to A3 .
Measure the resistance between driver heated switch
C2400-4, circuit GD115 (BK/GY), harness side and ground. No
REPAIR the circuit. TEST the

A3 CHECK THE BCM FOR CORRECT OPERATION
Disconnect all of the BCM connectors. Yes
Check for: INSTALL a new BCM .
corrosion. REFER to Section 419-10 .
pushed-out pins. TEST the system for normal
Connect all of the BCM connectors and make sure they seat operation.
correctly.
Operate the system and verify the concern is still present. No
Is the concern still present? The system is operating
correctly at this time. The
concern may have been
corroded connector. CLEAR
the DTCs. REPEAT the self-
test. TEST the system for
normal operation.
Pinpoint Test B: The Heated Seat is Inoperative/Does Not Operate Correctly — Driver
Normal Operation
The heated seat system only operates when the engine is running. When the driver heated seat switch
(located on the instrument panel) is activated, it supplies a ground signal to the Body Control Module
(BCM). When the BCM receives the heated seat switch signal, it activates the driver heated seat relay
(located in the Central Junction Box (CJB)) by grounding the relay control circuit. When the heated seat
relay is activated, voltage is supplied to the driver cushion heater mat. The driver cushion heater mat is
DTC B1034:12 (Left Front Seat Heater Element: Circuit Short To Battery) — if the driver heated
seat relay drive circuit CHS02 (YE/BU) is shorted to voltage and the BCM attempts to activate the
driver heated seat relay, this DTC sets and the seat fails to heat.
DTC B1034:14 (Left Front Seat Heater Element: Circuit Short To Ground or Open) — if the driver
heated seat relay drive circuit CHS02 (YE/BU) is open or shorted to ground and the BCM
attempts to activate the driver heated seat relay, this DTC sets and the seat fails to heat (circuit
open) or may be on at all times (circuit shorted to ground) until the ignition is turned OFF.
DTC B115B:23 (Front Driver Seat Heater: Signal Stuck Low) — sets when the BCM detects the
driver heated seat switch is active during on-demand self-test or has been active for more than 2
minutes.

Heated seat relay
Heated seat switch
Heater mat
BCM
PINPOINT TEST B: THE HEATED SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY —

DRIVER
NOTE: If a seat equipped with a seat mounted side air bag is being serviced, depower the Supplemental
Restraint System (SRS). Refer to Section 501-20B .
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 an SRS fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.

B1 CHECK THE BCM FOR DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test If DTC B1034:14 is
— BCM . present, GO to B7 .
Is DTC B1034:12, B1034:14 or B115B:23 retrieved?
If DTC B1034:12 is
present, GO to B6 .
If DTC B115B:23 is
present, GO to B4 .
For all other BCM DTCs,

REFER to the Master
DTC Chart in Section
419-10 .
No
GO to B2 .
B2 CHECK THE BCM DRIVER HEATED SEAT
(CC_SW_D_HSEATS) PID OPERATION
Enter the following diagnostic mode on the scan tool: Yes
DataLogger — BCM . GO to B9 .
While monitoring the BCM CC_SW_D_HSEATS PID, press and
release the driver heated seat switch. No
Does the PID agree with the driver heated switch status? GO to B3 .
B3 CHECK THE DRIVER HEATED SEAT SWITCH GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Driver Heated Seat Switch C2400. GO to B4 .
Measure the resistance between driver heated seat switch
C2400-4, circuit GD115 (BK/GY), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.
B4 CHECK THE BCM DRIVER HEATED SEAT
(CC_SW_D_HSEATS) PID OPERATION
Ignition OFF. Yes
Disconnect: Driver Heated Seat Switch C2400. INSTALL a new driver
Connect a fused jumper wire between driver heated seat switch heated seat switch.
C2400-4, circuit GD115 (BK/GY), harness side and driver heated CLEAR the DTCs.
seat switch C2400-1, circuit CHS32 (BN), harness side. REPEAT the self-test.
TEST the system for
normal operation.
No
GO to B5 .
Ignition ON.
Enter the following diagnostic mode on the scan tool:
DataLogger — BCM .
Observe the BCM CC_SW_D_HSEATS PID status.
Remove the fused jumper wire.
Observe the BCM CC_SW_D_HSEATS PID status.
Did the PID state change when the fused jumper wire was
removed?
B5 CHECK THE DRIVER HEATED SWITCH SIGNAL CIRCUIT FOR
AN OPEN OR SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to B13 .
Measure the resistance between driver heated seat switch
C2400-1, circuit CHS32 (BN), harness side and BCM C2280G-8, No
harness side; and between driver heated seat switch C2400-1, REPAIR the circuit.
circuit CHS32 (BN), harness side and ground. CLEAR the DTCs.
REPEAT the self-test.
TEST the system for
normal operation.
Is the resistance less than 5 ohms between the heated seat
switch and the BCM ; and greater than 10,000 ohms
between the heated seat switch and ground?
B6 CHECK THE RELAY CONTROL CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: Driver Heated Seat Relay. REPAIR the circuit.
Ignition ON. CLEAR the DTCs.
Measure the voltage between driver heated seat relay socket pin REPEAT the self-test.
2, circuit CHS02 (YE/BU), harness side and ground. TEST the system for
normal operation.
No
INSTALL a new driver
heated seat relay.
RECONNECT all
connectors and REPEAT
the self-test. If the DTC is
retrieved again, GO to
B13 .
Is any voltage present?

B7 CHECK THE RELAY CONTROL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Driver Heated Seat Relay. GO to B8 .
Disconnect: BCM C2280D.
Measure the resistance between driver heated seat relay socket No
pin 2, circuit CHS02 (YE/BU), harness side and ground. REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
Is the resistance greater than 10,000 ohms?

B8 CHECK THE RELAY CONTROL CIRCUIT FOR AN OPEN
Measure the resistance between driver heated seat relay socket Yes
pin 2, circuit CHS02 (YE/BU), harness side and BCM C2280D- INSTALL a new driver
10, circuit CHS02 (YE/BU), harness side. heated seat relay.
RECONNECT all
B13 .
No
REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
B9 CHECK FOR VOLTAGE TO THE DRIVER HEATED SEAT
RELAY
Ignition OFF. Yes
Ignition ON.
Measure the voltage between driver heated seat relay socket pin No
1, circuit CBP17 (BN/GN) and ground; and between driver VERIFY Central Junction
heated seat relay socket pin 3, circuit CBP17 (BN/GN) and Box (CJB) fuse 17 (7.5A)
ground. is OK. If OK, REPAIR the
circuit. If not OK, REFER
to the Wiring Diagrams
manual to identify the
possible causes of the
circuit short. CLEAR the
DTCs. REPEAT the self-
normal operation.
Is the voltage greater than 10 volts for both measurements?
B10 CHECK THE HEATER MAT CIRCUIT FOR VOLTAGE
Ignition OFF. Yes
Connect: Driver Heated Seat Relay. GO to B12 .
Depower the SRS . Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in the General Procedures No
portion of Section 501-20B . GO to B11 .
Disconnect: Driver Seat Side Air Bag Module C367.
Disconnect: Driver Seat Cushion Heater C364.
WARNING: Make sure no one is in the vehicle and

there is nothing blocking or placed in front of any air bag
module when the battery is connected. Failure to follow
these instructions may result in serious personal injury in
the event of an accidental deployment.
Connect the battery ground cable. Refer to Section 414-01 .
Start the engine.
Activate the driver heated seat switch and measure the voltage
between driver seat cushion heater C364-1, circuit CHS11
(VT/GN), harness side and ground.
B11 CHECK THE HEATER CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between driver heated seat relay socket
pin 5, circuit CHS11 (VT/GN), harness side and driver seat No
cushion heater C364-1, circuit CHS11 (VT/GN), harness side. REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
DISCONNECT the
battery ground cable.
CONNECT driver seat
side air bag module
C367.
REPOWER the SRS .

REFER to Section 501-
20B .

B12 CHECK THE HEATER MAT GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between driver seat cushion heater CHECK for loose or
C364-2, circuit GD143 (BK/VT), harness side and ground. damaged connector pins
and wiring damage. If
OK, INSTALL a new
driver seat cushion
heater mat. REFER to
Seat Cushion — Front in
this section. CLEAR the
normal operation.
DISCONNECT the
CONNECT driver seat
side air bag module
C367.
REPOWER the SRS .

Is the resistance less than 5 ohms? 20B .
No
REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
DISCONNECT the
CONNECT driver seat
side air bag module
C367.
REPOWER the SRS .

20B .
B13 CHECK THE BCM FOR CORRECT OPERATION
Ignition OFF. Yes
Disconnect all of the BCM connectors. INSTALL a new BCM .
Check for: REFER to Section 419-
corrosion. 10 . TEST the system for
pushed-out pins. normal operation.
Connect all of the BCM connectors and make sure they seat
correctly. No
Operate the system and verify the concern is still present. The system is operating
Is the concern still present? correctly at this time. The
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
B14 CHECK THE BCM FOR CORRECT OPERATION
Ignition OFF. Yes
correctly. DISCONNECT the
Operate the system and verify the concern is still present. battery ground cable.
Is the concern still present? CONNECT driver seat
side air bag module
C367.
REPOWER the SRS .
20B .
No
The system is operating
corroded connector.
DISCONNECT the
CONNECT driver seat
side air bag module
C367.
REPOWER the SRS .

20B .
CLEAR the DTCs.

TEST the system for
normal operation.
Pinpoint Test C: The Heated Seat is Inoperative/Does Not Operate Correctly — Passenger
Normal Operation
The heated seat system only operates when the engine is running. When the passenger heated seat
switch (located on the instrument panel) is activated, it supplies a ground signal to the Body Control
Module (BCM). When the BCM receives the heated seat switch signal, it activates the passenger heated
seat relay (located in the Central Junction Box (CJB)) by grounding the relay control circuit. When the
heated seat relay is activated, voltage is supplied to the passenger cushion heater mat. The passenger
cushion heater mat is directly connected to ground to complete the electrical circuit to heat the seat.
DTC B1036:12 (Right Front Seat Heater Element: Circuit Short To Battery) — if the passenger
heated seat relay drive circuit CHS07 (GY/BU) is shorted to voltage and the BCM attempts to
activate the passenger heated seat relay, this DTC sets and the seat fails to heat.
DTC B1036:14 (Right Front Seat Heater Element: Circuit Short To Ground or Open) — if the
passenger heated seat relay drive circuit CHS07 (GY/BU) is open or shorted to ground and the
BCM attempts to activate the passenger heated seat relay, this DTC sets and the seat fails to
heat (circuit open) or may be on at all times (circuit shorted to ground) until the ignition is turned
OFF.
DTC B115A:23 (Front Passenger Seat Heater: Signal Stuck Low) — sets when the BCM detects
the passenger heated seat switch is active during on-demand self-test or has been active for
more than 2 minutes.

Heated seat relay
Heated seat switch
Heater mat
BCM
PINPOINT TEST C: THE HEATED SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY —
PASSENGER

C1 CHECK THE BCM FOR DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test If DTC B1036:14 is
— BCM . present, GO to C7 .
Is DTC B1036:12, B1036:14 or B115A:23 retrieved?
If DTC B1036:12 is
present, GO to C6 .
If DTC B115A:23 is
present, GO to C4 .
For all other BCM DTCs,

REFER to the Master
DTC Chart in Section
419-10 .
No
GO to C2 .
C2 CHECK THE BCM PASSENGER HEATED SEAT
(CC_SW_P_HSEATS) PID OPERATION
DataLogger — BCM . GO to C9 .
While monitoring the BCM CC_SW_P_HSEATS PID, press and
release the passenger heated seat switch. No
Does the PID agree with the passenger heated switch GO to C3 .
status?
C3 CHECK THE PASSENGER HEATED SEAT SWITCH GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Passenger Heated Seat/Ambient Lighting Switch GO to C4 .
C2401.
Measure the resistance between passenger heated seat/ambient No
lighting switch C2401-4, circuit GD115 (BK/GY), harness side REPAIR the circuit.
and ground. TEST the system for
normal operation.
C4 CHECK THE BCM PASSENGER HEATED SEAT
(CC_SW_P_HSEATS) PID OPERATION
Ignition OFF. Yes
Disconnect: Passenger Heated Seat/Ambient Lighting Switch INSTALL a new
C2401. passenger heated
Connect a fused jumper wire between passenger heated seat/ambient lighting
seat/ambient lighting switch C2401-4, circuit GD115 (BK/GY), switch. CLEAR the
harness side and passenger heated seat/ambient lighting switch DTCs. REPEAT the self-
C2401-6, circuit CHS30 (GY/YE), harness side. test. TEST the system for
normal operation.
No
GO to C5 .
Ignition ON.
DataLogger — BCM .
Observe the BCM CC_SW_P_HSEATS PID status.
Observe the BCM CC_SW_P_HSEATS PID status.
removed?
C5 CHECK THE PASSENGER HEATED SWITCH SIGNAL CIRCUIT
FOR AN OPEN OR SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to C13 .
Measure the resistance between passenger heated seat/ambient
lighting switch C2401-6, circuit CHS30 (GY/YE), harness side No
and BCM C2280G-21, harness side; and between passenger REPAIR the circuit.
heated seat/ambient lighting switch C2401-6, circuit CHS30 CLEAR the DTCs.
(GY/YE), harness side and ground. REPEAT the self-test.
TEST the system for
normal operation.
Is the resistance less than 5 ohms between the heated seat
switch and the BCM ; and greater than 10,000 ohms
between the heated seat switch and ground?
C6 CHECK THE RELAY CONTROL CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: Passenger Heated Seat Relay. REPAIR the circuit.
Ignition ON. CLEAR the DTCs.
Measure the voltage between passenger heated seat relay REPEAT the self-test.
socket pin 2, circuit CHS07 (GY/BU), harness side and ground. TEST the system for
normal operation.
No
INSTALL a new
passenger heated seat
relay. RECONNECT all
C13 .

C7 CHECK THE RELAY CONTROL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Passenger Heated Seat Relay. GO to C8 .
Measure the resistance between passenger heated seat relay No
socket pin 2, circuit CHS07 (GY/BU), harness side and ground. REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.

C8 CHECK THE RELAY CONTROL CIRCUIT FOR AN OPEN
Measure the resistance between passenger heated seat relay Yes
socket pin 2, circuit CHS07 (GY/BU), harness side and BCM INSTALL a new
C2280D-4, circuit CHS07 (GY/BU), harness side. passenger heated seat
relay. RECONNECT all
C13 .
No
REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
C9 CHECK FOR VOLTAGE TO THE PASSENGER HEATED SEAT
RELAY
Ignition OFF. Yes
Ignition ON.
Measure the voltage between passenger heated seat relay No
socket pin 1, circuit CBP17 (BN/GN) and ground; and between VERIFY Central Junction
passenger heated seat relay socket pin 3, circuit CBP17 Box (CJB) fuse 17 (7.5A)
(BN/GN) and ground. is OK. If OK, REPAIR the
circuit. If not OK, REFER
normal operation.
Is the voltage greater than 10 volts for both measurements?
C10 CHECK THE HEATER MAT CIRCUIT FOR VOLTAGE
Ignition OFF. Yes
Connect: Passenger Heated Seat Relay. GO to C12 .
(SRS) Depowering and Repowering in the General Procedures No
portion of Section 501-20B . GO to C11 .
Disconnect: Passenger Seat Side Air Bag Module C337.
Disconnect: Passenger Seat Cushion Heater C334.
WARNING: Make sure no one is in the vehicle and

there is nothing blocking or placed in front of any air bag
module when the battery is connected. Failure to follow
these instructions may result in serious personal injury in
Connect the battery ground cable. Refer to Section 414-01 .
Start the engine.
Activate the passenger heated seat switch and measure the
voltage between passenger seat cushion heater C334-1, circuit
CHS12 (YE/GN), harness side and ground.
C11 CHECK THE HEATER CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between passenger heated seat relay
socket pin 5, circuit CHS12 (YE/GN), harness side and No
passenger seat cushion heater C334-1, circuit CHS12 (YE/GN), REPAIR the circuit.
harness side. CLEAR the DTCs.
TEST the system for
normal operation.
DISCONNECT the
CONNECT passenger
seat side air bag module
C337.
REPOWER the SRS .

20B .

C12 CHECK THE HEATER MAT GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between passenger seat cushion heater CHECK for loose or
C334-2, circuit GD145 (BK/BU), harness side and ground. damaged connector pins
and wiring damage. If
OK, INSTALL a new
passenger seat cushion
heater mat. REFER to
Seat Cushion — Front in
normal operation.
DISCONNECT the
CONNECT passenger
C337.
REPOWER the SRS .

Is the resistance less than 5 ohms? REFER to Section 501-
20B .
No
REPAIR the circuit.
CLEAR the DTCs.
TEST the system for
normal operation.
DISCONNECT the
CONNECT passenger
C337.
REPOWER the SRS .

20B .
C13 CHECK THE BCM FOR CORRECT OPERATION
Ignition OFF. Yes
correctly. No
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
C14 CHECK THE BCM FOR CORRECT OPERATION
Ignition OFF. Yes
correctly. DISCONNECT the
Operate the system and verify the concern is still present. battery ground cable.
Is the concern still present? CONNECT passenger
C337.
REPOWER the SRS .
20B .
No
corroded connector.
DISCONNECT the
CONNECT passenger
C337.
REPOWER the SRS .

20B .
CLEAR the DTCs.

TEST the system for
normal operation.
Pinpoint Test D: The Heated Seat Does Not Operate Correctly — Driver or Passenger Seat Heats
When the System is Off
Normal Operation
The heated seat system only operates when the engine is running. When the driver or passenger heated
seat switch (located on the instrument panel) is activated, it supplies a ground signal to the Body Control
Module (BCM). When the BCM receives the heated seat switch signal, it activates the appropriate
(driver or passenger) heated seat relay (located in the Central Junction Box (CJB)). When the heated
seat relay is activated, voltage is supplied to the cushion heater mat. The cushion heater mats are
DTC B1034:14 (Left Front Seat Heater Element: Circuit Short To Ground or Open) — if the driver
heated seat relay drive circuit CHS02 (YE/BU) is open or shorted to ground and the BCM
attempts to activate the driver heated seat relay, this DTC sets and the seat fails to heat (circuit
open) or may be on at all times (circuit shorted to ground) until the ignition is turned OFF.
DTC B1036:14 (Right Front Seat Heater Element: Circuit Short To Ground or Open) — if the
passenger heated seat relay drive circuit CHS07 (GY/BU) is open or shorted to ground and the
BCM attempts to activate the passenger heated seat relay, this DTC sets and the seat fails to
heat (circuit open) or may be on at all times (circuit shorted to ground) until the ignition is turned
OFF.

Heated seat relay
BCM
PINPOINT TEST D: THE HEATED SEAT DOES NOT OPERATE CORRECTLY — DRIVER OR
PASSENGER SEAT HEATS WHEN THE SYSTEM IS OFF

D1 CHECK THE AFFECTED HEATED SEAT OPERATION WITH
THE RELAY REMOVED
Ignition OFF. Yes
Disconnect: Driver or Passenger Heated Seat Relay. REPAIR circuit CHS11
Ignition ON. (VT/GN) (driver seat) or
Observe the affected driver or passenger heated seat switch. CHS12 (YE/GN)
Is the affected driver or passenger heated seat switch (passenger seat) for a short
indicator illuminated? to voltage. CLEAR the
normal operation.
No
GO to D2 .
D2 CHECK THE RELAY CONTROL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: BCM C2280D. INSTALL a new driver
For driver heated seat, measure the resistance between driver heated seat relay or
heated seat relay socket pin 2, circuit CHS02 (YE/BU), passenger heated seat
harness side and ground. relay. RECONNECT all
connectors. TEST the
system for normal
operation. If the concern is
still present, GO to D3 .
No
REPAIR the circuit. CLEAR
the DTCs. REPEAT the
self-test. TEST the system
For passenger heated seat, measure the resistance between
passenger heated seat relay socket pin 2, circuit CHS07
(GY/BU), harness side and ground.
D3 CHECK THE BCM FOR CORRECT OPERATION
Disconnect all of the BCM connectors. Yes
pushed-out pins. TEST the system for
Connect all of the BCM connectors and make sure they seat normal operation.
correctly.
corroded connector.
CLEAR the DTCs. REPEAT
the self-test. TEST the
system for normal
operation.
Seat — Front
NOTE: Refer to the installation steps in this procedure for seat track-to-floor retainer tightening sequence and
specification.
NOTE: Always install new seat track-to-floor bolts.

1 — Electrical connector (part of 14A005)
2 W700883 Seat track-to-floor bolt (4 required)
3 — Seat assembly
WARNING: Never probe the electrical connectors on air bag, Safety Canopy® or side air curtain
modules. Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed
and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the
vehicle to the customer.
1. Depower the SRS . For additional information, refer to Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of Section 501-20B .
2. Complete the removal by referring to the exploded view.

Note the wire harness routing and retainer locations.
Discard the seat-to-floor bolts.
Installation
1. Install 4 new seat-to-floor bolts by hand.
2. Install the new seat-to-floor bolts in the sequence shown.

3. Connect the wire harness.

Route the wire harness as noted in removal.
Attach the retainers.
4. Repower the SRS . For additional information, refer to Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of Section 501-20B .
Seat — Exploded View, Front
Seat Backrest
NOTE: Driver side shown, passenger similar.
NOTE: Refer to Seat Backrest — Front in this section for recliner-to-seat track bolt and side air bag module nut
tightening sequence and torque specification.

1 611A08 Head restraint
2 610A18 Head restraint guide sleeve (non-lockable)
3 610A16 Head restraint guide sleeve (lockable)
4 64416/RH 64417/LH Backrest cover
5 64810/LH 64811/RH Backrest foam pad
6 W790242 Side air bag module nut (2 required)
7 61018/RH 61019/LH Backrest frame
8 64842 Static lumbar
9 W790240 Recliner-to-seat track bolt (4 required)
10 611D10/RH 611D11/LH Side air bag module
11 W790244 Recliner handle screw
12 61198/RH 61199/LH Recliner handle and screw cover
13 — Anti-squeak bag
Seat Cushion — Driver
NOTICE: The heater mats are serviceable separately. A heater mat can be peeled away from a foam pad
and a new one adhered in its place providing the foam is not damaged. If foam is removed during
removal, a new foam pad must be installed. A heater mat cannot be reused; the 2-way tape adhesive
will no longer hold the heater mat position on the foam pad causing it to shift or bunch up.
NOTE: Refer to Seat Cushion — Front in this section for tightening sequence and torque specifications.
1 62901 Cushion cover
2 14D696 Heater mat
3 632A23 Cushion foam pad
4 64646 Cushion support spring
5 62187 Recliner cover
6 W790245 Cushion pan bolts (4 required)
7 60326 Cushion pan
8 W790246 Recliner cover screw
9 62187 Cushion side shield
10 W790246 Cushion side shield screw
11 61199 Recliner handle and screw cover
13 61753 Seat height adjust handle
14 14A699 Seat wiring harness
15 61705 Seat track
16 610E34 Seat track position sensor bracket
17 W790243 Seat track position sensor bracket screw
18 60328 Wire harness bracket
19 W790243 Wire harness bracket screw
20 W623455 Push nut
Seat Cushion — Passenger
NOTE: Refer to Seat Cushion — Front in this section for tightening sequence and torque specifications.
NOTE: For passenger seat cushion Occupant Classification System (OCS) system components, refer to
Section 501-20B .
NOTE: The heater mats are serviceable separately. A heater mat can be peeled away from a foam pad and a
new one adhered in its place providing the foam is not damaged. If foam is removed during removal, a new
foam pad must be installed. A heater mat cannot be reused; the 2-way tape adhesive will no longer hold the
heater mat position on the foam pad causing it to shift or bunch up.
Part
2 632A22 OCS (with and without heat)
3 64646 Cushion support spring
4 W790241 Occupant Classification System Module (OCSM)
bracket screws (2 required)
5 W790245 Cushion pan bolts (4 required)
6 60326 Cushion pan
7 W790246 Recliner cover screw
8 610E34 OCSM bracket
9 — OCSM (part of 632A22)
10 — OCSM screws (part of 632A22)
11 62186 Recliner cover
12 61704 Seat track
13 62186 Cushion side shield
14 61198 Recliner handle and screw cover
16 W790246 Cushion side shield screw
17 — Seat wiring harness (part of 632A22)
18 610E34 Seat track position sensor bracket
19 W790243 Seat track position sensor bracket screw
20 60328 Wire harness bracket
21 W790243 Wire harness bracket screw
22 W623455 Push nut
1. Refer to the procedures and/or exploded views in this section for any Warnings, Notices, Notes,
Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of
removal.
Seat Backrest — Front
Removal
NOTE: For parts identification and location, refer to Seat — Exploded View, Front in this section.
NOTE: Note all harness routing for correct installation.
1. Remove the seat. For additional information, refer to Seat — Front in this section.
2. NOTE: Passenger seat shown, driver seat similar.
Remove the recliner handle bolt cover, the bolt and the recliner handle.
3. If equipped, release the tab and remove the height adjust handle.
Lift height adjust handle.
Release the tab and slide the handle from the lever.
4. Remove the cushion side shield.

1. Remove the screw at the rear of the cushion side shield.
2. Pull out at the back of the cushion side shield to release the locator pins and tab.
3. Slide the cushion side shield forward to disengage the brackets and remove the cushion
side shield.
5. Remove the screw and the inner recliner cover.
From under the seat, carry out the following.

Disconnect the side air bag module electrical connector and detach the wire harness
retainer.
Disengage the 4 backrest cover elastic strap retainers attached to the bottom rear of the
seat.
7. Remove the 4 recliner-to-seat track bolts and the backrest.
Installation
1. Position the backrest to the cushion frame and install the 4 backrest mounting bolts.
Tighten to 48Nm (35 lb-ft).
2. From under the seat, carry out the following.

Engage the 4 backrest cover elastic strap retainers attach to the bottom rear of the seat.
Connect the side air bag module electrical connector and attach the wire harness retainer.
3. Install the cushion side shield in the following sequence.

1. Position and slide the cushion side shield rearward to engage the brackets.
2. Install the screw at the rear of the cushion side shield.
4. If equipped install the height adjust handle.
5. Install the recliner handle and bolt.

6. Push the recliner handle fully toward the inboard side of the seat then release the pressure on the
recliner handle.
7. NOTE: RH recliner plate is shown, LH recliner plate is similar.
Immobilize the recliner shaft by using 2 long nose locking pliers clamped to the shaft, flush to the
inside edges of both recliner plates.
8. Measure the clearance between the inboard push nut and bushing.
If the clearance between the inboard push nut and the bushing exceeds 0.5 mm (0.019 in),
install a 0.5 mm (0.019 in) feeler gauge or shim between the inboard push nut and the
bushing and slide the inboard push nut tight against the feeler gauge or shim.
9. Remove the feeler gauge or shim.
10. Remove the recliner handle.
11. Push the outboard push nut (located behind the recliner handle) flush to the outboard bushing.
12. Remove the long nose locking pliers.
13. Slide the recliner shaft outward until the inboard push nut contacts the bushing.
14. Verify the clearance between the outboard push nut and bushing is between 0.3 mm and 1.0 mm
(0.011 in and 0.039 in).
16. Install the inner recliner cover and screw.
17. Install the seat. For additional information, refer to Seat — Front in this section.
Seat Backrest Cover — Front
Special Tool(s)
tool
Removal
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air
bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to
follow these instructions may result in the seat side air bag module deploying incorrectly and
increase the risk of serious personal injury or death in a crash.
NOTE: Note all harness routing for correct installation.
1. Remove the front seat backrest. For additional information, refer to Seat Backrest — Front in this
section.
2. Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint
Guide Sleeve in this section.
3. Detach the backrest cover retainers.
4. Invert the backrest cover up enough to expose the side air bag deployment chute.
5. Remove the rivets from the deployment chute J-clip retainers.

From the back of the rivet, push the rivet stud end in and pull the head out from the other
side.
6. Slide the 2 deployment chute J-clip retainers apart.
7. Pull the side air bag module deployment chute and J-clips through the opening in the backrest
foam pad.
Note positioning of the deployment chute for correct installation.
8. Invert the backrest cover and remove row of hog rings.
9. Release the J-clip from the backrest frame.
10. Remove the backrest cover.
Installation
1. Install the backrest cover. Roll down the cover and install 3 hog rings.
2. Attach the J-clip to the backrest frame.
3. WARNING: Before installing the seat side air bag module/deployment chute
assembly:
Inspect the side air bag module and mounting surfaces for any damage or foreign
material.
Remove any foreign material from the mounting surfaces of the deployment chute,
the seat backrest frame mounting bracket and the air bag module cavity in the seat
backrest foam pad.
Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
WARNING: Check the seat side air bag deployment chute for damage. The
deployment chute must not be repaired. If there is any damage to the deployment chute, a
new seat back trim cover and deployment chute must be installed as a unit. Failure to
follow these instructions may result in the seat side air bag module deploying incorrectly
and increase the risk of serious personal injury or death in a crash.
WARNING: If the seat side air bag module deployment chute is not correctly
positioned and closed, the seat side air bag module may not deploy correctly. Failure to
follow these instructions may result in the seat side air bag module deploying incorrectly
and increases the risk of serious personal injury or death in a crash.
Wrap the deployment chute around the side air bag module and backrest frame.
1. Position the outboard side of the air bag deployment chute around the outboard side of the
backrest frame and pad.
2. Insert the inboard side of the air bag deployment chute between the seat backrest frame
and pad.
4. Engage the deployment chute J-clip retainers and install plastic rivets at the top and bottom of the
J-clip retainers.
5. Roll the backrest cover down around the backrest frame.
6. Attach the backrest cover retainers to the rear of the backrest frame.
7. Install the 2 head restraint guide sleeves. For additional information, refer to Head Restraint
Guide Sleeve in this section
8. Install the head restraint.
9. Install the front seat backrest. For additional information, refer to Seat Backrest — Front in this
section.
Seat Cushion Cover — Front
Special Tool(s)
tool
WARNING: Make sure the front passenger seat repair is complete, the seat and all attached
components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is
correctly installed to the vehicle before carrying out the System Reset. Failure to follow these
instructions may result in incorrect operation of the occupant classification system (OCS) and
increases the risk of serious personal injury or death in a crash.
NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification
System (OCS) reset when a front passenger seat cushion is disassembled, a new trim cover
installed or an OCS service kit is installed. A scan tool is used to carry out the OCS system reset
command.
NOTE: For component identification and locations, refer to Seat — Exploded View, Front .
All seats
1. Remove the seat. For additional information, refer to Seat — Front in this section.
Passenger seat with a service kit Occupant Classification System (OCS)
2. Remove the Occupant Classification System (OCS) sensor. For additional information, refer to
Section 501-20B .
Driver seat and passenger seat with Original Equipment (OE) OCS
Remove the recliner handle bolt cover, the bolt and the recliner handle.
4. If equipped, release the tab and remove the height adjust handle.
Lift height adjust handle.
Release the tab and slide the handle from the lever.

3. Slide the cushion side shield forward to disengage the brackets and remove the cushion
side shield.

Disconnect the side air bag module electrical connector and detach the wire harness
retainer.
Disengage the 4 backrest cover elastic strap retainers attached to the bottom rear of the
seat.
8. Remove the cushion and cover from the seat track and seat cushion frame.
All seats
9. Remove the cushion cover.

Release the hook -and-loop strip.
Remove the hog rings and the cushion cover.
Installation
All seats
1. Attach the cushion cover to the cushion.

Secure using new hog rings.
Secure the hook -and-loop strip.
Passenger seat with a service kit OCS
2. Install the Occupant Classification System (OCS) sensor. For additional information, refer to
Section 501-20B .
Driver seat and passenger seat with OE OCS
3. Install the cushion and cover as an assembly.


7. If equipped install the height adjust the handle.
8. Install the recliner handle, bolt and cover.

All seats
9. Install the seat. For additional information, refer to Seat — Front in this section.
Passenger Seat
10. WARNING: Occupant classification system(OCS) parts are calibrated as an assembly

and must only be replaced in the configuration they are sold. Never separate parts of an
assembly. Failure to follow this instruction may result in incorrect operation of the OCS
NOTICE: To prevent system failure, take the following precautions before carrying out the
Occupant Classification System (OCS) system reset:
Make sure the voltage to the Occupant Classification System Module (OCSM) is
greater than 8 volts and less than 18 volts.
Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C
(97°F) when initiating the OCS system reset process. If the vehicle has been
exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept
at a temperature between 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes.
Make sure nothing is present on the passenger seat before and during the OCS
system reset process.
Prior to carrying out the OCS system reset, make sure a minimum of 8 seconds has
elapsed after cycling the ignition switch ON.
Carry out the OCS system reset.
11. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the
following and repair any concerns found.
OCS system connector and wiring for damage.
Pressure sensor hose for kinks and/or damage.
Seat-related wiring harness and body wiring harness terminals and connectors for
damage.
12. NOTE: Cycle the ignition switch after the OCS system reset.
Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS
system service kit. For additional information, refer to Occupant Classification System in Section
501-20B .
13. Prove out the SRS as follows:

Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to
ON and visually monitor the air bag warning indicator with the air bag modules installed. The air
bag warning indicator will illuminate continuously for approximately 6 seconds and then turn off. If
an air bag SRS fault is present, the air bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash at a 5 Hz rate ( RCM not configured).
The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition
switch has been turned from the OFF to the ON position. This is the time required for the RCM to
complete the testing of the SRS . If the air bag warning indicator is inoperative and a SRS fault
exists, a chime sounds in a pattern of 5 sets of 5 beeps. If this occurs, diagnose and repair the air
bag warning indicator and any SRS fault discovered.
Use a scan tool and clear all continuous DTCs from the RCM and Occupant Classification
System Module (OCSM).
Seat Cushion Heater Mat
Removal
Passenger seat
1. NOTICE: Do not install a new heater mat on a front passenger seat cushion. If a new
cushion heater mat is needed on the front passenger seat, an Occupant Classification
System (OCS) service kit equipped with a heater mat must be installed. Failure to follow
this instruction may result in incorrect operation of the OCS .
Install a new OCS service kit. For additional information, refer to Section 501-20B .
Driver seat
2. Remove the driver seat cushion cover. For additional information, refer to Seat Cushion Cover —
Front in this section.
3. NOTICE: Do not reinstall any heater mat after removal. The adhesive will not adhere
correctly to the foam pad, causing it to bunch up or shift out of place. A new heater mat
must be installed. Failure to follow these instructions can result in heated seat component
damage and system failure.
Carefully peel and remove the cushion heater mat from the seat cushion foam pad and route the
wire harness through the cushion foam pad opening.
It is acceptable for a thin layer of foam to peel away with the old heater mat. The new
heater mat will adhere to the foam pad, but if foam tearing occurs or if any pieces of foam
are removed, install a new foam pad.
Installation
1. Install a new heater mat straight on the foam pad and without any wrinkles that may show through
the cover after installation.
2. Install the seat cushion cover. For additional information, refer to Seat Cushion Cover — Front in
this section.
Seat Track
Special Tool(s)
tool
Disassembly and Assembly
System (OCS) system reset when a front passenger seat cushion is disassembled, a new
cushion cover is installed or an OCS service kit is installed.
NOTICE: Do not install a new heater mat on a front passenger seat cushion, it is not serviceable
separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant
Classification System (OCS) service kit equipped with a heater mat must be installed. Failure to
follow this instruction may result in incorrect operation of the OCS . Refer to Section 501-20B for
the OCS removal and installation.
NOTE: Occupant Classification System (OCS) components, seat cushion foam pad, bladder with
pressure sensor and Occupant Classification System Module (OCSM) are calibrated to each other and
are serviced as an assembly. The OCS components are not to be installed separately. If a new OCS ,
OCS component or seat cushion foam pad are needed, a new OCS service kit (seat cushion foam pad,
bladder with pressure sensor and OCSM ) must be installed as an assembly.
NOTE: For component identification and locations, refer to Seat — Exploded View, Front in this section.
All seats
1. Remove the backrest. For additional information refer to Seat Backrest — Front in this section.
Passenger seat
2. Remove the OCS sensor. For additional information, refer to Section 501-20B .
Driver seat
3. Remove seat cushion and cover from the seat track and seat cushion frame.
4. NOTE: Note the wire harness routing for installation.
Remove the seat wire harness.

Release the retainers.
Passenger seat
5. Remove 2 screws and the OCSM bracket.
All seats
6. Remove the safety belt buckle.
Disconnect the safety belt buckle electrical connector.
Remove the bolt and the safety belt buckle assembly.
7. Remove the seat position sensor.

Remove the retaining clip.
Slide sensor rearward to remove.
8. Remove the screw and the wire harness bracket.
9. Remove the screw and the seat track position sensor bracket.
10. Remove the cushion support spring.

Release the cushion spring from the seat track and cushion pan.
11. Remove the 4 retainers and the cushion pan.
Assembly
All seats
1. Position the cushion pan and install the 4 screws in the sequence shown.
2. Install the cushion support spring.
3. Position the seat track position sensor bracket and install the screw.
4. Position the wire harness bracket and install the screw.
5. Install the seat position sensor.

Secure the lock tab.
6. Position the safety belt buckle and install the bolt.

Passenger seat
7. Position the OCSM bracket and install the 2 screws in the sequence shown.
8. Install the OCS . For additional information, refer to Section 501-20B .
Driver seat
9. Install the seat wire harness.

Attach retainers.
10. Install seat cushion and cover from the seat track and seat cushion frame.
All seats
Tighten to 48Nm (35 lb-ft).


recliner handle.
If the clearance between the inboard push nut and the bushing is less than 0.5 mm (0.019
in), remove and discard the push nut. Install a new push nut, using a 0.5 mm (0.019 in)
feeler gauge or shim between the inboard push nut and the bushing, slide the inboard
push nut tight against the feeler gauge or shim.
(0.011 in and 0.039 in).
Passenger seat with an OCS

damage.
501-20B .

- fail to light.
Heated Seat Switch

1 5404644 Lower finish panel
2 — Connector (part of 14401)
3 14D694 Heated seat switch
1. Remove the lower instrument panel finish panel. For additional information, refer to Section 501-12 .
2. Release the tabs and remove the heated seat switch.
Installation
1. Install the heated seat switch.
2. Install the lower instrument panel finish panel. For additional information, refer to Section 501-12 .
Head Restraint Guide Sleeve
Removal
NOTE: Typical head restraint guide sleeve shown, others similar.
1. Push in on the 2 head restraint guide sleeve release buttons and remove the head restraint.
2. Obtain a flat-head screwdriver with a width of 4 mm (0.157 in) to 7 mm (0.275 in) and a thickness
of approximately 1 mm (0.039 in).
3. Locate the lock feature on the head restraint guide sleeve.

1. Position the screwdriver between the head restraint guide sleeve neck and backrest trim
cover and foam pad.
2. Locate the screwdriver on the lock feature and position at a 45-degree angle.
4. NOTE: For retainer clarity, backrest trim cover and foam pad are removed.
Push in the screwdriver, bending the lock feature on the head restraint guide sleeve in.
5. While bending the lock feature in, push down on the screwdriver handle, prying the head restraint
guide sleeve up and disengaging it from the backrest frame crossmember.
6. Remove the head restraint guide sleeve.

Discard the head restraint guide sleeve.
7. Repeat these steps for the head restraint guide sleeve on the opposite side.
Installation
NOTICE: Always install new head restraint guide sleeves. Difficult adjustment of the head
restraint may occur. Failure to follow these instructions may result in component failure.
NOTICE: The head restraint guide sleeves are not interchangeable. Failure to install the correct
head restraint guide sleeve at the correct position may result in component failure.
1. Make sure the holes in the backrest foam pad and backrest trim cover are aligned to the holes in
the backrest frame.
2. NOTE: The guide sleeve will only fit into the backrest frame when the guide sleeve alignment
tabs align with the keyway opening in the backrest frame.
To allow the head restraint guide sleeve to slide freely through the backrest foam pad and
backrest trim cover, twist the head restraint guide sleeve to align the keyway tabs while pushing it
into the backrest frame hole as far as it will go with hand pressure.
3. Inspect the head restraint guide sleeve.

Pull the head restraint guide sleeve out by hand, making sure it is locked in place. If the
head restraint guide sleeve can be removed by hand, repeat the installation procedure. If
the head restraint guide sleeve can be removed again after installing a second time, install
a new head restraint guide sleeve.
4. Repeat these steps for the head restraint guide sleeve on the opposite side.
5. After installation of 2 new head restraint guide sleeves, install the head restraint in the following
sequence.
1. Position the head restraint rods to the head restraint guide sleeve holes.
2. Push the head restraint down, guiding the rods into the head restraint guide sleeve holes.
3. Make sure the head restraint adjusts without excessive effort and locks in place.
Seat — Exploded View, Rear
Seat Backrest — 40 Percent

1 611A08 Head restraint
2 610A16 Head restraint guide sleeve (lockable)
3 66800 Backrest foam pad
4 66600 Backrest cover
5 — Hinge pin bolt (part of 613B48)
6 613B48 Hinge pin
7 60508 Backrest frame
8 W790247 Backrest latch bolt (2 required)
9 61382 Backrest latch
10 624A08 Backrest latch bezel
Seat Backrest — 60 Percent, 4-Door Sedan

1 611A08 Head restraint (center)
2 611A08 Head restraint (LH)
4 610A16 Head restraint guide sleeve (3 required) (lockable)
9 613B48 Hinge pin
Seat Backrest — 60 Percent, 5-Door Hatchback

8 — Safety belt retractor bolt (part of 611B66)
10 613B48 Hinge pin
14 611B66 Safety belt retractor
15 611A70 Safety belt retractor bezel
Seat Cushion
2 63840 Cushion foam pad

Seat Backrest — Rear
Seat Backrest — Rear, 40 Percent
NOTE: Some parts removed for clarity.
Part
1 60508 Backrest frame, 40 percent
2 — Backrest frame mounting pin, 60 percent (part of
60509)
3 613B90 RH outboard backrest hinge
4 613B48 Hinge pin and bolt
NOTE: The 40 percent backrest must be removed before the 60 percent backrest can be removed.
NOTE: 5 door hatchback is shown, 4 door sedan is similar.
NOTE: Some parts removed for clarity.
Part
1 — Backrest frame mounting pin, 60 percent (part of 60509)
2 60615 Center backrest hinge
3 — Safety belt anchor bolt (part of 611B66) (5-door
hatchback only)
4 613B48 Hinge pin and bolt
5 613B91 Outboard backrest hinge
Seat Backrest Hinges — Rear
NOTE: RH outboard backrest hinge shown, LH similar.
NOTE: Always install new backrest hinge and safety belt anchor bolts.

1 W703708 Safety belt anchor bolt
2 — Safety belt anchor (part of 611B68/RH
611B69/LH)
3 613B90 (RH) / 613B91 Outboard backrest hinge
(LH)
4 W707941 Backrest hinge bolt (3 required)
5 60615 Center backrest hinge
5 - Door hatchback - 60 Percent backrest
1. Remove the rear seat cushion assembly. For additional information, refer to Seat Cushion — Rear in this
section.

All backrests
NOTE: The 40 percent seat backrest has to be removed before the 60 percent seat backrest.
3. Push the backrest release button at the top of the seat backrest and fold the seat down.
4. NOTE: The latch hook is identified with a white paint mark.
Tap the latch to unlock the outboard hook latch.

Pivot the outboard latch hook rearward to disengage.
To install, push the seat backrest hinge into the latch bracket until the hook latch is fully seated.
5. Remove the seat backrest.

1. Pull the outboard side of the backrest up out of the latch bracket.
2. Position the 40 percent outboard backrest hinge pin bolt to the rear of the outboard backrest
hinge.
3. Pull the seat backrest outward and slightly twist forward while removing from the center mounting
bracket.
All hinges
6. Remove the rear seat cushion assembly. For additional information, refer to Seat Cushion — Rear in this
section.
7. Remove the seat backrest(s) for the affected hinge.
8. Remove and discard the bolts of the affected hinge.

Install a new backrest hinge bolt(s) and tighten to 40 Nm (30 lb-ft).
Install a new safety belt anchor bolt and tighten to 48 Nm (35 lb-ft), if equipped.
All brackets and hinges

Seat Cushion — Rear
Part
1 — Cushion assembly
2 624A14 Seat cushion anchors (2 required)
3 — Retainer hooks (3 required) (part of 613B90/RH,
613B91/LH and 60615/center)
1. From under the front of the cushion assembly, push the 2 seat cushion anchor latch release levers
toward the driver side, while lifting up to disengage the front of the cushion assembly.
2. Remove the cushion assembly in the following sequence.
1. Push the cushion back as far as possible.
2. Lift up and pull forward at the rear outboard ends of the cushion, disengaging the wires from the
retainer hooks.
Remove the cushion.
3. NOTE: Before installation, make sure the safety belts and buckles are accessible to the occupants.
To Install, reverse the removal procedure.

Seat Latch Striker — Rear
NOTE: RH shown, LH similar.

1 62542 Backrest striker
RH/62543LH
2 W701802 Backrest striker bolts (2 required without backrest
retractor, 3 required with backrest retractor)
1. Remove the lower C-pillar trim panel. For additional information, refer to Section 501-05 .
2. Remove the bolts and the backrest striker.


DISASSEMBLY AND ASSEMBLY Procedure revision date: 10/26/2010
Seat Backrest — Front
Disassembly
1. Remove the front seat backrest. For additional information, refer to Seat Backrest — Front in this
section.
2. Remove the front seat backrest cover. For additional information, refer to Seat Backrest Cover —
Front in this section.
3. Detach the side air bag module wire harness retainer from the rear of the backrest frame.
4. Remove the 2 side air bag module nuts.
5. Remove the side air bag module in the following sequence:

1. Pull the side air bag module mounting studs back through the backrest frame.
2. Position the side air bag module away from the backrest frame.
3. Route out the wire harness.
6. Remove the backrest foam pad.
7. Remove the anti-squeak bag from the backrest frame.
8. Remove the 2 backrest foam retainer clips from the backrest frame.
9. Remove the static lumbar support.
Assembly
1. Install the static lumbar support.
2. Install the 2 backrest foam retainer clips to the backrest frame.
3. Install the anti-squeak bag to the backrest frame.
4. Install the backrest foam pad.
Route the side air bag module wire harness through the backrest foam pad opening.
6. Position the side air bag module studs through the backrest frame holes and install the nuts in the
sequence shown.
7. Attach the side air bag module wire harness retainer to the rear of the backrest frame.
8. Install the seat backrest cover. For additional information, refer to Seat Backrest Cover — Front in
this section.
9. Install the front seat backrest. For additional information, refer to Seat Backrest — Front in this
section.
Disassembly
Seat Backrest — 60 Percent, 4-Door Sedan

9 613B48 Hinge pin
Seat Backrest — 60 Percent, 5-Door Hatchback

10 613B48 Hinge pin
15 611A70 Safety belt retractor bezel
WARNING: After a crash, the following safety belt components and attaching hardware must be
inspected and tested to verify correct function:
Retractors
Buckles
Child safety seat tether bracket assemblies
Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions
only)
Belt tension sensor (BTS) (if equipped)
Front safety belt buckle support assemblies (slide bar) (if equipped)
Safety belt shoulder belt height adjusters (if equipped)
Components that do not operate correctly or pass all Functional Tests in the Component Tests of this
section must be replaced with new components.
Safety belt assembly attaching areas must be inspected. Damaged or distorted attaching areas must be
restored to their original structural integrity and a new safety belt assembly with new attaching
hardware must be installed.
After deployment of the front safety belt pretensioners, a new safety belt system (including retractors,
buckles and height adjusters) must be installed.
Failure to follow this instruction may result in incorrect operation of the safety belt system and
1. Remove the rear seat backrest. For additional information, refer to Seat Backrest — Rear in this section.
2. Detach the safety belt retractor bezel from the backrest frame wire and remove the bezel.
Pull where shown to unsnap the safety belt bezel from the backrest frame wire.
3. Push the buttons on the head restraint guide sleeves and remove the head restraint(s).
4. NOTE: If the locking tab on the head restraint guide is damaged during removal, a new head restraint
guide must be installed.
Remove the headrest guide sleeves.

Insert an appropriate flat-blade screwdriver along side the head restraint guide below the backrest
cover and release button.
Release the locking tab and pry upward to remove.
5. Detach the backrest latch bezel from the backrest latch and remove the bezel.
6. Remove the hinge pin and bolt.
7. Detach the backrest cover retainer from the backrest frame at the rear of the backrest.
8. Remove the backrest cover and foam pad as an assembly.
Route the safety belt and tongue out of the backrest cover.
9. Remove the backrest cover.

Remove the hog rings and separate the foam pad from the Backrest cover.
10. Mark the backrest latch alignment prior to removing the backrest latch to assist in installing and aligning
the backrest latch.
11. Remove the backrest latch.

Remove the 2 retainers and the backrest latch.
12. Make a small cross cut into the carpet above the safety belt retractor bolt.
Push into the carpet on the rear of the backrest and feel for the safety belt retractor bolt.
13. Remove the safety belt retractor.

1. Remove the safety belt retractor bolt.
2. Route the safety belt and tongue out of the backrest cover.
Assembly
1. Install the safety belt retractor.

1. Install the safety belt retractor.
2. Route the safety belt and tongue through the backrest cover.
3. Install the safety belt retractor bolt.
2. Position the backrest latch to the marks in the backrest frame and install the bolts.
3. Install the backrest cover.

Assemble the foam pad to the Backrest cover, secure using hog rings.
4. Install the backrest cover and foam pad as an assembly.

Route the safety belt and tongue through the backrest cover.
5. Attach the backrest cover retainer to the backrest frame at the rear of the backrest.
6. Install the hinge pin and bolt.

7. Attach the backrest latch bezel to the backrest latch.
8. NOTE: If the locking tab on the head restraint guide is damaged during removal, a new head restraint
guide must be installed.
Install the headrest guide sleeves.
9. Attach the safety belt retractor bezel to the backrest frame wire.
10. Install the rear seat backrest. For additional information, refer to Seat Backrest — Rear in this section.
Seat Cushion — Front
Special Tool(s)
tool
System (OCS) system reset when a front passenger seat cushion is disassembled, a new
cushion cover is installed or an OCS service kit is installed.
NOTICE: Do not install a new heater mat on a front passenger seat cushion, it is not serviceable
separately. If a new cushion heater mat is needed on the front passenger seat, an Occupant
Classification System (OCS) service kit equipped with a heater mat must be installed. Failure to
follow this instruction may result in incorrect operation of the OCS . Refer to Section 501-20B for
the OCS removal and installation.
NOTE: Occupant Classification System (OCS) components, seat cushion foam pad, bladder with
pressure sensor and Occupant Classification System Module (OCSM) are calibrated to each other and
are serviced as an assembly. The OCS components are not to be installed separately. If a new OCS ,
OCS component or seat cushion foam pad are needed, a new OCS service kit (seat cushion foam pad,
bladder with pressure sensor and OCSM ) must be installed as an assembly.
All seats
1. Remove the seat backrest. For additional information refer to Seat Backrest — Front in this
section.
Passenger seat
2. Remove the OCS sensor. For additional information, refer to Section 501-20B .
Driver seat
3. Remove seat cushion cover. For additional information, refer to Seat Cushion Cover — Front in
this section.
4. NOTE: Note the wire harness routing for installation.
Remove the seat wire harness.

Release retainers.
Passenger seat
5. Remove 2 screws and the OCSM bracket.

All seats
6. Remove the safety belt buckle.

Disconnect the safety belt buckle electrical connector.
Remove the bolt and the safety belt buckle assembly.
7. Remove the seat position sensor.

Remove the retaining clip.
Slide sensor rearward to remove.
8. Remove the screw and the wire harness bracket.
9. Remove the screw and the seat track position sensor bracket.
10. Remove the cushion support spring.

Release the cushion spring from the seat track and cushion pan.
11. Remove the 4 retainers and the cushion pan.
Assembly
All seats
1. Position the cushion pan and install the screws in the sequence shown.
2. Install the cushion support spring.
3. Position the seat track position sensor bracket and install the screw.
4. Position the wire harness bracket and install the screw.
5. Install the seat position sensor.

Secure the lock tab.
6. Position the safety belt buckle and install the bolt.

Passenger seat
7. Position the OCSM bracket and install the screws in the sequence shown.
8. Install the OCS . For additional information, refer to Section 501-20B .
Driver seat
9. Install the seat wire harness.

Attach retainers.
10. Install the seat cushion cover. For additional information, refer to Seat Cushion Cover — Front in
this section.
All seats


recliner handle.
If the clearance between the inboard push nut and the bushing is less than 0.5 mm (0.019
in), remove and discard the push nut. Install a new push nut, using a 0.5 mm (0.019 in)
feeler gauge or shim between the inboard push nut and the bushing, slide the inboard
push nut tight against the feeler gauge or shim.
(0.011 in and 0.039 in).
Passenger seat with an OCS

damage.
501-20B .

- fail to light.
SECTION 501-11: Glass, Frames and Mechanisms 2011 Fiesta Workshop Manual
Material
Capacity
Dow Urethane Adhesive — —
Betaseal™ Express
Dow Urethane One Step Glass — —
Primer
Betaprime™ 5500 / 5500A /
5500SA
Motorcraft® Lacquer Touch-Up ESR-M2P100- —
Paint (match color to exterior C
grid wire)
PMP-19500-XXXXX
Rear Window Defroster Repair — —
PM-11 (US); CPM-11 (Canada)
Seam Sealer — —
TA-2
Sika Urethane Adhesive — —
Sika Tack ASAP
Sika Urethane Metal and Glass — —
Primer
Sika 206 G+P
Motorcraft® Ultra-Clear Spray ESR-M14P5- —
Glass Cleaner A
ZC-23
General Specifications
Item Specification
Polypropylene Film Fine Line Tape (commercially available) —
Door carrier bolts 9 80
Door window glass clamp bolts 9 80
Glass, Frames and Mechanisms
The glass, frames and mechanisms consist of the following:

Door glass top run
Door window glass
Door window regulator
Door window regulator motor
Rear quarter glass
Rear window defrost switch (integral to the HVAC module)
Rear window glass
Window control switches
Windshield glass
The power window system only operates if the ignition is in the RUN position.
The master window control switch:
disables operation of the rear passenger windows when the lock-out switch is in the UNLOCK
position.
automatically raises/lowers the driver window when activated momentarily to the second detent
position.
The power window system can be operated from either the master window control switch or from the
window control switches located on each door panel.
Rear Window Defrost
The engine must be running for the rear window defrost system to operate. The rear window defrost
system is controlled by the BCM . When the rear window defrost switch (integral to the HVAC module) is
pressed, the BCM supplies voltage to the rear window defrost grid. An LED indicator illuminates when
the rear window defrost is activated. The rear defrost self actuates when the ambient air temperature is
less than 5° C (41° F) and engine coolant temperature is less than 60° C (140° F). The rear window
defroster LED indicator does not illuminate when the rear defroster self actuates.
Glass, Frames and Mechanisms
Special Tool(s)
Flex Probe Kit


tool
LH Front Window Operation
NOTE: The master window control switch and the LH front window motor each contains integral
electronics which must be initialized whenever:
a new window control switch is installed.

a new window regulator and motor is installed.
a new window glass is installed.
a glass top run removal and installation.
carrying out any operation in which grease or lubricants are applied to the window system.
battery voltage has been removed from the LH front window control switch for more than 3
minutes (for example, battery or window control switch disconnected).
For additional information, refer to Window Motor Initialization in this section.
The master window control switch contains electronics that control the one-touch up/down operation.
The master window control switch receives feedback from the Hall-effect sensors which are integral to
the LH front window motor. If the Hall-effect sensors or any associated circuitry fails, the window still
operates but the one-touch up/down and obstacle detection is inoperative.
If an obstacle has been detected in the window opening as the window glass is moving upward, the
window motor automatically reverses direction and moves the glass toward the bounce-back position.
To override a bounce-back condition (for example, to overcome the resistance of ice on the window or
seals), close the window glass twice until it reaches the resistance and allow it to reverse to the bounce-
back position. On the third attempt, activate and hold the master window control switch in the UP
position. The window travels up with no bounce-back protection.
Rear Window Defrost
The engine must be running for the rear window defrost system to operate. When the rear window
defrost switch (integral to the HVAC module) is pressed, a ground signal is sent to the Body Control
Module (BCM). When the BCM receives the defrost request signal, it supplies voltage to the rear window
defrost grid. The rear defrost self actuates when the ambient air temperature is less than 5° C (41° F)
and engine coolant temperature is less than 60° C (140° F). The rear window defroster LED indicator
does not illuminate when the rear defroster self actuates.
The BCM deactivates the rear window defrost grid when one of the following conditions is met:
The rear window defrost switch is pressed when the feature is active
The ignition state is changed from ON to OFF/LOCK
The 14-minute timing function is complete
2. Visually inspect for obvious signs of mechanical or electrical damage.

Window run weatherstrip Central Junction Box (CJB) fuse(s):
Window glass 16 (7.5A) (vehicles built after 1/14/2011)
Rear window defrost grid 31 (30A)
34 (30A)
Battery Junction Box (BJB) fuse(s):
26 (7.5A) (vehicles built up to 1/14/2011)
33 (30A)
Window motor
Window control switch
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).

refer to Section 418-00 No Power To The Scan Tool, to diagnose no power to the scan
tool.
verify the ignition key is in the ON position.

If the scan tool responds with no communication from one or more modules, refer to
Section 418-00 .
If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble
Codes (CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the BCM .
DTC Chart
NOTE: Refer to Description and Operation, Intelligent Access with Push Button Start in Section 419-01B
to review the procedures for achieving the various ignition states on vehicles with this feature.

B1013:23 Heater Rear Defog Switch: Signal GO to Pinpoint Test J .
Stuck Low
All Other — REFER to the Master DTC Chart in Section
DTCs 419-10 .
Symptom Chart
Symptom Chart
All power windows Wiring, GO to Pinpoint Test A .
are inoperative terminals or
connectors
Window
control
switch
The RH front, LH Wiring, GO to Pinpoint Test B .
rear and RH rear terminals or
power windows are connectors
inoperative Window
control
switch
The LH front and Wiring, GO to Pinpoint Test C .
RH front power terminals or
windows are connectors
inoperative Window
control
switch
The LH rear and Wiring, GO to Pinpoint Test D .
RH rear power terminals or
windows are connectors
inoperative Window
control
switch
A single power Fuse(s) GO to Pinpoint Test E .
window is Wiring,
inoperative — LH terminals or
front window connectors
Window
control
switch
Window
regulator
motor
A single power Wiring, GO to Pinpoint Test F .
window is terminals or
inoperative — RH connectors
front window Window
control
switch
Window
regulator
motor
A single power Wiring, GO to Pinpoint Test G .
inoperative — LH connectors
rear window Window
control
switch
Window
regulator
motor
A single power Wiring, GO to Pinpoint Test H .
inoperative — RH connectors
rear window Window
control
switch
Window
regulator
motor
The one-touch LH front GO to Pinpoint Test I .
up/down feature is window
inoperative motor not
initialized
Wiring,
terminals or
connectors
Window
control
switch
Window
regulator
motor
The defrost system Fuse GO to Pinpoint Test J .
is inoperative Wiring,
terminals or
connectors
Rear window
defrost grid
HVAC
module
Body Control
Module
(BCM)
The defrost system Wiring, GO to Pinpoint Test K .
will not shut off terminals or
automatically connectors
BCM
The defrost system Wiring, NOTE: The rear defrost self
LED does not terminals or actuates when the ambient air
illuminate when the connectors temperature is less than 5° C (41°
defrost system is HVAC F) and engine coolant temperature
active module is less than 60° C (140° F). The rear
BCM window defroster LED indicator
does not illuminate when the rear
defroster self actuates.
GO to Pinpoint Test L .
Pinpoint Tests
Pinpoint Test A: All Power Windows are Inoperative
Refer to Wiring Diagrams Cell 100 , Power Windows for schematic and connector information.
Normal Operation
There are two high current voltage circuits to the master window control switch. One of these circuits
provides voltage for front window operation, the other provides voltage for rear window operation. The
master window control switch supplies ground for all window motor operation.

PINPOINT TEST A: ALL POWER WINDOWS ARE INOPERATIVE
A1 CHECK ALL WINDOW OPERATION FROM THE MASTER
WINDOW CONTROL SWITCH
NOTE: Make sure the window lock-out switch is in the Yes

UNLOCK position. GO to Symptom Chart to
diagnose the inoperative
Ignition ON. window(s).
Attempt to operate each window from the master window
control switch. No
Do any of the windows operate from the master window GO to A2 .
control switch?
A2 CHECK THE MASTER WINDOW CONTROL SWITCH
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504A. INSTALL a new master
Measure the resistance between master window control window control switch.
switch C504A-2, circuit GD143 (BK/VT), harness side and REFER to Window Control
ground. Switch in this section. TEST
operation.
No
REPAIR the circuit. CARRY
OUT the window motor
initialization procedure.
REFER to Window Motor
Initialization in this section.
operation.
Pinpoint Test B: The RH Front, LH Rear and RH Rear Power Windows are Inoperative
Normal Operation
master window control switch supplies ground for all window motor operation through two different
circuits. One of the circuits provides ground only to the LH front window, the other provides ground for
the RH front, LH rear and RH rear window motor operation.

PINPOINT TEST B: THE RH FRONT, LH REAR AND RH REAR POWER WINDOWS ARE
INOPERATIVE
B1 CHECK ALL WINDOW OPERATION FROM THE MASTER
WINDOW CONTROL SWITCH
NOTE: Make sure the window lock-out switch is in the Yes

UNLOCK position. GO to Symptom Chart to
diagnose the inoperative
Ignition ON. window(s).
Attempt to operate each window from the master window
control switch. No
Does the RH front, LH rear or RH rear window operate GO to B2 .
from the master window control switch?
B2 CHECK THE MASTER WINDOW CONTROL SWITCH
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504C. INSTALL a new master
Measure the resistance between master window control window control switch.
switch C504C-4, circuit GD143 (BK/VT), harness side and REFER to Window Control
ground. Switch in this section. TEST
operation.
No
REPAIR the circuit. CARRY
OUT the window motor
operation.
Pinpoint Test C: The LH Front and RH Front Power Windows are Inoperative
Normal Operation
master window control switch supplies ground for all window motor operation through two different
circuits. One of the circuits provides ground only to the LH front window, the other provides ground for
the RH front, LH rear and RH rear window motor operation.

PINPOINT TEST C: THE LH FRONT AND RH FRONT POWER WINDOWS ARE INOPERATIVE
C1 CHECK FOR VOLTAGE TO THE MASTER WINDOW
CONTROL SWITCH
Ignition OFF. Yes
Ignition ON. window control switch.
Measure the voltage between master window control switch REFER to Window Control
C504A-7, circuit CBP34 (VT/BN), harness side and ground. Switch in this section. TEST
operation.
No
VERIFY Central Junction Box
(CJB) fuse 34 (30A) is OK, If
OK, REPAIR the circuit.
CARRY OUT the window
motor initialization procedure.
operation.
If not OK, REFER to the

Wiring Diagrams manual to
Is the voltage greater than 10 volts? identify the possible causes of
the circuit short. REPAIR the
circuit. CARRY OUT the
window motor initialization
procedure. REFER to Window
Motor Initialization in this
section. TEST the system for
normal operation.
Pinpoint Test D: The LH Rear and RH Rear Power Windows are Inoperative
Normal Operation
provides voltage for front window operation, the other provides voltage for rear window operation when
the master window lock-out switch is in the UNLOCK position. The master window control switch
supplies ground for all window motor operation through two different circuits. One of the circuits provides
ground only to the LH front window, the other provides ground for the RH front, LH rear and RH rear
window motor operation.

PINPOINT TEST D: THE LH REAR AND RH REAR POWER WINDOWS ARE INOPERATIVE

D1 CHECK FOR VOLTAGE TO THE MASTER WINDOW
CONTROL SWITCH
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504C. GO to D2 .
Ignition ON.
Measure the voltage between master window control switch No
C504C-2, circuit CBP31 (BU/OG), harness side and ground. VERIFY Central Junction
Box (CJB) fuse 31 (30A) is
OK, If OK, REPAIR the
circuit. CARRY OUT the
window motor initialization
procedure. REFER to
Window Motor Initialization
in this section. TEST the
system for normal
operation.

Wiring Diagrams manual
to identify the possible
REPAIR the circuit.
Is the voltage greater than 10 volts? CARRY OUT the window
motor initialization
procedure. REFER to
system for normal
operation.
D2 CHECK FOR AN OPEN CIRCUIT BETWEEN THE MASTER
WINDOW CONTROL SWITCH AND THE REAR WINDOW
CONTROL SWITCH
Ignition OFF. Yes
Disconnect: LH Rear Window Control Switch C701. INSTALL a new master
Measure the resistance between master window control switch window control switch.
C504C-1, circuit CPW01 (BN/BU), harness side and LH rear REFER to Window Control
window control switch C701-2, circuit CPW01 (BN/BU), Switch in this section.
harness side. TEST the system for
normal operation.
No
REPAIR the circuit.
procedure. REFER to
system for normal
operation.
Pinpoint Test E: A Single Power Window is Inoperative — LH Front Window
Normal Operation
There are two voltage supplies to the master window control switch for LH front window operation. One
circuit powers the integral electronics, the other provides high current voltage for the LH front window
motor. The master window control switch and LH front window motor are grounded through the same
circuit. The master window control switch provides voltage and ground to the LH front window motor.
Window direction is controlled by reversing polarity of the voltage and ground circuits being supplied to
the window motor.

Fuse(s)
Window regulator motor
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE — LH FRONT WINDOW

E1 CHECK FOR VOLTAGE TO THE MASTER WINDOW CONTROL
SWITCH
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504A. GO to E2 .
Ignition ON.
Measure the voltage between master window control switch No
C504A-7, circuit CBP34 (VT/BN), harness side and ground; and VERIFY Central Junction
between master window control switch C504A-8, circuit SBB26 Box (CJB) fuse 34 (30A)
(YE/RD) (vehicles built up to 1/14/2011) or SBP16 (VT/RD) and Battery Junction Box
(vehicles built after 1/14/2011), harness side and ground. (BJB) fuse 26 (7.5A)
(vehicles built up to
1/14/2011) or fuse 16
(7.5A) (vehicles built after
1/14/2011) are OK. If OK,
REPAIR the circuit(s).
procedure. REFER to
Window Motor
Initialization in this
section. TEST the
system for normal
operation.

Is the voltage greater than 10 volts for both measurements? Wiring Diagrams manual
causes of the circuit
short. REPAIR the circuit
(s). CARRY OUT the
window motor
section. TEST the
system for normal
operation.
E2 CHECK THE MASTER WINDOW CONTROL SWITCH GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between master window control switch GO to E3 .
C504A-2, circuit GD143 (BK/VT), harness side and ground.
No
REPAIR the circuit.
procedure. REFER to
Window Motor
section. TEST the
system for normal
operation.

E3 CHECK FOR VOLTAGE AND GROUND TO THE WINDOW
MOTOR
Ignition OFF. Yes
Connect: Master Window Control Switch C504A. INSTALL a new LH front
Disconnect: LH Front Power Window Motor C524. window regulator motor.
Ignition ON. REFER to Window
NOTE: During the following step, the voltage being measured Regulator Motor — Front
changes polarity dependent upon which direction the window Door in this section.
control switch is activated. TEST the system for
Measure the voltage between LH front power window motor normal operation.
C524-1, circuit CPW11 (BU/GY), harness side and LH front
power window motor C524-2, circuit CPW10 (YE/VT), harness No
side while operating the master window control switch in the GO to E4 .
down then up positions.
Is the voltage greater than 10 volts when the window control

switch is operated and 0 volt in the rest position?
E4 CHECK FOR AN OPEN CIRCUIT BETWEEN THE MASTER
WINDOW CONTROL SWITCH AND THE WINDOW MOTOR
Ignition OFF. Yes
Measure the resistance between master window control switch window control switch.
C504A, harness side and LH front power window motor C524, REFER to Window
harness side using the following chart: Control Switch in this
section. TEST the
Master Window LH Front Power system for normal
Control Switch Circuit Window Motor operation.
C504A-3 CPW11 C524-1 No
(BU/GY) REPAIR the circuit(s).
C504A-5 CPW10 C524-2 motor initialization
(YE/VT) procedure. REFER to
Window Motor
section. TEST the
system for normal
operation.
Are the resistances less than 5 ohms?
Pinpoint Test F: A Single Power Window is Inoperative — RH Front Window
Normal Operation
The RH front window control switch receives power from the Central Junction Box (CJB). Ground is
provided to the RH front window control switch through the master window control switch. The RH front
window control switch transfers power and ground to the RH front window motor. Window direction is
controlled by reversing polarity of the voltage and ground circuits being supplied to the window motor.
When operating the RH front window from the master window control switch, power and ground is sent
from the master window control switch through the normally closed contacts within the RH front window
control switch to operate the RH front window. Window direction is controlled by reversing polarity of the
voltage and ground circuits being supplied to the window motor.

PINPOINT TEST F: A SINGLE POWER WINDOW IS INOPERATIVE — RH FRONT WINDOW
Result / Action to
Test Step
Take
F1 CHECK THE RH FRONT WINDOW OPERATION FROM THE
MASTER WINDOW CONTROL SWITCH
Ignition ON. Yes
Operate the RH front window from the master window control GO to F2 .
switch.
Does the RH front window operate from the master window No
control switch? GO to F3 .
F2 CHECK FOR VOLTAGE TO THE RH FRONT WINDOW CONTROL
SWITCH
Ignition OFF. Yes
Disconnect: RH Front Window Control Switch C604. INSTALL a new RH
Ignition ON. front window control
Measure the voltage between RH front window control switch C604- switch. REFER to
2, circuit CBP34 (VT/BN), harness side and ground. Window Control
Switch in this section.
TEST the system for
normal operation.
No
REPAIR the circuit.
TEST the system for
normal operation.

F3 CHECK FOR VOLTAGE AND GROUND TO THE WINDOW MOTOR
Ignition OFF. Yes
Disconnect: RH Front Power Window Motor C608. INSTALL a new RH
Ignition ON. front window
NOTE: During the following step, the voltage being measured regulator motor.
changes polarity dependent upon which direction the window control REFER to Window
switch is activated. Regulator Motor —
Measure the voltage between RH front power window motor C608- Front Door in this
1, circuit CPW19 (VT), harness side and RH front power window section. TEST the
motor C608-2, circuit CPW20 (WH/OG), harness side while system for normal
operating the master window control switch in the down then up operation.
positions.
No
GO to F4 .

F4 CHECK THE RH FRONT WINDOW CONTROL SWITCH
Ignition OFF. Yes
Disconnect: RH Front Window Control Switch C604. GO to F5 .
Carry out the window control switch component test on the RH front
window control switch. No
INSTALL a new RH
Refer to Wiring Diagrams Cell 149 for component testing. front window control
switch. REFER to
Window Control
Did the RH front window control switch pass the component Switch in this section.
test? TEST the system for
normal operation.
F5 CHECK FOR AN OPEN CIRCUIT BETWEEN THE RH WINDOW
CONTROL SWITCH AND THE WINDOW MOTOR
Measure the resistance between RH front window control switch Yes
C604, harness side and RH front power window motor C608, GO to F6 .
harness side, using the following chart:
No
RH Front Window RH Front Power REPAIR the circuit(s).
Control Switch Circuit Window Motor TEST the system for
normal operation.
C604-1 CPW20 C608-2
(WH/OG)
C604-7 CPW19 (VT) C608-1

F6 CHECK FOR AN OPEN CIRCUIT BETWEEN THE RH WINDOW
CONTROL SWITCH AND THE MASTER WINDOW CONTROL SWITCH
Disconnect: Master Window Control Switch C504A. Yes
Measure the resistance between master window control switch INSTALL a new
C504A, harness side and RH front window control switch C604, master window
harness side using the following chart: control switch.
REFER to Window
Master Window RH Front Window Control Switch in this
Control Switch Circuit Control Switch section. TEST the
system for normal
C504A-1 CPW12 C604-3 operation.
(GN/OG)
No
C504A-4 CPW13 C604-6
(BN/YE)
CARRY OUT the
window motor
initialization
procedure. REFER to
Window Motor
section. TEST the
system for normal
operation.
Pinpoint Test G: A Single Power Window is Inoperative — LH Rear Window
Normal Operation
The LH rear window control switch receives power from the master window control switch when the lock-
out switch is in the UNLOCK position. Ground is provided to the LH rear window control switch through
the master window control switch. The LH rear window control switch transfers power and ground to the
LH rear window motor. Window direction is controlled by reversing polarity of the voltage and ground
circuits being supplied to the window motor.
When operating the LH rear window from the master window control switch, power and ground is sent
from the master window control switch through the normally closed contacts within the LH rear window
control switch to operate the LH rear window. Window direction is controlled by reversing polarity of the

PINPOINT TEST G: A SINGLE POWER WINDOW IS INOPERATIVE — LH REAR WINDOW
Result / Action to
Test Step
Take
G1 CHECK THE LH REAR WINDOW OPERATION FROM THE
Ignition ON. Yes
Operate the LH rear window from the master window control switch. GO to G2 .
Does the LH rear window operate from the master window
control switch? No
GO to G3 .
G2 CHECK FOR VOLTAGE TO THE LH REAR WINDOW CONTROL
SWITCH
Ignition OFF. Yes
Disconnect: LH Rear Window Control Switch C701. INSTALL a new LH
Ignition ON. rear window control
NOTE: Make sure the window lock-out switch is in the UNLOCK switch. REFER to
position. Window Control
Measure the voltage between LH rear window control switch C701- Switch in this section.
2, circuit CPW01 (BN/BU), harness side and ground. TEST the system for
normal operation.
No
REPAIR the circuit.
TEST the system for
normal operation.

G3 CHECK FOR VOLTAGE AND GROUND TO THE WINDOW MOTOR
Ignition OFF. Yes
Disconnect: LH Rear Power Window Motor C703. INSTALL a new LH
Ignition ON. rear window regulator
NOTE: During the following step, the voltage being measured motor. REFER to
changes polarity dependent upon which direction the window control Window Regulator
switch is activated. Motor — Rear Door
Measure the voltage between LH rear power window motor C703-1, in this section. TEST
circuit CPW22 (GN/VT), harness side and LH rear power window the system for normal
motor C703-2, circuit CPW21 (BN), harness side while operating the operation.
master window control switch in the down then up positions.
No
GO to G4 .

G4 CHECK THE LH REAR WINDOW CONTROL SWITCH
Ignition OFF. Yes
Disconnect: LH Rear Window Control Switch C701. GO to G5 .
Carry out the window control switch component test on the LH rear
INSTALL a new LH
Refer to Wiring Diagrams Cell 149 for component testing. rear window control
switch. REFER to
Window Control
Did the LH rear window control switch pass the component Switch in this section.
normal operation.
G5 CHECK FOR AN OPEN CIRCUIT BETWEEN THE REAR WINDOW
Measure the resistance between LH rear window control switch Yes
C701, harness side and LH rear power window motor C703, GO to G6 .
No
LH Rear Window LH Rear Power REPAIR the circuit(s).
normal operation.
C701-1 CPW22 C703-1
(GN/VT)
C701-7 CPW21 (BN) C703-2

G6 CHECK FOR AN OPEN CIRCUIT BETWEEN THE LH REAR
WINDOW CONTROL SWITCH AND THE MASTER WINDOW CONTROL
SWITCH
Disconnect: Master Window Control Switch C504C. Yes
C504C, harness side and LH rear window control switch C701, master window
REFER to Window
Master Window LH Rear Window Control Switch in this
system for normal
C504C-8 CPW15 (YE) C701-3 operation.
C504C-7 CPW16 C701-6
No
(BU/OG)
CARRY OUT the
window motor
initialization
procedure. REFER to
Window Motor
section. TEST the
system for normal
operation.
Pinpoint Test H: A Single Power Window is Inoperative — RH Rear Window
Normal Operation
The RH rear window control switch receives power from the master window control switch when the
lock-out switch is in the UNLOCK position. Ground is provided to the RH rear window control switch
through the master window control switch. The RH rear window control switch transfers power and
ground to the RH rear window motor. Window direction is controlled by reversing polarity of the voltage
and ground circuits being supplied to the window motor.
When operating the RH rear window from the master window control switch, power and ground is sent
from the master window control switch through the normally closed contacts within the RH rear window
control switch to operate the RH rear window. Window direction is controlled by reversing polarity of the

PINPOINT TEST H: A SINGLE POWER WINDOW IS INOPERATIVE — RH REAR WINDOW
Result / Action to
Test Step
Take
H1 CHECK THE RH REAR WINDOW OPERATION FROM THE
Ignition ON. Yes
Operate the RH rear window from the master window control switch. GO to H2 .
Does the RH rear window operate from the master window
control switch? No
GO to H3 .
H2 CHECK FOR VOLTAGE TO THE RH REAR WINDOW CONTROL
SWITCH
Ignition OFF. Yes
Disconnect: RH Rear Window Control Switch C801. INSTALL a new RH
Ignition ON. rear window control
NOTE: Make sure the window lock-out switch is in the UNLOCK switch. REFER to
position. Window Control
Measure the voltage between RH rear window control switch C801- Switch in this section.
2, circuit CPW01 (BN/BU), harness side and ground. TEST the system for
normal operation.
No
REPAIR the circuit.
TEST the system for
normal operation.

H3 CHECK FOR VOLTAGE AND GROUND TO THE WINDOW MOTOR
Ignition OFF. Yes
Disconnect: RH Rear Power Window Motor C803. INSTALL a new RH
Ignition ON. rear window regulator
NOTE: During the following step, the voltage being measured motor. REFER to
changes polarity dependent upon which direction the window control Window Regulator
switch is activated. Motor — Rear Door
Measure the voltage between RH rear power window motor C803-1, in this section. TEST
circuit CPW24 (WH/VT), harness side and RH rear power window the system for normal
motor C803-2, circuit CPW23 (GY), harness side while operating the operation.
master window control switch in the down then up positions.
No
GO to H4 .

H4 CHECK THE RH REAR WINDOW CONTROL SWITCH
Ignition OFF. Yes
Disconnect: RH Rear Window Control Switch C801. GO to H5 .
Carry out the window control switch component test on the RH rear
INSTALL a new RH
Refer to Wiring Diagrams Cell 149 for component testing. rear window control
switch. REFER to
Window Control
Did the RH rear window control switch pass the component Switch in this section.
normal operation.
H5 CHECK FOR AN OPEN CIRCUIT BETWEEN THE REAR WINDOW
Measure the resistance between RH rear window control switch Yes
C801, harness side and RH rear power window motor C803, GO to H6 .
No
RH Rear Window RH Rear Power REPAIR the circuit(s).
normal operation.
C801-1 CPW24 C803-1
(WH/VT)
C801-7 CPW23 (GY) C803-2

H6 CHECK FOR AN OPEN CIRCUIT BETWEEN THE RH REAR
WINDOW CONTROL SWITCH AND THE MASTER WINDOW CONTROL
SWITCH
Disconnect: Master Window Control Switch C504C. Yes
C504C, harness side and RH rear window control switch C801, master window
REFER to Window
Master Window RH Rear Window Control Switch in this
system for normal
C504C-5 CPW17 C801-3 operation.
(BN/GN)
No
C504C-6 CPW18 C801-6
(GY/VT)
CARRY OUT the
window motor
initialization
procedure. REFER to
Window Motor
section. TEST the
system for normal
operation.
Pinpoint Test I: The One-Touch Up/Down Feature is Inoperative
NOTE: The master window control switch and the LH front window motor each contain integral
electronics which must be initialized whenever:

battery voltage has been removed from the LH front window control switch for more than 3
minutes (for example, battery or window control switch disconnected).
For additional information, refer to Window Motor Initialization in this section.
Normal Operation
The master window control switch contains the electronics which controls the one-touch up/down
operation of the LH front window. The master window control switch determines window position based
upon feedback from two Hall-effect sensors (integral to the LH front window motor). Voltage and ground
is supplied to the Hall-effect sensors from the master window control switch. If any fault occurs in the
Hall-effect sensor circuits, the LH front window still operates (only the one-touch operation and obstacle
detection is inoperative).

LH front window motor not initialized
PINPOINT TEST I: ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE

I1 INITIALIZE THE LH FRONT WINDOW
Ignition ON. Yes
Carry out the window motor initialization procedure. Refer to The system is operating
Window Motor Initialization in this section. normally at this time. The
Is the one-touch up/down feature operating correctly? front window motor lost
initialization.
No
GO to I2 .
I2 CHECK THE HALL-EFFECT VOLTAGE SUPPLY AND
GROUND CIRCUIT OUTPUTS FROM THE MASTER WINDOW
CONTROL SWITCH
Ignition OFF. Yes
Disconnect: LH Front Power Window Motor C524. GO to I5 .
Ignition ON.
Measure the voltage between LH front power window motor No
C524-3, circuit RCA17 (WH/BN), harness side and LH front GO to I3 .
power window motor C524-4, circuit RPW37 (VT/GN), harness
side.

GROUND CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504B. GO to I4 .
Measure the resistance between master window control switch
C504B, harness side and LH front power window motor C524, No
harness side using the following chart: REPAIR the circuit(s).
Master Window LH Front Power motor initialization
Control Switch Circuit Window Motor procedure. REFER to
C504B-1 RCA17 C524-3 in this section. TEST the
(WH/BN) system for normal
operation.
C504B-2 RPW37 C524-4
(VT/GN)
GROUND CIRCUITS FOR A SHORT TO GROUND
Measure the resistance between master window control switch Yes
C504B-1, circuit RCA17 (WH/BN), harness side and ground; INSTALL a new master
and between master window control switch C504B-2, circuit window control switch.
RPW37 (VT/GN), harness side and ground. REFER to Window Control
TEST the system for
normal operation.
No
procedure. REFER to
system for normal
operation.
Is the resistance greater than 10,000 ohms for both

measurements?
I5 CHECK THE HALL-EFFECT SIGNAL CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Master Window Control Switch C504B. GO to I6 .
Measure the resistance between master window control switch
C504B, harness side and LH front power window motor C524, No
harness side using the following chart: REPAIR the circuit(s).
Master Window LH Front Power motor initialization
Control Switch Circuit Window Motor procedure. REFER to
C504B-3 VPW38 C524-6 in this section. TEST the
(YE/BU) system for normal
operation.
C504B-4 VPW39 C524-5
(BU/WH)
I6 CHECK THE HALL-EFFECT SIGNAL CIRCUITS FOR A SHORT
TO GROUND
Measure the resistance between master window control switch Yes
C504B-3, circuit VPW38 (YE/BU), harness side and ground; INSTALL a new LH front
and between master window control switch C504B-4, circuit window regulator motor.
VPW39 (BU/WH), harness side and ground. REFER to Window
Regulator Motor — Front
Door in this section.
procedure. REFER to
system for normal
operation.
If the concern is still

present, INSTALL a new
master window control
switch. REFER to Window
Is the resistance greater than 10,000 ohms for both section. TEST the system
measurements? for normal operation.
procedure. REFER to
system for normal
operation.
No
procedure. REFER to
system for normal
operation.
Pinpoint Test J: The Defrost System is Inoperative
Normal Operation
defrost grid. When the rear window defrost is active, the BCM supplies voltage through a dedicated
feedback circuit to the HVAC module to illuminate the LED indicator.
DTC B1013:23 (Heater Rear Defog Switch: Signal Stuck Low) — sets if the rear window defrost
switch is active during self-test, or if the rear window defrost switch has been active for more than
2 minutes.

Fuse
Rear window defrost grid
HVAC module
BCM
PINPOINT TEST J: THE DEFROST SYSTEM IS INOPERATIVE

J1 CHECK THE BCM REAR DEFROST SWITCH (R_DEFRST_SW)
PID OPERATION
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to J5 .
— BCM .
While monitoring the BCM R_DEFRST_SW PID, press and No
release the rear window defrost switch. If DTC B1013:23 is
Does the PID agree with the rear window defrost switch present, GO to J3 .
status?
If DTC B1013:23 is not
present, GO to J2 .
J2 CHECK THE HVAC MODULE (REAR WINDOW DEFROST
SWITCH) GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to J3 .
Measure the resistance between HVAC module C228A-13,
circuit GD115 (BK/GY), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

J3 CHECK THE BCM REAR DEFROST SWITCH (R_DEFRST_SW)
PID OPERATION
Ignition OFF. Yes
Disconnect: HVAC Module C228A. INSTALL a new HVAC
Connect a fused jumper wire between HVAC module C228A-13, module. REFER to
circuit GD115 (BK/GY), harness side and HVAC module C228A- Section 412-00 . CLEAR
16, circuit CRD09 (BU/GY), harness side. the DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
No
GO to J4 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: DataLogger
— BCM .
Observe the BCM R_DEFRST_SW PID status.
Observe the BCM R_DEFRST_SW PID status.
removed?
J4 CHECK THE REAR WINDOW DEFROST SWITCH CIRCUIT FOR
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to J9 .
Measure the resistance between BCM C2280E-10, circuit
CRD09 (BU/GY), harness side and HVAC module C228A-16, No
circuit CRD09 (BU/GY), harness side; and between BCM REPAIR the circuit.
C2280E-10, circuit CRD09 (BU/GY), harness side and ground. CLEAR all DTCs. TEST
operation.
Is the resistance less than 5 ohms between the BCM and the
HVAC module; and greater than 10,000 ohms between the
BCM and ground?
J5 CHECK FOR VOLTAGE TO THE REAR WINDOW DEFROST
GRID
Ignition OFF. Yes
Disconnect: Rear Window Defrost Grid C402A. If the rear window
Start the engine. defrost switch LED is
Activate the rear window defrost switch. illuminated, GO to J8 . If
Measure the voltage between rear window defrost grid C402A-1, the rear window defrost
circuit CRD06 (BN/YE), harness side and ground. switch LED is not
illuminated, GO to
Pinpoint Test L to
diagnose the LED
circuit.
No
GO to J6 .

J6 CHECK THE BCM VOLTAGE FEED FOR AN OPEN
Ignition OFF. Yes
Measure the voltage between BCM C2280A-1, circuit SBB33 GO to J7 .
(RD), harness side and ground.
No
VERIFY BJB fuse 33
(30A) is OK, If OK,
REPAIR the circuit.
CLEAR all DTCs. TEST
operation.

short. REPAIR the
circuit. CLEAR all DTCs.
TEST the system for
Is the voltage greater than 10 volts? normal operation.
J7 CHECK THE REAR WINDOW DEFROST GRID VOLTAGE
CIRCUIT FOR AN OPEN OR SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280C. GO to J9 .
Measure the resistance between BCM C2280C-10, circuit
CRD06 (BN/YE), harness side and rear window defrost grid No
C402A-1, circuit CRD06 (BN/YE), harness side; and between REPAIR the circuit.
BCM C2280C-10, circuit CRD06 (BN/YE), harness side and CLEAR all DTCs. TEST
ground. the system for normal
operation.
Is the resistance less than 5 ohms between the BCM and the
rear window defrost grid; and greater than 10,000 ohms
between the BCM and ground?
J8 CHECK THE REAR WINDOW DEFROST GRID GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Rear Window Defrost C402B. CARRY OUT the Grid
Measure the resistance between rear window defrost grid Wire component test in
C402B-1, circuit GD143 (BK/VT), harness side and ground. this section. REPAIR the
rear window defrost grid
or INSTALL a new rear
window glass as
necessary. REFER to
Window Grid Wire
Repair or Window Glass
— Rear in this section.
TEST the system for
normal operation.
No
REPAIR the circuit.
operation.
J9 CHECK FOR CORRECT BCM MODULE OPERATION
Disconnect all the BCM connectors. Yes
corrosion. REFER to Section 419-
pushed-out pins. 10 . TEST the system for
Connect all the BCM connectors and make sure they seat normal operation.
correctly.
correctly at this time.
The concern may have
been caused by a loose
or corroded connector.
operation.
Pinpoint Test K: The Defrost System Will Not Shut Off Automatically
Normal Operation
feedback circuit to the HVAC module to illuminate the LED indicator.

BCM
PINPOINT TEST K: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY

K1 CHECK FOR VOLTAGE TO THE REAR WINDOW DEFROST
GRID WITH BCM DISCONNECTED
Ignition OFF. Yes
Disconnect: BCM C2280C. REPAIR the short to voltage
Ignition ON. in circuit CRD06 (BN/YE).
Measure the voltage between BCM C2280C-10, circuit TEST the system for normal
CRD06 (BN/YE), harness side and ground. operation.
No
GO to K2 .

K2 CHECK FOR A SHORT TO VOLTAGE ON THE SWITCH
ILLUMINATION CIRCUIT
Ignition OFF. Yes
Disconnect: BCM C2280F. REPAIR the short to voltage
Disconnect: HVAC Module C228A. in circuit CRD04 (BN/GN).
Ignition ON. TEST the system for normal
Measure the voltage between HVAC module C228A-15, operation.
circuit CRD04 (BN/GN), harness side and ground.
No
GO to K3 .
K3 CHECK FOR CORRECT BCM MODULE OPERATION
pushed-out pins. TEST the system for normal
Connect all the BCM connectors and make sure they seat operation.
correctly.
all DTCs. TEST the system
Pinpoint Test L: The Defrost System LED Does Not Illuminate When the Defrost System is Active
Normal Operation
feedback circuit to the HVAC module to illuminate the LED indicator. The rear defrost self actuates when
the ambient air temperature is less than 5° C (41° F) and engine coolant temperature is less than 60° C
(140° F). The rear window defroster LED indicator does not illuminate when the rear defroster self
actuates.

HVAC module
BCM
PINPOINT TEST L: THE DEFROST SYSTEM LED DOES NOT ILLUMINATE WHEN THE DEFROST
SYSTEM IS ACTIVE
Result / Action to
Test Step
Take
L1 CHECK FOR VOLTAGE SIGNAL TO THE REAR WINDOW
DEFROST SWITCH LED
Ignition OFF. Yes
Disconnect: HVAC Module C228A. INSTALL a new
Start the engine. HVAC module.
Momentarily connect a fused jumper wire between HVAC module REFER to Section
C228A-13, circuit GD115 (BK/GY), harness side and HVAC module 412-00 . TEST the
C228A-16, circuit CRD09 (BU/GY), harness side. system for normal
operation.
No
GO to L2 .

Measure the voltage between HVAC module C228A-15, circuit
CRD04 (BN/GN), harness side and ground.

L2 CHECK THE REAR WINDOW DEFROST SWITCH LED CIRCUIT
Ignition OFF. Yes
Disconnect: BCM C2280F. GO to L3 .
Measure the resistance between HVAC module C228A-15, circuit
CRD04 (BN/GN), harness side and BCM C2280F-11, circuit CRD04 No
(BN/GN), harness side; and between HVAC module C228A-15, REPAIR the circuit.
circuit CRD04 (BN/GN), harness side and ground. TEST the system for
normal operation.
Is the resistance less than 5 ohms between the HVAC module
and the BCM ; and greater than 10,000 ohms between the HVAC
module and ground?
L3 CHECK FOR CORRECT BCM MODULE OPERATION
Check for: INSTALL a new
corrosion. BCM . REFER to
pushed-out pins. Section 419-10 .
Connect all the BCM connectors and make sure they seat correctly. TEST the system for
Operate the system and verify the concern is still present. normal operation.
Is the concern still present?
No
The system is
operating correctly at
this time. The
concern may have
been caused by a
loose or corroded
connector. CLEAR all
DTCs. TEST the
system for normal
operation.
Component Test
Grid Wire Test
1. Using a bright lamp inside the vehicle, inspect the wire grid from the outside. A broken grid wire
appears as a brown spot.
2. Run the engine at idle. Set the rear window defrost switch to ON. The indicator light should
illuminate.
3. Working inside the vehicle with a voltmeter, contact the broad, red-brown stripes of the back glass
window grid (positive lead to B+ side and negative lead to ground side). The meter should read
10-13 volts. A lower voltage reading may indicate a loose grid connection.
4. Contact a good ground point with the negative lead of the meter. The voltage reading should not
change. If the voltage increases, this indicates a loose ground connection. A voltage reading of
less than 10 volts indicates a loose B+ side connection.
5. With the negative lead of the meter grounded, touch each grid line of the rear window defrost
glass at its midpoint with the positive lead. A reading of approximately 6 volts indicates the line is
good. A reading of 0 volt indicates the line is broken between the midpoint and the B+ side of the
grid line. A reading of 12 volts indicates the circuit is broken between the midpoint of the grid line
and ground.
6. Pinpointing the exact position of the break can be accomplished (if the voltmeter reads 0 volt
when the midpoint of the grid line is touched with the positive lead of the voltmeter) by moving the
positive lead of the voltmeter toward the B+ side of the grid line and touching the grid line until the
voltmeter reads 12 volts. If the voltmeter reads 12 volts when the midpoint of the grid line is
touched with the positive lead of the voltmeter, simply move the positive lead of the voltmeter
toward the ground connection of the grid line and touch the grid line until the voltmeter reads 0
volt.
NOTE: Initialization is required to learn both the full UP and full DOWN positions and the profile of the glass
as it travels through the glass channel. Once initialized, obstacle detection is enabled. This procedure is only
required for the LH front window motor.
NOTE: The master window control switch and the LH front window motor each contain integral electronics
which must be initialized whenever:

battery voltage has been removed from the LH front window control switch for more than 3 minutes
(for example, battery or window control switch disconnected).
NOTE: Before carrying out the initialization procedure, make sure all window components (window glass,
window regulator, window motor, seals and glass top run) are installed and tightened to specifications.
1. Turn the ignition ON.
2. Activate and hold the window control switch in the UP position at the second detent until the window
glass stalls for 2 seconds into the glass top run and release the switch. While the window is up, repeat
this step 2 more times.
3. Activate and hold the window control switch in the DOWN position at the second detent until the
window glass stalls for 2 seconds at the bottom of its travel and release the switch.
4. Test for correct window operation by carrying out the one-touch up/down feature.
Window Glass Adjustment
1. If needed, remove the door trim panel. For additional information, refer to Section 501-05 .
2. If needed, remove the 2 access hole plugs.
3. If needed, connect the window control switch, or install the window regulator handle.
4. If needed, position the window glass in order to access the window glass clamp bolts.
5. If needed, loosen the 2 window glass clamp bolts.
6. NOTE: Make sure the window glass is correctly installed in door glass top run.
Manually lift the window glass by hand, to the top of the door.
7. NOTE: Make sure to lower the window glass evenly.
NOTE: Make sure the window glass is seated in the bottom of the window glass clamps.
Shift the glass rearward until it stops against the rear of the door glass top run while manually lowering
the glass back down into the window glass clamps.
8. Tighten the 2 window glass clamp bolts to 9 Nm (80 lb-in).
9. Using the window control switch, fully raise the window glass and check that the window glass seats
correctly in the upper door glass top run.
10. If the window glass does not seat correctly, repeat steps 4 - 8.
11. If this procedure was performed on the LH front window glass, the LH window motor must be
initialized. For additional information, refer to Window Motor Initialization in this section.
Window Grid Wire Repair
General Equipment
Polypropylene Film Fine Line Tape (Commercially
available)
Material
Item Specification
Motorcraft® Lacquer Touch-Up ESR-M2P100-
Paint (match color to exterior grid C
wire)
PMP-19500-XXXXX
Rear Window Defroster Repair —
PM-11 (US); CPM-11 (Canada)
Motorcraft® Ultra-Clear Spray ESR-M14P5-A
Glass Cleaner
ZC-23
NOTE: The grid line material is not embedded into the glass, but is baked to the glass surface and
consequently can be scraped off. An undamaged grid line will have small ridges that project above the
surface of the glass and can easily be felt when running a fingernail across them. Grid lines that have
been "razor bladed" will feel smooth when a fingernail is dragged across the affected area. Inoperative
lines may appear to the eye to be undamaged due to residue remaining on the glass and will require
diagnosis with a voltmeter or 12V test lamp. For additional information, refer to Diagnosis and Testing in
this section.
1. Bring the vehicle up to a room temperature of at least 16°C (60°F) or above.
2. NOTICE: Do not use scrapers, sharp instruments or abrasive window cleaners on the
interior surface of the rear window glass as this may cause damage to the grid lines.
Clean the entire grid line repair area with glass cleaner and 0000 steel wool to remove all dirt,
wax, grease, oil or other foreign material.
3. Mark the location of the grid break on the exterior of the rear window glass.
4. Using a polypropylene film fine line tape, mask the area directly above and below the grid break
extending the tape 26 mm (1.02 in) beyond the concern area in both directions. The break area
should be at the center of the mask.
5. NOTE: If the brown layer is not broken or missing, apply only the silver grid repair compound to
the break. If both the brown and silver layers of the grid are broken or missing, apply a coating of
the lacquer touch up paint across the break in the grid line prior to applying the rear window
defroster repair compound. Do not overlap the silver grid line with the paint. Several applications
may be necessary to achieve a color match.
NOTE: Allow at least 5 minutes of drying time between applications for the touch up paint or the
silver repair coating. Applying fewer coats or not allowing adequate drying time between coats will
produce repaired resistance that is greater than OEM resistance, resulting in poor defrost
performance and excessive localized heating.
Apply the repair coating to the grid break area in several smooth, continuous strokes. Extend the
silver repair coating at least 6.35 mm (0.25 in) on both sides of the break area.
Apply a minimum of 6 applications of the grid repair compound.
6. NOTE: The repair coating air-dries in approximately one minute and can be energized after 5
minutes. Optimum adhesion occurs after approximately 24 hours.
Allow the repair area to dry completely and remove the mask.
7. NOTICE: Be careful not to damage the grid line with the razor blade. If this occurs,
additional repair may be necessary.
Remove any excess repair compound above or below the grid line with a razor blade.
8. NOTE: The interior side of the grid lines are not painted, but due to the silver tarnishing will tend
to change the grid to a gold or brown color. The repair area will be bright silver and will also
tarnish over time to match the rest of the grid.
Test the system for normal operation.
Lead Terminal Repair
General Equipment
Terminal Kit — Back Glass 4F1Z-14421-AA
Material
Item Specification
Motorcraft® Ultra-Clear Spray ESR-M14P5-
Glass Cleaner A
ZC-23
1. Bring the vehicle up to room temperature of at least 16°C (60°F) or above.
2. NOTE: The new terminal will cover the original terminal location, but it must be placed so that the
terminal conductive areas will be placed on a good conductive base.
Clean the bus bar in the area to be repaired with steel wool (000 to 0000 grade), and then with
glass cleaner to remove all dirt, wax, grease, oil or other foreign material.
3. NOTICE: Do not use any type of flame torch or flame-heated soldering gun for this
procedure. Use of these tools provide inadequate heat generation at the tip and the
exhaust heat can cause damage to plastic trim parts in the area. Use only an electric
soldering gun with 100 watts or more of power. Before using the soldering gun, be sure to
melt a small amount of rosin core solder to the tip. The solder will assist in achieving
better heat transfer from the soldering gun tip to the new terminal.
NOTE: Depending on the original terminal location, and whether the terminal is covered by pillar
trim, will determine 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 will cover the original tab location, but still
allow 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 will be on a good conductive area. Do not place the terminal tab foot on the
original location, which does not have conductive material.
4. 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.)
5. NOTE: The new terminal has pre-applied solder, flux and temperature-sensitive paint. The paint
provides a visual indication when the terminal has reached the correct temperature to melt solder
on the terminal. When the correct temperature is achieved, the temperature paint will liquefy and
change color.
Place the soldering gun tip on the top of the terminal, but not on the painted areas of the tab.
Energize the soldering gun and watch for the painted area of the terminal to liquefy and change
color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint
color completely changes on 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.
6. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool
for another 2 minutes before the wiring lead is attached to the terminal.
7. Attach the electrical lead connection to this terminal, turn on the heated rear window and verify
the operation.
Glass Reseal — Windshield
Special Tool(s)
Air Caulking Gun
AST405 or equivalent
Material
Item Specification
Dow Urethane Adhesive —
Betaseal™ Express
Sika Urethane Adhesive —
Sika Tack ASAP
Glass Cleaner A
ZC-23
1. Remove the cowl panel grille. For additional information, refer to Section 501-02 .
2. Remove the LH and RH A-pillar trim panels. For additional information, refer to Section 501-05 .
3. If equipped, remove the overhead console.
4. If equipped, disconnect the automatic-dimming interior rear view mirror electrical connector.
5. Remove the 4 screws and LH and RH sun visors.
6. Remove the RH and LH sun visor clips.
7. Lower the front portion of the headliner and block with a suitable material.
8. Clean the edge formed by the existing urethane adhesive and the glass on the inside at the top
and sides and outside on the bottom of the windshield with glass cleaner.
9. Cut the urethane adhesive applicator tip to specification.

10. NOTE: Use either a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that
will apply the urethane adhesive with less effort and a continuous bead.
NOTE: Make sure there are no gaps in the urethane adhesive bead.
Apply urethane adhesive over the top of the existing urethane adhesive.
Apply the urethane adhesive to the top and sides of the windshield from the interior of the
vehicle.
Apply the urethane adhesive to the bottom of the windshield from the exterior of the
vehicle.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or
water leaks.
After the urethane adhesive has cured, check the windshield seal for air or water leaks through
the urethane adhesive bead and add urethane adhesive as necessary.
12. Position the front portion of the headliner.
13. Install the RH and LH sun visor clips.
14. Install the LH and RH sun visors and the 4 screws.
15. If equipped, connect the automatic-dimming interior rear view mirror electrical connector.
16. If equipped, install the overhead console.
17. Install the LH and RH A-pillar trim panels. For additional information, refer to Section 501-05 .
18. Install the cowl panel grille. For additional information, refer to Section 501-02 .
19. Clean the interior and exterior windshield glass with glass cleaner.
Glass Reseal — Rear
Special Tool(s)
Air Caulking Gun
Material
Item Specification
Betaseal™ Express
Sika Tack ASAP
Glass Cleaner A
ZC-23
1. 4-door vehicles: Remove the C-pillar trim panel, parcel shelf, high mounted stoplamp and lower
the headliner. For additional information, refer to Section 501-05 and Section 417-01 .
2. 5-door vehicles: Remove the liftgate trim panel. For additional information, refer to Section 501-
05 .
3. Disconnect the rear window glass electrical connectors.
4. Clean the interior and exterior of the rear window glass surface with glass cleaner.
6. NOTE: Use either a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that
applies the urethane adhesive with less effort and continuous bead.
NOTE: Make sure there are no gaps in the urethane adhesive bead.
Apply the urethane adhesive over the top of the existing urethane adhesive.
Apply the urethane adhesive to the top and sides of the rear window glass from the interior
of the vehicle.
4-door vehicles: Apply the urethane adhesive to the bottom of the rear window glass from
the exterior of the vehicle.
5-door vehicles: Apply the urethane adhesive to the bottom of the rear window glass from
the interior of the vehicle.
7. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or
water leaks.
After the urethane adhesive cures, check the rear window glass seal for air or water leaks through
8. Connect the rear window glass electrical connectors.
9. 4-door vehicles: Install the high mounted stoplamp, headliner, parcel shelf and C-pillar trim
panels. For additional information, refer to Section 417-01 and Section 501-05 .
10. 5-door vehicles: Install the liftgate trim panel. For additional information, refer to Section 501-05 .
Windshield Glass
Special Tool(s)
Air Caulking Gun
Deluxe Air Windshield Knife

300-AST1770E or equivalent
The Pumper
Material
Item Specification
Betaseal™ Express
Dow Urethane One Step Glass —
Primer
Betaprime™ 5500 / 5500A / 5500SA
Sika Tack ASAP
Sika Urethane Metal and Glass —
Primer
Sika 206 G+P
Motorcraft® Ultra-Clear Spray Glass ESR-M14P5-
Cleaner A
ZC-23
1 03100 Windshield glass
Removal
NOTE: If the windshield glass is being removed to repair a dust/water leak, remove and reinstall the existing
windshield glass.
1. Remove the A-pillar trim panels. For additional information, refer to Section 501-05 .
2. Remove the 4 screws and LH and RH sun visors.
3. Remove the RH and LH sun visor clips.
4. Remove the interior rear view mirror. For additional information, refer to Section 501-09 .
5. Partially lower the front portion of the headliner near the windshield header and block with suitable
material.
6. Remove the cowl panel grille. For additional information, refer to Section 501-02 .
7. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield
pinchweld area.
Use a clean shop towel or oil-free, compressed air.
8. NOTE: Refer to manufacturer's instructions before using the Deluxe Air Windshield Knife.
Lubricate the urethane adhesive with water to aid the Deluxe Air Windshield Knife when cutting.
9. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
WARNING: Wear protective gloves when handling components or parts that have pointed or
sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or
otherwise damage the pinchweld during glass removal.
NOTE: Insert the blade into the Deluxe Air Windshield Knife so that the flat side is against the glass. This
will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement
windshield glass.
NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane
adhesive.
Working from inside the vehicle, insert the Deluxe Air Windshield Knife at the upper center of the
windshield glass and work toward the bottom corners.
10. Using The Pumper, distance the windshield glass from the body.
11. Insert the Deluxe Air Windshield Knife into the bottom of the urethane adhesive and cut from corner to
corner.
12. Carefully remove the windshield glass from the vehicle and place on a stable work surface.
Installation
1. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
Position the windshield glass on the pinch weld.
Center the glass in the opening.
Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass
stop blocks) on the windshield glass and the body.
2. After the dry-fit alignment, remove the glass from the body opening and place on a stable work surface
with the interior side of the glass facing upward.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the
vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld
following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane
adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original
equipment urethane adhesive on the pinchweld.
4. Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the
existing urethane adhesive. Remove any foreign material or water that may have entered during glass
removal.
5. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving
a thin layer to bond with the new urethane adhesive bead.
6. Clean the inside of the windshield glass surface with glass cleaner.
Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.
7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass
primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in
this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at
least 6 minutes to dry.
9. NOTE: Use a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that will apply the
urethane adhesive with less effort and a continuous bead.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on
the pinch weld, starting and ending at the bottom of the windshield glass near the center, making sure
there are no gaps in the bead.
10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane
adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane
adhesive seal will adversely affect glass retention. Failure to follow these instructions may result
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the windshield glass on the pinch weld.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through the
urethane adhesive bead and add urethane adhesive as necessary.
12. Install the cowl panel grille. For additional information, refer to Section 501-02 .
13. Install the headliner. For additional information, refer to Section 501-05 .
14. Install the interior rear view mirror. For additional information, refer to Section 501-09 .
15. Install the RH and LH sun visor clips.
16. Install the LH and RH sun visors and the 4 screws.
17. Install the A-pillar trim panels. For additional information, refer to Section 501-05 .
Glass, Frames and Mechanisms — Exploded View, Front Door

1 21456 RH / 21457 Door window glass top run
LH
2 21410 RH/ 21411 Door window glass
LH
3 20562 RH/ 20563 Exterior door window glass belt moulding
LH
4 21456 RH/ 21457 Interior door window glass belt moulding
LH
5 23208 RH/ 23209 Window regulator
LH
6 235A86 RH/ 235A87 Door carrier
LH
7 202A84 Access hole plug (2 required)
8 W706127 Door carrier bolt (10 required)
9 23394 Window regulator motor
10 — Window regulator motor screws (part of 23394)
(3 required)

Window Glass — Front Door
1. Fully lower the front door window glass.
2. Remove the front door trim panel. For additional information, refer to Section 501-05 .
3. Remove the interior door window glass belt moulding.
4. Remove and discard the exterior door window glass belt moulding.
5. Remove the 2 access hole plugs.
6. Connect the window control switch, or install the window regulator handle.
7. Position the window glass in order to access the window glass clamp bolts.
8. Loosen the 2 window glass clamp bolts.
9. Tilt the window glass forward and lift upward to remove the window glass from the door.
Installation
1. Install the window glass into the door.
2. NOTE: The window glass clamp bolts will be tightened when performing this step.
Before tightening the window glass clamp bolts, make sure window glass is adjusted correctly.
For additional information, refer to Window Glass Adjustment in this section.
3. Install the 2 access hole plugs.
4. Fully lower the front door window glass.
5. Install a new exterior door window glass belt moulding.
6. Install the interior door window glass belt moulding.
7. Install the front door trim panel. For additional information, refer to Section 501-05 .
8. If installing a new LH front window glass, the LH window motor must be initialized. For additional
information, refer to Window Motor Initialization in this section.
Window Regulator Motor — Front Door
2. Disconnect the window regulator motor electrical connector.
3. Secure the window glass in position with tape.
4. Remove the 3 window regulator motor screws.
5. Remove the window regulator motor.

If installing a new LH front window regulator motor, it must be initialized. For additional
information, refer to Window Motor Initialization in this section.
Window Regulator — Front Door
All vehicles
1. Remove the front door window glass. For additional information, refer to Window Glass — Front
2. WARNING: Turn the ignition OFF and wait one minute to deplete the backup power
supply. Ignition must remain OFF until repair is complete. Failure to follow this instruction
may result in serious personal injury or death in the event of an accidental deployment.
Turn the ignition OFF and wait at least one minute.
3. Disconnect the speaker, window regulator motor and side impact sensor electrical connectors.
4. Remove the 9 wire harness retainers.
5. Remove the 10 door carrier bolts.

6. Slide the door carrier toward the front of the vehicle to release the door carrier retainers.
7. Position aside the door carrier and disconnect the door lock actuator electrical connector.
8. Route the interior door handle cable and door lock actuator electrical connector through the door
carrier.
Vehicles equipped with Intelligent Access (IA)
9. Remove the door handle electrical connector carrier from the exterior door handle reinforcement.
10. Using a flat-blade screwdriver, release the retaining tabs and press the electrical connector
upward to separate the door handle electrical connector from the door handle electrical connector
carrier.
11. Disconnect the door handle electrical connector.

12. Remove the exterior door handle reinforcement cover bolt.
13. Remove the exterior door handle reinforcement cover.
14. Detach the wire harness from the remove the exterior door handle reinforcement cover and the
door carrier.
All vehicles
15. Remove the 2 window regulator bolts from the door carrier.
16. Depress the retaining tabs and remove the window regulator from the door carrier.

If installing a new LH front window regulator, the LH window motor must be initialized. For
additional information, refer to Window Motor Initialization in this section.
Door Glass Top Run — Front
1. Remove the front door window glass. For additional information, refer to Window Glass — Front
2. Remove the 3 door speaker screws and the door speaker.

Disconnect the electrical connector.
3. Remove the front door glass top run.

If installing a new LH front door glass top run, the LH window motor must be initialized. For
additional information, refer to Window Motor Initialization in this section.
Window Glass — Front Quarter
Special Tool(s)
Air Caulking Gun

Pneumatic Knife with Offset Blade

Material
Item Specification
Betaseal™ Express
Primer
Betaprime™ 5500 / 5500A / 5500SA
Sika Tack ASAP
Primer
Sika 206 G+P
Cleaner A
ZC-23
1 29710 RH/ 29711 LH Front quarter window glass
Removal
1. Remove the A-pillar upper trim panel. For additional information, refer to Section 501-05 .
2. Before cutting the urethane adhesive, remove dirt and other foreign material from the front quarter
window glass pinch weld area.
Use a clean shop towel or oil-free compressed air.
Lubricate the urethane adhesive with water to aid the Deluxe Air Windshield Knife when cutting the
urethane adhesive.
NOTICE: Make sure the cutting blades are changed where the cutting depth changes to avoid
damage to the body and trim panels.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or
otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Air Windshield Knife so that the flat side is against the glass.
NOTE: Some resistance may be encountered when cutting through the glass locating pegs in the upper
right and lower left corners of the glass.
Working from inside the vehicle, insert the Deluxe Air Windshield Knife at the upper of the front quarter
window glass and work towards the corners and remove the front quarter window glass.
Installation
NOTE: For additional material guidelines, refer to the manufacturer's installation information.
adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base
of original equipment urethane adhesive on the pinch weld.
2. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
removal.
3. If installing the original front quarter window glass, remove the excess urethane adhesive.
4. Clean the inside of the front quarter window glass with glass cleaner.
5. NOTE: Be sure to use the same brand of cure-rate products for the urethane adhesive and glass primer.
Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this
procedure.
If installing a new front quarter window glass, apply glass primer according to the manufacturer's
instructions. Allow at least 6 minutes to dry.

7. NOTE: The front quarter window glass must be positioned within 10 minutes of applying the urethane
adhesive.
NOTE: Use either a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that will
apply the urethane adhesive with less effort and a continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld,
starting and ending at the bottom of the front quarter window glass near the center, making sure there
are no gaps in the bead.
NOTICE: Before positioning the front quarter window glass, open vehicle windows to prevent the
air pressure of closing doors from affecting the urethane adhesive bond.
Install the front quarter window glass.

Position the front quarter window glass to the flange, and press the retaining tabs into the flange
to engage.
After the urethane adhesive has cured, check the front quarter window glass seal for air or water leaks
through the urethane adhesive bead and add urethane adhesive as necessary.
10. Install the A-pillar upper trim panel. For additional information, refer to Section 501-05 .
Glass, Frames and Mechanisms — Exploded View, Rear Door

1 253A10 Exterior door window glass belt moulding
2 25766 RH / 25767 Door glass top run
LH
3 25712 RH/ 25713 Door window glass
LH
4 25860 RH/ 25861 Interior door window glass belt moulding
LH
5 27008 RH/ 27009 Window regulator
LH
6 235A88 RH/ 235A89 Door carrier
LH
7 202A84 Access hole plug (2 required)
8 W706127 Door carrier bolt (10 required)
9 23394 Window regulator motor
10 — Window regulator motor screws (part of 23394)
(3 required)

Window Glass — Rear Door
Removal
1. Fully lower the rear door window glass.
2. Remove the rear door trim panel. For additional information, refer to Section 501-05 .
3. Remove the interior door window glass belt moulding.
4. Remove and discard the exterior door window glass belt moulding.
5. Position aside the lower rear portion of the rear door glass top run.
6. Remove the 2 window extension screws and the window extension.
7. Remove the 2 access hole plugs.
8. Connect the window control switch, or install the window regulator handle.
9. Position the window glass in order to access the window glass clamp bolts.
10. Loosen the 2 window glass clamp bolts.

11. Tilt the window glass forward and lift upward to remove the window glass from the door.
Installation
1. Install the window glass into the door, but do not tighten the window glass clamps bolts.
2. Position the window glass downward.
3. Install the window extension and the tighten the 2 window extension screws.
4. Install the lower rear portion of the rear door glass top run.
5. NOTE: The window glass clamp bolts will be tightened when performing this step.
Before tightening the window glass mounting bolts, make sure window glass is adjusted correctly.
For additional information, refer to Window Glass Adjustment in this section.
6. Install the 2 access hole plugs.
7. Fully lower the rear door window glass.
8. Install a new exterior door window glass belt moulding.
9. Install the interior door window glass belt moulding.
10. Install the rear door trim panel. For additional information, refer to Section 501-05 .
Window Regulator Motor — Rear Door
2. Disconnect the window regulator motor electrical connector.
3. Secure the window glass in position with tape.
4. Remove the 3 window regulator motor screws.
5. Remove the window regulator motor.

Window Regulator — Rear Door
1. Remove the rear door window glass. For additional information, refer to Window Glass — Rear
2. Disconnect the speaker and window regulator motor electrical connectors.
3. Remove the 3 wire harness retainers and the door latch cable retainer.
4. Remove the 3 window regulator motor bolts and the window regulator motor.
5. Remove the 9 door carrier bolts.

6. Slide the door carrier toward the front of the vehicle to release the door carrier retainers.
7. Position aside the door carrier and disconnect the door lock actuator electrical connector.
8. Route the interior door handle cable and door lock actuator electrical connector through the front
door carrier.
9. Remove the 2 window regulator bolts from the door carrier.
10. Depress the retaining tabs and remove the window regulator from the door carrier.

Door Glass Top Run — Rear
1. Remove the rear door window glass. For additional information, refer to Window Glass — Rear
2. Remove the 9 rear door carrier bolts.

3. Slide the rear door carrier toward the front of the vehicle to release the door carrier retainers and
position it aside.
4. Remove the rear door glass top run.

Window Glass — Rear Quarter
Special Tool(s)
Air Caulking Gun

Pneumatic Knife with Offset Blade

Material
Item Specification
Betaseal™ Express
Primer
Betaprime™ 5500 / 5500A / 5500SA
Sika Tack ASAP
Primer
Sika 206 G+P
Cleaner A
ZC-23
NOTE: 4-door shown, 5-door similar.

1 29710 RH/ 29711 LH Rear quarter window glass
Removal
1. Remove the C-pillar upper trim panel. For additional information, refer to Section 501-05 .
2. Before cutting the urethane adhesive, remove dirt and other foreign material from the rear quarter
window glass pinch weld area.
Use a clean shop towel or oil-free compressed air.
Lubricate the urethane adhesive with water to aid the Deluxe Air Windshield Knife when cutting the
urethane adhesive.
NOTICE: Make sure the cutting blades are changed where the cutting depth changes to avoid
damage to the body and trim panels.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or
otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Air Windshield Knife so that the flat side is against the glass.
NOTE: Some resistance may be encountered when cutting through the glass locating pegs in the upper
right and lower left corners of the glass.
Working from inside the vehicle, insert the Deluxe Air Windshield Knife at the upper of the rear quarter
window glass and work towards the corners and and remove the rear quarter window glass.
Installation
NOTE: For additional material guidelines, refer to the manufacturer's installation information.
adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base
of original equipment urethane adhesive on the pinch weld.
2. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
removal.
3. If installing the original rear quarter window glass, remove the excess urethane adhesive.
4. Clean the inside of the rear quarter window glass with glass cleaner.
5. NOTE: Be sure to use the same brand of cure-rate products for the urethane adhesive and glass primer.
Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this
procedure.
If installing a new rear quarter window glass, apply glass primer according to the manufacturer's
instructions. Allow at least 6 minutes to dry.

7. NOTE: The rear quarter window glass must be positioned within 10 minutes of applying the urethane
adhesive.
NOTE: Use either a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that will
starting and ending at the bottom of the rear quarter window glass near the center, making sure there
are no gaps in the bead.
NOTICE: Before positioning the rear quarter window glass, open vehicle windows to prevent the
air pressure of closing doors from affecting the urethane adhesive bond.
Install the rear quarter window glass.

Position the rear quarter window glass to the flange, and press the retaining tabs into the flange to
engage.
After the urethane adhesive has cured, check the rear quarter window glass seal for air or water leaks
through the urethane adhesive bead and add urethane adhesive as necessary.
10. Install the C-pillar upper trim panel. For additional information, refer to Section 501-05 .
Window Glass — Rear
Special Tool(s)
Air Caulking Gun

The Pumper
Material
Item Specification
Betaseal™ Express
Primer
Betaprime™ 5500 / 5500A / 5500SA
Sika Tack ASAP
Primer
Sika 206 G+P
Cleaner A
ZC-23
1 42006 Rear window glass
Removal
NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing
rear window glass.
4-door vehicles
1. Remove the C-pillar trim panel and parcel shelf, and lower the headliner. For additional information, refer
to Section 501-05 .
2. Remove the high mounted stoplamp. For additional information, refer to Section 417-01 .
5-door vehicles
4. Remove the roof-mounted spoiler. For additional Information, refer to Section 501-08
All vehicles
5. Disconnect the 2 rear window defrost electrical connectors.
6. Before cutting the urethane adhesive, remove dirt and other foreign material from the rear window glass
pinchweld area.
Use a clean shop towel or oil-free, compressed air.
Lubricate the urethane adhesive with water to aid the Deluxe Air Windshield Knife when cutting.
4 Door vehicles
will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement rear
window glass.
NOTE: Support the rear window glass to prevent the glass from dropping while cutting the urethane
adhesive.
Working from inside the vehicle, insert the Deluxe Air Windshield Knife at the upper center of the rear
window glass and work toward the bottom corners.
9. Using The Pumper, distance the rear window glass from the body.
10. Insert the Deluxe Air Windshield Knife into the bottom of the urethane adhesive and cut from corner to
corner.
5 Door vehicles
will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement rear
window glass.
NOTE: Support the rear window glass to prevent the glass from dropping while cutting the urethane
adhesive.
Working from inside the vehicle, insert the Deluxe Air Windshield Knife at the upper center of the rear
window glass and work toward the upper corners.
12. Working from the outside of the vehicle, insert the Deluxe Air Windshield Knife at the upper corners of
the rear window glass and cut the remainder of the urethane adhesive.
All vehicles
13. Carefully remove the rear window glass from the vehicle and place on a stable work surface.
Installation
All vehicles
1. Dry-fit the rear window glass on the existing urethane adhesive bead on the pinch weld.
Position the glass on the pinch weld.
Center the glass in the opening.
Make alignment marks with tape or non-staining grease pencil on the rear window glass and the
body.
2. After the dry-fit alignment, remove the glass from the body opening and place on a stable work surface
with the interior side of the glass facing upward.
adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original
equipment urethane adhesive on the pinchweld.
4. Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around the
removal.
5. If reinstalling the same rear window glass, remove the remaining urethane adhesive from the glass
leaving a thin layer to bond with the new urethane adhesive bead.
6. Clean the inside of the new rear window glass surface with glass cleaner.
7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass
primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in
this procedure.
If installing a new rear window glass, apply glass primer according to manufacturer's instructions. Allow
at least 6 minutes to dry.
9. NOTE: Use either a Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun that will
NOTE: The rear window glass must be positioned within 10 minutes of applying the urethane adhesive.
starting and ending at the bottom of the rear window glass near the center, making sure there are no
gaps in the bead.
NOTICE: Before positioning the rear window glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the rear window glass on the pinch weld.
After the urethane adhesive has cured, check the rear window glass seal for air or water leaks through
12. Connect the LH and RH heated rear window electrical connector.
4-door vehicles
13. Install the C-pillar trim panel and parcel shelf, and raise the headliner. For additional information, refer to
Section 501-05 .
14. Install the high mounted stoplamp. For additional information, refer to Section 417-01 .
5-door vehicles
15. Install the liftgate trim panel. For additional information, refer to Section 501-05 .
16. Install the roof-mounted spoiler. For additional Information, refer to Section 501-08
Window Control Switch
NOTE: Driver window control switch shown, all others similar.
Part
1 14529 Master window control switch
2 — Master window control switch electrical connector (Part
of 14631 LH/ 14630 RH)
Passenger window control switch
1. Insert a non-marring tool under the window control switch bezel and pry upward.
2. Remove the window control switch from the door trim panel.
Master window control switch
4. Release the window control switch retaining tabs and remove the master window control switch from the
door trim panel.
All window control switches
5. Disconnect the electrical connector(s).

The master window control switch and the LH window motor must be initialized whenever battery
voltage has been removed from the driver window control switch for greater than 3 minutes (for
example, the battery or the master window switch is disconnected) or if a new driver window
control switch is installed. For additional information, refer to Window Motor Initialization in this
section.
SECTION 501-12: Instrument Panel and Console 2011 Fiesta Workshop Manual
Floor console front screws 3 — 27
Floor console rear screws 3 — 27
Instrument panel front screws 8 — 71
Instrument panel bolts 25 18 —
In-vehicle cross car beam to floor pan brace screw 25 18 —
In-vehicle cross car beam to instrument panel screw 2 — 18
Instrument panel-to-front of dash bolt 25 18 —
LH instrument panel side bolt 25 18 —
Exterior heater core housing nut 1 — 9
Upper steering column shaft-to-lower steering column shaft bolt 28 21 —
Instrument Panel — Exploded View
Instrument Panel Finish Panels

1 044C61 LH instrument panel side cover
2 W714972 LH instrument panel side cover clips (4 required)
3 045N68 Steering column opening trim panel
4 W714972 Steering column opening trim panel clips (6 required)
5 W714972 Upper finish panel clips (6 required)
6 58042A82 Upper finish panel
7 W505142 Front Controls Interface Module (FCIM) finish panel
screws (2 required)
8 W707628 FCIM finish panel screws (2 required)
9 18A802 Finish panel
10 W714972 Lower finish panel clips (8 required)
12 W714972 RH instrument panel side cover clips (4 required)
13 044C60 RH instrument panel side cover
14 06010 Glove compartment
15 13E002 / Close out bezel non-ambient / Ambient light pipe
13E726
Instrument Panel Mounting Fasteners
Part
1 W711557 Instrument panel screw (4 required)
2 3R827 Steering column shaft-to-steering column bolt
3 W701096 In-vehicle cross car beam to floor pan brace screw (2
required)
4 W711563 LH instrument panel bolt
5 W711563 Instrument panel-to-front of dash bolt
6 18N316 Exterior heater core housing nut

Instrument Panel
Vehicles with air conditioning
All vehicles
2. Remove the upper and lower cowl panel grille. For additional information, refer to Section 501-02 .
3. Remove the windshield wiper mounting arm and pivot shaft assembly and the windshield wiper motor. For
additional information, refer to Section 501-16 .
4. Remove the instrument panel-to-front of dash bolt.

NOTICE: Make sure all the coolant openings are sealed, or coolant may leak into the vehicle when the
instrument panel is removed.
5. Crimp the two heater hoses and remove the hoses from the heater core. Remove the Thermostatic Expansion
Valve (TXV) fitting nuts. Remove exterior heater core housing nut.
Vehicles without air conditioning
NOTICE: Make sure all the coolant openings are sealed, or coolant may leak into the vehicle when the
instrument panel is removed.
6. Crimp the two heater hoses and remove the hoses from the heater core. Remove exterior heater core housing
nut.
All vehicles
7. Remove the drivers side front door. For additional information, refer to Section 501-03 .
8. Remove the drivers seat. For additional information, refer to Section 501-10 .
9. Remove the transmission selector lever assembly. For additional information, refer to Section 307-05 .
Vehicles with manual transmission
10. Remove the gear shift lever. For additional information, refer to Section 308-06 .
All vehicles
11. Remove the 2 push pins and remove the hush panel from the lower right side of the instrument panel.
12. Remove the glove compartment.

13. Disconnect the 3 electrical connecters at the lower RH side of the cowl.
14. Remove the RH and LH instrument panel side covers.

15. Remove the RH and LH front scuff plates and the RH and LH cowl side trim panels.
16. Disconnect the lever lock electrical connector and push pin at the lower RH side cowl. Disconnect the yellow
connector and push pin at the lower RH side cowl.
NOTICE: Do not allow the steering wheel to rotate while the steering column shaft is disconnected, or damage
to the clockspring may result. If there is evidence that the shaft has rotated, remove and recenter the
clockspring. For additional information, refer to Section 501-20B .
17. Remove the bolt-in electrical connector at the lower LH side cowl. Disconnect the hood release lever from
bracket. Remove and discard the steering column shaft-to-steering column pinch bolt.
To install, use a new steering column shaft-to-steering column pinch bolt and tighten to 28 Nm (21 lb-ft).
18. Disconnect the 2 Restraints Control Module (RCM) electrical connectors. Remove the RCM harness from the
plastic channel. Remove the ground strap bolt. Disconnect the parking brake electrical connector. Remove the
2 RH and the 2 LH instrument panel bolts and remove the instrument panel braces.
19. Remove the LH instrument panel side bolt.

NOTICE: To avoid damage to the instrument panel, this step requires the help of an assistant.
NOTICE: Make sure that all electrical connectors and wiring are not hindered before removing the instrument
panel or damage to the components may occur.
NOTE: Rotate the instrument panel as necessary to remove from the vehicle.
20. Remove the 2 RH and the two LH instrument panel bolts and remove the instrument panel.

Instrument Panel Finish Panel — Upper

1. With a non-marring tool, lift the corners of the instrument panel upper finish panel upward to release the
retaining clips.
2. NOTICE: To avoid damage to the upper finish panel, remove any retaining clips from the
instrument panel and attach them to the upper finish panel before installing.

Make sure to align the finish panel retaining clips to the adjacent retaining clip holes.
Instrument Panel Finish Panel — Lower

2 W714972 Lower finish panel clips (8 required)
1. On vehicles equipped with automatic transmission, remove the selector lever trim ring using a non-
marring tool.
2. Using a non-marring tool, lift the corners of the instrument panel lower finish panel upward to release the
retaining clips.
Disconnect the electrical connectors.
3. NOTICE: To avoid damage to the lower finish panel, remove any retaining clips from the
instrument panel and attach them to the lower finish panel before installing.

Instrument Panel Finish Panel — RH

1 13E002/13E726 Close out bezel-not ambient/Ambient light pipe
1. Lower the glove compartment door completely.
2. Release the 3 RH instrument panel finish panel retaining tabs by reaching through the glove
compartment opening.
For vehicles equipped with the ambient light pipe, disconnect the electrical connector.

Instrument Panel Upper Section

1 04545 In-vehicle cross car beam
3 W711557 Instrument panel front screw (2 required)
5 W711557 Lower instrument panel screw (2 required)
6 04302 Upper instrument panel
1. Remove the knee air bag module. For additional information, refer to Section 501-20B .
2. Remove the steering wheel. For additional information, refer to Section 211-04 .
3. Remove the 3 torx screws and remove the steering column shroud.
NOTICE: Make sure the clockspring rotor does not rotate.
4. Secure the clockspring.
5. Remove the steering column switch carrier.
6. Remove the instrument cluster. For additional information, refer to Section 413-01 .
7. Remove the headlamp switch. For additional information, refer to Section 417-01 .
8. Remove the instrument panel dimmer swtich. For additional information, refer to Section 413-00 .
9. Remove the instrument panel upper finish panel. For additional information, refer to Instrument Panel
Finish Panel — Upper in this section.
10. Remove the Front Controls Interface Module (FCIM), the Audio Control Module (ACM), the Front
Control/Display Interface Module (FCDIM), and disconnect the Global Positioning System Module
(GPSM). For additional information, refer to Section 415-00 .
11. Remove the floor console. For additional information, refer to Console — Floor in this section.
12. Remove the 4 Heating Ventilation Air Conditioning (HVAC) module screws and remove the HVAC
module.
13. Remove the glove box.

14. Remove the Accessory Protocol Interface Module (APIM). For additional information, refer to Section
415-00 .
15. Disconnect the RH finish panel ambient light pipe electrical connector. For additional information on
connector location, refer to exploded view in Instrument Panel Finish Panel — RH in this section.
16. Disconnect and remove the LH and RH Light Emitting Diode (LED) connectors.
17. Remove the passenger side air bag module bracket. For additional information, refer to Section 501-
20B .
18. Remove the LH and RH A-Pillar trim panels. For additional information, refer to Section 501-05 .
19. Remove the LH and RH instrument panel side covers.

20. Position both front seats fully rearward.
21. Remove the 12 upper instrument panel screws.

22. NOTE: The RH and LH defroster ducts stay in the vehicle when the upper instrument panel is removed.
With the upper instrument panel loose release the RH and LH defroster duct clips.
23. Gently pull the upper instrument panel outward and release the 12 harness push pins and 6 metal
harness retaining clips.
24. NOTICE: To avoid damage to the instrument panel, an assistant is required when carrying out
this step.
NOTICE: Note the harness routing and make sure that all electrical connectors and wiring are not
hindered before removing the instrument panel or damage to the components may occur.
Remove the upper instrument panel.
25. NOTICE: To avoid damaging the instrument panel, use an assistant when positioning the
instrument panel to the vehicle.
NOTICE: Make sure that all electrical connectors and wiring are correctly routed when installing
the instrument panel or damage to the components may occur.

Console — Floor

1 045A76 Floor console finish panel
2 04608 RH floor console side panel
3 W714972 Floor console finish panel clips (6 required)
4 W714972 Floor console side panel clips (4 required)
5 N808720 Floor console rear screws (2 required)
6 W500214 Floor console front screws (2 required)
7 045A36 Floor console assembly
8 04609 LH floor console side panel
9 W707068 Side panel push pin (2 required)
1. On vehicles equipped with automatic transmission, remove the selector lever trim ring using a non-
marring tool.
2. Using a non-marring tool, lift the corners of the instrument panel lower finish panel upward to release the
retaining clips.
Disconnect the electrical connectors.
3. Remove the RH and LH floor console side trim panels.

1. Remove the side panel push pins.
2. Pull outward to release the floor console side panel clips.
4. Apply the parking brake handle in the full upright position.
5. Position the seats fully forward and remove the 2 floor console rear screws.
6. Remove the 2 floor console front screws.
7. Disconnect the 2 console electrical connectors on the right side and the 2 console electrical connectors
on the left side. Separate the data cable pin type retainer from the console on the right side.
8. Remove the floor console assembly.

Power Point
Special Tool(s)
Remover, Power Point Socket
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
Installation
2. Slide the power point socket into the retainer.

SECTION 501-14: Handles, Locks, Latches and Entry Systems 2011 Fiesta Workshop Manual
Material
Capacity
XG-4 and/or XL-5 B
Penetrating and Lock Lubricant — —
(US); Penetrating Fluid
(Canada)
XL-1 (US); CXC-51-A (Canada)
Door latch screws 8 — 71
Door striker bolts 20 — 177
Exterior door handle reinforcement screws 2 — 18
Exterior door handle bolts 1 — 9
Hood latch bolts 9 — 80
Hood striker bolts 10 — 89
Interior door handle screws 1 — 9
Luggage compartment lid/liftgate latch bolts 10 — 89
Luggage compartment lid/liftgate latch striker bolts 24 18 —
Handles, Locks, Latches and Entry Systems
Hood Latch
The hood latch system consists of the hood latch and the hood latch release handle and cable.
Front Door
The front door consists of the following components:
Door ajar switch (part of the front door latch)

Door lock cylinder
Exterior front door handle (contains an antenna and lock button on Intelligent Access (IA)-
equipped vehicles)
Exterior front door handle actuating cable
Exterior front door handle reinforcement
Front door latch
Front door lock actuator (part of the front door latch)
Interior door handle actuating cable
Interior door handle
Rear Door
The rear door consists of the following components:
Door ajar switch (part of the rear door latch)

Exterior rear door handle
Exterior rear door handle actuating cable
Exterior rear door handle reinforcement
Interior door handle actuating cable
Interior door handle
Rear door latch
Rear door lock actuator (part of the rear door latch)
Luggage Compartment Lid/Liftgate
The luggage compartment lid/liftgate consists of the following components:
Luggage compartment lid/liftgate latch

Luggage compartment lid/liftgate release switch (located on the luggage compartment lid/liftgate
trim)
Mechanical emergency release cable and handle (part of the luggage compartment lid latch)
Luggage compartment/liftgate IA antenna ( IA -equipped vehicles) (located behind the rear
bumper cover)
Manual Door Lock
In the event of a failure of the power door locks, the doors can be individually locked through the manual
door lock. The manual door lock is located on the rear edge of the door just above the door latch
opening. For the doors on the driver side of the vehicle, insert a key and turn the key clockwise to lock.
For the doors on the passenger side of the vehicle, insert a key and turn the key counterclockwise to
lock.
Power Lock/Unlock
The power lock/unlock feature requests all of the vehicle doors locked or unlocked upon a customer
request from the door lock control switch (part of the Front Controls Interface Module (FCIM)) in the
vehicle. The power door locking system functions independently of ignition status or vehicle speed.
Door Lock Indicator
The door lock indicator provides visual indication of the door lock status. When the light on the door lock
control switch is illuminated it indicates that all of the doors are locked. When the light is off it indicates
that one or more doors are unlocked.
Central Locking/Unlocking
The central locking/unlocking feature allows all of the doors to be locked or unlocked from a key in the
driver door lock cylinder. To unlock the driver door with stepped unlock enabled, turn the key once to the
unlock position. To unlock all of the doors with stepped unlock enabled, turn the key a second time to
unlock all of the doors. To unlock all of the doors with stepped unlock disabled, turn the key once to the
unlock position. Refer to Stepped Unlock Programming in this section for programming information.
To lock all of the doors, turn the key to the LOCK position.
Autolock
The autolock feature (when enabled) locks all the doors when the following conditions are met:
All the doors are closed

The ignition is in the RUN mode
The vehicle is shifted into any gear putting the vehicle in motion
The vehicle reaches a speed greater than 7 km/h (5 mph)
The autolock feature repeats when:
any door is opened then closed with the ignition in the RUN mode.
the vehicle reaches a speed greater than 7 km/h (5 mph).
Refer to Autolock and Auto-Unlock Programming in this section for programming information.
Auto-Unlock
NOTE: The doors will not auto-unlock if the vehicle has been electronically locked before the driver door
is opened.
The auto-unlock feature (when enabled) unlocks all the doors when the following conditions are met:

All the doors are closed
The vehicle has been in motion at a speed greater than 20 km/h (12 mph)
The vehicle then comes to a stop
The ignition is switched to the OFF or ACC mode
The driver door is opened within 10 minutes of the ignition being switched to the OFF mode.
Refer to Autolock and Auto-Unlock Programming in this section for programming information.
Smart Unlock
Without Intelligent Access (IA)

The smart unlock feature prevents the doors from locking with the key in the ignition lock cylinder. When
the vehicle is locked from the central lock control switch and the key is in the ignition lock cylinder with
one of the front doors open, the doors lock and then unlock.
The vehicle can still be locked with the key in the ignition lock cylinder by locking the doors with another
key in the driver door lock cylinder.
With Intelligent Access (IA)
NOTE: The IA smart unlock feature iIs only available on late build vehicles.
The smart unlock feature prevents the doors from electronically locking when an IA key is left inside the
vehicle. When a door becomes ajar, the interior of the vehicle is scanned for an IA key. If an IA key is
inside the vehicle when a door is ajar and a lock command is received the doors lock and then unlock.
The vehicle can still be locked with an IA key inside the vehicle by locking the doors with another key in
the driver door lock cylinder or the lock button pressed on another key.
Luggage Compartment/Liftgate Smart Unlock Feature — Intelligent Access (IA)
The luggage compartment/liftgate smart unlock feature prevents the luggage compartment/liftgate from
latching when an IA key is detected inside the luggage compartment area. When the luggage
compartment lid/liftgate is closed when the doors are locked, the luggage compartment is searched for
an IA key. If an IA key is detected inside the luggage compartment, the luggage compartment lid/liftgate
releases.
An IA key can still be locked inside a luggage compartment/ liftgate area by closing the luggage
compartment lid/liftgate when the doors are unlocked and then locking the doors after the luggage
compartment lid/ liftgate is closed with the key inside. Or if a second IA key is in range of the luggage
compartment/ liftgate IA antenna when the luggage compartment lid/liftgate is closed.
Driver/Passenger Door Intelligent Access (IA) Feature
The driver/passenger door IA feature allows the doors to be locked or unlocked without having to use
the door lock cylinder or the Remote Keyless Entry (RKE) transmitter feature. With a programmed IA key
within 1 m (3 ft) outside the driver or passenger front door, press the lock button on the exterior door
handle. The doors lock or unlock depending upon their current state (locked/unlocked).
Driver Door Intelligent Access (IA)
The driver door IA feature either unlocks just the driver door or all four doors. If stepped unlock Is
enabled, the driver door Is the only door that unlocks from the driver door IA feature. If stepped unlock Is
disabled, then all four doors unlock. The driver door IA feature always locks all four doors. Refer to
Stepped Unlock Programming in this section for programming information.
Passenger Door Intelligent Access (IA)
The passenger door IA feature always locks or unlocks all four doors.
Luggage Compartment/Liftgate Intelligent Access (IA) Feature
The luggage compartment IA feature allows the luggage compartment lid to be released without having
to use the interior luggage compartment lid release switch or the keyless entry keypad. With a
programmed IA key within 1 m (3 ft) outside the luggage compartment lid/liftgate, press the release
button, and the luggage compartment lid/liftgate latch releases.
Remote Keyless Entry (RKE)
The RKE transmitter carries out the following functions:

Unlocks the driver door
Unlocks all doors
Locks all doors
Releases the luggage compartment lid or liftgate latch
Arms/disarms the perimeter alarm (if equipped)
Commands the interior lamps on (when unlocking) and off (when locking)
Provides a long flash of the turn signals when UNLOCK is pressed
Sounds the horn once and flashes the turn signals when LOCK is pressed twice within 3 seconds,
and the doors are closed
Sounds the horn twice when LOCK is pressed twice within 3 seconds, and any door is ajar
The RKE transmitter has a normal operating range of 20 m (66 ft).
Without Intelligent Access (IA)
This RKE system uses an Integrated Keyhead Transmitter (IKT). The IKT incorporates both the Passive
Anti-Theft System (PATS) functions and the RKE transmitter functions in a single device. The key
programming is a two step procedure, the PATS information is programmed into the IPC and then the
RKE transmitter Transmitter Identification Code (TIC) is programmed into the Body Control Module
(BCM). The vehicle accepts the programming of up to 8 keys. Refer to the key programming procedures
in Section 419-01B for the PATS programming, and then refer to Remote Keyless Entry (RKE)
Transmitter Programming in this section to program the RKE transmitter.
With Intelligent Access (IA)
This RKE system uses an IA key. The IA key incorporates both the PATS functions and the RKE
transmitter functions in a single device. The RKE transmitter is programmed automatically during IA key
programming. During IA key programming, the Remote Function Actuator (RFA) module obtains the TIC
from the IA key. The RFA module accepts programming of up to 8 IA keys. Refer to the key
programming procedures in Section 419-01B for the for key programming information.
Remote Keyless Entry (RKE) Lock/Unlock Control — Unlock
The RKE feature provides a stepped (if enabled) process for unlocking the doors. Upon receipt of the
first request for unlocking the doors, the RKE control feature requests the BCM to unlock the driver door
only and provides a long flash of the turn signals. If another unlock request is received within 3 seconds
of the first, the RKE feature requests the BCM to unlock all of the doors. This feature can be disabled so
that all of the doors unlock on the first press of the unlock button. Refer to Stepped Unlock Programming
in this section.
Remote Keyless Entry (RKE) Lock/Unlock Control — Lock
The RKE feature requests that all of the doors be locked when the lock button is pressed. On any press
of the lock button with all doors closed, the BCM flashes the turn signals once. If any door is ajar, no
flash occurs. As soon as the last door is closed, the BCM provides the flash of the turn signals. If 2
presses of the lock button are received within 3 seconds, the horn chirps once and the turn signals flash
twice (once for each button press) to indicate that all of the doors are closed and locked. If any door is
ajar when the second lock request is received within 3 seconds of the first, the RKE transmitter feature
requests the BCM chirp the horn twice without flashing the turn signals to indicate it locked all the doors
but one or more doors are ajar.
Remote Keyless Entry (RKE) Luggage Compartment Lid/Liftgate Release
The RKE feature provides luggage compartment lid/liftgate release function. The luggage compartment
lid release system is inhibited when the ignition is on and vehicle speed exceeds 7 km/h (5 mph).
Handles, Locks, Latches and Entry Systems
Special Tool(s)
(VCM) and Integrated Diagnostic
System (IDS) software with
appropriate hardware, or equivalent
scan tool

Flex Probe Kit

Material
Item Specification
Multi-Purpose Grease ESB-M1C93-
XG-4 and/or XL-5 B
Penetrating and Lock Lubricant (US); —
Penetrating Fluid (Canada)
Principles of Operation — Without Intelligent Access (IA)
Power Door Locks
The Body Control Module (BCM) monitors the door lock control switch and the driver door lock cylinder. When
the BCM receives an unlock/lock command from either the door lock control switch or the driver door lock
cylinder, the BCM energizes a relay (internal to the SJB ) to supply the correct power and grounds for the door
lock actuators. The power door locks function independently of ignition status or vehicle speed.
Door Lock Indicator
For a visual indication of the door lock status, the BCM controls the door lock indicator on the door lock control
switch. If all four doors are locked, the indicator is illuminated. If any one door is unlocked, the indicator turns
off. The BCM monitors the door lock status through the unlock switches inside each of the 4 door latches. The
BCM uses the input from the unlock switches to determine if the indicator should be illuminated or off.
Luggage Compartment Lid/Liftgate Release
The luggage compartment lid/liftgate release system is inhibited when the vehicle speed exceeds 8 km/h (5
mph) and when the vehicle doors are locked. The luggage compartment lid/liftgate latch releases the luggage
compartment lid/liftgate when the release switch on the luggage compartment lid/liftgate or on the Remote
Keyless Entry (RKE) transmitter is pressed. When the BCM receives a signal to release the luggage
compartment lid/liftgate, the BCM supplies voltage to the latch. The luggage compartment lid/liftgate latch then
actuates to release the luggage compartment lid/liftgate.
The BCM interprets radio frequency signals from the RKE transmitters. The BCM requests the illuminated entry
feature to turn the interior lamps on when an unlock command is received. If a lock command is received, the
illuminated entry feature turns off.
The RKE transmitter supplies a signal to the antenna internal to the BCM when any button is pressed. The
BCM then supplies voltage to the appropriate door lock actuator(s) to lock or unlock the doors or release the
luggage compartment lid/liftgate.
Principles of Operation — WithIntelligent Access (IA)
Intelligent Access (IA) Components
Exterior Front Door Handles
The exterior front door handles both contain an Intelligent Access (IA) antenna and a lock switch. The antennas
and lock switches are hardwired to the Remote Function Actuator (RFA) module. When a lock switch is
pressed, it signals the RFA module there is an IA request. When the RFA module receives the request it
activates the IA antenna in the corresponding door handle. The low frequency signal from the IA antenna
activates an IA key.
Luggage Compartment/Liftgate Intelligent Access (IA) Antenna
The luggage compartment/liftgate IA antenna is hardwired to the RFA module and, when activated by the RFA
module, it transmits a low frequency signal that activates an IA key.
Remote Functions Receiver (RFR) Module
The Remote Functions Receiver (RFR) module is hardwired to the RFA module and is a receiving antenna that
receives the high frequency signals from an IA key. It also receives the signals from an RKE command.
Intelligent Access (IA) Key
The IA key receives the low frequency signals from the IA antennas. When the IA key is activated by one of the
low frequency signals, it sends out a high frequency signal that is received by the RFR module. The IA key also
contains a key blade that is used to enter the vehicle as a backup.
Power Door Locks
The BCM monitors the door lock control switch and the driver door lock cylinder. When the BCM receives an
unlock/lock command from either the door lock control switch or the driver door lock cylinder, the BCM
energizes a relay (internal to the SJB ) to supply the correct power and grounds for the door lock actuators. The
power door locks function independently of ignition status or vehicle speed.
Door Lock Indicator
For a visual indication of the door lock status, the BCM controls the door lock indicator on the door lock control
switch. If all 4 doors are locked, the indicator is illuminated. If any one door is unlocked, then the indicator turns
off. The BCM monitors the door lock status through the unlock switches inside each of the four door latches.
The BCM uses the input from the unlock switches to determine if the indicator should be illuminated or off.
Luggage Compartment Lid/Liftgate Release
The luggage compartment lid/liftgate release system is inhibited when the vehicle speed exceeds 8 km/h (5
mph) and when the vehicle doors are locked. The luggage compartment lid/liftgate latch releases the luggage
compartment lid/liftgate when the release switch on the luggage compartment lid/liftgate or on the Remote
Keyless Entry (RKE) transmitter is pressed. When the BCM receives a signal to release the luggage
compartment lid/liftgate, the BCM supplies voltage to the latch. The luggage compartment lid/liftgate latch then
actuates to release the luggage compartment lid/liftgate.
Driver/Passenger Door Intelligent Access (IA) Feature
The driver/passenger door IA feature allows the doors to be locked or unlocked without having to use the door
lock cylinder or the RKE transmitter. With a programmed IA key within 1 m (3 ft) of either front door handle
outside of the door, press the lock button on the exterior door handle and, depending upon their current state,
the doors either lock or unlock. The IA feature from the driver door only unlocks the driver door and the IA
feature from the passenger door unlocks all four doors. The IA feature from either front door locks all four
doors.
When the RFA module detects that a lock button is pressed on a front exterior door handle, it activates the low
frequency antenna in the corresponding exterior front door handle. The low frequency antenna sends out a
signal to the IA key. The low frequency signal activates the IA key and the IA key then sends a high frequency
signal back to the RFR module. The RFR module interprets the high frequency signal from the IA key and
sends the information to the RFA module. If the RFA module determines that it is a programmed key, it sends a
message over the Medium Speed Controller Area Network (MS-CAN) to the BCM . Depending upon the signal
received from the RFA module, the BCM either unlocks the driver door, unlocks all 4 doors, or locks all 4 doors.
Luggage Compartment/Liftgate Intelligent Access (IA) Feature
The luggage compartment/liftgate IA feature allows the luggage compartment lid to be released without using
an RKE transmitter. With a programmed IA key within 1 m (3 ft) outside of the luggage compartment lid/liftgate,
press the release button on the luggage compartment lid/liftgate, and the luggage compartment lid/liftgate latch
releases.
The luggage compartment/liftgate release switch is connected to both the BCM and the RFA module. When the
doors are unlocked, the BCM receives the signal from the switch and releases the luggage compartment
lid/liftgate. When the doors are locked, the BCM ignores the input from the switch and only releases the
luggage compartment lid/liftgate if it receives a signal from the RFA module for the luggage
compartment/liftgate IA feature.
When the RFA module detects a signal from the luggage compartment lid/liftgate release switch, it activates the
low frequency antenna in the rear bumper cover. The low frequency antenna sends out a signal to the IA key.
The low frequency signal activates the IA key and the IA key then sends a high frequency signal back to the
RFR module. The RFR module interprets the high frequency signal from the IA key and sends the information
to the RFA module. If the RFA module determines that it is a programmed key, it sends a message over the
MS-CAN to the BCM to release the luggage compartment lid/liftgate.
The IA key transmitter supplies a signal to the RFR module when any button is pressed. The RFR module
interprets the information from the IA key and sends a signal to the RFA module. If the RFA module determines
that it is a programmed key, it sends a message over the MS-CAN to the BCM . Depending upon the signal
received from the RFA module, the BCM either unlocks the driver door, unlocks all 4 doors, locks all 4 doors, or
releases the luggage compartment lid/liftgate.
The BCM requests the illuminated entry feature to turn the interior lamps on when an unlock command is
received. If a lock command is received, the illuminated entry feature turns off.

Binding latch mechanisms Battery Junction Box (BJB) fuse 6 (30A)
Door handles Wiring, terminals or connectors
Remote Keyless Entry (RKE) transmitter
Door lock control switch
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the
DLC are provided to the VCM .

refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.

the air bag warning indicator prove-out (other indicators may NOT prove ignition is ON)
confirms ignition ON. If ignition does not turn ON, refer to Section 211-05 to diagnose no
power in RUN.
refer to Section 418-00 , Inspection and Verification to establish a scan tool session.

If the scan tool responds with no communication for one or more modules, refer to Section 418-
00 .
If the network test passes, retrieve and record the continuous memory DTCs.
8. Carry out the self-test diagnostics for the RFA module and Body Control Module (BCM).
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the
Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
DTC Charts

B108F:23 Cabin Lock/Unlock Switch: Signal Stuck Low GO to Pinpoint Test C .
B1108:92 Driver Door Central Locking Motor: GO to Pinpoint Test D .
Performance or Incorrect Operation
B113E:23 External Boot/Trunk Release Switch: Signal GO to Pinpoint Test E .
Stuck Low
B1187:92 Trunk Motor: Performance or Incorrect GO to Pinpoint Test E .
Operation
All other — REFER to the Diagnostic Trouble Code (DTC)
DTCs Chart in Section 419-10 .
Remote Function Actuator (RFA) Module DTC Chart

B10C6:1F Exterior Trunk Antenna: Circuit GO to Pinpoint Test K .
Intermittent
B10D1:24 Left Front Lock Button: Signal Stuck High GO to Pinpoint Test J .
B10D3:24 Right Front Lock Button: Signal Stuck GO to Pinpoint Test J .
High
B113E:24 External Boot/Trunk Release Switch: GO to Pinpoint Test E .
Signal Stuck High
B11FD:1F Left Front Exterior Antenna: Circuit GO to Pinpoint Test J .
Intermittent
B1210:1F Right Front Exterior Antenna: Circuit GO to Pinpoint Test J .
Intermittent
U201F:00 External Receiver: No Sub Type GO to Pinpoint Test G .
Information
U201F:13 External Receiver: Circuit Open GO to Pinpoint Test G .
Symptom Charts
Symptom Chart — Electrical

All door locks are Fuse GO to Pinpoint Test
inoperative Wiring, terminals or A.
connectors
Anti-theft alarm horn (if
equipped)
Luggage compartment
lid/liftgate latch
Body Control Module
(BCM)
A single/more than one Wiring, terminals or GO to Pinpoint Test
door lock is inoperative connectors B.
Door lock actuator (part of
the door latch)
BCM
All door locks are Wiring, terminals or GO to Pinpoint Test
inoperative from the door connectors C.
lock control switch Door lock control switch
(part of the Front Controls
Interface Module (FCIM))
BCM
The central Wiring, terminals or REFER to Section
locking/unlocking does connectors 419-01A to diagnose
not operate correctly Driver door latch the perimeter alarm
BCM does not arm/disarm
from the driver door
lock cylinder.
The door lock control Wiring, terminals or GO to Pinpoint Test
switch indicator is connectors D.
inoperative/always on Door lock control switch
(part of the FCIM )
Door latches
BCM
The luggage Wiring, terminals or GO to Pinpoint Test
compartment lid/liftgate connectors E.
latch release is Luggage compartment
inoperative/does not lid/liftgate latch
operate correctly Luggage compartment
lid/liftgate release switch
BCM
Remote Function Actuator
(RFA) module (if
equipped)
The Remote Keyless RKE transmitter battery GO to Pinpoint Test
Entry (RKE) transmitter is RKE transmitter F.
inoperative — without programming
Intelligent Access (IA) RKE transmitter
BCM
The Remote Keyless RKE transmitter battery GO to Pinpoint Test
Entry (RKE) transmitter is RKE transmitter G.
inoperative — with programming
Intelligent Access (IA) RKE transmitter button
pressed a substantial
amount of times while
outside the range of the
vehicle
RKE transmitter
BCM
Medium Speed Controller
Area Network (MS-CAN)
Remote Functions
Receiver (RFR) module
RFA module
An individual Door locks GO to Pinpoint Test
button/feature is Luggage compartment H.
inoperative from the lid/liftgate release
Remote Keyless Entry RKE transmitter
(RKE) transmitter
The Remote Keyless RKE transmitter GO to Pinpoint Test I .
Entry (RKE) transmitter RKE transmitter battery
has poor range Aftermarket systems
performance High power devices
TV/radio transmission
towers
RFR module
BCM
The Intelligent Access Wiring, terminals or GO to Pinpoint Test J .
(IA) feature is inoperative connectors
from a front door External antenna (part of
the exterior front door
handle)
Lock button (part of the
exterior front door handle)
IA key
RFR module
RFA module
The luggage Wiring, terminals or GO to Pinpoint Test
compartment/liftgate connectors K.
Intelligent Access (IA) is Luggage
inoperative compartment/liftgate IA
antenna
IA key
RFR module
RFA module
The autolock is Programming GO to Pinpoint Test L .
inoperative Door ajar switches
Vehicle speed input
The auto-unlock is Programming GO to Pinpoint Test
inoperative Door ajar switches M.
Ignition switch
Vehicle speed input
The smart unlock is Key-in-ignition switch GO to Pinpoint Test
inoperative (vehicles without IA ) N.
Door ajar switch input
IA key
The luggage Luggage compartment GO to Pinpoint Test
compartment/liftgate lid/liftgate ajar switch input O.
smart unlock is Rear passive start
inoperative antenna
IA key
The 2-step door 2-step door unlocking is PROGRAM the 2-step
unlocking does not disabled door unlocking.
operate correctly REFER to Stepped
Unlock Programming
in this section. TEST
operation.
Symptom Chart — Mechanical

Hard to open/close door from either Door alignment GO to
door handle Door hinges Pinpoint Test
Striker adjustment P.
Door latch
A door is difficult/does not open from Binding cable GO to
the exterior door handle Exterior door handle Pinpoint Test
reinforcement Q.
Door latch
A door is difficult/does not open from Broken or binding GO to
the interior door handle cable/linkage Pinpoint Test
Door latch R.
Exterior door release handle sticks Binding cable GO to
Broken handle return Pinpoint Test
spring S.
Door latch
Interior door release handle sticks Binding cable GO to
Broken handle return Pinpoint Test
spring T.
Door latch
Squeak/rattle/chucking noise from Door alignment GO to
door Striker adjustment Pinpoint Test
Door latch U.
Manual door lock cylinder inoperative Bent or binding lock GO to
rod and lever Pinpoint Test
Door lock cylinder V.
Door latch
Ignition key cannot be returned to Wiring, terminals or GO to
OFF position connectors Pinpoint Test
Transmission selector W.
lever
Binding steering
column components
Ignition lock cylinder
Ignition switch
Pinpoint Tests
Pinpoint Test A: All Door Locks Are Inoperative
Refer to Wiring Diagrams Cell 117 , Remote Keyless Entry and Alarm for schematic and connector information.
Normal Operation
The Battery Junction Box (BJB) fuse 6 (30A) provides voltage for the power lock/unlock system, the luggage
compartment/liftgate release and the anti-theft alarm horn (if equipped). The BCM has a dedicated ground for
the power lock/unlock system. The BCM contains internal relays that are energized depending on input
received from the door lock control switch, driver door lock cylinder and the Remote Keyless Entry (RKE)
transmitters. Upon a lock request, the BCM supplies voltage on the all door lock circuit and ground on the driver
and passenger door unlock circuits. Upon an unlock request, the voltage and ground are reversed on the
previously listed circuits.
Fuse
Anti-theft alarm horn (if equipped)
BCM
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe
adapter(s) may damage the connector.

A1 VERIFY THE DOOR LOCK OPERATION FROM THE RKE
TRANSMITTER AND SWITCH
Press the LOCK and UNLOCK buttons on a RKE transmitter and Yes
also press the door lock control switch on the dash. VERIFY the BJB fuse 6 (30A)
Are the door locks inoperative from the RKE transmitter and is OK. If OK, GO to A2 .
door lock control switch?
If the fuse has failed, GO to
A5 .
No
If the door locks are
inoperative from the door lock
control switch, GO to Pinpoint
Test C .

inoperative from the RKE
transmitter (vehicles without
IA ), GO to Pinpoint Test F .

inoperative from the RKE
transmitter (vehicles with IA ),
GO to Pinpoint Test G .
A2 CHECK THE BCM POWER CIRCUIT FOR VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280A. GO to A3 .
Measure the voltage between the BCM C2280A-8, circuit SBB06
(BN/RD), harness side and ground. No
REPAIR circuit SBB06
(BN/RD) for an open. TEST
operation.

A3 CHECK THE BCM GROUND
Disconnect: BCM C2280B. Yes
Measure the voltage between the BCM C2280A-8, circuit SBB06 GO to A4 .
(BN/RD), harness side and the BCM C2280B-16, circuit GD115
(BK/GY), harness side. No
REPAIR circuit GD115
(BK/GY) for an open. TEST
operation.

A4 CHECK THE LOCK CIRCUIT FOR AN OPEN
Disconnect: BCM C2280C. Yes
Disconnect: RH Front Door Latch C609. GO to A11 .
Measure the resistance between the RH front door latch C609-2,
circuit CPL11 (GY/BN), harness side and the BCM C2280C-2, No
circuit CPL11 (GY/BN), harness side. REPAIR circuit CPL11
(GY/BN) for an open. TEST
operation.

A5 CHECK THE VEHICLE FOR THE OPTIONAL ANTI-THEFT
ALARM HORN
Check the vehicle to see if it is equipped with an anti-theft alarm Yes
horn. Refer to Section 419-01A for the location of the anti-theft GO to A6 .
alarm horn.
Is the vehicle equipped with an anti-theft alarm horn? No
GO to A8 .
A6 CHECK THE ANTI-THEFT ALARM HORN OUTPUT CIRCUIT FOR
A SHORT TO GROUND
NOTE: If BJB fuse 6 (30A) fails immediately upon installation, Yes

repair circuit SBB06 (BN/RD) for a short to ground. GO to A8 .
Install a new BJB fuse 6 (30A). No
Select the BCM PID (ANTITHFT_HRN) and active command the GO to A7 .
anti-theft alarm horn to sound.
Is BJB fuse 6 (30A) OK?
A7 CHECK THE ANTI-THEFT ALARM HORN USING THE BCM PID
ANTI-THEFT HORN STATUS (ANTITHFT_HRN)
Disconnect: Anti-Theft Alarm Horn C4380. Yes
Install a new BJB fuse 6 (30A). INSTALL a new anti-theft
Select the BCM PID ANTITHFT_HRN and active command the alarm horn. REFER to Section
anti-theft alarm horn to sound. 419-01A . TEST the system
Is BJB fuse 6 (30A) OK? for normal operation.
No
REPAIR circuit CRT02
(GY/VT) for a short to ground.
operation.
A8 CHECK THE LUGGAGE COMPARTMENT LID RELEASE
OUTPUT CIRCUIT FOR A SHORT TO GROUND
NOTE: If BJB fuse 6 (30A) fails immediately upon installation, Yes

repair circuit SBB06 (BN/RD) for a short to ground. GO to A10 .
Install a new BJB fuse 6 (30A). No
Operate the luggage compartment/liftgate release by pressing the GO to A9 .
luggage compartment/liftgate release button on an RKE
transmitter.
Is BJB fuse 6 (30A) OK?
A9 CHECK THE LUGGAGE COMPARTMENT LID/LIFTGATE
ACTUATOR FOR A SHORT
Disconnect: Luggage Compartment/Liftgate Latch C4223. Yes
Install a new BJB fuse 6 (30A). INSTALL a new luggage
Operate the luggage compartment/liftgate release by pressing the compartment lid/liftgate latch.
luggage compartment/liftgate release button on an RKE REFER to Liftgate Latch or
transmitter. Luggage Compartment Lid
Is BJB fuse 6 (30A) OK? Latch in this section. TEST
operation.
No
REPAIR circuit CPL20
(BU/OG) for a short to ground.
operation.
A10 CHECK THE LOCK CIRCUIT FOR A SHORT TO GROUND
Operate the door lock actuators by pressing the lock button on an Yes
RKE transmitter. REPAIR circuit CPL13
Is BJB fuse 6 (30A) OK? (BN/GN) or CPL51 (BU/GN)
for a short to ground. TEST
operation.
No
(GY/BN) for a short to ground.
operation.
A11 CHECK FOR CORRECT BCM OPERATION
corrosion REFER to Section 419-10 .
damaged pins TEST the system for normal
pushed-out pins operation.
Connect all the BCM connectors and make sure they seat
correctly. No
caused by a loose or corroded
connector.
Pinpoint Test B: A Single/More Than One Door Lock Is Inoperative
Normal Operation
The Battery Junction Box (BJB) fuse 6 (30A) provides voltage for the power lock/unlock system and the
luggage compartment/liftgate release. The BCM has a dedicated ground for the power lock/unlock system. The
BCM contains internal relays that are energized depending on input received from the door lock control switch,
driver door lock cylinder and the Remote Keyless Entry (RKE) transmitters. Upon a lock request, the BCM
supplies voltage on the all door lock circuit and ground on the driver and passenger door unlock circuits. Upon
an unlock request, the voltage and ground are reversed on the previously listed circuits.

Door lock actuator (part of the door latch)
BCM
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE


B1 CHECK THE ALL LOCK OUTPUT CIRCUIT FOR VOLTAGE
Ignition OFF. Yes
Disconnect: Inoperative Door Lock Actuator. GO to B2 .
NOTE: The BCM only supplies voltage to the actuator momentarily. It
is important to monitor the meter while pressing the door lock control No
switch. REPAIR circuit CPL11
While pressing the door lock control switch in the lock position, (GY/BN) for an open.
measure the voltage between the inoperative door lock actuator, TEST the system for
harness side and ground as follows: normal operation.
Inoperative Door Lock Actuator Connector-Pin Circuit

LH front C525-7 CPL11 (GY/BN)
RH front C609-2 CPL11 (GY/BN)
LH rear C705-7 CPL11 (GY/BN)
RH rear C805-2 CPL11 (GY/BN)
Is the voltage momentarily greater than 10 volts?

B2 CHECK THE UNLOCK OUTPUT CIRCUIT FOR VOLTAGE
NOTE: The BCM only supplies voltage to the actuator momentarily. It Yes
is important to monitor the meter while pressing the door lock control INSTALL a new door
switch. latch. REFER to Front
While pressing the door lock control switch in the unlock position, Door Latch or Rear Door
measure the voltage between the inoperative door lock actuator, Latch in this section. TEST
harness side and ground as follows: the system for normal
operation.
Inoperative Door Lock Actuator Connector-Pin Circuit
No
LH front C525-8 CPL51 (BU/GN) GO to B3 .
RH front C609-1 CPL13 (BN/GN)
LH rear C705-8 CPL13 (BN/GN)
RH rear C805-1 CPL13 (BN/GN)
B3 CHECK THE UNLOCK OUTPUT CIRCUIT FOR AN OPEN
Measure the resistance between the BCM , harness side and the GO to B4 .
inoperative door lock actuator, harness side as follows:
No
BCM Inoperative Door Lock Actuator REPAIR the circuit in
Connector-Pin Connector-Pin Circuit question for an open.
TEST the system for
C2280C-7 LH front C525-8 CPL51 normal operation.
(BU/GN)
C2280C-3 RH front C609-1 CPL13
(BN/GN)
C2280C-3 LH rear C705-8 CPL13
(BN/GN)
C2280C-3 RH rear C805-1 CPL13
(BN/GN)

B4 CHECK FOR CORRECT BCM OPERATION
corrosion REFER to Section 419-
damaged pins 10 . TEST the system for
pushed-out pins normal operation.
Connect all the BCM connectors and make sure they seat correctly.
corroded connector.
Pinpoint Test C: All Door Locks Are Inoperative From The Door Lock Control Switch
Normal Operation
The Body Control Module (BCM) sends a voltage signal to the door lock control switch. When the door lock
control switch is pressed, the voltage signal is routed to ground, signaling the BCM to lock or unlock the doors.
The BCM monitors the door lock actuator positions and either locks or unlocks the doors depending upon their
current state. If the doors are locked and the switch is pressed, the BCM unlocks the doors. If the doors are
unlocked and the switch is pressed, the BCM locks the doors. The door lock control switch is part of the Front
Controls Interface Module (FCIM) and shares the same ground.
DTC B108F:23 (Cabin Lock/Unlock Switch: Signal Stuck Low) — a continuous and on-demand DTC that
sets when the BCM detects a short to ground from the door lock control switch input circuit. This DTC
may also set if the door lock control switch is pressed for longer than 2 minutes.

Door lock control switch (part of the FCIM )
BCM
PINPOINT TEST C: ALL DOOR LOCKS ARE INOPERATIVE FROM THE DOOR LOCK CONTROL SWITCH

C1 CHECK THE OPERATION OF THE FCIM
Operate the radio through the FCIM . Yes
Does the FCIM operate the radio? GO to C2 .
No
00 to DIAGNOSE the
FCIM .
C2 CHECK THE RECORDED BCM DTCs FROM THE SELF-TEST
Check the recorded results from the BCM self-test. Yes
Is DTC B108F:23 present? GO to C3 .
No
GO to C5 .
C3 CHECK THE DOOR LOCK CONTROL SWITCH FOR A SHORT TO
GROUND
Disconnect: FCIM C2402. Yes
Enter the following diagnostic mode on the scan tool: Clear BCM DTCs. GO to C4 .
Enter the following diagnostic mode on the scan tool: BCM Self-Test.
Is DTC B108F:23 retrieved again? No
INSTALL a new FCIM .
00 . TEST the system
C4 CHECK THE INPUT CIRCUIT FOR A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280F. GO to C7 .
Measure the resistance between the FCIM C2402-6, circuit CPL75
(BN/WH), harness side and ground No
(BN/WH) for a short to
ground. CLEAR the
DTCs. REPEAT the
self-test.

C5 CHECK THE DOOR LOCK CONTROL SWITCH
Ignition OFF. Yes
Disconnect: FCDIM C2402. INSTALL a new FCIM .
Listen to the door locks while momentarily connecting a fused jumper REFER to Section 415-
wire between the FCIM C2402-6, circuit CPL75 (BN/WH), harness side 00 . TEST the system
and the FCIM C2402-5, circuit GD115 (BK/GY), harness side. for normal operation.
No
GO to C6 .
Do the doors lock and unlock with the jumper wire connected?
C6 CHECK THE INPUT CIRCUIT FOR AN OPEN
Disconnect: BCM C2280F. Yes
Measure the resistance between the BCM C2280F-8, circuit CPL75 GO to C7 .
(BN/WH), harness side and the FCIM C2402-6, circuit CPL75 (BN/WH),
harness side. No
(BN/WH) for an open.
TEST the system for
normal operation.

C7 CHECK FOR CORRECT BCM OPERATION
damaged pins 10 . TEST the system
pushed-out pins for normal operation.
Pinpoint Test D: The Door Lock Control Switch Indicator Is Inoperative/Always On
Normal Operation
The Body Control Module (BCM) controls the door lock control switch indicator. The door lock control switch is
illuminated when the doors are locked and off when the doors are unlocked. The BCM provides voltage to the
door lock control switch indicator and the indicator uses a common ground in the Front Controls Interface
Module (FCIM). When the ignition is in the RUN mode, the indicator is always on as long as the doors are
locked. When the ignition is in the OFF mode, the indicator illuminates for approximately 30 seconds when a
lock command is received and then it turns off.
The BCM monitors the lock/unlock monitor circuit to determine the status of the door locks and to turn the
indicator on or off. All 4 door latches have an internal switch that are connected to ground when the door is
unlocked and open when the door is locked.
DTC B1108:92 (Driver Door Central Locking Motor: Performance or Incorrect Operation) — an on-
demand DTC that sets when the BCM detects the incorrect feedback on the door lock/unlock monitor
circuit. During the BCM self-test, the BCM energizes the internal lock and unlock relays to lock and
unlock all of the doors. When the BCM commands the doors to lock, it checks for an open on the
lock/unlock monitor circuit. When the BCM commands the doors to unlock, it checks for a short to
ground on the lock/unlock monitor circuit.

Door lock control switch (part of the FCIM )
Door latches
BCM
PINPOINT TEST D: THE DOOR LOCK CONTROL SWITCH INDICATOR IS INOPERATIVE/ALWAYS ON

D1 CHECK THE DOOR LOCK ACTUATOR OPERATION
Close all 4 doors and the liftgate/luggage compartment lid. Yes
Press the lock button on a Remote Keyless Entry (RKE) transmitter. GO to Pinpoint Test B .
Attempt to open each door using the outside door handle.
Press the unlock button on an RKE transmitter. No
Attempt to open each door using the outside door handle. GO to D2 .
Is there a door that can be opened when the doors are locked
or that cannot be opened when the doors are unlocked?
D2 CHECK THE DOOR AJAR INPUT
Open and close the doors while checking the courtesy lamp Yes
operation. GO to D3 .
Do the courtesy lamps operate correctly?
No
DIAGNOSE the door ajar
inputs.
D3 CHECK THE DOOR LOCK INDICATOR OPERATION FROM EACH
DOOR
NOTE: Make sure the child safety lock is off before performing this Yes
pinpoint test. GO to D5 .
Lower the window glass in all 4 doors. No
Press the lock button on an RKE transmitter to lock all 4 doors. GO to D4 .
Observe the door lock indicator while pulling on the interior LH front
door handle to unlock the LH front door.
Press the lock button on an RKE transmitter to lock all 4 doors.
Observe the door lock indicator while pulling on the interior RH front
door handle to unlock the RH front door.
Observe the door lock indicator while pulling on the interior LH rear
door handle to unlock the LH rear door.
Observe the door lock indicator while pulling on the interior RH rear
door handle to unlock the RH rear door.
Is the door lock indicator inoperative/always on from all 4
doors?
D4 CHECK THE LATCH SWITCH FOR AN OPEN
Disconnect: Suspect Door Latch. Yes
Connect a fused jumper wire between the suspect door latch, INSTALL a new door latch
harness side as follows: for the latch in question.
REFER to Front Door Latch
Suspect Door Lock Actuator Suspect Door Lock Actuator or Rear Door Latch in this
Connector-Pin Connector-Pin section. TEST the system for
normal operation.
Circuit Circuit
No
LH front C525-4 LH front C525-5 REPAIR circuit CPL30
(BU/BN) for an open. TEST
CPL30 (BU/BN) GD143 (BK/VT) the system for normal
operation.
RH front C609-5 RH front C609-4
CPL30 (BU/BN) GD145 (BK/BU)

LH rear C705-4 LH rear C705-5
CPL30 (BU/BN) GD143 (BK/VT)

RH rear C805-5 RH rear C805-4
CPL30 (BU/BN) GD145 (BK/BU)
Does the door lock indicator turn off with the jumper wire
connected?
D5 CHECK THE RECORDED BCM DTCs FROM THE SELF-TEST
Check the recorded results from the BCM self-test. Yes
Is DTC B1108:92 present? GO to D11 .
No
GO to D6 .
D6 CHECK THE ILLUMINATION OF THE INDICATOR
Ignition ON. Yes
Observe the illumination of the door lock indicator with the doors GO to D7 .
unlocked.
Is the indicator always illuminated? No
GO to D8 .
D7 CHECK THE INDICATOR OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280E. REPAIR circuit CPL22
Ignition ON. (GN/VT) for a short to
Observe the illumination of the door lock indicator. voltage. TEST the system for
Is the indicator still illuminated? normal operation.
No
GO to D17 .
D8 CHECK THE OPERATION OF THE FCIM
Operate the radio through the FCIM . Yes
Does the FCIM operate the radio? GO to D9 .
No
DIAGNOSE the FCDIM .
D9 BYPASS THE BCM
NOTE: If the fuse in the jumper wire fails, REPAIR circuit CPL22 Yes
(GN/VT) for a short to ground. REMOVE the jumper wire.
GO to D17 .
Ignition OFF.
Disconnect: BCM C2280A. No
Disconnect: BCM C2280E. LEAVE the jumper wire
Connect a fused jumper wire between the BCM C2280A-8, circuit connected. GO to D10 .
SBB06 (BN/RD), harness side and the BCM C2280E-23, circuit
CPL22 (GN/VT), harness side.
Does the indicator illuminate?

D10 CHECK FOR VOLTAGE TO THE FCIM
Disconnect: FCIM C2402. Yes
Measure the voltage between the FCIM C2402-2, circuit CPL22 INSTALL a new FCIM .
(GN/VT), harness side and ground. REFER to Section 415-00 .
operation.
No
(GN/VT) for an open. TEST
operation.

D11 CHECK THE LOCK/UNLOCK MONITOR CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Press the unlock button twice on an RKE transmitter to unlock all GO to D12 .
doors.
Disconnect: BCM C2280G. No
Measure the resistance between the BCM C2280G-5, circuit CPL30 REPAIR circuit CPL30
(BU/BN), harness side and ground. (BU/BN) for an open. CLEAR
test.

D12 CHECK THE LOCK/UNLOCK MONITOR CIRCUIT FOR A SHORT
TO GROUND
Press the lock button on an RKE transmitter to lock all doors. Yes
Measure the resistance between the BCM C2280G-5, circuit CPL30 GO to D17 .
(BU/BN), harness side and ground.
No
GO to D13 .

D13 CHECK THE LH FRONT DOOR LATCH FOR A SHORT TO
GROUND
Disconnect: LH Front Door Latch C525. Yes
Measure the resistance between the BCM C2280G-5, circuit CPL30 INSTALL a new LH front
(BU/BN), harness side and ground. door latch. REFER to Front
Door Latch in this section.
the self-test.
No
GO to D14 .

D14 CHECK THE RH FRONT DOOR LATCH FOR A SHORT TO
GROUND
Disconnect: RH Front Door Latch C609. Yes
Measure the resistance between the BCM C2280G-5, circuit CPL30 INSTALL a new RH front
(BU/BN), harness side and ground. door latch. REFER to Front
the self-test.
No
GO to D15 .

D15 CHECK THE LH REAR DOOR LATCH FOR A SHORT TO
GROUND
Disconnect: LH Rear Door Latch C705. Yes
Measure the resistance between the BCM C2280G-5, circuit CPL30 INSTALL a new LH rear door
(BU/BN), harness side and ground. latch. REFER to Rear Door
Latch in this section. CLEAR
test.
No
GO to D16 .

D16 CHECK THE RH REAR DOOR LATCH FOR A SHORT TO
GROUND
Disconnect: RH Rear Door Latch C805. Yes
Measure the resistance between the BCM C2280G-5, circuit CPL30 INSTALL a new RH rear
(BU/BN), harness side and ground. door latch. REFER to Rear
the self-test.
No
(BU/BN) for a short to
ground. CLEAR the DTCs.

D17 CHECK FOR CORRECT BCM OPERATION
corroded connector.
Pinpoint Test E: The Luggage Compartment Lid/Liftgate Latch Release Is Inoperative/Does Not Operate
Correctly
Refer to Wiring Diagrams Cell 113 , Luggage Compartment for schematic and connector information.
Normal Operation
When the Body Control Module (BCM) receives an open request from the luggage compartment lid/liftgate
switch or a Remote Keyless Entry (RKE) transmitter, the BCM supplies voltage to the luggage compartment
lid/liftgate latch which releases the latch. The luggage compartment lid/liftgate latch has a dedicated ground
circuit.
The BCM sends a voltage signal to the luggage compartment lid/liftgate release switch through the input circuit.
When the luggage compartment lid/liftgate release switch is pressed, the voltage signal is routed to ground,
signaling the BCM to release the luggage compartment lid/liftgate. The luggage compartment lid/liftgate release
switch has a dedicated ground circuit. The BCM disregards the input from the switch and does not release the
luggage compartment lid/liftgate if the doors are locked.
The luggage compartment lid/liftgate release switch is also hardwired to the Remote Function Actuator (RFA)
module on vehicles with Intelligent Access (IA). The RFA module uses the switch input for the luggage
compartment lid/liftgate IA feature.
DTC B113E:23 (External Boot/Trunk Release Switch: Signal Stuck Low) — a continuous and on-
demand DTC that sets if the BCM detects a short to ground on the luggage compartment lid/liftgate
release switch input circuit. This DTC also sets if the switch is pressed for longer than 2 minutes.
DTC B113E:24 (External Boot/Trunk Release Switch: Signal stuck high) — a DTC that sets if the RFA
module detects a short to ground on the luggage compartment lid/liftgate release switch input circuit.
DTC B1187:92 (Trunk Motor: Performance or Incorrect Operation) — an on-demand DTC that sets if the
BCM detects a short to ground on the luggage compartment lid/liftgate ajar switch input circuit. During
the BCM self-test, the BCM energizes the internal luggage compartment lid/liftgate relay to release the
latch. When the BCM commands the luggage compartment lid/liftgate relay to release, it checks for an
open on the luggage compartment lid/liftgate ajar input circuit, indicating the luggage compartment
lid/liftgate opened.

Luggage compartment lid/liftgate release switch
BCM
RFA module (if equipped)
PINPOINT TEST E: THE LUGGAGE COMPARTMENT LID/LIFTGATE LATCH RELEASE IS

INOPERATIVE/DOES NOT OPERATE CORRECTLY

E1 CHECK THE DOOR LOCK OPERATION
Lock and unlock the doors using the door lock control switch. Yes
Do the door locks operate correctly? GO to E2 .
No
GO to Pinpoint Test A .
E2 CHECK THE LUGGAGE COMPARTMENT/LIFTGATE AJAR
INPUT
For 4-door sedans, open the luggage compartment lid while Yes
observing the luggage compartment lamps. GO to E3 .
For 5-door hatchbacks, open the liftgate while observing the
courtesy lamps. No
Do the luggage compartment or courtesy lamps illuminate? REFER to Section 417-02 to
DIAGNOSE the luggage
compartment lid/liftgate ajar
input.
E3 RETRIEVE THE RECORDED BCM DTCs FROM THE SELF-TEST
Check for recorded BCM DTCs from the self-test. Yes
Is DTC B113E:23 present? Vehicles equipped with IA ,
GO to E4 .
Vehicles equipped without IA ,

GO to E5 .
No
GO to E7 .
E4 CHECK THE RFA MODULE
Disconnect: RFA Module C3503B. Yes
Enter the following diagnostic mode on the scan tool: Clear BCM GO to E5 .
DTCs.
Enter the following diagnostic mode on the scan tool: BCM Self- No
Test. GO to E17 .
Is DTC B113E:23 retrieved?
E5 REPEAT THE BCM SELF-TEST
Disconnect: Luggage Compartment Lid/Liftgate Release Switch Yes
C4224. GO to E6 .
Enter the following diagnostic mode on the scan tool: Clear BCM
DTCs. No
Enter the following diagnostic mode on the scan tool: BCM Self- INSPECT the jumper harness
Test. for any shorts to ground.
Is DTC B113E:23 retrieved? REPAIR as necessary. TEST
operation.
If the jumper harness is OK,
INSTALL a new luggage
compartment lid/liftgate
release switch. REFER to
Luggage Compartment Lid
Release Switch in this section.
operation.
E6 CHECK THE LUGGAGE COMPARTMENT LID/LIFTGATE
RELEASE INPUT CIRCUIT FOR A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to E16 .
Measure the resistance between the luggage compartment lid
release switch C4224-3, circuit CPL10 (GN/WH), harness side No
and ground. REPAIR circuit CPL45 (BN) for
a short to ground. CLEAR the
DTCs. REPEAT the self-test.

E7 CARRY OUT THE BCM TRUNK/LIFTGATE RELEASE OUTPUT
(TRNK/LG_RLS) ACTIVE COMMAND USING THE SCAN TOOL
Enter the following diagnostic mode on the scan tool: BCM Yes
DataLogger. GO to E8 .
Select the BCM PID TRNK/LG_RLS and active command the
luggage compartment lid/liftgate to release. No
Does the luggage compartment lid/liftgate release? GO to E11 .
E8 CHECK THE RELEASE SWITCH
Disconnect: Luggage Compartment Lid/Liftgate Release Switch Yes
C4224. INSPECT the jumper harness
Connect a fused jumper wire between the luggage compartment for any opens. REPAIR as
lid/liftgate release switch C4224-3, circuit CPL10 (GN/WH), necessary. TEST the system
harness side and the luggage compartment lid/liftgate release for normal operation.
switch C4224-4, circuit GD143 (BK/VT), harness side.
INSTALL a new luggage
compartment lid/liftgate
release switch. REFER to
Luggage Compartment Lid
Release Switch in this section.
operation.
No
GO to E9 .
Does the luggage compartment lid release?

E9 CHECK THE RELEASE SWITCH GROUND CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Connect a fused jumper wire between the luggage compartment GO to E10 .
lid/liftgate release switch C4224-3, circuit CPL10 (GN/WH),
harness side and ground. No
INSPECT the jumper harness
for any opens. REPAIR as
necessary. TEST the system

(BK/VT) for an open. TEST the
Does the luggage compartment lid release?

E10 CHECK THE RELEASE SWITCH INPUT CIRCUIT FOR AN
OPEN
Disconnect: BCM C2280G . Yes
Measure the resistance between the luggage compartment GO to E16 .
lid/liftgate release switch C4224-3, circuit CPL10 (GN/WH),
harness side and the BCM C2280G-20, circuit CPL10 (GN/WH), No
harness side. REPAIR circuit CPL10
(GN/WH) for an open. TEST
operation.

E11 CHECK FOR A SHORT TO VOLTAGE TO THE LATCH
Disconnect: Luggage Compartment Lid/Liftgate Latch C4223. Yes
Ignition ON. GO to E12 .
Measure the voltage between the luggage compartment lid/liftgate
latch C4223-1, circuit CPL20 (BU/OG), harness side and ground. No
GO to E13 .

E12 CHECK THE LATCH RELEASE OUTPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280C. REPAIR circuit CPL20
Ignition ON. (BU/OG) for a short to voltage.
Measure the voltage between the luggage compartment lid/liftgate TEST the system for normal
latch C4223-1, circuit CPL20 (BU/OG), harness side and ground. operation.
No
GO to E16 .

E13 CHECK FOR VOLTAGE TO THE LUGGAGE COMPARTMENT
LID LATCH USING THE BCM PID TRUNK/LIFTGATE RELEASE
OUTPUT (TRNK/LG_RLS)
DataLogger. GO to E14 .
Select the BCM PID TRNK/LG_RLS and command the luggage
compartment lid/liftgate release relay. No
NOTE: The BCM only supplies voltage to the luggage GO to E15 .
compartment lid/liftgate latch momentarily. It is important to
monitor the meter while active commanding the latch to release.
Measure the voltage between the luggage compartment lid/liftgate
latch C4223-1, circuit CPL20 (BU/OG), harness side and ground.

E14 CHECK THE LATCH GROUND CIRCUIT FOR AN OPEN USING
THE BCM PID TRUNK/LIFTGATE RELEASE OUTPUT
(TRNK/LG_RLS)
DataLogger. INSTALL a new luggage
Select the BCM PID TRNK/LG_RLS and command the luggage compartment/liftgate lid latch.
compartment lid/liftgate release relay. REFER to Luggage
NOTE: The BCM only supplies voltage to the luggage Compartment Lid Latch or
compartment lid/liftgate latch momentarily. It is important to Liftgate Latch in this section.
monitor the meter while active commanding the latch to release. TEST the system for normal
Measure the voltage between the luggage compartment lid/liftgate operation.
latch C4223-1, circuit CPL20 (BU/OG), harness side and the
luggage compartment lid/liftgate latch C4223-2, circuit GD143 No
(BK/VT), harness side. REPAIR circuit GD143
(BK/VT) for an open. TEST the

E15 CHECK THE LATCH RELEASE OUTPUT CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: BCM C2280C. GO to E16 .
Measure the resistance between the BCM C2280C-15, circuit
CPL20 (BU/OG), harness side and the luggage compartment No
lid/liftgate latch C4223-1, circuit CPL20 (BU/OG), harness side. REPAIR circuit CPL20
(BU/OG) for an open. TEST
operation.

E16 CHECK FOR CORRECT BCM OPERATION
Check for: INSTALL a new BCM . REFER
corrosion to Section 419-10 . TEST the
damaged pins system for normal operation.
pushed-out pins
Connect all the BCM connectors and make sure they seat No
correctly. The system is operating
Operate the system and verify the concern is still present. correctly at this time. The
Is the concern still present? concern may have been
connector.
E17 CHECK FOR CORRECT RFA MODULE OPERATION
Disconnect all the RFA module connectors. Yes
Check for: INSTALL a new RFA module.
Connect all the RFA module connectors and make sure they seat
correctly. No
connector.
Pinpoint Test F: The Remote Keyless Entry (RKE) Transmitter Is Inoperative — Without Intelligent
Access (IA)
Normal Operation
Remote locking and unlocking of the doors and releasing the luggage compartment lid/liftgate is accomplished
by the Body Control Module (BCM) receiving a command message from the Remote Keyless Entry (RKE)
transmitter. The BCM processes the command and provides the appropriate output. The RKE feature operates
only when the ignition is off.
If the vehicle has been inactive for 28 days or longer, the RKE feature is switched off in the BCM to conserve
battery power. The RKE feature is enabled again when the ignition is switched to RUN.
RKE transmitter battery

RKE transmitter programming
RKE transmitter
BCM
PINPOINT TEST F: THE RKE TRANSMITTER IS INOPERATIVE — WITHOUT IA
NOTE: Aftermarket or dealer-installed systems may adversely affect the RKE system operation. Disconnect
these systems before diagnosing any RKE concerns.

F1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
NOTE: All RKE transmitters must be Yes
present to begin diagnosis of the RKE GO to F2 .
system.
NOTE: Make sure the RKE transmitters No
are those provided with the OEM system The system cannot be tested without all of the RKE
and not from an aftermarket system, or a transmitters. INFORM the customer that all of the
dealer-installed system that may have correct RKE transmitters must be present to proceed
been installed on the vehicle. with diagnosis of the system.
Verify the correct RKE transmitters are
used with the vehicle. Compare the RKE
transmitters with the one shown in the
Handles, Locks, Latches and Entry
Systems portion of this section.
Are all the correct RKE transmitters
present?
F2 CHECK THE OPERATION OF THE RKE
TRANSMITTER WITH THE KEY IN THE OFF
POSITION
Ignition OFF. Yes
Check the operation of the RKE The system is operating correctly. INFORM the
transmitter. customer of the correct vehicle behavior.
Does the system operate correctly
now? No
GO to F3 .
F3 CHECK THE FUNCTIONALITY OF THE
RKE TRANSMITTER
Press each button on the transmitter. Yes
Does any button operate correctly? GO to Pinpoint Test H .
No
GO to F4 .
F4 CHECK THE RKE SYSTEM FOR
NORMAL OPERATION WITH A SECOND
TRANSMITTER
Using the customer's second RKE Yes
transmitter that is correct for the vehicle, GO to F5 .
attempt to lock and unlock the doors.
Do the doors lock and unlock with the No
second transmitter? GO to F7 .
F5 CHECK THE INOPERATIVE RKE
TRANSMITTER BATTERY
Open the inoperative RKE transmitter. Yes
Do not clean off any grease from the GO to F6 .
battery terminals on the back surface of
the circuit board. No
Verify the correct battery is used INSTALL a new battery. DO NOT reprogram the RKE
(CR2032). transmitters (weak or dead batteries do not erase
Remove the RKE transmitter battery and Transmitter Identification Codes (TICs) from memory).
measure the voltage. TEST the system for normal operation.
Is the voltage greater than 2.5 volts?
F6 CHECK IF THE RKE TRANSMITTER IS
PROGRAMMED
Program all of the RKE transmitters. Yes
Refer to Remote Keyless Entry (RKE) The concern was caused by an unprogrammed RKE
Transmitter Programming in this section. transmitter. INFORM the customer that any RKE
Check the inoperative RKE transmitter for transmitters not present need to be programmed.
correct operation.
Does the inoperative RKE transmitter No
operate now? REPLACE the inoperative RKE transmitter.
PROGRAM all RKE transmitters. REFER to Remote
Keyless Entry (RKE) Transmitter Programming in this
section. INFORM the customer that any RKE
transmitters not present need to be programmed.
TEST the system for normal operation.
F7 PROGRAM ALL OF THE RKE
TRANSMITTERS
Program all of the RKE transmitters. Yes
Refer to Remote Keyless Entry (RKE) The concern was caused by unprogrammed RKE
Transmitter Programming in this section. transmitters. INFORM the customer that any RKE
Check the RKE transmitters for correct transmitters not present need to be programmed.
operation.
Do any of the RKE transmitters No
operate now? GO to F8 .
F8 CHECK THE BCM FOR CORRECT
OPERATION
Check for: INSTALL a new BCM . REFER to Section 419-10 .
corrosion TEST the system for normal operation.
damaged pins
pushed-out pins No
Connect all the BCM connectors and The system is operating correctly at this time. The
make sure they seat correctly. concern may have been caused by a loose or corroded
Operate the system and verify the connector.
concern is still present.
Pinpoint Test G: The Remote Keyless Entry (RKE) Transmitter Is Inoperative — With Intelligent Access
(IA)
Normal Operation
When an Remote Keyless Entry (RKE) button is pressed on a Intelligent Access (IA) key, the IA key sends a
radio signal to the Remote Functions Receiver (RFR) module based on the user selected RKE transmitter
button. The RFR module then communicates the RKE command to the Remote Function Actuator (RFA)
module over a dedicated single circuit network. Once the RFA module receives the RKE command, it sends the
command to the Body Control Module (BCM) over the Medium Speed Controller Area Network (MS-CAN). The
BCM receives the RKE command and either locks or unlocks the doors or releases the luggage compartment
lid/liftgate. The RKE transmitters and RFA module use a rolling code to prevent the code from being captured
by a code grabber. The system advances the counter in the RKE transmitter and RFA module every time an
RKE transmitter button is pressed.
The RFR module receives voltage from Central Junction Box (CJB) fuse 7 (7.5A) and has a dedicated ground
circuit. The RFR module sends all RKE and IA key information and requests to the RFA module through a
dedicated single circuit network.
DTC U201F:00 (External Receiver: No Sub Type Information) — sets when the RFA module has lost
communication with the RFR module.
DTC U201F:13 (External Receiver: Circuit Open) — sets when the RFA module has lost communication
with the RFR module with an open communication circuit.
RKE transmitter
RKE transmitter button pressed a substantial amount of times while outside the range of the vehicle
RKE transmitter programming
MS-CAN
BCM
RFR module
RFA module
PINPOINT TEST G: THE RKE TRANSMITTER IS INOPERATIVE — WITH IA
NOTE: Aftermarket or dealer-installed systems may adversely affect the RKE system operation. Disconnect
these systems before diagnosing any RKE concerns.

G1 CHECK FOR THE CORRECT RKE TRANSMITTERS
NOTE: Make sure the IA keys are those provided with the OEM Yes
system and not from an aftermarket system, or a dealer-installed GO to G2 .
system that may have been installed on the vehicle.
Verify the correct IA keys are used with the vehicle. Compare the No
IA keys with the one shown in Handles, Locks, Latches and Entry The system cannot be tested
Systems in the Description and Operation portion of this section. without the correct IA keys.
Are all the correct IA keys present? INFORM the customer that
all of the correct IA keys must
be present to proceed with
diagnosis of the system.
G2 CHECK THE FUNCTIONALITY OF THE RKE TRANSMITTER
Press each button on the IA key. Yes
Does any button operate correctly? GO to Pinpoint Test H .
No
GO to G3 .
G3 CHECK FOR COMMUNICATION WITH THE BCM AND RFA
MODULE
Enter the following diagnostic mode on the scan tool: Network Test. Yes
Does the BCM or RFA module fail the network test? REFER to Section 418-00 to
DIAGNOSE the module with
no communication.
No
GO to G4 .
G4 CHECK THE RECORDED RFA MODULE DTCs FROM THE SELF-
TEST
Check the recorded results from the RFA module self-test. Yes
Are any DTCs recorded? For DTC U201F:00 or
U201F:13, GO to G9 .
For all other RFA module

DTCs, REFER to the RFA
module DTC Chart in this
section.
No
GO to G5 .
G5 RESYNCHRONIZE THE INOPERATIVE IA KEY
Ignition OFF. Yes
Within 30 seconds, press any button on the inoperative IA key 4 The system is now OK. TEST
times consecutively. the system for normal
Does the IA key operate correctly now? operation.
No
GO to G6 .
G6 RESYNCHRONIZE THE INOPERATIVE IA KEY USING THE
SECOND IA KEY
Ignition OFF. Yes
Press any button on the operational IA key. The system is now OK. TEST
Within 30 seconds, press any button on the inoperative IA key. the system for normal
Check the inoperative IA key for correct operation. operation
Does the inoperative IA key operate now?
No
GO to G7 .
G7 CHECK THE IA KEY
Place the IA key next to the steering column shroud by the Passive Yes
Anti-Theft System (PATS)/backup transceiver. GO to G8 .
Start the engine.
Does the engine start? No
REFER to Section 419-01B
to continue diagnosis of the
IA key.
G8 CHECK THE IA KEY BATTERY
Open the IA key. Yes
Do not clean off any grease from the battery terminals on the back GO to G9 .
surface of the circuit board.
Verify the correct battery is used (CR2032). No
Remove the IA key battery and measure the voltage. INSTALL a new battery. DO
Is the voltage greater than 2.5 volts? NOT reprogram the IA key
(damaged or dead batteries
do not erase IA keys from
memory). TEST the system
G9 CHECK FOR VOLTAGE TO THE RFR MODULE
Disconnect: RFR Module C9026. Yes
Measure the voltage between the RFR module C9026-3, circuit GO to G11 .
SBP07 (WH/RD), harness side and the RFR module C9026-2,
circuit GD143 (BK/VT). No
GO to G10 .
G10 CHECK THE RFR MODULE VOLTAGE SUPPLY CIRCUIT
Measure the voltage between the RFR module C9026-3, circuit Yes
SBP07 (WH/RD), harness side and ground. REPAIR circuit GD143
(BK/VT) for an open. CLEAR
test.
No
VERIFY CJB fuse 7 (7.5A) is
OK. If OK, REPAIR circuit
SBP07 (WH/RD) for an open.
Wiring Diagrams mannual to
identify the possible causes
of the circuit short. CLEAR
test.

G11 CHECK THE RFR MODULE COMMUNICATION CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: RFA Module C3503B. REMOVE the jumper wire.
Disconnect: Smart Keyless Entry Ignition Relay. INSTALL the smart keyless
Connect a fused jumper wire between the smart keyless entry entry ignition relay. REPAIR
ignition relay pin 3, circuit SBP01 (RD), Central Junction Box (CJB) circuit VDB10 (GY) for a
face side and the smart keyless entry ignition relay pin 5, circuit short to voltage. CLEAR the
CDC32 (BN/YE), CJB face side. DTCs. REPEAT the self-test.
No
REMOVE the jumper wire.
INSTALL the smart keyless
entry ignition relay. GO to
G12 .
Measure the voltage between the RFR module C9026-1, circuit
VDB10 (GY), harness side and ground.

G12 CHECK THE RFR MODULE COMMUNICATION CIRCUIT FOR
Measure the resistance between the RFR module C9026-1, circuit Yes
VDB10 (GY), harness side and the RFA module C3503B-3, circuit INSTALL a new RFR
VDB10 (GY), harness side; and between the RFR module C9026- module. REFER to Section
1, circuit VDB10 (GY), harness side and ground. 419-01B . CLEAR the DTCs.
REPEAT the self-test. If the
concern is still present, GO to
G13 .
No
REPAIR circuit VDB10 (GY)
for an open or short to
Is the resistance less than 5 ohms between the RFR module
and the RFA module; and greater than 10,000 ohms between
the RFR module and ground?
G13 CHECK FOR CORRECT RFA MODULE OPERATION
correctly. No
corroded connector.
Pinpoint Test H: An Individual Button/Feature Is Inoperative From The Remote Keyless Entry (RKE)
Transmitter
Normal Operation
For vehicles without Intelligent Access (IA) the remote locking and unlocking of the doors and releasing the
luggage compartment lid/liftgate latch is accomplished by the Body Control Module (BCM) receiving a
command message from the Remote Keyless Entry (RKE) transmitter. The BCM processes the command and
provides the appropriate output.
For vehicles with IA , when an RKE button is pressed on a IA key, it sends a radio signal to the Remote
Functions Receiver (RFR) module based on the user selected RKE transmitter button. The RFR module then
communicates the RKE command to the Remote Function Actuator (RFA) module over a dedicated single
circuit network. Once the RFA module receives the RKE command, it sends the command to the BCM over the
Medium Speed Controller Area Network (MS-CAN). The BCM receives the RKE command and either locks or
unlocks the doors or releases the luggage compartment lid/liftgate.
Door locks
Luggage compartment lid/liftgate release
RKE transmitter
PINPOINT TEST H: AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE

TRANSMITTER

H1 VERIFY THE DOOR LOCK OPERATION
Press the door lock control switch twice Yes
while observing the door lock operation. GO to H2 .
Do the door locks operate correctly?
No
IDENTIFY the correct symptom and GO to Symptom
Chart - Electrical .
H2 VERIFY THE LUGGAGE COMPARTMENT
LID/LIFTGATE LATCH OPERATION USING
THE BCM PID TRUNK/LIFTGATE RELEASE
OUTPUT (TRNK/LG_RLS)
Enter the following diagnostic mode on the Yes
scan tool: BCM DataLogger. REPLACE and REPROGRAM the inoperative key.
Select the BCM PID TRNK/LG_RLS and REFER to Section 419-01B for the key programming
active command the luggage procedures. INFORM the customer that any keys not
compartment lid/liftgate to release. present need to be programmed. TEST the system for
Does the luggage compartment normal operation.
lid/liftgate release?
No
GO to Pinpoint Test E .
Pinpoint Test I: The Remote Keyless Entry (RKE) Transmitter Has Poor Range Performance
Normal Operation
For vehicles without Intelligent Access (IA) the Remote Keyless Entry (RKE) transmitter sends a radio signal to
the Body Control Module (BCM) internal antenna based on the user selected RKE transmitter button. The BCM
then carries out the selected action. The RKE transmitter has a normal operating range of 20 m (66 ft).
For vehicles with IA the RKE transmitter sends a radio signal to the Remote Functions Receiver (RFR) module
based on the user selected RKE transmitter button.
RKE transmitter
Aftermarket systems
High power devices
TV/radio transmission towers
RFR module
BCM
PINPOINT TEST I: THE RKE TRANSMITTER HAS POOR RANGE PERFORMANCE
NOTE: All RKE transmitters must be present to begin diagnosis of the RKE system.
NOTE: Aftermarket or dealer-installed systems can adversely affect RKE system operation. Disconnect these
systems before diagnosing any RKE concerns.

I1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
NOTE: Make sure the RKE transmitters are Yes
those provided with the OEM system and not GO to I2 .
from an aftermarket system, or a dealer-installed
system, that may have been installed on the No
vehicle. The system cannot be tested without the
Verify the correct RKE transmitters are used with correct RKE transmitters. INFORM the
the vehicle. Compare the RKE transmitters with customer that all the correct RKE transmitters
the one shown in Handles, Locks, Latches and must be present to proceed with diagnosis of
Entry Systems in the Description and Operation the system.
portion of this section.
Are all the correct RKE transmitters present?
I2 CHECK ALL RKE TRANSMITTERS FOR POOR
RANGE PERFORMANCE
NOTE: The 20m (66 ft) measurement of range is Yes
not the standard but a guideline that clearly GO to I4 .
indicates a vehicle is experiencing normal range
performance. No
Check all RKE transmitters for normal range GO to I3 .
performance (less than 20 m [66 ft]).
Do all RKE transmitters experience poor
range?
I3 CHECK THE RKE TRANSMITTER BATTERY
Open the RKE transmitter. Yes
Do not clean off any grease from the battery REPLACE and REPROGRAM the inoperative
terminals on the back surface of the circuit board. key. REFER to Section 419-01B for the key
Verify the correct battery is used (CR2032). programming procedures. INFORM the
Remove the RKE transmitter battery and customer that any keys not present need to be
measure the voltage. programmed. TEST the system for normal
Is the voltage greater than 2.5 volts? operation.
No
INSTALL a new battery. DO NOT reprogram
the RKE transmitters (weak or dead batteries
do not erase Transmitter Identification Codes
(TICs) from memory). TEST the system for
normal operation.
I4 CHECK THE LOCATION OF THE VEHICLE AND
THE APPROACH ANGLES AROUND THE VEHICLE
Make sure the poor performance is consistent in Yes
nature and is not from one approaching angle. For vehicles without IA , GO to I5 .
The RKE transmitter range performance may be
degraded in certain locations. For example, if the For vehicles with IA , INSTALL a new RFR
vehicle is within 0.8 km (0.5 miles) of high-power module. REFER to Section 419-01B . TEST the
devices or radio/TV towers, the operating system for normal operation.
distance of the transmitters may be reduced.
Is the poor range performance consistent No
around the vehicle? The system is operating correctly at this time.
The range may have been affected by
environmental interference.
I5 CHECK FOR CORRECT BCM OPERATION
Check for: INSTALL a new BCM . REFER to Section 419-
corrosion 10 . TEST the system for normal operation.
damaged pins
pushed-out pins No
Connect all the BCM connectors and make sure The system is operating correctly at this time.
they seat correctly. The concern may have been caused by a loose
Operate the system and verify the concern is still or corroded connector.
present.
Pinpoint Test J: The Intelligent Access (IA) Feature Is Inoperative From A Front Door
Normal Operation
The Remote Function Actuator (RFA) module controls the unlocking and locking of the doors when requested
by the Intelligent Access (IA) feature. When the lock button is pressed on either front door exterior door handle,
the RFA module activates the external antenna (located in the front exterior door handles), which sends out a
low frequency signal. If an IA key is within 1 m (3 ft) of the front exterior door handle, the low frequency signal
activates the IA key. When the IA key is activated, it sends a high frequency signal back to the Remote
Functions Receiver (RFR) module. Once the RFR module receives the IA key information, it sends it to the
RFA module. If the RFA module determines that it was a programmed IA key, it sends the lock or unlock
request to the Body Control Module (BCM) over the Medium Speed Controller Area Network (MS-CAN). Once
the unlock request is received the BCM unlocks the driver door if stepped unlock is enabled, or all doors if
stepped unlock is disabled.
DTC B10D1:24 (Left Front Lock Button: Signal Stuck High) — a DTC that sets when the RFA module
detects a short to ground on the driver door lock button input circuit.
DTC B10D3:24 (Right Front Lock Button: Signal Stuck High) — a DTC that sets when the RFA module
detects a short to ground on the passenger door lock button input circuit.
DTC B11FD:1F (Left Front Exterior Antenna: Circuit Intermittent) — a DTC that sets when an open or
short is detected on one of the circuits for the driver door external antenna.
DTC B1210:1F (Right Front Exterior Antenna: Circuit Intermittent) — a DTC that sets when an open or
short is detected on one of the circuits for the passenger door external antenna.

External antenna (part of the exterior front door handle)
Lock button (part of the exterior front door handle)
IA key
RFR module
RFA module
PINPOINT TEST J: THE IA FEATURE IS INOPERATIVE FROM A FRONT DOOR
Result / Action to
Test Step
Take
J1 CHECK THE RKE OPERATION
Press the unlock button on an IA key. Yes
Does the driver door unlock? GO to J2 .
No
GO to Pinpoint Test
G.
J2 CHECK THE DOOR LOCK OPERATION
Lock and unlock the doors using the door lock control switch. Yes
Does the doors lock and unlock? GO to J3 .
No
IDENTIFY the
correct symptom
and GO to Symptom
Chart - Electrical .
J3 CHECK THE IA KEY
Place the IA key on the center console and start the engine. Yes
Does the engine start? GO to J4 .
No
REFER to Section
419-01B to
DIAGNOSE the IA
key.
J4 RETRIEVE THE RECORDED RFA MODULE DTCs FROM THE SELF-TEST
Check for recorded RFA module DTCs from the self-test. Yes
Are any DTCs present? For DTC B10D1:24
or B10D3:24, GO to
J5 .
For DTC B11FD:1F

or B1210:1F, GO to
J11 .
No
GO to J7 .
J5 REPEAT THE RFA MODULE SELF-TEST
Disconnect: LH Front Exterior Door Handle C543 (if DTC B10D1:24 is Yes
present). GO to J6 .
Disconnect: RH Front Exterior Door Handle C645 (if DTC B10D3:24 is
present). No
Enter the following diagnostic mode on the scan tool: Clear RFA Module INSTALL a new
DTCs. exterior door handle
Enter the following diagnostic mode on the scan tool: RFA Module Self-Test. for the handle in
Is DTC B10D1:24 or B10D3:24 present? question. REFER to
Exterior Front Door
Handle in this
section. TEST the
system for normal
operation.
J6 CHECK THE LOCK SWITCH INPUT CIRCUIT FOR A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: RFA Module C3503B. GO to J14 .
Measure the resistance between the LH front exterior door handle C543-4
(DTC B10D1:24), circuit CPL27 (WH/BN), harness side and ground; or No
between the RH front exterior door handle C645-4 (DTC B10D3:24), circuit REPAIR the circuit
CPL32 (GY/BU), harness side and ground. in question for a
short to ground.
CLEAR the DTCs.
REPEAT the self-
test.

J7 CHECK THE RFA MODULE PIDs LEFT FRONT LOCK BUTTON
(FL_LK_BUT) AND RIGHT FRONT LOCK BUTTON (FR_LK_BUT)
Enter the following diagnostic mode on the scan tool: RFA DataLogger. Yes
Press both of the lock switches while monitoring the RFA module PIDs GO to J11 .
FL_LK_BUT and FR_LK_BUT.
Do the PIDs indicate that the switches are being pressed? No
GO to J8 .
J8 CHECK THE LOCK SWITCH PIDs LEFT FRONT LOCK BUTTON
(FL_LK_BUT) AND RIGHT FRONT LOCK BUTTON (FR_LK_BUT)
Disconnect: Suspect Front Exterior Door Handle. Yes
Enter the following diagnostic mode on the scan tool: RFA Module INSTALL a new
DataLogger. exterior door handle
While monitoring the RFA module PID FL_LK_BUT, connect a fused jumper for the handle in
wire between the LH front exterior door handle C543-4, circuit CPL27 question. REFER to
(WH/BN), harness side and the LH front exterior door handle C543-7, circuit Exterior Front Door
GD143 (BK/VT), harness side; or while monitoring the RFA module PID Handle in this
FR_LK_BUT, connect a fused jumper wire between the RH front exterior section. TEST the
door handle C645-4, circuit CPL32 (GY/BU), harness side and the RH front system for normal
exterior door handle C645-7, circuit GD145 (BK/BU), harness side. operation.
No
GO to J9 .
Does the PID indicate that the switch is being pressed?

J9 CHECK THE LOCK SWITCH GROUND CIRCUIT FOR AN OPEN USING
THE RFA MODULE PIDs LEFT FRONT LOCK BUTTON (FL_LK_BUT) AND
RIGHT FRONT LOCK BUTTON (FR_LK_BUT)
Enter the following diagnostic mode on the scan tool: RFA Module Yes
DataLogger. GO to J10 .
While monitoring the RFA module PID FL_LK_BUT, connect a fused jumper
wire between the LH front exterior door handle C543-4, circuit CPL27 No
(WH/BN), harness side and ground; or while monitoring the RFA module REPAIR circuit
PID FR_LK_BUT, connect a fused jumper wire between the RH front GD143 (BK/VT) or
exterior door handle C645-4, circuit CPL32 (GY/BU), harness side and GD145 (BK/BU) for
ground. an open. TEST the
system for normal
operation.
Does the PID indicate that the switch is being pressed?

J10 CHECK THE LOCK SWITCH INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: RFA Module C3503B. GO to J14 .
Measure the resistance between the LH front exterior door handle C543-4,
circuit CPL27 (WH/BN), harness side and the RFA module C3503B-12, No
circuit CPL27 (WH/BN), harness side; or between the RH front exterior door REPAIR the circuit
handle C645-4, circuit CPL32 (GY/BU), harness side and the RFA module in question for an
C3503B-11, circuit CPL32 (GY/BU), harness side open. TEST the
system for normal
operation.
J11 CHECK THE EXTERNAL ANTENNA CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: LH Front Exterior Door Handle C543 (if DTC B11FD:1F is REMOVE the
present). jumper wire.
Disconnect: RH Front Exterior Door Handle C645 (if DTC B1210:1F is INSTALL the smart
present). keyless entry
Disconnect: RFA Module C3503E. ignition relay.
Disconnect: Smart Keyless Entry Ignition Relay. REPAIR the circuit
Connect a fused jumper wire between the smart keyless entry ignition relay in question for a
pin 3, circuit SBP01 (RD), Central Junction Box (CJB) face side and the short to voltage.
smart keyless entry ignition relay pin 5, circuit CDC32 (BN/YE), CJB face CLEAR the DTCs.
side. REPEAT the self-
test.
No
REMOVE the
jumper wire.
INSTALL the smart
keyless entry
ignition relay. GO to
J12 .
Measure the voltage between the LH front exterior door handle C543-2,
circuit VPK01 (BN/YE), harness side and ground, and between the LH front
exterior door handle C543-3, circuit RPK01 (WH/GN), harness side and
ground; or between the RH front exterior door handle C645-2, circuit VPK02
(VT/WH), harness side and ground, and between the RH front exterior door
handle C645-3, circuit RPK02 (GY/YE), harness side and ground.
J12 CHECK THE EXTERNAL ANTENNA CIRCUITS FOR A SHORT TO
GROUND
Measure the resistance between the LH front exterior door handle C543-2, Yes
circuit VPK01 (BN/YE), harness side and ground, and between the LH front GO to J13 .
exterior door handle C543-3, circuit RPK01 (WH/GN), harness side and
ground; or between the RH front exterior door handle C645-2, circuit VPK02 No
(VT/WH), harness side and ground, and between the RH front exterior door REPAIR the circuit
handle C645-3, circuit RPK02 (GY/YE), harness side and ground. in question for a
short to ground.
CLEAR the DTCs.
REPEAT the self-
test.
Are the resistances greater than 10,000 ohms?

J13 CHECK THE EXTERNAL ANTENNA CIRCUITS FOR AN OPEN
Measure the resistance between the suspect exterior door handle, harness Yes
side and the RFA module, harness side as follows: INSTALL a new
exterior door handle
RFA Module Suspect Front Exterior Door for the handle in
Connector-Pin Handle Connector-Pin Circuit question. REFER to
Exterior Front Door
C3503E-8 LH front exterior door handle C543- VPK01 Handle in this
2 (BN/YE) section. CLEAR the
DTCs. REPEAT the
C3503E-1 LH front exterior door handle C543- RPK01
self-test. If the
3 (WH/GN)
concern is still
C3503E-10 RH front exterior door handle C645- VPK02 present, GO to J14 .
2 (VT/WH)
C3503E-3 RH front exterior door handle C645- RPK02
No
3 (GY/YE)
REPAIR the circuit
in question for an
open. CLEAR the
DTCs. REPEAT the
self-test.
J14 CHECK FOR CORRECT RFA MODULE OPERATION
corrosion RFA module.
damaged pins REFER to Section
pushed-out pins 419-10 . TEST the
Connect all the RFA module connectors and make sure they seat correctly. system for normal
Operate the system and verify the concern is still present. operation.
No
The system is
operating correctly
at this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test K: The Luggage Compartment/Liftgate Intelligent Access (IA) Is Inoperative
Refer to Wiring Diagrams Cell 113 , Luggage Compartment Lid Release for schematic and connector
information.
Normal Operation
The Remote Function Actuator (RFA) module controls the release of the luggage compartment/liftgate when
requested by the Intelligent Access (IA) feature. When the luggage compartment/liftgate button is pressed on
the luggage compartment lid/liftgate, the RFA module activates the external antenna (located behind the rear
bumper cover), which sends out a low frequency signal. If an IA key is within 1 m (3 ft) of the antenna, the low
frequency signal activates the IA key. When the IA key is activated, it sends a high frequency signal back to the
Remote Functions Receiver (RFR) module. Once the RFR module receives the IA key information, it sends it to
the RFA module. If the RFA module determines that it was a programmed IA key, it sends the release request
to the Body Control Module (BCM) over the Medium Speed Controller Area Network (MS-CAN). Once the BCM
receives the request, it releases the luggage compartment lid/liftgate.
DTC B10C6:1F (Exterior Trunk Antenna: Circuit Intermittent) — a DTC that sets when an open or short
is detected on one of the circuits for the luggage compartment/liftgate external antenna.

Luggage compartment/liftgate IA antenna
IA key
RFR module
RFA module
PINPOINT TEST K: THE LUGGAGE COMPARTMENT/LIFTGATE IA IS INOPERATIVE

K1 CHECK THE RKE OPERATION
Press the unlock button on an IA key. Yes
Does the driver door unlock? GO to K2 .
No
GO to Pinpoint Test G .
K2 CHECK THE LUGGAGE COMPARTMENT LID/LIFTGATE LATCH
RELEASE OPERATION
Press the luggage compartment lid/liftgate release switch located Yes
on the luggage compartment lid/liftgate. GO to K3 .
Does the luggage compartment lid/liftgate latch release?
No
K3 CHECK THE IA KEY
Place the IA key on the center console and start the engine. Yes
Does the engine start? GO to K4 .
No
REFER to Section 419-01B to
DIAGNOSE the IA key.
K4 CHECK THE RFA MODULE TRUNK/LIFTGATE RELEASE
SWITCH (TR_UNLK_H_SW) PID
Enter the following diagnostic mode on the scan tool: RFA Yes
DataLogger. GO to K6 .
Press the external luggage compartment lid/liftgate release switch
while monitoring the RFA module PID TR_UNLK_H_SW. No
Does the PID indicate the switch is being pressed? GO to K5 .
K5 CHECK THE LUGGAGE COMPARTMENT LID/LIFTGATE
RELEASE SWITCH INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: RFA Module C3503B. GO to K9 .
Disconnect: BCM C2280G.
Measure the resistance between the BCM C2280G-20, circuit No
CPL10 (GN/WH), harness side and the RFA module C3503B-9, REPAIR circuit CPL10
circuit CPL10 (GN/WH), harness side. (GN/WH) for an open. TEST
operation.

K6 CHECK THE LUGGAGE COMPARTMENT ANTENNA CIRCUITS
FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: RFA Module C3503E. REMOVE the jumper wire.
Disconnect: Luggage Compartment/Liftgate IA Antenna C4082. INSTALL the smart keyless
Disconnect: Smart Keyless Entry Ignition Relay. entry ignition relay. REPAIR
Connect a fused jumper wire between the smart keyless entry the circuit in question for a
ignition relay pin 3, circuit SBP01 (RD), Central Junction Box short to voltage. CLEAR the
(CJB) face side and the smart keyless entry ignition relay pin 5, DTCs. REPEAT the self-test.
circuit CDC32 (BN/YE), CJB face side.
No
INSTALL the smart keyless
entry ignition relay. GO to K7 .
Measure the voltage between the luggage compartment/liftgate IA

antenna C4082-1, circuit VPK07 (VT), harness side and ground,
and between the luggage compartment/liftgate IA antenna C4082-
2, circuit RPK07 (GN/OG), harness side and ground.

K7 CHECK THE LUGGAGE COMPARTMENT/LIFTGATE ANTENNA
CIRCUITS FOR A SHORT TO GROUND
Measure the resistance between the luggage compartment/liftgate Yes
IA antenna C4082-1, circuit VPK07 (VT), harness side and GO to K8 .
ground, and between the luggage compartment/liftgate IA antenna
C4082-2, circuit RPK07 (GN/OG), harness side and ground. No
REPAIR the circuit in question
for a short to ground. CLEAR
test.

K8 CHECK THE ANTENNA CIRCUITS FOR AN OPEN
Measure the resistance between the luggage compartment/liftgate Yes
antenna, harness side and the RFA module, harness side as INSTALL a new luggage
follows: compartment/liftgate IA
antenna. REFER to Intelligent
RFA Module Luggage Compartment/Liftgate Access (IA) Antenna in this
Connector-Pin IA Antenna Connector-Pin Circuit section. CLEAR the DTCs.
REPEAT the self-test. If the
C3503E-16 C4082-1 VPK07 concern is still present, GO to
(VT) K9 .
C3503E-7 C4082-2 RPK07
No
(GN/OG)
REPAIR the circuit in question
for an open. CLEAR the

K9 CHECK FOR CORRECT RFA MODULE OPERATION
correctly. No
connector.
Pinpoint Test L: The Autolock Is Inoperative
Normal Operation
The Body Control Module (BCM) energizes the lock relay based on input from the ajar switches, the ignition
mode, and the vehicle speed signal. The BCM locks the doors when the following conditions are met:
All of the doors are closed

The vehicle is shifted into any gear putting the vehicle in motion
The vehicle reaches a speed greater than 7 km/h (5 mph)
Programming
Door ajar switches
Vehicle speed input
PINPOINT TEST L: THE AUTOLOCK IS INOPERATIVE

L1 CHECK THE COURTESY LAMP
OPERATION
Open and close the doors while Yes
checking the courtesy lamp GO to L2 .
operation.
Do the courtesy lamps operate No
correctly? REFER to Section 417-02 to DIAGNOSE the door ajar
inputs.
L2 CHECK THE OPERATION OF THE
SPEEDOMETER
Observe the speedometer while Yes
driving the vehicle. ENABLE the autolock feature. REFER to Autolock and Auto-
Does the speedometer operate Unlock Programming in this section. TEST the system for
correctly? normal operation.
No
REFER to Section 413-01 to DIAGNOSE the speedometer.
Pinpoint Test M: The Auto-Unlock Is Inoperative
Normal Operation
The Body Control Module (BCM) energizes the unlock relay based upon input from the door ajar switches and
the vehicle speed signal. The BCM unlocks the doors when the following conditions are met:
The vehicle speed has exceeded 20 km/h (12 mph), then dropped to 0 km/h (0 mph)
The ignition is in the OFF mode
The LH front door is opened within 10 minutes of the ignition being turned to the OFF mode
Programming
Door ajar switches
Ignition switch
Vehicle speed input
PINPOINT TEST M: THE AUTO-UNLOCK IS INOPERATIVE

M1 CHECK THE COURTESY LAMP
OPERATION
Open and close the doors while Yes
checking the courtesy lamp GO to M2 .
operation.
Do the courtesy lamps operate No
correctly? REFER to Section 417-02 to DIAGNOSE the door ajar
inputs.
M2 CHECK THE BCM IGNITION STATUS
PID
Enter the following diagnostic mode Yes
on the scan tool: BCM DataLogger. GO to M3 .
Monitor the BCM PID
(IGN_SW_RUN). No
Does the ignition status PID REFER to Section 211-05 to continue diagnosis of the
indicate RUN? ignition outputs.
M3 CHECK THE OPERATION OF THE
SPEEDOMETER
Observe the speedometer while Yes
driving the vehicle. ENABLE the autolock feature. REFER to Autolock and
Does the speedometer operate Auto-Unlock Programming in this section. TEST the system
correctly? for normal operation.
No
REFER to Section 413-01 to DIAGNOSE the speedometer.
Pinpoint Test N: The Smart Unlock Is Inoperative
Normal Operation
For vehicles without Intelligent Access (IA), when the key is in the ignition lock cylinder and the door lock
control switch is pressed to lock the doors with any door ajar the Body Control Module (BCM) automatically
unlocks all the doors. This feature helps prevent the keys from being locked in the vehicle by unlocking the
doors if the key is in the ignition and either front door is ajar.
NOTE: For vehicles with IA , the smart unlock feature is only available on late build vehicles.
For vehicles with IA , the Remote Function Actuator (RFA) module sends a message over the Medium Speed
Controller Area Network (MS-CAN) to the BCM to command all doors to unlock to prevent an IA key from being
inadvertently locked inside the vehicle. When the vehicle is locked using the door lock control switch with the
door ajar and then closed, the RFA module searches the interior of the vehicle for an IA key. The RFA module
searches the interior of the vehicle by activating all 3 low frequency passive start antennas. If an IA key is inside
the vehicle the signal from the passive start antennas activate the IA key, and it sends a signal back to the RFA
module through the Remote Functions Receiver (RFR) module. If the RFA module detects there is an IA key
inside the vehicle, it sends a command to the BCM to unlock all of the doors.
The vehicle can still be locked with the key in the ignition (vehicles without IA ) or a key inside the vehicle
(vehicles with IA ), a key in the door lock cylinder, or the lock button on another Remote Keyless Entry (RKE)
transmitter.
Key-in-ignition switch (vehicles without IA )

Door ajar switch input
IA key
PINPOINT TEST N: THE SMART UNLOCK DOES NOT OPERATE CORRECTLY

N1 CHECK THE DOOR LOCK OPERATION
Check the operation of the door locks from Yes
the door lock control switch. GO to N2 .
Do all of the doors lock and unlock?
No
IDENTIFY the correct symptom and GO to
Symptom Chart - Electrical .
N2 CHECK THE COURTESY LAMP
OPERATION
Open and close the left and right front doors Yes
while checking the courtesy lamp operation. For vehicles without IA , REFER to Section 413-01
Do the courtesy lamps operate correctly? to DIAGNOSE the key-in-ignition warning chime.
For vehicles with IA , REFER to Section 419-01B to

DIAGNOSE the IA key and passive start antennas.
No
REFER to Section 417-02 to DIAGNOSE the door
ajar inputs.
Pinpoint Test O: The Luggage Compartment/Liftgate Smart Unlock Is Inoperative
Normal Operation
The luggage compartment/liftgate smart unlock feature prevents the luggage compartment/liftgate from latching
when an Intelligent Access (IA) key is detected inside the luggage compartment. When the Remote Function
Actuator (RFA) module detects the luggage compartment lid/liftgate is closed with the doors locked, it searches
the luggage compartment using the low frequency passive start antenna located behind the rear seat for an IA
key. If an IA key is inside the luggage compartment the signal from the passive start antenna activates the IA
key, and it sends a signal back to the RFA module through the Remote Functions Receiver (RFR) module. If an
IA key is detected, the luggage compartment lid/liftgate releases. To override the luggage compartment/liftgate
smart unlock and intentionally latch the luggage compartment lid/liftgate, unlock the doors and then close the
luggage compartment lid with the IA key inside.
Luggage compartment lid/liftgate ajar switch input

Rear passive start antenna
IA key
PINPOINT TEST O: THE LUGGAGE COMPARTMENT/LIFTGATE SMART UNLOCK DOES NOT OPERATE
CORRECTLY

O1 CHECK THE LUGGAGE COMPARTMENT AJAR
MESSAGE IN THE MESSAGE CENTER
Ignition ON. Yes
Observe the message center while opening and REFER to Section 419-01B to DIAGNOSE the
closing the luggage compartment lid. IA key and the rear passive start antenna.
Does the ajar message in the message center
operate correctly? No
REFER to Section 413-01 to DIAGNOSE the
ajar indicator.
Pinpoint Test P: Hard To Open/Close Door From Either Door Handle

Normal Operation
The door latch can be actuated from the interior or exterior door handle. When actuated, the door latch releases
and allows the door to open. If the door latch or the door hinges have insufficient lubrication or if the striker or
door are misaligned, it causes extra force to be used when opening or closing the door.
Door alignment
Door hinges
Striker adjustment
Door latch
PINPOINT TEST P: HARD TO OPEN/CLOSE DOOR FROM EITHER DOOR HANDLE

P1 CHECK THE LATCH OPERATION FROM BOTH DOOR
HANDLES
Open the door using both the interior and exterior door Yes
handles. If the door is difficult/does not open
Does the door open normally from one of the door from the exterior door handle, GO to
handles? Pinpoint Test Q .
If the door is difficult/does not open

from the interior door handle, GO to
Pinpoint Test R .
No
If the door is hard to open from both
door handles, GO to P2 .
P2 CHECK THE LATCH OPERATION
Open the door. Yes
Using a screwdriver, fully close the latch (2 clicks). GO to P4 .
No
GO to P3 .
Verify the latch releases easily while pulling on the

interior/exterior door handle.
Does the latch release easily?
P3 CHECK THE LATCH OPERATION AFTER LUBRICATION
Lubricate the door latch. Refer to Latch Lubrication in this Yes
section. The concern was caused by an
Using a screwdriver, fully close the latch (2 clicks). insufficiently lubricated door latch.
No
INSTALL a new door latch. REFER
to Front Door Latch or Rear Door
Latch in this section. TEST the
Verify the latch releases easily while pulling on the

interior/exterior door handle.
Does the latch release easily?
P4 CHECK THE STRIKER ADJUSTMENT
Check the adjustment of the striker. Refer to Section 501- Yes
03 . GO to P5 .
Is the striker adjusted correctly?
No
ADJUST the striker as necessary.
operation.
P5 CHECK THE DOOR ALIGNMENT
Check the alignment of the door. Refer to Section 501-03 . Yes
Is the door aligned correctly? LUBRICATE the door hinges. TEST
the system for normal operation.
No
ADJUST the door as necessary.
operation.
Pinpoint Test Q: A Door Is Difficult/Does Not Open From The Exterior Door Handle
Normal Operation
The exterior door handle is connected to the door latch with an actuating cable. When the exterior door handle
is pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open.
Binding cable
Exterior door handle reinforcement
Door latch
PINPOINT TEST Q: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE EXTERIOR DOOR HANDLE

Q1 CHECK THE LATCH OPERATION
FROM BOTH DOOR HANDLES
NOTE: The rear door interior door Yes

handle has to be pulled twice to If the door is difficult/does not open from only the exterior door
unlock and unlatch. handle, GO to Q2 .
Open and close the door using If the door is difficult/does not open from only the interior door
both the interior and exterior door handle, GO to Pinpoint Test R .
handles.
Does the door open normally No
from one of the door handles? If the door does not operate correctly from both door handles,
GO to Pinpoint Test P .
Q2 CHECK THE EXTERIOR DOOR
HANDLE AND CABLE OPERATION
Disconnect the exterior door Yes
handle actuating cable from the GO to Q3 .
door latch.
Operate the exterior door handle No
while observing the linkage and INSTALL a new door latch. REFER to Front Door Latch or
cable. Rear Door Latch in this section. TEST the system for normal
Are any of the exterior door operation.
handle components or linkages
binding or broken?
Q3 CHECK THE EXTERIOR DOOR
HANDLE REINFORCEMENT
handle actuating cable from the INSTALL a new exterior door handle cable. TEST the system
exterior door handle for normal operation.
reinforcement.
Pull and release the exterior door No
handle. INSTALL a new exterior door handle reinforcement. REFER to
Does the exterior door handle Door Handle Reinforcement — Exterior, Front or Door Handle
operate correctly? Reinforcement — Exterior, Rear in this section. TEST the
Pinpoint Test R: A Door Is Difficult/Does Not Open From The Interior Door Handle
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open.
Broken or binding cable/linkage

Door latch
PINPOINT TEST R: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE

R1 CHECK THE LATCH OPERATION FROM
BOTH DOOR HANDLES
NOTE: The rear door interior door handle Yes

has to be pulled twice to unlock and If the door is difficult/does not open from only the
unlatch. interior door handle, GO to R2 .
For the rear doors, make sure the If the door is difficult/does not open from only the
childlock is in the unlock position. exterior door handle, GO to Pinpoint Test Q .
Open the door using both the interior and
exterior door handles. No
Does the door open normally from one If the door does not operate correctly from both door
of the door handles? handles, GO to Pinpoint Test P .
R2 CHECK THE INTERIOR DOOR HANDLE

AND CABLE/LINKAGE OPERATION
Remove the door trim panel. Refer to Yes
Section 501-05 . REPAIR as necessary. TEST the system for normal
Install the interior door handle back onto operation.
the release cable.
Operate the interior door handle while No
observing the cable/linkage. INSTALL a new door latch. REFER to Front Door
Are any of the interior door handle Latch or Rear Door Latch in this section. TEST the
components or cable/linkages binding system for normal operation.
or broken?
Pinpoint Test S: Exterior Door Release Handle Sticks
Normal Operation
The exterior door handle is connected to the door latch with an actuating cable. When the exterior door handle
is pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open. The handle has a return spring to make sure the handle returns to a closed position.
Binding cable
Broken handle return spring
Door latch
PINPOINT TEST S: EXTERIOR DOOR RELEASE HANDLE STICKS

S1 CHECK THE EXTERIOR DOOR
HANDLE AND LINKAGE OPERATION
handle actuating cable from the GO to S2 .
door latch.
Operate the exterior door handle No
while observing the linkage. INSTALL a new door latch. REFER to Front Door Latch or
Are any of the exterior door Rear Door Latch in this section. TEST the system for normal
handle components or linkages operation.
binding?
S2 CHECK FOR A BROKEN RETURN
SPRING
handle actuating cable from the INSTALL a new exterior door handle cable. TEST the system
exterior door handle for normal operation.
reinforcement.
Pull and release the exterior door No
handle INSTALL a new exterior door handle reinforcement. REFER to
Does the exterior door handle Door Handle Reinforcement — Exterior, Front or Door Handle
return to a closed position once Reinforcement — Exterior, Rear in this section. TEST the
released? system for normal operation.
Pinpoint Test T: Interior Door Release Handle Sticks
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open. The handle has a return spring to make sure the handle returns to a closed position.
Binding cable
Broken handle return spring
Door latch
PINPOINT TEST T: INTERIOR DOOR RELEASE HANDLE STICKS

T1 CHECK FOR A BROKEN RETURN
SPRING
Remove the interior door handle. Refer to Yes
Interior Door Handle — Front or Interior GO to T2 .
Door Handle — Rear in this section.
Pull and release the interior door handle. No
Does the interior door handle return to INSTALL a new interior door handle. REFER to Interior
a closed position once released? Door Handle — Front or Interior Door Handle — Rear
in this section. TEST the system for normal operation.
T2 CHECK THE INTERIOR DOOR HANDLE
CABLE OPERATION
Remove the interior door latch release Yes
cable. INSTALL a new door latch. REFER to Front Door
Observe the door latch release cable for Latch or Rear Door Latch in this section. TEST the
any damage or binding. system for normal operation.
Is the door latch release cable OK?
No
INSTALL a new interior door handle cable. TEST the
Pinpoint Test U: Squeak/Rattle/Chucking Noise From Door
Door alignment
Striker adjustment
Door latch
PINPOINT TEST U: SQUEAK/RATTLE/CHUCKING NOISE FROM DOOR

U1 CHECK FOR ANY LOOSE COMPONENTS
Remove the door trim panel. Refer to Section 501-05 . Yes
Inspect inside the door for any loose components. REPAIR as necessary. TEST the
Are there any loose components inside the door? system for normal operation.
No
GO to U2 .
U2 CHECK THE STRIKER ADJUSTMENT
Check the adjustment of the striker. Refer to Section 501- Yes
03 . GO to U3 .
Is the striker adjusted correctly?
No
ADJUST the striker as necessary.
U3 CHECK THE DOOR ALIGNMENT
Check the alignment of the door. Refer to Section 501- Yes
03 . GO to U4 .
Is the door aligned correctly?
No
ADJUST the door as necessary. TEST
U4 CHECK THE LATCH OPERATION AFTER
LUBRICATION
Lubricate the door latch. Refer to Latch Lubrication in this Yes
section. INSTALL a new door latch. REFER to
Using a screwdriver, fully close the latch (2 clicks). Front Door Latch or Rear Door Latch in
this section. TEST the system for
normal operation.
No
The concern was caused by an
insufficiently lubricated door latch.
Operate the door latch and listen for the noise.

Is the original noise still present after the latch is
lubricated?
Pinpoint Test V: Manual Door Lock Cylinder Inoperative
Normal Operation
The door lock cylinder is connected to the door latch via a lock rod and can be used to manually lock/unlock a
door.
Bent or binding lock rod and lever

Door lock cylinder
Door latch
PINPOINT TEST V: MANUAL DOOR LOCK CYLINDER INOPERATIVE

V1 CHECK THE LOCK AND UNLOCK
OPERATION
Insert a key into the lock cylinder Yes
and rotate the lock cylinder to the GO to V2 .
lock and unlock positions.
Does the door lock cylinder No
freely rotate without locking and GO to V3 .
unlocking the door?
V2 CHECK THE DOOR LOCK
CYLINDER
Yes
Remove the door lock cylinder. INSTALL a new door lock cylinder. REFER to Door Lock
Refer to Door Lock Cylinder in this Cylinder in this section. TEST the system for normal
section. operation.
Operate the door lock cylinder with
the key while holding the lever on No
the lock cylinder. GO to V5 .
Does the key in the door lock
cylinder rotate freely while the
lever is stationary?
V3 CHECK THE LOCK CYLINDER
OPERATION AFTER LUBRICATION
Spray a lock lubricant such as Yes
Motorcraft™ XL-1 into the lock The concern was caused by an insufficiently lubricated lock
cylinder opening for a couple cylinder. SPRAY a multi-purpose grease such as Motorcraft™
seconds. XL-5 into the lock cylinder for a couple seconds to provide
Operate the door lock cylinder with long term lubrication.
the key.
Does the door lock and unlock No
using the door lock cylinder? GO to V4 .
CYLINDER
Remove the door lock cylinder. Yes
Refer to Door Lock Cylinder in this GO to V5 .
section.
Operate the door lock cylinder with No
the key. INSTALL a new door lock cylinder. REFER to Door Lock
Does the door lock cylinder Cylinder in this section. TEST the system for normal
rotate freely? operation.
CYLINDER LINKAGE
Operate the door lock cylinder Yes
while observing the linkage. REPAIR as necessary. TEST the system for normal
Is the door lock cylinder rod and operation.
lever bent or binding?
No
INSTALL a new door latch. REFER to Front Door Latch in this
section. TEST the system for normal operation.
Pinpoint Test W: Ignition Key Cannot Be Returned To OFF Position
Refer to Wiring Diagrams Cell 37 , Shift Interlock for schematic and connector information.
Normal Operation
The ignition switch contains a key removal inhibit solenoid. The solenoid prevents the ignition lock cylinder to
be turned to lock and the key removed any time the transmission selector lever is in any position except PARK
(P) (automatic transaxle only). The inhibit solenoid receives voltage at all times from Central Junction Box
(CJB) fuse 1 (15A). When the transmission selector lever is in any gear except PARK (P), the selector switch
closes, supplying ground to the solenoid.

Transmission selector lever
Binding steering column components
Ignition switch
PINPOINT TEST W: IGNITION KEY CANNOT BE RETURNED TO OFF POSITION

W1 CHECK FOR AN ENERGIZED KEY REMOVAL
INHIBIT SOLENOID
Remove CJB fuse 1 (15A). Yes
Attempt to turn the ignition key to the RUN REFER to Section 211-05 to continue diagnosis of
position and then back to the LOCK position the key removal inhibit solenoid system.
and remove the key.
Does the ignition lock cylinder turn to the No
lock position and can the key be removed? GO to W2 .
W2 CHECK THE IGNITION LOCK CYLINDER
FOR BINDING
Remove the ignition lock cylinder. Refer to Yes
Ignition Lock Cylinder in this section. REFER to Section 211-05 to continue diagnosis of
Rotate the ignition lock cylinder through all the steering column for any binding steering
positions using the key. column components or ignition switch.
Does the ignition lock cylinder freely rotate
through all positions and can the key be No
removed from the lock cylinder? INSTALL a new ignition lock cylinder. REFER to
Ignition Lock Cylinder in this section. TEST the
Autolock and Auto-Unlock Programming
NOTE: Make sure the ignition is in the OFF mode and the doors are closed and unlocked.
NOTE: When programming the autolock feature, carry out the following steps within 30 seconds or the
procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming
sessions.
1. Turn the ignition from OFF to RUN mode.
2. Press the door lock control switch 3 times.
3. Turn the ignition from RUN to OFF mode.
4. Press the door lock control switch 3 times.
5. NOTE: A chime sounds as acknowledgement that programming mode has been entered. The safety belt
must be engaged otherwise the Belt-Minder® chime will take priority over other chimes.
Turn the ignition to the RUN position. The module is now in programming mode.
6. Once in programming mode, the autolock or auto-unlock feature can be programmed independently of
each other.
To program the autolock feature, press the door lock control switch for greater than 2 seconds
and release. Each long press of the door lock control switch toggles the state of the autolocking
feature between enabled and disabled. A chime sounds when the feature is enabled or disabled.
To program the auto-unlock feature, press the door lock control switch for less than 1 second and
release. Each short press of the door lock control switch toggles the state of the auto-unlocking
feature between enabled and disabled. A chime sounds when the feature is enabled or disabled.
7. Turn the ignition to the OFF mode to exit programming. If a setting was toggled, a chime will be heard.
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: A maximum of 8 Remote Keyless Entry (RKE) transmitters can be programmed to the vehicle.
Programming must be done at the same time for all the RKE transmitters.
NOTE: This procedure is for programming the RKE transmitter portion of the Integrated Keyhead
Transmitter (IKT). The RKE transmitter for an Intelligent Access (IA) key is programmed automatically
during key programming. Refer to the key programming procedures in Section 419-01B .
NOTE: There is an audible feedback chime heard indicating that the programming mode for the RKE
transmitter portion of the Integrated Keyhead Transmitter (IKT) has been initiated. The chime is also
heard for every key that is programmed and when programming of a RKE transmitter was successful.
The chime is not heard if the vehicle has not been transitioned from transport to NORMAL mode.
1. Close all doors.
2. Buckle the front safety belts.
3. Use the door lock control switch to electronically unlock all door locks.
4. Turn the ignition from the OFF to RUN position 4 times in rapid succession (within 6 seconds),
with the fourth turn ending in OFF.
5. NOTE: If no action is taken within 10 seconds after a transmitter has been programmed, the
programming sequence ends.
Within 10 seconds, press any button on the RKE transmitter to be programmed. After the first
RKE transmitter is programmed, press a button on each subsequent RKE transmitter to be
programmed (each within 10 seconds of each other).
6. NOTE: If programming mode is exited and no key is learned, all keys (if one or two were
programmed) are erased for RKE transmitter operation.
Exiting the programming mode is accomplished if one of the following occurs:

The key transitions to the RUN position.
10 seconds have passed since entering programming mode or since the last RKE
transmitter was programmed.
The maximum number (8) of RKE transmitters have been programmed.
7. Check the operation of the transmitter. If the door locks do not respond for the programmed RKE
transmitter(s), wait several seconds and press the button again. If the door locks still fail to
respond, refer to Handles, Locks, Latches and Entry Systems in this section.
Stepped Unlock Programming
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the
Remote Keyless Entry (RKE) transmitter simultaneously for 4 seconds.
The turn signals flash twice to indicate the mode change.
2. Repeat Step 1 to enable/disable the stepped unlocking feature.

Latch Lubrication
Material
Item Specification
XG-4 and/or XL-5
1. Open the door.
2. Using a screwdriver, fully close the latch (2 clicks).
3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using either the interior or exterior door handle.
5. Open and close the door several times to circulate the lubricant inside the latch.
6. Wipe off any excess grease.

Hood Latch and Components — Exploded View

1 W702928 Hood latch bolts (2 required)
2 16700 Hood latch
3 16916 Hood latch release handle and cable

Hood Latch
1. NOTE: Mark the hood latch position prior to removal of the hood latch bolts.
Remove the 2 hood latch bolts.

2. Remove the hood latch.

Disconnect the hood latch from the hood latch cable.

When the hood latch is installed, the latch adjustment must be checked to make sure the
latch is installed and aligned correctly.
Hood Latch Release Handle
1. Using a suitable tool, depress the hood latch release handle retaining tab.
2. Remove the hood latch release handle.

Pull the hood latch release handle rearward.
3. Disconnect the hood release cable from the hood latch release handle.

Front Door Handles, Locks and Latches — Exploded View
NOTE: Vehicle without Intelligent Access (IA) shown, Vehicle with IA similar.

1 224A44 RH/ 224A45 LH Exterior front door handle bezel
2 21990 RH (if equipped)/ Door lock cylinder
21991LH
3 22404 (non-PEPS)/ Exterior front door handle
26604 (PEPS)
4 W703168 Exterior front door handle reinforcement
screw
5 W710048 Exterior front door handle bolt cover
6 — Exterior front door handle bolt (Part of
26684 RH/ 26685 LH)
7 W715340 Front door latch screws (3 required)
8 22464 RH/ 22465 LH Exterior front door handle reinforcement
9 21978 RH/ 21979 LH Exterior front door handle reinforcement
carrier
10 221A00 Interior front door handle actuating cable
11 218B26 Exterior front door handle actuating cable
12 — Front door latch mounting screw (2
required)
13 218812 RH/ 218813 LH Front door latch

Front Door Latch
1. Remove the exterior front door handle reinforcement. For additional information, refer to Door
Handle Reinforcement — Exterior, Front in this section.
2. Remove the 2 screws and separate the front door latch from the exterior front door handle
reinforcement carrier.
3. Detach the exterior front door handle cable from the front door latch and separate the front door
latch from the exterior front door handle reinforcement carrier.

Exterior Front Door Handle
All vehicles
1. Remove the exterior front door handle bezel bolt cover.
2. NOTICE: Overtightening the exterior front door handle bezel bolt will result in the increased opening
effort of the door handle and possible damage to the exterior front door handle bezel.
Loosen, but do not remove, the exterior front door handle bezel bolt.
To install, tighten the exterior front door handle bezel bolt by hand, until the exterior front door handle
bezel is no longer loose.
3. Pull outward and remove the exterior front door handle bezel.
4. Remove the exterior front door handle.

Pull the exterior front door handle rearward and then outward.
Vehicles with Intelligent Access (IA)
5. Position the exterior door handle electrical connector carrier in order to access the exterior door handle
electrical connector.
6. Disconnect the exterior door handle electrical connector.
All vehicles

Door Handle Reinforcement — Exterior, Front
1. NOTE: Do not separate the window regulator or window regulator motor from the front door
carrier.
Remove the window regulator. For additional information, refer to Section 501-11 .
2. Remove the exterior front door handle. For additional information, refer to Exterior Front Door
Handle in this section.
3. Loosen, but do not remove, the exterior front door handle reinforcement screw.
4. Remove the 3 front door latch screws.

5. Remove the door latch, carrier, and reinforcement assembly from vehicle.
Pull the front edge of the door latch, carrier, and reinforcement assembly inward and then
toward the front of the vehicle.
6. Disconnect exterior front door handle cable from the exterior front door handle reinforcement.
7. Separate the exterior front door handle reinforcement from the exterior front door handle

Interior Door Handle — Front

1 237W10 Interior door handle screw cover
2 46058 Interior door handle screw
3 22600 RH/ 22601 LH Interior door handle
4 221A00 Interior door handle cable
1. Remove the interior door handle screw cover.
2. Remove the interior door handle screw.
3. NOTICE: Do not pry outward at the bottom of the front interior door handle. Otherwise, damage
to the front interior door handle may occur.
Using a non-marring tool, pry outward at the top of the front interior door handle.
4. Disconnect door latch cable from the front interior door handle.
5. If equipped, disconnect the electrical connector.

Door Lock Cylinder
1. Remove the exterior front door handle bezel bolt cover.
2. Loosen, but do not remove, the exterior front door handle bezel bolt.
3. Pull outward and remove the exterior front door handle bezel.
4. Separate the door lock cylinder from the exterior front door handle.

Rear Door Handles, Locks and Latches — Exploded View

1 224A44 Exterior rear door handle bezel
2 26604 Exterior rear door handle
3 — Exterior rear door handle reinforcement bolt (Part
of 26684 RH/ 26685 LH)
4 W710048 Exterior rear door handle bezel bolt cover
5 W703168 Exterior rear door handle bezel bolt
6 W715340 Rear door latch screws (3 required)
7 265B10 Exterior rear door handle actuating cable
8 26684 RH/ 26685 Exterior rear door handle reinforcement
LH
9 224A52 RH/ Exterior rear door handle reinforcement carrier
224A53 LH
10 264B58 Interior rear door handle actuating cable
11 — Rear door latch mounting screw (2 required)
12 26412 RH/ 26413 Rear door latch
LH

Rear Door Latch
1. Remove the exterior rear door handle reinforcement. For additional information, refer to Door
Handle Reinforcement — Exterior, Rear .
2. Remove the 2 screws and separate the rear door latch from the exterior rear door handle
3. Detach the exterior rear door handle cable from the rear door latch and separate the rear door
latch from the exterior rear door handle reinforcement carrier.

Exterior Rear Door Handle
1. Remove the exterior rear door handle bezel bolt cover.
2. NOTICE: Overtightening the exterior front door handle bezel bolt will result in the
increased opening effort of the door handle and possible damage to the exterior front door
handle bezel.
Loosen, but do not remove, the exterior rear door handle bezel bolt.
To install, tighten the exterior front door handle bezel bolt by hand, until the exterior front
door handle bezel is no longer loose.
3. Pull outward and remove the exterior rear door handle bezel.
4. Remove the exterior rear door handle.

Pull the exterior rear door handle rearward and then outward.

Door Handle Reinforcement — Exterior, Rear
1. NOTE: Do not separate the window regulator or window regulator motor from the front door
carrier.
Remove the window regulator. For additional information, refer to Section 501-11 .
2. Remove the exterior rear door handle. For additional information, refer to Exterior Rear Door
Handle in this section.
3. Loosen, but do not remove, the exterior rear door handle reinforcement screw.
4. Remove the 3 front door latch screws.

5. Remove the door latch, door carrier, and reinforcement assembly from vehicle.
Pull the front edge of the latch, carrier, and reinforcement assembly inward and then
toward the front of the vehicle.
6. Disconnect exterior rear door handle cable from the exterior rear door handle reinforcement.
7. Separate the exterior rear door handle reinforcement from the exterior rear door handle

Interior Door Handle — Rear
NOTE: RH side shown, LH side similar.

1 237W10 Rear interior door handle screw cover
2 46058 Rear interior door handle screw
3 22600 RH/ 2260 1LH Rear interior door handle
4 264B58 Rear interior door handle cable
2. Release the 3 retaining tabs and remove the rear interior door handle from the rear door trim panel.

Liftgate Latch

1 W705125 Liftgate latch bolt
2 442A66 Liftgate latch
3 W500212 Liftgate striker bolt
4 404B12 Liftgate striker
2. Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications, and Special
Tools. Items in the exploded views may not be listed in order of removal.
Liftgate Release Switch

1 14018 Liftgate release switch
1. Remove the liftgate applique. For additional information, refer to Section 501-08 .
2. Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items
in the exploded views may not be listed in order of removal.
Luggage Compartment Lid Latch

1 W705125 Luggage compartment latch bolt
2 442A66 Luggage compartment latch
3 W500212 Luggage compartment striker bolt
4 404B12 Luggage compartment striker
1. Remove the 10 pin-type retainers and the luggage compartment lid trim panel.
Luggage Compartment Lid Release Switch

1 19B514 Luggage compartment lid release switch
1. Remove the luggage compartment lid applique. For additional information, refer to Section 501-08 .
2. Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items
in the exploded views may not be listed in order of removal.
Ignition Lock Cylinder

1 11582 Ignition lock cylinder
1. Remove the PATS transceiver. For additional information, refer to Section 419-01B .
2. Remove the ignition lock cylinder.

1. Position the ignition key to the ACC position.
2. Inset a suitable tool into the ignition lock cylinder release access hole and depress the
ignition lock cylinder release button.
3. Pull outward on the ignition key and remove the ignition lock cylinder.
Ignition Lock Cylinder Housing

1 W709942 Ignition lock cylinder housing bolt
2 3F527 Ignition lock cylinder housing
1. Remove the steering wheel and steering column shrouds. For additional information, refer to Section
211-04 .
2. Remove the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to Section
419-01B .
3. Remove the ignition lock cylinder. For additional information, refer to Ignition Lock Cylinder in this
section.
4. Remove the ignition switch and the steering column multifunction switch. For additional information, refer
to Section 211-05 .
5. Remove the wiper/washer switch. For additional information, refer to Section 501-16 .
6. Remove the steering column switch carrier. For additional information, refer to the steering column
exploded view in Section 211-05 .
7. NOTE: Clean all metal shavings and foreign material after cutting a slot into the ignition lock cylinder
housing bolt.
Cut a slot into the head of the ignition lock cylinder housing bolt.
8. Remove and discard the ignition lock cylinder housing bolt.

To install, tighten the new bolt until the head of the bolt shears off.
9. Remove the ignition lock cylinder housing.

Door Lock Control Switch
1. The door lock control switch is integrated into the FCIM . For additional information, refer to
Section 415-00 .
Intelligent Access (IA) Antenna
Part
1 16K262 Pin-type retainers (2 required)
2 — Intelligent Access (IA) antenna electrical connector (part of
14D559)
3 15K603 IA antenna
1. Remove the rear bumper cover. For additional information, refer to Section 501-19 .
2. Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications, and Special Tools.
Items in the exploded views may not be listed in order of removal.
SECTION 501-16: Wipers and Washers 2011 Fiesta Workshop Manual
Material
Capacity
Motorcraft® Premium Quality — —
Windshield Washer Fluid
(Canada)
CXC-37-(A, B, D, and F)
(Canada)
Motorcraft® Premium WSB-M8B16- —
Windshield Washer Concentrate A2
(US)
ZC-32-A or B (US)
Front wiper pivot arm nut 24 18 —
Rear wiper motor bolts 9 — 80
Rear wiper pivot arm nut 15 — 133
Washer reservoir bolts 3 — 27
Front wiper mounting arm and pivot shaft center bolt 24 18 —
Front wiper mounting arm and pivot shaft end bolts 5 — 44
Wipers and Washers
The wiper and washer system consists of the following components:
Front/rear washer pump and reservoir (located in the front right corner of the engine compartment)
Front and rear wiper pivot arms
Windshield and rear window wiper motors
Windshield wiper mounting arm and pivot shaft assembly
Wiper/washer switch
Front and rear wiper blades
The wiper and washer system functions are activated by the wiper/washer switch which provides an input to
the BCM . The BCM then provides an output to operate the desired wiper system feature. The windshield
and rear window wiper systems share the window washer pump and cannot be used simultaneously.
The windshield wiper system offers 4 wipe modes:
Single
Intermittent (6 settings)
Normal
Fast
When activated by the wiper/washer switch, the rear wiper offers 3 wipe modes which are based on the
windshield wiper mode selected.
4 second rest between wipes (windshield wiper system in off or normal modes)
Intermittent (6 settings based on windshield wiper system setting)
Continuously (windshield wiper system in fast mode)
Wipers and Washers
Special Tool(s)
Flex Probe Kit

FLU77-IV or equivalent

tool
Windshield Wiper System
The wiper and washer system functions are activated by the wiper/washer switch which provides an
input to the Body Control Module (BCM). The BCM then provides an output to operate the desired wiper
system feature. The windshield and rear window wiper systems share the window washer pump and
cannot be used simultaneously. The windshield wiper system only operates when the ignition is ON.
The windshield wiper system offers 4 wipe modes:
Single
Intermittent (6 settings)
Normal
Fast
The wiper system setting of the wiper/washer switch is transmitted to the BCM to actuate the wiper
motor and set the wiper speed. Normal wipe speed remains available in the event of BCM failure.
Windshield Intermittent Wipe
The windshield intermittent wipe setting of the wiper/washer switch is transmitted to the BCM to actuate
the wiper motor and set the wiper delay interval. The wiper/washer switch has 6 intermittent wiper delay
settings ranging from a short to a long delay:
Level 1 delay = 1.2 seconds
Level 2 delay = 4 seconds
Level 5 delay = 17.5 seconds
Windshield Wiper Motor
The integrated park switch is directly connected to the BCM . The windshield wiper motor park switch
contacts are open in all wiper motor positions except PARK. When the windshield wiper motor park
switch contacts are open, the windshield wiper motor remains switched on even if a signal from the BCM
requests the wipers to stop. In PARK position, the windshield wiper motor park switch contacts create a
ground connection. The BCM recognizes this ground connection and switches the windshield wiper
motor off.
Front Washer System
When the front washer system is switched ON, the BCM switches the window washer pump ON. The
windshield and rear window wiper systems share the window washer pump and cannot be used
simultaneously. The BCM delays wiper operation for 360 ms after operation of the wiper/washer switch
washer setting. If the wiper/washer switch washer setting is not operated for at least 360 ms, the BCM
does not switch the windshield wiper motor ON. The BCM activates the windshield wiper motor for as
long as the wiper/washer switch washer setting is operated, up to 10 seconds maximum. After the
washer pump is turned OFF, the BCM allows the windshield wipers to wipe 4 more times. An additional
courtesy wipe follows the 4 wipes after a brief pause.
Rear Window Wiper System
The rear window wiper system only operates if the ignition is ON. The position that the wiper/washer
switch is in for the front windshield wipers determines the action of the rear wiper:
When the wiper/washer switch is in a position that commands the rear wiper ON and the front
windshield wipers are in the OFF position, the rear wiper is activated by the BCM with a 4 second
delay between wipes.
When the front windshield wipers are being operated in the intermittent mode, the rear wiper also
operates in the intermittent mode. The rear wiper reacts along with the front windshield wipers to
changes in the position of the rotary interval switch. When the rotary switch is positioned for a
long delay between wipes, the rear wiper also operates with a long delay between wipes. The
same is true for a short delay between wipes.
When the front windshield wipers are operated at normal speed, the rear wiper operates with a 4
second delay between wipes when switched on.
When the front windshield wipers are operated at high speed, the rear wiper operates
continuously when switched on.
Rear Washer System
When the rear wash system is switched ON, the BCM supplies power to the washer pump. Reversing
the polarity of the pump enables the washing fluid to flow to the rear washer jet instead of the front
washer jets. The BCM activates the window wiper for as long as the window washer switch is operated.
The window washer pump is switched OFF after a maximum of 10 seconds. After clearance from the
switch, the BCM allows the wiper to wipe 2 or 3 more times.
Rear Wiper Motor
The integrated park switch is directly connected to the BCM . The rear window wiper motor park switch
contacts are closed in all rear window wiper motor positions except PARK. When the rear window wiper
motor park switch contacts are closed, the rear window wiper motor is supplied with a voltage by the
BCM . When the rear window wiper motor reaches the PARK position, the park switch contacts open
and the power supply is interrupted by the BCM . While the wiper/washer switch remains in the rear
washer position, the rear window wiper motor is again supplied with a voltage by the BCM and continues
to run. This process is repeated during every revolution of the rear window wiper motor.

Wiper/washer switch Central Junction Box (CJB) fuses:
Wiper linkage 11 (20A)
Windshield washer pump hoses 13 (15A)
Windshield washer nozzles 15 (15A)
Rear window washer pump hoses 21 (10A)
Rear window washer nozzles Body Control Module (BCM)
Washer reservoir Wiring, terminals or connectors
Wiper/washer switch
Windshield wiper motor
Rear window wiper motor
Washer pump
4. NOTE: The windshield wiper motor does not communicate on the network. The windshield wiper
motor provides wiper on/off status directly to the Body Control Module (BCM).
NOTE: Make sure to use the latest scan tool software release.

tool.

verify the ignition is in ON.
refer to Section 418-00 to diagnose no response from the BCM .

Section 418-00 .
If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble
Codes (CMDTCs).
DTC Chart

B1008:92 Wiper Mode Switch: Performance or Incorrect Operation GO to Pinpoint Test E .
B1051:92 Front Washer Switch: Performance or Incorrect Operation GO to Pinpoint Test G .
B1052:92 Rear Washer Switch: Performance or Incorrect Operation GO to Pinpoint Test G .
B11DC:92 Rear Wiper Mode Switch: Performance or Incorrect GO to Pinpoint Test D .
Operation
B1C45:24 Front Wiper Park Position Switch: Signal Stuck High GO to Pinpoint Test I .
B1C53:13 Front Wiper Intermittent Data: Circuit Open GO to Pinpoint Test E .
All other — REFER to Section 419-
DTCs 10 .
Symptom Chart
Symptom Chart
The wipers are inoperative — Fuse(s) GO to
windshield Wiring, terminals Pinpoint
or connectors Test A .
Wiper/washer
switch
Windshield wiper
motor
Body Control
Module (BCM)
The wipers are inoperative — rear Fuse(s) GO to
window Wiring, terminals Pinpoint
or connectors Test B .
Wiper/washer
switch
Rear window
wiper motor
BCM
The wipers stay ON continuously — Wiring, terminals GO to
windshield or connectors Pinpoint
Wiper/washer Test C .
switch
Windshield wiper
motor
BCM
The wipers stay ON continuously — Wiring, terminals GO to
rear window or connectors Pinpoint
Wiper/washer Test D .
switch
Rear window
wiper motor
BCM
The high/low/intermittent wiper Wiring, terminals GO to
speeds do not operate correctly — or connectors Pinpoint
windshield Wiper/washer Test E .
switch
Windshield wiper
motor
BCM
The continuous or intermittent wiper Wiring, terminals GO to
speeds do not operate correctly — or connectors Pinpoint
rear window Wiper/washer Test F .
switch
Rear window
wiper motor
BCM
The washer pump is inoperative — Wiring, terminals GO to
front/rear or connectors Pinpoint
Wiper/washer Test G .
switch
Washer pump
BCM
The wipers will not PARK at the Wiring, terminals GO to
correct position — windshield or connectors Pinpoint
Windshield wiper Test H .
motor
Linkage
BCM
The wipers will not PARK at the Wiring, terminals GO to
correct position — rear window or connectors Pinpoint
Rear window Test I .
wiper motor
BCM
Pinpoint Tests
Pinpoint Test A: The Wipers Are Inoperative — Windshield
Refer to Wiring Diagrams Cell 81 , Wipers and Washers for schematic and connector information.
Normal Operation
Power is supplied from the Central Junction Box (CJB) to the Body Control Module (BCM) for the front
wiper system when the ignition is in the ON position. The BCM supplies a signal voltage(s) to the
wiper/washer switch for the HIGH speed, LOW speed, and INTERMITTENT functions. Each function
has its own dedicated signal (sense) voltage. The wiper/washer switch physically grounds the signal
voltage(s) when a function is selected. The BCM then reacts to the grounded signal voltage(s) and its
integral electronics make a decision on which wiper system function to carry out. Ground is supplied to
the wiper motor through a circuit that is shared by the BCM windshield wiper return circuit.

Fuse(s)
Wiper/washer switch
BCM
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE — WINDSHIELD

A1 CHECK FOR BCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self-Test — REFER to the Body
BCM . Control Module (BCM)
Are any BCM DTCs present? DTC Chart for further
diagnosis.
No
GO to A2 .
A2 CHECK THE BCM WINDSHIELD WIPER SWITCH PIDs
Enter the following diagnostic mode on the scan tool: DataLogger Yes
— BCM . GO to A6 .
Monitor the BCM PIDs listed below while operating the
wiper/washer switch in the INTERMITTENT, LOW and HIGH No
positions. GO to A3 .
Front Wiper Interval/Auto Wiper Switch (FRNWIPER_Int)
Front Wiper Command Low Speed (FRNWIPER_Lo)
Front Wiper Command High Speed (FRNWIPER_Hi)
Does the status of each PID match the wiper/washer switch
setting?
A3 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to A4 .
Carry out the wiper/washer switch component test.
No
wiper/washer switch.
Does the wiper/washer switch pass the component test? 05 . TEST the system
A4 CHECK THE WIPER GROUND CIRCUIT FROM THE BCM
Measure the resistance between the wiper/washer switch C2081- GO to A5 .
5, circuit CRW17 (GN/VT), harness side and BCM C2280F-16,
circuit CRW17 (GN/VT), harness side. No
REPAIR the circuit.
TEST the system for
normal operation.
A5 CHECK THE WINDSHIELD WIPER MOTOR GROUND FOR AN
OPEN OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: Windshield Wiper Motor C125. GO to A6 .
Measure the resistance between windshield wiper motor C125-4,
circuit GD133 (BK), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

A6 CHECK THE BCM VOLTAGE
Measure the voltage between BCM C2280B-10, circuit CBP11
(BN), harness side and ground and between BCM C2280B-15, No
circuit CBP13 (GY/BN), harness side and ground. If circuit CBP11 (BN)
was less than 10 volts,
VERIFY CJB fuse 11
(20A) is OK. If OK,
REPAIR circuit CBP11
(BN) for an open or high
resistance. If not OK,
REFER to the Wiring
Diagrams manual to
causes of the short to
ground.
If circuit CBP13
(GY/BN) was less than
10 volts, VERIFY
Central Junction Box
Are the voltages greater than 10 volts? (CJB) fuse 13 (15A) is
OK. If OK, REPAIR
circuit CBP13 (GY/BN)
for an open or high
REFER to the Wiring
Diagrams manual to
ground.
A7 CHECK THE BCM GROUND CIRCUIT FOR AN OPEN OR HIGH
RESISTANCE
Ignition OFF. Yes
Disconnect: BCM C2280A. GO to A8 .
Measure the resistance between BCM C2280A-16, circuit GD156
(BK/VT), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

A8 CHECK WINDSHIELD WIPER MOTOR LOW AND HIGH RELAY
OUTPUT CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
Measure the resistance between windshield wiper motor C125-1, Yes
circuit CRW15 (BN/WH), harness side and BCM C2280A-10, GO to A9 .
circuit CRW15 (BN/WH), harness side and between windshield
wiper motor C125-2, circuit CRW16 (GY/BN), harness side and No
BCM C2280A-9, circuit CRW16 (GY/BN), harness side. REPAIR the affected
circuit. TEST the system
A9 CHECK FOR VOLTAGE TO THE WINDSHIELD WIPER MOTOR
USING THE BCM PIDs FRONT WIPER RELAY - LOW SPEED
(WPR_RLY_F_Lo) AND FRONT WIPER RELAY - FAST SPEED
(WPR_RLY_F_Hi)
Connect: BCM C2280A. Yes
Connect: BCM C2280B. GO to A10 .
Connect: BCM C2280F (if previously disconnected).
Connect: Wiper/Washer Switch C2081 (if previously No
disconnected). GO to A11 .
Ignition ON.
Command the BCM PID WPR_RLY_F_Lo on.
Measure the voltage between windshield wiper motor C125-2,
circuit CRW16 (GY/BN), harness side and ground.
Command the BCM PID WPR_RLY_F_Hi on.

Measure the voltage between windshield wiper motor C125-1,
circuit CRW15 (BN/WH), harness side and ground.
Are the voltages greater than 10 volts?

A10 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
Ignition OFF. Yes
Inspect windshield wiper motor C125 for the following conditions: INSTALL a new
corrosion windshield wiper motor.
damaged or pushed out pins REFER to Wiper Motor
Connect the windshield wiper motor C125 and make sure it seats — Windshield in this
correctly. section. TEST the
Operate the system and verify if the concern is still present. system for normal
Is the concern still present? operation.
No
Concern may have been
corroded connector.
Ignition OFF. Yes
Inspect the BCM connectors for the following conditions: INSTALL a new BCM .
damaged or pushed out pins 10 . TEST the system
Connect the BCM connectors and make sure they seat correctly. for normal operation.
Connect: Windshield Wiper Motor C125.
Operate the system and verify if the concern is still present. No
corroded connector.
Pinpoint Test B: The Wipers are Inoperative — Rear Window
Normal Operation
Power is supplied from the Central Junction Box (CJB) to the Body Control Module (BCM) for the rear
window wiper system when the ignition is in the ON position. The BCM supplies a signal voltage(s) to
the wiper/washer switch for the CONTINUOUS and INTERMITTENT wiper functions. Both functions
share a dedicated signal (sense) line. The wiper/washer switch physically grounds the signal voltage(s)
when a function is selected. The BCM then reacts to the grounded signal voltage(s) and its integral
electronics make a decision on which wiper system function to carry out (depending on the windshield
wiper setting). Ground is supplied to the rear window wiper motor through its own dedicated circuit.

Fuse(s)
Wiper/washer switch
BCM
PINPOINT TEST B: THE WIPERS ARE INOPERATIVE — REAR WINDOW
Test Step Result / Action to

Take
B1 CHECK FOR BCM DTCs
Ignition ON. Yes
diagnosis.
No
GO to B2 .
B2 CHECK THE BCM PID REAR WIPER INPUT SWITCH STATUS
(R_WP-SW)
— BCM . GO to B5 .
Monitor the BCM PID R_WP-SW while operating the wiper/washer
switch in the rear wiper mode. No
Does the status of the PID match the wiper/washer switch GO to B3 .
setting?
B3 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to B4 .
No
Does the wiper/washer switch pass the component test? 05 . TEST the system
B4 CHECK THE WIPER GROUND CIRCUIT FROM THE BCM AND
THE REAR WIPER INTERVAL CIRCUIT
Disconnect: BCM C2280E. Yes
Disconnect: BCM C2280F. GO to B5 .
Measure the resistance between wiper/washer switch C2081-4,
circuit CRW20 (GY/YE), harness side and BCM C2280E-5, circuit No
CRW20 (GY/YE), harness side and between wiper/washer switch REPAIR the affected
C2081-5, circuit CRW17 (GN/VT), harness side and BCM C2280F- circuit. TEST the
16, circuit CRW17 (GN/VT), harness side. system for normal
operation.
B5 CHECK THE REAR WINDOW WIPER MOTOR GROUND FOR AN
Ignition OFF. Yes
Disconnect: Rear Window Wiper Motor C4218. GO to B6 .
Measure the resistance between rear window wiper motor C4218-
3, circuit GD143 (BK/VT), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

B6 CHECK THE BCM VOLTAGE
Ignition ON. GO to B7 .
Measure the voltage between BCM C2280B-15, circuit CBP13
(GY/BN), harness side and ground. No
VERIFY Central
Junction Box (CJB)
fuse 13 (15A) is OK. If
OK, REPAIR circuit
CBP13 (GY/BN) for an
open or high
REFER to the Wiring
Diagrams manual to
ground.

B7 CHECK REAR WINDOW WIPER MOTOR SUPPLY AND RELAY
OUTPUT CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: BCM C2280C. GO to B8 .
1, circuit CRW02 (GY/BU), harness side and BCM C2280C-11, No
circuit CRW02 (GY/BU), harness side and between rear window REPAIR the affected
wiper motor C4218-2, circuit CRW05 (BU), harness side and BCM circuit. TEST the
C2280C-9, circuit CRW05 (BU), harness side. system for normal
operation.

B8 CHECK FOR VOLTAGE TO THE REAR WINDOW WIPER MOTOR
USING THE BCM PID REAR WIPER RELAY (WPR_RLY_REAR)
Connect: BCM C2280B. Yes
Connect: BCM C2280C. GO to B9 .
Connect: BCM C2280E.
Connect: BCM C2280F. No
Connect: Wiper/Washer Switch C2081. GO to B10 .
Ignition ON.
Command the BCM PID WPR_RLY_REAR on.
Measure the voltage between rear window wiper motor C4218-1,
circuit CRW02 (GY/BU), harness side and ground and between
rear window wiper motor C4218-2, circuit CRW05 (BU), harness
side and ground.
B9 CHECK FOR CORRECT WIPER MOTOR OPERATION
Ignition OFF. Yes
Inspect rear window wiper motor C4218 for the following INSTALL a new rear
conditions: window wiper motor.
corrosion REFER to Wiper Motor
damaged or pushed out pins — Rear Window in this
Connect the rear window wiper motor C4218 and make sure it section. TEST the
seats correctly. system for normal
Operate the system and verify if the concern is still present. operation.
No
The system is
this time. Concern may
have been caused by a
loose or corroded
connector.
Ignition OFF. Yes
Connect: Rear Window Wiper Motor C4218.
Is the concern still present? The system is
have been caused by a
loose or corroded
connector.
Pinpoint Test C: The Wipers Stay ON Continuously — Windshield
Normal Operation
The Body Control Module (BCM) supplies a signal voltage(s) to the wiper/washer switch for the HIGH
speed, LOW speed, and INTERMITTENT functions. Each function has its own dedicated signal (sense)
line. The wiper/washer switch physically grounds the signal voltage(s) when a function is selected. The
BCM then reacts to the grounded signal voltage(s) and its integral electronics make a decision on which
wiper system function to carry out.
Wiper/washer switch
BCM
PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY — WINDSHIELD
Result / Action to
Test Step
Take
C1 CHECK FOR BCM DTCs
Ignition ON. Yes
BCM . Control Module
Are any BCM DTCs present? (BCM) DTC Chart for
further diagnosis.
No
GO to C2 .
C2 CHECK THE BCM WINDSHIELD WIPER SWITCH PIDs
Enter the following diagnostic mode on the scan tool: DataLogger — Yes
BCM . GO to C4 .
Monitor the BCM PIDs listed below while operating the wiper/washer
switch in the INTERMITTENT, LOW and HIGH positions. No
Front Wiper Interval/Auto Wiper Switch (FRNWIPER_Int) GO to C3 .
setting?
C3 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to C5 .
No
REFER to Section
Does the wiper/washer switch pass the component test? 211-05 . TEST the
system for normal
operation.
C4 CHECK WINDSHIELD WIPER MOTOR LOW AND HIGH RELAY
OUTPUT CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Windshield Wiper Motor C125. REPAIR the affected
Disconnect: BCM C2280A. circuit. TEST the
Ignition ON. system for normal
Measure the voltage between windshield wiper motor C125-1, circuit operation.
CRW15 (BN/WH), harness side and ground and between windshield
wiper motor C125-2, circuit CRW16 (GY/BN), harness side and No
ground. GO to C5 .
Is voltage present on either circuit?
Ignition OFF. Yes
Inspect the BCM connectors for the following conditions: INSTALL a new
corrosion BCM . REFER to
damaged or pushed out pins Section 419-10 .
Connect the BCM connectors and make sure they seat correctly. TEST the system for
Connect: Windshield Wiper Motor C125. normal operation.
Operate the system and verify if the concern is still present.
Is the concern still present? No
The system is
this time. Concern
may have been
corroded connector.
Pinpoint Test D: The Wipers Stay ON Continuously — Rear Window
Normal Operation
The Body Control Module (BCM) supplies a signal voltage(s) to the wiper/washer switch for the
CONTINUOUS and INTERMITTENT wiper functions. Both functions share a dedicated signal (sense)
BCM then reacts to the grounded signal voltage(s) and its integral electronics make a decision on which
wiper system function to carry out (depending on windshield wiper setting).
DTC B11DC:92 (Rear Wiper Mode Switch: Performance or Incorrect Operation) — sets during
self-test when the rear wiper interval switch circuit is grounded.

Wiper/washer switch
BCM
PINPOINT TEST D: THE WIPERS STAY ON CONTINUOUSLY — REAR WINDOW

Take
D1 CHECK FOR BCM DTCs
Ignition ON. Yes
BCM . Control Module
Are any BCM DTCs present? (BCM) DTC Chart for
further diagnosis.
No
GO to D2 .
D2 CHECK THE BCM PID REAR WIPER INPUT SWITCH STATUS
(R_WP-SW)
BCM . GO to D5 .
Does the status of the PID match the wiper/washer switch GO to D3 .
setting?
D3 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to D4 .
No
REFER to Section
system for normal
operation.
D4 CHECK THE REAR WIPER INTERVAL CIRCUIT FOR A SHORT TO
GROUND
Measure the resistance between wiper/washer switch C2081-4, GO to D6 .
circuit CRW20 (GY/YE), harness side and ground.
No
REPAIR the affected
circuit. TEST the
system for normal
operation.

D5 CHECK REAR WINDOW WIPER SUPPLY AND WIPER MOTOR
RELAY OUTPUT CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Rear Window Wiper Motor C4218. REPAIR the affected
Measure the voltage between rear window wiper motor C4218-1, circuit. TEST the
circuit CRW02 (GY/BU), harness side and ground and between rear system for normal
window wiper motor C4218-2, circuit CRW05 (BU), harness side operation.
and ground.
No
GO to D6 .

Ignition OFF. Yes
damaged or pushed out pins Section 419-10 .
Connect the BCM connectors and make sure they seat correctly. TEST the system for
Connect: Wiper/Washer Switch C2081. normal operation.
Connect: Rear Window Wiper Motor C4218.
this time. Concern
may have been
corroded connector.
Pinpoint Test E: The HIGH/LOW/INTERMITTENT Wiper Speeds Do Not Operate Correctly —

Windshield
Normal Operation
The Body Control Module (BCM) supplies a signal voltage(s) to the wiper/washer switch for the HIGH
speed, LOW speed, and INTERMITTENT functions. Each function has its own dedicated signal (sense)
BCM reacts to the grounded signal voltage(s) and its integral electronics make a decision on which
wiper system function to carry out. The wiper/washer switch has a rheostat (variable resistor) which,
when moved, changes the time delay between wipes. The BCM monitors the position of the rheostat
through a sense line.
DTC B1008:92 (Wiper Mode Switch: Performance or Incorrect Operation) — sets when the
INTERMITTENT mode is grounded at the same time as the LOW and/or HIGH speed functions
for more than 2 seconds.
DTC B1C53:13 (Front Wiper Intermittent Data: Circuit Open) — sets when the front interval
potentiometer input circuit is open.

Wiper/washer switch
BCM
PINPOINT TEST E: THE HIGH/LOW/INTERMITTENT WIPER SPEEDS DO NOT OPERATE
CORRECTLY — WINDSHIELD
Result / Action
Test Step
to Take
E1 CHECK FOR BCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self-Test — BCM . For DTC
Are any BCM DTCs present? B1008:92, GO
to E5 .
For DTC
B1C53:13, GO
to E4 .
For all other

BCM DTCs,
REFER to the
Body Control
Module (BCM)
DTC Chart for
further
diagnosis.
No
GO to E2 .
E2 CHECK THE BCM WINDSHIELD WIPER SWITCH PIDs
BCM . GO to E6 .
Monitor the BCM PIDs listed below while operating the wiper/washer
switch in the INTERMITTENT, LOW and HIGH positions. No
Front Wiper Select Switch A (FRNWIPER_A) GO to E3 .
Front Wiper Select Switch B (FRNWIPER_B)
Front Wiper Select Switch C (FRNWIPER_C)
Front Wiper Interval / Auto Wiper Switch (FRNWIPER_Int)
Monitor the BCM PIDs FRNWIPER_A, FRNWIPER_B and
FRNWIPER_C in each INTERMITTENT setting and refer to the table
below.
INTERMITTENT
Setting FRNWIPER_A FRNWIPER_B FRNWIPER_C
Level 1 Active Inactive Inactive
Level 2 Inactive Active Inactive
Level 3 Active Active Inactive
Level 4 Inactive Inactive Active
Level 5 Active Inactive Active
Level 6 Inactive Active Active
Does the status of each PID match the wiper/washer switch setting?
E3 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to E4 .
No
wiper/washer
switch. REFER
Does the wiper/washer switch pass the component test? to Section 211-
05 . TEST the
system for
normal
operation.
E4 CHECK WIPER/WASHER SWITCH WINDSHIELD WIPER CIRCUITS FOR
AN OPEN OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081 (if not previously disconnected). GO to E5 .
Disconnect: BCM C2280E.
Disconnect: BCM C2280F. No
Measure the resistance between wiper/washer switch C2081, harness REPAIR the
side and BCM C2280E and C2280F, harness side as follows: affected circuit.
TEST the
Wiper/Washer Switch Circuit BCM system for
normal
C2081-3 CRW10 (BU/GN) C2280F-3 operation.
C2081-5 CRW17 (GN/VT) C2280F-16
C2081-8 CRW08 (VT/OG) C2280F-9
C2081-9 VRW11 (GN/BN) C2280E-6
C2081-10 CRW18 (VT/WH) C2280F-6
E5 CHECK WIPER/WASHER SWITCH WINDSHIELD WIPER CIRCUITS FOR
A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081 (if not previously disconnected). GO to E9 .
Disconnect: BCM C2280E (if not previously disconnected).
Disconnect: BCM C2280F (if not previously disconnected). No
Measure the resistance between wiper/washer switch C2081, harness REPAIR the
side and ground as follows: affected circuit.
TEST the
Wiper/Washer Switch Circuit system for
normal
C2081-3 CRW10 (BU/GN) operation.
C2081-8 CRW08 (VT/OG)
C2081-9 VRW11 (GN/BN)
C2081-10 CRW18 (VT/WH)
E6 CHECK WINDSHIELD WIPER MOTOR LOW AND HIGH RELAY OUTPUT
CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: Windshield Wiper Motor C125. GO to E7 .
Disconnect: BCM C2280A.
Measure the resistance between windshield wiper motor C125-1, circuit No
CRW15 (BN/WH), harness side and BCM C2280A-10, circuit CRW15 REPAIR the
(BN/WH), harness side and between windshield wiper motor C125-2, affected circuit.
circuit CRW16 (GY/BN), harness side and BCM C2280A-9, circuit TEST the
CRW16 (GY/BN), harness side. system for
normal
operation.

E7 CHECK FOR VOLTAGE TO THE WINDSHIELD WIPER MOTOR USING
THE BCM PIDs FRONT WIPER RELAY - LOW SPEED (WPR_RLY_F_Lo)
AND FRONT WIPER RELAY - FAST SPEED (WPR_RLY_F_Hi)
Command the BCM PID WPR_RLY_F_Lo on.
Measure the voltage between windshield wiper motor C125-2, circuit No
CRW16 (GY/BN), harness side and ground. GO to E9 .
Command the BCM PID WPR_RLY_F_Hi on.
Measure the voltage between windshield wiper motor C125-1, circuit
CRW15 (BN/WH), harness side and ground.

E8 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR OPERATION
Ignition OFF. Yes
corrosion windshield wiper
damaged or pushed out pins motor. REFER
Connect the windshield wiper motor C125 and make sure it seats to Wiper Motor
correctly. — Windshield in
Connect: BCM C2280E. this section.
Connect: BCM C2280F. TEST the
Operate the system and verify if the concern is still present. system for
Is the concern still present? normal
operation.
No
The system is
operating
correctly at this
time. Concern
may have been
caused by a
loose or
corroded
connector.
Ignition OFF. Yes
corrosion BCM . REFER
damaged or pushed out pins to Section 419-
Connect the BCM connectors and make sure they seat correctly. 10 . TEST the
Connect: Wiper/Washer Switch C2081 (if previously disconnected). system for
Connect: Windshield Wiper Motor C125 (if previously disconnected). normal
Operate the system and verify if the concern is still present. operation.
No
The system is
operating
correctly at this
time. Concern
may have been
caused by a
loose or
corroded
connector.
Pinpoint Test F: The CONTINUOUS or INTERMITTENT Wiper Speeds Do Not Operate Correctly —
Rear Window
Refer to Wiring Diagrams Cell 81 , Front Wipers and Washers for schematic and connector information.
Normal Operation
The Body Control Module (BCM) supplies a signal voltage(s) to the wiper/washer switch for
CONTINUOUS and INTERMITTENT wiper functions. Both functions share a dedicated signal (sense)
BCM reacts to the grounded signal voltage(s) and its integral electronics make a decision on which
wiper system function to carry out (depending on the windshield wiper setting).

Wiper/washer switch
BCM
PINPOINT TEST F: THE CONTINUOUS OR INTERMITTENT WIPER SPEEDS DO NOT OPERATE

CORRECTLY — REAR WINDOW
Result / Action to
Test Step
Take
F1 CHECK FOR BCM DTCs
Ignition ON. Yes
diagnosis.
No
GO to F2 .
F2 CHECK OPERATION OF THE WINDSHIELD WIPERS
Operate the windshield wipers in LOW, HIGH and in each Yes
INTERMITTENT mode. GO to F3 .
Do the windshield wipers operate correctly?
No
IDENTIFY the
windshield wiper
system symptom and
GO to Symptom Chart
for further diagnosis.
F3 CHECK THE BCM PID REAR WIPER INPUT SWITCH STATUS
(R_WP-SW)
— BCM . GO to F5 .
Does the status of the PID match the wiper/washer switch GO to F4 .
setting?
F4 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to F8 .
No
REFER to Section
system for normal
operation.
F5 CHECK THE REAR WINDOW WIPER MOTOR GROUND FOR
HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: Rear Window Wiper Motor C4218. GO to F6 .
3, circuit GD143 (BK/VT), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

F6 CHECK FOR VOLTAGE TO THE REAR WINDOW WIPER MOTOR
USING THE BCM PID REAR WIPER RELAY (WPR_RLY_REAR)
Ignition ON. Yes
Command the BCM PID WPR_RLY_REAR on. GO to F7 .
Measure the voltage between rear window wiper motor C4218-1,
circuit CRW02 (GY/BU), harness side and ground and between No
rear window wiper motor C4218-2, circuit CRW05 (BU), harness GO to F8 .
side and ground.
F7 CHECK FOR CORRECT WIPER MOTOR OPERATION
Ignition OFF. Yes
Inspect rear window wiper motor C4218 for the following INSTALL a new rear
conditions: window wiper motor.
corrosion REFER to Wiper Motor
damaged or pushed out pins — Rear Window in this
Connect the rear window wiper motor C4218 and make sure it section. TEST the
seats correctly. system for normal
Connect: Wiper/Washer Switch C2081. operation.
The system is
have been caused by
a loose or corroded
connector.
F8 CHECK FOR CORRECT BCM OPERATION
Ignition OFF. Yes
corrosion REFER to Section
damaged or pushed out pins 419-10 . TEST the
Connect the BCM connectors and make sure they seat correctly. system for normal
Connect: Wiper/Washer Switch C2081. operation.
Connect: Rear Window Wiper C4218.
have been caused by
a loose or corroded
connector.
Pinpoint Test G: The Washer Pump is Inoperative — Front/Rear
Normal Operation
The front and rear washer systems share the same washer pump motor. The Body Control Module
(BCM) supplies a signal voltage(s) to the wiper/washer switch for the front/rear wash functions. Each
function has its own dedicated signal (sense) line. The wiper/washer switch physically grounds the
signal voltage when a wash function is selected. The BCM reacts to the grounded signal voltage(s) and
its integral electronics make a decision on what polarity to supply the washer pump motor with. The
BCM changes the polarity to the washer pump motor in reaction to a front or rear wash selection,
changing the rotational direction of the motor.
DTC B1051:92 (Front Washer Switch: Performance or Incorrect Operation) — sets during self-
test when the wiper/washer switch front washer circuit to the BCM or the front washer pump
circuit is grounded.
DTC B1052:92 (Rear Washer Switch: Performance or Incorrect Operation) — sets during self-test
when the wiper/washer switch rear washer circuit to the BCM or rear washer pump circuit is
grounded.

Wiper/washer switch
Washer pump
BCM
PINPOINT TEST G: THE WASHER PUMP IS INOPERATIVE — FRONT/REAR
Result / Action to
Test Step
Take
G1 CHECK THE BCM PIDs FRONT WASHER SWITCH
(FRNWIPER_Wsh) AND REAR WASHER SWITCH INPUT
(RWASH_SW)
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to G7 .
— BCM .
NOTE: The rear window washer feature is only available on 5-door No
hatchback vehicles. GO to G2 .
Monitor the BCM PIDs FRNWIPER_Wsh and RWASH_SW while
operating the wiper/washer switch front and rear washer modes.
setting?
G2 CHECK THE WIPER/WASHER SWITCH
Ignition OFF. Yes
Disconnect: Wiper/Washer Switch C2081. GO to G3 .
No
REFER to Section
system for normal
operation.
G3 CHECK VOLTAGE AND GROUND CIRCUITS TO THE
WIPER/WASHER SWITCH
Ignition ON. Yes
Measure the voltage between wiper/washer switch C2081-1, circuit GO to G5 .
CBP15 (BN/BU), harness side and C2081-6, circuit GD115
GO to G4 .
G4 CHECK THE VOLTAGE CIRCUIT TO THE WIPER/WASHER
SWITCH FOR AN OPEN OR HIGH RESISTANCE
Measure the voltage between wiper/washer switch C2081-1, circuit Yes
CBP15 (BN/BU), harness side and ground. REPAIR circuit GD115
for an open or high
resistance. TEST the
system for normal
operation.
No
VERIFY Central
Junction Box (CJB)
OK, REPAIR circuit
CBP15 (BN/BU). If not
OK, REFER to the
Wiring Diagrams
Is the voltage greater than 10 volts? short to ground.
G5 CHECK THE WIPER/WASHER SWITCH WASHER PUMP MOTOR
REQUEST CIRCUITS TO THE BCM FOR AN OPEN OR HIGH
RESISTANCE
Ignition OFF. Yes
Disconnect: BCM C2280B. GO to G6 .
Measure the resistance between wiper/washer switch C2081-2,
circuit CRW07 (GY/BN), harness side and BCM C2280B-12, circuit No
CRW07 (GY/BN), harness side and between wiper/washer switch REPAIR the affected
C2081-7, circuit CRW12 (GY/OG), harness side and BCM C2280B- circuit. TEST the
14, circuit CRW12 (GY/OG), harness side system for normal
operation.

G6 CHECK THE WIPER/WASHER SWITCH WASHER PUMP MOTOR
REQUEST CIRCUITS TO THE BCM FOR A SHORT TO GROUND
Measure the resistance between wiper/washer switch C2081-2, Yes
circuit CRW07 (GY/BN), harness side and ground and between GO to G10 .
wiper/washer switch C2081-7, circuit CRW12 (GY/OG), harness
side and ground. No
REPAIR the affected
circuit. CLEAR the
BCM DTCs. REPEAT
system for normal
operation.

G7 CHECK FOR VOLTAGE AND GROUND TO THE WASHER PUMP
MOTOR
Disconnect: Washer Pump Motor C137. Yes
NOTE: On 5-door hatchback vehicles, make sure to operate both INSTALL a new
the front and rear washer modes. washer pump motor.
While using the wiper/washer switch to activate the washer pump REFER to Washer
motor, measure the voltage between washer pump motor C137-2, Pump in this section.
circuit CRW23 (VT/GN), harness side and washer pump motor TEST the system for
C137-1, circuit CRW14 (BU/WH), harness side. normal operation.
No
GO to G8 .

G8 CHECK THE WASHER PUMP MOTOR CIRCUITS FOR AN OPEN
OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: BCM C2280B. GO to G9 .
Measure the resistance between BCM C2280B-4, circuit CRW23
(VT/GN), harness side and washer pump motor C137-2, circuit No
CRW23 (VT/GN), harness side and between BCM C2280B-13, REPAIR the affected
circuit CRW14 (BU/WH), harness side and washer pump motor circuit. TEST the
C137-1, circuit CRW14 (BU/WH), harness side. system for normal
operation.
G9 CHECK THE WASHER PUMP MOTOR CIRCUITS FOR A SHORT
TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280A. GO to G10 .
Measure the resistance between washer pump motor C137-1,
circuit CRW14 (BU/WH), harness side and ground and between No
washer pump motor C137-2, circuit CRW23 (VT/GN), harness side REPAIR the affected
and ground. circuit. CLEAR the
BCM DTCs. REPEAT
system for normal
operation.

G10 CHECK FOR CORRECT BCM OPERATION
Ignition OFF. Yes
damaged or pushed out pins 419-10 . TEST the
Connect the BCM connectors and make sure they seat correctly. system for normal
Connect: Wiper/Washer Switch C2081 (if previously disconnected). operation.
Connect: Windshield Wiper Motor C125 (if previously
disconnected). No
Operate the system and verify if the concern is still present. The system is
Is the concern still present? operating correctly at
this time. Concern
may have been
corroded connector.
Pinpoint Test H: The Wipers Will Not PARK at the Correct Position — Windshield
Normal Operation
Integral to the wiper motor is a set of contacts that only close when the wipers are in the PARK position.
When closed the contacts supply ground to the Body Control Module (BCM) which uses the ground to
sense when the wipers are in the PARK position. If the wipers are in use, the BCM continues to supply
power to the wiper motor after the wipers are commanded OFF and in a NON-PARK position. Once the
wipers are in the PARK position, the BCM removes power from the wiper motor and the wipers remain
PARKED.
DTC B1C45:24 (Front Wiper Position Switch: Signal Stuck High) — sets during self-test when the
wipers are not initially PARKED or are still PARKED after 500 ms with the wiper/washer switch
set to LOW SPEED. Also sets while being continuously monitored when the wiper/washer switch
is set to SINGLE WIPE or INTERMITTENT and the wipers remain PARKED for longer than 1.5
seconds or when the wiper/washer switch is set to OFF and the wipers remain in a NON-
PARKED position for longer than 12 seconds.

Linkage
BCM
PINPOINT TEST H: THE WIPERS WILL NOT PARK AT THE CORRECT POSITION — WINDSHIELD

H1 INSPECT THE WINDSHIELD WIPERS
Inspect the wiper pivot arms and wiper mounting arm and pivot Yes
shaft assembly for damage or obstructions. REMOVE any damaged
Are any parts damaged or is an obstruction present? parts and INSTALL new.
REMOVE any debris or
obstructions. TEST the
system for normal
operation.
No
GO to H2 .
H2 CHECK FOR BCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self-Test — For DTC B1C45:24, GO
BCM . to H4 .
Are any BCM DTCs present?
For all other BCM
DTCs, REFER to the
Body Control Module
(BCM) DTC Chart for
further diagnosis.
No
GO to H3 .
H3 CHECK THE BCM PID FRONT WIPER PARK SWITCH
(FRNWIPER_Prk) WHILE OPERATING THE WINDSHIELD WIPERS
— BCM . GO to H7 .
Monitor the BCM PID FRNWIPER_Prk while operating the
windshield wipers in LOW mode. No
Does the status of the PID alternate between Wipe and GO to H4 .
Parked?
H4 CHECK THE FRONT WIPER PARK SWITCH CIRCUIT FOR AN
Ignition OFF. Yes
Disconnect: Windshield Wiper Motor C125. GO to H5 .
Measure the resistance between windshield wiper motor C125-3, No
circuit CRW09 (BN/BU), harness side and BCM C2080D-3, circuit REPAIR the circuit.
CRW09 (BN/BU), harness side. TEST the system for
normal operation.

H5 CHECK THE FRONT WIPER PARK SWITCH CIRCUIT FOR A
SHORT TO GROUND
Measure the resistance between windshield wiper motor C125-3, Yes
circuit CRW09 (BN/BU), harness side and ground. GO to H6 .
No
REPAIR the circuit.
TEST the system for
normal operation.

H6 CHECK THE BCM PID FRONT WIPER PARK SWITCH
(FRNWIPER_Prk)
Connect: BCM C2280D. Yes
Ignition ON. GO to H8 .
Enter the following diagnostic mode on the scan tool: DataLogger
— BCM . No
With the windshield wiper motor C125 disconnected, monitor the GO to H9 .
BCM PID FRNWIPER_Prk.
Connect a fused jumper wire between windshield wiper motor
C125-3, circuit CRW09 (BN/BU), harness side and ground.
With the front wiper park switch circuit shorted to ground, monitor
the BCM PID FRNWIPER_Prk.
Does the status of the PID read Wipe with the windshield
wiper motor disconnected and Parked with the wiper park
switch circuit shorted to ground?
H7 CHECK THE FRONT WIPER RETURN CIRCUIT FOR AN OPEN
OR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: BCM C2280A. GO to H9 .
Measure the resistance between BCM C2080A-12, circuit GD133
(BK), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

H8 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR
OPERATION
Ignition OFF. Yes
corrosion windshield wiper motor.
damaged or pushed out pins REFER to Wiper Motor
Connect the windshield wiper motor C125 and make sure it seats — Windshield in this
correctly. section. TEST the
Operate the system and verify if the concern is still present. system for normal
No
corroded connector.
H9 CHECK FOR CORRECT BCM OPERATION
Ignition OFF. Yes
corroded connector.
Pinpoint Test I: The Wipers Will Not PARK at the Correct Position — Rear Window
Normal Operation
Integral to the wiper motor is a set of contacts that only close when the wipers are in a NON-PARK
position. The Body Control Module (BCM) supplies power to the wiper motor as long as the contacts are
closed or the wipers are in a NON-PARK position. When the wipers are commanded OFF during use,
the BCM continues to supply the wiper motor with power until the contacts open when the PARK
position is reached.

BCM
PINPOINT TEST I: THE WIPERS WILL NOT PARK AT THE CORRECT POSITION — REAR
WINDOW

I1 CHECK FOR BCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode REFER to the Body Control Module (BCM) DTC
on the scan tool: Self-Test — BCM . Chart for further diagnosis.
Are any BCM DTCs present?
No
GO to I2 .
I2 CHECK OPERATION OF THE
WINDSHIELD WIPERS
Operate the windshield wipers in Yes
LOW, HIGH and in each GO to I3 .
INTERMITTENT mode.
Do the windshield wipers operate No
correctly? IDENTIFY the windshield wiper system symptom
and GO to Symptom Chart for further diagnosis.
I3 CHECK OPERATION OF THE REAR
WINDOW WIPER
Operate the windshield wipers in Yes
HIGH and turn the rear window wiper GO to I4 .
ON.
Does the rear window wiper No
operate continuously and GO to Pinpoint Test F .
correctly?
I4 CHECK FOR CORRECT WIPER
MOTOR OPERATION
Ignition OFF. Yes
Inspect the rear window wiper motor INSTALL a new rear window wiper motor. REFER
C4218 for the following conditions: to Wiper Motor — Rear Window in this section.
damaged or pushed out pins
Connect the rear window wiper motor No
C4218 and make sure it seats The system is operating correctly at this time.
correctly. Concern may have been caused by a loose or
Connect: Rear Window Wiper Motor corroded connector.
C4218.
Operate the system and verify if the
Wiper Blade and Pivot Arm Adjustment — Windshield
1. Cycle and park the windshield wipers.
2. Verify that the RH and LH wiper blade tips are aligned to the "T" marks on the lower windshield
glass.
3. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from
returning to the full PARK position.
If not within specification, remove the wiper pivot arms and reposition to the correct location. For
additional information, refer to Wiper Pivot Arm — Front In this section.
Wiper and Washer System — Exploded View
Windshield Wipers

1 W710461 Front wiper pivot arm nut cover (2 required)
2 W520404 Front wiper pivot arms nut (2 required)
3 17526 RH/ 17527 Front wiper pivot arm
LH
4 W714182 Wiper mounting arm and pivot shaft center bolt
5 W701121 Wiper mounting arm and pivot shaft end bolt (2
required)
6 — Windshield wiper motor pivot arm nut (part of
17566)
7 — Windshield wiper motor bolt (part of 17566) (3
required)
8 17508 Windshield wiper motor
9 — Windshield wiper motor electrical connector (part
of 14290)
10 17566 Wiper mounting arm and pivot shaft assembly
11 — Wiper mounting arm and pivot shaft mount (part
of 17566)
Rear Window Wipers

1 W520403 Rear wiper pivot arm nut
2 17526 Rear wiper pivot arm
3 W701389 Rear wear wiper motor bolt
4 17508 Rear wear wiper motor
Washer Reservoir
1 W700133 Washer reservoir bolt (2 required)
2 17618 Washer reservoir
Washer Pump
NOTE: 5 door washer pump shown, 4 door washer pump similar.

1 — Windshield washer hose (part of 17618)
2 — Rear window washer hose (part of 17618)
3 — Washer pump electrical connector (part of 14K012)
4 17664 Washer pump

Wiper Pivot Arm — Front
Removal
1. Remove the front wiper pivot arm nut cover.
2. Remove the front wiper pivot arm nut.
3. Using a suitable 2 jaw puller, remove the front wiper pivot arm.
Installation
1. Using a wire brush, clean the front wiper pivot arm shaft.
2. NOTE: Make sure the wiper motor is in the full PARK position before installing the wiper pivot
arms.
Install the front wiper pivot arm so that the wiper blade tip is aligned to the "T" marks on the lower
windshield glass.
3. Install the front wiper pivot arm nut.

4. Install the front wiper pivot arm nut cover.

Wiper Mounting Arm and Pivot Shaft
1. Remove the cowl panel grilles. For additional information, refer to Section 501-02 .
2. NOTE: Make sure to align the wiper mounting arm pivot shaft mount to the body when installing the wiper
mounting arm pivot shaft.
Remove the wiper mounting arm pivot shaft in the following sequence:
1. Remove the wiper mounting arm pivot shaft center bolt.
2. Remove the wiper mounting arm pivot shaft end bolts.
Detach the electrical wiring harness retainers and disconnect the electrical connector.

Wiper Motor — Windshield
1. Remove the wiper mounting arm and pivot shaft. For additional information, refer to Wiper
Mounting Arm and Pivot Shaft in this section.
2. NOTE: Note the position of the component before removal.
Remove the windshield wiper motor.

1. Remove the windshield wiper pivot arm nut.
2. Remove the 3 windshield wiper motor bolts.

Wiper Pivot Arm — Rear
1. Lift the rear wiper pivot arm nut cover upwards and remove the rear wiper pivot arm nut.
2. Remove the rear pivot wiper arm.

Wiper Motor — Rear Window
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm — Rear in
this section.
2. Remove the lower liftgate trim panel. For additional information, refer to Section 501-05 .
3. Remove the 3 rear wiper motor bolts.

4. Remove the rear wiper motor.

Wiper/Washer Switch

1 17A553 Steering column switch carrier
2 6475 Wiper/washer switch
1. Remove the steering column shrouds. For additional information, refer to the exploded view in Section
211-05 .
2. Remove the wiper/washer switch.

2. Release the wiper/washer switch retaining tab.
3. Lift upward and remove the wiper/washer switch.

Washer Pump
Material
Item Specification
Motorcraft® Premium Quality —
(Canada)
(Canada)
Motorcraft® Premium Windshield WSB-M8B16-
Washer Concentrate (US) A2
ZC-32-A or B (US)

injury.
NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure
to follow these instructions may result in premature pump failure.
1. Remove the LF fender splash shield. For additional information, refer to Section 501-02 .
2. NOTICE: When replacing the washer pump, be careful not to damage the rubber grommet.
NOTE: To prevent spilling windshield washer fluid, drain the washer reservoir before washer
pump removal.
Remove the washer pump in the following sequence:

2. Disconnect the 2 washer hoses.
3. Remove the washer pump.
Fill the washer reservoir with windshield washer fluid.
Washer Pump and Reservoir
Material
Item Specification
Motorcraft® Premium Quality —
(Canada)
(Canada)
Motorcraft® Premium Windshield WSB-M8B16-
Washer Concentrate (US) A2
ZC-32-A or B (US)

injury.
NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure
to follow these instructions may result in premature pump failure.
1. Remove the LF headlamp assembly. For additional information, refer to Section 417-01 .
2. Remove the upper washer reservoir bolt.
3. Disconnect the washer reservoir hose(s).
4. Remove the LH fender splash shield. For additional information, refer to Section 501-02 .
5. Remove the lower washer reservoir bolt and disconnect the electrical connector.
6. To remove the washer reservoir, lift the washer reservoir slightly upward and then lower the
washer reservoir.

SECTION 501-17: Roof Opening Panel 2011 Fiesta Workshop Manual
Item Specification
Roof opening panel glass clearance — front edge -1.0 - 0.0 mm ( -0.04 - 0.0 in) flush at front
Roof opening panel glass clearance — rear edge 0.0 - 1.0 mm (0.0 - 0.04 in) flush at rear
Roof opening panel frame bolts 9 80
Roof opening panel frame bracket bolts 9 80
Roof opening panel glass screws 3 27
Roof opening panel motor bolts 3 27
Roof Opening Panel
The roof opening panel consists of the following components:
Air deflector
Control switch
Drain hoses
Frame
Glass
Motor/Module
Shield
Trim lace
Trough assembly
Weatherstrip
Roof Opening Panel Operation
The roof opening panel is an electronically operated glass panel with one-touch open and one-touch vent
features. The roof opening panel assembly uses an integrated motor and module to operate the roof opening
panel.
To open the roof opening panel, press and release the rear of the SLIDE control switch. The roof opening panel
opens automatically. Press the SLIDE control switch at any time to stop roof opening panel movement.
To vent the roof opening panel, the roof opening panel must be in the CLOSED position. Press and release the
rear of the TILT control switch. The roof opening panel automatically moves to the VENT position.
To close the roof opening panel from the VENT (or any other open position), press and hold the front of the
TILT or SLIDE control switch until the glass panel stops moving.
Roof Opening Panel Drain Hose Routing — 4-Door Sedan
NOTE: Passenger side shown, driver side similar.

Roof Opening Panel Drain Hose Routing — 5-Door Hatchback
NOTE: Passenger side shown, driver side similar.

Roof Opening Panel
Special Tool(s)
Flex Probe Kit

NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the
roof opening panel system, including:
whenever the roof opening panel motor has been removed from the roof opening panel system.
whenever the roof opening panel glass has been removed from the roof opening panel system.
whenever the roof opening panel assembly has been removed from the vehicle.
whenever a new roof opening panel motor has been installed.
whenever a new roof opening panel glass has been installed.
whenever a new roof opening panel assembly has been installed.
The roof opening panel is an electronically operated glass panel that can be opened, closed or vented
by the roof opening panel switch. The roof opening panel assembly uses an integrated motor and
module to operate the roof opening panel. The roof opening panel motor and module are installed new
as an assembly.

Roof opening panel glass Central Junction Box (CJB)
Roof opening panel air deflector fuse(s):
Roof opening panel alignment 24 (7.5A)
Roof opening panel shield 35 (20A)
Trough assembly Wiring, terminals or
Roof opening panel weatherstrip (part of the roof opening connectors
panel glass) Roof opening panel switch
4. If the concern is not visually evident, determine the symptom. GO to Symptom Chart - Roof
Opening Panel or GO to Symptom Chart - NVH .
Symptom Chart — Roof Opening Panel
Symptom Chart — Roof Opening Panel
The roof Roof opening GO to Pinpoint Test B .
opening panel panel
leaks alignment
Drain tube
attachment
points
Roof opening
panel drain
hose(s)
Roof opening
panel
weatherstrip
Trough
assembly
The roof Roof opening GO to Pinpoint Test E .
opening panel panel motor not
does not open initialized
or close Fuse
Wiring,
terminals or
connectors
Roof opening
panel switch
Roof opening
pane
motor/module
Roof opening
pane lifter
assemblies
Roof opening
panel
alignment
The roof Wiring, GO to Pinpoint Test F .
opening panel terminals or
does not open connectors
or close in Roof opening
VENT position panel switch
Roof opening
panel
motor/module
The express Roof opening INITIALIZE the roof opening panel
open is panel motor not motor/module. REFER to Roof
inoperative initialized Opening Panel Initialization in this
Roof opening section. If concern is still present after
panel initialization, INSTALL a new roof
motor/module opening panel motor/module. REFER
to Roof Opening Panel — Exploded
View and Roof Opening Panel Motor
in this section. TEST the system for
normal operation.
The roof Roof opening REFER to Roof Opening Panel
opening panel panel Alignment in this section.
does not stop alignment
in FLUSH from
any position
The roof opening panel has Roof opening panel GO to Pinpoint
excessive wind noise alignment Test A .
Roof opening panel
weatherstrip
Roof opening panel air
deflector
The roof opening panel Roof opening panel GO to Pinpoint
rattles glass Test C .
Roof opening panel air
deflector
Roof opening panel
shield
Roof opening panel
frame
Trough assembly
The roof opening panel is Roof opening panel GO to Pinpoint
noisy during operation alignment Test D .
Roof opening panel
frame
Roof opening panel
shield
Roof opening panel
motor/module
Pinpoint Tests
Pinpoint Test A: The Roof Opening Panel Has Excessive Wind Noise
Normal Operation
When the roof opening panel glass is completely closed, it is flush with the roof panel.

Roof opening panel alignment
Roof opening panel weatherstrip
Roof opening panel motor/module
PINPOINT TEST A: THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE

A1 VERIFY ROOF OPENING PANEL
NOISE
Road test the vehicle with the roof Yes
opening panel in the CLOSED and GO to A4 .
OPEN positions.
Is the wind noise present only in No
the OPEN position? GO to A2 .
A2 CHECK THE ROOF OPENING
PANEL WEATHERSTRIP
NOTE: Make sure the weatherstrip Yes

is secured to the glass, not cut, GO to A3 .
cracked, pinched, loose or
obstructed in CLOSED, VENT and No
OPEN positions. INSTALL a new roof opening panel glass. REFER to
Roof Opening Panel Glass in this section. TEST the
Check the roof opening panel system for normal operation.
weatherstrip.
Is the roof opening panel
weatherstrip OK?
A3 CHECK ROOF OPENING PANEL
ALIGNMENT
Check the roof opening panel Yes
alignment. CHECK for correct installation of the roof opening
Is the alignment OK? panel and motor/module. REFER to Roof Opening
Panel — Exploded View , Roof Opening Panel and
Roof Opening Panel Motor in this section. TEST the
No
ALIGN the roof opening panel. REFER to Roof
Opening Panel Alignment in this section. TEST the
A4 CHECK THE AIR DEFLECTOR
Make sure the air deflector is Yes
securely attached and check for Partially CLOSE the roof opening panel until the noise
damaged or unsecured springs. is eliminated. If the noise is eliminated, INFORM the
Is the air deflector OK? customer that changing glass location will eliminate the
wind noise. If the wind noise is not eliminated, RE-
ALIGN panel. TEST the system for normal operation.
No
INSTALL new air deflector. REFER to Air Deflector in
this section. TEST the system for normal operation.
Pinpoint Test B: The Roof Opening Panel Leaks
Normal Operation
When the roof opening panel glass is completely closed, it should be within specifications. Refer to
Specifications in this section.

Roof opening panel drain hose(s)
Roof opening panel seal/weatherstrip
Roof opening panel frame
Trough assembly
PINPOINT TEST B: THE ROOF OPENING PANEL LEAKS

B1 CHECK THE ROOF OPENING
PANEL WEATHERSTRIP AND GLASS
ALIGNMENT
NOTE: Make sure the roof opening Yes
panel weatherstrip is not cracked or GO to B2 .
loose.
Check the roof opening panel No
weatherstrip condition and verify the INSTALL a new roof opening panel glass and/or
roof opening panel glass is aligned ALIGN the roof opening panel. REFER to Roof
properly. Opening Panel Glass and/or Roof Opening Panel
Is the roof opening panel glass Alignment in this section. TEST the system for normal
aligned and weatherstrip sealing operation.
correctly?
PANEL DRAIN HOSES
panel drain hoses are not cracked, GO to B3 .
slit, pinched or obstructed.
Check the 4 roof opening panel No
drain hoses for correct operation. REPAIR or INSTALL a new roof opening panel drain
Are the roof opening panel drain hose(s). TEST the system for normal operation.
hoses OK?
PANEL DRAIN HOSE ATTACHMENT
POINTS
panel drain hose attachment points GO to B4 .
are not damaged or obstructed.
Check the roof opening panel drain No
hose attachment points for correct REPAIR or INSTALL a new roof opening panel frame.
attachment. REFER to Roof Opening Panel in this section. TEST
Are the roof opening panel drain the system for normal operation.
hose attachment points OK?
PANEL TROUGH ASSEMBLY
CONDITION
Check the roof opening panel Yes
trough assembly for damage. GO to B5 .
Is the roof opening panel trough
assembly OK? No
REPAIR or INSTALL a new roof opening panel trough
assembly. REFER to Trough Assembly in this section.
B5 CHECK THE CONDITION OF THE
ROOF OPENING GLASS
Check the roof opening panel frame Yes
for damage that may cause the roof INSTALL a new roof opening panel glass. REFER to
opening panel glass seal to seat Roof Opening Panel Glass in this section. TEST the
incorrectly. system for normal operation.
Is the roof opening panel frame
OK? No
REPAIR or INSTALL a new roof opening panel frame.
REFER to Roof Opening Panel in this section. TEST
Pinpoint Test C: The Roof Opening Panel Rattles
Normal Operation
When the roof opening panel glass is completely closed, it should be within specifications. Refer to
Specifications in this section. Make sure all components are properly secured.
Roof opening panel glass

Roof opening panel air deflector
Roof opening panel shield
Trough assembly
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES

C1 CHECK THE ROOF OPENING PANEL
TIGHTNESS
With the roof opening panel in the Yes
CLOSED position, manually push up ALIGN and TIGHTEN the roof opening panel glass
and fore/aft on the glass panel. fasteners to specification. REFER to Roof
Is the roof opening panel glass Opening Panel Alignment in this section. TEST the
loose? system for normal operation.
No
GO to C2 .
TRACKS
Open the roof opening panel. Yes
Check the roof opening panel tracks for GO to C3 .
obstructions and damage.
Are the roof opening panel tracks No
OK? REMOVE all the roof opening panel track
obstructions and REPAIR the roof opening panel
tracks. If the roof opening panel tracks cannot be
repaired, INSTALL a new roof opening panel
frame. REFER to Roof Opening Panel in this
SHIELD
Check the roof opening panel shield for Yes
correct installation. GO to C4 .
Is the roof opening panel shield
installed correctly? No
INSTALL the roof opening panel shield correctly.
REFER to Roof Opening Panel Shield in this
C4 CHECK THE AIR DEFLECTOR
Check the air deflector for obstructions Yes
and damage. GO to C5 .
Is the air deflector OK?
No
REMOVE all obstructions and REPAIR or
INSTALL a new air deflector. REFER to Air
Deflector in this section. TEST the system for
normal operation.
LIFTER ASSEMBLIES
Verify the roof opening panel lifter Yes
assemblies are free from obstructions GO to C6 .
and damage.
Are the roof opening panel lifter No
assemblies OK? REMOVE all obstructions from the roof opening
panel lifter assemblies and REPAIR any damage.
If the roof opening panel lifter assemblies cannot
be repaired, INSTALL a new roof opening panel
frame. REFER to Roof Opening Panel —
Exploded View and Roof Opening Panel in this
C6 CHECK ROOF OPENING PANEL
FRAME INSTALLATION
Lower the headliner and check all roof Yes
opening fasteners for correct torque GO to C7 .
and verify correct installation of the roof
opening panel frame. Refer to Roof No
Opening Panel — Exploded View and TIGHTEN the loose fasteners to the correct
Roof Opening Panel in this section. specifications or INSTALL the roof opening panel
Is the roof opening panel frame frame correctly. REFER to Roof Opening Panel —
correctly installed and tightened to Exploded View and Roof Opening Panel in this
specification? section. TEST the system for normal operation.
TROUGH ASSEMBLY FOR RATTLES
Check the roof opening panel trough Yes
assembly for any loose parts or for any GO to C8 .
condition that will cause rattles.
Is the trough assembly installed No
securely and free from any condition REPAIR or INSTALL a new roof opening panel
that will cause rattles? trough assembly. REFER to Trough Assembly in
this section. TEST the system for normal
operation.
FRAME FOR RATTLES
Check the roof opening panel frame Yes
assembly for any loose parts or for any INSTALL a suitable sound damper material to
condition that will cause rattles. correct the condition. If the rattle still persists,
Is there a condition that will cause INSTALL a new roof opening panel frame. REFER
rattles? to Roof Opening Panel — Exploded View and
Roof Opening Panel in this section. TEST the
No
INSTALL a new roof opening panel frame. REFER
to Roof Opening Panel in this section. TEST the
Pinpoint Test D: The Roof Opening Panel is Noisy During Operation
Normal Operation
The roof opening panel operates smoothly and quietly while opening and closing.

Roof opening panel shield
PINPOINT TEST D: THE ROOF OPENING PANEL IS NOISY DURING OPERATION

D1 CHECK THE ROOF
OPENING PANEL FOR
OBSTRUCTIONS OR
DAMAGE
Check the roof opening Yes
panel for any REMOVE all obstructions. REPAIR any damage. If the damage
obstructions and cannot be repaired, INSTALL a new roof opening panel frame.
damage. REFER to Roof Opening Panel in this section. TEST the system
Are there any for normal operation.
obstructions and/or
damage? No
GO to D2 .
D2 CHECK THE ROOF
OPENING PANEL
OPERATION
panel during operation. ALIGN the roof opening panel. REFER to Roof Opening Panel
Is the roof opening Alignment in this section. TEST the system for normal operation.
panel glass loose or
incorrectly aligned?
No
GO to D3 .
D3 CHECK THE ROOF
OPENING PANEL TRACKS
Open the roof. Yes
Check the roof opening GO to D4 .
panel tracks for
obstructions and No
damage. REMOVE all obstructions and REPAIR any damage. If the roof
Are the roof opening opening panel tracks cannot be repaired, INSTALL a new roof
panel tracks OK? opening panel frame. REFER to Roof Opening Panel in this
D4 CHECK THE ROOF
OPENING PANEL SHIELD
panel shield for correct GO to D5 .
movement.
Is the roof opening No
panel shield moving REMOVE and REINSTALL the roof opening panel shield. If
correctly? necessary, INSTALL a new roof opening panel shield. REFER to
Roof Opening Panel Shield in this section. TEST the system for
normal operation.
D5 CHECK THE ROOF
OPENING PANEL LIFTER
ASSEMBLIES
panel lifter assemblies GO to D6 .
for obstructions and
damage. No
Are the roof opening REMOVE all obstructions and REPAIR any damage. If the roof
panel lifter assemblies opening panel lifter assemblies cannot be repaired, INSTALL a
OK? new roof opening panel frame. REFER to Roof Opening Panel in
D6 CHECK THE ROOF
OPENING PANEL
MOTOR/MODULE
Remove the roof opening Yes
panel motor/module and INSTALL a new roof opening panel motor/module. REFER to
leave the electrical Roof Opening Panel Motor in this section. TEST the system for
connector connected. normal operation.
Operate the roof opening
panel to the fully OPEN No
and CLOSED position. REINSTALL the roof opening panel motor/module. TEST the
Does the motor/module system for normal operation. If the roof opening panel is still
make excessive noise? noisy, INSTALL a new roof opening panel frame. REFER to Roof
Opening Panel in this section. If the roof opening panel is no
longer noisy, the system is operating correctly. The concern may
have been caused by an incorrectly installed roof opening panel
motor.
Pinpoint Test E: The Roof Opening Panel Does Not Open or Close
Refer to Wiring Diagrams Cell 101 , Roof Opening Panel for schematic and connector information.
Refer to Roof Opening Panel Motor Initialization in this section.
Normal Operation
The roof opening panel uses an integrated motor and module to operate the roof opening panel. A new
roof opening panel motor/module is installed as an assembly.
The roof opening panel motor/module and switch receive voltage from the Central Junction Box (CJB)
when the ignition is in the RUN position. The roof opening panel switch supplies voltage signals to the
roof opening panel motor/module to operate the roof opening panel.
Fuse(s)
Roof opening panel switch
PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE

E1 CHECK THE ROOF OPENING PANEL SWITCH
Ignition OFF. Yes
Disconnect: Roof Opening Panel Switch C912. GO to E2 .
Carry out the roof opening panel switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new roof
opening panel switch. TEST
Is the roof opening panel switch OK? operation.
E2 CHECK THE ROOF OPENING PANEL MODULE GROUND
CIRCUIT FOR AN OPEN
Disconnect: Roof Opening Panel Module C921. Yes
Measure the resistance between roof opening panel module GO to E3 .
C921-1, circuit GD145 (BK/BU), harness side and ground.
No
operation.
E3 CHECK VOLTAGE TO THE ROOF OPENING PANEL
MODULE
Ignition ON. Yes
Measure the voltage between ground and GO to E4 .
roof opening panel module C921-3, circuit CBP08
(GY/YE) No
roof opening panel module C921-6, circuit SBP35 VERIFY CJB fuses 24
(BU/RD) (7.5A) and 35 (20A) are OK.
If OK, REPAIR the affected
circuit(s). TEST the system
for normal operation. If not

E4 CHECK VOLTAGE TO THE ROOF OPENING PANEL
SWITCH
Ignition OFF. Yes
Connect: Roof Opening Panel Module C921. GO to E5 .
Ignition ON.
Measure the voltage between roof opening panel switch No
C912-1, circuit CBP24 (VT/GN), harness side and ground. GO to E8 .
E5 CHECK THE ROOF OPENING PANEL TILT UP CIRCUIT
FOR AN OPEN
Measure the resistance between roof opening panel switch Yes
C912-3, circuit CPR38 (WH/BU), and roof opening panel GO to E6 .
module C921-4, circuit CPR38 (WH/BU) harness side.
No
operation.

E6 CHECK THE ROOF OPENING PANEL CLOSE/DOWN
CIRCUIT FOR AN OPEN
Measure the resistance between roof opening panel module Yes
C921-10, circuit CPR40 (YE/OG), harness side and: GO to E7 .
roof opening panel switch C912-2, circuit CPR40
(YE/OG), harness side. No
roof opening panel switch C912-5, circuit CPR40 REPAIR the affected circuit
(YE/OG), harness side. (s). TEST the system for
normal operation.

E7 CHECK THE ROOF OPENING PANEL OPEN CIRCUIT FOR
AN OPEN
C912-4, circuit CPR31 (VT/BN), and roof opening panel GO to E9 .
module C921-5, circuit CPR31 (VT/BN), harness side.
No
operation.

E8 CHECK THE ROOF OPENING PANEL SWITCH VOLTAGE
CIRCUIT FOR AN OPEN
C912-1, circuit CPR39 (VT/WH), and roof opening panel GO to E9 .
module C921-2, circuit CPR39 (VT/WH), harness side.
No
operation.

E9 CHECK THE ROOF OPENING PANEL MOTOR/MODULE
FOR CORRECT OPERATION
Inspect the roof opening panel motor/module electrical Yes
connector. INSTALL a new roof
Check for: opening panel
corrosion. motor/module. REFER to
bent pins. Roof Opening Panel Motor
pushed-out pins. in this section. TEST the
Connect the roof opening panel motor/module connector and system for normal operation.
make sure it seats correctly.
Operate the system and verify the concern is still present.
corroded connector. TEST
operation.
Pinpoint Test F: The Roof Opening Panel Does Not Open or Close in VENT Position
Refer to Wiring Diagrams Cell 101 , Roof Opening Panel for schematic and connector information.
Refer to Roof Opening Panel Motor Initialization in this section.
Normal Operation
The roof opening panel uses an integrated motor and module to operate the roof opening panel. A new
roof opening panel motor/module is installed as an assembly.
The roof opening panel motor/module and switch receive voltage from the Central Junction Box (CJB)
when the ignition is in the RUN position. The roof opening panel switch supplies voltage signals to the
roof opening panel motor/module to operate the roof opening panel.

Roof opening panel switch
PINPOINT TEST F: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE IN VENT POSITION

F1 CHECK THE ROOF OPENING PANEL SWITCH
Ignition OFF. Yes
Disconnect: Roof Opening Panel Switch C912. GO to F2 .
Carry out the roof opening panel switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new roof
opening panel switch.
TEST the system for
Is the roof opening panel switch OK? normal operation.
F2 CHECK THE ROOF OPENING PANEL CONTROL CIRCUIT FOR
AN OPEN
Disconnect: Roof Opening Panel Motor/Module C921. Yes
Measure the resistance between roof opening panel switch GO to F3 .
C912-3, circuit CPR38 (WH/BU), and roof opening panel
motor/module C921-4, circuit CPR38 (WH/BU) harness side. No
REPAIR the circuit.
TEST the system for
normal operation.

F3 CHECK THE ROOF OPENING PANEL CONTROL CIRCUIT FOR
AN OPEN
Measure the resistance between roof opening panel module Yes
C921-10, circuit CPR40 (YE/OG), harness side and: GO to F4 .
roof opening panel switch C912-2, circuit CPR40
(YE/OG), harness side. No
roof opening panel switch C912-5, circuit CPR40 REPAIR the affected
(YE/OG), harness side. circuit(s). TEST the
system for normal
operation.

F4 CHECK THE ROOF OPENING PANEL MOTOR/MODULE FOR
CORRECT OPERATION
Inspect the roof opening panel motor/module electrical Yes
connector. INSTALL a new roof
Check for: opening panel
corrosion. motor/module. REFER to
bent pins. Roof Opening Panel
pushed-out pins. Motor in this section.
Connect the roof opening panel motor/module connector and TEST the system for
make sure it seats correctly. normal operation.
corroded connector.
TEST the system for
normal operation.
Roof Opening Panel Alignment
roof opening panel system, including: whenever the roof opening panel motor has been removed from
the roof opening panel system, the roof opening panel glass has been removed from the roof opening
panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening
panel motor has been installed, a new roof opening panel glass has been installed or a new roof
opening panel assembly has been installed. For additional information, refer to Roof Opening Panel
Motor Initialization in this section.
1. Position the roof opening panel to the CLOSED position.
2. Place a suitable 1.0-1.2 mm (0.040-0.050 in) thick, 150 mm (5.9 in) long plastic spacer between
the rear edge of the roof opening panel glass and the roof panel opening.
3. Loosen the 4 roof opening panel glass screws.
4. Make sure the roof opening panel is centered in the roof opening. Adjust the roof opening panel
glass height to specification.
5. Tighten the 4 roof opening panel glass screws to 3 Nm (27 lb-in).
6. NOTE: Remove the plastic spacer.
Initialize the roof panel opening motor. For additional information, refer to Roof Opening Panel
Roof Opening Panel Motor Initialization
WARNING: Keep objects and body parts clear of the glass panel when carrying out the
initialization procedure. During the initialization procedure, the glass panel closes with high
force and cannot detect objects in its path. Failure to follow this instruction may result in serious
personal injury.
NOTE: A new roof opening panel motor only moves towards the VENT position until it is initialized.
1. Turn the ignition OFF. For a new roof opening panel motor , only carry out Step 2. For an
existing roof opening panel motor , only carry out Step 3.
2. For a new roof opening panel motor:

2. Press and hold the front of the SLIDE control switch until the roof opening panel glass
moves slightly past the full VENT position and suddenly returns back to the full VENT
position.
3. Release and quickly press and hold the front of the SLIDE control switch while the roof
opening panel glass moves to the full OPEN position and then back to fully CLOSED
position (movement starts approximately 3 seconds after the switch is pressed).
4. Release the switch and verify successful initialization by performing one-touch open and
one-touch VENT operations
3. For an existing roof opening panel motor:

2. Using the SLIDE and/or TILT control switch, position the roof opening panel into the full
VENT position.
3. Press and hold the front of the SLIDE control switch (for approximately 10 seconds) until
the roof opening panel glass moves slightly past the full VENT position and suddenly
returns back to the full VENT position.
4. Release the switch and quickly press and hold the front of the SLIDE control switch while
the roof opening panel glass moves to the full OPEN position and then back to fully
CLOSED position (movement starts approximately 3 seconds after the switch is pressed).
5. Release the switch and verify successful initialization by performing one-touch open and
one-touch VENT operations
Roof Opening Panel — Exploded View

1 31014 Roof opening panel glass screws (4
required)
2 500A18 Roof opening panel glass
3 518A30 Trough assembly
4 500A26 Air deflector
5 38682 Roof opening panel motor bolts (3
required)
6 15B1689 Roof opening panel motor
7 519A02 Roof opening panel shield
8 5450980 Headliner retainer
9 502C52 Front drain hose (2 required)
10 502C53 Rear drain hose (2 required)
11 2919891 (RH) / 2929892 Roof opening panel frame brackets
(LH)
12 W505253 Roof opening panel frame bracket bolts (2
required)
13 W702704 Roof opening panel frame bolts (10
required)

Air Deflector
1. Place the roof opening panel in the full OPEN position.
2. From the top of the vehicle and using a flat-blade screwdriver, press the spring steel locating tab
down on each side while pushing the deflector toward the rear of the vehicle.
3. Tilt the air deflector upward and pull forward to remove.

Make sure the locating tabs are locked firmly in place.
Initialize the roof opening panel motor. For additional information, refer to Roof Opening
Panel Motor Initialization in this section.
Roof Opening Panel
Removal
1. NOTE: Make sure the roof opening panel is in the CLOSED position.
Remove the headliner. For additional information, refer to Section 501-05 .
2. Disconnect the 2 front and the 2 rear drain hoses from the roof opening panel.
3. Disconnect the roof opening panel motor electrical connector.
4. Remove the 10 roof opening panel frame bolts, the 2 roof opening panel frame bracket bolts and
the roof opening panel.
With the aid of an assistant, compress the legs of the roof opening panel retaining clip and
lower the roof opening panel.
5. If installing a new roof opening panel frame, transfer components as necessary.
Installation
1. NOTE: Make sure the roof opening panel is positioned correctly on the retaining clip before
tightening the roof opening panel bolts.
NOTE: Do not fully tighten the roof opening panel frame bolts at this stage.
Compress the legs of the roof opening panel retaining clip and install the roof opening panel.
Loosely install the 10 roof opening panel frame bolts and the 2 roof opening panel frame
bracket bolts.
2. Tighten the 10 roof opening panel frame bolts and the 2 roof opening panel frame bracket bolts in
the sequence shown.
3. Connect the roof opening panel motor electrical connector.
4. Connect the 2 front and the 2 rear drain hoses to the roof opening panel.
6. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel
Roof Opening Panel Glass
Removal
1. Position the roof opening panel to the CLOSED position.
2. Remove the 4 roof opening panel glass screws.
3. Remove the roof opening panel glass.
Installation
1. NOTE: Do not fully tighten the roof opening panel glass screws at this stage.
Position the roof opening panel glass and loosely install the 4 screws.
2. Align the roof opening panel glass. For additional information, refer to Roof Opening Panel
Alignment in this section.
Roof Opening Panel Shield
1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel
Glass in this section.
2. Slide the roof opening panel shield forward halfway.
3. Disengage the roof opening panel shield guide feet.

Lift the front portion of the roof opening panel shield upward at center until able to
disengage one of the front guide feet.
4. With one of the guide feet released, carefully rotate the roof opening panel to disengage the
remaining guide feet.

Roof Opening Panel Motor
Removal
1. Remove the LH and RH A- and B-pillar trim panels. For additional information, refer to Section
501-05 .
2. Remove the roof opening panel headliner retainer (trim ring).
4. Position aside the front door weatherstrip as necessary and lower the front portion of the
headliner.
5. Disconnect the roof opening panel motor electrical connector.
6. Remove the 3 bolts and the roof opening panel motor.
Installation
1. Install the roof opening panel motor and the 3 bolts.

2. Connect the roof opening panel motor electrical connector.
3. Raise the front of the headliner and reposition the front door weatherstrip.
4. Install the LH and RH sun visors.
5. Install the roof opening panel headliner retainer (trim ring).
6. Install the LH and RH A- and B-pillar trim panels. For additional information, refer to Section 501-
05 .
Trough Assembly
1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel
Glass .
2. Remove the roof opening panel, For additional information, refer to Roof Opening Panel .
3. Using a suitable tool, pry the trough assembly guides from the trough assembly.
4. Gently raise the trough assembly and slide the trough assembly guides under the trough
assembly.
5. Slide the trough assembly rearward until the trough assembly is approximately 76.2 mm (3 in)
from the roof opening panels rear edge.
6. NOTICE: Use care when disconnecting the trough assembly from the roof opening panel
tracks to prevent damage to the trough assembly.
Gently flex the roof opening panel tracks and release the trough assembly from the tracks.
SECTION 501-19: Bumpers 2011 Fiesta Workshop Manual
Front bumper bolts 25 18 —
Front bumper cover bolts 8 — 71
Rear bumper nuts 25 18 —
Bumper — Exploded View, Front

1 W705297 License plate bracket rivet (3 required)
2 17A385 License plate bracket
3 8200 Lower radiator grille outer frame
4 8200 Lower radiator grille
5 8213 Emblem
6 8200 Upper radiator grille
7 N807389 Upper radiator grille pin-type retainer (4 required)
8 8213 Emblem base (5-door hatchback only)
9 8A284 Upper radiator grille reinforcement
10 W714040 Upper radiator grille reinforcement pin-type retainer
(4 required)
11 17D957 Front bumper cover
12 17E856/ Front bumper cover bracket (RH/LH)
17E857
13 W520822 Front bumper cover bracket nut (6 required)
14 W706737 Upper radiator grille lower reinforcemnet bracket rivet
15 8A284 Upper radiator grille lower reinforcement bracket
16 W503924 Front bumper cover screw (6 required)
17 W710763 Radiator lower air deflector retainer (3 required)
18 W701054 Front fender splash shield retainers (4 required)
19 17E810/ Supplemental parking lamps cover (RH/LH)
17E811

Bumper Cover — Front
100-02 .
2. Remove the front wheels and tires. For additional information, refer to Section 204-04 .
3. If equipped, remove the 2 front stone deflector extension retainers on both sides from inside the
front wheel wells.
4. If equipped, remove the 2 bolts and both of the front stone deflector extension.
5. Remove both front fender splash shields. For additional information, refer to Section 501-02 .
6. Disconnect the front bumper cover from the bumper cover brackets.
1. Remove the 3 front bumper cover-to-front bumper cover bracket bolts on both sides.
2. Gently pull down on the front bumper cover to disconnect it from the bumper cover
brackets on both sides.
7. If equipped, disconnect the auxiliary parking lamp electrical connectors.
8. Remove the front bumper cover bolt on the underside of vehicle.
9. Remove the 4 upper radiator grille reinforcement-to-radiator support pin-type retainers and
remove the front bumper cover assembly.
Transfer all necessary components.
Bumper — Front

1 W709933 Front bumper bolt (8 required)
2 W701121 Front bumper-to-radiator grille opening panel
reinforcement bolt (4 required)
3 W713533 Radiator grille opening panel reinforcement-to-front
bumper bolts (2 required)
4 17B749/ Front bumper mounting bracket (RH/LH)
17B750
5 17757 Front bumper
1. Remove the front severity sensors. For additional information, refer to Section 501-20B .
2. Disconnect the front severity sensors wiring harness retainers from the front bumper.
3. Remove the both headlamp assemblies.

2. Disconnect and remove both headlamp assemblies.
4. Disconnect the horn electrical connector.
5. Disconnect the wiring harnesses attached to the front bumper.

3 on the RH side.
4 on the LH side.
6. If equipped, remove the 2 radiator side air deflector upper retainers.

7. If equipped, remove the 2 retainers and the both lower air deflectors.
8. Disconnect and remove the ambient temperature sensor from the bottom of the front bumper.
9. Support the underside of the radiator support housing prior to removing the front bumper bolts.
10. Remove the 2 radiator grille opening panel reinforcement-to-front bumper bolts.
11. Remove the 4 front bumper-to-radiator grille opening panel reinforcement bolts.
12. Remove the radiator grille opening panel reinforcement support-front bumper bolt.
13. With the help of an assistant, remove the 8 front bumper bolts and remove the front bumper.

Bumper — Exploded View, Rear
4-Door Sedan

1 W711035 Rear stone deflector pin-type retainer (2 required)
2 17808 Rear stone deflector
3 17K835 Rear bumper cover
4 16A550 Rear mudflap (RH/LH)
5 W710754 Rear mudflap clip (6 required)
6 17D942/ Rear bumper cover mounting bracket (RH/LH)
17D943
7 W709095 Rear bumper cover mounting bracket rivet (4 required)
8 W706817 Rear bumper nut (6 required)
9 17906 Rear bumper
10 17D995 Rear bumper cover center reinforcement
11 W709095 Rear bumper cover center reinforcement rivet (4
required)
12 16K262 Rear bumper cover-to-rear bumper cover mounting
bracket pin-type retainer (2 required)
13 W707977 Rear bumper cover retainer nut (2 required)
14 W713090 Rear bumper cover screw (2 required)
15 17A750 Rear bumper mounting bracket (RH/LH)
16 17D942/ Rear bumper cover reinforcement (RH/LH)
17D943
17 W708590 Rear bumper cover reinforcement retainer nut (2
required)
18 W700092 Rear bumper cover-to-rear bumper cover
reinforcement retainer (2 required)
19 W709095 Rear bumper cover reinforcement rivet (12 required)
20 W701054 Rear wheel splash shield pin-type retainer (2 required)
21 W707433 Rear mudflap retainer (2 required)
5-Door Hatchback

1 W711035 Rear stone deflector pin-type retainer (2 required)
2 17808 Rear stone deflector
3 17K835 Rear bumper cover
4 17D942/ Rear bumper cover mounting bracket (RH/LH)
17D943
5 W709095 Rear bumper cover mounting bracket rivet (4 required)
6 17906 Rear bumper
7 W706817 Rear bumper nut (8 required)
8 17A750 Rear bumper mounting bracket (RH/LH)
9 17D942/ Rear bumper cover reinforcement (RH/LH)
17D943
10 W708590 Rear bumper cover reinforcement retainer nut (2
required)
11 W700092 Rear bumper cover-to-rear bumper cover
reinforcement retainer (2 required)
12 W709095 Rear bumper cover reinforcement rivet (8 required)
13 W701054 Rear wheel splash shield pin-type retainer (4 required)
14 17D995 Rear bumper cover center reinforcement
15 W707977 Rear bumper cover retainer nut (2 required)
16 16K262 Rear bumper cover-to-rear bumper cover mounting
bracket pin-type retainer (2 required)
17 W713090 Rear bumper cover screw (2 required)

Bumper Cover — Rear
4-Door Sedan and 5-Door Hatchback
NOTE: Illustrations are from a 5-door hatchback, 4-door sedan similar.
100-02 .
2. Remove the 2 rear bumper screws.
3. Remove the rear lamp assembly. For additional information, refer to Section 417-01 .
4. Remove the rear bumper cover-to-rear bumper cover mounting bracket pin-type retainer.
5. Remove both rear wheels and tires. For additional information, refer to Section 204-04 .
4-Door Sedan
6. If equipped, remove the 3 rear mudflap retainers.

7. If equipped, disconnect the 3 clips and remove the rear mudflaps.
8. Position both rear wheel splash shields aside.
5-Door Hatchback
9. Remove the 2 pin-type retainers and position both rear wheel splash shields.
4-Door Sedan and 5-Door Hatchback
NOTE: 5-door hatchback shown, 4-door sedan similar.
10. Remove the rear bumper cover-to-bumper cover bracket bolt.
11. Remove the 2 rear stone deflector-to-rear bumper bracket pin-type retainers.
12. NOTE: The rear bumper cover is attached to the rear bumper cover brackets by 6 clips on each
side.
Release the 6 clips on each side and remove the rear bumper cover.
13. Inspect the rear bumper cover mounting brackets for damage at the attaching points. If
necessary, install new bumper cover mounting reinforcements before installation.

Bumper — Rear
1. Remove the rear bumper cover. For additional information, refer to Bumper Cover — Rear in this
section.
2. Remove the rear bumper nuts.

4-door sedan has 6 nuts (3 each side).
5-door hatchback has 8 nuts (4 each side).
3. Remove the rear bumper.

SECTION 501-20A: Safety Belt System 2011 Fiesta Workshop Manual
Front Safety Belts
D-ring bolt 40 30 —
Safety belt anchor bolt 40 30 —
Safety belt buckle bolt 48 35 —
Safety belt retractor and pretensioner large bolt 40 30 —
Safety belt retractor and pretensioner small bolt 14 — 124
Safety belt retractor bolt 40 30 —
Safety belt shoulder height adjuster bolt 40 30 —
Rear Safety Belts
Child safety seat tether anchor bolt 28 21 —
D-ring bolt 40 30 —
Hinge pin bolt 38 28 —
Safety belt anchor bolt (with and without safety belt buckle) 48 35 —
Safety belt buckle bolt 48 35 —
Safety belt retractor bolt, rear, center, 4-door sedan 40 30 —
Safety belt retractor bolt, rear, center, 5-door hatchback 48 35 —
Safety belt retractor bolt, rear, outboard 40 30 —
Safety Belt System
WARNING: After any crash, all of the following safety belt assemblies and attaching
hardware must be inspected to verify correct function:
Retractors
Buckles
Automatic locking retractor (ALR) feature for child safety seats (passenger seating
positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Component Tests of this section, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety
belt pretensioners, new driver and/or front outboard passenger safety belt systems (including
retractors, buckles and height adjusters) must be installed. Failure to install new safety belt
systems increases the risk of serious personal injury or death in a crash.
Use only the replacement parts specified in the Ford Catalog Advantage™ or equivalent when installing
new safety belt buckles and/or retractor assemblies.
Active Restraint System Components
The active restraint system consists of the following serviceable items:
Front safety belt shoulder height adjusters

Front safety belt buckles attached to the inboard side of the seats
Front safety belt retractors and pretensioners (pretensioner feature available only on vehicles
equipped with Supplemental Restraint System (SRS)) located behind the lower B-pillar trim
panels
Rear center safety belt retractor attached to the parcel shelf sheet metal (4-door sedan) or LR
seat frame (5-door hatchback) and LH safety belt buckle assembly attached to the floor pan
under the rear seat cushion
Rear safety belt retractors (outboard) attached to the parcel shelf sheet metal (4-door sedan) or
C-pillars (5-door hatchback)
Rear dual safety belt buckle assembly (RH and center safety belt buckles) attached to the floor
pan
Child safety seat tether anchors located on the parcel shelf (4-door sedan) or on the back of the
second row seat back rest (5-door hatchback), at all 3 seating positions
Lower Anchors and Tethers for CHildren (LATCH) attached to the floor pan
Safety Belt Retractors
The safety belt retractors consist of the following components:
Safety belt retractor pretensioner (front only), on vehicles equipped with SRS
Adaptive load limiting (front passenger only), on vehicles equipped with SRS
Dual locking mode
Emergency Locking Retractor (ELR)
Automatic Locking Retractor (ALR) (all except driver seat)
Belt Tension Sensor (BTS) (front passenger only), on vehicles equipped with SRS
Automatic Locking Retractor (ALR)
The ALR mode is used when locking a child seat in any passenger seating position. The ALR mode
automatically activates when the safety belt webbing is fully extracted from the retractor and then
allowed to retract. As the safety belt webbing retracts back onto the spool, an audible clicking sound is
made indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out
of the safety belt retractor. The ALR mode disengages when the webbing is allowed to fully retract back
into the retractor. For testing, refer to the appropriate Functional Test procedure in Safety Belt System in
this section.
Safety Belt Retractor Pretensioner
The safety belt retractor pretensioner is a pyrotechnic device that removes excess webbing from the
safety belt system when deployed by the SRS . When the pretensioner deploys, the retractor spools in
the safety belt webbing, removing excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a crash resulting in pretensioner deployment, install a new safety belt
retractor pretensioner. For safety belt retractor pretensioner diagnosis and disposal information, refer to
Section 501-20B .
If the ignition is ON with the safety belt retractor pretensioner electrical connector(s) disconnected, a
DTC sets.
The pretensioner feature is only available on the front safety belt retractors of SRS -equipped vehicles.
Adaptive Load Limiting
Adaptive load limiting safety belt retractors are pyrotechnic devices integrated with the front passenger
safety belt retractor assembly. The adaptive load limiting safety belt retractor works in conjunction with
the safety belt pretensioner to control the tension of the front passenger safety belt. The Restraints
Control Module (RCM) monitors the readiness of the adaptive load limiting safety belt retractor. The
RCM uses this information and all other information provided by the restraints system to determine what
action is to be taken.
The adaptive load limiting pyrotechnic device feature is only available on the front passenger safety belt
retractors of SRS -equipped vehicles.
Emergency Locking Retractor (ELR)
The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during hard
braking, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps
reduce the forward movement of the driver and passengers. For testing, refer to the appropriate
Functional Test procedure in Safety Belt System in this section.
Belt Tension Sensor (BTS)
The BTS is located at the front passenger safety belt retractor anchor point and operates as part of the
Occupant Classification System (OCS) system on the front passenger seat. To diagnose the BTS , refer
to Section 501-20B .
Safety Belt Buckles
Front Safety Belt Buckles
The front seat safety belt buckles are attached to the front seat tracks.
On vehicles equipped with an SRS , the front safety belt buckles have a switch indicating buckle status
to the RCM . To diagnose the buckle switch, refer to Section 501-20B .
Rear Safety Belt Buckles
The rear seat safety belt buckles are attached to the floor pan under the rear seat cushion. The LH
safety belt buckle is part of the rear center safety belt retractor and is serviced as an assembly. The rear
dual safety belt buckle assembly (RH and center buckle) is also serviced as an assembly.
Child Safety Seat Restraints
The child safety seat restraints include the following items:
Serviceable child safety seat tether anchor located at the rear seating positions, bolted to the
parcel shelf sheet metal on 4-door sedans. On 5-door hatchbacks, the child safety seat tether
anchors are part of the second row seat back and are not serviced separately from the seat back.
Non-serviceable Lower Anchors and Tethers for CHildren (LATCH), welded to the floor pan.
If a child safety seat was in use during a collision, inspect the vehicle structure at the child safety seat
component mounting areas, repair any damage and restore the vehicle to the original production
configuration.
Safety Belt System
Retractors
Buckles
positions only)
Safety Belt Warning System
The safety belt warning system is present only on vehicles equipped with a Supplemental Restraint
System (SRS). The conditions of operation for the safety belt warning indicator and chime are as
follows:
If the driver safety belt is not buckled when the ignition is ON, the safety belt warning indicator
illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds.
If the driver safety belt is buckled while the warning indicator is illuminated and the chime is
sounding, the warning indicator and warning chime turn OFF.
If the driver safety belt is buckled before the ignition is turned ON, the warning indicator and
chime remain off.
Belt-Minder®
The Belt-Minder® feature is present only on vehicles equipped with an SRS and is a supplemental
warning to the safety belt warning function. This feature provides additional reminders that the driver
and/or front passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the
safety belt warning indicator in the Instrument Panel Cluster (IPC).
Either the driver or front passenger safety belt systems may activate the Belt-Minder®. If the Belt-
Minder® warnings have expired (warnings last for approximately 5 minutes) for one occupant (driver or
front passenger), the other occupant can still activate the Belt-Minder® feature.
The passenger Belt-Minder® feature is activated only when the Occupant Classification System (OCS)
system detects a passenger in the right front seat and the passenger weight exceeds a programmed
limit. For information on the OCS system, refer to Section 501-20B .
To activate or deactivate the Belt-Minder® feature, refer to Section 413-01 .
If... Then...
the driver or front passenger safety belt is not the Belt-Minder® feature is activated, safety belt
buckled when the vehicle has reached at least 5 warning indicator illuminates and warning chime
km/h (3 mph) and 1 to 2 minutes have elapsed sounds for 6 seconds every 30 seconds,
since the ignition has been turned ON... repeating for approximately 5 minutes or until the
safety belt(s) is buckled.
the driver or front passenger safety belt becomes the Belt-Minder® feature is activated, the safety
unbuckled for approximately 1 minute while the belt warning indicator illuminates and warning
vehicle is traveling at least 5 km/h (3 mph) and chime sounds for 6 seconds every 30 seconds,
more than 1 to 2 minutes have elapsed since the repeating for approximately 5 minutes or until the
ignition has been turned ON... safety belt(s) is buckled.
the driver and/or passenger safety belt is buckled the Belt-Minder® feature will not activate.
before the ignition is turned ON or less than 1 to 2
minutes have elapsed since the ignition has been
turned ON...
1. Verify the customer concern by operating the active restraint system to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply:

Safety belt webbing integrity (torn, frayed, Wiring, terminals or connectors
cut or stretched) Safety belt warning indicator burned out or
Safety belt buckle and tongue broken
Safety belt retractor High Speed Controller Area Network (HS-
CAN) concern
3. If the inspection reveals an obvious concern(s) that can be readily identified, service 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.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
5. To check the active restraint system for correct operation, carry out the appropriate Functional
Test procedure(s). Refer to Component Test in this section.
Symptom Chart
Symptom Chart
The safety belt Burned-out If the air bag warning indicator is
warning indicator indicator illuminated, REFER to Section 501-
does not operate Wiring, 20B . If the air bag warning
terminals or indicator is not illuminated, REFER
connectors to Section 413-01 .
Instrument
Panel Cluster
(IPC)
Restraints
Control Module
(RCM)
The safety belt Wiring, If the air bag warning indicator is
warning chime terminals or illuminated, REFER to Section 501-
does not operate connectors 20B . If the air bag warning
Safety belt indicator is not illuminated, REFER
buckle switch to Section 413-01 .
IPC
RCM
The safety belt Safety belt CARRY OUT the Functional Test
retractor webbing retractor is in — Safety Belt Retractor and
does not extract Automatic Functional Test — Safety Belt
or exhibits Locking Retractor, ALR Mode. REFER to
excessive Retractor Component Test in this section.
pressure on the (ALR) mode INSTALL new components as
occupant during Safety belt directed.
use retractor
binding
internally
The safety belt Twisted or CORRECT the twisted safety belt
retractor webbing incorrectly webbing. REFER to Safety Belt
does not retract routed safety Tongue Rotated on Belt or Safety
or has excessive belt webbing Belt Twisted at the Safety Belt
slack during use Safety belt Guide in this section. CARRY OUT
retractor the appropriate Functional Test
binding procedure. REFER to Component
internally Test in this section.
Safety belt INSTALL a new safety belt
retractor retractor. REFER to Safety Belt
Retractor — Front , Safety Belt
Retractor — Rear, Center, 4-Door
Sedan , Safety Belt Retractor —
Rear, Center, 5-Door Hatchback ,
Safety Belt Retractor — Rear,
Outboard, 4-Door Sedan , or
Safety Belt Retractor — Rear,
Outboard, 5-Door Hatchback in this
section.
The Belt-Minder® Belt-Minder® REFER to Section 413-01 or the
feature is feature is Seating and Safety Restraints
inoperative deactivated section of the Owner's Literature to
Wiring, activate the Belt-Minder® feature.
terminals or If the Belt-Minder® is activated,
connectors REFER to Section 413-01 to
diagnose.
The safety belt Twisted or REFER to Safety Belt Tongue
tongue is rotated incorrectly Rotated on Belt in this section.
on the safety belt routed safety
webbing belt webbing
The safety belt Twisted or REFER to Safety Belt Twisted at
webbing is incorrectly the Safety Belt Guide in this
twisted at the routed safety section.
safety belt guide belt webbing
The safety belt Dirty or soiled REFER to Safety Belt Cleaning in
webbing is dirty or safety belt this section.
soiled webbing
Component Test
Retractors
Buckles
positions only)
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test — Safety Belt Buckle and Tongue
The safety belt buckle and tongue assembly must operate freely during the latching and unlatching
function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion).
1. Verify the following during the latching sequence:

Tongue insertion is not hindered by excessive effort.
A click is heard when the safety belt buckle latches the tongue.
2. Verify the system integrity by forcefully pulling on the safety belt webbing.
3. Unlatch the safety belt by fully pressing the safety belt buckle release button and allowing the
safety belt to release and retract.
4. Verify the following during the unlatching process:
Pressing the push-button does not require excessive effort.
The tongue can be removed easily from the buckle.
5. Repeat the above steps 3 times.
6. If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor
as required.
Functional Test — Safety Belt Retractor
The safety belt retractor must be freely operational for extraction and retraction of the safety belt
webbing between full extension and in-vehicle stowed positions.
1. Extract and retract the safety belt between the full extension and stowed positions.
2. Verify the safety belt retractor operates without excessive effort or binding.
3. Install a new safety belt retractor if any concern is found or the complaint has been verified.
Functional Test — Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode
1. Position the seat backrest fully upright (if adjustable).
2. Position the safety belt shoulder height adjuster (if equipped) in the full down position.
3. Fasten the safety belt.
4. Pull out the safety belt webbing until the Automatic Locking Retractor (ALR) feature is activated.
5. Allow the safety belt webbing to retract until it stops.
6. Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR
mode. If the safety belt retractor is not locked, install a new safety belt retractor.
7. Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position.
8. Pull out and retract the safety belt webbing to verify the safety belt retractor has converted
automatically out of ALR mode. If the safety belt retractor remains locked in the ALR mode, install
a new safety belt retractor.
Functional Test — Safety Belt Retractor, Road Test Inspection
WARNING: The driver and passenger must be prepared to brace themselves in the event
the safety belt retractor does not lock. Failure to follow this instruction may result in serious
personal injury.
NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing.
NOTE: Do not jerk on the safety belt webbing when carrying out this test.
1. Test the safety belts in the following sequence:
1. Fasten the safety belts and proceed to a safe area.
2. Reach a speed of 24 km/h (15 mph).
3. WARNING: Apply maximum brake force only on dry concrete or equivalent

hard surface, NEVER on wet pavement or gravel. Failure to follow this instruction
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum
braking application without a skid.
4. The safety belts should lock up with minimum webbing extension.
5. If there is a lockup of all safety belt retractors being tested, the safety belt retractors are
functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt
retractor(s).
Safety Belt Cleaning
1. WARNING: Do not bleach or re-dye the safety belt webbing, as the webbing may
weaken. Failure to follow this instruction may increase the risk of serious personal injury
or death in a crash.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning
upholstery or carpets. Follow the instructions provided with the soap.
Safety Belt Maintenance
Retractors
Buckles
positions only)
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
Procedures. For additional information, refer to Safety Belt System in this section.
Safety Belt Procedure After a Collision
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected to verify correct function:
Retractors
Buckles
Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional
Tests in the Component Tests of this section, a new safety belt assembly must be installed. If any safety
belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original
structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to
install new safety belt assemblies and attaching hardware may increase the risk of serious personal
injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the
risk of serious personal injury or death in a crash.
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). For additional information, refer to the procedure in this section. Carry out
the Functional Test. For additional information, refer to the appropriate Functional Test procedure in
Safety Belt System in this section.
Safety Belt Tongue Rotated on Belt
1. Fold the safety belt as indicated.
2. Pull the safety belt tongue over the fold in the safety belt.
Safety Belt Twisted at the Safety Belt Guide
NOTE: These procedures apply to both wire-formed and stamped D-ring designs.
1. Grasp the safety belt webbing at the D-ring and fold the twisted portion of the belt webbing over
itself.
2. Feed the folded portion of the safety belt webbing through the safety belt guide (D-ring) to remove
the twist from the belt webbing.
Safety Belt Buckle — Front

1 — Safety belt buckle bolt (part of 61202 RH/ 61203 LH)
2 61202 RH/ Safety belt buckle assembly
61203 LH
3 — Safety belt buckle switch electrical connector (part of
61202 RH/ 61203 LH) (if equipped)
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware
must be inspected to verify correct function:
Retractors
Buckles
only)
Functional Tests in the Component Tests of this section, a new safety belt assembly must be installed.
If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored
to its original structural integrity and new safety belt assembly and attaching hardware must be
installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of
1. Remove the front seat. For additional information, refer to Section 501-10 .
2. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupants.
Complete the removal by referring to the exploded view.
3. Check the active restraint system for correct operation. For additional information, refer to Safety Belt
System in this section.
Safety Belt Retractor — Front
NOTE: LH shown, RH similar.

1 60262 D-ring cover
2 — Safety belt D-ring bolt (part of 611B08 (RH) /
611B09 (LH))
3 — Safety belt guide (part of 611B08 (RH) /
611B09 (LH))
4 611B08 (RH) / Safety belt retractor
611B09 (LH)
5 — Safety belt anchor bolt (part of 611B08 (RH) /
611B09 (LH))
6 W712015 Safety belt retractor bolt
7 63918 B-pillar lower trim panel retaining clip (2
required)
(LH)
Retractors
Buckles
only)
1. Remove the lower B-pillar trim panel. For additional information, refer to Section 501-05 .
2. Pull straight out on the D-ring cover and remove.
Safety Belt Buckle — Rear

1 60045 Safety belt buckle assembly
2 — Safety belt buckle bolt (part of 60045)
Retractors
Buckles
only)
NOTE: The LH safety belt buckle is a part of the rear center safety belt retractor and is not serviced separately.
To remove the LH safety belt buckle, refer to Safety Belt Retractor — Rear, Center, 4-Door Sedan or Safety
Belt Retractor — Rear, Center, 5-Door Hatchback In this section.
Safety Belt Retractor — Rear, Center, 4-Door Sedan

Retractors
Buckles
only)
1. Remove the parcel shelf. For additional information, refer to Section 501-05 .
Safety Belt Retractor — Rear, Center, 5-Door Hatchback

1 66601/66801 Backrest cover/backrest foam pad
2 611B66 Safety belt retractor assembly
3 611A70 Safety belt bezel
4 60509 Seatback panel assembly
5 W790240 Safety belt retractor bolt - 48 Nm (35 lb-ft)
6 613B48 Hinge pin and bolt - 38 Nm (28 lb-ft)
Retractors
Buckles
only)
1. Remove the 60 percent rear seat backrest. For additional information, refer to Section 501-10 .
2. Detach the safety belt retractor bezel from the backrest frame wire and remove the bezel.
Pull where shown to unsnap the safety belt bezel from the backrest frame wire.
3. Remove the hinge pin and bolt.
4. Detach the backrest cover retainer from the backrest frame at the rear of the backrest.
5. Make a small cross cut into the carpet above the safety belt retractor bolt.
Push into the carpet on the rear of the backrest and feel for the safety belt retractor bolt.

1. Remove the safety belt retractor bolt.
2. Lift the backrest foam pad and cover.
3. Route the safety belt and tongue out of the backrest cover.
Safety Belt Retractor — Rear, Outboard, 4-Door Sedan

1 52018 (RH) / 52016 Parcel shelf upper trim panel
(LH)
2 W714232 Parcel shelf upper trim panel retaining clip (2
required)
3 W710338 Parcel shelf upper trim panel retaining clip

Retractors
Buckles
only)
1. Remove the parcel shelf upper trim panel. For additional information, refer to Section 501-05 .
Safety Belt Retractor — Rear, Outboard, 5-Door Hatchback

1 31010 (RH)/31011 C-pillar upper trim panel
(LH)
required)
3 W714232 C-pillar upper trim panel 2-stage high-
retention retaining clip
4 — D-ring bolt (part of 611B68)
5 W504775 Safety belt retractor bolt
6 611B68 (RH)/611B69 Safety belt retractor
(LH)
7 W703708 Rear safety belt anchor bolt
Retractors
Buckles
only)
1. Remove the quarter trim panel. For additional information, refer to Section 501-05 .
3. Complete the removal by referring to the exploded view.
Safety Belt Retractor and Pretensioner

1 60262 D-ring cover
2 — Safety belt D-ring bolt (part of 611B08 (RH) /
611B09 (LH))
3 — Safety belt guide (part of 611B08 (RH) / 611B09
(LH))
4 — Safety belt retractor and pretensioner electrical
connector (part of 14A005)
5 611B08 (RH) / Safety belt retractor and pretensioner
611B09 (LH)
6 — Belt Tension Sensor (BTS) electrical connector
(part of 14A005) (passenger side only)
7 — Safety belt retractor and pretensioner load limiting
electrical connector (part of 14A005) (passenger
side only)
8 W505252 Safety belt retractor and pretensioner bolt
9 W712015 Safety belt retractor and pretensioner bolt
10 — Safety belt anchor bolt (part of 611B08 (RH) /
611B09 (LH))
Retractors
Buckles
only)
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners or

adaptive load limiting retractors or probe the electrical connectors. Failure to follow this instruction
may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting
retractors which increases the risk of serious personal injury or death.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is
removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing
the vehicle to the customer.
1. Depower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of Section 501-20B .
2. Remove the lower B-pillar trim panel. For additional information, refer to Section 501-05 .
3. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a
new D-ring cover.
Remove the D-ring cover and D-ring bolt.

Pull straight out on the D-ring cover to remove.

For passenger seat, disconnect the Belt Tension Sensor (BTS) electrical connector.
5. NOTICE: Do not pull the electrical connector out by the locking button. Damage to the locking
button can occur.
Disconnect the safety belt retractor and pretensioner electrical connector(s).

Lift up and release the locking button and disconnect the electrical connector.
For driver and passenger sides, disconnect the pretensioner electrical connector.
For passenger side, disconnect the load limiter electrical connector.
6. Detach the safety belt guide from the B-pillar.
7. Remove the 2 bolts and the safety belt retractor and pretensioner.
Installation
NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles
are accessible to the occupants.
1. Position the safety belt retractor and pretensioner and install the bolts.
Tighten the large bolt to 40 Nm (30 lb-ft).
Tighten the small bolt to 14 Nm (124 lb-in).
2. Attach the safety belt guide to the B-pillar.
3. NOTICE: The locking button must be in the released position before installing the connector into
the safety belt retractor and pretensioner. Failure to have the locking button in the released
position may break the tabs on the locking button causing Diagnostic Trouble Codes (DTCs) to
set in the Restraints Control Module (RCM).
Connect the safety belt retractor and pretensioner electrical connector(s).

With the locking button released, install the electrical connector fully into the safety belt retractor
and pretensioner and seat the locking button.
For driver and passenger sides, connect the pretensioner electrical connector.
For passenger side, connect the load limiter electrical connector.
4. Install the safety belt anchor bolt.
For passenger seat, connect the Belt Tension Sensor (BTS) electrical connector.
5. Install the lower B-pillar trim panel. For additional information, refer to Section 501-05 .
6. NOTE: If the D-ring cover is damaged or does not remain closed, install a new D-ring cover.
Install the D-ring bolt and cover.

7. Repower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of Section 501-20B .
Safety Belt Shoulder Height Adjuster

1 — Safety belt height adjuster bolt (part of 602B82)
2 602B82 Safety belt shoulder height adjuster
Retractors
Buckles
only)
1. Remove the upper B-pillar trim panel. For additional information, refer to Section 501-05 .
SECTION 501-20B: Supplemental Restraint System 2011 Fiesta Workshop Manual
Front impact severity sensor nut 11 — 97
Ignition switch housing bolt 8 — 71
Knee air bag module nuts 8 — 71
Passenger air bag module nuts 6 — 53
Passenger air bag module bracket nuts 6 — 53
Restraints Control Module (RCM) nuts 11 — 97
Side air bag module nuts a — — —
Side air curtain module bolts 9 — 80
Side air curtain roof bracket bolts (5-door hatchback) 9 — 80
Side impact sensor bolts (front door) 2 — 18
Side impact sensor bolt (second row) 11 — 97
Steering wheel bolt 40 30 —
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
The air bag Supplemental Restraint System (SRS) is designed to provide increased collision protection for front
and rear seat occupants in addition to the collision protection provided by the 3-point safety belt system. Safety
belt use is necessary to obtain the best occupant protection and to receive the full advantage of the SRS .
The serviceable air bag and safety belt pretensioner SRS components are shown in the following illustrations.
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components — Illustration
1 of 2
1 54632A22 Occupant Classification System (OCS) system
2 14B416 Driver/passenger seat track position sensor
3 14B345 Driver/passenger first row side impact sensor
(pressure sensor) (located in front door)
4 14B004 Driver/passenger second row side impact
sensor (C-pillar)
5 14B004 LH/RH front impact severity sensor
6 10A936 Passenger Air Bag Deactivation (PAD) indicator
7 14B321 Restraints Control Module (RCM)
8 5461202 Safety belt buckle (includes safety belt buckle
(RH)/5461203 (LH) switch)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Components — Illustration
2 of 2
1 54044A74 Passenger air bag module
2 54611B08 Passenger safety belt retractor and
pretensioner (includes deployable load limiter
and Belt Tension Sensor (BTS))
3 54611D10 Driver/passenger seat side air bag module
(LH)/54611D11 (RH)
4 54042D94 Driver/passenger side air curtain module
(RH)/54042D95 (LH)
5 14A664 Clockspring
6 54043B13 Driver air bag module
7 54045J77 Driver knee air bag module
8 54611B09 Driver safety belt retractor and pretensioner
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Special Tool(s)
Flex Probe Kit


System (IDS)
software with appropriate hardware,
or equivalent scan tool
The Restraints Control Module (RCM) continuously receives/monitors all inputs from the following
Supplemental Restraint System (SRS) components:
LH and RH front impact severity sensors

Driver and passenger front door side impact sensor
Driver and passenger second row side impact sensors (C-pillar)
Safety belt buckle switches (driver and passenger)
Seat track position sensors (driver and passenger)
Occupant Classification System Module (OCSM)
Safing sensors internal to the RCM
If the RCM detects sudden vehicle deceleration and/or lateral deceleration based on the information received
from all sensors and switches and determines that deployment is required, the RCM sends voltage and current
to deploy the appropriate SRS components.
During a frontal or side crash, the RCM may deploy the following SRS components, based on crash severity
and sensor input.
Safety belt retractor pretensioner(s)

Safety belt load limiter (passenger side only)
Seat side air bag(s)
Side air curtain(s)
Driver and passenger dual-stage air bag(s) (one or both stages)
Driver knee air bag
The fact that the safety belt retractor pretensioner, safety belt load limiter, side air curtain, or air bags did not
activate for both front seat occupants in a crash does not mean that something is wrong with the system.
The RCM performs a self-test of the complete SRS during each start up. If a SRS fault exists, the air bag
warning indicator illuminates and remains illuminated for the rest of the ignition cycle. In addition to the self-test
at start up, the RCM continuously monitors all of its SRS components and circuitry for correct operation.
Air Bag Warning Indicator
The air bag warning indicator:
located in the Instrument Panel Cluster (IPC), proves out by illuminating for 6 seconds and then turning
off.
flashes and/or illuminates based on the message the IPC receives from the RCM .
illuminates if the IPC does not receive a message from the RCM .
Air Bag Module Second Stage Deployment Check
Because the driver and passenger front air bags each have 2 deployment stages, it is possible that stage 1 has
deployed and stage 2 has not.
If a front air bag module has deployed, it is mandatory the front air bag module be remotely deployed using the
appropriate air bag disposal procedure.
For information on driver air bag module and/or passenger air bag module remote deployment, refer to
Pyrotechnic Device Disposal in this section.
Clockspring
The clockspring allows for continuous electrical connections between the driver air bag module and the RCM
when the steering wheel is turned.
Driver Air Bag Module
The driver air bag module is a dual-stage air bag, upon receiving a flow of current from the RCM , deploying at
1 of 2 different rates depending upon vehicle impact severity and sensor input.
High Speed Controller Area Network (HS-CAN)
This vehicle utilizes a communication system called a High Speed Controller Area Network (HS-CAN). The
RCM communicates with various modules for required information about the vehicle. Refer to Section 418-00
for additional information about the HS-CAN .
Occupant Classification System (OCS) System
The Occupant Classification System (OCS) system is found only on the front passenger seat. The OCS system
classifies the size of front passenger seat occupant and provides this information to the Restraints Control
Module (RCM). The RCM uses this information (and other inputs) in determining the deployment strategy of the
passenger air bag and safety belt pretensioner.
The OCS system is also used for operation of the passenger Belt-Minder®. For information on the passenger
Belt-Minder® feature, refer to Section 413-01 or the Owner's Literature.
The OCS system consists of:

a silicone gel-filled bladder mounted between the seat cushion foam and pan
a pressure sensor that is mounted to the seat frame
an OCSM mounted to the seat frame
Pressure is applied to the OCS system bladder when weight of any occupant or object in the front passenger
seat is present. The pressure is then transferred through a tube, sensed by the OCS system pressure sensor,
then electronically communicated to the OCSM . The components of an OCS bladder system (bladder,
pressure sensor and tube, OCSM ) are serviced as an assembly.
Belt Tension Sensor (BTS)
The Belt Tension Sensor (BTS):
is a 3-wire Hall-effect sensor located at the safety belt anchor point and is part of the front passenger
safety belt and retractor assembly.
is used in conjunction with the OCS system.
The BTS is used by the OCS system to identify the presence of a child safety seat on the front passenger seat.
The BTS senses the tension on the safety belt assembly then provides an output to the OCSM , indicating the
safety belt assembly is cinched. After sensing the weight applied to the seat by the occupant and using the BTS
input, the OCSM determines how the occupant should be classified and communicates this information to the
RCM . If the occupant is classified as a child, the RCM automatically deactivates the passenger air bag module
and illuminates the Passenger Air Bag Deactivation (PAD) indicator.
Passenger Air Bag Deactivation (PAD) Indicator
The RCM controls the state of the PAD indicator through a direct, hard-wired connection, based on information
provided by the OCS system. The PAD indicator illuminates to indicate the passenger air bag module is
disabled. An exception to this is when the front passenger seat is determined to be empty and indication of a
deactivated passenger air bag module is not necessary. In all other cases, the PAD indicator is off when the
passenger air bag module is enabled.
The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front occupants
that the PAD indicator is operating correctly.
The following table indicates the passenger air bag and PAD indicator status based on the size of the front
passenger occupant.
Passenger Air Bag and Passenger Air Bag Deactivation (PAD) Indicator Status
Occupant Size Passenger Safety Belt Buckle Status Pass. Air Bag Status PAD Ind. Status
Empty Unbuckled Disabled Unlit
Empty Buckled Disabled Lit
Small Buckled/ Unbuckled Disabled Lit
Large Buckled/ Unbuckled Enabled Unlit
Passenger Air Bag Module
The passenger air bag module is a dual-stage air bag, deploying at 1 of 2 different rates depending upon
vehicle impact severity and sensor input.
Restraints Control Module (RCM)

WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to
follow this instruction may result in the accidental deployment of the Safety Canopy® and cause
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to
the original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or death
in a crash.
NOTE: This vehicle may be equipped with the SYNC® feature which contains the 911 assist option. For
additional information, refer to Owner's Literature.
The RCM carries out the following functions:
deploys the air bag(s)/safety curtains in the event of a deployable collision

activates the safety belt retractor pretensioners to remove slack from the safety belts in the event of a
deployable collision
activates the passenger retractor to control the tension of the passenger safety belt in the event of a
deployable collision
monitors the SRS for faults
sends a message to the IPC to illuminate the air bag warning indicator if a fault is detected
The RCM monitors the SRS for possible faults. If a fault is detected, the RCM requests the IPC to illuminate the
air bag warning indicator. When the ignition is turned OFF and then ON, the IPC proves out the air bag warning
indicator by illuminating it for 6 seconds. If no faults are detected by the RCM , the IPC turns the air bag
warning indicator off and it remains off. If the RCM detects a fault, it sends a message to the IPC to illuminate
the air bag warning indicator and it remains illuminated for the rest of the ignition cycle. If the RCM requests
illumination of the air bag warning indicator and the air bag warning indicator does not function, the IPC
automatically activates an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard,
the SRS and the air bag warning indicator require repair.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags
in the event the ignition circuit is lost or damaged during impact. The backup power supply depletes its stored
energy approximately one minute after power and/or ground has been removed from the RCM .
Event Notification Signal
The deployment event notification signal provides other vehicle subsystems with information pertaining to
restraint system deployment or fuel cutoff status. Signal communication between the RCM and fuel pump relay
allows the PCM to initiate fuel cut-off to disable the fuel system in the event of a crash.
The RCM does not monitor the event notification signal circuit for faults and will not set a DTC if a fault occurs.
Safety Belt Buckle Switches
The safety belt buckles contain integrated circuits called Hall-effect switches. The safety belt buckle switches
indicate to the RCM whether the safety belts are buckled or unbuckled.
The RCM also communicates the status of each safety belt buckle switch to the IPC , which monitors the
information to control the safety belt warning indicator. For information on the safety belt warning indicator, refer
to Section 413-01 .
Safety Belt Retractor Pretensioners
The safety belt retractor pretensioners remove excess slack from the safety belt webbing. The pretensioners
are activated by the RCM when the module detects a crash event force exceeding a programmed limit.
Safety Belt Retractor
The front passenger safety belt retractor is equipped with the adaptive load limiting feature that controls the
tension of the front passenger safety belt in the event of a crash. The adaptive load limiter is activated by the
RCM . The driver safety belt retractor is equipped with a non-deployable (mechanical) load limiter. The front
safety belt retractor may also be referred to as a seatbelt load limiter.
Side Air Curtain Modules
WARNING: Anytime the Safety Canopy® or side air curtain module has deployed, a new headliner
and new A-, B- and C-pillar upper trim panels and attaching hardware must be installed. Remove any
other damaged components and hardware and install new components and hardware as needed.
Failure to follow these instructions may result in the Safety Canopy® or side air curtain module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
The side air curtain module:
deploys upon receiving a flow of current from the RCM , initiated by the RCM .
is installed as an assembly.
is mounted above the headliner.
attaches from the A-pillar frame to the C-pillar frame.
Seat Track Position Sensors
The seat track position sensors indicate the position of the driver and passenger seats along the seat track to
the RCM . The sensor detects the presence of a shunt bracket on the track, indicating that the seat has moved
forward beyond a certain point of adjustment. The RCM uses seat track position sensor information to
determinine the deployment rate of the dual-stage driver air bag and/or passenger air bag module(s).
Secondary Air Bag Warning (Chime)
The secondary air bag warning chime is an audible chime located in and controlled by the IPC . If a fault is
detected with the air bag warning indicator, a DTC is stored in IPC memory. Upon receiving the message from
the RCM that a SRS fault has been detected, the IPC sounds the secondary air bag warning chime in a pattern
of 5 sets of 5 beeps.
Impact Sensors
In addition to the RCM , the SRS uses 6 satellite impact sensors. The RCM is mounted to the center tunnel
beneath the floor console. All vehicles have 2 front impact severity sensors (frontal restraints sensor), 2 first row
(front door) impact sensors (side restraints sensor 1), and 2 second row impact sensors (side restraints sensor
2). The front impact severity sensors are located in the front of the vehicle, behind the bumper. The front door
impact sensors are mounted behind each front door trim panel and each second row sensor is located on each
C-pillar. Mounting orientation is critical for correct operation of all impact sensors.
Seat Side Air Bag Modules
The seat side air bag module:

deploys upon receiving a flow of current from the RCM , initiated by the side restraints sensor and
internal RCM circuitry.
is mounted in the seat backrest.
is used in conjunction with a side air curtain module.
Driver Knee Bolster Air Bag Module
The driver knee bolster air bag module is part of the steering column opening trim panel and deploys upon
receiving a flow of current from the RCM .
Fault Reporting
There are 2 types of fault reporting that can be utilized by the OCSM . The first type, considered conventional,
has only one level of fault reporting and identifies a specific concern for a given component and points to a
particular diagnostic path (for example, DTC B1317 (Battery Voltage High)).
The second type uses a process within the software of the controller that maps the byte and bit to name a
specific device and fault condition. This process is called Bit-mapping and referred to as fault PIDs in the
diagnosis of the vehicle. This type does not identify the specific concern or component on the first level of fault
reporting (for example, DTC B2290 (Occupant Classification System Fault)). DTC B2290 can have up to 3
specific on-demand fault PIDs (areas of concern) associated with this DTC.
The RCM does not utilize fault PIDs for this vehicle.
Those associated fault PIDs are an extension of the information provided by the DTC and are identified by the
same DTC number. Use a scan tool to view DTCs and their fault PIDs. Once a scan tool has retrieved a DTC,
use the scan tool to view the fault PIDs. In the diagnostic path, other types of PIDs are sometimes used to
determine the root cause (for example, resistance or voltage PIDs).
When viewing of fault PIDs has been carried out, the scan tool can display the PIDs associated with that DTC,
including the status or state that exists (on-demand [active] DTC) or existed (continuous memory [historic])
DTC. Refer to the scan tool manufacturer's instructions for the scan tool being used on how to view fault PIDs.
1. Verify the customer concern by checking the air bag warning indicator in the IPC . Refer to Prove Out the
With the ignition OFF, wait 10 seconds, then turn the ignition ON and monitor the air bag warning
indicator with the air bag modules installed. The air bag warning indicator illuminates continuously for
approximately 6 seconds and then turns off. If an air bag SRS fault is detected, the air bag warning
indicator indicates the fault in one of the following ways:
— fails to light
— remains lit continuously
— flashes
The flashing might not occur until approximately 30 seconds after the ignition has been turned from OFF
to ON. This is the time required to complete testing of the SRS . If the air bag warning 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
diagnose and repair the air bag warning indicator and any SRS fault discovered.
2. Visually inspect for obvious signs of mechanical or electrical damage. Do not disconnect electrical
connectors until directed to do so within the pinpoint test.

Damaged Restraints Control Module (RCM) or loose Open Central Junction Box (CJB) fuse
mounting 20 (10A) and/or 4 (7.5A)
Damaged LH or RH front impact severity sensor(s) or Damaged wiring harness
loose mounting Loose, damaged or corroded
Damaged side impact sensor B- and/or C-pillar side connectors
impact sensor(s) or loose mounting Circuitry open/shorted
Damaged or disconnected Passenger Air Bag Damaged shorting bars
Deactivation (PAD) indicator Loose, damaged or pinched passenger
Damaged front driver/passenger seat assembly seat wire harness
If the cause is not visually evident, connect the scan tool to the DLC .
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the



00 .
If the network test passes, retrieve and record on-demand and Continuous Memory Diagnostic
Trouble Codes (CMDTCs) from the RCM and OCSM .
8. If the DTCs retrieved are related to the concern, go to the Restraints Control Module (RCM) DTC Chart
or Occupant Classification System Module (OCSM) DTC Chart. For all other DTCs, refer to Section 419-
10 .
DTC Charts
NOTE: Refer to Description and Operation, Intelligent Access with Push Button Start in Section 419-01B to
review the procedures for achieving the various ignition states on vehicles with this feature.
The DTCs can be retrieved from the RCM and the OCSM with a scan tool via the DLC .
Restraints Control Module (RCM) DTC Chart
NOTE: Always make sure the correct Supplemental Restraint System (SRS) component is being installed.
Parts released for other vehicles may not be compatible even if they appear physically similar. Check the part
number listed in the Ford Catalog Advantage™ or equivalent to make sure the correct component is being
installed. If an incorrect SRS component is installed, DTCs may set.
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle repair procedures such as module reprogramming often set
network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent
repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery, refer
to Section 414-01 .
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure type
code provides information about specific fault conditions such as opens or shorts to ground. Continuous
Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status code suffix to assist
in determining DTC history.
DTC Description Action To Take

B0001:11 Driver Frontal Stage 1 GO to Pinpoint Test A .
Deployment Control: Circuit
Short to Ground
Short to Battery
Open
B0001:1A Driver Frontal Stage 1 GO to Pinpoint Test A .
Resistance Below Threshold
B0001:2B Driver Frontal Stage 1 GO to Pinpoint Test W .
Deployment Control: Signal
Cross Coupled
B0001:4A Driver Frontal Stage 1 GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0002:11 Driver Frontal Stage 2 GO to Pinpoint Test B .
Short to Ground
Short to Battery
Open
B0002:1A Driver Frontal Stage 2 GO to Pinpoint Test B .
B0002:2B Driver Frontal Stage 2 GO to Pinpoint Test W .
Cross Coupled
B0002:4A Driver Frontal Stage 2 GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0004:11 Driver Knee Bolster GO to Pinpoint Test C .
Short to Ground
Short to Battery
Open
B0004:1A Driver Knee Bolster GO to Pinpoint Test C .
B0004:2B Driver Knee Bolster GO to Pinpoint Test W .
Cross Coupled
B0004:4A Driver Knee Bolster GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0010:11 Passenger Frontal Stage 1 GO to Pinpoint Test D .
Short to Ground
Short to Battery
Open
B0010:1A Passenger Frontal Stage 1 GO to Pinpoint Test D .
B0010:2B Passenger Frontal Stage 1 GO to Pinpoint Test W .
Cross Coupled
B0010:4A Passenger Frontal Stage 1 GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0011:11 Passenger Frontal Stage 2 GO to Pinpoint Test E .
Short to Ground
Short to Battery
Open
B0011:1A Passenger Frontal Stage 2 GO to Pinpoint Test E .
B0011:2B Passenger Frontal Stage 2 GO to Pinpoint Test W .
Cross Coupled
B0011:4A Passenger Frontal Stage 2 GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0020:11 Left Side Airbag Deployment GO to Pinpoint Test F .
Control: Circuit Short to
Ground
Battery
Control: Circuit Open
B0020:1A Left Side Airbag Deployment GO to Pinpoint Test F .
Control: Circuit Resistance
Below Threshold
B0020:2B Left Side Airbag Deployment GO to Pinpoint Test W .
Control: Signal Cross
Coupled
B0020:4A Left Side Airbag Deployment GO to Pinpoint Test X .
Control: Incorrect
Component Installed
B0021:11 Left Curtain Deployment GO to Pinpoint Test G .
Control 1: Circuit Short to
Ground
Battery
Control 1: Circuit Open
B0021:1A Left Curtain Deployment GO to Pinpoint Test G .
Control 1: Circuit Resistance
Below Threshold
B0021:2B Left Curtain Deployment GO to Pinpoint Test W .
Control 1: Signal Cross
Coupled
B0021:4A Left Curtain Deployment GO to Pinpoint Test X .
Control 1: Incorrect
Component Installed
B0028:11 Right Side Airbag GO to Pinpoint Test H .
Short to Ground
Short to Battery
Open
B0028:1A Right Side Airbag GO to Pinpoint Test H .
B0028:2B Right Side Airbag GO to Pinpoint Test W .
Cross Coupled
B0028:4A Right Side Airbag GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
B0029:11 Right Curtain Deployment GO to Pinpoint Test I .
Ground
Battery
Control 1: Circuit Open
B0029:1A Right Curtain Deployment GO to Pinpoint Test I .
Control 1: Circuit Resistance
Below Threshold
B0029:2B Right Curtain Deployment GO to Pinpoint Test W .
Control 1: Signal Cross
Coupled
B0029:4A Right Curtain Deployment GO to Pinpoint Test X .
Control 1: Incorrect
Component Installed
B0050:11 Driver Seatbelt Sensor: GO to Pinpoint Test J .
Circuit Short to Ground
Circuit Short to Battery
Circuit Open
B0050:1D Driver Seatbelt Sensor: GO to Pinpoint Test J .
Circuit Current Out of Range
B0050:2B Driver Seatbelt Sensor: GO to Pinpoint Test W .
Signal Cross Coupled
B0050:4A Driver Seatbelt Sensor: GO to Pinpoint Test X .
Incorrect Component
Installed
B0052:11 Passenger Seatbelt Sensor: GO to Pinpoint Test K .
Circuit Open
B0052:1D Passenger Seatbelt Sensor: GO to Pinpoint Test K .
B0052:2B Passenger Seatbelt Sensor: GO to Pinpoint Test W .
B0052:4A Passenger Seatbelt Sensor: GO to Pinpoint Test X .
Incorrect Component
Installed
B0082:11 Passenger Seatbelt Load GO to Pinpoint Test L .
Limiter Deployment Control:
Circuit Open
B0082:1A Passenger Seatbelt Load GO to Pinpoint Test L .
Circuit Resistance Below
Threshold
B0082:2B Passenger Seatbelt Load GO to Pinpoint Test W .
B0082:4A Passenger Seatbelt Load GO to Pinpoint Test X .
Incorrect Component
Installed
B0090:11 Left Frontal Restraints GO to Pinpoint Test M .
Sensor: Circuit Short to
Ground
B0090:4A Left Frontal Restraints GO to Pinpoint Test X .
Sensor: Incorrect
Component Installed
B0090:81 Left Frontal Restraints INSTALL a new LH front impact severity sensor. REFER to Front
Sensor: Invalid Serial Data Impact Severity Sensor in this section.
Received
B0090:93 Left Frontal Restraints GO to Pinpoint Test M .
Sensor: No Operation
B0090:96 Left Frontal Restraints INSTALL a new LH front impact severity sensor. REFER to Front
Sensor: Component Internal Impact Severity Sensor in this section.
Failure
B0091:11 Left Side Restraints Sensor GO to Pinpoint Test N .
1: Circuit Short to Ground
B0091:4A Left Side Restraints Sensor GO to Pinpoint Test X .
1: Incorrect Component
Installed
B0091:81 Left Side Restraints Sensor INSTALL a new driver front door impact sensor. REFER to Side
1: Invalid Serial Data Impact Sensor — Front Door in this section.
Received
B0091:93 Left Side Restraints Sensor GO to Pinpoint Test N .
1: No Operation
B0091:96 Left Side Restraints Sensor INSTALL a new driver front door impact sensor. REFER to Side
1: Component Internal Impact Sensor — Front Door in this section.
Failure
B0092:11 Left Side Restraints Sensor GO to Pinpoint Test O .
B0092:4A Left Side Restraints Sensor GO to Pinpoint Test X .
Installed
B0092:81 Left Side Restraints Sensor INSTALL a new driver second row C-pillar side impact sensor.
2: Invalid Serial Data REFER to Side Impact Sensor — Second Row, 4-Door Sedan or
Received Side Impact Sensor — Second Row, 5-Door Hatchback in this
section.
B0092:93 Left Side Restraints Sensor GO to Pinpoint Test O .
2: No Operation
B0092:96 Left Side Restraints Sensor INSTALL a new driver second row C-pillar side impact sensor.
2: Component Internal REFER to Side Impact Sensor — Second Row, 4-Door Sedan or
Failure Side Impact Sensor — Second Row, 5-Door Hatchback in this
section.
B0095:11 Right Frontal Restraints GO to Pinpoint Test P .
Ground
B0095:4A Right Frontal Restraints GO to Pinpoint Test X .
Sensor: Incorrect
Component Installed
B0095:81 Right Frontal Restraints INSTALL a new RH front impact severity sensor. REFER to Front
Sensor: Invalid Serial Data Impact Severity Sensor in this section.
Received
B0095:93 Right Frontal Restraints GO to Pinpoint Test P .
Sensor: No Operation
B0095:96 Right Frontal Restraints INSTALL a new RH front impact severity sensor. REFER to Front
Sensor: Component Internal Impact Severity Sensor in this section.
Failure
B0096:11 Right Side Restraints Sensor GO to Pinpoint Test O .
B0096:4A Right Side Restraints Sensor GO to Pinpoint Test X .
Installed
B0096:81 Right Side Restraints Sensor INSTALL a new passenger front door side impact sensor. REFER
1: Invalid Serial Data to Side Impact Sensor — Front Door in this section.
Received
B0096:93 Right Side Restraints Sensor GO to Pinpoint Test O .
1: No Operation
B0096:96 Right Side Restraints Sensor INSTALL a new passenger front door side impact sensor. REFER
1: Component Internal to Side Impact Sensor — Front Door in this section.
Failure
B0097:11 Right Side Restraints Sensor GO to Pinpoint Test N .
B0097:4A Right Side Restraints Sensor GO to Pinpoint Test X .
Installed
B0097:81 Right Side Restraints Sensor INSTALL a new passenger second row C-pillar side impact sensor.
2: Invalid Serial Data REFER to Side Impact Sensor — Second Row, 4-Door Sedan or
Received Side Impact Sensor — Second Row, 5-Door Hatchback in this
section.
B0097:93 Right Side Restraints Sensor GO to Pinpoint Test N .
2: No Operation
B0097:96 Right Side Restraints Sensor INSTALL a new passenger second row C-pillar side impact sensor.
2: Component Internal REFER to Side Impact Sensor — Second Row, 4-Door Sedan or
Failure Side Impact Sensor — Second Row, 5-Door Hatchback in this
section.
B00A0:09 Occupant Classification GO to Pinpoint Test Q .
System: Component Failure
B00A0:4A Occupant Classification GO to Pinpoint Test Q .
System: Incorrect
Component Installed
System: Circuit / Component
Protection Time-Out
System: Signal Plausibility
Failure
System: Event Information
B00B5:11 Driver Seat Track Position GO to Pinpoint Test R .
Restraints Sensor: Circuit
Short to Ground
Short to Battery
Open
B00B5:1D Driver Seat Track Position GO to Pinpoint Test R .
Current Out of Range
B00B5:2B Driver Seat Track Position GO to Pinpoint Test W .
Restraints Sensor: Signal
Cross Coupled
B00B5:4A Driver Seat Track Position GO to Pinpoint Test X .
Restraints Sensor: Incorrect
Component Installed
B00C5:11 Passenger Seat Track GO to Pinpoint Test S .
Position Restraints Sensor:
Circuit Open
B00C5:1D Passenger Seat Track GO to Pinpoint Test S .
B00C5:2B Passenger Seat Track GO to Pinpoint Test W .
B00C5:4A Passenger Seat Track GO to Pinpoint Test X .
Incorrect Component
Installed
B00D5:11 Restraint System Passenger GO to Pinpoint Test T .
Disable Indicator: Circuit
Short to Ground
Short to Battery
Open
B00D5:4A Restraint System Passenger GO to Pinpoint Test X .
Disable Indicator: Incorrect
Component Installed
B1193:00 Crash Event Storage Full NOTE: Always make sure the correct SRS component is being
and Locked: No Sub Type installed. Parts released for other vehicles may not be compatible
Information even if they appear physically similar. Check the part number listed
in the Ford Catalog Advantage™; or equivalent to make sure the
correct component is being installed. If an incorrect SRS
component is installed, DTCs may set.
This DTC indicates the vehicle has been in a crash. INSTALL a

new Restraints Control Module (RCM) and impact sensors. REFER
to Inspection and Repair After a Supplemental Restraint System
(SRS) Deployment in this section.
B1211:11 Driver Seatbelt Retractor GO to Pinpoint Test U .
Pretensioner Deployment
Ground
Battery
Control: Circuit Open
B1211:1A Driver Seatbelt Retractor GO to Pinpoint Test U .
Control: Circuit Resistance
Below Threshold
B1211:2B Driver Seatbelt Retractor GO to Pinpoint Test W .
Control: Signal Cross
Coupled
B1211:4A Driver Seatbelt Retractor GO to Pinpoint Test X .
Control: Incorrect
Component Installed
B1214:11 Passenger Seatbelt GO to Pinpoint Test V .
Retractor Pretensioner
Short to Ground
Short to Battery
Open
B1214:1A Passenger Seatbelt GO to Pinpoint Test V .
B1214:2B Passenger Seatbelt GO to Pinpoint Test W .
Cross Coupled
B1214:4A Passenger Seatbelt GO to Pinpoint Test X .
Deployment Control:
Incorrect Component
Installed
U0028:08 Vehicle Communication Bus GO to Pinpoint Test Y .
A: Bus Signal / Message
Failures
U0028:88 Vehicle Communication Bus GO to Pinpoint Test Y .
A: Bus Off
U0154:00 Lost Communication With NOTE: The DTC sets in a module that is reporting a
Restraints Occupant communication fault from another module on the data bus. The
Classification System module that reports the fault is not the problem module. Do not
Module: No Sub Type install a new RCM as part of repair.
Information
REFER to Section 418-00 to diagnose the Occupant Classification
System Module (OCSM). The OCSM does not respond to the scan
tool.
U0155:00 Lost Communication With NOTE: The DTC sets in a module that is reporting a
Instrument Panel Cluster communication fault from another module on the data bus. The
(IPC) Control Module: No module that reports the fault is not the problem module. Do not
Sub Type Information install a new RCM as part of repair.
REFER to Section 418-00 to diagnose the IPC . The IPC does not
respond to the scan tool.
U0253:00 Lost Communication With NOTE: This DTC sets in the RCM if a message is not received
Accessory Protocol Interface from the Accessory Protocol Interface Module (APIM).
Module: No Sub Type
Information Check for additional RCM and APIM DTCs.
REFER to the appropriate section to diagnose DTCs concern. If no

other DTCs are present, REFER to APIM Software Level Check in
the General Procedures portion of Section 415-00 .
U0300:00 Internal Control Module CARRY OUT Programmable Module Installation (PMI). RETRIEVE
Software Incompatibility: No RCM DTCs. If RCM DTC U0300:00 is retrieved on-demand during
Sub Type Information self-test. INSTALL a new RCM . REFER to Restraints Control
Module (RCM) in this section.
U0554:00 Invalid Data Received From CHECK for additional RCM and APIM DTCs. REFER to the
Accessory Protocol Interface appropriate section to diagnose the DTCs. If no other DTCs are
Module: No Sub Type present, REFER to Accessory Protocol Interface Module (APIM)
Information Software Level Check in the General Procedures portion of Section
415-00 .
U2100:00 Initial Configuration Not CARRY OUT Programmable Module Installation (PMI). RETRIEVE
Complete: No Sub Type RCM DTCs. If RCM DTC U0300:00 is retrieved on-demand during
Information self-test, INSTALL a new RCM . REFER to Restraints Control
U2200:00 Control Module INSTALL a new RCM and CARRY OUT Programmable Module
Configuration Memory Installation (PMI). Use as-built data when CARRYING out PMI for
Corrupt: No Sub Type this DTC. REFER to Restraints Control Module (RCM) in this
Information section.
U3000:46 Control Module: Calibration / INSTALL a new RCM and CARRY OUT Programmable Module
Parameter Memory Failure Installation (PMI). REFER to Restraints Control Module (RCM) in
this section.
U3000:49 Control Module: Internal INSTALL a new RCM and CARRY OUT Programmable Module
Electronic Failure Installation (PMI). If DTC U2200:00 is also present, use as-built
data when CARRYING out PMI . REFER to Restraints Control
U3000:4A Control Module: Incorrect GO to Pinpoint Test X .
Component Installed
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test Z .
Voltage Below Threshold
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test Z .
Voltage Above Threshold
Occupant Classification System Module (OCSM) DTC Chart

DTC Description Action To Take
B1231 Event Threshold Exceeded INSPECT the passenger seat for damage. REFER to Inspection and
(Crash Data Memory Full) Repair After a Supplemental Restraint System (SRS) Deployment in this
section.
B1317 Battery Voltage High GO to Pinpoint Test Z .
B1318 Battery Voltage Low GO to Pinpoint Test Z .
B1342 ECU is Faulted INSTALL an Occupant Classification System (OCS) service kit. REFER
to Occupant Classification Sensor in this section.
B2290 Occupant Classification GO to Pinpoint Test AA .
System Fault
B2909 Belt Tension Sensor Fault GO to Pinpoint Test AB .
C1941 Zero Seat Weight Test This DTC is only reported when carrying out the System Reset. GO to
Failure Pinpoint Test AA .
U0151 Lost Communication with NOTE: The DTC will set in a module that is reporting a communication
Restraints Control Module fault from another module on the data bus. The module that reports the
(RCM) fault is not the problem module. Do not install a new OCSM as part of
repair.
REFER to Section 418-00 to diagnose the RCM . RCM does not

respond to the scan tool.
U2050 No Application Present INSTALL a new OCS system service kit. REFER to Occupant
Classification Sensor in this section.
U2051 One or More Calibration INSTALL a new OCS system service kit. REFER to Occupant
Files Missing/Corrupt Classification Sensor in this section.
Symptom Chart
NOTE: Refer to Description and Operation, Intelligent Access with Push Button Start in Section 419-01B to
review the procedures for achieving the various ignition states on vehicles with this feature.
Symptom Chart
Air bag warning Fuse CARRY OUT RCM and OCSM
indicator is Wiring, terminals or self-tests. REFER to Restraints
illuminated connectors Control Module (RCM) DTC
continuously Instrument Panel Chart or Occupant Classification
Cluster (IPC) System Module (OCSM) DTC
RCM Chart in this section.
If no DTCs were retrieved from
the RCM or OCSM , REFER to
Section 413-01 to diagnose the
IPC concern.
If the RCM or OCSM does not
respond to the scan tool,
Section 418-00 to diagnose the
no communication concern.
Air bag indicator Air bag/pretensioner CARRY OUT RCM and
flashing Supplemental Occupant Classification System
Restraint System Module (OCSM) self-test.
(SRS) fault REFER to DTC Charts.
Audible tone Air bag SRS system CARRY OUT RCM and IPC
fault or air bag self-test. REFER to Restraints
warning indicator fault Control Module (RCM) DTC
Chart in this section and the
Instrument Panel Cluster (IPC)
DTC Chart in Section 413-01 .
The RCM does not Fuse REFER to Section 418-00 to
respond to the scan Scan tool diagnose the no communication
tool DLC concern.
Wiring, terminals or
connectors
RCM
The Occupant Fuse REFER to Section 418-00 to
Classification Scan tool diagnose the no communication
System Module DLC concern.
(OCSM) does not Wiring, terminals or
respond to the scan connectors
tool OCSM
Pinpoint Test — Restraints Control Module (RCM)
Pinpoint Test A: DTCs B0001:11, B0001:12, B0001:13 and B0001:1A
Refer to Wiring Diagrams Cell 46 , Supplemental Restraint System for schematic and connector information.
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 1 circuits for the
following faults:
Resistance out of range

Unexpected voltage
Short to ground
Faulted driver air bag module
If a fault is detected, the RCM stores DTC B0001:11, B0001:12, B0001:13 or B0001:1A in memory and sends a
message to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.
The RCM analyzes the deployment loop resistance and uses this measurement in combination with an age
correction factor to determine if a fault exists. The value displayed in the PID is the deployment loop resistance
as measured by the RCM . If the value displayed is lower or higher than the desired range (refer to diagram
below), the RCM can set a DTC. As the deployment loop resistance drifts farther outside the desired range, the
chance for a DTC increases. The RCM fault trigger threshold may vary as the vehicle ages. Small variations in
resistance can occur due to the effect of road vibrations on terminal fit and/or temperature changes. These
variables can result in an intermittent fault. For this reason, the test requires the PID value to be within the
desired range before the fault is considered repaired, regardless if the module is reporting an on-demand DTC
at time of diagnosis. Following this direction helps make sure that minor changes in resistance do not create a
repeat concern. This test uses a process of elimination to diagnose each part of the deployment loop circuit
including:
Wiring
Connections
Clockspring
Driver air bag module
RCM
DTC Description Fault Trigger Condition

B0001:11 — Driver Frontal Stage 1 When the RCM senses a short to ground on either driver
Deployment Control: Circuit Short to Ground air bag stage 1 circuit, a fault is indicated.
B0001:12 — Driver Frontal Stage 1 When the RCM senses a short to voltage on either
Deployment Control: Circuit Short to Battery driver air bag stage 1 circuit, a fault is indicated.
B0001:13 — Driver Frontal Stage 1 When the RCM measures more than the desired
Deployment Control: Circuit Open resistance range between driver air bag stage 1 circuits,
a fault is indicated.
B0001:1A — Driver Frontal Stage 1 When the RCM measures less than the desired
Deployment Control: Circuit Resistance resistance range between driver air bag stage 1 circuits,
Below Threshold a fault is indicated.

Clockspring
RCM
PINPOINT TEST A: DTCs B0001:11, B0001:12, B0001:13 AND B0001:1A
modules. Failure to follow this instruction may result in the accidental deployment of these modules,
which increases the risk of serious personal injury or death.
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Failure
to use the correct probe adapter(s) may damage the connector.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and
verification before proceeding with the pinpoint test.
NOTE: Only disconnect or reconnect Supplemental Restraint System (SRS) components when
instructed to do so within a pinpoint test step. Failure to follow this instruction may result in incorrect
diagnosis of the SRS .
NOTE: Always make sure the correct SRS component is being installed. Parts released for other vehicles may
not be compatible even if they appear physically similar. Check the part number listed in the Ford Catalog
Advantage™ or equivalent to make sure the correct component is being installed. If an incorrect SRS

A1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test — This fault cannot be cleared
RCM . until it is corrected and the
Was DTC B0001:11, B0001:12, B0001:13 or B0001:1A retrieved DTC is no longer retrieved
on-demand during self-test? on-demand during self-test.
For DTC B0001:13 or

B0001:1A, GO to A2 .
For DTC B0001:11, GO to

A12 .

A15 .
No
This is an intermittent fault
when present as a
Continuous Memory
Diagnostic Trouble Code
(CMDTC) only.
For DTC B0001:13 or

B0001:1A, GO to A20 .

A21 .

A22 .
A2 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT
CONTROL RESISTANCE (DEPLOY_00_R) PID
RCM . GO to A19 .
DEPLOY_00_R PID
Does the PID value read between 2 and 3.68 ohms? No
GO to A3 .
CONTROL RESISTANCE (DEPLOY_00_R) PID WHILE CARRYING OUT
THE HARNESS TEST
Remove the lower steering column shroud to access the clockspring Yes
electrical connector. DEPOWER the SRS and
While monitoring the DEPLOY_00_R PID, carry out the harness test REPAIR the connector,
of the driver air bag circuits and accessible connectors (including any terminals or wire harness
in-line connectors) by wiggling and flexing the wire harness, or INSTALL a new
connectors, tilting and rotating the steering wheel frequently. clockspring as needed.
Does the PID value read between 2 and 3.68 ohms while carrying REFER to Clockspring in
out the harness test? this section.
Refer to Wiring Diagrams

Cell 5 , Connector Repair
Procedures for schematic
and connector information.
GO to A23 .
No
For PID value less than 2
ohms, GO to A4 .
For PID value greater than

3.68 ohms, GO to A8 .
CONTROL DTC FOR A FAULT STATUS CHANGE (LOW RESISTANCE
INDICATED)
NOTE: This pinpoint test step attempts to change the fault reported Yes
by the RCM by inducing a different fault condition. If the fault reported GO to A17 .
changes, this indicates the RCM is functioning correctly and is not
the source of the fault. No
GO to A5 .
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in this section.
Remove the driver air bag module. Refer to Driver Air Bag Module in
this section.
Repower the SRS . Do not prove out the SRS at this time. Refer to
Supplemental Restraint System (SRS) Depowering and Repowering
in this section.
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test —
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver air bag
module disconnected, open circuit faults would normally be retrieved
on stages 1 and 2.
Did the on-demand DTC change from B0001:1A to B0001:13?
INDICATED) (CLOCKSPRING DISCONNECTED)
GO to A6 .
Ignition OFF.
Disconnect: Clockspring C218A.
Ignition ON.
RCM .
module / clockspring disconnected, open circuit faults would normally
be retrieved on stages 1 and 2.
A6 CHECK FOR A SHORT BETWEEN DRIVER AIR BAG STAGE 1
CIRCUITS
Measure the resistance between clockspring C218A-2, circuit CR101 Yes
(VT/BN), harness side, and clockspring C218A-1, circuit RR101 GO to A7 .
(YE/GN), harness side.
No
REPAIR circuits CR101
(VT/BN) and RR101
(YE/GN).

GO to A24 .

A7 CHECK THE RCM FOR LOW RESISTANCE
Depower the SRS . Refer to Supplemental Restraint System (SRS) Yes
Depowering and Repowering in this section. REPAIR circuits CR101
Disconnect: RCM C310A and C310B. (VT/BN) and RR101
Measure the resistance between RCM C310A pins 3 and 4, (YE/GN).
component side.
GO to A24 .
No
GO to A19 .

A8 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to A10 .
Remove the driver air bag module. Refer to Driver Air Bag Module in No
this section. GO to A9 .
Disconnect: RCM C310A and C310B.
Measure the resistance between RCM C310A, harness side, and
driver air bag module stage 1 C216A, harness side, using the
following chart.
Driver Air Bag Module Electrical

RCM Circuit Connector
C310A- CR101 (VT/BN)/ C216A-1
4 (WH)
C310A- RR101 (YE/GN)/ C216A-2
3 (OG)
Are the resistances less than 1 ohm?
A9 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR AN OPEN
(CLOCKSPRING DISCONNECTED)
Disconnect: Clockspring C218A. Yes
Measure the resistance between RCM C310A, harness side, and GO to A18 .
clockspring C218A, harness side, using the following chart.
No
RCM Circuit Clockspring Electrical Connector REPAIR circuit CR101
(VT/BN) or RR101
C310A-4 CR101 (VT/BN) C218A-2 (YE/GN).
C310A-3 RR101 (YE/GN) C218A-1
GO to A24 .
Are the resistances less than 0.5 ohm?

CONTROL DTC FOR A FAULT STATUS CHANGE (OPEN INDICATED)
by the RCM by inducing a different fault condition. If the fault reported REMOVE the fused jumper
changes, this indicates the RCM is functioning correctly and is not wire and GO to A17 .
the source of the fault.
No
Connect: RCM C310A and C310B. REMOVE the fused jumper
Connect a fused jumper wire between driver air bag module stage 1 wire and GO to A11 .
C216A-1, circuit CR101 (WH), harness side, and C216A-2, circuit
RR101 (OG), harness side.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver air bag stage
1 circuits shorted together, a low resistance fault would normally be
retrieved on stage 1. Stage 2 will show an open circuit fault due to
the driver air bag being disconnected.
Was DTC B0001:1A retrieved on-demand during self-test?
A11 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR AN
OPEN (CLOCKSPRING DISCONNECTED)
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) REMOVE the fused jumper
Depowering and Repowering in this section. wire and GO to A18 .
Connect a fused jumper wire between clockspring C218A-1, circuit No
RR101 (YE/GN), harness side, and C218A-2, circuit CR101 (VT/BN), REMOVE the fused jumper
harness side. wire and GO to A19 .
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the clockspring stage 1
circuits shorted together, a low resistance fault would normally be
CONTROL DTC FOR A FAULT STATUS CHANGE (SHORT TO GROUND
INDICATED)
Ignition OFF. GO to A13 .
this section.
in this section.
Ignition ON.
RCM .
on stages 1 and 2.
Did the on-demand DTC change from B0001:11 to B0001:13?
GO to A14 .
Ignition OFF.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the clockspring
disconnected, open circuit faults would normally be retrieved on
driver air bag stages 1 and 2.
A14 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to A19 .
Disconnect: RCM C310A and C310B. No
Measure the resistance between clockspring: Due to the shorting bar
C218A-2, circuit CR101 (VT/BN), harness side, and ground. feature in the RCM
C218A-1, circuit RR101 (YE/GN), harness side, and ground. electrical connector, the
fault can exist in either
circuit. Do not remove or
defeat the shorting bar.
REPAIR circuit CR101

(VT/BN) or RR101
(YE/GN).

GO to A24 .

CONTROL DTC FOR A FAULT STATUS CHANGE (SHORT TO
BATTERY INDICATED) (CLOCKSPRING DISCONNECTED)
this section.
in this section.
Ignition ON.
RCM .
module/clockspring disconnected, open circuit faults would normally
be retrieved on driver air bag stages 1 and 2.
A16 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) Due to the shorting bar
Depowering and Repowering in this section. feature in the RCM
Disconnect: RCM C310A and C310B. electrical connector, the
Repower the SRS . Do not prove out the SRS at this time. Refer to fault can exist in either
Supplemental Restraint System (SRS) Depowering and Repowering circuit. Do not remove or
in this section. defeat the shorting bar.
Ignition ON.
Measure the voltage between clockspring: REPAIR circuit CR101
C218A-2, circuit CR101 (VT/BN), harness side, and ground. (VT/BN) or RR101
C218A-1, circuit RR101 (YE/GN), harness side, and ground. (YE/GN).

GO to A24 .
No
GO to A19 .

A17 CONFIRM THE DRIVER AIR BAG MODULE FAULT
NOTE: Make sure all SRS components and the RCM electrical Yes
connectors are connected before carrying out the self-test. If not, INSTALL a new driver air
DTCs will be recorded. bag module. REFER to
Driver Air Bag Module in
Ignition OFF. this section. GO to A24 .
Depowering and Repowering in this section. No
Prior to reconnecting any previously disconnected SRS component: In the process of
inspect connector(s) (including any in-line connectors) for diagnosing the fault, the
pushed-out, loose or spread terminals and loose or frayed wire fault condition has become
connections at terminals. intermittent. Do not install
inspect wire harness for any damaged, pinched, cut or pierced any new SRS
wires. components at this time.
inspect RCM C310A and C310B Connector Position Install SRS components
Assurance (CPA) lever/lock for correct operation. Refer to only when directed to do
Restraints Control Module (RCM) in this section. so in the pinpoint test.
repair any concerns found.
For DTC B0001:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0001:1A, GO to A20 .
Procedures for schematic and connector information.
A21 .
Install the driver air bag module. Refer to Driver Air Bag Module in
this section. For DTC B0001:12, GO to
Repower the SRS . Do not prove out the SRS at this time. Refer to A22 .
in this section.
Ignition ON.
RCM .
Was the original DTC retrieved on-demand during self-test?
A18 CONFIRM THE CLOCKSPRING FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new
DTCs will be recorded. clockspring. REFER to
Clockspring in this section.
For DTC B0001:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0001:1A, GO to A20 .
Connect: Clockspring C218A. A21 .
in this section.
Ignition ON.
RCM .
A19 CONFIRM THE RCM FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new RCM .
DTCs will be recorded. REFER to Restraints
Control Module (RCM) in
Ignition OFF. this section. GO to A24 .
Refer to Wiring Diagrams Cell 5 , Connector Repair For DTC B0001:13 or
Procedures for schematic and connector information. B0001:1A, GO to A20 .
If previously removed, install the driver air bag module. Refer to For DTC B0001:11, GO to
Driver Air Bag Module in this section. A21 .
Connect: Clockspring C218A (if previously disconnected).
Connect: RCM C310A and C310B. For DTC B0001:12, GO to
in this section.
Ignition ON.
RCM .
CONTROL RESISTANCE (DEPLOY_00_R) PID FOR AN INTERMITTENT
LOW RESISTANCE OR OPEN CIRCUIT FAULT
RCM . The fault is not present and
DEPLOY_00_R PID cannot be recreated at this
Attempt to recreate the fault by wiggling connectors (including any in- time. Do not install any
line connectors) and flexing the wire harness, tilting and rotating the new SRS components at
steering wheel frequently. this time. Install SRS
Does the PID value read between 2 and 3.68 ohms? components only when
directed to do so in the
pinpoint test. GO to A23 .
No
If the driver air bag PID
indicates incorrect
resistance only when the
steering wheel is rotated,
INSTALL a new
clockspring. REFER to
For all other faults,

DEPOWER the SRS and
REPAIR as necessary.

GO to A24 .
CONTROL FOR AN INTERMITTENT SHORT TO GROUND FAULT
Attempt to recreate the fault by wiggling connectors (including any in- Yes
line connectors) and flexing the wire harness, tilting and rotating the DEPOWER the SRS and
steering wheel frequently. REPAIR as necessary.
RCM . Refer to Wiring Diagrams
Was DTC B0001:11 retrieved on-demand during self-test? Cell 5 , Connector Repair
GO to A24 .
No
The fault is not present and
cannot be recreated at this
time. Do not install any
new SRS components at
this time. Install SRS
components only when
CONTROL FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) DEPOWER the SRS and
Depowering and Repowering in this section. REPAIR as necessary.
this section. Refer to Wiring Diagrams
Repower the SRS . Do not prove out the SRS at this time. Refer to Cell 5 , Connector Repair
Supplemental Restraint System (SRS) Depowering and Repowering Procedures for schematic
in this section. and connector information.
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any in- GO to A24 .
line connectors) and flexing the wire harness, tilting and rotating the
steering wheel frequently. No
RCM . cannot be recreated at this
Was DTC B0001:12 retrieved on-demand during self-test? time. Do not install any
A23 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) REPAIR as necessary.
Remove the driver air bag module: Refer to Wiring Diagrams
inspect connector(s) (including any in-line connectors) for Cell 5 , Connector Repair
corrosion, loose or spread terminals and loose or frayed wire Procedures for schematic
connections at terminals. and connector information.
inspect wire harness for any damage, pinched, cut or pierced
wires. GO to A24 .
Inspect RCM C310A and C310B CPA lever/lock for correct operation.
Refer to Restraints Control Module (RCM) in this section. No
Were any concerns found?
A24 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Do not clear any DTCs until
WARNING: Turn the ignition OFF and wait one minute to all DTCs have been
deplete the backup power supply. Failure to follow this resolved. GO to the DTC
instruction may result in serious personal injury or death in the Charts in this section for
event of an accidental deployment. pinpoint test direction.
Reconnect all SRS components (if previously disconnected).
If previously directed to depower the SRS , repower the SRS . Do No
not prove out the SRS at this time. Refer to Supplemental Restraint CLEAR all RCM and
System (SRS) Depowering and Repowering in this section. OCSM CMDTCs . PROVE
Ignition ON. OUT the SRS . Repair is
Enter the following diagnostic mode on the scan tool: Self Test — complete. RETURN the
Restraints. vehicle to the customer.
NOTE: When selecting Restraints from the Self Test menu, DTCs
are retrieved from the RCM and OCSM .
Are any RCM and/or OCSM DTCs retrieved on-demand during
self-test?
Pinpoint Test B: DTCs B0002:11, B0002:12, B0002:13 and B0002:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 2 circuits for the
following faults:

Unexpected voltage
Short to ground
Faulted driver air bag module
including:
Wiring
Connections
Clockspring
RCM

B0002:11 — Driver Frontal Stage 2 When the RCM senses a short to ground on either driver
Deployment Control: Circuit Short to Ground air bag stage 2 circuit, a fault is indicated.
B0002:12 — Driver Frontal Stage 2 When the RCM senses a short to voltage on either
Deployment Control: Circuit Short to Battery driver air bag stage 2 circuit, a fault is indicated.
B0002:13 — Driver Frontal Stage 2 When the RCM measures more than the desired
Deployment Control: Circuit Open resistance range between driver air bag stage 2 circuits,
a fault is indicated.
B0002:1A — Driver Frontal Stage 2 When the RCM measures less than the desired
Deployment Control: Circuit Resistance resistance range between driver air bag stage 2 circuits,

Clockspring
RCM
PINPOINT TEST B: DTCs B0002:11, B0002:12, B0002:13 AND B0002:1A

B1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0002:13 or

B0002:1A, GO to B2 .

B11 .

B14 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0002:13 or

B0002:1A, GO to B19 .

B20 .

B21 .
B2 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT
RCM . GO to B18 .
DEPLOY_01_R PID
Does the PID value read between 2 and 3.68 ohms? No
GO to B3 .
THE HARNESS TEST
Remove the lower steering column shroud to access the clockspring Yes
connector. DEPOWER the SRS and
While monitoring the DEPLOY_01_R PID, carry out the harness test REPAIR the connector,
of the driver air bag circuits and accessible connectors (including any terminals or wire harness
in-line connectors), by wiggling and flexing the wire harness, or INSTALL a new
connectors, tilting and rotating the steering wheel frequently. clockspring as needed.
Does the PID value read between 2 and 3.68 ohms while carrying REFER to Clockspring in
out the harness test? this section.

GO to B23 .
No
For PID value less than 2
ohms, GO to B4 .

3.68 ohms, GO to B7 .
INDICATED)
by the RCM by inducing a different fault condition. If the fault reported GO to B16 .
GO to B5 .
Ignition OFF.
this section.
in this section.
Ignition ON.
RCM .
on stages 1 and 2.
GO to B6 .
Ignition OFF.
Ignition ON.
RCM .
B6 CHECK FOR A SHORT BETWEEN DRIVER AIR BAG STAGE 2
CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to B18 .
Measure the resistance between C218A-4, circuit CR102 (BU), REPAIR circuits CR102
harness side and C218A-3, circuit RR102 (WH), harness side. (BU) and RR102 (WH).

GO to B23 .

B7 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Remove the driver air bag module. Refer to Driver Air Bag Module in No
this section. GO to B8 .
Measure the resistance between RCM C310A, harness side and
driver air bag module stage 2 C216B, harness side using the
following chart.
Driver Air Bag Module Electrical

RCM Circuit Connector
C310A- CR102 (BU)/ C216B-1
7 (BN)
C310A- RR102 (WH)/ C216B-2
8 (BU)
Are the resistances less than 1 ohm?
B8 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR AN OPEN
(CLOCKSPRING DISCONNECTED)
Disconnect: Clockspring C218A. Yes
Measure the resistance between RCM C310A, harness side, and GO to B17 .
clockspring C218A, harness side, using the following chart.
No
RCM Circuit Clockspring REPAIR circuit CR102
(BU) or RR102 (WH).
C310A-7 CR102 (BU) C218A-4
C310A-8 RR102 (WH) C218A-3 Refer to Wiring Diagrams
GO to B23 .

changes, this indicates the RCM is functioning correctly and is not and GO to B16 .
the source of the fault.
No
Connect a fused jumper wire between driver air bag module stage 2 and GO to B10 .
C216B-1, circuit CR102 (BN), harness side, and C216B-2, circuit
RR102 (BU), harness side.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with driver air bag module
stage 2 circuits shorted together, a low resistance fault would
normally be retrieved on stage 2. Stage 1 will show an open circuit
fault due to the driver air bag being disconnected.
B10 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR AN
OPEN (CLOCKSPRING DISCONNECTED)
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) REMOVE the fused jumper
Depowering and Repowering in this section. and GO to B17 .
Connect a fused jumper wire between clockspring C218A-3, circuit No
RR102 (WH), harness side, and C218A-4, circuit CR102 (BU), REMOVE the fused jumper
harness side. and GO to B18 .
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the clockspring stage 2
circuits shorted together, a low resistance fault would normally be
INDICATED)
Ignition OFF. GO to B12 .
this section.
in this section.
Ignition ON.
RCM .
on stages 1 and 2.
B12 CHECK DRIVER FRONTAL STAGE 2 DEPLOYMENT CONTROL
DTC FOR A FAULT STATUS CHANGE (SHORT TO GROUND
GO to B13 .
Ignition OFF.
Ignition ON.
RCM .
be retrieved on stage 1 and 2.
B13 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between clockspring: REPAIR circuit CR102
C218A-4, circuit CR102 (BU), harness side and ground. (BU) or RR102 (WH).
C218A-3, circuit RR102 (WH), harness side and ground.
GO to B23 .

CONTROL DTC FOR A FAULT STATUS CHANGE (SHORT TO
BATTERY INDICATED) (CLOCKSPRING DISCONNECTED)
this section.
in this section.
Ignition ON.
RCM .
B15 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) REPAIR circuit CR102
Depowering and Repowering in this section. (BU) or RR102 (WH).
Repower the SRS . Do not prove out the SRS at this time. Refer to Refer to Wiring Diagrams
Supplemental Restraint System (SRS) Depowering and Repowering Cell 5 , Connector Repair
in this section. Procedures for schematic
Ignition ON. and connector information.
Measure the voltage between clockspring:
C218A-4, circuit CR102 (BU), harness side and ground. GO to B23 .
C218A-3, circuit RR102 (WH), harness side and ground.
No
GO to B18 .

B16 CONFIRM THE DRIVER AIR BAG MODULE FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new driver air
DTCs will be recorded. bag module. REFER to
Driver Air Bag Module in
Ignition OFF. this section. GO to B23 .
inspect wire harness for any damage, pinched, cut or pierced any new SRS
For DTC B0002:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0002:1A, GO to B19 .
B20 .
Repower the SRS . Do not prove out the SRS at this time. Refer to B21 .
in this section.
Ignition ON.
RCM .
B17 CONFIRM THE CLOCKSPRING FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new
DTCs will be recorded. clockspring. REFER to
For DTC B0002:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0002:1A, GO to B19 .
Connect: Clockspring C218A. B20 .
in this section.
Ignition ON.
RCM .
B18 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to B23 .
Refer to Wiring Diagrams Cell 5 , Connector Repair For DTC B0002:13 or
Procedures for schematic and connector information. B0002:1A, GO to B19 .
If previously removed, install the driver air bag module. Refer to For DTC B0002:11, GO to
Driver Air Bag Module in this section. B20 .
Connect: Clockspring C218A (if previously disconnected).
in this section.
Ignition ON.
RCM .
Does the PID value read between 2 and 3.68 ohms? components only when
pinpoint test. GO to B22 .
No
If the driver air bag PID
indicates incorrect
resistance only when the
steering wheel is rotated,
INSTALL a new
For all other faults,

DEPOWER the SRS and

GO to B23 .
line connectors) and flexing the wire harness, tilting and rotating the DEPOWER the SRS and
steering wheel frequently. REPAIR as necessary.
RCM . Refer to Wiring Diagrams
Was DTC B0002:11 retrieved on-demand during self-test? Cell 5 , Connector Repair
GO to B23 .
No
Ignition OFF. Yes
this section. Refer to Wiring Diagrams
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any in- GO to B23 .
line connectors) and flexing the wire harness, tilting and rotating the
steering wheel frequently. No
B22 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Remove the driver air bag module. Refer to Wiring Diagrams
wires. GO to B23 .
Inspect RCM C310A and C310B CPA lever/lock for correct operation.
Refer to Restraints Control Module (RCM) in this section. No
B23 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test C: DTCs B0004:11, B0004:12, B0004:13 and B0004:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver knee bolster air bag module circuits for
the following faults:

Unexpected voltage
Short to ground
Faulted driver knee bolster air bag module
including:
Wiring
Connections
Driver knee bolster air bag module
RCM

B0004:11 — Driver Knee Bolster When the RCM senses a short to ground on either driver
Deployment Control: Circuit Short to knee bolster air bag module circuit, a fault is indicated.
Ground
B0004:12 — Driver Knee Bolster When the RCM senses a short to voltage on either driver
Deployment Control: Circuit Short to knee bolster air bag module circuit, a fault is indicated.
Battery
B0004:13 — Driver Knee Bolster When the RCM measures greater than the desired
Deployment Control: Circuit Open resistance range between driver knee bolster air bag
module circuits, a fault is indicated.
B0004:1A — Driver Knee Bolster When the RCM measures less than the desired resistance
Deployment Control: Circuit Resistance range between driver knee bolster air bag module circuits,

Driver knee bolster air bag module
RCM
PINPOINT TEST C: DTCs B0004:11, B0004:12, B0004:13 AND B0004:1A
Advantage™ to make sure the correct component is being installed. If an incorrect SRS component is installed,
DTCs may set.

C1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0004:13 or

B0004:1A, GO to C2 .

C8 .

C10 .
No
when present as a CMDTC
only.
For DTC B0004:13 or

B0004:1A, GO to C13 .
C14 .

C15 .
C2 CHECK THE DRIVER KNEE BOLSTER DEPLOYMENT CONTROL
RESISTANCE (DEPLOY_02_R) PID
RCM . GO to C12 .
DEPLOY_02_R PID
Does the PID value read between 1.7 and 2.78 ohms? No
GO to C3 .
RESISTANCE (DEPLOY_02_R) PID WHILE CARRYING OUT THE
HARNESS TEST
While monitoring the DEPLOY_02_R PID, carry out the harness test Yes
of the driver knee air bag module circuits and accessible connectors DEPOWER the SRS and
(including any in-line connectors), by wiggling connectors and REPAIR the connector,
flexing the wire harness frequently. terminals or wire harness as
Does the PID value read between 1.7 and 2.78 ohms while needed.
carrying out the harness test?
GO to C17 .
No
For PID value less than 1.7
ohms, GO to C4 .

2.78 ohms, GO to C6 .
DTC FOR A FAULT STATUS CHANGE (LOW RESISTANCE
INDICATED)
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to C11 .
Disconnect: Driver Knee Air Bag Module C2432. No
Repower the SRS . Do not prove out the SRS at this time. Refer to GO to C5 .
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver knee air bag
module disconnected, open circuit faults would normally be
retrieved.
C5 CHECK FOR A SHORT BETWEEN DRIVER KNEE AIR BAG
MODULE CIRCUITS
Ignition OFF. Yes
Measure the resistance between driver knee air bag module C2432- REPAIR circuits CR139
1, circuit CR139 (VT/WH), harness side and C2432-2, circuit RR139 (VT/WH) and RR139 (YE).
(YE), harness side.
GO to C17 .

C6 CHECK THE DRIVER KNEE AIR BAG MODULE CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Driver Knee Air Bag Module C2432. No
Disconnect: RCM C310A and C310B. REPAIR circuit CR139
Measure the resistance between RCM C310B, harness side and (VT/WH) or RR139 (YE).
driver knee air bag module C2432, harness side using the following
chart. Refer to Wiring Diagrams
RCM Circuit Driver Knee Air Bag Module Procedures for schematic
C310B-4 RR139 (YE) C2432-2
C310B-3 CR139 (VT/WH) C2432-1 GO to C17 .

DTC FOR A FAULT STATUS CHANGE (OPEN INDICATED)
Connect: RCM C310A and C310B. Yes
Connect a fused jumper wire between driver knee air bag module REMOVE the fused jumper
C2432-1, circuit CR139 (VT/WH), harness side and C2432-2, circuit wire and GO to C11 .
RR139 (YE), harness side.
No
REMOVE the fused jumper
wire and GO to C12 .
in this section.
Ignition ON.
RCM .
module circuits shorted together, a low resistance fault would
normally be retrieved.
Did the on-demand DTC change from B0004:13 to B0004:1A?
DTC FOR A FAULT STATUS CHANGE (SHORT TO GROUND
INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to C11 .
reported changes, this indicates the RCM is functioning correctly
and is not the source of the fault. No
GO to C9 .
Ignition OFF.
Disconnect: Driver Knee Bolster Air Bag Module C2432.
in this section.
Ignition ON.
RCM .
module disconnected, an open circuit fault would normally be
retrieved.
C9 CHECK THE DRIVER KNEE AIR BAG MODULE CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between driver knee air bag module: REPAIR circuit CR139
C2432-1, circuit CR139 (VT/WH), harness side and ground. (VT/WH) or RR139 (YE).
C2432-2, circuit RR139 (YE), harness side and ground.
GO to C17 .
C10 CHECK THE DRIVER KNEE AIR BAG MODULE CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (VT/WH) or RR139 (YE).
Disconnect: Driver Knee Air Bag Module C2432.
Disconnect: RCM C310A and C310B. Refer to Wiring Diagrams
Ignition ON.
Measure the voltage between driver knee air bag module: GO to C17 .
C2432-1, circuit CR139 (VT/WH), harness side and ground.
C2432-2, circuit RR139 (YE), harness side and ground. No
GO to C12 .

C11 CONFIRM THE DRIVER KNEE AIR BAG MODULE FAULT
NOTE: Make sure all SRS components, sensor electrical connectors Yes
and the RCM electrical connectors are connected before carrying INSTALL a new driver knee
out the self-test. If not, DTCs will be recorded. air bag module. REFER to
Knee Air Bag Module in this
Ignition OFF. section. GO to C17 .
Connect: Driver Knee Air Bag Module C2432. In the process of diagnosing
Repower the SRS . Do not prove out the SRS at this time. Refer to the fault, the fault condition
Supplemental Restraint System (SRS) Depowering and Repowering has become intermittent. Do
in this section. not install any new SRS
Ignition ON. components at this time.
Enter the following diagnostic mode on the scan tool: Self Test — Install SRS components
RCM . only when directed to do
Was the original DTC retrieved on-demand during self-test? so in the pinpoint test.
For DTC B0004:13 or

B0004:1A, GO to C13 .
C14 .

C15 .
C12 CONFIRM THE RCM FAULT
NOTE: Make sure all SRS components, sensor electrical connectors Yes
and the RCM electrical connectors are connected before carrying INSTALL a new RCM .
out the self-test. If not, DTCs will be recorded. REFER to Restraints
Ignition OFF. this section. GO to C17 .
Prior to reconnecting any previously disconnected SRS component: In the process of diagnosing
inspect connector(s) (including any in-line connectors) for the fault, the fault condition
pushed out, loose or spread terminals and loose or frayed has become intermittent. Do
wire connections at terminals. not install any new SRS
inspect wire harness for any damage, pinched, cut or pierced components at this time.
wires. Install SRS components
inspect C310A and C310B Connector Position Assurance only when directed to do
(CPA) lever/lock for correct operation. Refer to Restraints so in the pinpoint test.
Control Module (RCM) in this section.
repair any concerns found. For DTC B0004:13 or
B0004:1A, GO to C13 .
Refer to Wiring Diagrams Cell 5 , Connector Repair
Procedures for schematic and connector information. For DTC B0004:11, GO to
C14 .
Connect: Driver Knee Air Bag Module C2432 (if previously
disconnected). For DTC B0004:12, GO to
Connect: RCM C310A and C310B (if previously disconnected). C15 .
in this section.
Ignition ON.
RCM .
RESISTANCE (DEPLOY_02_R) PID FOR AN INTERMITTENT LOW
RESISTANCE OR OPEN CIRCUIT FAULT
Attempt to recreate the fault by wiggling connectors (including any time. Do not install any
in-line connectors), and flexing the wire harness frequently. new SRS components at
Does the PID value read between 1.7 and 2.78 ohms? this time. Install SRS
pinpoint test. GO to C16 .
No
DEPOWER the SRS and

GO to C17 .
CIRCUITS FOR AN INTERMITTENT SHORT TO GROUND FAULT
Attempt to recreate the fault by wiggling connectors (including any Yes
in-line connectors) and flexing the wire harness frequently. DEPOWER the SRS and
Enter the following diagnostic mode on the scan tool: Self Test — REPAIR as necessary.
RCM .
Was DTC B0004:11 retrieved on-demand during self-test? Refer to Wiring Diagrams
GO to C17 .
No
CIRCUITS FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF. Yes
Disconnect: Driver Knee Air Bag Module C2432.
Attempt to recreate the fault by wiggling connectors (including any
in-line connectors) and flexing the wire harness frequently.
GO to C17 .
RCM . No
Was DTC B0004:12 retrieved on-demand during self-test? The fault is not present and
C16 CHECK HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Driver Knee Bolster Air Bag Module C2432 (if not Refer to Wiring Diagrams
previously disconnected). Cell 5 , Connector Repair
inspect connector(s) (including any in-line connectors) for Procedures for schematic
corrosion, loose or spread terminals and loose or frayed wire and connector information.
connections at terminals.
GO to C17 .
wires.
inspect C310A and C310B Connector Position Assurance No
(CPA) lever/lock for correct operation. Refer to Restraints
Control Module (RCM) in this section. cannot be recreated at this
Were any concerns found? time. Do not install any
C17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
not prove out the SRS at this time. Refer to Supplemental Restraint CLEAR all RCM and OCSM
System (SRS) Depowering and Repowering in this section. CMDTCs . PROVE OUT the
Ignition ON. SRS . Repair is complete.
Enter the following diagnostic mode on the scan tool: Self Test — RETURN the vehicle to the
Restraints. customer.
are retrieved from the RCM and Occupant Classification System
Module (OCSM).
Are any RCM and/or OCSM retrieved on-demand during self-
test?
Pinpoint Test D: DTCs B0010:11, B0010:12, B0010:13 and B0010:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger air bag module stage 1 circuits for

Unexpected voltage
Short to ground
Faulted passenger air bag module
including:
Wiring
Connections
Passenger air bag module
RCM
DTC Description Fault Trigger Conditions
B0010:11 — Passenger Frontal Stage 1 When the RCM senses a short to ground on either
Deployment Control: Circuit Short to Ground passenger air bag stage 1 circuit, a fault is indicated.
B0010:12 — Passenger Frontal Stage 1 When the RCM senses a short to voltage on either
Deployment Control: Circuit Short to Battery passenger air bag stage 1 circuit, a fault is indicated.
B0010:13 — Passenger Frontal Stage 1 When the RCM measures more than the desired
Deployment Control: Circuit Open resistance range between passenger air bag stage 1
circuits, a fault is indicated.
B0010:1A — Passenger Frontal Stage 1 When the RCM measures less than the desired
Deployment Control: Circuit Resistance resistance range between passenger air bag stage 1
Below Threshold circuits, a fault is indicated.

RCM
PINPOINT TEST D: DTCs B0010:11, B0010:12, B0010:13 AND B0010:1A
D1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0010:13 or

B0010:1A, GO to D2 .

D9 .

D11 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0010:13 or

B0010:1A, GO to D14 .

D15 .

D16 .
D2 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT
RCM . GO to D13 .
DEPLOY_05_R PID
GO to D3 .
THE HARNESS TEST
of the passenger air bag module circuits and accessible connectors DEPOWER the SRS and
(including any in-line connectors) by wiggling connectors and flexing REPAIR the connector,
the wire harness. terminals or wire harness
Does the PID value read between 1.7 and 2.78 ohms while as needed.
GO to D18 .
No
ohms, GO to D4 .

2.78 ohms, GO to D7 .
INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to D12 .
reported changes, this indicates the RCM is functioning correctly and
is not the source of the fault. No
GO to D5 .
Ignition OFF.
Remove and disconnect the passenger air bag module. Refer to
Passenger Air Bag Module in this section.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the passenger air bag
module removed, open circuit faults would normally be retrieved on
passenger air bag stage 1 and stage 2 circuits.
D5 CHECK FOR A SHORT BETWEEN PASSENGER AIR BAG STAGE
1 CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to D13 .
Measure the resistance between passenger air bag module stage 1 No
C256A-1, circuit CR103 (GY/BU), harness side and C256A-2, circuit GO to D6 .
RR103 (VT/GN), harness side.

D6 CHECK RCM FOR LOW RESISTANCE
Disconnect: RCM C310A and C310B. Yes
Measure the resistance between RCM C310A pins 1 and 2, REPAIR circuits CR103
component side. (GY/BU) and RR103
(VT/GN).

GO to D18 .
No
GO to D13 .

D7 CHECK THE PASSENGER AIR BAG STAGE 1 CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Remove the passenger air bag module and disconnect the No
passenger air bag module connectors C256A and C256B. Refer to REPAIR circuit CR103
Passenger Air Bag Module in this section. (GY/BU) or RR103
Disconnect: RCM C310A and C310B. (VT/GN).
passenger air bag module stage 1 C256A, harness side using the Refer to Wiring Diagrams
following chart. Cell 5 , Connector Repair
RCM Circuit Passenger Air Bag Module Stage 1 and connector information.
C310A-1 CR103 (GY/BU) C256A-1
GO to D18 .
C310B-2 RR103 (VT/GN) C256A-2

by the RCM by inducing a different fault condition. If the fault REMOVE the fused jumper
reported changes, this indicates the RCM is functioning correctly and wire and GO to D12 .
is not the source of the fault.
No
Prior to reconnecting any previously disconnected SRS component: REMOVE the fused jumper
inspect connector(s) (including any in-line connectors) for wire and GO to D13 .
pushed-out, loose or spread terminals and loose or frayed
wire connections at terminals.
wires.
inspect C310A and C310B CPA lever/lock for correct
operation. Refer to Restraints Control Module (RCM) in this
section.

Connect: RCM C310A and C310B.

Connect a fused jumper wire between passenger air bag module
stage 1 C256A-1, circuit CR103 (GY/BU), harness side and C256A-
2, circuit RR103 (VT/GN), harness side.
in this section.
Ignition ON.
RCM .
module stage 1 circuits shorted together, a low resistance fault would
normally be retrieved on stage 1. Stage 2 shows an open circuit fault
due to the passenger air bag being removed.
INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to D12 .
GO to D10 .
Ignition OFF.
Remove the passenger air bag module and disconnect the
passenger air bag module connectors C256A and C256B. Refer to
in this section.
Ignition ON.
RCM .
passenger air bag stage 1 and stage 2 circuits.
D10 CHECK THE PASSENGER AIR BAG STAGE 1 CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between passenger air bag module: Due to the shorting bar
C256A-1, circuit CR103 (GY/BU), harness side and ground. feature in the RCM
C256A-2, circuit RR103 (VT/GN), harness side and ground. electrical connector, the
fault can exist in either
circuit. Do not remove or
defeat the shorting bar.

(GY/BU) or RR103
(VT/GN).
GO to D18 .

D11 CHECK THE PASSENGER AIR BAG STAGE 1 CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) Due to the shorting bar
Depowering and Repowering in this section. feature in the RCM
Remove the passenger air bag module and disconnect the electrical connector, the
passenger air bag module connectors C256A and C256B. Refer to fault can exist in either
Passenger Air Bag Module in this section. circuit. Do not remove or
Disconnect: RCM C310A and C310B. defeat the shorting bar.
Supplemental Restraint System (SRS) Depowering and Repowering REPAIR circuit CR103
in this section. (GY/BU) or RR103
Ignition ON. (VT/GN).
Measure the voltage between passenger air bag module:
C256A-1, circuit CR103 (GY/BU), harness side and ground. Refer to Wiring Diagrams
C256A-2, circuit RR103 (VT/GN), harness side and ground. Cell 5 , Connector Repair
GO to D18 .
No
GO to D13 .
Is any voltage present on either circuit?

D12 CONFIRM THE PASSENGER AIR BAG MODULE FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new passenger
DTCs will be recorded. air bag module. REFER to
Ignition OFF. in this section. GO to D18 .
pushed-out, loose or spread terminals and loose or frayed fault condition has become
wire connections at terminals. intermittent. Do not install
inspect C310A and C310B CPA lever/lock for correct Install SRS components
operation. Refer to Restraints Control Module (RCM) in this only when directed to do
section. so in the pinpoint test.
For DTC B0010:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0010:1A, GO to D14 .
D15 .
Connect and install the passenger air bag module (if previously
disconnected). Refer to Passenger Air Bag Module in this section. For DTC B0010:12, GO to
Repower the SRS . Do not prove out the SRS at this time. Refer to D16 .
in this section.
Ignition ON.
RCM .
D13 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to D18 .
For DTC B0010:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0010:1A, GO to D14 .
Connect and install the passenger air bag module (if previously D15 .
disconnected). Refer to Passenger Air Bag Module in this section.
Repower the SRS . Do not prove out the SRS at this time. Refer to D16 .
in this section.
Ignition ON.
RCM .
RCM . DEPOWER the SRS and
DEPLOY_05_R PID REPAIR as necessary.
Attempt to recreate the fault by wiggling connectors (including any in-
line connectors) and flexing the wire harness frequently. Refer to Wiring Diagrams
Does the PID value read between 1.7 and 2.78 ohms? Cell 5 , Connector Repair
GO to D17 .
No
line connectors) and flexing the wire harness. DEPOWER the SRS and
Was DTC B0010:11 retrieved on-demand during self-test? REPAIR as necessary.

GO to D18 .
No
Ignition OFF. Yes
passenger air bag module connectors C256A and C256B. Refer to Refer to Wiring Diagrams
Passenger Air Bag Module in this section. Cell 5 , Connector Repair
Repower the SRS . Do not prove out the SRS at this time. Refer to Procedures for schematic
Supplemental Restraint System (SRS) Depowering and Repowering and connector information.
in this section.
Ignition ON.
GO to D18 .
line connectors) and flexing the wire harness. No
D17 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Remove and disconnect the passenger air bag module. Refer to Refer to Wiring Diagrams
inspect connector(s) (including any in-line connectors) for Procedures for schematic
corrosion, loose or spread terminals and loose or frayed wire and connector information.
connections at terminals.
inspect wire harness for any damage, pinched, cut or pierced GO to D18 .
wires.
inspect C310A and C310B Connector Position Assurance No
Control Module (RCM) in this section. cannot be recreated at this
D18 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
System (SRS) Depowering and Repowering in this section. CMDTCs . PROVE OUT
Ignition ON. the SRS . Repair is
self-test?
Pinpoint Test E: DTCs B0011:11, B0011:12, B0011:13 and B0011:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger air bag module 2 circuits for the
following faults:

Unexpected voltage
Short to ground
Faulted passenger air bag module
at the time of diagnosis. Following this direction helps make sure that minor changes in resistance do not create
a repeat concern. This test uses a process of elimination to diagnose each part of the deployment loop circuit
including:
Wiring
Connections
RCM
B0011:11 — Passenger Frontal Stage 2 When the RCM senses a short to ground on either
Deployment Control: Circuit Short to passenger frontal stage 2 deployment control circuit, a fault
Ground is indicated.
B0011:12 — Passenger Frontal Stage 2 When the RCM senses a short to voltage on either
Deployment Control: Circuit Short to passenger frontal stage 2 deployment control circuit, a fault
Battery is indicated.
B0011:13 — Passenger Frontal Stage 2 When the RCM measures more than the desired resistance
Deployment Control: Circuit Open range between passenger frontal stage 2 deployment
control circuits, a fault is indicated.
B0011:1A — Passenger Frontal Stage 2 When the RCM measures less than the desired resistance
Deployment Control: Circuit Resistance range between passenger frontal stage 2 deployment
Below Threshold control circuits, a fault is indicated.

RCM
PINPOINT TEST E: DTCs B0011:11, B0011:12, B0011:13 AND B0011:1A

E1 RETRIEVE RCM DTCs
Ignition ON. Yes
on-demand during self-test? on-demand during the self-
test.
For DTC B0011:13 or

B0011:1A, GO to E2 .

E8 .

E10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0011:13 or

B0011:1A, GO to E13 .

E14 .

E15 .
E2 CHECK THE PASSENGER FRONTAL STAGE 2 DEPLOYMENT
RCM . GO to E12 .
DEPLOY_06_R PID
GO to E3 .
THE HARNESS TEST
of the passenger air bag module circuits and accessible connectors DEPOWER the SRS and
the wire harness. terminals or wire harness
Does the PID value read between 1.7 and 2.78 ohms while as needed.
GO to E16 .
No
ohms, GO to E4 .

2.78 ohms, GO to E6 .
INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to E11 .
GO to E5 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
on passenger air bag stage 1 and 2 circuits.
E5 CHECK FOR A SHORT BETWEEN PASSENGER AIR BAG STAGE
2 CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to E11 .
Measure the resistance between passenger air bag module stage 2 REPAIR circuits CR104
C256B-1, circuit CR104 (YE/GY), harness side and C256B-2, circuit (YE/GY) and RR104
RR104 (WH/BU), harness side. (WH/BU).

GO to E17 .

E6 CHECK THE PASSENGER AIR BAG STAGE 2 CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Remove the passenger air bag module and disconnect the No
passenger air bag module connectors C256A and C256B. Refer to REPAIR circuit CR104
Passenger Air Bag Module in this section. (YE/GY) or RR104
Disconnect: RCM C310A and C310B. (WH/BU).
passenger air bag module stage 2 C256B, harness side using the Refer to Wiring Diagrams
following chart. Cell 5 , Connector Repair
RCM Circuit Passenger Air Bag Module Stage 2 and connector information.
C310A-10 CR104 (YE/GY) C256B-1
GO to E17 .
C310A-9 RR104 (WH/BU) C256B-2

reported changes, this indicates the RCM is functioning correctly and wire and GO to E11 .
No
Connect a fused jumper wire between passenger air bag module wire and GO to E12 .
stage 2 C256B-1, circuit CR104 (YE/GY), harness side and C256B-
2, circuit RR104 (WH/BU), harness side.
in this section.
Ignition ON.
RCM .
stage 2 circuits shorted together, a low resistance fault would
normally be retrieved on stage 2. Stage 1 shows an open circuit fault
due to the passenger air bag module being removed.
INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to E11 .
GO to E9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
stage 1 and stage 2.
E9 CHECK THE PASSENGER AIR BAG STAGE 2 CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between passenger air bag module stage 2: REPAIR circuit CR104
C256B-1, circuit CR104 (YE/GY), harness side and ground. (YE/GY) or RR104
C256B-2, circuit RR104 (WH/BU), harness side and ground. (WH/BU).

GO to E17 .

E10 CHECK THE PASSENGER AIR BAG STAGE 2 CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (YE/GY) or RR104
Remove and disconnect the passenger air bag module. Refer to (WH/BU).
Ignition ON.
Measure the voltage between passenger air bag module stage 2:
GO to E17 .
C256B-1, circuit CR104 (YE/GY), harness side and ground.
C256B-2, circuit RR104 (WH/BU), harness side and ground. No
GO to E12 .
E11 CONFIRM THE PASSENGER AIR BAG MODULE FAULT
Ignition OFF. in this section. GO to E17 .
inspect C310A and C310B SRS lever/lock for correct Install SRS components
For DTC B0011:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0011:1A, GO to E13 .
Connect and install the passenger air bag module (if previously E14 .
disconnected). Refer to Passenger Air Bag Module in this section.
Repower the SRS . Do not prove out the SRS at this time. Refer to For DTC B0011:12, GO to
Supplemental Restraint System (SRS) Depowering and Repowering E15 .
in this section.
Ignition ON.
RCM .
E12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to E17 .
For DTC B0011:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B0011:1A, GO to E13 .
Install the passenger air bag module (if previously removed) and E14 .
connect passenger air bag module connectors C256A and C256B.
Refer to Passenger Air Bag Module in this section. For DTC B0011:12, GO to
Connect: RCM C310A and C310B. E15 .
in this section.
Ignition ON.
RCM .
Does the PID value read between 1.7 and 2.78 ohms? components only when
pinpoint test. GO to E16 .
No
DEPOWER the SRS and

GO to E17 .
line connectors) and flexing the wire harness. DEPOWER the SRS and
RCM .
GO to E17 .
No
Ignition OFF. Yes
passenger air bag module connectors C256A and C256B. Refer to Refer to Wiring Diagrams
in this section.
line connectors) and flexing the wire harness. No
E16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Remove the passenger air bag module and disconnect the Refer to Wiring Diagrams
passenger air bag module connectors C256A and C256B. Refer to Cell 5 , Connector Repair
Passenger Air Bag Module in this section. Procedures for schematic
inspect connector(s) (including any in-line connectors) for and connector information.
corrosion, loose or spread terminals and loose or frayed wire
connections at terminals. GO to E17 .
wires. No
E17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
System (SRS) Depowering and Repowering in this section. CMDTCs . PROVE OUT
Ignition ON. the SRS . Repair is
Restraints. vehicle to the customer on-
NOTE: When selecting Restraints from the Self Test menu, DTCs demand during self-test.
self-test?
Pinpoint Test F: DTCs B0020:11, B0020:12, B0020:13 and B0020:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver seat side air bag module circuits for the
following faults:

Unexpected voltage
Short to ground
Faulted driver seat side air bag module
including:
Wiring
Connections
Driver seat side air bag module
RCM

B0020:11 — Left Side Airbag Deployment When the RCM senses a short to ground on either driver
Control: Circuit Short to Ground seat side air bag circuit, a fault is indicated.
B0020:12 — Left Side Airbag Deployment When the RCM senses a short to voltage on either driver
Control: Circuit Short to Battery seat side air bag circuit, a fault is indicated.
B0020:13 — Left Side Airbag Deployment When the RCM measures more than the desired
Control: Circuit Open resistance range between the driver seat side air bag
circuit, a fault is indicated.
B0020:1A — Left Side Airbag Deployment When the RCM measures less than the desired resistance
Control: Circuit Resistance Below range between the driver seat side air bag circuits, a fault
Threshold is indicated.

Driver seat side air bag module
RCM
PINPOINT TEST F: DTCs B0020:11, B0020:12, B0020:13 AND B0020:1A
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners, adaptive
load limiting retractors, safety belt inflators, or probe the electrical connectors. Failure to follow this
instruction may result in the accidental deployment of the safety belt pretensioners, adaptive load
limiting retractors, or safety belt inflators, which increases the risk of serious personal injury or death.

F1 RETRIEVE RCM DTCs
Ignition ON. Yes
test.
For DTC B0020:13 or

B0020:1A, GO to F2 .

F8 .

F10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0020:13 or

B0020:1A, GO to F13 .

F14 .

F15 .
F2 CHECK THE LEFT SIDE AIRBAG DEPLOYMENT CONTROL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger — GO to F12 .
RCM .
DEPLOY_10_R PID No
Does the PID value read between 1.7 and 2.78 ohms? GO to F3 .
HARNESS TEST
While monitoring the DEPLOY_10_R PID carry out the harness test Yes
of the driver seat side air bag circuits and accessible connectors DEPOWER the SRS and
the wire harness. terminals or wire harness as
GO to F17 .
No
ohms, GO to F4 .

2.78 ohms, GO to F6 .
F4 CHECK THE LEFT SIDE AIRBAG DEPLOYMENT CONTROL DTC
FOR A FAULT STATUS CHANGE (LOW RESISTANCE INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to F11 .
GO to F5 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver seat side air
bag disconnected, an open circuit fault would normally be retrieved.
F5 CHECK FOR A SHORT BETWEEN DRIVER SEAT SIDE AIR BAG
CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to F12 .
Measure the resistance between driver seat side air bag module REPAIR circuits CR105
C367-3, circuit CR105 (GN/BU), harness side and C367-1, circuit (GN/BU) and RR105
RR105 (GY/YE), harness side. (GY/YE).
GO to F17 .

F6 CHECK THE DRIVER SEAT SIDE AIR BAG CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Driver Seat Side Air Bag Module C367. No
Measure the resistance between RCM C310B, harness side and (GN/BU) or RR105 (GY/YE).
driver seat side air bag module C367, harness side using the
following chart. Refer to Wiring Diagrams
RCM Circuit Driver Seat Side Air Bag Module Procedures for schematic
C310B-6 CR105 (GN/BU) C367-3
C310B-5 RR105 (GY/YE) C367-1 GO to F17 .

FOR A FAULT STATUS CHANGE (OPEN INDICATED)
reported changes, this indicates the RCM is functioning correctly wire and GO to F11 .
and is not the source of the fault.
No
Connect a fused jumper wire between driver seat side air bag wire and GO to F12 .
module C367-1, circuit RR105 (GY/YE), harness side and C367-3,
circuit CR105 (GN/BU), harness side.
in this section.
Ignition ON.
RCM .
bag module circuits shorted together, a low resistance fault would
FOR A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to F11 .
GO to F9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
bag module disconnected, an open circuit fault would normally be
retrieved.
F9 CHECK THE DRIVER SEAT SIDE AIR BAG CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between driver seat side air bag module: REPAIR circuit CR105
C367-1, circuit RR105 (GY/YE), harness side and ground. (GN/BU) or RR105 (GY/YE).
C367-3, circuit CR105 (GN/BU), harness side and ground.
GO to F17 .
F10 CHECK THE DRIVER SEAT SIDE AIR BAG CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (GN/BU) or RR105 (GY/YE).
Ignition ON.
Measure the voltage between driver seat side air bag module: GO to F17 .
C367-1, circuit RR105 (GY/YE), harness side and ground.
C367-3, circuit CR105 (GN/BU), harness side and ground. No
GO to F12 .

F11 CONFIRM THE DRIVER SEAT SIDE AIR BAG MODULE FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new driver side
Side Air Bag Module in this
Ignition OFF. section. GO to F17 .
pushed-out, loose or spread terminals and loose or frayed has become intermittent. Do
B0020:1A, GO to F13 .
F14 .
Connect: Driver Side Air Bag Module C367.
Repower the SRS . Do not prove out the SRS at this time. Refer to F15 .
in this section.
Ignition ON.
RCM .
F12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to F17 .
B0020:1A, GO to F13 .
F14 .
Connect: Driver Seat Side Air Bag Module C367.
Connect: RCM C310A and C310B (if previously disconnected). For DTC B0020:12, GO to
Repower the SRS . Do not prove out the SRS at this time. Refer to F15 .
in this section.
Ignition ON.
RCM .
Monitor the DEPLOY_10_R PID. time. Do not install any
Attempt to recreate the fault by wiggling connectors (including any new SRS components at
in-line connectors) and flexing the wire harness. this time. Install SRS
Does the PID value read between 1.7 and 2.78 ohms? components only when
pinpoint test. GO to F16 .
No
DEPOWER the SRS and

GO to F17 .
F14 CHECK THE LEFT SIDE AIRBAG DEPLOYMENT CONTROL FOR
AN INTERMITTENT SHORT TO GROUND FAULT
in-line connectors) and flexing the wire harness. DEPOWER the SRS and
RCM .
GO to F17 .
No
F15 CHECK THE LEFT SIDE AIRBAG DEPLOYMENT CONTROL FOR
AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF. Yes
in-line connectors) and flexing the wire harness.
GO to F17 .
RCM . No
F16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect the driver seat side air bag module C367: Refer to Wiring Diagrams
wires. GO to F17 .
No
F17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test G: DTCs B0021:11, B0021:12, B0021:13 and B0021:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver side air curtain circuits for the following
faults:

Unexpected voltage
Short to ground
Faulted driver side air curtain
including:
Wiring
Connections
Driver side curtain module
RCM
B0021:11 — Left Curtain Deployment When the RCM senses a short to ground on either driver
Control 1: Circuit Short to Ground side air curtain circuit, a fault is indicated.
B0021:12 — Left Curtain Deployment When the RCM senses a short to voltage on either driver
Control 1: Circuit Short to Battery side air curtain circuit, a fault is indicated.
B0021:13 — Left Curtain Deployment When the RCM measures more than the desired resistance
Control 1: Circuit Open range between the driver side air curtain circuits, a fault is
indicated.
B0021:1A — Left Curtain Deployment When the RCM measures less than the desired resistance
Control 1: Circuit Resistance Below range between the driver side air curtain circuits, a fault is
Threshold indicated.

Driver side air curtain module
RCM
PINPOINT TEST G: DTCs B0021:11, B0021:12, B0021:13 AND B0021:1A
G1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0021:13 or

B0021:1A, GO to G2 .

G8 .

G10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0021:13 or

B0021:1A, GO to G13 .

G14 .

G15 .
G2 CHECK THE LEFT CURTAIN DEPLOYMENT CONTROL 1
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger — GO to G12 .
RCM .
DEPLOY_11_R PID No
Does the PID value read between 1.7 and 2.78 ohms? GO to G3 .
HARNESS TEST
of the driver side air curtain circuits and accessible connectors DEPOWER the SRS and
the wire harness. terminals or wire harness as
GO to G17 .
No
ohms, GO to G4 .

2.78 ohms, GO to G6 .
G4 CHECK THE LEFT CURTAIN DEPLOYMENT CONTROL 1 DTC
by the RCM by inducing a different fault condition. If the fault GO to G11 .
GO to G5 .
Ignition OFF.
Disconnect: Driver Side Air Curtain C9018.
Remove the headliner. Refer to the appropriate procedure in
Section 501-05 .
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver side air
curtain disconnected, an open circuit fault would normally be
retrieved.
G5 CHECK FOR A SHORT BETWEEN DRIVER SIDE AIR CURTAIN
CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to G12 .
Measure the resistance between driver side air curtain C9018-1, REPAIR circuits CR109
circuit CR109 (BN/BU), harness side and C9018-2, circuit RR109 (BN/BU) and RR109
(BU/GN), harness side. (BU/GN).

GO to G17 .

G6 CHECK THE DRIVER SIDE AIR CURTAIN CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Driver Side Air Curtain C9018. No
Remove the headliner. Refer to the appropriate procedure in REPAIR circuit CR109
Section 501-05 . (BN/BU) or RR109 (BU/GN).
Measure the resistance between RCM C310B, harness side and Refer to Wiring Diagrams
driver side air curtain C9018, harness side using the following chart. Cell 5 , Connector Repair
RCM Circuit Driver Side Air Curtain and connector information.
C310B-7 CR109 (BN/BU) C9018-1
GO to G17 .
C310B-8 RR109 (BU/GN) C9018-2
reported changes, this indicates the RCM is functioning correctly wire and GO to G11 .
No
Connect a fused jumper wire between driver side air curtain C9018- wire and GO to G12 .
1, circuit CR109 (BN/BU), harness side and C9018-2, circuit RR109
(BU/GN), harness side.
in this section.
Ignition ON.
RCM .
curtain circuits shorted together, a low resistance fault would
by the RCM by inducing a different fault condition. If the fault GO to G11 .
GO to G9 .
Ignition OFF.
Section 501-05 .
in this section.
Ignition ON.
RCM .
retrieved.
G9 CHECK THE DRIVER SIDE AIR CURTAIN CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between driver side air curtain: REPAIR circuit CR109
C9018-1, circuit CR109 (BN/BU), harness side and ground. (BN/BU) or RR109 (BU/GN).
C9018-2, circuit RR109 (BU/GN), harness side and ground.
GO to G17 .

G10 CHECK THE DRIVER SIDE AIR CURTAIN CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (BN/BU) or RR109 (BU/GN).
Remove the headliner. Refer to the appropriate procedure in Refer to Wiring Diagrams
Section 501-05 . Cell 5 , Connector Repair
Disconnect: RCM C310A and C310B. Procedures for schematic
Repower the SRS . Do not prove out the SRS at this time. Refer to and connector information.
in this section. GO to G17 .
Ignition ON.
Measure the voltage between driver side air curtain: No
C9018-1, circuit CR109 (BN/BU), harness side and ground. GO to G12 .
C9018-2, circuit RR109 (BU/GN), harness side and ground.
G11 CONFIRM THE DRIVER SIDE AIR CURTAIN MODULE FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new driver side
DTCs will be recorded. air curtain. REFER to Side
Air Curtain Module in this
Ignition OFF. section. GO to G17 .
B0021:1A, GO to G13 .
G14 .
Connect: Driver Side Air Curtain C9018.
Repower the SRS . Do not prove out the SRS at this time. Refer to G15 .
in this section.
Ignition ON.
RCM .
G12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to G17 .
B0021:1A, GO to G13 .
G14 .
Connect: Driver Side Air Curtain C9018.
Repower the SRS . Do not prove out the SRS at this time. Refer to G15 .
in this section.
Ignition ON.
RCM .
in-line connectors) and flexing the wire harness. new SRS components at
pinpoint test. GO to G16 .
No
DEPOWER the SRS and

GO to G17 .
G14 CHECK THE LEFT CURTAIN DEPLOYMENT CONTROL 1 FOR
AN INTERMITTENT SHORT TO GROUND FAULT
RCM .
GO to G17 .
No
G15 CHECK THE LEFT CURTAIN DEPLOYMENT CONTROL 1 FOR
AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF. Yes
in this section.
Ignition ON. GO to G17 .
in-line connectors) and flexing the wire harness. No
Enter the following diagnostic mode on the scan tool: Self Test — The fault is not present and
G16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Driver Side Air Curtain C9018. Refer to Wiring Diagrams
wires. GO to G17 .
No
G17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test H: DTCs B0028:11, B0028:12, B0028:13 and B0028:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger seat side air bag circuits for the
following faults:
Unexpected voltage
Short to ground
Faulted passenger seat side air bag module
including:
Wiring
Connections
Passenger seat side air bag module
RCM

B0028:11 — Right Side Airbag When the RCM senses a short to ground on either
Deployment Control: Circuit Short to passenger seat side air bag circuit, a fault is indicated.
Ground
B0028:12 — Right Side Airbag When the RCM senses a short to voltage on either
Deployment Control: Circuit Short to passenger seat side air bag circuit, a fault is indicated.
Battery
B0028:13 — Right Side Airbag When the RCM measures more than the desired resistance
Deployment Control: Circuit Open range between the passenger seat side air bag circuits, a
fault is indicated.
B0028:1A — Right Side Airbag When the RCM measures less than the desired resistance
Deployment Control: Circuit Resistance range between the passenger seat side air bag circuits, a
Below Threshold fault is indicated.

Passenger seat side air bag module
RCM
PINPOINT TEST H: DTCs B0028:11, B0028:12, B0028:13 AND B0028:1A


H1 RETRIEVE RCM DTCs
Ignition ON. Yes
test.
For DTC B0028:13 or

B0028:1A, GO to H2 .

H8 .

H10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0028:13 or

B0028:1A, GO to H13 .

H14 .
H15 .
H2 CHECK THE RIGHT SIDE AIRBAG DEPLOYMENT CONTROL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger — GO to H12 .
RCM .
DEPLOY_13_R PID No
Does the PID value read between 1.7 and 2.78 ohms? GO to H3 .
HARNESS TEST
of the passenger seat side air bag circuits and accessible DEPOWER the SRS and
connectors (including any in-line connectors) by wiggling connectors REPAIR the connector,
and flexing the wire harness. terminals or wire harness as
GO to H17 .
No
ohms, GO to H4 .

2.78 ohms, GO to H6 .
H4 CHECK THE RIGHT SIDE AIRBAG DEPLOYMENT CONTROL DTC
by the RCM by inducing a different fault condition. If the fault GO to H11 .
GO to H5 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the passenger seat
side air bag module disconnected, an open circuit fault would
H5 CHECK FOR A SHORT BETWEEN PASSENGER SEAT SIDE AIR
BAG CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to H12 .
Measure the resistance between passenger seat side air bag REPAIR circuits CR106
module C337-3, circuit CR106 (VT/GY), harness side and C337-1, (VT/GY) and RR106
circuit RR106 (YE/OG), harness side. (YE/OG).

GO to H17 .

H6 CHECK PASSENGER SEAT SIDE AIR BAG CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Passenger Seat Side Air Bag Module C337. No
Measure the resistance between RCM C310B, harness side and (VT/GY) or RR106 (YE/OG).
passenger seat side air bag module C337, harness side using the
following chart. Refer to Wiring Diagrams
Passenger Seat Side Air Bag Procedures for schematic
RCM Circuit Module and connector information.
C310B- CR106 (VT/GY) C337-3
16 GO to H17 .
C310B- RR106 C337-1

15 (YE/OG)

reported changes, this indicates the RCM is functioning correctly wire and GO to H11 .
No
Connect a fused jumper wire between passenger seat side air bag wire and GO to H12 .
module C337-3, circuit CR106 (VT/GY), harness side and C337-1,
circuit RR106 (YE/OG), harness side.
in this section.
Ignition ON.
RCM .
side air bag circuits shorted together, a low resistance fault would
by the RCM by inducing a different fault condition. If the fault GO to H11 .
GO to H9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
side air bag module disconnected, an open circuit fault would
H9 CHECK PASSENGER SEAT SIDE AIR BAG CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between passenger seat side air bag REPAIR circuit CR106
module: (VT/GY) or RR106 (YE/OG).
C337-1, circuit RR106 (YE/OG), harness side and ground.
C337-3, circuit CR106 (VT/GY), harness side and ground. Refer to Wiring Diagrams
GO to H17 .
H10 CHECK THE PASSENGER SEAT SIDE AIR BAG CIRCUITS FOR
A SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (VT/GY) or RR106 (YE/OG).
Ignition ON.
Measure the voltage between passenger seat side air bag module: GO to H17 .
C337-1, circuit RR106 (YE/OG), harness side and ground.
C337-3, circuit CR106 (VT/GY), harness side and ground. No
GO to H12 .

H11 CONFIRM THE PASSENGER SEAT SIDE AIR BAG MODULE
FAULT
connectors are connected before carrying out the self-test. If not, REMOVE and INSPECT the
DTCs will be recorded. seat side air bag module
harness for damage.
Ignition OFF. REFER to Side Air Bag
Depower the SRS . Refer to Supplemental Restraint System (SRS) Module in this section. If a
Depowering and Repowering in this section. concern is found, REPAIR
Prior to reconnecting any previously disconnected SRS component: as necessary.
inspect connector(s) (including any in-line connectors) for
pushed-out, loose or spread terminals and loose or frayed If a concern was not found,
wire connections at terminals. INSTALL a new passenger
inspect wire harness for any damage, pinched, cut or pierced side air bag module. REFER
wires. to Side Air Bag Module in
inspect C310A and C310B Connector Position Assurance this section. GO to H17 .
Control Module (RCM) in this section. No
repair any concerns found. In the process of diagnosing
Refer to Wiring Diagrams Cell 5 , Connector Repair the fault, the fault condition
Procedures for schematic and connector information. has become intermittent. Do
not install any new SRS
Connect: Passenger Seat Side Air Bag Module C337. components at this time.
Connect: RCM C310A and C310B. Install SRS components
Repower the SRS . Do not prove out the SRS at this time. Refer to only when directed to do
Supplemental Restraint System (SRS) Depowering and Repowering so in the pinpoint test.
in this section.
Ignition ON. For DTC B0028:13 or
Enter the following diagnostic mode on the scan tool: Self Test — B0028:1A, GO to H13 .
RCM .
Was the original DTC retrieved on-demand during self-test? For DTC B0028:11, GO to
H14 .

H15 .
H12 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system components and the RCM Yes
electrical connectors are connected before carrying out the self-test. INSTALL a new RCM .
If not, DTCs will be recorded. REFER to Restraints
Ignition OFF. this section. GO to H17 .
B0028:1A, GO to H13 .
H14 .
Connect: Passenger Seat Side Air Bag Module C337.
Repower the SRS . Do not prove out the SRS at this time. Refer to H15 .
in this section.
Ignition ON.
RCM .
pinpoint test. GO to H16 .
No
DEPOWER the SRS and

GO to H17 .
FOR AN INTERMITTENT SHORT TO GROUND FAULT
RCM .
GO to H17 .
No
FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF. Yes
in-line connectors) and flexing the wire harness.
GO to H17 .
RCM . No
H16 CHECK HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Passenger Seat Side Air Bag Module C337. Refer to Wiring Diagrams
wires. GO to H17 .
No
H17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
NOTE: When selecting Restraints from the Self-Test menu, DTCs
self-test?
Pinpoint Test I: DTCs B0029:11, B0029:12, B0029:13 and B0029:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger side air curtain circuits for the
following faults:

Unexpected voltage
Short to ground
Faulted passenger side air curtain
including:
Wiring
Connections
Passenger side air curtain module
RCM
B0029:11 — Right Curtain Deployment When the RCM senses a short to ground on either
Control 1: Circuit Short to Ground passenger side air curtain circuit, a fault is indicated.
B0029:12 — Right Curtain Deployment When the RCM senses a short to voltage on either
Control 1: Circuit Short to Battery passenger side air curtain circuit, a fault is indicated.
B0029:13 — Right Curtain Deployment When the RCM measures more than the desired resistance
Control 1: Circuit Open range between the passenger side air curtain circuits, a
fault is indicated.
B0029:1A — Right Curtain Deployment When the RCM measures less than the desired resistance
Control 1: Circuit Resistance Below range between the passenger side air curtain circuits, a
Threshold fault is indicated.

Passenger side air curtain module
RCM
PINPOINT TEST I: DTCs B0029:11, B0029:12, B0029:13 AND B0029:1A
I1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0029:13 or

B0029:1A, GO to I2 .

I8 .

I10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0029:13 or

B0029:1A, GO to I13 .

I14 .

I15 .
I2 CHECK RIGHT CURTAIN DEPLOYMENT CONTROL 1
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: DataLogger — GO to I12 .
RCM .
DEPLOY_14_R PID No
Does the PID value read between 1.7 and 2.78 ohms? GO to I3 .
I3 CHECK THE RIGHT CURTAIN DEPLOYMENT CONTROL 1
HARNESS TEST
of the passenger side air curtain circuits and accessible connectors DEPOWER the SRS and
(including any in-line connectors), by wiggling connectors and REPAIR the connector,
flexing the wire harness. terminals or wire harness as
GO to I17 .
No
ohm, GO to I4 .

2.78 ohms, GO to I6 .
I4 CHECK THE RIGHT CURTAIN DEPLOYMENT CONTROL 1 DTC
by the RCM by inducing a different fault condition. If the fault GO to I11 .
GO to I5 .
Ignition OFF.
Disconnect: Passenger Side Air Curtain C9019.
Section 501-05 .
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the passenger side air
retrieved.
I5 CHECK THE FOR A SHORT BETWEEN PASSENGER SIDE AIR
CURTAIN CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to I12 .
Measure the resistance between passenger side air curtain C9019- REPAIR circuits CR111
1, circuit CR111 (BN/WH), harness side and C9019-2, circuit RR111 (BN/WH) and RR111
(YE/VT), harness side. (YE/VT).

GO to I17 .

I6 CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Passenger Side Air Curtain C9019. No
Remove the headliner. Refer to the appropriate procedure in REPAIR circuit CR111
Section 501-05 . (BN/WH) or RR111 (YE/VT).
Measure the resistance between RCM C310B, harness side and Refer to Wiring Diagrams
passenger side air curtain C9019, harness side using the following Cell 5 , Connector Repair
chart. Procedures for schematic
RCM Circuit Passenger Side Air Curtain
C310B-17 CR111 (BN/WH) C9019-1 GO to I17 .
C310B-18 RR111 (YE/VT) C9019-2

reported changes, this indicates the RCM is functioning correctly wire and GO to I11 .
No
Connect a fused jumper wire between passenger side air curtain wire and GO to I12 .
C9019-1, circuit CR111 (BN/WH), harness side and C9019-2, circuit
RR111 (YE/VT), harness side.
in this section.
Ignition ON.
RCM .
curtain circuits shorted together, a low resistance fault would
by the RCM by inducing a different fault condition. If the fault GO to I11 .
GO to I9 .
Ignition OFF.
Section 501-05 .
in this section.
Ignition ON.
RCM .
retrieved.
I9 CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between passenger side air curtain: REPAIR circuit CR111
C9019-1, circuit CR111 (BN/WH), harness side and ground. (BN/WH) or RR111 (YE/VT).
C9019-2, circuit RR111 (YE/VT), harness side and ground.
GO to I17 .

I10 CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (BN/WH) or RR111 (YE/VT).
Disconnect: RCM C310A and C310B. Procedures for schematic
Repower the SRS . Do not prove out the SRS at this time. Refer to and connector information.
in this section.
GO to I17 .
Ignition ON.
Measure the voltage between passenger side air curtain: No
C9019-1, circuit CR111 (BN/WH), harness side and ground. GO to I12 .
I11 CONFIRM THE PASSENGER SIDE AIR CURTAIN MODULE FAULT
DTCs will be recorded. side air curtain. REFER to
Side Air Curtain Module in
Ignition OFF. this section. GO to I17 .
B0029:1A, GO to I13 .
I14 .
Connect: Passenger Side Air Curtain C9019.
Repower the SRS . Do not prove out the SRS at this time. Refer to I15 .
in this section.
Ignition ON.
RCM .
I12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to I17 .
B0029:1A, GO to I13 .
I14 .
Connect: Passenger Side Air Curtain C9019.
Repower the SRS . Do not prove out the SRS at this time. Refer to I15 .
in this section.
Ignition ON.
RCM .
I13 CHECK THE RIGHT CURTAIN DEPLOYMENT CONTROL 1
pinpoint test. GO to I16 .
No
DEPOWER the SRS and

GO to I17 .
I14 CHECK FOR AN INTERMITTENT RIGHT CURTAIN DEPLOYMENT
CONTROL 1 SHORT TO GROUND FAULT
RCM .
GO to I17 .
No
I15 CHECK FOR AN INTERMITTENT RIGHT CURTAIN DEPLOYMENT
CONTROL 1 SHORT TO BATTERY FAULT
Ignition OFF. Yes
in this section.
Ignition ON. GO to I17 .
in-line connectors) and flexing the wire harness. No
Enter the following diagnostic mode on the scan tool: Self Test — The fault is not present and
I16 CHECK HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Passenger Side Air Curtain C9019. Refer to Wiring Diagrams
wires. GO to I17 .
No
I17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
will be retrieved from the RCM and OCSM .
self-test?
Pinpoint Test J: DTCs B0050:11, B0050:12, B0050:13 and B0050:1D
Normal Operation
The Restraints Control Module (RCM) monitors the driver safety belt buckle switch circuits for the following
faults:
Open circuit
Short to voltage
Short to ground
Current out of range
Faulted driver safety belt buckle switch
If a fault is detected, the RCM stores DTC B0050:11, B0050:12, B0050:13 or B0050:1D in memory and sends a

B0050:11 — Driver Seatbelt When the RCM senses a short to ground on the driver safety belt
Sensor: Circuit Short to Ground buckle switch circuit, a fault is indicated.
B0050:12 — Driver Seatbelt When the RCM senses a short to voltage on the driver safety belt
Sensor: Circuit Short to Battery buckle switch circuit, a fault is indicated.
B0050:13 — Driver Seatbelt When the RCM senses an open on either driver safety belt buckle
Sensor: Circuit Open switch circuit, a fault is indicated.
B0050:1D — Driver Seatbelt When the RCM senses current out of an acceptable range
Sensor: Circuit Current Out of between the driver safety belt buckle switch circuits, a fault is
Range indicated.

Driver safety belt buckle assembly
RCM
PINPOINT TEST J: DTCs B0050:11, B0050:12, B0050:13 AND B0050:1D

J1 RETRIEVE RCM DTCs
Ignition ON. Yes
Was DTC B0050:11, B0050:12, B0050:13 or B0050:1D DTC is no longer retrieved on-
retrieved on-demand during self-test? demand during the self-test.
For DTC B0050:11 or

B0050:1D, GO to J2 .
For DTC B0050:12, GO to J4 .
No
when present as a Continuous
Memory Diagnostic Trouble
Code (CMDTC) only. GO to
J10 .
J2 CHECK THE DRIVER SEATBELT SENSOR DTC FOR A FAULT
STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT OF
RANGE INDICATED)
NOTE: This pinpoint test step attempts to change the fault Yes
reported by the RCM by inducing a different fault condition. If the GO to J8 .
fault reported changes, this indicates the RCM is functioning
correctly and is not the source of the fault. No
Ignition OFF.
WARNING: Turn the ignition OFF and wait one minute to For DTC B0050:1D, GO to
deplete the backup power supply. Failure to follow this J9 .
instruction may result in serious personal injury or death in
Disconnect: Driver Safety Belt Buckle Switch C3065.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver safety belt
buckle switch disconnected, an open circuit fault would normally
be retrieved.
Did the on-demand DTC change from B0050:11 or B0050:1D
to B0050:13?
J3 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT
FOR A SHORT TO GROUND
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to J9 .
(SRS) Depowering and Repowering in this section.
Measure the resistance between driver safety belt buckle switch REPAIR circuit CR201
C3065-2, circuit CR201 (GN/BU), harness side and ground. (GN/BU).
Refer to Wiring Diagrams Cell

5 , Connector Repair
Procedures for schematic and
connector information.
GO to J11 .

Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit CR201
(SRS) Depowering and Repowering in this section. (GN/BU).
Disconnect: Driver Safety Belt Buckle Switch C3065. Refer to Wiring Diagrams Cell
Disconnect: RCM C310A and C310B. 5 , Connector Repair
Repower the SRS . Do not prove out the SRS at this time. Refer Procedures for schematic and
to Supplemental Restraint System (SRS) Depowering and connector information.
Repowering in this section.
Ignition ON. GO to J11 .
Measure the voltage between driver safety belt buckle switch
C3065-2, circuit CR201 (GN/BU), harness side and ground. No
GO to J9 .

J5 CHECK THE DRIVER SEATBELT SENSOR DTC FOR A FAULT
STATUS CHANGE (OPEN INDICATED)
reported by the RCM by inducing a different fault condition. If the REMOVE the fused jumper
fault reported changes, this indicates the RCM is functioning wire and GO to J8 .
correctly and is not the source of the fault.
No
Depower the SRS . Refer to Supplemental Restraint System REMOVE the fused jumper
(SRS) Depowering and Repowering in this section. wire and GO to J6 .
Ignition OFF.
Disconnect: Driver Safety Belt Buckle Switch C3065.
Repower the SRS . Do not prove out the SRS at this time. Refer
to Supplemental Restraint System (SRS) Depowering and
Connect a fused jumper wire between driver safety belt buckle
switch C3065-2, circuit CR201 (GN/BU), harness side and C3065-
1, circuit GD143 (BK/VT), harness side.
Ignition ON.
RCM .
buckle switch circuits shorted together, a short to ground fault
would normally be retrieved.
FOR A OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to J7 .
Measure the resistance between RCM C310B-34, circuit CR201 REPAIR circuit CR201
(GN/BU), harness side and driver safety belt buckle switch C3065- (GN/BU).
2, circuit CR201 (GN/BU), harness side.
GO to J11 .
Is the resistance less than 0.5 ohm?

J7 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH GROUND
CIRCUIT FOR AN OPEN
Measure the resistance between driver safety belt buckle switch Yes
C3065-1, circuit GD143 (BK/VT), harness side and ground. GO to J9 .
No
(BK/VT).

GO to J11 .
J8 CONFIRM DRIVER SEATBELT SENSOR FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new driver safety
DTCs will be recorded. belt buckle assembly. REFER
to Section 501-20A . GO to
Ignition OFF. J11 .
(SRS) Depowering and Repowering in this section. No
Prior to reconnecting any previously disconnected SRS In the process of diagnosing
component: the fault, the fault condition
inspect connector(s) (including any in-line connectors) for has become intermittent. Do
pushed-out, loose or spread terminals and loose or frayed not install any new SRS
wire connections at terminals. components at this time.
inspect wire harness for any damage, pinched, cut or Install SRS components
pierced wires. only when directed to do so
inspect C310A and C310B Connector Position Assurance in the pinpoint test. GO to
(CPA) lever/lock for correct operation. Refer to Restraints J10 .


Connect: Driver Safety Belt Buckle Switch C3065.
Ignition ON.
RCM .
J9 CONFIRM THE RCM FAULT
DTCs will be recorded. REFER to Restraints Control
Ignition OFF. GO to J11 .
(CPA) lever/lock for correct operation. Refer to Restraints J10 .

Connect: Driver Safety Belt Buckle Switch C3065.

Connect: RCM C310A and C310B (if previously disconnected).
Ignition ON.
RCM .
J10 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System The fault condition is now
(SRS) Depowering and Repowering in this section. present. This fault cannot be
Disconnect: RCM C310A and C310B. cleared until it is corrected and
Disconnect: Driver Safety Belt Buckle Switch C3065. the DTC is no longer retrieved
inspect connector(s) (including any in-line connectors) for on-demand during self-test.
corrosion, loose or spread terminals and loose or frayed
wire connections at terminals. For DTC B0050:11 or
inspect wire harness for any damage, pinched, cut or B0050:1D, GO to J2 .
pierced wires.
repair any concerns found. For DTC B0050:12, GO to J4 .

Procedures for schematic and connector information. For DTC B0050:13, GO to J5 .
Connect: All Previously Disconnected Component(s)/Connector No

(s). The fault is not present and
Repower the SRS . Do not prove out the SRS at this time. Refer cannot be recreated at this
to Supplemental Restraint System (SRS) Depowering and time. Do not install any new
Repowering in this section. SRS components at this
Ignition ON. time. Install SRS
Enter the following diagnostic mode on the scan tool: Self Test — components only when
RCM . directed to do so in the
Was DTC B0050:11, B0050:12, B0050:13 or B0050:1D pinpoint test. REPAIR any
retrieved on-demand during self-test? intermittent wiring, terminal or
connector concerns found.
GO to J11 .
J11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Do not clear any DTCs until all
WARNING: Turn the ignition OFF and wait one minute to DTCs have been resolved.
deplete the backup power supply. Failure to follow this GO to the DTC Charts in this
instruction may result in serious personal injury or death in section for pinpoint test
the event of an accidental deployment. direction.
not prove out the SRS at this time. Refer to Supplemental CLEAR all RCM and OCSM
Restraint System (SRS) Depowering and Repowering in this CMDTCs . PROVE OUT the
section. SRS . Repair is complete.
Ignition ON. RETURN the vehicle to the
Enter the following diagnostic mode on the scan tool: Self Test — customer.
Restraints.
self-test?
Pinpoint Test K: DTCs B0052:11, B0052:12, B0052:13 and B0052:1D
Normal Operation
The Restraints Control Module (RCM) monitors the passenger safety belt buckle switch and circuits for the
following faults:
Open circuit
Short to voltage
Short to ground
Faulted safety belt buckle switch
If a fault is detected, the RCM stores DTC B0052:11, B0052:12, B0052:13 or B0052:1D in memory and sends a

B0052:11 — Passenger Seatbelt When the RCM senses a short to ground on the passenger
Sensor: Circuit Short to Ground safety belt buckle switch circuit, a fault is indicated.
B0052:12 — Passenger Seatbelt When the RCM senses a short to voltage on the passenger
Sensor: Circuit Short to Battery safety belt buckle switch circuit, a fault is indicated.
B0052:13 — Passenger Seatbelt When the RCM senses an open on either passenger safety belt
Sensor: Circuit Open buckle switch circuit, a fault is indicated.
B0052:1D — Passenger Seatbelt When the RCM senses current out of an acceptable range
Sensor: Circuit Current Out of between the passenger safety belt buckle switch circuits, a fault
Range is indicated.

Passenger safety belt buckle assembly
RCM
PINPOINT TEST K: DTCs B0052:11, B0052:12, B0052:13 AND B0052:1D

K1 RETRIEVE RCM DTCs
Ignition ON. Yes
Were any DTC B0052:11, B0052:12, B0052:13 or B0052:1D DTC is no longer retrieved on-
retrieved on-demand during self-test? demand during the self-test.
For DTC B0052:11 or

B0052:1D, GO to K2 .

K4 .

K5 .
No
when present as a Continuous
K10 .
K2 CHECK THE PASSENGER SEATBELT SENSOR DTC FOR A
FAULT STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT
OF RANGE INDICATED)
reported by the RCM by inducing a different fault condition. If the GO to K8 .
Ignition OFF. K3 .
WARNING: Turn the ignition OFF and wait one minute to For DTC B0052:1D, GO to
deplete the backup power supply. Failure to follow this K9 .
Disconnect: Passenger Safety Belt Buckle Switch C3066.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the passenger safety
belt buckle switch disconnected, an open circuit fault would
Did the on-demand DTC change from B0052:11 or B0052:1D
to B0052:13?
K3 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH
CIRCUIT FOR A SHORT TO GROUND
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to K9 .
Measure the resistance between passenger seat belt buckle REPAIR circuit CR202
switch C3066-2, circuit CR202 (BN/GN), harness side and ground. (BN/GN).

GO to K11 .
K4 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH
CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit CR202
(SRS) Depowering and Repowering in this section. (BN/GN).
Disconnect: Passenger Safety Belt Buckle Switch C3066. Refer to Wiring Diagrams Cell
Repower the SRS . Do not prove out the SRS at this time. Refer 5 , Connector Repair
to Supplemental Restraint System (SRS) Depowering and Procedures for schematic and
Repowering in this section. connector information.
Ignition ON.
Measure the voltage between passenger seat belt buckle switch GO to K11 .
C3066-2, circuit CR202 (BN/GN), harness side and ground.
No
GO to K9 .

K5 CHECK THE PASSENGER SEATBELT SENSOR DTC FOR A
FAULT STATUS CHANGE (OPEN INDICATED)
fault reported changes, this indicates the RCM is functioning wire and GO to K8 .
No
Ignition OFF. REMOVE the fused jumper
Depower the SRS . Refer to Supplemental Restraint System wire and GO to K6 .
Disconnect: Passenger Safety Belt Buckle Switch C3066.
Connect a fused jumper wire between passenger safety belt
buckle switch C3066-2, circuit CR202 (BN/GN), harness side and
C3066-1, circuit GD145 (BK/BU), harness side.
Ignition ON.
RCM .
belt buckle switch circuits shorted together, a short to ground fault
K6 CHECK PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT
FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to K7 .
Measure the resistance between RCM C310B-33, circuit CR202 REPAIR circuit CR202
(BN/GN), harness side and the passenger safety belt buckle (BN/GN).
switch C3066-2, circuit CR202 (BN/GN), harness side.
GO to K11 .

K7 CHECK PASSENGER SAFETY BELT BUCKLE SWITCH
Measure the resistance between passenger safety belt buckle Yes
switch C3066-1, circuit GD145 (BK/BU), harness side and ground. GO to K9 .
No
(BK/BU).

GO to K11 .
K8 CONFIRM PASSENGER SEATBELT SENSOR FAULT
DTCs will be recorded. safety belt buckle assembly.
REFER to Section 501-20A .
Ignition OFF. GO to K11 .
(CPA) lever/lock for correct operation. Refer to Restraints K10 .


Connect: Passenger Safety Belt Buckle Switch C3066.
Ignition ON.
RCM .
K9 CONFIRM THE RCM FAULT
DTCs will be recorded. REFER to Restraints Control
Ignition OFF. GO to K11 .
(CPA) lever/lock for correct operation. Refer to Restraints K10 .

Connect: Passenger Safety Belt Buckle Switch C3066.

Ignition ON.
RCM .
K10 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Disconnect: Passenger Safety Belt Buckle Switch C3066. cleared until it is corrected and
inspect connector(s) (including any in-line connectors) for the DTC is no longer retrieved
corrosion, loose or spread terminals and loose or frayed on-demand during the self-
wire connections at terminals. test.
inspect wire harness for any damage, pinched, cut or
pierced wires. For DTC B0052:11 or
repair any concerns found. B0052:1D, GO to K2 .
Refer to Wiring Diagrams Cell 5 , Connector Repair For DTC B0052:12, GO to

Procedures for schematic and connector information. K4 .

Connect: All Previously Disconnected Component(s)/Connector K5 .
(s).
Repower the SRS . Do not prove out the SRS at this time. Refer No
to Supplemental Restraint System (SRS) Depowering and The fault is not present and
Repowering in this section. cannot be recreated at this
Ignition ON. time. Do not install any new
Enter the following diagnostic mode on the scan tool: Self Test — SRS components at this
RCM . time. Install SRS
Was DTC B0052:11, B0052:12, B0052:13 or B0052:1D components only when
retrieved on-demand during self-test? directed to do so in the
pinpoint test. REPAIR any
intermittent wiring, terminal or
GO to K11 .
K11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute to DTCs have been resolved.
Restraints.
self-test?
Pinpoint Test L: DTCs B0082:11, B0082:12, B0082:13 and B0082:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger safety belt load limiter circuits for

Unexpected voltage
Short to ground
Faulted passenger safety belt load limiter
including:
Wiring
Connections
Passenger safety belt load limiter
RCM

B0082:11 — Passenger Seatbelt Load When the RCM senses a short to ground on either
Limiter Deployment Control: Circuit Short to passenger safety belt load limiter circuit, a fault is
Ground indicated.
B0082:12 — Passenger Seatbelt Load When the RCM senses a short to battery on either
Limiter Deployment Control: Short to Battery passenger safety belt load limiter circuit, a fault is
indicated.
B0082:13 — Passenger Seatbelt Load When the RCM measures more than the desired
Limiter Deployment Control: Circuit Open resistance range between the passenger safety belt load
limiter circuits, a fault is indicated.
B0082:1A — Passenger Seatbelt Load When the RCM measures less than the desired
Limiter Deployment Control: Circuit resistance range between the passenger safety belt load
Resistance Below Threshold limiter circuits, a fault is indicated.
Passenger safety belt load limiter
RCM
PINPOINT TEST L: DTCs B0082:11, B0082:12, B0082:13 AND B0082:1A

L1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B0082:13 or

B0082:1A, GO to L2 .

L8 .

L10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B0082:13 or

B0082:1A, GO to L13 .
L14 .

L15 .
L2 CHECK THE PASSENGER SEATBELT LOAD LIMITER
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_26_R) PID
RCM . GO to L12 .
DEPLOY_26_R PID
GO to L3 .
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_26_R) PID WHILE
CARRYING OUT THE HARNESS TEST
of the passenger safety belt load limiter circuits and accessible DEPOWER the SRS and
connectors (including any in-line connectors), by wiggling connectors REPAIR the connector,
and flexing the wire harness frequently. terminals or wire harness as
GO to L17 .
No
ohms, GO to L4 .

2.78 ohms, GO to L6 .
DEPLOYMENT CONTROL DTC FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to L11 .
GO to L5 .
Ignition OFF.
Disconnect: Passenger Safety Belt Load Limiter C389.
in this section.
Ignition ON.
RCM .
belt load limiter disconnected, an open circuit fault would normally be
retrieved.
L5 CHECK FOR A SHORT BETWEEN PASSENGER SAFETY BELT
LOAD LIMITER CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to L12 .
Measure the resistance between passenger safety belt load limiter REPAIR circuits CR122
C389-1, circuit CR122 (WH/OG), harness side and C389-2, circuit (WH/OG) and RR122 (BN).
RR122 (BN), harness side.
GO to L17 .

L6 CHECK THE PASSENGER SAFETY BELT LOAD LIMITER
CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Passenger Safety Belt Load Limiter C389. No
Measure the resistance between RCM C310B, and passenger safety (WH/OG) or RR122 (BN).
belt load limiter C389, harness side using the following chart.
Passenger Safety Belt Load Cell 5 , Connector Repair
RCM Circuit Limiter Procedures for schematic
C310B- CR122 C389-1
13 (WH/OG)
GO to L17 .
C310B- RR122 (BN) C389-2
14

DEPLOYMENT CONTROL DTC FOR A FAULT STATUS CHANGE
(OPEN INDICATED)
reported changes, this indicates the RCM is functioning correctly and wire and GO to L11 .
No
Connect a fused jumper wire between passenger safety belt load wire and GO to L12 .
limiter C389-1, circuit CR122 (WH/OG), harness side and C389-2,
circuit RR122 (BN), harness side.
in this section.
Ignition ON.
RCM .
belt retractor circuits shorted together, a low resistance fault would
(SHORT TO GROUND INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to L11 .
GO to L9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
belt load limiter disconnected, an open circuit fault would normally be
retrieved.
Ignition OFF. Yes
Measure the resistance between passenger safety belt load limiter: REPAIR circuit CR122
C389-1, circuit CR122 (WH/OG), harness side and ground. (WH/OG) or RR122 (BN).
C389-2, circuit RR122 (BN), harness side and ground.
GO to L17 .
CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (WH/OG) or RR122 (BN).
Ignition ON.
Measure the voltage between passenger safety belt load limiter: GO to L17 .
C389-1, circuit CR122 (WH/OG), harness side and ground.
C389-2, circuit RR122 (BN), harness side and ground. No
GO to L12 .

L11 CONFIRM THE PASSENGER SAFETY BELT RETRACTOR FAULT
DTCs will be recorded. safety belt load limiter.
Ignition OFF. 20A . GO to L17 .
inspect RCM C310A and C310B Connector Position only when directed to do
Assurance (CPA) lever/lock for correct operation. Refer to so in the pinpoint test.
Restraints Control Module (RCM) in this section.
B0082:1A, GO to L13 .
L14 .
Connect: Passenger Safety Belt Load Limiter C389.
Repower the SRS . Do not prove out the SRS at this time. Refer to L15 .
in this section.
Ignition ON.
RCM .
L12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to L17 .
inspect RCM C310A and C310B CPA lever/lock for correct only when directed to do
operation. Refer to Restraints Control Module (RCM) in this so in the pinpoint test.
section.
B0082:1A, GO to L13 .
L14 .
Connect: All Previously Disconnected Restraint System
Components. For DTC B0082:12, GO to
Connect: RCM C310A and C310B (if previously disconnected). L15 .
in this section.
Ignition ON.
RCM .
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_26_R) PID FOR AN
INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT FAULT
in-line connectors) and flexing the wire harness frequently. new SRS components at
pinpoint test. GO to L16 .
No
DEPOWER the SRS and

GO to L17 .
L14 CHECK FOR AN INTERMITTENT PASSENGER SEATBELT LOAD

LIMITER DEPLOYMENT CONTROL SHORT TO GROUND FAULT
in-line connectors) and flexing the wire harness frequently. DEPOWER the SRS and
RCM .
GO to L17 .
No
L15 CHECK FOR AN INTERMITTENT PASSENGER SEATBELT LOAD
LIMITER DEPLOYMENT CONTROL SHORT TO VOLTAGE FAULT
Ignition OFF. Yes
Attempt to recreate the fault by wiggling connectors (including any and connector information.
in-line connectors) and flexing the wire harness frequently.
Enter the following diagnostic mode on the scan tool: Self Test — GO to L17 .
RCM .
Was DTC B0082:12 retrieved on-demand during self-test? No
L16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Passenger Safety Belt Load Limiter C389. Refer to Wiring Diagrams
pushed-out, loose or spread terminals and loose or frayed Procedures for schematic
wire connections at terminals. and connector information.
wires. GO to L17 .
inspect RCM C310A and C310B CPA lever/lock for correct
operation. Refer to Restraints Control Module (RCM) in this No
section. The fault is not present and
Were any concerns found? cannot be recreated at this
L17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test M: DTC B0090:11 or B0090:93
Normal Operation
The Restraints Control Module (RCM) checks the LH front impact severity sensor and circuits for the following
faults:
Open circuit
Short to voltage
Short to ground
Faulted LH front impact severity sensor
If a fault is detected, the RCM stores DTC B0090:11, B0090:81, B0090:93 or B0090:96 in memory and sends a
DTC B0090:11 (Left Frontal Restraints Sensor: Circuit Short to Ground) — When the RCM senses a
short to ground on the feed circuit of the LH front severity impact sensor, a fault is indicated.
DTC B0090:93 (Left Frontal Restraints Sensor: No Operation) — When the RCM senses a faulted
sensor, a short to voltage on the feed circuit, open on the feed or return circuit, a fault is indicated.

LH front impact severity sensor
RCM
PINPOINT TEST M: DTCs B0090:11 OR B0090:93
NOTE: Do not probe any impact sensor. The impact sensor can not be tested using a multi-meter.

M1 RETRIEVE RCM DTCs
Ignition ON. Yes
Was DTC B0090:11 or B0090:93 retrieved on-demand during DTC is no longer retrieved
self-test? on-demand during self-test.

M2 .

M5 .
No
The fault is intermittent when
present as a Continuous
M10 .
M2 CHECK THE LEFT FRONTAL RESTRAINTS SENSOR DTC FOR A
FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
by the RCM by inducing a different fault condition. If the fault INSTALL a new LH front
reported changes, this indicates the RCM is functioning correctly impact severity sensor.
and is not the source of the fault. REFER to Front Impact
Severity Sensor in this
Ignition OFF. section. GO to M11 .
Disconnect: LH Front Impact Severity Sensor C1465. GO to M3 .
Supplemental Restraint System (SRS) Depowering and
Ignition ON.
RCM .
M3 CHECK THE LH FRONT IMPACT SEVERITY SENSOR FEED
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to M4 .
Measure the resistance between LH front impact severity sensor REPAIR circuit VR213
C1465-1, circuit VR213 (VT/GN), harness side and ground. (VT/GN).
GO to M11 .

M4 CHECK FOR A SHORT BETWEEN LH FRONT IMPACT SEVERITY
SENSOR CIRCUITS
Measure the resistance between LH front impact severity sensor Yes
C1465-1, circuit VR213 (VT/GN), harness side and C1465-2, circuit GO to M9 .
RR129 (YE/GY), harness side.
No
REPAIR circuits VR213
(VT/GN) and RR129
(YE/GY).

GO to M11 .

M5 CHECK THE LH FRONT IMPACT SEVERITY SENSOR AND RCM
CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF. Yes
GO to M6 .
WARNING: Turn the ignition OFF and wait one minute to
deplete the backup power supply. Failure to follow this No
instruction may result in serious personal injury or death in the Fault corrected. GO to M11 .
event of an accidental deployment.
Inspect LH front impact severity sensor C1465 to be fully seated
and locked. Seat and lock connector as necessary.
Gain access to the RCM and inspect C310A and C310B to be sure
they are fully seated and locked. Seat and lock the connector(s) as
necessary. Refer to Restraints Control Module (RCM) in this
section.
Ignition ON.
RCM .
Was DTC B0090:93 retrieved on-demand during self-test?
M6 CHECK THE LH FRONT IMPACT SEVERITY SENSOR CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) REPAIR circuit VR213
Depowering and Repowering in this section. (VT/GN) or RR129 (YE/GY).
Disconnect: LH Front Impact Severity Sensor C1465. Refer to Wiring Diagrams
Supplemental Restraint System (SRS) Depowering and Procedures for schematic
Repowering in this section. and connector information.
Ignition ON. GO to M11 .
Measure the voltage between LH front impact severity sensor:
C1465-1, circuit VR213 (VT/GN), harness side and ground. No
C1465-2, circuit RR129 (YE/GY), harness side and ground. GO to M7 .

M7 CHECK THE LH FRONT IMPACT SEVERITY SENSOR CIRCUITS
FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to M8 .
Measure the resistance between RCM C310B, harness side and LH No
front impact severity sensor C1465, harness side using the REPAIR circuit VR213
following chart. (VT/GN) or RR129 (YE/GY).
RCM Circuit LH Front Impact Severity Sensor Refer to Wiring Diagrams

C310B-27 VR213 (VT/GN) C1465-1 Procedures for schematic
C310B-28 RR129 (YE/GY) C1465-2 and connector information.
GO to M11 .

M8 CHECK THE LEFT FRONTAL RESTRAINTS SENSOR DTC FOR A
FAULT STATUS CHANGE (NO OPERATION INDICATED)
reported changes, this indicates the RCM is functioning correctly wire and INSTALL a new
and is not the source of the fault. sensor. REFER to Front
Impact Severity Sensor in
Connect: RCM C310A and C310B. this section. GO to M11 .
Connect a fused jumper wire between LH front impact severity
sensor C1465-1, circuit VR213 (VT/GN), harness side and C1465- No
2, circuit RR129 (YE/GY), harness side. REMOVE the fused jumper
wire and GO to M9 .
Ignition ON.
RCM .
M9 CONFIRM THE RCM FAULT
NOTE: Make sure all SRS components, sensor electrical Yes

connectors and the RCM electrical connectors are connected INSTALL a new RCM .
before carrying out the self-test. If not, DTCs will be recorded. REFER to Restraints Control
Module (RCM) in this
Ignition OFF. section. GO to M11 .
(CPA) lever/lock for correct operation. Refer to Restraints so in the pinpoint test. GO
Control Module (RCM) in this section. to M10 .


Connect: LH Front Impact Severity Sensor C1465.
Ignition ON.
RCM .
M10 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) The fault condition is now
Depowering and Repowering in this section. present. This fault cannot be
Disconnect: LH Front Impact Severity Sensor C1465. cleared until it is corrected
Disconnect: RCM C310A and C310B. and the DTC is no longer
Inspect for the following: retrieved on-demand during
inspect harness and component connectors for loose or self-test.
spread terminals and loose or frayed wire connections at
terminals. For DTC B0090:11, GO to
inspect wire harness for any damage, pinched, cut or pierced M2 .
wires.
inspect RCM C310A and C310B Connector Position For DTC B0090:93, GO to
Assurance (CPA) lever/lock for correct operation. Refer to M5 .
repair any concerns found. No
Refer to Wiring Diagrams Cell 5 , Connector Repair cannot be recreated at this
Procedures for schematic and connector information. time. Do not install any
Connect: All Previously Disconnected Component(s)/Connector(s). components only when
Repower the SRS . Do not prove out the SRS at this time. Refer to directed to do so in the
Supplemental Restraint System (SRS) Depowering and pinpoint test. GO to M11 .
Ignition ON.
RCM .
Was DTC B0090:11 or B0090:93 retrieved on-demand during
self-test?
M11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Are any RCM and/or OCSM DTCs retrieved on-demand self
test?
Pinpoint Test N: DTCs B0091:11, B0091:93, B0097:11 and B0097:93
Normal Operation
The Restraints Control Module (RCM) monitors the driver front door and passenger second row C-pillar side
impact sensors and circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted driver front door side impact sensor
Faulted passenger second row C-pillar side impact sensor
The RCM communicates with each impact sensor. If the RCM is unable to communicate with the sensor, a
DTC is stored in memory. A Continuous Memory Diagnostic Trouble Code (CMDTC) no operation (failure
type :93) can be set by a short to voltage on the return circuit of the impact sensor.
NOTE: A short to ground on either impact sensor feed circuit sets DTCs B0091:11 and B0097:11.
A short to voltage on either impact sensor feed or return circuit sets DTCs B0091:93 and B0097:93.
B0091:11 — Left When the RCM senses a shorted driver front door side impact sensor, a shorted
Side Restraints passenger second row C-pillar side impact sensor, a short to ground on the
Sensor 1: Circuit driver front door side impact sensor feed circuit or a short to ground on the
Short to Ground passenger second row C-pillar side impact sensor feed circuit, a fault is
indicated.
B0091:93 — Left When the RCM senses a faulted driver front door side impact sensor, a short to
Side Restraints voltage on the feed or return circuit of the driver front door side impact sensor, a
Sensor 1: No short to voltage on the feed or return circuit of passenger second row C-pillar
Operation side impact sensor or an open feed or return circuit of the driver front door side
impact sensor, a fault is indicated.
B0097:11 — Right When the RCM senses a shorted driver front door side impact sensor, a shorted
Side Restraints passenger second row C-pillar side impact sensor, a short to ground on the
Sensor 2: Circuit driver front door side impact sensor feed circuit or a short to ground on the
Short to Ground passenger second row C-pillar side impact sensor feed circuit, a fault is
indicated.
B0097:93 — Right When the RCM senses a faulted passenger second row C-pillar side impact
Side Restraints sensor, a short to voltage on the feed or return circuit of passenger second row
Sensor 2: No C-pillar side impact sensor, a short to voltage on the feed or return circuit of the
Operation driver front door side impact sensor or an open feed or return circuit of the
passenger second row C-pillar side impact sensor, a fault is indicated.

Driver front door side impact sensor
Passenger second row C-pillar side impact sensor
RCM
PINPOINT TEST N: DTCs B0091:11, B0091:93, B0097:11 AND B0097:93
NOTE: Do not probe any impact sensor. The impact sensor cannot be tested using a multi-meter.

N1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test — Fault(s) cannot be cleared
RCM . until corrected and the DTC
Were any DTCs retrieved on-demand during self-test? (s) are no longer retrieved
on-demand during self-test.
For DTC B0091:11 AND

B0097:11, GO to N2 .

B0097:93, GO to N6 .
For DTC B0091:93 ONLY ,

GO to N8 .

GO to N11 .
For any other DTCs,

REFER to the DTC Chart in
this section.
No
The fault is intermittent
when present as a
Continuous Memory
(CMDTC) only. GO to N15 .
N2 CHECK THE LEFT SIDE RESTRAINTS SENSOR 1 DTC FOR A
by the RCM by inducing a different fault condition. If the fault reported INSTALL a new driver front
changes, this indicates the RCM is functioning correctly and is not door side impact sensor.
the source of the fault. REFER to Side Impact
Sensor — Front Door in
Ignition OFF. this section. GO to N16 .
Disconnect: Driver Front Door Side Impact Sensor C567. GO to N3 .
in this section.
Ignition ON.
RCM .
Did the on-demand DTCs change from B0091:11 and B0097:11
to B0091:93?
N3 CHECK THE RIGHT SIDE RESTRAINTS SENSOR 2 DTC FOR A
by the RCM by inducing a different fault condition. If the fault reported INSTALL a new passenger
changes, this indicates the RCM is functioning correctly and is not second row C-pillar side
the source of the fault. impact sensor. REFER to
Side Impact Sensor —
Ignition OFF. Second Row, 4-Door
Depower the SRS . Refer to Supplemental Restraint System (SRS) Sedan or Side Impact
Depowering and Repowering in this section. Sensor — Second Row, 5-
Connect: Driver Front Door Side Impact Sensor C567. Door Hatchback in this
Disconnect: Passenger Second Row C-Pillar Side Impact Sensor section. GO to N16 .
C3249.
Repower the SRS . Do not prove out the SRS at this time. Refer to No
Supplemental Restraint System (SRS) Depowering and Repowering GO to N4 .
in this section.
Ignition ON.
RCM .
Did the on-demand DTC change from B0091:11 and B0097:11 to
B0097:93?
N4 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR FEED
CIRCUIT FOR A SHORT TO GROUND AND SHORT BETWEEN SENSOR
CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to N5 .
Disconnect: Driver Front Door Side Impact Sensor C567. No
Disconnect: RCM C310A and C310B. REPAIR circuit VR217
Measure the resistance between driver front door side impact sensor: (GY/YE) and/or RR131
C567-1, circuit VR217 (GY/YE), harness side and ground. (VT/GY).
C567-1, circuit VR217 (GY/YE), harness side and C567-2,
circuit RR131 (VT/GY), harness side. Refer to Wiring Diagrams
GO to N16 .

N5 CHECK THE PASSENGER SECOND ROW C-PILLAR SIDE IMPACT
SENSOR FEED CIRCUIT FOR A SHORT TO GROUND AND SHORT
BETWEEN SENSOR CIRCUITS
Measure the resistance between passenger second row C-pillar side Yes
impact sensor: GO to N14 .
C3249-1, circuit VR220 (VT/OG), harness side and ground.
C3249-1, circuit VR220 (VT/OG), harness side and C3249-2, No
circuit RR134 (BN/BU), harness side. REPAIR circuit VR220
(VT/OG) and/or RR134
(BN/BU).

GO to N16 .

N6 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR
CIRCUITS FOR A SHORT TO VOLTAGE (NO OPERATION INDICATED)
Ignition OFF. Yes
Depowering and Repowering in this section. (GY/YE) or RR131
Disconnect: RCM C310A and C310B. (VT/GY).
Disconnect: Driver Front Door Side Impact Sensor C567. Refer to Wiring Diagrams
Ignition ON.
Measure the voltage between driver front door side impact sensor: GO to N16 .
C567-1, circuit VR217 (GY/YE), harness side and ground.
C567-2, circuit RR131 (VT/GY), harness side and ground. No
GO to N7 .

N7 CHECK THE PASSENGER SECOND ROW C-PILLAR SIDE IMPACT
SENSOR CIRCUITS FOR A SHORT TO VOLTAGE (NO OPERATION
INDICATED)
Ignition OFF. Yes
Depowering and Repowering in this section. (VT/OG) or RR134
Disconnect: Passenger Second Row C-Pillar Side Impact Sensor (BN/BU).
C3249.
Measure the voltage between passenger second row C-pillar side
impact sensor:
GO to N16 .
C3249-1, circuit VR220 (VT/OG), harness side and ground.
C3249-2, circuit RR134 (BN/BU), harness side and ground. No
GO to N14 .

N8 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR AND
RCM CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF. Yes
Gain access to the driver front door side impact sensor and inspect No
C567 to be fully seated and locked. Seat and lock the connector as Fault corrected. GO to
necessary. Refer to Side Impact Sensor — Front Door in this section. N16 .
Gain access to the RCM and inspect C310A and C310B to be fully
seated and locked. Seat and lock the connector(s) as necessary.
Refer to Restraints Control Module (RCM) in this section.
in this section.
Ignition ON.
RCM .
N9 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR
CIRCUITS FOR AN OPEN (NO OPERATION INDICATED)
Ignition OFF. Yes
Disconnect: Driver Front Door Side Impact Sensor C567. REPAIR circuit VR217
Measure the resistance between RCM C310B, harness side and (GY/YE) or RR131
driver front door side impact sensor C567, harness side using the (VT/GY).
following chart.
Driver Front Door Side Impact Cell 5 , Connector Repair
RCM Circuit Sensor Procedures for schematic
C310B- VR217 C567-1
36 (GY/YE)
GO to N16 .
C310B- RR131 C567-2
35 (VT/GY)

N10 CHECK THE LEFT SIDE RESTRAINTS SENSOR 1 DTC FOR A
changes, this indicates the RCM is functioning correctly and is not wire and INSTALL a new
the source of the fault. driver front door side
impact sensor. REFER to
Connect: RCM C310A and C310B. Side Impact Sensor —
Connect a fused jumper wire between driver front door side impact Front Door in this section.
sensor C567-1, circuit VR217 (GY/YE), harness side and C567-2, GO to N16 .
circuit RR131 (VT/GY), harness side.
No
wire and GO to N14 .
in this section.
Ignition ON.
RCM .
Did the DTC change from B0091:93 to B0091:11 and B0097:11?
N11 CHECK THE PASSENGER SECOND ROW C-PILLAR SIDE
IMPACT SENSOR AND RCM CONNECTIONS (NO OPERATION
INDICATED)
Ignition OFF. Yes
Gain access to the passenger second row C-pillar side impact sensor No
and inspect C3249 to be fully seated and locked. Seat and lock the Fault corrected. GO to
connector as necessary. Refer to Side Impact Sensor — Second N16 .
Row, 4-Door Sedan or Side Impact Sensor — Second Row, 5-Door
Hatchback in this section.
in this section.
Ignition ON.
RCM .
N12 CHECK THE PASSENGER SECOND ROW C-PILLAR SIDE
IMPACT SENSOR CIRCUITS FOR AN OPEN (NO OPERATION
INDICATED)
Ignition OFF. Yes
Disconnect: Passenger Second Row C-Pillar Side Impact Sensor REPAIR circuit VR220
C3249. (VT/OG) or RR134
Measure the resistance between RCM C310B, harness side and (BN/BU).
passenger second row C-pillar side impact sensor C3249, harness
side using the following chart. Refer to Wiring Diagrams
Passenger Second Row C-Pillar Side Procedures for schematic
RCM Circuit Impact Sensor and connector information.
C310B- VR220 C3249-1
37 (VT/OG) GO to N16 .
C310B- RR134 C3249-2

38 (BN/BU)
N13 CHECK THE RIGHT SIDE RESTRAINTS SENSOR 2 DTC FOR A
Yes
NOTE: This pinpoint test step attempts to change the fault reported
by the RCM by inducing a different fault condition. If the fault reported
wire and INSTALL a new
the source of the fault. passenger second row C-
pillar side impact sensor.
Connect: RCM C310A and C310B. REFER to Side Impact
Connect a fused jumper wire between passenger second row C-pillar Sensor — Second Row, 4-
side impact sensor C3249-1, circuit VR220 (VT/OG), harness side Door Sedan or Side Impact
and C3249-2, circuit RR134 (BN/BU), harness side. Sensor — Second Row, 5-
Door Hatchback in this
section. GO to N16 .
No
wire and GO to N14 .
in this section.
Ignition ON.
RCM .
N14 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to N16 .
repair any concerns found. GO to N15 .

Connect: Driver Front Door Side Impact Sensor C567 (if previously
disconnected).
Connect: Passenger Second Row C-Pillar Side Impact Sensor
C3249 (if previously disconnected).
in this section.
Ignition ON.
RCM .
N15 CHECK FOR AN INTERMITTENT FAULT

Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) Fault(s) cannot be cleared
Depowering and Repowering in this section. until corrected and the DTC
Disconnect: Driver Front Door Side Impact Sensor C567 and/or is no longer retrieved on-
Passenger Second Row C-Pillar Side Impact Sensor C3249. demand during self-test.
Inspect for the following: For DTC B0091:11 AND
inspect harness and component connectors for loose or B0097:11, GO to N2 .
terminals. For DTC B0091:93 AND
inspect wire harness for any damage, pinched, cut or pierced B0097:93, GO to N6 .
wires.
inspect RCM C310A and C310B CPA lever/lock for correct For DTC B0091:93 ONLY ,
operation. Refer to Restraints Control Module (RCM) in this GO to N8 .
section.
repair any concerns found. For DTC B0097:93 ONLY ,
GO to N11 .
Procedures for schematic and connector information. No
Connect: All Previously Disconnected Component(s)/Connector(s). time. Do not install any
Repower the SRS . Do not prove out the SRS at this time. Refer to new SRS components at
Supplemental Restraint System (SRS) Depowering and Repowering this time. Install SRS
in this section. components only when
Ignition ON. directed to do so in the
Enter the following diagnostic mode on the scan tool: Self Test — pinpoint test. GO to N16 .
RCM .
Was DTC B0091:11, B0091:93, B0097:11 or B0097:93 retrieved
on-demand during self-test?
N16 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test O: DTCs B0092:11, B0092:93, B0096:11 and B0096:93
Normal Operation
The Restraints Control Module (RCM) monitors the driver second row C-pillar and passenger front door side
impact sensors and circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted driver second row C-pillar side impact sensor
Faulted passenger front door side impact sensor
The RCM communicates with each impact sensor. If the RCM is unable to communicate with the sensor, a
DTC is stored in memory. A Continuous Memory Diagnostic Trouble Code (CMDTC) no operation (failure type
status :93) can be set by a short to voltage on the return circuit of the impact sensor.
NOTE: A short to ground on either impact sensor feed circuit sets DTCs B0092:11 and B0096:11.
A short to voltage on either impact sensor feed or return circuit sets DTCs B0092:93 and B0096:93.

B0092:11 — Left When the RCM senses a shorted passenger front door side impact sensor, a
Side Restraints shorted driver second row C-pillar side impact sensor, a short to ground on the
Sensor 2: Circuit passenger front door side impact sensor feed circuit or a short to ground on the
Short to Ground driver second C-pillar side impact sensor feed circuit, a fault is indicated.
B0092:93 — Left When the RCM senses a faulted driver second row C-pillar side impact sensor,
Side Restraints a short to voltage on the feed or return circuit of the driver second row C-pillar
Sensor 2: No side impact sensor, a short to voltage on the feed or return circuit of passenger
Operation front door side impact sensor or an open feed or return circuit of the passenger
front door side impact sensor, a fault is indicated.
B0096:11 — Right When the RCM senses a shorted passenger front door side impact sensor, a
Side Restraints shorted driver second row C-pillar side impact sensor, a short to ground on the
Sensor 1: Circuit passenger front door side impact sensor feed circuit or a short to ground on the
Short to Ground driver second row C-pillar side impact sensor feed circuit, a fault is indicated.
B0096:93 — Right When the RCM senses a faulted passenger front door side impact sensor, a
Side Restraints short to voltage on the feed or return circuit of passenger front door side impact
Sensor 1: No sensor, a short to voltage on the feed or return circuit of the driver second row
Operation C-pillar side impact sensor or an open feed or return circuit of the passenger
front door side impact sensor, a fault is indicated.

Driver second row C-pillar side impact sensor
Passenger front door side impact sensor
RCM
PINPOINT TEST O: DTCs B0092:11, B0092:93, B0096:11 AND B0096:93
NOTE: Do not probe any impact sensor. The impact sensor cannot be tested using a multi-meter.

O1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test — Fault(s) cannot be cleared
RCM . until corrected and the DTC
Were any DTCs retrieved on-demand during self-test? (s) are no longer retrieved

B0096:11, GO to O2 .

B0096:93, GO to O6 .

GO to O8 .

GO to O11 .
For any other DTCs,

REFER to the DTC Chart in
this section.
No
The fault is intermittent
when present as a
Continuous Memory
(CMDTC) only. GO to
O15 .
O2 CHECK THE LEFT SIDE RESTRAINTS SENSOR 2 DTC FOR A
by the RCM by inducing a different fault condition. If the fault reported INSTALL a new driver
changes, this indicates the RCM is functioning correctly and is not second row C-pillar side
the source of the fault. impact sensor. REFER to
Side Impact Sensor —
Ignition OFF. Second Row, 4-Door
Depower the SRS . Refer to Supplemental Restraint System (SRS) Sedan or Side Impact
Depowering and Repowering in this section. Sensor — Second Row, 5-
Disconnect: Driver Second Row C-Pillar Side Impact Sensor C3248. Door Hatchback in this
Repower the SRS . Do not prove out the SRS at this time. Refer to section. GO to O16 .
in this section. No
Ignition ON. GO to O3 .
RCM .
B0092:93?
O3 CHECK THE RIGHT SIDE RESTRAINTS SENSOR 1 DTC FOR A
by the RCM by inducing a different fault condition. If the fault reported INSTALL a new passenger
changes, this indicates the RCM is functioning correctly and is not front door side impact
the source of the fault. sensor. REFER to Side
Impact Sensor — Front
Ignition OFF. Door in this section. GO to
Depower the SRS . Refer to Supplemental Restraint System (SRS) O16 .
Connect: Driver Second Row C-Pillar Side Impact Sensor C3248. No
Disconnect: Passenger Front Door Side Impact Sensor C644. GO to O4 .
in this section.
Ignition ON.
RCM .
B0096:93?
O4 CHECK THE DRIVER SECOND ROW C-PILLAR SIDE IMPACT
SENSOR FEED CIRCUIT FOR A SHORT TO GROUND AND SHORT
BETWEEN SENSOR CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to O5 .
Disconnect: Driver Second Row C-Pillar Side Impact Sensor C3248. No
Disconnect: RCM C310A and C310B. REPAIR circuit VR219
Measure the resistance between driver second row C-pillar side (GN/WH) and/or RR133
impact sensor: (GY/BN).
C3248-1, circuit VR219 (GN/WH), harness side, and ground.
C3248-1, circuit VR219 (GN/WH), harness side, and C3248-2, Refer to Wiring Diagrams
circuit RR133 (GY/BN), harness side. Cell 5 , Connector Repair
GO to O16 .

O5 CHECK THE PASSENGER FRONT DOOR SIDE IMPACT SENSOR
FEED CIRCUIT FOR A SHORT TO GROUND AND SHORT BETWEEN
SENSOR CIRCUITS
Measure the resistance between passenger front door side impact Yes
sensor: GO to O14 .
C644-1, circuit VR218 (YE/OG), harness side, and ground.
C644-1, circuit VR218 (YE/OG), harness side, and C644-2, No
circuit RR132 (BU/WH), harness side. REPAIR circuits VR218
(YE/OG) and/or RR132
(BU/WH).

GO to O16 .

SENSOR FEED CIRCUIT FOR A SHORT TO VOLTAGE (NO
OPERATION INDICATED)
Ignition OFF. Yes
Depowering and Repowering in this section. (GN/WH) or RR133
Disconnect: RCM C310A and C310B. (GY/BN).
Disconnect: Driver Second Row C-Pillar Side Impact Sensor C3248.
Measure the voltage between driver second row C-pillar side impact
sensor: GO to O16 .
C3248-1, circuit VR219 (GN/WH), harness side and ground.
C3248-2, circuit RR133 (GY/BN), harness side and ground.
No
GO to O7 .

FEED CIRCUIT FOR A SHORT TO VOLTAGE (NO OPERATION
INDICATED)
Ignition OFF. Yes
Depowering and Repowering in this section. (YE/OG) or RR132
Disconnect: Passenger Front Door Side Impact Sensor C644. (BU/WH).
Supplemental Restraint System (SRS) Depowering and Repowering Refer to Wiring Diagrams
in this section. Cell 5 , Connector Repair
Ignition ON. Procedures for schematic
Measure the voltage between passenger front door side impact and connector information.
sensor: GO to O16 .
C644-1, circuit VR218 (YE/OG), harness side and ground.
C644-2, circuit RR132 (BU/WH), harness side and ground. No
GO to O14 .

SENSOR AND RCM CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF. Yes
Gain access to the driver second row C-pillar side impact sensor and No
inspect C3248 to be fully seated and locked. Seat and lock the Fault corrected. GO to
connector as necessary. Refer to Side Impact Sensor — Second O16 .
Row, 4-Door Sedan or Side Impact Sensor — Second Row, 5-Door
Hatchback in this section.
in this section.
Ignition ON.
RCM .
SENSOR CIRCUITS FOR AN OPEN (NO OPERATION INDICATED)
Ignition OFF. Yes
Disconnect: Driver Second Row C-Pillar Side Impact Sensor C3248. REPAIR circuit VR219
Measure the resistance between RCM C310B, harness side and (GN/WH) or RR133
driver second row C-pillar side impact sensor C3248, harness side, (GY/BN).
using the following chart.
Driver Second Row C-Pillar Side Cell 5 , Connector Repair
RCM Circuit Impact Sensor Procedures for schematic
C310B- VR219 C3248-1
23 (GN/WH)
GO to O16 .
C310B- RR133 C3248-2
24 (GY/BN)
O10 CHECK THE LEFT SIDE RESTRAINTS SENSOR 2 DTC FOR A
by the RCM by inducing a different fault condition. If the fault reported
the source of the fault. driver second row C-pillar
side impact sensor. REFER
Connect: RCM C310A and C310B. to Side Impact Sensor —
Connect a fused jumper wire between driver second row C-pillar side Second Row, 4-Door
impact sensor C3248-1, circuit VR219 (GN/WH), harness side, and Sedan or Side Impact
C3248-2, circuit RR133 (GY/BN), harness side. Sensor — Second Row, 5-
Door Hatchback in this
section. GO to O16 .
No
wire and GO to O14 .
in this section.
Ignition ON.
RCM .
AND RCM CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF. Yes
Gain access to passenger front door side impact sensor and inspect No
C644 to be fully seated and locked. Seat and lock the connector as Fault corrected. GO to
necessary. Refer to Side Impact Sensor — Front Door in this section. O16 .
in this section.
Ignition ON.
RCM .
CIRCUITS FOR AN OPEN (NO OPERATION INDICATED)
Ignition OFF. Yes
Disconnect: Passenger Front Door Side Impact Sensor C644. REPAIR circuit VR218
Measure the resistance between RCM C310B, harness side and (YE/OG) or RR132
passenger front door side impact sensor C644, harness side, using (BU/WH).
the following chart.
Passenger Front Door Side Impact Cell 5 , Connector Repair
RCM Circuit Sensor Procedures for schematic
C310B- VR218 C644-1
22 (YE/OG)
GO to O16 .
C310B- RR132 C644-2
21 (BU/WH)

O13 CHECK THE RIGHT SIDE RESTRAINTS SENSOR 1 DTC FOR A
the source of the fault. passenger front door side
impact sensor. REFER to
Connect: RCM C310A and C310B. Side Impact Sensor —
Connect a fused jumper wire between passenger front door side Front Door in this section.
impact sensor C644-1, circuit VR218 (YE/OG), harness side, and GO to O16 .
C644-2, circuit RR132 (BU/WH), harness side.
No
wire and GO to O14 .
in this section.
Ignition ON.
RCM .
O14 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to O16 .
repair any concerns found. GO to O15 .

Connect: Driver Second Row C-Pillar Side Impact Sensor C3248 (if
previously disconnected).
Connect: Passenger Front Door Side Impact Sensor C644 (if
previously disconnected).
in this section.
Ignition ON.
RCM .
O15 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) Fault(s) cannot be cleared
Depowering and Repowering in this section. until corrected and the DTC
Disconnect: Affected Impact Sensor — Driver Second Row C-Pillar is no longer retrieved on-
Side Impact Sensor C3248 and/or Passenger Front Door Side Impact demand during self-test.
Sensor C644.
Disconnect: RCM C310A and C310B. For DTC B0092:11 AND
Inspect for the following: B0096:11, GO to O2 .
inspect harness and component connectors for loose or
spread terminals and loose or frayed wire connections at For DTC B0092:93 AND
terminals. B0096:93, GO to O6 .
wires. For DTC B0092:93 ONLY ,
inspect RCM C310A and C310B CPA lever/lock for correct GO to O8 .
operation. Refer to Restraints Control Module (RCM) in this
section. For DTC B0096:93 ONLY ,
repair any concerns found. GO to O11 .
Refer to Wiring Diagrams Cell 5 , Connector Repair No

Procedures for schematic and connector information. The fault is not present and
Connect: All Previously Disconnected Component(s)/Connector(s). new SRS components at
Repower the SRS . Do not prove out the SRS at this time. Refer to this time. Install SRS
Supplemental Restraint System (SRS) Depowering and Repowering components only when
in this section.
Ignition ON. directed to do so in the
Enter the following diagnostic mode on the scan tool: Self Test — pinpoint test. GO to O16 .
RCM .
Was DTC B0092:11, B0092:93, B0096:11 or B0096:93 retrieved
O16 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test.
Pinpoint Test P: DTC B0095:11 or B0095:93
Normal Operation
The Restraints Control Module (RCM) checks the RH front impact severity sensor and circuits for the following
faults:
Open circuit
Short to voltage
Short to ground
Faulted RH front impact severity sensor
DTC B0095:11 (Right Front Restraints Sensor: Circuit Short to Ground) — When the RCM senses a
short to ground on the RH front impact severity sensor feed circuit, a fault is indicated.
DTC B0095:93 (Right Front Restraints Sensor: No Operation) — When the RCM senses a faulted
sensor, short to voltage or open on either RH front impact severity sensor circuit, a fault is indicated.

RH front impact severity sensor
RCM
PINPOINT TEST P: DTC B0095:11 OR B0095:93
NOTE: Do not probe any impact sensor. The impact sensor can not be tested using a multi-meter.

P1 RETRIEVE RCM DTCs
Enter the following diagnostic mode on the scan tool: Self Test — Yes
RCM . This fault cannot be cleared
Was DTC B0095:11 or B0095:93 retrieved on-demand during until it is corrected and the
self-test? DTC is no longer retrieved

P2 .

P5 .
No
The fault is intermittent when
P10 .
P2 CHECK THE RIGHT FRONT RESTRAINTS SENSOR DTC FOR A
by the RCM by inducing a different fault condition. If the fault INSTALL a new RH front
reported changes, this indicates the RCM is functioning correctly impact severity sensor.
and is not the source of the fault. REFER to Front Impact
Severity Sensor in this
Ignition OFF. section. GO to P11 .
Disconnect: RH Front Impact Severity Sensor C1466. GO to P3 .
Ignition ON.
RCM .
P3 CHECK THE RH FRONT IMPACT SEVERITY SENSOR CIRCUIT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to P4 .
Measure the resistance between RH front impact severity sensor REPAIR circuit VR214
C1466-1, circuit VR214 (WH/BU), harness side and ground. (WH/BU).

GO to P11 .

P4 CHECK FOR A SHORT BETWEEN RH FRONT IMPACT SEVERITY
SENSOR CIRCUITS
Measure the resistance between RH front impact severity sensor Yes
C1466-1, circuit VR214 (WH/BU), harness side and C1466-2, circuit GO to P9 .
RR130 (GN/BU), harness side.
No
REPAIR circuits VR214
(WH/BU) and RR130
(GN/BU).

GO to P11 .

P5 CHECK THE RH FRONT IMPACT SEVERITY SENSOR AND RCM
CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF. Yes
Inspect RH front impact severity sensor C1466 to be fully seated No
and locked. Fault corrected. GO to P11 .
Gain access to the RCM and inspect C310A and C310B to be sure
they are fully seated and locked. Refer to Restraints Control Module
(RCM) in this section.
Ignition ON.
RCM .
P6 CHECK THE RH FRONT IMPACT SEVERITY SENSOR CIRCUITS
Ignition OFF. Yes
Depowering and Repowering in this section. (WH/BU) or RR130
Disconnect: RH Front Impact Severity Sensor C1466. (GN/BU).
Supplemental Restraint System (SRS) Depowering and Cell 5 , Connector Repair
Repowering in this section. Procedures for schematic
Measure the voltage between RH front impact severity sensor:
C1466-1, circuit VR214 (WH/BU), harness side and ground. GO to P11 .
C1466-2, circuit RR130 (GN/BU), harness side and ground.
No
GO to P7 .

P7 CHECK THE RH FRONT IMPACT SEVERITY SENSOR CIRCUITS
FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between RCM C310B, harness side and No
RH front impact severity sensor C1466, harness side using the REPAIR circuit VR214
following chart. (WH/BU) or RR130
(GN/BU).
RCM Circuit RH Front Impact Severity Sensor
C310B-30 VR214 (WH/BU) C1466-1 Cell 5 , Connector Repair
C310B-29 RR130 (GN/BU) C1466-2 Procedures for schematic
GO to P11 .

P8 CHECK THE RIGHT FRONT RESTRAINTS SENSOR DTC FOR A
reported changes, this indicates the RCM is functioning correctly wire and INSTALL a new
and is not the source of the fault. sensor. REFER to Front
Impact Severity Sensor in
Connect: RCM C310A and C310B. this section. GO to P11 .
Connect a fused jumper wire between RH front impact severity
sensor C1466-1, circuit VR214 (WH/BU), harness side and C1466- No
2, circuit RR130 (GN/BU), harness side.
wire and GO to P8 .
Ignition ON.
RCM .
P9 CONFIRM THE RCM FAULT

Module (RCM) in this
Ignition OFF. section. GO to P11 .
(CPA) lever/lock for correct operation. Refer to Restraints so in the pinpoint test. GO
Control Module (RCM) in this section. to P10 .

Connect: RH Front Impact Severity Sensor C1466.

Ignition ON.
RCM .
P10 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) The fault condition is now
Depowering and Repowering in this section. present. This fault cannot be
Disconnect: RH Front Impact Severity Sensor C1466. cleared until it is corrected
Disconnect: RCM C310A and C310B. and the DTC is no longer
Inspect for the following: retrieved on-demand during
inspect harness and component connectors for loose or self-test.
terminals. For DTC B0095:11, GO to
inspect wire harness for any damage, pinched, cut or pierced P2 .
wires.
inspect RCM C310A and C310B Connector Position For DTC B0095:93, GO to
Assurance (CPA) lever/lock for correct operation. Refer to P5 .
Refer to Wiring Diagrams Cell 5 , Connector Repair cannot be recreated at this
Procedures for schematic and connector information. time. Do not install any
Connect: All Previously Disconnected Component(s)/Connector(s). components only when
Repower the SRS . Do not prove out the SRS at this time. Refer to directed to do so in the
Supplemental Restraint System (SRS) Depowering and pinpoint test. GO to P11 .
Ignition ON.
RCM .
Was DTC B0095:11 or B0095:93 retrieved on-demand during
self-test?
P11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
self-test?
Pinpoint Test Q: DTCs B00A0:09, B00A0:4A, B00A0:63, B00A0:64 and B00A0:68
Normal Operation
The Restraints Control Module (RCM) is in constant communication with various control modules on the High
Speed Controller Area Network (HS-CAN), including the Occupant Classification System Module (OCSM). The
RCM continuously monitors the HS-CAN for fault messages reported by the Occupant Classification System
(OCS) system. The RCM also checks for the correct identification of the OCSM . If the RCM detects one of the
following faults reported by the OCS system, it stores DTC B00A0:09, B00A0:4A, B00A0:63, B00A0:64 or
B00A0:68 in memory and sends a message to the Instrument Panel Cluster (IPC) to illuminate the air bag
warning indicator.

OCSM
RCM

B00A0:09 — Occupant Classification When the RCM receives a message from the OCSM that
System: Component Failure a fault exists within the OCS system, this fault is indicated.
B00A0:4A — Occupant Classification When the RCM senses the OCS system is present but not
System: Incorrect Component Installed configured, a fault is indicated.
B00A0:63 — Occupant Classification When the RCM receives 8 or more invalid states from the
System: Circuit / Component Protection OCSM , a fault is indicated.
Time-Out
B00A0:64 — Occupant Classification When the RCM receives messages containing upper or
System: Signal Plausibility Failure lower data limits other than limits stored in memory, a fault
is indicated.
B00A0:68 — Occupant Classification When the RCM receives a message containing incorrect
System: Event Information data, a fault is indicated.
PINPOINT TEST Q: DTCs B00A0:09, B00A0:4A, B00A0:63, B00A0:64 and B00A0:68
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor
(if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation,
which increases the risk of personal injury or death in a crash.

Q1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan This fault cannot be cleared until it is corrected
tool: Self Test — RCM . and the DTC is no longer retrieved on-demand
Was DTC B00A0:09, B00A0:4A, B00A0:63, during self-test.
B00A0:64 or B00A0:68 retrieved on-demand
during self-test? For DTCs B00A0:09, B00A0:63 and B00A0:68,
RETRIEVE DTCs from the OCSM and REFER
to the Occupant Classification System Module
(OCSM) DTC chart for diagnostic direction.
For DTC B00A0:4A or B00A0:64, GO to Q2 .
No
CHECK for causes of the intermittent fault.
Refer to Wiring Diagrams Cell 46 ,

Supplemental Restraint System for schematic
ATTEMPT to recreate the hard fault by flexing

the wire harness and cycling the ignition
frequently. Do not install any new SRS
components at this time. Install SRS
components only when directed to do so in
the pinpoint test. GO to Q5 .
Q2 CHECK THE OCS
Ignition OFF. Yes
GO to Q3 .
WARNING: Turn the ignition OFF and
wait one minute to deplete the backup power No
supply. Failure to follow this instruction may INSTALL the correct OCS system service kit.
result in serious personal injury or death in REFER to Occupant Classification Sensor in
the event of an accidental deployment. this section. GO to Q5 .
Verify the correct OCS system service kit has
been installed in the vehicle.
Is the correct OCS system service kit
installed?
Q3 CHECK FOR THE CORRECT RCM
Disconnect the scan tool. Yes
Ignition ON. GO to Q4 .
Enter the following diagnostic mode on the scan
tool: Log Viewer. No
Retrieve and record the RCM part number from INSTALL the correct RCM . REFER to
Log Viewer and check the recorded part number Restraints Control Module (RCM) in this
against the part number listed in the Ford section. GO to Q5 .
Catalog Advantage TM or equivalent.
Is the correct RCM installed?
Q4 CHECK THE RCM
Ignition ON. Yes
Carry out Programmable Module Installation INSTALL a new RCM . REFER to Restraints
(PMI) for the RCM . Manually enter as-built data. Control Module (RCM) in this section. GO to
Refer to Section 418-01 . Q5 .
tool: Self Test — RCM . No
Was DTC B00A0:4A or B00A0:64 retrieved Fault corrected. GO to Q5 .
Q5 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Do not clear any DTCs until all DTCs have
WARNING: Turn the ignition OFF and been resolved. GO to the DTC Charts in this
wait one minute to deplete the backup power section for pinpoint test direction.
supply. Failure to follow this instruction may
result in serious personal injury or death in No
the event of an accidental deployment. CLEAR all RCM and OCSM DTCs. PROVE
Reconnect all SRS components (if previously OUT the SRS . Repair is complete. RETURN
disconnected). the vehicle to the customer.
If previously directed to depower the SRS ,
repower the SRS . Do not prove out the SRS at
this time. Refer to Supplemental Restraint
System (SRS) Depowering and Repowering in
this section.
Ignition ON.
tool: Self Test — Restraints.
NOTE: When selecting Restraints from the Self-
Test menu, DTCs are retrieved from the RCM
and OCSM .
Are any RCM and/or OCSM DTCs retrieved
Pinpoint Test R: DTCs B00B5:11, B00B5:12, B00B5:13 and B00B5:1D
Normal Operation
The Restraints Control Module (RCM) monitors the driver seat track position sensor and circuits for the
following faults:
Short to ground
Short to voltage
Open circuit
Faulted driver seat track position sensor
If a fault is detected, the RCM stores DTC B00B5:11, B00B5:12, B00B5:13 or B00B5:1D in memory and sends
a message to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.

B00B5:11 — Driver Seat Track Position When the RCM senses a short to ground on the driver seat
Restraints Sensor: Circuit Short to track position sensor circuit, a fault is indicated.
Ground
B00B5:12 — Driver Seat Track Position When the RCM senses a short to voltage on the driver seat
Restraints Sensor: Circuit Short to track position sensor circuit, a fault is indicated.
Battery
B00B5:13 — Driver Seat Track Position When the RCM senses an open on either of the driver seat
Restraints Sensor: Circuit Open track position sensor circuits, a fault is indicated.
B00B5:1D — Driver Seat Track Position When the RCM senses current out of an acceptable range
Restraints Sensor: Circuit Current Out of between the driver seat track position sensor circuits, a fault
Range is indicated.

Driver seat track position sensor
RCM
PINPOINT TEST R: DTCs B00B5:11, B00B5:12, B00B5:13 AND B00B5:1D

R1 RETRIEVE RCM DTCs
Was DTC B00B5:11, B00B5:12, B00B5:13 or B00B5:1D until it is corrected and the
retrieved on-demand during self-test? DTC is no longer retrieved on-
demand during the self-test.
For DTC B00B5:11 or

B00B5:1D, GO to R2 .
For DTC B00B5:12, GO to

R4 .

R5 .
No
when present as a
Continuous Memory
(CMDTC) only. GO to R10 .
R2 CHECK THE DRIVER SEAT TRACK POSITION RESTRAINTS
SENSOR DTC FOR A FAULT STATUS CHANGE (SHORT TO
GROUND OR CURRENT OUT OF RANGE INDICATED)
reported by the RCM by inducing a different fault condition. If the GO to R8 .
For DTC B00B5:1D, GO to
Ignition OFF. R9 .
WARNING: Turn the ignition OFF and wait one minute to For DTC B00B5:11, GO to
deplete the backup power supply. Failure to follow this R3 .
Disconnect: Driver Seat Track Position Sensor C356.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver seat track
position sensor disconnected, an open circuit fault would normally
be retrieved.
Did the on-demand DTC change from B00B5:11 or B00B5:1D
to B00B5:13?
R3 CHECK THE DRIVER SEAT TRACK POSITION SENSOR CIRCUIT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to R9 .
Measure the resistance between driver seat track position sensor REPAIR circuit VR215
C356-2, circuit VR215 (YE/VT) and ground. (YE/VT).
GO to R11 .

Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit VR215
(SRS) Depowering and Repowering in this section. (YE/VT).
Disconnect: Driver Seat Track Position Sensor C356. Refer to Wiring Diagrams Cell
Disconnect: Driver Seat Side Air Bag Module C367. 5 , Connector Repair
Ignition ON.
GO to R11 .
Measure the voltage between driver seat track position sensor
C356-2, circuit VR215 (YE/VT), harness side and ground. No
GO to R9 .

R5 CHECK THE DRIVER SEAT TRACK POSITION RESTRAINTS
SENSOR DTC FOR A FAULT STATUS CHANGE (OPEN INDICATED)
fault reported changes, this indicates the RCM is functioning wire and GO to R8 .
No
Depower the SRS . Refer to Supplemental Restraint System wire and GO to R6 .
Connect a fused jumper wire between driver seat track position
sensor C356-2, circuit VR215 (YE/VT), harness side and C356-1,
circuit GD143 (BK/VT), harness side.
RCM .
Ignition ON.
DIAGNOSTIC TIP: When viewing DTCs with the driver seat track
position sensor circuits shorted together, a short to ground fault
Did the on-demand DTC change from B00B5:13 to B00B5:11?
FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to R7 .
Measure the resistance between RCM C310B-32, circuit VR215 REPAIR circuit VR215
(YE/VT), harness side and driver seat track position sensor C356- (YE/VT).
2, circuit VR215 (YE/VT), harness side.
GO to R11 .

R7 CHECK THE DRIVER SEAT TRACK POSITION SENSOR
Measure the resistance between driver seat track position sensor Yes
C356-1, circuit GD143 (BK/VT) and ground. GO to R9 .
No
(BK/VT).

GO to R11 .
R8 CONFIRM THE DRIVER SEAT TRACK POSITION RESTRAINTS
SENSOR FAULT

connectors and the RCM electrical connectors are connected INSTALL a new driver seat
before carrying out the self-test. If not, DTCs will be recorded. track position sensor. REFER
to Seat Position Sensor in this
Ignition OFF. section. GO to R11 .
WARNING: Turn the ignition OFF and wait one minute to No
deplete the backup power supply. Failure to follow this In the process of diagnosing
instruction may result in serious personal injury or death in the fault, the fault condition
the event of an accidental deployment. has become intermittent. Do
Prior to reconnecting any previously disconnected SRS not install any new SRS
component: components at this time.
inspect connector(s) (including any in-line connectors) for Install SRS components
pushed-out, loose or spread terminals and loose or frayed only when directed to do so
wire connections at terminals. in the pinpoint test. GO to
inspect wire harness for any damage, pinched, cut or R10 .
pierced wires.
inspect C310A and C310B Connector Position Assurance


RCM .
R9 CONFIRM THE RCM FAULT

Ignition OFF. GO to R11 .
(CPA) lever/lock for correct operation. Refer to Restraints R10 .
Connect: Driver Seat Track Position Sensor C356.

Ignition ON.
RCM .
R10 CHECK FOR AN INTERMITTENT FAULT

Ignition OFF. Yes
Disconnect: Driver Seat Track Position Sensor C356. cleared until it is corrected
inspect connector(s) (including any in-line connectors) for and the DTC is no longer
corrosion, loose or spread terminals and loose or frayed retrieved on-demand during
wire connections at terminals. the self-test.
pierced wires. For DTC B00B5:11 or
repair any concerns found. B00B5:1D, GO to R2 .
Refer to Wiring Diagrams Cell 5 , Connector Repair For DTC B00B5:12, GO to

Procedures for schematic and connector information. R4 .

Connect: All Previously Disconnected Component(s)/Connector(s). R5 .
to Supplemental Restraint System (SRS) Depowering and No
Repowering in this section. The fault is not present and
Ignition ON. cannot be recreated at this
Enter the following diagnostic mode on the scan tool: Self Test — time. Do not install any new
RCM . SRS components at this
Was DTC B00B5:11, B00B5:12, B00B5:13 or B00B5:1D time. Install SRS
retrieved on-demand during self-test? components only when

GO to R11 .
R11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute to all DTCs have been resolved.
Restraints.
Are any RCM and/or OCSM DTCs retrieved?
Pinpoint Test S: DTCs B00C5:11, B00C5:12, B00C5:13 and B00C5:1D
Normal Operation
The Restraints Control Module (RCM) monitors the passenger seat track position sensor and circuits for the
following faults:
Short to ground
Short to voltage
Open circuit
Faulted passenger seat track position sensor
If a fault is detected, the RCM stores DTC B00C5:11, B00C5:12, B00C5:13 or B00C5:1D in memory and sends
a message to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.

B00C5:11 — Passenger Seat Track When the RCM senses a short to ground on the passenger
Position Restraints Sensor: Circuit Short seat track position sensor circuit, a fault is indicated.
to Ground
B00C5:12 — Passenger Seat Track When the RCM senses a short to voltage on the passenger
Position Restraints Sensor: Circuit Short seat track position sensor circuit, a fault is indicated.
to Battery
B00C5:13 — Passenger Seat Track When the RCM senses an open on either of the passenger
Position Restraints Sensor: Circuit Open seat track position sensor circuits, a fault is indicated.
B00C5:1D — Passenger Seat Track When the RCM senses current out of an acceptable range
Position Restraints Sensor: Circuit between the passenger seat track position sensor circuits,
Current Out of Range a fault is indicated.

Passenger seat track position sensor
RCM
PINPOINT TEST S: DTCs B00C5:11, B00C5:12, B00C5:13 AND B00C5:1D

S1 RETRIEVE RCM DTCs
Was DTC B00C5:11, B00C5:12, B00C5:13 or B00C5:1D until it is corrected and the
retrieved on-demand during self-test? DTC is no longer retrieved on-
demand during the self-test.
For DTC B00C5:11 or

B00C5:1D, GO to S2 .
For DTC B00C5:12, GO to

S4 .

S5 .
No
when present as a
Continuous Memory
(CMDTC) only. GO to S10 .
S2 CHECK THE PASSENGER SEAT TRACK POSITION
RESTRAINTS SENSOR DTC FOR A FAULT STATUS CHANGE
(SHORT TO GROUND OR CURRENT OUT OF RANGE INDICATED)
reported by the RCM by inducing a different fault condition. If the GO to S8 .
For DTC B00C5:1D, GO to
Ignition OFF. S9 .
WARNING: Turn the ignition OFF and wait one minute to For DTC B00C5:11, GO to
deplete the backup power supply. Failure to follow this S3 .
Disconnect: Passenger Seat Track Position Sensor C3617.
RCM .
track position sensor disconnected, an open circuit fault would
Did the on-demand DTC change from B00C5:11 or B00C5:1D
to B00C5:13?
S3 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to S9 .
Measure the resistance between passenger seat track position REPAIR circuit VR216
sensor C3617-2, circuit VR216 (GN/OG) and ground. (GN/OG).

GO to S11 .

Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit VR216
(SRS) Depowering and Repowering in this section. (GN/OG).
Disconnect: Passenger Seat Track Position Sensor C3617. Refer to Wiring Diagrams Cell
Disconnect: Passenger Seat Side Air Bag Module C337. 5 , Connector Repair
Ignition ON. GO to S11 .
Measure the voltage between passenger seat track position
sensor C3617-2, circuit VR216 (GN/OG), harness side and
No
ground. GO to S9 .

S5 CHECK THE PASSENGER SEAT TRACK POSITION
RESTRAINTS SENSOR DTC FOR A FAULT STATUS CHANGE (OPEN
INDICATED)
fault reported changes, this indicates the RCM is functioning wire and GO to S8 .
No
Depower the SRS . Refer to Supplemental Restraint System wire and GO to S6 .
Connect a fused jumper wire between passenger seat track
position sensor C3617-2, circuit VR216 (GN/OG), harness side
and C3617-1, circuit GD145 (BK/BU), harness side.
RCM .
Ignition ON.
track position restraints sensor circuits shorted together, a short to
ground fault would normally be retrieved.
Did the on-demand DTC change from B00C5:13 to B00C5:11?
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to S7 .
Measure the resistance between RCM C310B-31, circuit VR216 REPAIR circuit VR216
(GN/OG), harness side and passenger seat track position sensor (GN/OG).
C3617-2, circuit VR216 (GN/OG), harness side.
GO to S11 .

Measure the resistance between passenger seat track position Yes
sensor C3617-1, circuit GD145 (BK/BU) and ground. GO to S9 .
No
(BK/BU).

GO to S11 .

S8 CONFIRM THE PASSENGER SEAT TRACK POSITION
RESTRAINTS SENSOR FAULT

connectors and the RCM electrical connectors are connected INSTALL a new passenger
before carrying out the self-test. If not, DTCs will be recorded. seat track position sensor.
REFER to Seat Position
Ignition OFF. Sensor in this section. GO to
S11 .
instruction may result in serious personal injury or death in In the process of diagnosing
the event of an accidental deployment. the fault, the fault condition
Prior to reconnecting any previously disconnected SRS has become intermittent. Do
component: not install any new SRS
inspect connector(s) (including any in-line connectors) for components at this time.
pushed-out, loose or spread terminals and loose or frayed Install SRS components
wire connections at terminals. only when directed to do so
inspect wire harness for any damage, pinched, cut or in the pinpoint test. GO to
pierced wires. S10 .
inspect C310A and C310B Connector Position Assurance


RCM .
S9 CONFIRM THE RCM FAULT

Ignition OFF. GO to S11 .
(CPA) lever/lock for correct operation. Refer to Restraints S10 .
Connect: Passenger Seat Track Position Sensor C3617.

Ignition ON.
RCM .
S10 CHECK FOR AN INTERMITTENT FAULT

Ignition OFF. Yes
Disconnect: Passenger Seat Track Position Sensor C3617. cleared until it is corrected
inspect connector(s) (including any in-line connectors) for and the DTC is no longer
corrosion, loose or spread terminals and loose or frayed retrieved on-demand during
wire connections at terminals. the self-test.
pierced wires. For DTC B00C5:11 or
repair any concerns found. B00C5:1D, GO to S2 .
Refer to Wiring Diagrams Cell 5 , Connector Repair For DTC B00C5:12, GO to

Procedures for schematic and connector information. S4 .

Connect: All Previously Disconnected Component(s)/Connector(s). S5 .
to Supplemental Restraint System (SRS) Depowering and No
Repowering in this section. The fault is not present and
Ignition ON. cannot be recreated at this
Enter the following diagnostic mode on the scan tool: Self Test — time. Do not install any new
RCM . SRS components at this
Was DTC B00C5:11, B00C5:12, B00C5:13 or B00C5:1D time. Install SRS
retrieved on-demand during self-test? components only when

GO to S11 .
S11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute to all DTCs have been resolved.
not prove out the SRS at this time. Refer to Supplemental CLEAR all RCM and
Restraint System (SRS) Depowering and Repowering in this Occupant Classification
section. System Module (OCSM)
Ignition ON. CMDTCs . PROVE OUT the
Enter the following diagnostic mode on the scan tool: Self Test — SRS . Repair is complete.
Restraints. RETURN the vehicle to the
NOTE: When selecting Restraints from the Self-Test menu, DTCs customer.
Pinpoint Test T: DTCs B00D5:11, B00D5:12 and B00D5:13
Normal Operation
The RCM briefly activates the Passenger Air Bag Deactivation (PAD) indicator to prove-out and verify to the
occupants correct functional operation of the PAD indicator.
The RCM monitors the PAD indicator circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted PAD indicator
If a fault is detected, the RCM stores DTC B00D5:11, B00D5:12 or B00D5:13 in memory and sends a message
to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.
DTC B00D5:11 (Restraint System Passenger Disable Indicator: Circuit Short to Ground) — When the
RCM senses a short to ground on the PAD indicator circuit, a fault is indicated.
DTC B00D5:12 (Restraint System Passenger Disable Indicator: Circuit Short to Battery) — When the
RCM senses a short to voltage on the PAD indicator circuit, a fault is indicated.
DTC B00D5:13 (Restraint System Passenger Disable Indicator: Circuit Open) — When the RCM senses
an open circuit on the PAD indicator, a fault is indicated. An open ignition circuit to the PAD indicator can
set this DTC.

PAD indicator
RCM
PINPOINT TEST T: DTCs B00D5:11, B00D5:12 AND B00D5:13

T1 RETRIEVE RCM DTCs
Enter the following diagnostic mode on the scan tool: Self Test Yes
— RCM . This fault cannot be cleared until
Was DTC B00D5:11, B00D5:12 or B00D5:13 retrieved on- it is corrected and the DTC is no
demand during self-test? longer retrieved on-demand
during self-test.
For DTC B00D5:11, GO to T2 .
For DTC B00D5:13, GO to T4
For DTC B00D5:12, GO to T7 .
No
This is an intermittent fault when
T10 .
T2 CHECK THE PAD INDICATOR CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
GO to T9 .
WARNING: Turn the ignition OFF and wait one minute
to deplete the backup power supply. Failure to follow this No
instruction may result in serious personal injury or death in GO to T3 .
Disconnect: PAD Indicator C2286.
Measure the resistance between PAD indicator C2286-2, circuit
RR116 (BN/GN), harness side and ground.

T3 CHECK THE RCM FOR LOW RESISTANCE
Depower the SRS . Refer to Supplemental Restraint System Yes
(SRS) Depowering and Repowering in this section. GO to T9 .
Measure the resistance between PAD indicator C2286-2, circuit No
RR116 (BN/GN), harness side and ground. REPAIR circuit RR116 (BN/GN).

Connector Repair Procedures for
schematic and connector
information.
GO to T11 .
T4 CHECK THE PAD INDICATOR CIRCUIT FOR AN OPEN
Disconnect: PAD Indicator C2286. No
Measure the resistance between PAD indicator C2286-2, circuit REPAIR circuit RR116 (BN/GN).
RR116 (BN/GN) and RCM C310A-22, circuit RR116 (BN/GN),
harness side. Refer to Wiring Diagrams Cell 5 ,
information.
GO to T11 .

T5 CHECK THE IGNITION CIRCUIT AT PAD INDICATOR FOR
VOLTAGE
Repower the SRS . Do not prove out the SRS at this time. Yes
Refer to Supplemental Restraint System (SRS) Depowering GO to T6 .
and Repowering in this section.
Ignition ON. No
Measure the voltage between PAD indicator C2286-1, circuit VERIFY Central Junction Box
CBP04 (VT), harness side and ground. (CJB) fuse 4 (7.5A) is OK. If OK,
REPAIR circuit CBP04 (VT).

information.
If not OK, REFER to the Wiring

Diagrams manual to identify the
possible causes of the circuit
short. GO to T11 .

T6 CHECK THE PAD INDICATOR
Ignition OFF. Yes
Connect: PAD Indicator C2286. REMOVE the fused jumper wire
Connect a fused jumper wire between RCM C310A-22, circuit and GO to T9 .
RR116 (BN/GN), harness side and ground.
No
REMOVE the fused jumper wire
and INSTALL a new PAD
indicator. REFER to Passenger
Air Bag Deactivation (PAD)
Indicator in this section. GO to
T11 .
Ignition ON.
Monitor the PAD indicator.
Does the PAD indicator illuminate?
T7 CHECK THE PAD INDICATOR CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit RR116 (BN/GN).
Disconnect: RCM C310A and C310B. Refer to Wiring Diagrams Cell 5 ,
Disconnect: PAD Indicator C2286. Connector Repair Procedures for
Repower the SRS . Do not prove out the SRS at this time. schematic and connector
Refer to Supplemental Restraint System (SRS) Depowering information.
Ignition ON. GO to T11 .
Measure the voltage between PAD indicator C2286-2, circuit
RR116 (BN/GN), harness side and ground. No
GO to T8 .

T8 CHECK THE RCM
reported by the RCM by inducing a different fault condition. If INSTALL a new PAD indicator.
the fault reported changes, this indicates the RCM is functioning REFER to Passenger Air Bag
correctly and is not the source of the fault. Deactivation (PAD) Indicator in
this section.
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System No
Repower the SRS . Do not prove out the SRS at this time.
Refer to Supplemental Restraint System (SRS) Depowering
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test
— RCM .
DIAGNOSTIC TIP: When viewing DTCs with the PAD indicator
disconnected, an open circuit fault would normally be retrieved.
Did the on-demand DTC change from B00D5:12 to
B00D5:13?
T9 CONFIRM THE RCM FAULT
connectors are connected before carrying out the self-test. If INSTALL a new RCM . REFER
not, DTCs will be recorded. to Restraints Control Module
(RCM) in this section. GO to
Ignition OFF. T11 .
Prior to reconnecting any previously disconnected SRS In the process of diagnosing the
component: fault, the fault condition has
inspect connector(s) (including any in-line connectors) for become intermittent. Do not
pushed-out, loose or spread terminals and loose or install any new SRS
frayed wire connections at terminals. components at this time.
inspect wire harness for any damage, pinched, cut or Install SRS components only
pierced wires. when directed to do so in the
inspect RCM C310A and C310B Connector Position pinpoint test. GO to T10 .
Assurance (CPA) lever/lock for correct operation. Refer
to Restraints Control Module (RCM) in this section.

Connect: PAD Indicator C2286.

Ignition ON.
— RCM .
T10 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
This fault cannot be cleared until
WARNING: Turn the ignition OFF and wait one minute it is corrected and the DTC is no
to deplete the backup power supply. Failure to follow this longer retrieved on-demand
instruction may result in serious personal injury or death in during self-test.
Disconnect: PAD Indicator C2286. For DTC B00D5:11, GO to T2 .
corrosion, loose or spread terminals and loose or frayed For DTC B00D5:13, GO to T4 .
wire connections at terminals.
inspect wire harness for any damage, pinched, cut or For DTC B00D5:12, GO to T7 .
pierced wires.
CHECK for causes of
Refer to Wiring Diagrams Cell 5 , Connector Repair intermittent open, short to
Procedures for schematic and connector information. ground or short to voltage on
circuit RR116 (BN/GN).
Connect: All Previously Disconnected Component(s)/Connector ATTEMPT to recreate the hard
(s). fault by flexing the wire harness
and cycling the ignition
Ignition ON.
frequently. ACTIVATE other
— RCM . systems in the same wire
Was DTC B00D5:11, B00D5:12 or B00D5:13 retrieved on- harness. Do not install any new
SRS components at this time.
demand during self-test?
Install SRS components only
when directed to do so in the
pinpoint test. GO to T11 .
T11 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute DTCs have been resolved. GO
to deplete the backup power supply. Failure to follow this to the DTC Charts in this section
instruction may result in serious personal injury or death in for pinpoint test direction.
Reconnect all SRS components (if previously disconnected). No
If previously directed to depower the SRS , repower the SRS . CLEAR all RCM and OCSM
Do not prove out the SRS at this time. Refer to Supplemental CMDTCs . PROVE OUT the
Restraint System (SRS) Depowering and Repowering in this SRS . Repair is complete.
section. RETURN the vehicle to the
Ignition ON. customer.
— Restraints.
NOTE: When selecting Restraints from the Self-Test menu,
DTCs are retrieved from the RCM and OCSM .
Are any on-demand RCM and/or Occupant Classification
System Module (OCSM) DTCs retrieved on-demand during
self-test?
Pinpoint Test U: DTCs B1211:11, B1211:12, B1211:13 and B1211:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver safety belt retractor circuits for the
following faults:

Unexpected voltage
Short to ground
Faulted driver safety belt retractor pretensioner
as measured by the RCM . If the value displayed is lower or higher than the desired range (refer to the diagram
including:
Wiring
Connections
Driver safety belt retractor
RCM
B1211:11 — Driver Seatbelt Retractor When the RCM senses a short to ground on the driver
Pretensioner Deployment Control: Circuit safety belt retractor pretensioner circuit, a fault is
Short to Ground indicated.
B1211:12 — Driver Seatbelt Retractor When the RCM senses a short to battery on the driver
Pretensioner Deployment Control: Circuit safety belt retractor pretensioner circuit, a fault is
Short to Battery indicated.
B1211:13 — Driver Seatbelt Retractor When the RCM measures more than the desired
Pretensioner Deployment Control: Circuit resistance range between the driver safety belt retractor
Open pretensioner circuits, a fault is indicated.
B1211:1A — Driver Seatbelt Retractor When the RCM measures less than the desired
Pretensioner Deployment Control: Circuit resistance range between the driver safety belt retractor
Resistance Below Threshold pretensioner circuits, a fault is indicated.

Driver safety belt retractor pretensioner
RCM
PINPOINT TEST U: DTCs B1211:11, B1211:12, B1211:13 AND B1211:1A

U1 RETRIEVE RCM DTCs
Ignition ON. Yes
test.
For DTC B1211:13 or

B1211:1A, GO to U2 .

U8 .

U10 .
No
when present as a
Continuous Memory
(CMDTC) only.
For DTC B1211:13 or

B1211:1A, GO to U13 .

U14 .

U15 .
U2 CHECK THE DRIVER SEATBELT RETRACTOR PRETENSIONER
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_23_R) PID
RCM . GO to U12 .
DEPLOY_23_R PID
GO to U3 .
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_23_R) PID WHILE
CARRYING OUT THE HARNESS TEST
of the driver safety belt retractor pretensioner circuits and accessible DEPOWER the SRS and
connectors (including any in-line connectors), by wiggling REPAIR the connector,
connectors and flexing the wire harness. terminals or wire harness as
GO to U17 .
No
ohms, GO to U4 .

2.78 ohms, GO to U6 .
DEPLOYMENT CONTROL DTC FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to U11 .
GO to U5 .
Ignition OFF.
Disconnect: Driver Safety Belt Retractor Pretensioner C323.
in this section.
Ignition ON.
RCM .
retractor pretensioner disconnected, an open circuit fault would
U5 CHECK FOR A SHORT BETWEEN DRIVER SAFETY BELT
RETRACTOR PRETENSIONER CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to U12 .
Measure the resistance between the driver safety belt retractor REPAIR circuit CR146
pretensioner C323-2, circuit CR146 (GY/VT), harness side and (GY/VT) or RR146 (BU/BN).
C323-1, circuit RR146 (BU/BN), harness side.
GO to U17 .

U6 CHECK THE DRIVER SAFETY BELT RETRACTOR
PRETENSIONER CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Driver Safety Belt Retractor Pretensioner C323. No
Measure the resistance between RCM C310B, harness side and (GY/VT) or RR146 (BU/BN).
driver safety belt retractor pretensioner C323, harness side using
the following chart. Refer to Wiring Diagrams
Driver Safety Belt Retractor Procedures for schematic
RCM Circuit Pretensioner and connector information.
C310B- CR146 C323-2
2 (GY/VT) GO to U17 .
C310B- RR146 C323-1

1 (BU/BN)

(OPEN INDICATED)
reported changes, this indicates the RCM is functioning correctly wire and GO to U11 .
No
Connect a fused jumper wire between the driver safety belt retractor REMOVE the fused jumper
pretensioner C323-2, circuit CR146 (GY/VT), harness side and wire and GO to U12 .
C323-1, circuit RR146 (BU/BN), harness side.

in this section.
Ignition ON.
RCM .
retractor pretensioner circuits shorted together, a low resistance
fault would normally be retrieved.
(SHORT TO GROUND INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to U11 .
GO to U9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
retractor pretensioner disconnected, an open circuit fault would
PRETENSIONER CIRCUITS FOR A SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between driver safety belt retractor REPAIR circuit CR146
pretensioner: (GY/VT) or RR146 (BU/BN).
C323-2, circuit CR146 (GY/VT), harness side and ground.
C323-1, circuit RR146 (BU/BN), harness side and ground. Refer to Wiring Diagrams
GO to U17 .

PRETENSIONER CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (GY/VT) or RR146 (BU/BN).
Ignition ON.
Measure the voltage between the driver safety belt retractor GO to U17 .
pretensioner:
C323-2, circuit CR146 (GY/VT), harness side and ground.
No
C323-1, circuit RR146 (BU/BN), harness side and ground. GO to U12 .
U11 CONFIRM THE DRIVER SAFETY BELT RETRACTOR
PRETENSIONER FAULT
connectors are connected before carrying out the self-test. If not, INSTALL a new driver
DTCs will be recorded. safety belt retractor
pretensioner. REFER to
Ignition OFF. Section 501-20A . GO to
Depower the SRS . Refer to Supplemental Restraint System (SRS) U17 .
Prior to reconnecting any previously disconnected SRS component: No
inspect connector(s) (including any in-line connectors) for In the process of diagnosing
pushed-out, loose or spread terminals and loose or frayed the fault, the fault condition
wire connections at terminals. has become intermittent. Do
inspect wire harness for any damage, pinched, cut or pierced not install any new SRS
inspect C310A and C310B Connector Position Assurance Install SRS components
(CPA) lever/lock for correct operation. Refer to Restraints only when directed to do
Control Module (RCM) in this section. so in the pinpoint test.
For DTC B1211:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B1211:1A, GO to U13 .
Connect: Driver Safety Belt Retractor Pretensioner C323. U14 .
Supplemental Restraint System (SRS) Depowering and Repowering U15 .
in this section.
Ignition ON.
RCM .
U12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to U17 .
Refer to Wiring Diagrams Cell 5 , Connector Repair B1211:1A, GO to U13 .
Connect: Driver Safety Belt Retractor Pretensioner C323. U14 .
Supplemental Restraint System (SRS) Depowering and Repowering U15 .
in this section.
Ignition ON.
RCM .
U13 CHECK FOR INTERMITTENT DRIVER SEATBELT RETRACTOR
PRETENSIONER DEPLOYMENT CONTROL RESISTANCE
(DEPLOY_23_R) PID LOW RESISTANCE OR OPEN CIRCUIT FAULT
Attempt to recreate the fault by wiggling the connectors (including time. Do not install any
any in-line connectors) and flexing the wire harness. new SRS components at
pinpoint test. GO to U16 .
No
DEPOWER the SRS and

GO to U17 .
U14 CHECK FOR AN INTERMITTENT DRIVER SEATBELT
RETRACTOR PRETENSIONER DEPLOYMENT CONTROL SHORT TO
GROUND FAULT
RCM .
GO to U17 .
No
U15 CHECK FOR AN INTERMITTENT DRIVER SEATBELT
VOLTAGE FAULT
Ignition OFF. Yes
in-line connectors) and flexing the wire harness. GO to U17 .
RCM . No
U16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Driver Safety Belt Retractor Pretensioner C323. Refer to Wiring Diagrams
wires. GO to U17 .
No
U17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
System (SRS) Depowering and Repowering in this section. Occupant Classification
Ignition ON. System Module (OCSM)
Enter the following diagnostic mode on the scan tool: Self Test — CMDTCs . PROVE OUT the
Restraints. SRS . Repair is complete.
NOTE: When selecting Restraints from the Self-Test menu, DTCs RETURN the vehicle to the
are retrieved from the RCM and OCSM . customer.
self-test?
Pinpoint Test V: DTCs B1214:11, B1214:12, B1214:13 and B1214:1A
Normal Operation
The Restraints Control Module (RCM) continuously monitors the passenger safety belt retractor pretensioner
and circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger safety belt retractor pretensioner
including:
Wiring
Connections
Passenger safety belt retractor pretensioner
RCM

B1214:11 — Passenger Seatbelt Retractor When the RCM senses a short to ground on the
Pretensioner Deployment Control: Circuit passenger safety belt retractor pretensioner circuit, a
Short to Ground fault is indicated.
B1214:12 — Passenger Seatbelt Retractor When the RCM senses a short to battery on the
Pretensioner Deployment Control: Circuit passenger safety belt retractor pretensioner circuit, a
Short to Battery fault is indicated.
B1214:13 — Passenger Seatbelt Retractor When the RCM measures more than the desired
Pretensioner Deployment Control: Circuit resistance range between the passenger safety belt
Open retractor pretensioner circuits, a fault is indicated.
B1214:1A — Passenger Seatbelt Retractor When the RCM measures less than the desired
Pretensioner Deployment Control: Circuit resistance range between the passenger safety belt
Resistance Below Threshold retractor pretensioner circuits, a fault is indicated.

Passenger safety belt retractor pretensioner
RCM
PINPOINT TEST V: DTCs B1214:11, B1214:12, B1214:13 and B1214:1A

V1 RETRIEVE RCM DTCs
Ignition ON. Yes
For DTC B1214:13 or

B1214:1A, GO to V2 .

V8 .

V10 .
No
when present as a
Continuous Memory
(CMDTC) only. The fault
condition is not present at
this time.
For DTC B1214:13 or

B1214:1A, GO to V13 .

V14 .

V15 .
V2 CHECK THE PASSENGER SEATBELT RETRACTOR
(DEPLOY_24_R) PID
RCM . GO to V12 .
DEPLOY_24_R PID
GO to V3 .
(DEPLOY_24_R) PID WHILE CARRYING OUT THE HARNESS TEST
of the passenger safety belt retractor pretensioner circuits and DEPOWER the SRS and
accessible connectors (including any in-line connectors), by wiggling REPAIR the connector,
connectors and flexing the wire harness. terminals or wire harness as
GO to V17 .
No
ohms, GO to V4 .

2.78 ohms, GO to V6 .
PRETENSIONER DEPLOYMENT CONTROL DTC FOR A FAULT
STATUS CHANGE (LOW RESISTANCE INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to V11 .
GO to V5 .
Ignition OFF.
Disconnect: Passenger Safety Belt Retractor Pretensioner C303.
in this section.
Ignition ON.
RCM .
belt retractor pretensioner disconnected, an open circuit fault would
V5 CHECK FOR A SHORT BETWEEN PASSENGER SAFETY BELT
RETRACTOR PRETENSIONER CIRCUITS
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to V12 .
Measure the resistance between the passenger safety belt retractor REPAIR circuits CR147
pretensioner C303-1, circuit RR147 (YE/VT), harness side and (GN/OG) and RR147
C303-2, circuit CR147 (GN/OG), harness side. (YE/VT).

GO to V17 .

V6 CHECK THE PASSENGER SAFETY BELT RETRACTOR
PRETENSIONER CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Passenger Safety Belt Retractor Pretensioner C303. No
Measure the resistance between RCM C310B, harness side and (GN/OG) or RR147
passenger safety belt retractor pretensioner C303, harness side (YE/VT).
Passenger Safety Belt Retractor Cell 5 , Connector Repair
RCM Circuit Pretensioner Procedures for schematic
C310B- RR147 C303-1
11 (YE/VT)
GO to V17 .
C310B- CR147 C303-2
12 (GN/OG)

PRETENSIONER DEPLOYMENT CONTROL DTCs FOR FAULT STATUS
CHANGE (OPEN INDICATED)
reported changes, this indicates the RCM is functioning correctly wire and GO to V11 .
Disconnect: Passenger Seat Side Air Bag Module C337. No
Connect a fused jumper wire between the passenger safety belt wire and GO to V12 .
retractor pretensioner C303-1, circuit RR147 (YE/VT), harness side
and C303-2, circuit CR147 (GN/OG), harness side.
in this section.
Ignition ON.
RCM .
belt retractor pretensioner circuits shorted together, a low resistance
fault would normally be retrieved.
PRETENSIONER DEPLOYMENT CONTROL DTC FOR A FAULT
STATUS CHANGE (SHORT TO GROUND INDICATED)
by the RCM by inducing a different fault condition. If the fault GO to V11 .
GO to V9 .
Ignition OFF.
in this section.
Ignition ON.
RCM .
belt retractor pretensioner disconnected, an open circuit fault would
PRETENSIONER CIRCUITS FOR A SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the passenger safety belt retractor REPAIR circuit CR147
pretensioner: (GN/OG) or RR147
C303-2, circuit CR147 (GN/OG), harness side and ground. (YE/VT).
GO to V17 .

PRETENSIONER CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (GN/OG) or RR147
Disconnect: Passenger Seat Side Air Bag Module C337. (YE/VT).
Ignition ON.
Measure the voltage between the passenger safety belt retractor
GO to V17 .
pretensioner:
C303-2, circuit CR147 (GN/OG), harness side and ground. No
C303-1, circuit RR147 (YE/VT), harness side and ground. GO to V12 .

V11 CONFIRM THE PASSENGER SAFETY BELT RETRACTOR
PRETENSIONER FAULT
DTCs will be recorded. safety belt retractor
pretensioner. REFER to
Ignition OFF. Section 501-20A . GO to
Depower the SRS . Refer to Supplemental Restraint System (SRS) V17 .
Prior to reconnecting any previously disconnected SRS component: No
inspect connector(s) (including any in-line connectors) for In the process of diagnosing
pushed-out, loose or spread terminals and loose or frayed the fault, the fault condition
wire connections at terminals. has become intermittent. Do
inspect wire harness for any damage, pinched, cut or pierced not install any new SRS
inspect C310A and C310B Connector Position Assurance Install SRS components
(CPA) lever/lock for correct operation. Refer to Restraints only when directed to do
Control Module (RCM) in this section. so in the pinpoint test.
For DTC B1214:13 or
Refer to Wiring Diagrams Cell 5 , Connector Repair B1214:1A, GO to V13 .
V14 .
Connect: Passenger Safety Belt Retractor Pretensioner C303.
Supplemental Restraint System (SRS) Depowering and Repowering V15 .
in this section.
Ignition ON.
RCM .
V12 CONFIRM THE RCM FAULT
Ignition OFF. this section. GO to V17 .
B1214:1A, GO to V13 .
V14 .
Connect: All Restraint System Components.
Repower the SRS . Do not prove out the SRS at this time. Refer to V15 .
in this section.
Ignition ON.
RCM .
V13 CHECK FOR AN INTERMITTENT PASSENGER SEATBELT
RETRACTOR PRETENSIONER DEPLOYMENT CONTROL
RESISTANCE (DEPLOY_24_R) PID LOW RESISTANCE OR OPEN
CIRCUIT FAULT
Attempt to recreate the fault by wiggling the connectors (including time. Do not install any
any in-line connectors) and flexing the wire harness. new SRS components at
Does the PID value read between 1.7 ohms and 2.78 ohms? this time. Install SRS
pinpoint test. GO to V16 .
No
DEPOWER the SRS and

GO to V17 .
GROUND FAULT
RCM .
GO to V17 .
No
VOLTAGE FAULT
Ignition OFF. Yes
Attempt to recreate the fault by wiggling the connectors (including
any in-line connectors) and flexing the wire harness. GO to V17 .
No
V16 CHECK THE HARNESS AND CONNECTORS
Ignition OFF. Yes
Disconnect: Passenger Safety Belt Retractor Pretensioner C303. Refer to Wiring Diagrams
loose or spread terminals and loose or frayed wire Procedures for schematic
wires. GO to V17 .
No
V17 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
System (SRS) Depowering and Repowering in this section. Occupant Classification
Ignition ON. System Module (OCSM)
Enter the following diagnostic mode on the scan tool: Self Test — CMDTCs . PROVE OUT the
Restraints. SRS . Repair is complete.
NOTE: When selecting Restraints from the Self-Test menu, DTCs RETURN the vehicle to the
are retrieved from the RCM and OCSM . customer.
self-test?
Pinpoint Test W: DTCs B0001:2B, B0002:2B, B0004:2B, B0010:2B, B0011:2B, B0020:2B, B0021:2B,
B0028:2B, B0029:2B, B0050:2B, B0052:2B, B0082:2B, B00B5:2B, B00C5:2B, B1211:2B and B1214:2B
Normal Operation
The Restraints Control Module (RCM) monitors all deployable device and sensor circuits for a signal cross-
coupled (short) between circuits. If the RCM detects a short between the circuits of one device and another
device, it stores a DTC for each of the signal-cross coupled faults in memory. The RCM sends a message to
the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator. When a normal loop fault is
present (one loop is either shorted to battery/ground, open circuit or low resistance), signal cross-coupled
diagnostics are not active. Once the normal loop fault is repaired, the signal cross-coupled diagnostics resume.

B0001:2B — Driver Frontal Stage 1 If the RCM detects a short between the driver air bag module
Deployment Control: Signal Cross stage 1 circuits and the circuits of another SRS component, it
Coupled sets this DTC and the DTC of the corresponding SRS
component.
B0002:2B — Driver Frontal Stage 2 If the RCM detects a short between the driver air bag module
Deployment Control: Signal Cross stage 2 circuits and the circuits of another SRS component, it
component.
B0004:2B — Driver Knee Bolster If the RCM detects a short between the driver knee bolster
Deployment Control: Signal Cross circuits and the circuits of another SRS component, it sets this
Coupled DTC and the DTC of the corresponding SRS component.
B0010:2B — Passenger Frontal If the RCM detects a short between the passenger air bag
Stage 1 Deployment Control: Signal module stage 1 circuits and the circuits of another SRS
Cross Coupled component, it sets this DTC and the DTC of the corresponding
SRS component.
B0011:2B — Passenger Frontal If the RCM detects a short between the passenger air bag
Stage 2 Deployment Control: Signal module stage 2 circuits and the circuits of another SRS
SRS component.
B0020:2B — Left Side Airbag If the RCM detects a short between the driver seat side air bag
Deployment Control: Signal Cross module circuits and the circuits of another SRS component, it
component.
B0021:2B — Left Curtain If the RCM detects a short between the driver side air curtain
Deployment Control 1: Signal Cross module circuits and the circuits of another SRS component, it
component.
B0028:2B — Right Side Airbag If the RCM detects a short between the passenger seat side air
Deployment Control: Signal Cross bag module circuits and the circuits of another SRS component,
Coupled it sets this DTC and the DTC of the corresponding SRS
component.
B0029:2B — Right Curtain If the RCM detects a short between the passenger side air
Deployment Control 1: Signal Cross curtain module circuits and the circuits of another SRS
Coupled component, it sets this DTC and the DTC of the corresponding
SRS component.
B0050:2B — Driver Seatbelt If the RCM detects a short between the driver safety belt buckle
Sensor: Signal Cross Coupled switch circuits and the circuits of another SRS component, it sets
this DTC and the DTC of the corresponding SRS component.
B0052:2B — Passenger Seatbelt If the RCM detects a short between the passenger safety belt
Sensor: Signal Cross Coupled buckle switch circuits and the circuits of another SRS
component, it sets this DTC and the DTC of the corresponding
SRS component.
Load Limiter Deployment Control: adaptive load limiter circuits and the circuits of another SRS
Signal Cross Coupled component, it sets this DTC and the DTC of the corresponding
SRS component.
B00B5:2B — Driver Seat Track If the RCM detects a short between the driver seat track position
Position Restraints Sensor: Signal sensor circuits and the circuits of another SRS component, it
Cross Coupled sets this DTC and the DTC of the corresponding SRS
component.
B00C5:2B — Passenger Seat Track If the RCM detects a short between the passenger seat track
Position Restraints Sensor: Signal position sensor circuits and the circuits of another SRS
SRS component.
B1211:2B — Driver Seatbelt If the RCM detects a short between the driver safety belt buckle
Retractor Pretensioner Deployment pretensioner circuits and the circuits of another SRS component,
Control: Signal Cross Coupled it sets this DTC and the DTC of the corresponding SRS
component.
Retractor Pretensioner Deployment buckle pretensioner circuits and the circuits of another SRS
Control: Signal Cross Coupled component, it sets this DTC and the DTC of the corresponding
SRS component.

RCM
PINPOINT TEST W: DTCs B0001:2B, B0002:2B, B0004:2B, B0010:2B, B0011:2B, B0020:2B, B0021:2B,
B0028:2B, B0029:2B, B0050:2B, B0052:2B, B0082:2B, B00B5:2B, B00C5:2B, B1211:2B AND B1214:2B

W1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test This fault cannot be cleared until it
— RCM . is corrected and the DTC is no
NOTE: Signal cross-coupled DTCs are only retrieved in pairs. longer retrieved during the on-
Were any signal cross coupled DTCs retrieved on-demand demand self test. GO to W2 .
during self-test?
No
present as a Continuous Memory
(CMDTC) only. GO to W4 .
W2 CHECK THE AFFECTED DEPLOYABLE CIRCUITS FOR A
SIGNAL CROSS COUPLED FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to W3 .
Disconnect ALL of the affected SRS devices. REPAIR the affected circuits.
NOTE: Most signal cross coupled faults are due to connector
and/or wiring harness damage. Carry out a thorough Refer to Wiring Diagrams Cell 5 ,
inspection of connector(s) and/or wiring harness for damage. Connector Repair Procedures for
Using the following table, measure resistance between the schematic and connector
circuits of the affected SRS devices. information.
Signal Cross Coupled Fault Table GO to W5 .

Device/Loop (DTC) Connector Circuit
Driver air bag module C216A- CR101
stage 1 (B0001:2B) 1 (VT/BN)/
C216A- (WH)
2 RR101
(YE/GN)/
(OG)
Driver air bag module C216B- CR102
stage 2 (B0002:2B) 1 (BU)/(BN)
C216B- RR102
2 (WH)/(BU)
Driver knee air bag C2432- CR139
(B0004:2B) 1 (VT/WH)
C2432- RR139 (YE)
2
Passenger air bag C256A- CR103
module stage 1 1 (GY/BU)
(B0010:2B) C256A- RR103
2 (VT/GN)
Passenger air bag C256B- CR104
module stage 2 1 (YE/GY)
(B0011:2B) C256B- RR104
2 (WH/BU)
Driver seat side air bag C367-1 RR105
module (B0020:2B) C367-3 (GY/YE)
CR105
(GN/BU)
Driver side air curtain C9018- CR109
(B0021:2B) 1 (BN/BU)
C9018- RR109
2 (BU/GN)
Passenger seat side air C337-1 RR106
bag module (B0028:2B) C337-3 (YE/OG)
CR106
(VT/GY)
Passenger side air C9019- CR111
curtain (B0029:2B) 1 (BN/WH)
C9019- RR111
2 (YE/VT)
Driver safety belt buckle C3065- CR201
switch (B0050:2B) 2 (GN/BU)
— —
Passenger safety belt C3066- CR202
buckle switch 2 (BN/GN)
(B0052:2B) — —
Passenger safety belt C389-1 CR122
load limiter (B0082:2B) C389-2 (WH/OG)
RR122 (BN)
Driver seat track C356-2 VR215
position sensor — (YE/VT)
(B00B5:2B) —
Passenger seat track C3617- VR216
position sensor 2 (GN/OG)
(B00C5:2B) — —
Driver safety belt C323-1 RR146
retractor pretensioner C323-2 (BU/BN)
(B1211:2B) CR146
(GY/VT)
Passenger safety belt C303-2 CR147
retractor pretensioner C303-1 (GN/OG)
(B1214:2B) RR147
(YE/VT)
Are the resistances greater than 10,000 ohms between the

affected circuits?
W3 CONFIRM THE RCM FAULT

connectors and the RCM electrical connectors are connected INSTALL a new RCM . REFER to
before carrying out the self-test. If not, DTCs will be recorded. Restraints Control Module (RCM)
in this section. GO to W5 .
Prior to reconnecting any previously disconnected SRS
component: No
inspect connector(s) (including any in-line connectors) In the process of diagnosing the
for pushed-out, loose or spread terminals and loose or fault, the fault condition has
frayed wire connections at terminals. become intermittent. Do not
inspect wire harness for any damage, pinched, cut or install any new SRS
pierced wires. components at this time. Install
inspect C310A and C310B Connector Position SRS components only when
Assurance (CPA) lever/lock for correct operation. Refer directed to do so in the pinpoint
to Restraints Control Module (RCM) in this section. test. GO to W4 .

Connect: All Previously Disconnected Restraint System

Component(s).
— RCM .
Were any signal cross coupled DTCs retrieved on-demand
during self-test?
W4 CHECK FOR AN INTERMITTENT FAULT
NOTE: Most cross link faults are due to connector and/or Yes
wiring harness damage. Carry out a thorough inspection of The fault condition is now present.
connector(s) and/or wiring harness for damage. This fault cannot be cleared until it
is corrected and the DTC is no
Ignition OFF. longer retrieved on-demand
Depower the SRS . Refer to Supplemental Restraint System during the self-test. GO to W2 .
Disconnect ALL of the affected SRS devices. No
Inspect the wiring harness(es) for any type of damage. Repair The fault is not present and
as necessary. cannot be recreated at this time.
Refer to Wiring Diagrams Cell 46 , Supplemental Restraint CHECK for causes of the
System for schematic and connector information. intermittent fault. ATTEMPT to
recreate the hard fault by flexing
Repower the SRS . Do not prove out the SRS at this time. the wire harness and cycling the
Refer to Supplemental Restraint System (SRS) Depowering ignition frequently. Do not install
and Repowering in this section. any new SRS components at
Enter the following diagnostic mode on the scan tool: Self Test this time. Install SRS
— RCM . components only when directed
Were any signal cross coupled DTCs retrieved on-demand to do so in the pinpoint test. GO
during self-test? to W5 .
W5 CHECK FOR ADDITIONAL SRS DTCs

Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one DTCs have been resolved. GO to
minute to deplete the backup power supply. Failure to the DTC Charts in this section for
follow this instruction may result in serious personal pinpoint test direction.
injury or death in the event of an accidental deployment.
If previously directed to depower the SRS , repower the SRS . CLEAR all RCM and Occupant
Do not prove out the SRS at this time. Refer to Supplemental Classification System Module
Restraint System (SRS) Depowering and Repowering in this (OCSM) DTCs. PROVE OUT the
Enter the following diagnostic mode on the scan tool: Self Test customer.
— Restraints.
NOTE: When selecting Restraints from the Self Test menu,
Are any RCM and/or OCSM DTCs retrieved on-demand
during self-test?
Pinpoint Test X: DTCs B0001:4A, B0002:4A, B0004:4A, B0010:4A, B0011:4A, B0020:4A, B0021:4A,
B0028:4A, B0029:4A, B0050:4A, B0052:4A, B0082:4A, B0090:4A, B0091:4A, B0092:4A, B0095:4A,
B0096:4A, B0097:4A, B00B5:4A, B00C5:4A, B00D5:4A, B1211:4A, B1214:4A and U3000:4A
Normal Operation
The Restraints Control Module (RCM) monitors all of Supplemental Restraint System (SRS) device
connections. If the RCM detects a connection or device connected that is not stored in memory, the RCM sets
a DTC and sends a message to the Instrument Panel Cluster (IPC) to illuminate air bag warning indicator.

B0001:4A — Driver Frontal Stage 1 This DTC sets if the RCM detects the device but it is not
Deployment Control: Incorrect Component configured for this component.
Installed
B0002:4A — Driver Frontal Stage 2 This DTC sets if the RCM detects the device but it is not
Installed
B0004:4A — Driver Knee Bolster This DTC sets if the RCM detects the device but it is not
Installed
B0010:4A — Passenger Frontal Stage 1 This DTC sets if the RCM detects the device but it is not
Installed
B0011:4A — Passenger Frontal Stage 2 This DTC sets if the RCM detects the device but it is not
Installed
B0020:4A — Left Side Airbag Deployment This DTC sets if the RCM detects the device but it is not
Control: Incorrect Component Installed configured for this component.
B0021:4A — Left Curtain Deployment This DTC sets if the RCM detects the device but it is not
Control 1: Incorrect Component Installed configured for this component.
B0028:4A — Right Side Airbag Deployment This DTC sets if the RCM detects the device but it is not
Control: Incorrect Component Installed configured for this component.
B0029:4A — Right Curtain Deployment This DTC sets if the RCM detects the device but it is not
Control 1: Incorrect Component Installed configured for this component.
B0050:4A — Driver Seatbelt Sensor: This DTC sets if the RCM detects the device but it is not
Incorrect Component Installed configured for this component.
B0052:4A — Passenger Seatbelt Sensor: This DTC sets if the RCM detects the device but it is not
B0082:4A — Passenger Seatbelt Load This DTC sets if the RCM detects the device but it is not
Limiter Deployment Control: Incorrect configured for this component.
Component Installed
B0090:4A — Left Frontal Restraints Sensor: This DTC sets if the RCM detects the device but it is not
B0091:4A — Left Side Restraints Sensor 1: This DTC sets if the RCM detects the device but it is not
B0092:4A — Left Side Restraints Sensor 2: This DTC sets if the RCM detects the device but it is not
B0095:4A — Right Frontal Restraints This DTC sets if the RCM detects the device but it is not
Sensor: Incorrect Component Installed configured for this component.
B0096:4A — Right Side Restraints Sensor This DTC sets if the RCM detects the device but it is not
1: Incorrect Component Installed configured for this component.
B0097:4A — Right Side Restraints Sensor This DTC sets if the RCM detects the device but it is not
2: Incorrect Component Installed configured for this component.
B00B5:4A — Driver Seat Track Position This DTC sets if the RCM detects the device but it is not
Restraints Sensor: Incorrect Component configured for this component.
Installed
B00C5:4A — Passenger Seat Track This DTC sets if the RCM detects the device but it is not
Position Restraints Sensor: Incorrect configured for this component.
Component Installed
B00D5:4A — Restraint System Passenger This DTC sets if the RCM detects the device but it is not
Disable Indicator: Incorrect Component configured for this component.
Installed
B1211:4A — Driver Seatbelt Retractor This DTC sets if the RCM detects the device but it is not
Pretensioner Deployment Control: Incorrect configured for this component.
Component Installed
B1214:4A — Passenger Seatbelt Retractor This DTC sets if the RCM detects the device but it is not
Pretensioner Deployment Control: Incorrect configured for this component.
Component Installed
U3000:4A — Control Module: Incorrect This DTC sets if the RCM detects the incorrect vehicle or
Component Installed model year ID from the Occupant Classification System
Module (OCSM) or ABS module.

Incorrect RCM for vehicle
RCM not configured
PINPOINT TEST X: DTCs B0001:4A, B0002:4A, B0004:4A, B0010:4A, B0011:4A, B0020:4A, B0021:4A,
B0028:4A, B0029:4A, B0050:4A, B0052:4A, B0082:4A, B0090:4A, B0091:4A, B0092:4A, B0095:4A,
B0096:4A, B0097:4A, B00B5:4A, B00C5:4A, B00D5:4A, B1211:4A, B1214:4A AND U3000:4A

X1 RETRIEVE RCM DTCs
Connect the scan tool. Yes
Enter the following diagnostic mode on the scan This fault cannot be cleared until it is corrected
tool: Self Test — RCM . and the DTC is no longer retrieved on-demand
Were any incorrect component installed during self-test. GO to X2 .
DTCs retrieved?
No
This is an intermittent fault when present as a
Continuous Memory Diagnostic Trouble Code
(CMDTC) only. The fault condition is not present
at this time. GO to X7 .
X2 CHECK THE VEHICLE HISTORY
Ignition OFF. Yes
Check the vehicle repair history. GO to X3 .
Has a new RCM or OCSM been installed
during this or a prior repair? No
GO to X4 .
X3 CHECK THE RCM AND OCSM VEHICLE
IDENTIFICATION PIDs
Ignition ON. Yes
Enter the following diagnostic mode on the scan GO to X4 .
tool: DataLogger — RCM .
View and record the following PID values: No
V_ID_14229_RCM INSTALL the correct RCM or Occupant
OCS_MY Classification System (OCS) system service kit.
Enter the following diagnostic mode on the scan REFER to Restraints Control Module (RCM) or
tool: DataLogger — OCSM . Occupant Classification Sensor in this section.
View and record the following PID values: GO to X8 .
OCS_MY_OCS
OCS_VEH_ID
Verify the correct vehicle application.
Does the PID values match the vehicle
application?
X4 CHECK ABS MODULE
Enter the following diagnostic mode on the scan Yes
tool: Log Viewer. GO to X5 .
Retrieve and record the ABS module part
number from Log Viewer. No
Check the recorded part number against the INSTALL the correct ABS module. REFER to
part number listed in the Ford Catalog Section 206-09 . GO to X8 .
Advantage™ or equivalent.
Is the correct ABS module installed in the
vehicle?
X5 CHECK RCM
Carry out Programmable Module Installation Yes
(PMI) for the RCM . Use as-built data when GO to X6 .
carrying out PMI . Refer to Section 418-01 .
Enter the following diagnostic mode on the scan No
tool: Self Test — RCM . Fault corrected. GO to X8 .
Were any incorrect component installed
DTCs retrieved on-demand during self-test?
X6 CONFIRM THE RCM FAULT
NOTE: Make sure all SRS components and the Yes

RCM electrical connectors are connected INSTALL a new RCM . REFER to Restraints
before carrying out the self-test. If not, DTCs will Control Module (RCM) in this section. GO to X8 .
be recorded.
Ignition OFF. No
Prior to reconnecting any previously In the process of diagnosing the fault, the fault
disconnected SRS component: condition has become intermittent.
inspect connector(s) (including any in-
line connectors) for pushed-out, loose or Do not install any new SRS components at
spread terminals and loose or frayed wire this time. Install SRS components only when
connections at terminals. directed to do so in the pinpoint test. GO to
inspect wire harness for any damage, X7 .
pinched, cut or pierced wires.
inspect RCM C310A and C310B
Connector Position Assurance (CPA)
lever/lock for correct operation. Refer to
Restraints Control Module (RCM) in this
section.

schematic and connector information.
Connect: All Previously Disconnected

Component(s)/Connector(s).
Ignition ON.
tool: Self Test — RCM .
Were any incorrect component installed
DTCs retrieved?
X7 CHECK FOR AN INTERMITTENT FAULT
tool: Self Test — RCM . INSTALL a new RCM . REFER to Restraints
Were any incorrect component installed Control Module (RCM) in this section. GO to X8 .
DTCs retrieved on-demand during self-test?
No
CHECK for causes of the intermittent fault.
ATTEMPT to recreate the hard fault by flexing
the wire harness and cycling the ignition
frequently. ACTIVATE other systems in the
same wire harness. Do not install any new
SRS components at this time. Install SRS
components only when directed to do so in
the pinpoint test. GO to X8 .
X8 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Do not clear any DTCs until all DTCs have been
WARNING: Turn the ignition OFF and resolved. GO to the DTC Charts in this section
wait one minute to deplete the backup power for pinpoint test direction.
supply. Failure to follow this instruction may
result in serious personal injury or death in No
the event of an accidental deployment. CLEAR all RCM and OCSM DTCs. PROVE OUT
Reconnect all SRS components (if previously the SRS . Repair is complete. RETURN the
disconnected). vehicle to the customer.
If previously directed to depower the SRS ,
repower the SRS . Do not prove out the SRS at
this time. Refer to Supplemental Restraint
System (SRS) Depowering and Repowering in
this section.
Ignition ON.
tool: Self Test — Restraints.
NOTE: When selecting Restraints from the Self-
Test menu, DTCs are retrieved from the RCM
and OCSM .
Are any RCM and/or OCSM DTCs retrieved
on-demand during the self-test?
Pinpoint Test Y: DTCs U0028:08 and U0028:88
Refer to Wiring Diagrams Cell 42 , Vehicle Dynamic Systems for schematic and connector information.
Normal Operation
The Restraints Control Module (RCM) supplies the stability/traction control system with the yaw rate, roll rate,
lateral and longitudinal accelerometer readings over a dedicated Controller Area Network (CAN) bus. If the
RCM detects a fault with communications with the ABS module or dedicated CAN bus circuits, it stores DTC
U0028:08 or U0028:88.
The RCM will not request the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator if either
DTC U0028:08 or U0028:88 sets. The air bag warning indicator remains off if either of these DTCs are set.
DTC U0028:08 (Vehicle Communication Bus A: Bus Signal / Message Failures) — When the RCM does
not receive dedicated CAN bus messages from the ABS module for 5 seconds, a fault is indicated. An
open dedicated CAN circuit, incorrect installed ABS module or loss of power and/or ground to the ABS
module also sets this DTC.
DTC U0028:88 (Vehicle Communication Bus A: Bus Off) — When the RCM detects the dedicated CAN
circuits are shorted to ground, shorted to voltage or shorted to each other, a fault is indicated.
The ABS module may set similar DTCs, U0151 (Lost Communication With Restraints Control Module) and
U0452 (Invalid Data Received From Restraints Control Module).

RCM
ABS module
PINPOINT TEST Y: DTCs U0028:08 and U0028:88

Y1 RETRIEVE RCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test This fault cannot be cleared until
— RCM . it is corrected and the DTC is no
Was DTC U0028:08 or U0028:88 retrieved on-demand during longer retrieved during the self-
self-test? test.
For DTC U0028:08, GO to Y2 .
For DTC U0028:88, GO to Y6 .
No
Y13 .
Y2 CHECK FOR CORRECT RCM
Enter the following diagnostic mode on the scan tool: Log Yes
Viewer. GO to Y3 .
Retrieve and record the RCM part number from Log Viewer.
Check the recorded RCM part number against the part number No
listed in the Ford Catalog Advantage™ or equivalent. Refer to INSTALL the correct RCM .GO
Restraints Control Module (RCM) in this section. to Y14 .
Is the correct RCM installed in the vehicle?
Y3 CHECK FOR CORRECT ABS MODULE
Retrieve and record the ABS module part number from Log Yes
Viewer. GO to Y4 .
Check the recorded ABS module part number against the part
number listed in the Ford Catalog Advantage™ or equivalent. No
Is the correct ABS module installed in the vehicle? INSTALL the correct ABS
module. REFER to Section 206-
09 . GO to Y14 .
Y4 CHECK THE HS-CAN NETWORK COMMUNICATIONS (ABS
MODULE COMMUNICATIONS)
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Network GO to Y5 .
Test.
NOTE: The Network Test does not test the dedicated CAN No
communications between the ABS module and RCM . REFER to Section 418-00 to
Did the Network Test pass (ABS module communicate with diagnose the High Speed
the scan tool)? Controller Area Network (HS-
CAN)/ ABS module
communication concern. GO to
Y14 .
Y5 CHECK THE DEDICATED CAN CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to Y9 .
Disconnect: ABS Module C135. REPAIR circuit VCA24 (GN/OG)
Measure the resistance between the ABS module C135, and VCA23 (BU/WH).
harness side and the RCM C310B, harness side as indicated in
the following chart: Refer to Wiring Diagrams Cell
ABS Module Circuit RCM Procedures for schematic and
C135-18 VCA23 (BU/WH) C310B-20
C135-19 VCA24 (GN/OG) C310B-19 GO to Y14 .
Are the resistances less 5 ohms?

Y6 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit VCA24 (GN/OG)
(SRS) Depowering and Repowering in this section. or VCA23 (BU/WH).
Disconnect: ABS Module C135. Refer to Wiring Diagrams Cell
Repower the SRS . Refer to Supplemental Restraint System 5 , Connector Repair
(SRS) Depowering and Repowering in this section. Procedures for schematic and
Ignition ON. connector information.
Measure the voltage between ABS module:
C135-18, circuit VCA23 (WH/BU), harness side and
GO to Y14 .
ground.
C135-19, circuit VCA24 (GN/OG), harness side and No
ground. GO to Y7 .

Y7 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF. Yes
Measure the resistance between ABS module: GO to Y8 .
C135-18, circuit VCA23 (WH/BU), harness side and
ground. No
C135-19, circuit VCA24 (GN/OG), harness side and REPAIR circuit VCA24 (GN/OG)
ground. or VCA23 (BU/WH).

GO to Y14 .

Y8 CHECK FOR SHORT BETWEEN THE DEDICATED CAN
CIRCUITS
Measure the resistance between ABS module C135-18, circuit Yes
VCA23 (WH/BU), harness side and C135-19, circuit VCA24 GO to Y9 .
(GN/OG), harness side.
No
REPAIR circuit VCA24 (GN/OG)
and VCA23 (BU/WH).

GO to Y14 .

Y9 CHECK THE RCM TERMINATING RESISTOR
(SRS) Depowering and Repowering in this section. GO to Y10 .
Connect: RCM C310B.
Measure the resistance between ABS module C135-18, circuit No
VCA23 (WH/BU), harness side and C135-19, circuit VCA24 GO to Y11 .
(GN/OG), harness side.
Is the resistance between 108 and 132 ohms?

Y10 CHECK THE ABS MODULE TERMINATING RESISTOR
Disconnect: RCM C310B. Yes
Connect: ABS Module C135. For DTC U0028:08, GO to Y11 .
Measure the resistance between RCM C310B-20, circuit VCA23
(WH/BU), harness side and C310B-19, circuit VCA24 (GN/OG),
harness side. For DTC U0028:88, GO to Y12 .
No
GO to Y12 .

Y11 CONFIRM THE RCM FAULT
connectors are connected before carrying out the self-test. If INSTALL a new RCM . REFER
not, DTCs will be recorded. to Restraints Control Module
(RCM) in this section. GO to
If previously directed to repower the SRS , depower the SRS . Y14 .
Refer to Supplemental Restraint System (SRS) Depowering and
Repowering in this section. No
Prior to reconnecting any previously disconnected SRS In the process of diagnosing the
component: fault, the fault condition has
inspect connector(s) (including any in-line connectors) for become intermittent.
pushed-out, loose or spread terminals and loose or
frayed wire connections at terminals. Do not install any new SRS
inspect wire harness for any damage, pinched, cut or components at this time.
pierced wires. Install SRS components only
inspect RCM C310A and C310B Connector Position when directed to do so in the
Assurance (CPA) lever/lock for correct operation. Refer to pinpoint test. GO to Y13 .
inspect ABS module C135 for dirt, corrosion, water
intrusion, pushed-out, loose or spread terminals and
loose or frayed wire connections at terminals.

Connect: All Previously Disconnected Component(s)/Connector

(s).
Ignition ON.
— RCM .
Was DTC U0028:08 retrieved on-demand during self-test?
Y12 CONFIRM THE ABS MODULE FAULT
NOTE: Make sure all restraint system components and the RCM Yes
electrical connectors are connected before carrying out the self- INSTALL a new ABS module.
test. If not, DTCs will be recorded. REFER to Section 206-09 . GO
to Y14 .
If previously directed to repower the SRS , depower the SRS .
Refer to Supplemental Restraint System (SRS) Depowering and No
Repowering in Section 501-20B . In the process of diagnosing the
Prior to reconnecting any previously disconnected SRS fault, the fault condition has
component: become intermittent.
pushed-out, loose or spread terminals and loose or CHECK for causes of the
frayed wire connections at terminals. intermittent fault. ATTEMPT to
inspect wire harness for any damage, pinched, cut or recreate the hard fault by flexing
pierced wires. the wire harness and cycling the
inspect RCM C310A and C310B Connector Position ignition frequently. ACTIVATE
Assurance (CPA) lever/lock for correct operation. Refer to other systems in the same wire
Restraints Control Module (RCM) in this section. harness. Do not install any
inspect ABS module C135 for dirt, corrosion, water new SRS components at this
intrusion, pushed-out, loose or spread terminals and time. Install SRS components
loose or frayed wire connections at terminals. only when directed to do so in
repair any concerns found. the pinpoint test. GO to Y13 .


(s).
Ignition ON.
— RCM .
Was DTC U0028:88 retrieved on-demand during self-test?
Y13 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Disconnect: RCM C310B. cleared until it is corrected and
Disconnect: ABS Module C135. the DTC is no longer retrieved
inspect connector(s) (including any in-line connectors) for on-demand during the self-test.
corrosion, loose or spread terminals and loose or frayed
wire connections at terminals. CHECK for causes of the
inspect wire harness for any damage, pinched, cut or intermittent fault in the areas
pierced wires. previously worked in, particularly
repair any concerns found. the pins and terminals of any
electrical connector that were
Refer to Wiring Diagrams Cell 5 , Connector Repair disconnected. REPAIR any
Procedures for schematic and connector information. intermittent wiring, terminal or
(s). Refer to Wiring Diagrams Cell
Repower the SRS . Do not prove out the SRS at this time. Refer 5 , Connector Repair
to Supplemental Restraint System (SRS) Depowering and Procedures for schematic and
Repowering in this section. connector information.
Ignition ON.
— RCM .
Was DTC U0028:08 or U0028:88 retrieved on-demand during GO to Y14 .
self-test?
No
cannot be recreated at this time.
Do not install any new SRS
components at this time.

GO to Y14 .
Y14 CHECK FOR ADDITIONAL RCM AND ABS MODULE DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute DTCs have been resolved. GO
to deplete the backup power supply. Failure to follow this to the appropriate DTC Chart(s)
instruction may result in serious personal injury or death in in this section and/or Section
the event of an accidental deployment. 206-09 for pinpoint test
Reconnect all SRS components (if previously disconnected). direction.
If previously directed to depower the SRS , repower the SRS .
Do not prove out the SRS at this time. Refer to Supplemental No
Restraint System (SRS) Depowering and Repowering in Section CLEAR all CMDTCs . PROVE
501-20B . OUT the SRS . Repair is
Ignition ON. complete. RETURN the vehicle
Enter the following diagnostic mode on the scan tool: Self Test to the customer.
— RCM .
— ABS Module.
Were any DTCs retrieved on-demand from the RCM or ABS
module during self-test?
Pinpoint Test Z: DTCs B1317, B1318, U3003:16 and U3003:17
NOTE: DTCs B1317, B1318, B1676, U3003:16 and U3003:17 can be set if the vehicle has been recently jump
started, the battery has been recently charged or the battery has been discharged. The battery may become
discharged due to excessive load(s) on the charging system from aftermarket accessories or if the battery has
been left unattended with the accessories on.
Normal Operation — Restraints Control Module (RCM)
The Restraints Control Module (RCM) continuously monitors the input voltage for correct operation. If the RCM
detects input voltage below 9.5 volts, it stores DTC U3003:16 in memory. If the RCM detects input voltage
above 20 volts, it stores DTC U3003:17 in memory. If the RCM sets DTC U3003:16 or U3003:17, it sends a
Normal Operation — Occupant Classification System Module (OCSM)
The Occupant Classification System Module (OCSM) continuously monitors the input voltage for correct
operation. If the OCSM detects input voltage below 8 volts, it stores DTC B1318 in memory. If the OCSM
detects input voltage above 17.2 volts, it stores DTC B1317 in memory. If the OCSM sets DTC B1317 or
B1318, it sends a fault message to the RCM . The RCM then sends a message to the IPC module to illuminate
the air bag warning indicator.

U3003:16 — Battery Voltage: Circuit If the RCM detects voltage below 9.5 volts with a Supplemental
Voltage Below Threshold Restraint System (SRS) fault, it sets this DTC.
U3003:17 — Battery Voltage: Circuit If the RCM detects voltage above 16 volts with a SRS fault or
Voltage Above Threshold above 20 volts without a SRS fault, it sets this DTC.
B1317 — Battery Voltage High If the OCSM detects voltage above 17.2 volts, it sets this DTC.
B1318 — Battery Voltage Low If the OCSM detects voltage below 8 volts, it sets this DTC.

RCM
OCSM
PINPOINT TEST Z: DTCs B1317, B1318, U3003:16 and U3003:17
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor
(if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation,
which increases the risk of personal injury or death in a crash.

Z1 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test — REFER to Section 414-00
ALL CMDTC (Continuous Memory). to diagnose the charging
Is DTC B1317, B1318, B1676, U3003:16 or U3003:17 present in system.
one or more modules AND P0562, P0563, P0620, P0625, P0626
or P065B retrieved from the PCM? No
GO to Z2 .
Z2 TEST BATTERY CONDITION
Ignition OFF. Yes
Carry out the battery condition test. Refer to Section 414-01 . If the battery passed the
Did battery pass the condition test? condition test but required
a recharge, REFER to
Section 414-00 to diagnose
the charging system.
CLEAR all Continuous
Codes (CMDTCs). TEST
operation.
If the battery passed the

condition test and did not
require a recharge, GO to
Z3 .
No
INSTALL a new battery.
CLEAR all CMDTCs .
TEST the SRS for normal
operation.
Z3 CHECK CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine speed to exceed 2,000 rpm while Yes
performing this step or the generator may self excite and result in For DTC B1318 or
default charging system output voltage. If engine speed exceeds U3003:16, GO to Z4 .
2,000 rpm, shut the vehicle OFF and restart the engine before
performing this step. For DTC B1317 or
Measure the voltage of the battery: U3003:17, GO to Z6 .
For DTC B1317 or U3003:17, turn off all accessories and run
the engine at 1,500 rpm for a minimum of 2 minutes while No
measuring battery voltage. REFER to Section 414-00
For DTC B1318 or U3003:16, turn on headlights and HVAC to diagnose the charging
fan on high and run engine at 1,500 rpm for a minimum of 2 system. CLEAR all
minutes while measuring battery voltage. CMDTCs . TEST the SRS
Is the voltage between 13 and 15.2 volts?

Z4 CHECK FOR OPEN IGNITION CIRCUIT TO THE MODULE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System (SRS) GO to Z5 .
Disconnect the module with the concern: No
For the RCM , disconnect C310A and C310B. REPAIR the affected
For the Occupant Classification System Module (OCSM), circuit.
disconnect C3159.
For the RCM , measure the resistance between RCM C310A-13, Refer to Wiring Diagrams
circuit CBP20 (YE/VT), harness side and Central Junction Box (CJB) Cell 5 , Connector Repair
fuse 20. Procedures for schematic
CLEAR all CMDTCs .

operation.
For the OCSM , measure the resistance between OCSM C3159-1,
circuit CBP04 (VT), harness side and CJB fuse 4.
Is the resistance less than 1 ohm?

Z5 CHECK FOR OPEN GROUND TO THE MODULE
For the RCM : Yes
Measure the resistance between the RCM case and a good GO to Z6 .
ground.
Measure the resistance between RCM C310A-14, circuit No
GD174 (BK/WH), harness side and ground. For the RCM , VERIFY
there is no corrosion
between the RCM case
and mounting and VERIFY
the fasteners are clean and
tightened to specification
with no corrosion or
(BK/WH).
For the OCSM , REPAIR

circuit GD145 (BK/BU).

For the OCSM , measure the resistance between OCSM C3159-14,
circuit GD145 (BK/BU), harness side and ground.
CLEAR all CMDTCs .

operation.
Is the resistance less than 1 ohm?
Z6 CHECK FOR MODULE OPERATION
Depower the SRS . Refer to Supplemental Restraint System (SRS) Yes
Depowering and Repowering in this section. INSTALL a new module.
Disconnect the module with the concern: REFER to Restraints
For the RCM , disconnect C310A and C310B. Control Module (RCM) or
For the OCSM , disconnect C3159. Occupant Classification
Check for the following: Sensor in this section.
corrosion.
damaged pins. No
pushed-out pins. The system is operating
Connect the RCM C310A and C310B or OCSM C3159 and make correctly at this time. The
sure the connector seats correctly. concern may have been
Repower the SRS . Refer to Supplemental Restraint System (SRS) caused by a loose or
Depowering and Repowering in this section. corroded connector.
Operate the system and verify the concern is still present. CLEAR all CMDTCs .
Is the concern still present? TEST the SRS for normal
operation.
Pinpoint Test — Occupant Classification System Module (OCSM)
Pinpoint Test AA: DTCs B2290 and C1941
Normal Operation
The Occupant Classification System Module (OCSM) monitors the pressure sensor and circuity for faults. If a
fault is detected, the OCSM stores DTC B2290 in memory and sends a message to the Restraints Control
Module (RCM). The RCM stores DTC B00A0:09 in memory and sends a message to the Instrument Panel
Cluster (IPC) to illuminate the air bag warning indicator.
The Occupant Classification System (OCS) system components are not to be serviced separately.
DTC C1941 sets when system reset fails to complete the testing. DTC C1941 clears upon a successful system
reset.
Fault PIDs a Description Fault Trigger Condition

2290_12_OD and Passenger Seat OCS Sensor When the OCSM senses a short to voltage on the
2290_12_CM No. 1 Circuit Short to Battery bladder pressure sensor VREF and/or signal circuit, a
fault is indicated.
2290_13_OD and Passenger Seat OCS Sensor When the OCSM senses a short to ground on the
2290_13_CM No. 1 Circuit Short to Ground bladder pressure sensor circuits, a fault is indicated.
2290_15_OD and Passenger Seat OCS Sensor When the OCSM senses an internal failure with the
2290_15_CM No. 1 Internal Fault bladder pressure sensor, a fault is indicated.
a FaultPIDs that end in OD indicate on-demand status and are associated with DTC B2290. Fault PIDs that
end in CM indicate continuous memory status and are associated with DTC B2290.
DTC C1941 (Zero Seat Weight Test Failure) — This DTC sets if the OCSM is unable to complete a
successful System Reset. All other OCS system DTCs must be diagnosed and repaired before carrying
out the OCS system reset.

Faulty OCS system component
Pressure sensing fault
Mounting condition
PINPOINT TEST AA: DTCs B2290 AND C1941
NOTE: A production OCS system allows the disconnect of the electrical connector from the OCSM .
An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be
disconnected or altered.

AA1 RETRIEVE OCSM DTCs
OCSM . This fault cannot be
Enter the following diagnostic mode on the scan tool: DataLogger — cleared until it is corrected
OCSM — View and Record All 2290 Fault PIDs. and the DTC is no longer
Refer to PID list in Normal Operation to view 2290 fault PIDs. retrieved on-demand
Do any on-demand 2290 fault PIDs indicate a fault and/or was during self-test.
DTC C1941 retrieved during self-test?
GO to AA2 .
No
when present as a
Continuous Memory
(CMDTC) only. GO to
AA13 .
AA2 CHECK THE SEAT WIRING AND CONNECTORS
Ignition OFF. Yes
DEPOWER the SRS and
WARNING: Turn the ignition OFF and wait one minute to REPAIR the seat
deplete the backup power supply. Failure to follow this connectors and wiring as
instruction may result in serious personal injury or death in the needed. GO to AA14 .
event of an accidental deployment.
Carry out a thorough inspection of the OCS system wiring, terminals If DTC C1941 was
and connectors and the related seat wiring harness and body wiring present, GO to AA9 .
harness terminals and connectors.
Were any problems noted? If DTC C1941 was not
present, GO to AA14 .
No
Vehicles with a
production OCS
system:
For DTC C1941, GO to

AA9 .
For fault PID

2290_15_OD, GO to
AA3 .
For fault PID

2290_13_OD, GO to
AA10 .
For fault PID

2290_12_OD, GO to
AA11 . Vehicles with a
OCS system service kit ,
INSTALL a new OCS
system service kit.
REFER to Occupant
Classification Sensor in
this section. GO to AA14 .
AA3 CHECK THE OCS PRESSURE SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
Depower the Supplemental Restraint System (SRS). Refer to Yes
Supplemental Restraint System (SRS) Depowering and Repowering in REPAIR circuit CR152
this section. (GY/YE), RR152 (YE/VT)
Disconnect: Passenger Seat Side Air Bag Module C337. or VR223 (BU/WH).
Disconnect: Seat Pressure Sensor C3042.
Disconnect: OCSM C3159. Refer to Wiring Diagrams
Ignition ON. Cell 5 , Connector Repair
Measure the voltage between seat pressure sensor: Procedures for schematic
C3042-1, circuit CR152 (GY/YE), harness side and ground. and connector
C3042-2, circuit VR223 (BU/WH), harness side and ground. information.
GO to AA14 .
No
GO to AA4 .
Is any voltage present on any circuit?
AA4 CHECK THE SEAT PRESSURE SENSOR CIRCUITS FOR A SHORT
TO GROUND
Ignition OFF. Yes
GO to AA5 .
instruction may result in serious personal injury or death in the REPAIR circuit CR152
event of an accidental deployment. (GY/YE), RR152 (YE/VT)
Measure the resistance between seat pressure sensor: or VR223 (BU/WH).
C3042-1, circuit CR152 (GY/YE), harness side and ground.
C3042-2, circuit VR223 (BU/WH), harness side and ground. Refer to Wiring Diagrams
C3042-3, circuit RR152 (YE/VT), harness side and ground. Cell 5 , Connector Repair
and connector
information.
GO to AA14 .

AA5 CHECK THE SEAT PRESSURE SENSOR CIRCUIT VREF FOR AN
OPEN
Measure the resistance between OCSM C3159-3, circuit CR152 Yes
(GY/YE), harness side, and seat pressure sensor C3042-1, circuit GO to AA6 .
CR152 (GY/YE), harness side.
No
(GY/YE).

and connector
information.
GO to AA14 .

AA6 CHECK THE SEAT PRESSURE SENSOR RETURN CIRCUIT FOR
AN OPEN
Measure the resistance between OCSM C3159-5, circuit RR152 Yes
(YE/VT), harness side, and seat pressure sensor C3042-3, circuit GO to AA7 .
RR152 (YE/VT), harness side.
No
REPAIR circuit RR152
(YE/VT).

and connector
information.
GO to AA14 .

AA7 CHECK THE SEAT PRESSURE SENSOR SIGNAL CIRCUIT FOR
AN OPEN
Measure the resistance between OCSM C3159-4, circuit VR223 Yes
(BU/WH), harness side, and seat pressure sensor C3042-2, circuit GO to AA8 .
VR223 (BU/WH), harness side.
No
REPAIR circuit VR223
(BU/WH).

and connector
information.
GO to AA14 .

AA8 CHECK FOR A SHORT BETWEEN SEAT PRESSURE SENSOR
CIRCUITS
Measure the resistance between seat pressure sensor: Yes
C3042-1, circuit CR152 (GY/YE), harness side, and C3042-2, INSTALL a new OCS
circuit VR223 (BU/WH), harness side. system service kit.
C3042-1, circuit CR152 (GY/YE), harness side, and C3042-3, REFER to Occupant
circuit RR152 (YE/VT), harness side. Classification Sensor in
C3042-2, circuit VR223 (BU/WH), harness side, and C3042-3, this section. GO to AA14 .
circuit RR152 (YE/VT), harness side.
No
(GY/YE), RR152 (YE/VT)
and/or VR223 (BU/WH).

and connector
information.
GO to AA14 .
AA9 CHECK THE OCS SYSTEM
NOTE: Make sure all OCS system components, SRS components, Yes
sensor electrical connectors and the RCM electrical connectors are GO to AA12 .
connected before carrying out self-test. If not, DTCs will be recorded.
No
Enter the following diagnostic mode on the scan tool: OCS System Fault corrected. GO to
Reset. AA14 .
WARNING: Make sure the front passenger seat repair is
complete, the seat and all attached components (head restraint,
seat side shield, etc.) are correctly assembled, and the seat is
correctly installed to the vehicle before carrying out the System
Reset. Failure to follow these instructions may result in incorrect
operation of the occupant classification system (OCS) and
NOTICE: To prevent system failure, take the following
precautions before carrying out the Occupant Classification
System (OCS) system reset:
Make sure the OCS system components are connected and
no Occupant Classification System Module (OCSM) faults
are present, with the exception of DTC C1941. All other
OCS system DTCs must be diagnosed and repaired before
carrying out the OCS system reset.
Make sure the voltage to the OCSM is greater than 8 volts
and less than 18 volts.
Make sure the OCS system is not at a temperature below 6°
C (42°F) or above 36°C (97°F) when initiating the OCS
system reset process. If the vehicle has been exposed to
extreme cold or hot temperatures, the vehicle must be
exposed and kept at a temperature within the limits, 6°C to
36°C (42°F to 97°F) for a minimum of 30 minutes.
Make sure nothing is present on the 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 carrying out
the OCS system reset process.
If the first system reset attempt was unsuccessful, carry out a thorough
inspection of the following and repair any concerns found.
OCS system connector and wiring for damage
Pressure sensor hose for kinks and/or damage
Seat-related wiring harness and body wiring harness terminals
and connectors for damage
Carry out a second OCS system reset.
Ignition OFF.
Ignition ON.
OCSM .
Enter the following diagnostic mode on the scan tool: DataLogger —
OCSM — View and Record All 2290 Fault PIDs.
Refer to PID list in Normal Operation to view 2290 fault PIDs.
Do any on-demand 2290 fault PIDs indicate a fault and/or was
DTC C1941 retrieved on-demand during self-test?
AA10 CHECK THE SEAT PRESSURE SENSOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
GO to AA12 .
instruction may result in serious personal injury or death in the REPAIR circuit CR152
event of an accidental deployment. (GY/YE), RR152 (YE/VT)
Disconnect: Seat Pressure Sensor C3042. or VR223 (BU/WH).
Disconnect: OCSM C3159.
Measure the resistance between seat pressure sensor: Refer to Wiring Diagrams
C3042-1, circuit CR152 (GY/YE), harness side and ground. Cell 5 , Connector Repair
C3042-2, circuit VR223 (BU/WH), harness side and ground. Procedures for schematic
C3042-3, circuit RR152 (YE/VT), harness side and ground. and connector
information.
GO to AA14 .

AA11 CHECK THE SEAT PRESSURE SENSOR CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Depowering and Repowering in this section. (GY/YE), RR152 (YE/VT)
Disconnect: Passenger Seat Side Air Bag Module C337. or VR223 (BU/WH).
Disconnect: Seat Pressure Sensor C3042.
Disconnect: OCSM C3159. Refer to Wiring Diagrams
Repower the SRS . Do not prove out the system at this time. Refer to Cell 5 , Connector Repair
Supplemental Restraint System (SRS) Depowering and Repowering in Procedures for schematic
this section. and connector
Ignition ON. information.
Measure the voltage between seat pressure sensor:
C3042-1, circuit CR152 (GY/YE), harness side and ground. GO to AA14 .
C3042-2, circuit VR223 (BU/WH), harness side and ground.
C3042-3, circuit RR152 (YE/VT), harness side and ground. No
GO to AA12 .
Is any voltage present on any circuit?
AA12 CONFIRM THE OCS FAULT
NOTE: Make sure all OCS system components, SRS components, Yes
sensor electrical connectors and the RCM electrical connectors are INSTALL a new OCS
connected before carrying out self-test. If not, DTCs will be recorded. system service kit.
REFER to Occupant
Ignition OFF. Classification Sensor in
deplete the backup power supply. Failure to follow this
instruction may result in serious personal injury or death in the No
event of an accidental deployment. In the process of
Prior to reconnecting any previously disconnected SRS component: diagnosing the fault, the
OCS system connector and wiring for damage. fault condition has
pressure sensor hose for kinks and/or damage. become intermittent. Do
seat-related wiring harness and body wiring harness terminals not install any new SRS
and connectors for damage. components at this
inspect wire harness for any damage, pinched, cut or pierced time. Install SRS
wires. components only when
inspect connector(s) (including any in-line connectors) for directed to do so in the
pushed-out, loose or spread terminals and loose or frayed wire pinpoint test. GO to
connections at terminals. AA13 .
Refer to Wiring Diagrams Cell 5 , Connector Repair Procedures

for schematic and connector information.
Connect: OCSM C3159 (if disconnected previously).

Connect: Seat Pressure Sensor C3042 (if previously disconnected).
OCSM .
Enter the following diagnostic mode on the scan tool: DataLogger —
OCSM — View and Record All 2290 Fault PIDs.
Refer to PID list in Normal Operation to view 2290 fault PIDs.
Does the original on-demand 2290 fault PID indicate a fault or was
DTC C1941 retrieved on-demand during self-test?
AA13 CHECK FOR AN INTERMITTENT FAULT
OCSM . This fault cannot be
Enter the following diagnostic mode on the scan tool: DataLogger — cleared until it is corrected
OCSM — View and Record All 2290 Fault PIDs. and the DTC is no longer
Do any on-demand 2290 fault PIDs indicate a fault? retrieved on-demand
during self-test.
CHECK for causes of the

intermittent fault at or near
the affected SRS
component connector.
REPAIR any intermittent
wiring, terminal or
connector concerns
found.

and connector
information.
If an intermittent concern
was found and repaired,
GO to AA14 .
If an intermittent concern
was not found and
repaired, USE the fault
PIDs recorded and GO to
the appropriate pinpoint
test step.
Vehicles with a
production OCS system
For fault PID

2290_15_OD, GO to
AA3 .
For fault PID

2290_13_OD, GO to
AA10 .
For fault PID

2290_12_OD, GO to
AA11 .
Vehicles with an OCS

system service kit :
INSPECT the seat wiring

harness for damage and
REPAIR as needed.

and connector
information.
If OK, INSTALL a new

OCS system service kit.
REFER to Occupant
Classification Sensor in
No

intermittent fault.
ATTEMPT to recreate the
hard fault by flexing the
wire harness and cycling
the ignition frequently.
ACTIVATE other systems
in the same wire harness.
Do not install any new
SRS components at this
time. Install SRS
pinpoint test. GO to
AA14 .
AA14 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
Do not clear any DTCs
WARNING: Turn the ignition OFF and wait one minute to until all DTCs have been
If previously directed to depower the SRS , repower the SRS . Do not No
prove out the SRS at this time. Refer to Supplemental Restraint CLEAR all RCM and
System (SRS) Depowering and Repowering in this section. OCSM CMDTCs .
Ignition ON. PROVE OUT the SRS .
Enter the following diagnostic mode on the scan tool: Self Test — Repair is complete.
Restraints. RETURN the vehicle to
NOTE: When selecting Restraints from the Self Test menu, DTCs are the customer.
retrieved from the RCM and OCSM .
Are any RCM and/or OCSM DTCs retrieved on-demand during self
test?
Pinpoint Test AB: DTC B2909
Normal Operation
The Belt Tension Sensor (BTS) operates in conjunction with the Occupant Classification System (OCS) system.
The OCS system interprets a variable voltage signal provided by the BTS to identify the possible presence of a
child safety seat in the front passenger seat. The voltage output of the BTS is proportional to the amount of
tension applied to the sensor by the belt. No tension on the belt returns a low voltage (approximately 0.95 volt)
to the Occupant Classification System Module (OCSM), while high tension returns a higher voltage
(approximately 3.8 volts) to the OCSM .
The OCSM monitors the BTS and circuitry for faults. If a fault is detected, the OCSM stores DTC B2909 in
memory and sends a message to the Restraints Control Module (RCM). The RCM stores DTC B00A0:09 in
memory and sends a message to the Instrument Panel Cluster (IPC) to illuminate the air bag warning indicator.
Fault PIDs a Description Fault Trigger Condition

2909_29_OD and Front Passenger Side Belt Tension When the OCSM senses a short to ground on
2909_29_CM Sensor Short to Ground the BTS circuits, a fault is indicated.
2909_31_OD and Front Passenger Side Belt Tension When the OCSM senses a failure on the BTS
2909_31_CM Sensor Circuit Fault circuits, a fault is indicated.
2909_30_OD and Front Passenger Side Belt Tension When the OCSM senses an open on the BTS
2909_30_CM Sensor Circuit Open circuits, a fault is indicated.
2909_28_OD and Front Passenger Side Belt Tension When the OCSM senses a short to voltage on
2909_28_CM Sensor Circuit Short to Battery the BTS signal circuit, a fault is indicated.
a FaultPIDs that end in OD indicate on-demand status and are associated with DTC B2909. Fault PIDs that
end in CM indicate continuous memory status and are associated with DTC B2909.

BTS (part of RH front safety belt retractor)
OCSM
PINPOINT TEST AB: DTC B2909

AB1 RETRIEVE OCSM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test This fault cannot be cleared until
— OCSM . it is corrected and the DTC is no
Enter the following diagnostic mode on the scan tool: longer retrieved on-demand
DataLogger — OCSM — View and Record All 2909 Fault PIDs. during self-test.
Refer to PID list in Normal Operation to view 2909 fault
PIDs. For fault PID 2909_31_OD, GO
Do any on-demand 2909 fault PIDs indicate a fault? to AB2 .
For fault PID 2909_28_OD, GO

to AB8 .

to AB9 .

to AB10 .
No
present as a Continuous Memory
(CMDTC) only. GO to AB13 .
AB2 CHECK THE BTS CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit LR142 (YE/BU)
(SRS) Depowering and Repowering in this section. or RR142 (GN).
Disconnect: BTS C3238. Refer to Wiring Diagrams Cell 5 ,
Disconnect: OCSM C3159 (vehicles with an OE OCS system). Connector Repair Procedures for
Disconnect: Passenger Seat Harness C3007 (vehicles with an schematic and connector
OCS system service kit). information.
Refer to Supplemental Restraint System (SRS) Depowering GO to AB14 .
Ignition ON. No
Measure the voltage between BTS : GO to AB3 .
C3238-1, circuit RR142 (GN), harness side and ground.
C3238-3, circuit LR142 (YE/BU), harness side and
ground.
AB3 CHECK THE BTS CIRCUITS FOR AN OPEN
Ignition OFF. Yes
For vehicles with an OE OCS system, measure the resistance GO to AB4 .
between OCSM C3159, harness side and BTS C3238, harness
side using the following chart. No
REPAIR the affected circuit(s).
OCSM Circuit BTS
C3159-11 LR142 (YE/BU) C3238-3 Connector Repair Procedures for
C3159-12 RR142 (GN) C3238-1 schematic and connector
information.
C3159-13 VR210 (BU/BN) C3238-2
GO to AB14 .
For vehicles with an OCS system service kit, measure the

resistance between passenger seat harness C3007, main body
harness side and BTS C3238, harness side using the following
chart.
Passenger Seat Harness Circuit BTS

C3007-13 LR142 (YE/BU) C3238-3
C3007-14 RR142 (GN) C3238-1
C3007-12 VR210 (BU/BN) C3238-2
AB4 CHECK THE BTS VREF AND SIGNAL CIRCUIT FOR A
SHORT TO GROUND
Measure the resistance between BTS : Yes
C3238-1, circuit RR142 (GN), harness side and ground. GO to AB5 .
ground. No
REPAIR circuit LR142 (YE/BU)
or RR142 (GN).

information.
GO to AB14 .

AB5 CHECK FOR A SHORT BETWEEN BTS CIRCUITS
Measure the resistance between BTS : Yes
C3238-1, circuit RR142 (GN), harness side and C3238- GO to AB6 .
3, circuit LR142 (YE/BU), harness side.
C3238-1, circuit RR142 (GN), harness side and C3238- No
2, circuit VR210 (BU/BN), harness side. REPAIR the affected circuit(s).
C3238-2, circuit VR210 (BU/BN), harness side. Refer to Wiring Diagrams Cell 5 ,
information.
GO to AB14 .

AB6 CHECK THE OCSM OUTPUT
Prior to reconnecting any previously disconnected SRS Yes
component: GO to AB7 .
inspect connector(s) (including any in-line connectors)
for pushed-out, loose or spread terminals and loose or No
frayed wire connections at terminals. GO to AB12 .
pierced wires.

Connect: OCSM C3159 (vehicles with an OE OCS system).

Connect: Passenger Seat Harness C3007 (vehicles with an
OCS system service kit).
Ignition ON.
Measure the voltage between BTS C3238-3, circuit LR142
(YE/BU), harness side and C3238-1, circuit RR142 (GN),
harness side.
Is the voltage approximately 5 volts?

AB7 CHECK BTS VOLTAGE OUTPUT
Ignition OFF. Yes
Connect a fused jumper wire between BTS C3238-3, circuit REMOVE the fused jumper wires
LR142 (YE/BU), harness side and C3238 pin 3, component and GO to AB12 .
side.
Connect a fused jumper wire between BTS C3238-1, circuit No
RR142 (GN), harness side and C3238 pin 1, component side. REMOVE the fused jumper wires
Ignition ON. and INSTALL a new RH safety
Measure the voltage between BTS C3238 pin 3, component belt retractor assembly. REFER
side and ground as the tension of the BTS varies by pulling to Section 501-20A . GO to
upward at the safety belt webbing. AB14 .
Does the voltage vary from approximately 0.95 volt with no

tension applied to the sensor to approximately 3.8 volts
with full tension applied to the sensor?
AB8 CHECK THE BTS CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REPAIR circuit LR142 (YE/BU)
(SRS) Depowering and Repowering in this section. or RR142 (GN).
Disconnect: BTS C3238. Refer to Wiring Diagrams Cell 5 ,
Disconnect: OCSM C3159 (vehicles with an OE OCS system). Connector Repair Procedures for
Disconnect: Passenger Seat Harness C3007 (vehicles with an schematic and connector
OCS system service kit). information.
Refer to Supplemental Restraint System (SRS) Depowering GO to AB14 .
Ignition ON. No
Measure the voltage between BTS : GO to AB12 .
C3238-1, circuit RR142 (GN), harness side and ground.
ground.

AB9 CHECK THE BTS CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to AB11 .
Disconnect: BTS C3238. No
Disconnect: OCSM C3159 (vehicles with an OE OCS system). REPAIR the affected circuit(s).
Disconnect: Passenger Seat Harness C3007 (vehicles with an
OCS system service kit). Refer to Wiring Diagrams Cell 5 ,
For vehicles with an OE OCS system, measure the resistance Connector Repair Procedures for
between OCSM C3159, harness side and BTS C3238, harness schematic and connector
side using the following chart. information.
OCSM Circuit BTS GO to AB14 .

C3159-11 LR142 (YE/BU) C3238-3
C3159-12 RR142 (GN) C3238-1
C3159-13 VR210 (BU/BN) C3238-2
For vehicles with an OCS system service kit, measure the
resistance between passenger seat harness C3007, harness
side and BTS C3238, harness side using the following chart.
Passenger Seat Harness Circuit BTS

C3007-13 LR142 (YE/BU) C3238-3
C3007-14 RR142 (GN) C3238-1
C3007-12 VR210 (BU/BN) C3238-2

AB10 CHECK THE BTS CIRCUITS FOR A SHORT TO GROUND
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to AB11 .
Disconnect: BTS C3238. No
Disconnect: OCSM C3159 (vehicles with an OE OCS system). REPAIR circuit LR142 (YE/BU)
Disconnect: Passenger Seat Harness C3007 (vehicles with an or RR142 (GN).
Measure the resistance between BTS : Refer to Wiring Diagrams Cell 5 ,
C3238-1, circuit RR142 (GN), harness side and ground. Connector Repair Procedures for
C3238-3, circuit LR142 (YE/BU), harness side and schematic and connector
ground. information.
GO to AB14 .
AB11 CHECK THE OCSM OUTPUT
Disconnect: Passenger Seat Side Air Bag Module C337. Yes
Prior to reconnecting any previously disconnected component: GO to AB7 .
frayed wire connections at terminals. GO to AB12 .
pierced wires.

Connect: OCSM C3159 (vehicles with an OE OCS system).

Connect: Passenger Seat Harness C3007 (vehicles with an
Ignition ON.
Measure the voltage between BTS C3238-3, circuit LR142
(YE/BU), harness side and C3238-1, circuit RR142 (GN),
harness side.

AB12 CONFIRM THE OCS SYSTEM FAULT
NOTE: Make sure all OCS system components, SRS sensor Yes
electrical connectors and the RCM electrical connectors are INSTALL a new OCS system
connected before carrying out self-test. If not, DTCs will be service kit. REFER to Occupant
recorded. Classification Sensor in this
section. GO to AB14 .
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System No
(SRS) Depowering and Repowering in this section. In the process of diagnosing the
Prior to reconnecting any previously disconnected SRS fault, the fault condition has
component: become intermittent. Do not
inspect connector(s) (including any in-line connectors) install any new SRS
for pushed-out, loose or spread terminals and loose or components at this time.
frayed wire connections at terminals. Install SRS components only
inspect wire harness for any damage, pinched, cut or when directed to do so in the
pierced wires. pinpoint test. GO to AB13 .

Connect: BTS C3238.

Connect: OCSM C3159 (if previously disconnected) (vehicles
with an OE OCS system).
Connect: Passenger Seat Harness C3007 (if previously
disconnected) (vehicles with an OCS system service kit).
Ignition ON.
— OCSM .
DataLogger — OCSM — View and Record All 2909 Fault PIDs.
Refer to PID list in Normal Operation to view 2909 fault
PIDs.
Does the original on-demand 2909 fault PID indicate a
fault?
AB13 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Disconnect: BTS C3238. This is a hard fault. This fault
inspect connector(s) (including any in-line connectors) cannot be cleared until it is
for loose or spread terminals and loose or frayed wire corrected and the DTC is no
connections at terminals. longer retrieved on-demand
inspect wire harness for any damage, pinched, cut or during self-test.
pierced wires.
repair any concerns found. Using the on-demand fault PIDs
recorded, GO to the appropriate
Refer to Wiring Diagrams Cell 5 , Connector Repair pinpoint test step.
to AB2 .
Connect: BTS C3238.
Ignition ON. For fault PID 2909_28_OD, GO
Enter the following diagnostic mode on the scan tool: Self Test to AB8 .
— OCSM .
Enter the following diagnostic mode on the scan tool: For 2909_30_OD, GO to AB9 .
DataLogger — OCSM — View and Record All 2909 Fault PIDs.
Refer to PID list in Normal Operation to view 2909 fault For fault PID 2909_29_OD, GO
PIDs. to AB10 .
Do any on-demand 2909 fault PIDs indicate a fault?
No
intermittent fault. ATTEMPT to
recreate the hard fault by flexing
the wire harness and cycling the
ignition frequently. ACTIVATE
other systems in the same wire
harness. Do not install any new
SRS components at this time.
connector concerns found. GO to
AB14 .
AB14 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one minute DTCs have been resolved. GO to
to deplete the backup power supply. Failure to follow this the DTC Charts in this section for
instruction may result in serious personal injury or death pinpoint test direction.
in the event of an accidental deployment.
If previously directed to depower the SRS , repower the SRS . CLEAR all RCM and OCSM
Do not prove out the SRS at this time. Refer to Supplemental CMDTCs . PROVE OUT the
Restraint System (SRS) Depowering and Repowering in this SRS . Repair is complete.
section. RETURN the vehicle to the
Ignition ON. customer.
— Restraints.
NOTE: When selecting Restraints from the Self Test menu,
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing.
If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a
crash. Failure to follow this instruction may result in serious personal injury or death in a crash
and possibly violate vehicle safety standards.
NOTE: After diagnosing or repairing a Supplemental Restraint System (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various
combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs
affecting the SRS and safety belt system.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices have deployed and/or the Restraints
Control Module (RCM) has DTC B1231/B1193:00 (Event Threshold Exceeded) in memory, the
repair of the vehicle SRS is to include the removal of all deployed devices and the installation of
new deployable devices, the removal and installation of new impact sensors and the removal and
installation of a new RCM . DTCs must be cleared from all required modules after repairs are
carried out.
Vehicles with Occupant Classification System (OCS) system
2. NOTE: After installation of new Occupant Classification System (OCS) components, carry out the
Occupant Classification System (OCS) System Reset procedure as instructed in the workshop
manual. Refer to the appropriate workshop manual for OCS system removal and installation
procedure.
When a vehicle has been involved in a collision and the Occupant Classification System Module
(OCSM) has DTC B1231/B1193:00 stored in memory, the repair of the OCS system is to include
the following procedures for the specified system:
For rail-type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS system rails. Do not install a new OCSM unless DTC B1231
cannot be cleared.
For weight sensor bolt-type OCS system, inspect the passenger side floorpan for damage
and repair as necessary. Install a new seat track with OCS system weight sensor bolts.
DTC must be cleared from the OCSM before carrying out Occupant Classification System
(OCS) System Reset. Do not install a new OCSM unless DTC B1231/B1193:00 cannot be
cleared.
For bladder-type OCS system, inspect for damage and repair as necessary. If installation
of an OCS system component is required, an OCS system service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the
driver and/or front passenger safety belt pretensioners. For additional information, refer to Section
501-20A .
6. Inspect the entire vehicle for damage, including the following components:
Steering column (deployable column if equipped)
Instrument panel knee bolsters and mounting points
Instrument panel braces and brackets
Instrument panel and mounting points
Seats and seat mounting points
Safety belts, safety belt buckles and safety belt retractors. For additional information, refer
to Section 501-20A .
SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Pyrotechnic Device Disposal
Disposal of Deployable Devices and Pyrotechnic Devices That are Undeployed/Inoperative
NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the
Mandatory Return List. All discolored or damaged air bag modules must be treated the same as any
inoperative live air bag being returned.
1. Depower the Supplemental Restraint System (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures
2. Remove the undeployed/inoperative device. For additional information, refer to the appropriate
procedure in this section or Section 501-20A .
3. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the
replacement air bag module. The serial number for the new part and the Vehicle Identification
Number (VIN) must be recorded and sent to Ford Motor Company.
If installing a new air bag module, record the necessary information and return the inoperative air
bag module to Ford Motor Company.
Disposal of Deployable Devices and Pyrotechnic Devices That Are Deployed
Depowering and Repowering in the General Procedures portion of this section.
2. Remove the deployed device. For additional information, refer to the appropriate procedure in this
section or Section 501-20A .
3. NOTE: 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 module. To determine if a vehicle is equipped
with dual stage driver or passenger air bag modules, refer to the Description and Operation
Dispose of the deployed device in the same manner as any other part to be scrapped.
Disposal of Deployable Devices and Pyrotechnic Devices That Require Manual Deployment
1. Safety and environmental concerns require consideration and treatment of restraints system
deployable and pyrotechnic devices when disposing of vehicles, deployable devices or
pyrotechnic devices. Deploying deployable and pyrotechnic devices before scrapping a vehicle or
the device eliminates the potential for hazardous exposures or reactions during processing. If
special handling procedures are followed, deployable and pyrotechnic devices can be deployed
safely and recycled with the vehicle, shipped separately to a recycling facility or disposed of
safely.
NOTE: To determine the deployable devices a vehicle is equipped with, refer to the Description
and Operation portion of this section.
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.
Knee air bag module
Seat side air bag modules
Safety Canopy® modules
Side air curtain modules
2. NOTE: To determine the pyrotechnic devices a vehicle is equipped with, refer to the Description
and Operation portion of this section.
A vehicle equipped with any of the following pyrotechnic devices requires manual deployment of
the devices before scrapping the vehicle or component. For additional information, refer to the
appropriate portion of this procedure.
Safety belt buckle pretensioners
Safety belt retractor pretensioners
Adaptive load-limiting retractors
Deployable steering column
3. NOTE: To determine if a vehicle is equipped with dual stage driver or passenger air bag modules,
refer to Principles of Operation in the Diagnosis and Testing portion of this section.
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 module. For additional information, refer to Driver Air Bag
Module, Knee Air Bag Module, Passenger Air Bag Module and Seat Side Air Bag Modules —
Remote Deployment in this procedure.
Driver Air Bag Module, Knee Air Bag Module, Passenger Air Bag Module and Seat Side Air Bag
Modules — Remote Deployment
WARNING: Always carry or place a live air bag module with the air bag and deployment
door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down
with the deployment door/trim cover/tear seam face down. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
WARNING: Always carry or place a live Safety Canopy®, or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result
in serious personal injury or death in the event of an accidental deployment.
NOTE: For air bag modules with multiple loops, all the loops on the air bag module must be deployed.
NOTE: Some driver and passenger front air bags have 2 deployment stages. After a collision it is
possible that Stage 1 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 remotely
deployed using the appropriate air bag disposal procedure.
NOTE: A typical air bag disposal is shown that is similar for all vehicles.
All driver, knee, passenger and seat side air bag modules
1. Make a container to house the air bag module for deployment.

NOTE: The tires must be of sufficient size to accommodate the air bag module.
Obtain a tire and wheel assembly and an additional 4 tires (without wheels) of the same
size.
With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.
3. Remove the air bag module. For additional information, refer to the appropriate procedure in this
section.
4. NOTE: If the air bag module 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 air bag module.
Cut each of the air bag module wires near the electrical connector that connects to the vehicle
wire harness.
5. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires.
6. NOTE: Typical driver air bag module with 2 loops shown, other air bag modules with multiple
loops similar.
For air bag modules with multiple loops, twist together a wire from each loop then repeat for the
remaining wires from each loop.
7. Make a jumper harness to deploy the air bag module.

Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each
wire.
At one end of the jumper harness, connect the wires together.
8. Using the end of the jumper harness where 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 loops. 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 the bottom, carefully place the driver air bag
module, with the trim cover facing up, on the wheel.
Passenger, knee and seat side air bag modules
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.
11. Place the tire stack upright, with the wheel on top.
All driver, knee, passenger and seat side air bag modules
12. Remain at least 9.14 m (30 ft) away from the air bag module.
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.
14. Deploy the air bag module by touching the ends 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

NOTE: A typical safety belt buckle and retractor disposal is shown that is similar for all vehicles.
1. Make a container to house the safety belt buckle or retractor for deployment.
NOTE: The tires must be of sufficient size to accommodate the safety belt buckle or
retractor.
Obtain a tire and wheel assembly and an additional 4 tires (without wheels) of the same
size.
With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.
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.
4. NOTE: If the safety belt buckle or retractor 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 safety belt
buckle or retractor.
Cut each of the safety belt buckle or retractor wires near the electrical connector that connects to
the vehicle wire harness.
6. Make a jumper harness to deploy the safety belt buckle or retractor.
wire.
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 wires are not connected together, attach each wire
of the jumper harness to each wire of 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.
8. NOTE: Make sure to maintain the connections to the safety belt buckle or retractor.
Tip the stack of tires on its side and place the safety belt buckle or retractor inside the center tire,
making sure that there are 2 tires beneath the tire containing the safety belt buckle or retractor
and 2 tires (including the tire and wheel assembly) above the tire containing the safety belt buckle
or retractor.
9. Place the tire stack upright, with the wheel on top.

10. Remain at least 9.14 m (30 ft) away from the safety belt buckle or retractor.
11. From the end of the jumper harness that is not 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.
13. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt buckle
or retractor.
14. Dispose of the deployed safety belt buckle or retractor in the same manner as any other part to
be scrapped.
Safety Belt Buckle Pretensioners, Safety Belt Retractor Pretensioners and Load Limiting Safety
Belt Retractors — In-Vehicle Deployment

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 .
3. Cut each of the safety belt buckle or retractor wires, leaving at least 101.6 mm (4 in) to work with.
5. Make a jumper harness to deploy the safety belt buckle or retractor.

wire.
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 wires are not connected together, attach each wire
of the jumper harness to each wire of the safety belt buckle or retractor. Use tape or other
7. Remain at least 9.14 m (30 ft) away from the safety belt buckle or retractor.
8. From the end of the jumper harness that is not connected to the safety belt buckle or retractor,
9. 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.
10. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt buckle
or retractor.
11. Dispose of the deployed safety belt buckle or retractor in the same manner as any other part to
be scrapped.
Safety Canopy® Modules and Side Air Curtain Modules — In-Vehicle Deployment
NOTE: The Safety Canopy® or side air curtain module deployment for a scrapped vehicle will occur in
its installed position in the vehicle.
NOTE: A typical Safety Canopy® or side air curtain module disposal is shown that is similar for all
vehicles.
2. Access the Safety Canopy®/side air curtain module electrical connectors. For additional
information, refer to the appropriate procedure in this section.
3. Cut each of the Safety Canopy®/side air curtain module wires leaving at least 101.6 mm (4 in) to
work with.
5. NOTE: Typical Safety Canopy®/side air curtain module with 2 loops shown, other Safety
Canopy®/side air curtain modules with 2 loops are similar.
For Safety Canopy®/side air curtain modules with multiple loops, twist together a wire from each
loop then repeat for the remaining wires from each loop.
6. Make a jumper harness to deploy the Safety Canopy®/side air curtain module.
wire.
wire of the jumper harness to each wire of the Safety Canopy®/side air curtain module or to the
twisted-together wires if multiple loops. Use tape or other insulating material to make sure that the
leads do not make contact with each other.
8. From the end of the jumper harness that is not connected to the Safety Canopy®/side air curtain
module, disconnect the 2 wires of the jumper harness from each other.
9. Deploy the Safety Canopy®/side air curtain module by touching the ends of the 2 wires of the
jumper harness to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes 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
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.
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 101.6 mm (4 in) to work with.
5. Make a jumper harness to deploy the deployable steering column.

wire.
wire of the jumper harness to each wire of the deployable steering column. Use tape or other
7. Remain at least 9.14 m (30 ft) away from the deployable steering column.
8. From the end of the jumper harness that is not connected to the deployable steering column,
9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness
to the terminals of a 12-volt battery.
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.
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
WARNING: Always carry or place a live air bag module with the air bag and deployment
door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down
with the deployment door/trim cover/tear seam face down. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
restraints control module (RCM) while the RCM is connected and the ignition switch is ON.
Failure to follow this instruction may result in the accidental deployment of the Safety Canopy®
and cause serious personal injury or death.
WARNING: To reduce the risk of accidental deployment, do not use any memory saver
devices. Failure to follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse
is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before
releasing the vehicle to the customer.
1. Depower the Supplemental Restraint System (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures
2. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module in
this section.
3. Remove the knee air bag module. For additional information, refer to Knee Air Bag Module in this
section.

Open the glove compartment and carefully pry at each end to separate the glove
compartment from the hinges.
5. Pull up and out to release the clips and remove the upper center instrument panel finish panel.
6. Separate the center instrument panel finish panel.

1. Remove the 4 screws.
2. Pull out and separate the center instrument panel finish panel.
7. NOTICE: Do not pull the passenger air bag module electrical connectors out by the locking
button. Damage to the locking buttons can occur.
Disconnect both passenger air bag module electrical connectors.

Using a small screwdriver, lift up and release the locking button on the passenger air bag
module electrical connector. With the locking button released, disconnect the electrical
connector.
Repeat for the other electrical connector.
8. From under the rear of the RH front seat, disconnect side air bag module electrical connector
C337.
9. From under the rear of the LH front seat, disconnect side air bag module electrical connector
C367.
10. Drop the headliner to access the side air curtain module electrical connectors. For additional
information, refer to Section 501-05 .
11. Squeeze the tabs and disconnect the RH and LH side air curtain module electrical connectors.
12. Install RCM fuse 20 (10A) to the Central Junction Box (CJB).
13. Connect the battery ground cable.
Reactivation
1. Remove RCM fuse 20 (10A) from the CJB .
2. Disconnect the battery ground cable and wait at least one minute.
3. Connect the RH and LH side air curtain module electrical connectors.
5. From under the rear of the LH front seat, connect side air bag module electrical connector C367.
6. From under the rear of the RH front seat, connect side air bag module electrical connector C337.
7. NOTICE: The passenger air bag module electrical connector locking buttons must be in
the released position when connected. Do not install the passenger air bag module
electrical connectors by the locking buttons. Failure to follow these instructions may
cause connector damage.
With the locking button released, install the passenger air bag module electrical connectors fully
into the passenger air bag module and seat the locking buttons.
8. Install the center instrument panel finish panel.

1. Position the center instrument panel finish panel and push in seating the retaining clips.
2. Install the 4 screws.
9. Position the upper center instrument panel finish panel and push in seating the retaining clips.
10. Install the glove compartment.
11. Install the knee air bag module. For additional information, refer to Knee Air Bag Module in this
section.
12. Install the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
Special Tool(s)
Vehicle Communication Module (VCM)
and Integrated Diagnostic System
(IDS)
software with appropriate hardware, or
equivalent scan tool
Depowering Procedure
modules. Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners, adaptive load
limiting retractors, safety belt inflators, or probe the electrical connectors. Failure to follow this instruction
may result in the accidental deployment of the safety belt pretensioners, adaptive load limiting retractors, or
safety belt inflators, which increases the risk of serious personal injury or death.
WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure
to follow this instruction may result in serious personal injury or death.
1. Turn all vehicle accessories OFF.
2. Turn the ignition OFF.
3. At the Central Junction Box (CJB), located behind the glove box, remove RCM fuse 20 (10A) from the CJB .
For additional information, refer to the Wiring Diagrams manual.
4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air bag warning
indicator flashes once, then remains illuminated continuously (no flashing) if the correct RCM fuse has been
removed. If the air bag warning indicator does not remain illuminated continuously, remove the correct RCM
fuse before proceeding.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches.
Refer to the Description and Operation portion of Section 501-20B for location of the RCM and impact
sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section
414-01 .
Repowering Procedure
Vehicles with keyed ignition (vehicles with ignition switch)
1. Turn the ignition from OFF to ON.
2. Install RCM fuse 20 (10A) to the CJB .
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is connected. Failure to follow these instructions may result in
serious personal injury in the event of an accidental deployment.
Connect the battery ground cable.

Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back to ON and monitor the air bag
warning indicator with the air bag modules installed. The air bag warning indicator illuminates continuously for
approximately 6 seconds and then turns off. If a SRS fault is present, the air bag warning indicator indicates the
fault in one of the following ways:
- fail to light.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from OFF to ON.
This is the time required for the RCM to complete the testing of the SRS . If the air bag warning indicator is
inoperative and a SRS fault exists, a chime sounds in a pattern of 5 sets of 5 beeps. If this occurs, diagnose
and repair the air bag warning indicator and any SRS fault discovered.
Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan
tool.
Vehicles with Intelligent Access (IA) (vehicles with push button start system)
5. Install RCM fuse 20 (10A) to the CJB and install the cover.
6. Remove the Smart Keyless Ignition Relay ( CJB relay 7).

7. Install a fused (15A) jumper wire between Smart Keyless Entry Ignition Relay ( CJB relay 7) socket pins 3 and
5 as shown..
8. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is connected. Failure to follow these instructions may result in
Connect the battery ground cable.
9. Remove the fused jumper wire from the CJB .

10. Install the Smart Keyless Ignition Relay ( CJB relay 7).

With the ignition OFF, wait 10 seconds, then turn the ignition ON and monitor the air bag warning indicator with
the air bag modules installed. The air bag warning indicator illuminates continuously for approximately 6
seconds and then turns off. If an air bag SRS fault is detected, the air bag warning indicator indicates the fault
in one of the following ways:
- fail to light.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from OFF to ON.
This is the time required to complete testing of the SRS . If the air bag warning 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 diagnose and repair the
air bag warning indicator and any SRS fault discovered.
Clear all RCM and OCSM CMDTCs .
Clockspring
Part
1 W750985 Steering wheel bolt
2 3600 Steering wheel
3 3530 Upper steering column shroud
5 W701928 Steering column shroud bolt (2 required)
6 3530 Lower steering column shroud
7 13341 Switch assembly
8 3F791 Steering column multifunction switch
9 17A553 Switch assembly wiper/washer
10 3C529 Steering column
11 — Steering column lock bolt
12 11582 Ignition switch cylinder
13 15607 Passive Anti-Theft System (PATS) transceiver electrical
connector (part of 14401)
14 3F790 Ignition switch housing
15 66154 Ignition switch housing bolt (part of 3F790)
Removal
1. NOTICE: Make sure the road wheels are in the straight-ahead position to prevent damage to the
clockspring.
Remove the steering wheel. For additional information, refer to Section 211-04 .
2. Remove the steering column shroud. For additional information, refer to Section 211-04 .
3. Disconnect the clockspring electrical connectors, disengage the 3 retaining tabs and remove the
clockspring.
Installation
1. NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation key until the
steering wheel is installed. If the anti-rotation key has been removed before installing the
steering wheel, the clockspring must be centered. Failure to follow this instruction may result in
component damage and/or system failure.
Position the clockspring onto the steering column and engage the retaining tabs to the multi-function
switch.
2. Connect the clockspring electrical connectors.
3. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt,
repeat the centralizing procedure. Failure to follow these instructions may increase the risk of
NOTICE: Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected to
the clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its internal
connection. Failure to follow this instruction may result in component damage and/or system
failure.
If a new clockspring was installed and the anti-rotation key has not been removed proceed to Step 5.
If a new clockspring was installed and the anti-rotation key has been removed before the steering wheel
is installed or the same clockspring is being installed, rotate the clockspring inner rotor
counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance. Stop
rotating the clockspring inner rotor at this point.
4. Starting with the clockspring rotated fully counterclockwise as indicated in Step 3, rotate the clockspring
inner rotor, wiring and connector clockwise through 3.75 full revolutions with the connector ending up in
the 12 o'clock position.
Verify the clockspring is correctly centralized by observing that the clockspring rotor, wiring and
connector are in the 12 o'clock position.
5. Install the steering column shroud. For additional information, refer to Section 211-04 .
6. Install the steering wheel. For additional information, refer to Section 211-04 .
7. If a new clockspring was installed, remove the anti-rotation key.
8. Install the driver air bag module. For additional information, refer to Driver Air Bag Module in this section.
Driver Air Bag Module
Part
2 — Driver air bag module electrical connectors (2 required)
(part of 14A664)
3 — Horn switch electrical connector (part of 14A664)
4 — Driver air bag module locking pins (part of 43B13)
Removal
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim
cover/tear seam pointed away from the body. Do not set a live air bag module down with the
deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in
removed and the ignition switch is ON.
2. Insert a 3 mm (0.118 in) Allen wrench or a suitable tool into 1 of the access holes on the steering wheel
back cover.
3. Separate the driver air bag module from the steering wheel in the following sequence.
1. Position the tool against the wire clip.
2. Push the tool in, disengaging the wire clip from 1 of the driver air bag module locking pins.
It may be necessary to gently pull back on that side of the driver air bag module to release
it from the steering wheel.
3. Turn the steering wheel for access and repeat this step at all 3 steering wheel back cover
openings.
4. Remove the driver air bag module.

Disconnect the 2 driver air bag module and the horn switch electrical connectors.
Installation
1. Connect the 2 driver air bag module and the horn switch electrical connectors.
2. Align the driver air bag module locking pins to the steering wheel and, while pushing inward, seat the 3
driver air bag module locking pins to the steering wheel wire clips.
Front Impact Severity Sensor
NOTE: LH side shown, RH similar.

1 W700101 Front impact severity sensor nut
2 14B004 Front impact severity sensor
3 — Electrical connector (part of 14K012)
in a crash.
3. Remove the nut, disconnect the electrical connector and remove the front impact severity sensor.
4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
NOTE: Make sure the radiator support and front impact severity sensor and bracket assembly mating
surfaces are clean and free of foreign material.
Knee Air Bag Module
Part
1 54045J77 Knee air bag module
2 W701014 Knee air bag module nuts (2 required)
3 — Knee air bag module electrical connector (part of
14K024)
Removal
2. Remove the 2 nuts, pull out to release the clips and separate the knee air bag from the instrument panel.
3. NOTICE: Do not pull the knee air bag module electrical connector out by the locking button.
Damage to the locking button can occur.
Using a small screwdriver, lift up and release the locking button on the knee air bag module electrical
connector. With the locking button released, disconnect the electrical connector and remove the knee air
bag module.
Installation
1. NOTICE: Make sure the knee air bag module electrical connector locking button is in the released
position when connected. Do not install the knee air bag module electrical connector by the
locking button. Failure to follow these instructions may cause connector damage.
With the locking button released, install the knee air bag module electrical connector fully into the knee
air bag module and seat the locking button.
2. Position the knee air bag module to the instrument panel, push in and seat the retaining clips.
3. Install the 2 knee air bag module nuts.

Occupant Classification Sensor
Special Tool(s)
System (IDS)
Original Equipment Manufacturer (OEM) Occupant Classification System (OCS) System
Part
1 62900 Seat cushion cover
2 — Heater mat (part of Original Equipment Manufacturer
(OEM) Occupant Classification System (OCS)) (if
equipped)
3 — Cushion foam pad (part of OEM OCS )
4 — Pin-type retainers (2 required) (part of OEM OCS )
5 — OCS bladder and pressure sensor (part of OEM OCS )
6 61704 Seat track assembly
7 — Occupant Classification System Module (OCSM) (part of
OEM OCS )
8 — OCSM screws (2 required) (part of OEM OCS )
Service Kit Occupant Classification System (OCS) System
Part
1 62900 Seat cushion cover
2 — Heater mat (part of 632A22) (if equipped)
3 — Cushion foam pad (part of 632A22)
4 — Passenger seat wire harness (part of 632A22)
5 — Occupant Classification System Module (OCSM) (part
of 632A22)
6 — Pressure sensor (part of 632A22)
7 61704 Seat track assembly
8 — OCSM screws (part of 632A22)
Removal
WARNING: Make sure the front passenger seat repair is complete, the seat and all attached
components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly
installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may
result in incorrect operation of the occupant classification system (OCS) and increases the risk of
NOTICE: Carry out the Occupant Classification System (OCS) system reset when a front passenger
seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed.
Use a scan tool to carry out the OCS system reset. Failure to follow this instruction may result in
system failure and incorrect operation of the OCS system.
NOTE: Occupant Classification System (OCS) system components, seat cushion foam pad, bladder with
pressure sensor and Occupant Classification System Module (OCSM), are calibrated to each other and are
serviced as an assembly. If a new OCS system or OCS system component is needed, install a new OCS
system service kit.
NOTE: To identify between a production OCS system and a OCS system service kit, inspect the OCSM and
pressure sensor electrical connectors. An OCS system service kit has the electrical connectors glued and
should not be disconnected or altered.
NOTE: The heater mat is not serviced separately. If a new heater mat is needed on the front passenger seat
cushion, install a new OCS system service kit with a heater mat.
1. Remove the front passenger seat. For additional information, refer to Section 501-10 .
2. Remove the recliner handle bolt cover, the bolt and the recliner handle.

3. Slide the cushion side shield forward to disengage the brackets Remove the cushion side shield.
5. Detach the J-clip retainers.
6. Disengage the remaining cushion cover retainers attached to the seat track and seat cushion frame.
If Original Equipment Manufacturer (OEM) Occupant Classification System (OCS), remove the
cushion foam pad and cover.
7. Remove the Occupant Classification System Module (OCSM).

1. For OEM OCS , disconnect the electrical connector, if equipped.
2. Remove the 2 screws.
3. Release the tab and remove the OCSM .
8. Disengage the 2 retainers and slide the pressure sensor off the bracket.
9. NOTE: Note the wire routing for installation.
Disconnect all the seat cushion wire harness electrical connectors and detach the retainers.
10. For OEM OCS , lift the foam pad and remove the Occupant Classification System (OCS) bladder pin-
type retainers.
11. Route the OCS components out from between the cushion supports.
At installation, make sure the hose is not kinked.
12. Remove the hog rings and the cushion cover.
14. Repower the SRS . Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion
of this section.
15. WARNING: Occupant Classification System (OCS) parts are calibrated as an assembly and
must only be replaced in the configuration they are sold. Never separate parts of an assembly.
Failure to follow this instruction may result in incorrect operation of the OCS and increases the
Make sure the voltage to the Occupant Classification System Module (OCSM) is greater
than 8 volts and less than 18 volts.
Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F)
when initiating the OCS system reset process. If the vehicle has been exposed to extreme
cold or hot temperatures, the vehicle must be exposed and kept at a temperature between
6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes.
Make sure nothing is present on the passenger seat before and during the OCS system
reset process.
16. If the first system reset attempt was unsuccessful, carry out a thorough visual inspection of the following
and repair any concerns found.
OCS system connector and wiring for damage
Pressure sensor hose for kinks and/or damage
Seat-related wiring harness and body wiring harness terminals and connectors for damage
Carry out a second OCS system reset. If the second attempt is unsuccessful, install a new OCS system
service kit. For additional information, refer to Occupant Classification System in Section 501-20B .

Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON and
visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning
indicator will illuminate continuously for approximately 6 seconds and then turn off. If an air bag SRS
fault is present, the air bag warning indicator will:
- fail to light.
The air bag warning indicator may not illuminate until approximately 30 seconds after the ignition switch
has been turned from the OFF to the ON position. This is the time required for the RCM to complete the
testing of the SRS . If the air bag warning indicator is inoperative and a SRS fault exists, a chime sounds
in a pattern of 5 sets of 5 beeps. If this occurs, diagnose and repair the air bag warning indicator and any
SRS fault discovered.
Use a scan tool and clear all continuous DTCs from the RCM and Occupant Classification System
Module (OCSM).
Passenger Air Bag Deactivation (PAD) Indicator
Part
1 W707628 Front Controls Interface Module (FCIM) finish panel
screw (2 required)
2 W505142 FCIM finish panel screw (2 required)
3 5404320 FCIM finish panel
4 W715260 Passenger Air Bag Deactivation (PAD) indicator screw
(2 required)
5 10A936 PAD indicator

1. WARNING: Turn the ignition OFF and wait one minute to deplete the backup power supply.
Failure to follow this instruction may result in serious personal injury or death in the event of an
NOTE: A DTC sets in the Restraints Control Module (RCM) if the Passenger Air Bag Deactivation (PAD)
indicator electrical connector is disconnected with the ignition ON. Clear the RCM memory before
releasing the vehicle.
2. Pull up and out to release the clips and remove the upper panel finish panel.
3. Remove 4 screws, pull out and separate the Front Controls Interface Module (FCIM) finish panel.
4. Remove 2 screws, disconnect the electrical connector and remove the PAD indicator.

- fail to light.
Module (OCSM).

1 W702147 Passenger air bag module nuts (6 required)
2 044A74 Passenger air bag module assembly
3 045F38 Passenger air bag module bracket
4 W520101 Passenger air bag module bracket nuts (4 required)
5 — Electrical connectors (part of 14401)
Removal

Open the glove compartment and carefully pry at each end to separate the glove compartment
from the hinges.
3. Remove the nuts and the passenger air bag module bracket.
Detach the wire harness retainers.
4. Remove the nuts and separate the passenger air bag module.
Detach the wire harness retainers.
5. NOTICE: Do not pull the passenger air bag module electrical connectors out by the locking
button. Damage to the locking buttons can occur.
Using a small screwdriver, lift up and release the locking button on the passenger air bag module
electrical connector. With the locking button released, disconnect the electrical connector.
Repeat for the other electrical connector.
Remove the passenger air bag module.
Installation
1. Position the passenger air bag module into the instrument panel and install the nuts.
2. NOTICE: Make sure the passenger air bag module electrical connector locking buttons are in the
released position when connected. Do not install the passenger air bag module electrical
connectors by the locking buttons. Failure to follow these instructions may cause connector
damage.
With the locking button released, install the passenger air bag module electrical connectors fully into the
passenger air bag module and seat the locking buttons.
Attach the wire harness retainers.
3. Position the passenger air bag module bracket and install the nuts.
4. Install the glove compartment.
Restraints Control Module (RCM)
Special Tool(s)
System (IDS)

1 W707142 Restraints Control Module (RCM) nuts (3 required)
2 14B321 RCM
3 — RCM small electrical connector (part of 14K024)
4 — RCM large electrical connector (part of 14A005)
Removal
in a crash.
NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is
disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully
support 911 assist functionality.
1. When installing a new RCM , carry out the appropriate steps necessary for the Programmable Module
Installation (PMI) procedure. For additional information, refer to Section 418-01 .
3. Remove the floor console. For additional information, refer to Section 501-12 .
4. Slide the locking wedge back, press to release the locking tab and disconnect the small RCM electrical
connector.
5. Disconnect the large RCM electrical connector.

1. Pinch the thumb tab and pivot the Connector Position Assurance (CPA) lever all the way back
until it stops.
2. Pull out and disconnect the RCM electrical connector.
6. Remove the 3 nuts and the RCM .
Installation
Install the RCM and 3 nuts.

2. Make sure the CPA lever is in the full release position before attempting to connect the connector.
3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on
an angle can cause bad electrical connections and damage components.
Position the large RCM electrical connector into the RCM .

NOTICE: Do not push the connector to where the lever pivots and seats itself. Light
pressure is needed to get the connector into position on the Restraints Control Module
(RCM) before using the lever to fully seat the connector. Failure to follow this instruction
may result in component damage and/or system failure.
With the large RCM electrical connector uniformly aligned to the RCM , lightly push in until a
subtle audible click is heard and slight resistance is felt.
4. Connect the large RCM electrical connector.

Using the CPA lever, pivot it toward the RCM , drawing the connector into the RCM .
Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
5. Connect the small RCM electrical connector and push the locking wedge in.
6. Install the floor console. For additional information, refer to Section 501-12 .
7. Repower the SRS . Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion
of this section.
8. If a new RCM was installed, carry out the appropriate steps to complete the Programmable Module
Installation (PMI) procedure. For additional information, refer to Section 418-01 .

- fail to light.
Module (OCSM).
Side Air Curtain Module
4-Door Sedan

1 W505252 Side air curtain module bolt (9 required)
2 — Side air curtain module pin-type retainers (4 required)
(part of 042D94/95)
3 — Side air curtain module T-tab bracket (part of
042D94/95)
4 042D94/RH Side air curtain module
042D95/LH
5 — Side air curtain module electrical connector (part of
14A005)
5-Door Hatchback
1 W505252 Side air curtain module bolt (9 required)
2 — Side air curtain module pin-type retainers (4 required)
(part of 042D94/95)
3 — Side air curtain module T-tab bracket (part of
042D94/95)
4 042D94/RH Side air curtain module
042D95/LH
5 611D78/RH Side air curtain roof bracket
611D79/LH
6 W706681 Side air curtain roof bracket bolts
7 — Pin-type retainer (part of 611D78/79) (2 required)
8 — Side air curtain module electrical connector (part of
14A005)
WARNING: Always carry or place a live Safety Canopy®, or side air curtain module, with the module and
tear seam pointed away from your body. Failure to follow this instruction may result in serious personal
injury or death in the event of an accidental deployment.
WARNING: Anytime the Safety Canopy® or side air curtain module has deployed, a new headliner and
new A-, B- and C-pillar upper trim panels and attaching hardware must be installed. Remove any other
damaged components and hardware and install new components and hardware as needed. Failure to follow
these instructions may result in the Safety Canopy® or side air curtain module deploying incorrectly and
WARNING: Inspect a Safety Canopy® or side air curtain module before installation. If the module is
damaged, the cover has separated or the Safety Canopy® or side air curtain material has been exposed,
install a new module. Do not attempt to repair the module. Failure to follow these instructions may result in
the Safety Canopy® or side air curtain deploying incorrectly, which increases the risk of serious personal
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy® or side air
curtain module. Failure to follow this instruction may result in the Safety Canopy® or side air curtain module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy® module, side
air curtain module or interior trim panel. This will prevent the Safety Canopy® or side air curtain module from
deploying correctly. Failure to follow this instruction may increase the risk of serious personal injury or death
in a crash.
WARNING: Before installing a Safety Canopy® or side air curtain module, inspect the roofline for any
damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity.
Install new fasteners if damaged and remove foreign material. Failure to follow these instructions may result
in the Safety Canopy® or side air curtain deploying incorrectly, which increases the risk of serious personal
1. Remove the headliner. For additional information, refer to Section 501-05 .
2. Depower the SRS . For additional information, refer to Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of this section.
3. Squeeze the tabs and disconnect the side air curtain module electrical connector.
4. If equipped with a roof opening panel, remove the 2 bolts and the roof opening panel frame bracket.
5. Remove all the side air curtain module bolts.
6. Disengage all the side air curtain module pin-type retainers.
7. At all screw attachment points except the rear, lift and rotate the top of the bracket out of the roof sheet metal
slots.
For the rear bracket, pull rearward and rotate out of the roof sheet metal slot.
8. Slide the side air curtain module canister forward and disengage the T-tab bracket from the roof sheet metal
slot.
Remove the side air curtain module.
10. Repower the SRS . For additional information, refer to Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures portion of this section.
Seat Position Sensor
NOTE: Driver seat shown, passenger similar.
Part
1 14B416 Seat position sensor
2 — Seat position sensor lock tab (part of 14B416)
3 — Seat position sensor electrical connector (part of
14A698/RH 14A699/LH)
1. Position the seat all the way up (if equipped) and to the middle of the seat track.
2. WARNING: Turn the ignition OFF and wait one minute to deplete the backup power supply.
Failure to follow this instruction may result in serious personal injury or death in the event of an
3. From under the rear of the affected seat, remove the retaining clip, disconnect the electrical connector
and remove the seat position sensor.

- fail to light.
Module (OCSM).
Side Air Bag Module
NOTE: Driver side shown, passenger similar.
NOTE: For side air bag module nut torque specification and tightening sequence, refer to the step in this
procedure.

1 64416 Backrest cover and deployment chute
2 — Seat backrest assembly
3 611D11/LH 611D10/RH Side air bag module
4 W790242 Side air bag module nuts (2 required)
5 — Wire harness retainers (part of 611D10/11)
6 — Electrical connector (part of 611D10/11)
Removal
WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if
the air bag material has been exposed, install a new seat side air bag module. Never try to repair the
seat side air bag module. Failure to follow these instructions may result in the seat side air bag
deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
NOTE: If a side air bag deployment took place, install a new seat back pad, trim cover and side air bag module.
The seat backrest frame should be installed new if necessary.
NOTE: When installing a new side air bag module after a deployment, refer to Section 501-10 for additional
information concerning new side air bag module installation.
1. Remove the front seat from the vehicle. For additional information, refer to Section 501-10 .

Disconnect the side air bag module electrical connector and detach the wire harness retainer.
Disengage the 4 backrest cover elastic strap retainers attached to the bottom rear of the seat.
3. Detach the backrest cover retainers and the side air bag module wire harness retainer from the rear of
the backrest frame.
4. Invert the backrest cover up enough to expose the side air bag deployment chute.
5. Remove 1 rivet from the deployment chute J-clip retainers.

From the back of the rivet, push the rivet stud end in and pull the head out from the other side.
6. Slide the 2 deployment chute J-clip retainers apart.
7. Remove the 2 side air bag module nuts.
8. Remove the side air bag module in the following sequence:

1. Pull the side air bag module mounting studs back through the backrest frame.
2. Position the side air bag module away from the backrest frame.
3. Route out the wire harness.
Installation
Route the side air bag module wire harness through the backrest foam pad opening.
2. WARNING: Before installing the seat side air bag module/deployment chute assembly:
Inspect the side air bag module and mounting surfaces for any damage or foreign material.
Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam
pad.
Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly,
which increases the risk of serious personal injury or death in a crash.
Position the side air bag module studs through the backrest frame holes and install the nuts in the
sequence shown.
3. WARNING: Check the seat side air bag deployment chute for damage. The deployment
chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim
cover and deployment chute must be installed as a unit. Failure to follow these instructions may
result in the seat side air bag module deploying incorrectly and increase the risk of serious
personal injury or death in a crash.
WARNING: If the seat side air bag module deployment chute is not correctly positioned and
closed, the seat side air bag module may not deploy correctly. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increases the
Wrap the deployment chute around the side air bag module and backrest frame.
1. Position the outboard side of the air bag deployment chute around the outboard side of the
backrest frame and pad.
2. Insert the inboard side of the air bag deployment chute between the seat backrest frame and pad.
4. Engage the deployment chute J-clip retainers and install plastic rivets at the top and bottom of the J-clip
retainers.
5. Roll the backrest cover down around the backrest frame.
6. Attach the side air bag module wire harness to the backrest frame.
7. Attach the backrest cover retainers to the rear of the backrest frame.
8. Route, attach and connect the side air bag module wire harness.
9. Attach the 4 backrest cover elastic strap retainers to the bottom rear of the seat.
10. Install the front seat. For additional information, refer to Section 501-10 .
Side Impact Sensor — Front Door

1 14B345 Side impact sensor
2 W506964 Side impact sensor bolts
3 — Side impact sensor electrical connector (part of 14631)
in a crash.
3. Slide the locking wedge back and disconnect the side impact sensor electrical connector.
4. Remove the 2 bolts and the side impact sensor.

NOTE: Make sure the door sheet metal and side impact sensor mating surfaces are clean.
Side Impact Sensor — Second Row, 4-Door Sedan

1 5446808 RH / 5446809 LH Upper parcel shelf trim panel
2 5431012 RH / 5431013 LH Lower C-pillar trim panel
3 W505256 Side impact sensor bolt
in a crash.
2. Position the rear door opening weather-strip aside.
3. Pull to release the clips and position the upper parcel shelf trim panel aside.
4. Position the seat backrest down.
5. Position the lower C-pillar trim panel away enough to access the side impact sensor.
Pull to release the clips and locate the side impact sensor just below the quarter glass.
NOTE: Make sure the C-pillar and side impact sensor mating surface is clean and free of foreign
material.
Remove the bolt, disconnect the electrical connector and remove the side impact sensor.
Side Impact Sensor — Second Row, 5-Door Hatchback

1 5852018 RH / 5852019 LH Upper quarter trim panel
2 5431012 RH / 5431013 LH Lower C-pillar trim panel
3 W505256 Side impact sensor bolt
in a crash.
2. Position the door opening weather-strip aside.

3. Pull to release the clips and position the upper quarter trim panel aside.
4. Position the seat backrest down.
5. Position the lower C-pillar trim panel away enough to access the side impact sensor.
Pull to release the clips and locate the side impact sensor just below the quarter glass.
NOTE: Make sure the C-pillar and side impact sensor mating surface is clean and free of foreign
material.
Remove the bolt, disconnect the electrical connector and remove the side impact sensor.
SECTION 501-35: Body Repairs 2011 Fiesta Workshop Manual
Material
Capacity
Clear Silicone Rubber ESB-M4G92- —
TA-32 A
Metal Bonding Adhesive — —
TA-1
Motorcraft® Acid Neutralizer — —
ZC-1-A
Motorcraft® Alkaline Neutralizer — —
ZC-2-A
3M™ Perfect-It™ Show Car — —
Liquid Wax
39026
Motorcraft® Detail Wash — —
ZC-3-A
Motorcraft® Metal Surface Prep — —
ZC-31-A
Premium Undercoating — —
ValuGard™ VG101, VG101A
(aerosol)
Rust Inhibitor — —
(aerosol)
Plastic Bonding Adhesive — —
TA-9
Roof Ditch Sealer — —
Fusor® 122EZ or equivalent,
obtain locally
Seam Sealer — —
TA-2
Trim and Weatherstrip — —
Adhesive
Permatex® 81850 or equivalent
Motorcraft® Ultra-Clear Spray ESR-M14P5- —
Glass Cleaner A
ZC-23
General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015
General Specifications -Welding Specifications
Item Specification
Plug Weld Hole 8 mm (0.31 in)
Weld Wire ER70S-3 or equivalent 0.9-0.11 mm
(0.035-0.045 in)
Weld Nugget Chart

Test Thickness of Metal (mm) Nugget Size
0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7 4.3 mm (0.16 in)
0.7 + 3.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
Descriptions of Ford Steel Families

Typical
Grade Alloy Content Heat Treatment Applications Comments
Mild Steel, Bake Low Fully Body panels —
Hardened, Solid annealed/dead soft (closures, floor pan,
Solution dash panel)
Strengthened
High-Strength Low Low Fully Rails, structural Strengthened with
Alloy (HSLA) annealed/dead soft members fine particles and
small grain size
Dual Phase Medium Fully Rails, structural 15-50% of
(Manganese annealed/partially members structure is hard
Silicon, hardened martensite
Molybdenum
Chromium)
Ultra High Strength Low Fully hardened Rocker 100% of structure
Steel (UHSS) reinforcements, is hard martensite
(Martensitic, Boron) door beams,
bumper beams
Transformation High (Manganese, Fully annealed/ To be determined Complex
Induced Plasticity Phosphorous, partially hardened microstructure for
Steel Silicon, Aluminum) high strength and
ductility
Ford Recommended Steel Repairability Matrix

Welding Method
Squeeze-
Metal Type Resist-
Trade Inert ance Spot Use of Temp- Max-
Descrip- Gas Welding MIG Cold Heat for erature imum
Grade tions (MIG) (STRW) Braze Repairs Repair Range Heat
Mild Steel Mild Yes Yes NA Yes a Yes Up to 90
650°C sec. x
(1,200° 2
F)
Laminate Steel Quiet Steel No Yes No Yes a NA NA NA
Bake Hardened BH 180, Yes Yes Yes b Yes a Yes Up to 90
BH210, BH 650°C sec. x
250, BH (1,200° 2
280 F)
Solid Solution — Yes Yes Yes b Yes a Yes Up to 90
Strength- ened 650° C sec. x
(1,200° 2
F)
High- Strength HSLA 250, Yes Yes Yes b Yes a Yes Up to 90
Low Alloy (HSLA) HSLA 350, 650°C sec. x
HSLA 550 (1,200° 2
F)
Dual Phase = 600 DP 500, Yes Yes Yes b Yes a No NA NA
MPa Ultimate DP 600
Tensile Strength
Dual Phase = 600 DP 700, Yes d Yes Yes b No No NA NA
MPa Ultimate DP 780,
Tensile Strength DP 900
(particular to 780
and 980 grades) c
Ultra High Boron Yes a Yes Yes b No No NA NA
Strength Steel
(UHSS) (Martens-
itic, Boron) e
Transform- ation TRIP 590, NA NA NA NA NA NA NA
Induced Plasticity TRIP 780,
(TRIP) Steel TRIP 980
a Coldrepairs can be performed if damage excludes kinks. May section only if approved procedure in
workshop manual.
b MIG braze allowed for non-structural applications only.
c Dual phase steels DP 700, DP 780 and DP 980 must be replaced at factory joints, no sectioning unless
approved procedure in workshop manual.
d For DP 980, use MIG plug welding only, no stitch welding.
e Boron components must be replaced at factory joints, no sectioning allowed.
Body
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts
or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or
legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as
they may contain damage which is not visible.

air bags
crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out
by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural
component repair procedures approved by Ford, using genuine Ford parts, have been validated by
Ford Motor Company engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding
structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor
Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the
vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods
have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength,
quality, durability and corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using
alternative structural component repair procedures and/or parts.
The body consists of the following:
Four-door sedan
Five-door hatchback
Bolted, removable front fenders, hinged doors and hood
Steel roof panel constructed of mild steel
Steel hood constructed of dent-resistant steel
Steel fenders constructed of dent-resistant steel
Steel doors with outer door panels constructed of high-strength bake hardenable steel
Steel luggage compartment lid constructed of dent-resistant steel
Door panels on all models have sound deadener (mastic) applied
Mastic and sound deadener material applied to floor pan interior and exterior
Boron reinforced bolt-on front bumper beam
Boron reinforced bolt-on rear bumper beam
Front subframe assembly housing suspension and steering components
Front frame rail service kit is not available
Sound deadener mastic material used in roof panel, floor pan and door panels
For dimensional information, refer to the following illustrations:
Body Margins
NOTE: Dimensions apply to right and left side.
Item Description Margin Specification Flushness Specification

1 Hood to front fascia 6.0 mm (0.236 in) ± 1.5 mm (0.059 0.1 mm (0.003 in) ± 1.5 mm (0.059
in) in)
2 Headlamp assembly to 4.5 mm (0.177 in) ± 2.0 mm (0.078 —
fascia in)
3 Lamp assembly to hood 4.0 mm (0.157 in) ± 1.5 mm (0.059 1.4 mm (0.055 in) ± 1.5 mm (0.059
in) in)
4 Hood to fender 4.5 mm (0.177 in) ± 2.0 mm (0.07 —
in)
5 Headlamp assembly to 2.5 mm (0.098 in) ± 1.0 mm (0.03 1 mm (0.039 in) ± -0.8 mm (-0.031
fender in) in)
6 Fender to fascia 0.0 mm (0 in) ± 0.5 mm (0.019 in) 0.5 mm (0.019 in) ± 0.8 mm (0.031
in)
Body Margins — 4-Door Sedan

1 Headlamp to fender 2.5 mm (0.098 in) ± 1.0 mm (0.039 1.0 mm (0.039 in) ± -0.8 mm (-0.031
in) in)
2 Front fascia to fender 0.0 mm (0 in) ± 0.5 mm (0.019 in) 0.5 mm (0.019 in) ± 0.8 mm (0.031
in)
3 Fender to hood 4.5 mm (0.177 in) ± 2.0 mm (0.07 —
in)
4 Fender to front door 3.4 mm (0.133 in) ± 1.5 mm (0.05 1.0 mm (0.039 in) ± 1.0 mm (0.039
in) in)
5 Front door to body side 5.0 mm (0.196 in) ± 1.5 mm (0.059 6.1 mm (0.24 in) ± 1.5 mm (0.059 in)
in)
6 Front door to rear door 3.5 mm (0.137 in) ± 1.5 mm (0.059 0 mm ( in) ± 1.5 mm (0.059 in)
in)
7 Doors to rocker panel 5.9 mm (0.232 in) ± 1.5 mm (0.059 —
in)
8 Rear door to body side 4.8 mm (0.188 in) ± 1.5 mm (0.059 0 mm ( in) ± 1.5 mm (0.059 in)
(upper) in)
9 Rear door to body side 3.6 mm (0.141 in) ± 1.5 mm (0.059 0 mm ( in) ± 1.5 mm (0.059 in)
(lower) in)
10 Body side to rear fascia mm (0 in) ± 0.5 mm (0.019 in) 0.5 mm (0.019 in) ± 0.5 mm (0.019
in)
11 Deck lid to body side (side) 4.0 mm (0.157 in) ± 1.5 mm (0.019 1.5 mm (0.059 in) ± 2.0 mm (0.078
in) in)
12 Deck lid to rear fascia (side) 4.0 mm (0.157 in) ± 2.0 mm (0.078 -2.5 mm (-0.098 in) ± 1.5 mm (0.059
in) in)
13 Deck lid to rear fascia 6.0 mm (0.236 in) ± 2.0 mm (0.078 —
(lower) in)
Body Margins — 5-Door Hatchback

1 Fender to front door 3.4 mm (0.133 in) ± 1.5 mm (0.059 1.0 mm (0.039 in) ± 1.0 mm (0.039
in) in)
2 Front door to body side 5.0 mm (0.196 in) ± 1.5 mm (0.059 6.1 mm (0.24 in) ± 1.5 mm (0.059 in)
in)
3 Front door to rocker panel 5.9 mm (0.232 in) ± 1.5 mm (0.059 —
in)
4 Front door to rear door 3.5 mm (0.137 in) ± 1.5 mm (0.05 in) 0.0 mm ( in) ± 1.5 mm (0.059 in)
5 Rear door to body side 4.8 mm (0.188 in) ± 1.5 mm (0.059 0.0 mm ( in) ± 1.5 mm (0.059 in)
(top) in)
6 Rear door to rocker panel 6.0 mm (0.236 in) ± 1.5 mm (0.05 in) —
7 Rear door to body side 3.6 mm (0.141 in) ± 1.5 mm (0.059 0.0 mm ( in) ± 1.5 mm (0.059 in)
in)
8 Body side to tail lamp 2.0 mm (0.078 in) ± 1.0 mm (0.039 1 mm (0.039 in) ± 1.0 mm (0.039 in)
in)
9 Tail lamp to rear fascia 0.4 mm (0.078 in) ± 1.5 mm (0.059 2.0 mm (0.078 in) ± 2.0 mm (0.078
in) in)
10 Body side to rear fascia 0.0 mm (0 in) ± 0.5 mm (0.019 in) .5 mm (0.196 in) ± 1.0 mm (0.039 in)
11 Rear fascia to liftgate 4.2 mm (0.165 in) ± 1.5 mm (0.059 2.3 mm (0.09 in) ± 1.5 mm (0.059 in)
in)
Underhood Dimensions
NOTE: Measurements are obtained on center, unless otherwise indicated.
NOTE: Underhood dimensions shown in this illustration apply to all body styles.
Body Side Closure Dimensions
NOTE: 4-door sedan shown, 5-door hatchback the same.

1 A-pillar upper door hinge to B-pillar upper door hinge 1081 mm
2 A-pillar upper door hinge to front door striker upper bolt 1050 mm
3 A-pillar lower door hinge to rear door upper hinge 1135 mm
4 A-pillar lower door hinge to front door striker upper bolt 1055 mm
5 A-pillar upper door hinge to B-pillar lower door hinge 1115 mm
6 A-pillar lower door hinge to B-Pillar lower door hinge 1042 mm
7 B-pillar upper door hinge to rear door striker upper bolt 910 mm
8 B-pillar lower door hinge to rear door striker upper bolt 1048 mm
Rear Opening Dimensions
4-Door Sedan

5-Door Hatchback

Underbody Dimensions
Datum Height — Front Structure
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if
damaged. Straighten damaged frame rails to correct frame dimensions prior to frame member
sectioning. Failure to follow these instructions may adversely affect frame rail performance and may
result in serious personal injury to vehicle occupant(s).
NOTE: A structural frame rail sectioning kit is not available. Frame rails must be replaced at factory seams.
Datum Height — 4-Door Sedan
Datum Height — 5-Door Hatchback
Underbody Dimensions — 4-Door Sedan
NOTE: A structural frame rail sectioning kit is not available for the front frame rail section. Frame rails must be
replaced at factory seams. It is mandatory to maintain factory body dimensions when carrying out any repair
procedure to the frame rails. Refer to Frame Members — Front in this section.

Underbody Dimensions — 5-Door Hatchback
NOTE: A structural frame rail sectioning kit is not available for the front frame rail section. Frame rails must be
replaced at factory seams. It is mandatory to maintain factory body dimensions when carrying out any repair
procedure to the frame rails. Refer to Frame Members — Front in this section.

Welding Precautions — Steel
Material
Item Specification
Motorcraft Premium Undercoating PM-25-A (or equivalent) —
Motorcraft Rust Inhibitor Aerosol PM-24-A (or equivalent) —
General Equipment
Weld Nugget Chart

Test Thickness of Metal (mm) Nugget Size
0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7 4.3 mm (0.16 in)
0.7 + 3.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
Item Specification
Plug weld hole 8 mm (0.31 in)
Weld wire ER70S-3 or equivalent 0.9-1.1 mm
(0.035-0.045 in)
The correct equipment and settings must be used when welding mild or high-strength steel. Metal Inert
Gas (MIG) and Squeeze-Type Resistance Spot Welding (STRW) are the preferred methods. Surfaces
must be clean and free of foreign materials.
Correct eye protection must be worn.

The correct protective clothing should always be worn.
Adequate ventilation must be provided to avoid accumulation of poisonous gases.
A test weld should always be carried out on a test sample.
Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being
welded.
Follow equipment manufacturer's prescribed procedures and equipment settings for the type of
welder being used. ER70S-3 or ER70S-6 wire are typically used for MIG welding steel.
Disconnect the battery ground cable. Refer to Section 414-01 .
Disconnect on-vehicle modules and protect them from possible heat damage and electrical
currents when welding.
Corrosion protection must be restored whenever bare metal repairs are made. Refer to Restoring
Corrosion Protection Following Repair in this section.
Adequate power supply needs to be used to make sure of correct equipment performance.
Factory spot welds may be substituted with either STRW 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.
Vehicles equipped with optional safety canopy require removal of these components prior to any
welding procedures being carried out in the roof-line or body side areas of the vehicle. Refer to
Section 501-20B .
Sealers
Material
Item Specification
Seam Sealer TA-2 —
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious personal injury.
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:
Seam Sealer — Heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed
seams, tooled door skin seams and floor pans.
Sealers should remain flexible after curing and must be paintable. Follow the manufacturer's 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.
Hood Sealer
Floor Sealer
NOTE: RH side shown. LH side removed for clarity.
Roof Sealer
Front Door Sealer
Rear Door Sealer
Deck Lid Sealer — 4-Door Sedan

Deck Lid Sealer — 5-Door Hatchback
Sound Deadeners and Insulators
NOTICE: Mastic is made of a combustible material and should be removed prior to carrying out welding
procedures to the area. Heat zones from welding near the mastic may cause the mastic material to
burn.
NOTICE: Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products may be wax based and loss of adhesion may occur.
NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be
installed with the correct service replacement component.
Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly cleaned to
make sure correct adhesion will occur. The surface should be 10°C (50°F) or greater before applying the
mastic. The use of a heat gun to warm the metal surface will aid in adhesion.
NOTE: Noise, Vibration and Harshness (NVH) pads are obtained locally.
NVH Pads — Floor
NVH Pads — Roof

NVH Foam — Roof Bows
NVH Pad — Front Door

NVH Pad — Rear Door
Plastic Components
NOTE: The following illustration(s) are not all-inclusive of trim levels available. The actual trim level of the
vehicle will determine the viability of carrying out a plastic repair.
Exterior Plastics — Painted, 4-Door Sedan
Part
1 17D957 Front bumper fascia — Thermoplastic Olefin (TPO)
2 5444210 Decklid spoiler — Acrylonitrile Butadiene Styrene
(ABS)
3 17K835 Rear bumper fascia — TPO
Exterior Plastics — Painted, 5-Door Hatchback

1 17D957 Front bumper fascia — TPO
2 17K835 Rear bumper fascia — TPO
3 5844210 Rear spoiler — ABS
Several considerations will determine viability of plastic repair procedure(s):
Is the damage cosmetic or structural?

Can the repair be carried out on the vehicle?
Is the part readily available?
Is component repair the most cost effective method?
Can the component be economically restored to original strength and appearance?
Will the repair provide for the fastest, highest quality repair?
Several types of plastic are in use for automotive application. However, all plastics will fall into 2 primary
categories of thermoplastic or thermosetting plastic.
Thermosetting Plastic
Generally, thermosetting plastics are made with 2-part thermosetting resins. When mixed together, heat is
generated, producing a cure that is irreversible. Because of this, thermosetting plastics will require the use of a
2-part adhesive for repair.
Sheet-Molded Composite (SMC)
Sheet-Molded Composite (SMC) is a type of thermosetting plastic that uses glass fibers or nylon fibers in
combination with thermosetting polyester resins. When fully cured, SMC is strong and rigid.
SMC is similar, but not identical, to fiberglass. Ford Motor Company uses SMC in components such as fenders,
hoods and liftgates.
Thermoplastic Compounds
Thermoplastic compounds are manufactured by a process that is reversible. Thermoplastics can be remolded
repeatedly by reheating. This characteristic of thermoplastics makes plastic welding a possible repair
alternative. A repair of thermoplastic compounds is still possible through the use of 2-part adhesive and filler
repair materials and reinforcements as needed. Thermoplastics are widely used in interior trim components,
wheel flares, body side cladding and bumper covers.
Polyolefin
Polyolefins fall into the family of thermoplastics with one unique characteristic: an oily or waxy feel to the
material when sanded or ground. Polyolefin lends itself very well to remolding through the use of heat. Because
of this, components made of this material lend themselves well to the possibility of plastic welding. Most
adhesive repair materials and paint will not bond to surface of a polyolefin unless an adhesion promoter
specially formulated for plastic is first applied to the exposed raw surface. Otherwise, polyolefins are repaired
like most other thermoplastics. Some typical uses of polyolefins are bumper covers, fan shrouds and wheel
housings.
Correct identification of the various types of plastic is necessary to select the appropriate repair method(s) to
carry out high quality plastic repairs. Refer to Plastics Identification in this section.
Adhesives
Material
Item Specification
Metal Bonding Adhesive TA-1 —
Motorcraft Metal Surface Prep ZC-31-A —
Plastic Bonding Adhesive TA-9 —
Trim and Weatherstrip Adhesive TA-14-A —
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
Structural Adhesives
Adhesives are used in a variety of applications. Typical uses for adhesives include roof panels, door skins and
quarter panels. Trim applications include body side mouldings, emblems, stationary glass and weatherstripping.
Combination sealer/adhesives are also used. Surface preparation is critical to a high quality repair. Following
the label instructions for the product is essential.
Work in a well-ventilated area and protect adjacent surfaces when working with adhesives. Carry 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.
Trim and Weatherstrip Adhesive — For use on body side moulding, emblems, trim, bumper impact strips
and carpeting.
NOTE: Ford Motor Company does not approve or recognize structural repair procedures using anything but
genuine Ford parts.
Structural repairs (frames, rails, aprons and body panels) carried out using other than Ford Motor Company
parts have not been tested. In addition, structural equivalence and corrosion protection cannot be assured.
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled
technicians using genuine Ford Motor Company parts and approved methods.
Structural component repair procedures approved by Ford using genuine parts have been validated through
testing by Ford Motor Company engineers. Should alternative structural component repair procedures and/or
parts be used, repairers should be aware of the potential liability they incur.
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.
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (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.
Hood Adhesive
Front Door Adhesive

Rear Door Adhesive
Roof Ditch Adhesive
Deck Lid Adhesive — 4-Door Sedan

Deck Lid Adhesive — 5-Door Hatchback
Sectioning Guidelines
General Equipment
Material
Item Specification
Premium Undercoating —
(aerosol)
Rust Inhibitor —
(aerosol)
Seam Sealer —
TA-2
4-Door Sedan

1 54211A10 (RH)/ 54211A11 (LH) Door frame — mild steel
2 5427840 (RH)/ 5427841 (LH) Body side panel — mild steel
3 54280B62 Outer air vent grille
5-Door Hatchback

1 58211A10 (RH)/ 58211A11 (LH) Door frame — mild steel
2 5827840 (RH)/ 5827841 (LH) Body side panel — mild steel
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes
and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct
density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest
shade providing adequate visibility are recommended. It is strongly recommended that persons
working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow
WARNING: Do not carry out body side sectioning repairs in areas of laser welds. Factory laser
welds cannot be duplicated with conventional welding equipment and structural integrity may be
compromised. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect
operation of restraint devices. For additional restraints anchoring location information, refer to Section
501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise
structural integrity during a collision. Failure to follow these instructions may result in serious injury to
sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy®
module and related components. Failure to comply may result in accidental deployment or damage to
the Safety Canopy®. Refer to Section 501-20B . Failure to follow these instructions may result in
serious injury to technician or vehicle occupant(s).

air bags
crash sensors
1. NOTE: Observe prescribed welding procedures when carrying out repairs. 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.
Detrim the vehicle as necessary and drill out the spot welds from the damaged area. Using an air chisel
or reciprocating saw, cut off the portion of the panel to be replaced.
2. Where possible, create a backer piece using a portion of the old panel. This will create a stronger joint.
3. When welding overlapping surfaces or substrates, apply a high quality weld-through primer between the
surfaces prior to welding.
Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture
intrusion. Water and moisture migrate to horizontal joints and corrosion tends to occur more
rapidly in these areas. Metal surfaces must be clean and dry before applying seam sealer.
4. Proceed with refinish procedures following Ford-approved paint guidelines.
5. Apply corrosion protection as necessary to repair area.

Restoring Corrosion Protection Following Repair
Special Tool(s)
Rust Inhibitor Installation Kit
286-00002
Undercoating Spray Gun

286-00001
Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
ValuGard™ VG101, VG101A (aerosol)
Rust Inhibitor —
ValuGard™ VG104, VG104A (aerosol)
protective equipment as directed. Examples may include but are not limited to respirators and chemically
resistant gloves. Failure to follow these instructions may result in serious personal injury.
WARNING: Always wear protective equipment including eye protection with side shields, and a dust
mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
NOTICE: Drilling access holes in body panels is not recommended. Drilling holes will break the original paint
finish and promote corrosion.
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.
NOTE: Refer to product label for preparation and handling instructions.
1. The surfaces must be free of oil, dirt and other foreign material. Carry out the process in the following
sequence.
1. Thoroughly clean and degrease metal surfaces using metal surface prep to remove wax and grease.
2. For best results, the vehicle should be at room temperature. Attach the rust inhibitor canister to the Rust
Inhibitor Installation Kit 286-00002.
3. Rust inhibitor should be applied after the welding and refinishing process. Product cannot be welded
through.
4. Air pressure setting for applicator gun is 448-517 kPa (65-75 psi).
Use the long wand when spraying enclosed areas. The spray nozzle provides a 360-degree spray
pattern. Insert the wand as far as possible into the access hole, pull the trigger and wait 2-3
seconds and slowly pull the wand out of the access hole.
The short, hook-shaped wand sprays in one direction and must be rotated to provide complete
coverage.
Apply the material in light mist coats.
Material displaces moisture.
5. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
NOTE: The following illustrations provide typical applications of body seams and spot welded flanges and are not
vehicle specific.
2. NOTE: Door assembly lower view.
Apply rust inhibitor as shown to the inside of the door shell on all the interior metal surfaces using the most
suitable applicator wand. Apply material to the exposed edges after carrying out the welding process. Make
sure horizontal surfaces are well protected as they are more susceptible to corrosion. Keep door drain holes
clear to prevent moisture buildup.
3. NOTE: Quarter panel inner view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short, hook-shaped
wand. Apply material to the exposed edges after carrying out the welding process. Make sure horizontal
surfaces are well protected as they are more susceptible to corrosion.
4. NOTE: Door frame opening view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short, hook-shaped
wand. Make sure horizontal surfaces are well protected as they are more susceptible to corrosion.
Body and Frame Undercoating
1. WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
WARNING: Always wear protective equipment including eye protection with side shields, and a
dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal
injury.
NOTICE: Do not allow undercoating on powertrain components. Failure to follow these instructions
may result in incorrect operation of these components.
NOTE: Refer to product label for preparation and handling instructions.
NOTE: Avoid high-pressure water spray cleaning to treated underbody area for 24 hours.
Wire brush the area and make sure the surfaces are free of oil, dirt and other foreign material. Carry out the
undercoating process in the following sequence.
1. Thoroughly clean and degrease metal surfaces using metal surface prep to remove wax and grease.
2. For best results, the vehicle should be at room temperature.
Canister attaches directly to the dispensing gun. Attach the undercoating canister to the
Undercoating Spray Gun 286-00001.
3. Undercoat should be applied after the welding and refinishing process. Product cannot be welded
through.
4. Air pressure setting for applicator gun is 552-621 kPa (80-90 psi).
Apply light mist coats, applicator sprays in fogging pattern.
Material displaces moisture.
5. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
NOTE: The following illustrations provide typical applications to frame rails and are not vehicle specific.
2. NOTE: Frame rail exterior spot-weld flange view.
Apply undercoat material to the exterior exposed edges after carrying out the welding and refinishing process.
3. NOTE: Cross section view of typical unibody frame rail shown.
Apply rust inhibitor to the inner surfaces of the rail after carrying out welding process. Use the long wand and
insert as far as possible, depress trigger and wait 2-3 seconds and slowly pull the wand to make sure the area
is completely fogged.
4. NOTE: Full frame vehicle, front rail-to-mid rail section repair shown.
Apply undercoat material to the exposed surfaces after carrying out the welding process. Make sure to
completely cover any bare metal areas.
Refinishing — Environmental Damage
Material
Item Specification
Motorcraft® Acid Neutralizer —
ZC-1-A
Motorcraft® Alkaline Neutralizer —
ZC-2-A
3M™ Perfect-It™ Show Car Liquid —
Wax
39026
Motorcraft® Detail Wash —
ZC-3-A
Iron Oxide (Rail Dust) or Acid Rain Decontamination
personal injury.
NOTICE: In extreme cases of contamination, the vehicle may require refinishing. To avoid paint
failure, follow the appropriate decontamination procedure prior to carrying out any panel
refinishing procedure.
NOTE: Iron oxide contamination appears as tiny rust spots on horizontal surfaces and in severe cases
can be felt. This damage is typically caused from rail shipment, storage near railroad tracks or fallout
from industrial manufacturing facilities.
NOTE: Acid rain contamination can be identified as water spotting and, in severe cases, staining within
the water spots.
1. NOTICE: Never paint over iron particles as rust spots will reoccur. Use only the
recommended decontamination procedure detailed below.
Rinse any dust, dirt and foreign material from the vehicle body with cold water. Flush liberally.
2. Prepare the acid neutralizer by mixing 8 parts of water to 1 part neutralizer in a bucket.
3. NOTICE: To avoid paint failure, 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.
5. Dry only the horizontal surfaces of the vehicle, do not dry the glass at this time.
6. NOTICE: To avoid damage to the paint surface, do not apply the alkaline neutralizer
directly to the vehicle plastic trim.
NOTE: Use a separate wash mitt for each product applied to the vehicle.
NOTE: Alkaline neutralizer is a ready-to-use product. Do not mix with water.
Pour the alkaline neutralizer into a squirt bottle and apply the solution to a clean wash mitt.
7. NOTICE: To avoid paint failure, do not allow the alkaline neutralizer to dry on the vehicle.
Apply the product to the vehicle keeping the solution wet and lightly agitate for 5 to 7 minutes. For
severe conditions, work the product for up to 8 minutes.
8. Rinse the vehicle completely with cold water to remove the product.
9. Prepare the detail wash by mixing 29.5 ml (1 oz) with 3.78L (1 gal) of water.
10. Using a clean wash mitt, shampoo the entire vehicle and rinse with cold water. Dry the vehicle
completely.
11. Visually inspect the paint surface for any remaining evidence of ferrous metal particles. Repeat
procedure as necessary.
Surface Finishing Following Decontamination
1. NOTICE: When attempting to affect a repair by buffing, polishing or color sanding, do not
remove an excess of 0.3 mil of paint film or refinishing will be required.
NOTE: Acid rain discoloring or etching may require color sanding in addition to buffing and
polishing. In extreme cases, refinishing may be required if the following procedure does not
restore the vehicle finish.
NOTE: Do not intermix buffing products. Use only one manufacturer's product.
NOTE: Always follow the manufacturer's 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.
2. Apply machine glaze to the vehicle surface as recommended by the product manufacturer.
3. Use an alcohol and water mixture (1 to 1) to clean the buffed and polished areas. Verify removal
of scratches and swirls before the application of the final polish.
4. Apply a final polish material by hand, with a dual-action sander and foam pad, or with an orbital
polisher and appropriate polishing bonnet.
5. Wash and dry the vehicle.

Refinishing — Manufacturing Damage
Material
Item Specification
3M™ Perfect-It™ Show Car Liquid —
Wax
39026
Motorcraft® Detail Wash —
ZC-3-A
personal injury.
NOTICE: To avoid overspray damage to adjacent panels, protect adjacent areas/substrates when
preparing for and during refinishing.
NOTE: Peeling/delamination concerns can be described as lack of adhesion, either between the
substrate and topcoats or between individual coats of paint.
1. Wash the repair area with detail wash or pH-neutral soap and water.
2. Remove any trim, emblems and hardware from the area to be repaired.
3. NOTE: All delamination must be removed.
Sand or media blast the damaged surface, keeping the repair area as minimal as possible.
4. Treat any bare metal surface to prevent flash corrosion, and prime and block sand as necessary
prior to refinishing.
5. Mask the adjacent panels to protect from overspray.
6. Spot repair the base coat as necessary, following the paint manufacturer's prescribed procedures.
7. Following the paint manufacturer's prescribed procedure, apply clear coat to the entire panel.
Weld-Bonding
General Equipment
Material
Item Specification
Metal Bonding Adhesive —
TA-1
ZC-31-A
Rust Inhibitor —
(aerosol)
Seam Sealer —
TA-2
Weld-Bonding — Squeeze-Type Resistance Spot Welding (STRW) Method
personal injury.

air bags
crash sensors
NOTE: On door shells that are manufactured with structural adhesives only, weld bonding door skins is
not recommended. Only metal bonding adhesive should be used.
NOTE: Weld-bonding is a method used to join metals using Squeeze-Type Resistance Spot Welding
(STRW) or Metal Inert Gas (MIG) welding and structural adhesive. The steps listed in this procedure
apply to both types of welding. STRW is the preferred method. MIG welding should only be used when
areas to be welded cannot be accessed using STRW -type machinery.
NOTE: Factory spot welds should 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
1. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
2. Remove damaged panels with an air saw or air chisel. Remove only large portions of the
damaged panel. Avoid cutting into mating flanges or adjacent parts.
3. Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining portions
of the panel to be replaced.
4. Prepare any damaged flanges on the vehicle using hammer and dolly.
5. Grind the mating surface of the original flanges no greater than 25 mm (0.98 in) where the metal
bonding adhesive will be applied.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
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 only where the spot welds are to be placed. Clean
surfaces with metal surface prep or equivalent.
6. Dry-fit and clamp the replacement service parts to verify a correct fit.
Remove the service part after verifying correct fit and alignment.
7. NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material
when welding is carried out.
Follow manufacturer's prescribed welding procedures and settings. For additional information,
8. Prepare the adhesive. Dispense a small amount of metal bonding adhesive from the cartridge to
make sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip
length of adhesive to make sure of a correct mix ratio.
9. NOTE: Welding can be carried out anytime during the adhesive curing process, or after the
adhesive is fully cured. Welder settings will vary when welding through wet adhesive versus
welding through fully cured adhesive. Refer to welder manufacturer's recommended settings for
welding through fully cured adhesive. It is recommended to place a shunt weld in an area with no
adhesive to make sure of conductivity, particularly when welding through fully cured adhesive.
NOTE: Refer to the product label for handling and preparation instructions.
Create a test sample.

1. Prepare the metal and adhesive as described. Apply a 6-9 mm (0.23-0.35 in) bead of
adhesive and weld the sample.
2. Place the welded sample in a vice and carry out destructive weld tests by peeling the scrap
metal apart using large lock-type pliers. Measure the weld nugget to determine that the
nugget meets Ford weld nugget requirements. If the weld nugget does not meet required
size, adjust welder settings until the correct weld nugget size is achieved.
3. When the correct weld nugget size is achieved, the service part can be weld-bonded. For
additional information, refer to the weld nugget table in Specifications in this section.
10. Apply a 6-9 mm (0.23-0.35 in) bead of metal bonding adhesive to the vehicle prepared flange
surface.
11. Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.
12. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping
the component.
13. NOTE: Refer to product label for cure times and handling instructions. Clamps may be removed
immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
14. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply
conventional body filler after the adhesive cures and block-sand the area.
15. Use seam sealer wherever a cosmetic seam sealer is required.
16. Mix and apply primer surfacer per Ford-approved paint recommendations.
17. Mix and apply basecoat per Ford-approved paint recommendations.
18. Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
19. Apply anti-corrosion treatment to the repair area as required. For additional information, refer to
Restoring Corrosion Protection Following Repair in this section.
Weld-Bonding — Metal Inert Gas (MIG) Welding Method

air bags
crash sensors
personal injury.
NOTE: Metal Inert Gas (MIG) weld-bonding can be substituted as an alternative to Squeeze-Type
Resistance Spot Welding (STRW). It may only be used to weld areas that are inaccessible to STRW
machinery. However, when accessible, STRW is the preferred method.
NOTE: On door shells that are manufactured with structural adhesives only, weld-bonding door skins is
not recommended. Only metal bonding adhesive should be used.
NOTE: Factory spot welds should be substituted with either resistance spot welds or MIG plug welds.
1. Remove damaged panels with an air saw or air chisel. Remove only large portions of the
damaged panel. Avoid cutting into mating flanges or adjacent parts.
Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining
portions of the panel to be replaced.
2. After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle
using a hammer and dolly.
3. Using an appropriate grinder, carefully grind around the entire receiving flange area following the
original welds. Be sure to remove all E-coat, paint or galvanized coating from the mating surfaces
of the joint.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
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 only where the spot welds are to be placed. Clean the
surface with metal surface prep or equivalent.
4. Repeat the procedure from Step 3 on the mating surface of the replacement service part(s).
5. Prepare the new service panel for plug welds.

Using the original panel as a reference, drill or punch 8 mm (0.31 in) diameter holes in the
exact number as the original spot welds. The holes should be positioned as close as
possible to the original spot weld locations, without lining up exactly on top of an original
spot weld site.
To make sure of correct weld performance, grind the immediate perimeter of the plug weld
hole. Grind only in the area of the plug weld; this will keep corrosion to a minimum.
6. Dry-fit and clamp the replacement service parts to verify a correct fit and alignment.
Remove the service part after verifying correct fit and alignment.
7. The vehicle prepared flange areas where plug welds will be located must be kept free of
adhesive. Apply 25 mm (0.98 in) tape to the plug weld areas to prevent contamination from the
adhesive.
8. Prepare the adhesive. Dispense a small amount of metal bonding adhesive from the cartridge to
make sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip
length of adhesive to make sure of correct mix ratio.
9. NOTE: Refer to product label for cure times and handling instructions.
Apply a 6-9 mm (0.23-0.35 in) bead of adhesive to the vehicle prepared flange surface. Remove
the tape from the plug weld areas.
10. Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.
11. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping
the component.
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, refer to product label for cure times and
handling instructions. Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
13. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply
conventional body filler after the adhesive cures and block-sand the area.
14. Use seam sealer wherever a cosmetic seam sealer is required.
15. Mix and apply primer surfacer per Ford-approved paint recommendations.
16. Mix and apply basecoat per Ford-approved paint recommendations.
17. Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
18. Apply anti-corrosion treatment to the repair area as required. For additional information, refer to
Restoring Corrosion Protection Following Repair in this section.
Plastics Identification
personal injury.
NOTE: Identification of the various plastic types is necessary to select the appropriate repair methods to
make high quality plastic repairs. Plastics can generally be broken down into 2 categories,
thermoplastics and thermosetting plastics. Thermoplastics can be remolded by heating. This makes
plastic welding a possible repair alternative.
1. NOTE: In some instances, a code or material designation is stamped indicating the plastic type.
Thermoplastics are solvent reactive. Types of thermoplastics include Thermoplastic Olefin (TPO),
Polyvinyl Chloride (PVC) and Acrylonitrile Butadiene Styrene (ABS). Polyolefins have an oily or
waxy appearance. Examples include some bumper covers, stone shields, fender aprons and fan
shrouds. Polyolefins require an adhesion promoter prior to carrying out any refinish procedure.
To determine if the part is a polyolefin, grind the damaged area in an out-of-sight area.
Grinding a polyolefin will melt and smear the plastic and leave a ragged edge. If the part is
non-polyolefin, the area will grind or sand smoothly, producing a powdery dust.
Rigid Plastic Parts

Code Family Name Common Trade Name Typical Application
ABS Acrylonitrile Butadiene ABS, Cycolac, Lustran, A-Pillars, Consoles,
Styrene Kralistic Grilles
SMC Sheet Molded Composite SMC Body Panels
Flexible Plastic Parts

Code Family Name Common Trade Name Typical Application
RRIM Reinforced Reaction RRIM Fascias, Body Panels, Body
Injection-Mold Material Trims
PUR
TPO Thermoplastic Polytrope, Renflex, Bumpers, End Caps, Rubber
Polyolefin Santropren Telcar, Strips, Sight Shields,
Vistaflex, ETA, Apex, Claddings, Interior B-Post
TPO
2. Polyolefin plastic can also be identified by placing a small sliver in a container of water, if the
sample floats, it is a polyolefin plastic. A non-polyolefin will sink when placed in a container of
water.
3. Generally, thermosetting plastics are rigid or semi-rigid. Sheet-Molded Composite (SMC) is

reinforced with glass and other fibers and are strong and rigid. SMC is used for large panels such
as hoods, liftgates, fenders and quarter panels.
A burn test can be a reliable method to determine if a plastic is a thermosetting plastic.
Extreme care must be exercised when using this method.
Apply an open flame to the corner of the damaged component. If the material
crystallizes and becomes hard, it is a thermosetting plastic.
Plastics Refinishing
All Components
personal injury.
WARNING: Do not paint any air bag module trim covers or deployment doors. Paint may
cause the air bag to deploy incorrectly. Failure to follow this instruction may increase the risk of
NOTE: When using any Ford-approved refinishing product, it is recommended to stay within the same
paint system throughout the process. For example, do not use one manufacturer's primers and another
manufacturer's topcoats.
1. NOTE: Care must be used if applying heat to parts. Thermoplastics soften and tend to lose their
shape when heated.
The first step for any repair or refinish procedure is to identify the type of plastic. Is it
thermosetting or thermoplastic, grained or smooth? This will determine how it should be cleaned
and prepared for refinishing. For additional information, refer to Plastics Identification in this
section.
It is essential that the correct cleaner is used, depending on which painting system is
employed, solvent-based or water-based.
Clean part with warm water/mild detergent, then with plastic cleaner to remove wax,
silicone and other contaminants. Do not allow parts to remain wet for extended periods.
As a general rule, if water beads on the part, it requires additional cleaning as all the
manufacturing release agents have not been removed.
2. New parts may require baking in a spray booth or heating with heat lamps to release trapped
solvents or mold release agents used in the manufacturing processes.
Non-grained components
3. After cleaning, lightly sand with 600-grit or finer sandpaper. Remove sanding residue with plastic
cleaner and wipe dry.
Grained components
4. After cleaning, light use of a gray scuff pad is permissible providing the graining not be flattened.
Remove sanding residue with plastic cleaner and wipe dry.
All components
5. Apply a plastics adhesion promoter to any bare plastic part following manufacturer's
recommendation. Throughout the refinish procedure, any time bare plastic is exposed for any
reason, it is essential that adhesion promoter be reapplied to that area.
6. A sealer may be required to prevent wrinkling and lifting of the topcoat prior to carrying out the
refinish procedure.
7. Flexible and non-flexible components should be refinished separately as a flex additive may be
required when refinishing flexible parts (refer to the paint manufacturer's recommendation).
8. It is recommended to carry out refinishing of exterior components on-vehicle (after cut-in) to

control color match and blending to adjacent panels.
9. Proceed with the refinish process and follow the Ford-approved paint system procedures. Steps
may vary between paint manufacturers.
Plastics Repair
Material
Item Specification
Plastic Bonding Adhesive —
TA-9
personal injury.
1. In deciding whether to repair or install a new component, follow these guidelines.

Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?
Will repair provide for the fastest, highest quality repair?
2. NOTICE: Never apply solvents such as lacquer thinner or reducer at any stage of plastic
repair. Solvents, cleaners and water are absorbed by many types of plastics and by the
glass fibers used for reinforcements. If this occurs, the plastic may swell in the area of
repair and cause the repair to fail. Remove cleaners and water quickly and use air and heat
to speed up drying.
NOTICE: During the repair of many plastics and particularly polyolefin plastics, an
adhesion promoter must be applied to the substrate to allow repair materials and paint to
bond correctly. Reapplication is required when grinding or sanding through the sealer or
primered layers.
NOTE: When possible, it is recommended to carry out as much of the plastic repair as possible
on the vehicle. Parts mounted on the vehicle are held in correct alignment throughout the repair.
Attempting to repair the part off the vehicle may cause misalignment. This could lead to failure of
the repair.
Select the correct repair method by identifying the type of plastic being repaired. For additional
information, refer to Plastics Identification in this section to determine the type of plastic being
repaired.
3. NOTE: Always refer to the manufacturer's label directions for the type of repair materials, fillers
and bonding agents being used as they are material specific.
Determine whether a reinforcement piece is needed as a backer on large repairs.

Construct a reinforcement piece from a scrap piece of the type of plastic being repaired
and follow manufacturer's label directions for the type of system being used.
When repairing Sheet-Molded Composite (SMC), a reinforcement piece can be
constructed using several layers of glass cloth saturated with resin or structural adhesive.
The weave of the cloth or screening should be loose enough to allow the resin to
thoroughly penetrate. Reinforcement should cover the entire area of damage and extend
outward beyond the damage or joint area.
Sheet-Molded Composite (SMC) Panel Repair
NOTE: The following procedure applies to repair of structural cracks and large gouges. If damage is
cosmetic, use of reinforcing cloth may not be necessary.
1. Panels to be repaired should be dry and at room temperature 18°C (65°F) to 24°C (75°F) prior to
carrying out any repairs. Both sides of the panel must be thoroughly cleaned before sanding or
grinding.
2. Cover the break in the SMC (front and back) with masking tape. This protects the damaged area
from absorbing the prep cleaner and eliminates wicking of the cleaner through the fibers into the
SMC .
3. Remove all waxes, silicones, dirt and road oils from the area surrounding both sides of the
damaged area with a plastics wax and grease remover.
Remove the tape and sand the back of the repair area with an angle grinder, Dual Action
(D/A) sander or by hand using 80-grit sandpaper. Remove all dust with a vacuum and tack
cloth.
4. Create a reinforcing patch using a piece of scrap SMC that conforms well to the back of the
damaged area or form a patch from fiberglass cloth.
Cut a section of cloth large enough to cover the repair, plus 25.4 mm (1 in) around the
repair area.
Cut a section of plastic film backing approximately 25.4 mm (1 in) larger than the cloth. Lay
the plastic on a smooth, flat surface where it will be used to create a pyramid patch.
5. Follow manufacturer's directions and apply plastic repair adhesive to the plastic film backing and
smooth with plastic spreader to recommended thickness. Place the pre-cut fiberglass cloth on the
adhesive-coated plastic film. Cover the cloth with a coat of repair adhesive and spread to the
recommended thickness.
6. Apply the prepared patch to the backside of the panel and compress. Follow manufacturer's
instructions for adhesive cure. Remove plastic film after adhesive cures and sand as necessary to
remove roughness.
7. Remove masking tape from the front side of damaged area and grind down to the backing patch.
Use an angle grinder with a 30- to 40-grit wheel. Make a gradual taper in the area, this will
prevent bull's-eyes or read-through in the finished repair. Sand prepared area with a D/A sander
or hand-sand with 80-grit sandpaper.
8. Build a pyramid patch using fiberglass cloth or equivalent and plastic repair adhesive. Following
manufacturer's directions, apply patch to damaged area.
9. Rough-grind area to remove excess adhesive. Sand repair area with 80-grit sandpaper, making
sure to cut slightly below the SMC finished surface. This will allow for a finish coat of plastic body
repair material.
10. Apply a finish coat of plastic repair filler material per manufacturer's directions.
11. Finish-sand, prime and topcoat using Ford-approved paint systems.
Thermoplastic Compounds
1. In deciding whether to repair or install a new component, follow these guidelines.
Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?
Will repair provide for the fastest, highest quality repair?
2. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives
or patch materials are used, procedures may vary slightly.
Thoroughly clean the damaged area with wax and grease remover formulated for use with
plastics.
3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with
compressed air.
4. Apply a plastics adhesion promoter per label directions to the repair area.
5. For small repairs, a plastic adhesive filler can be applied to the damaged area. Follow
manufacturer's directions and build layers to form a thickness above the damaged area. This will
allow the area to be sanded smooth.
6. To repair large holes or cracks, measure and cut a piece of fiberglass cloth or equivalent 25.4 mm
(1 in) larger than the crack or hole.
Apply plastic repair adhesive to the damaged area and immediately apply fiberglass cloth
into plastic adhesive for reinforcement. Apply additional plastic repair adhesive for strength
and shape as required.
7. Contour and shape the repair as necessary with a D/A sander. Avoid sanding through the repair.
8. Finish-sand the area and carry out any required paint operations using Ford-approved paint
systems.
Tab Repair — Bumper
1. NOTE: Inspect the bumper cover to determine if part of it can be repaired to an acceptable level
of quality of appearance, fit and durability. Will labor and material cost of the repair meet or
exceed the cost of a new replacement bumper cover? If the bumper cover is determined to be
repairable, proceed to the following steps.
NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives
or patch materials are used, procedures may vary slightly.
Remove the affected bumper. For additional information, refer to Section 501-19 .
NOTE: Illustration is not vehicle specific.
2. Clean the broken tab(s) with a plastics wax and grease remover.
3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with
compressed air.
4. Apply a plastics adhesion promoter per label directions to the repair area.
5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab,
then slope back in a wedge shape approximately 51 mm (2 in) from original tab.
6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected
area.
Immediately position the plastic repair material patch to form the tab shape.
7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme
care to not sand through the exterior surface.
8. Carry out any required paint repair operations to the bumper cover using Ford-approved paint
systems.
9. Reassemble and install the bumper cover. For additional information, refer to Section 501-19 .
Door Outer Panel — Front
Special Tool(s)
Heat Gun
107-R0300
Pro 230 MIG Welder

208-00030
Material
Item Specification
Flexible Foam Repair —
Fusor® 121, or equivalent; obtain
locally
TA-1
Rust Inhibitor —
(aerosol)
Seam Sealer —
TA-2
Door Assembly — Front
NOTE: Door intrusion beam is constructed of boron steel and is non-serviceable.

1 5420200 (RH)/ 5420201 (LH) Door outer panel — mild steel
2 5420124 (RH)/ 5420125 (LH) Door shell — mild and boron steel

air bags
crash sensors
injury.
1. Inspect the door hinges prior to panel replacement. Install new or rebuild as necessary.
2. Remove the door window glass. For additional information, refer to Section 501-11 .
3. Remove the door. For additional information, refer to Section 501-03 .
4. Remove the door outer latch and outer door handle. For additional information, refer to Section 501-14 .
5. Remove the side view mirror. For additional information, refer to Section 501-09 .
6. Remove the door applique.
7. NOTICE: To prevent damage to the mating surfaces of the door assembly, use extreme care to
avoid cutting into the door shell.
Using a suitable grinder, grind along the perimeter of the outer door panel to separate the hem edges as
indicated.
8. NOTICE: Drill though the outer panel sheet metal only to avoid damage to the door assembly.
Carefully remove the tack weld at the upper rear of the outer door panel.
9. NOTE: The use of a heat gun may be required to soften the door panel adhesive.
Prior to removing the outer door panel, use a sharp knife to cut the adhesive between the door shell and
outer panel and the intrusion beam.
Using a flat-blade chisel or equivalent, remove the original panel.
Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange from
the door shell.
Remove any remaining adhesive from the door shell flange.
Installation
1. Prepare the door shell assembly.

Grind clean all mating surfaces.
Dress any tack welds.
2. Prepare the service replacement outer door panel.

Sand clean all the mating surfaces of the replacement panel.
Apply a mastic sound-deadener patch (obtain locally) to the inner side of the replacement panel.
For additional information, refer to Sound Deadeners and Insulators in this section.
3. NOTE: Hemming and alignment must be completed before the adhesive has begun to cure.
Apply metal bonding adhesive to the replacement panel hem flange and position on the door shell and
begin the hemming process.
Using a door panel installation tool or the hammer and dolly method, close the door hem flange
around the entire perimeter of the door and smooth any residual adhesive in the joints.
4. Fit the door assembly to the vehicle and assure correct alignment with the adjoining panels.
5. Clamp the upper front portion of the door outer panel to the door shell and allow adhesive to cure.
6. WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected
the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of
the deepest shade providing adequate visibility are recommended. It is strongly recommended
Clamp the upper rear portion of the door outer panel to the door shell and apply a MIG tack weld where
previously removed.
7. Remove the door assembly from the vehicle.
8. Apply flexible foam repair material between the door outer panel and the intrusion beam.
9. Sand and prime the flange area and apply a continuous bead of seam sealer to the entire door hem
flange perimeter.
10. Prime and paint the door flange area using a Ford approved paint system.
11. Apply rust inhibitor to the inside of the door assembly to all hem flange areas. For additional information,
refer to Restoring Corrosion Protection Following Repair in this section.
12. Install the door on the vehicle. For additional information, refer to Section 501-03 and refinish using a
Ford approved paint system.
13. Install the door latch and outer door handle. For additional information, refer to Section 501-14 .
14. Install the window glass. For additional information, refer to Section 501-11 .
15. Install the side view mirror. For additional information, refer to Section 501-09 .
16. Install a new door applique.

Door Outer Panel — Rear
Special Tool(s)
Heat Gun
107-R0300
Pro 230 MIG Welder

208-00030
Material
Item Specification
Fusor® 121, or equivalent; obtain
locally
TA-1
Rust Inhibitor —
(aerosol)
Seam Sealer —
TA-2
Door Assembly — Rear
NOTE: Door intrusion beam is constructed of boron steel and is non-serviceable.

1 5824700 (RH)/ 5825701 (LH) Door outer panel — mild steel
2 5420124 (RH)/ 5420125 (LH) Door shell — mild and boron steel

air bags
crash sensors
injury.
1. Inspect the door hinges prior to panel replacement. Install new or rebuild as necessary.
2. Remove the door window glass. For additional information, refer to Section 501-11 .
3. Remove the door. For additional information, refer to Section 501-03 .
4. Remove the door outer latch and outer door handle. For additional information, refer to Section 501-14 .
5. Remove the door applique.

6. NOTICE: To prevent damage to the mating surfaces of the door assembly, use extreme care to
avoid cutting into the door shell.
Using a suitable grinder, grind along the perimeter of the outer door panel to separate the hem edges as
indicated.
7. Carefully remove the tack weld at the upper front of the outer door panel.
8. NOTE: The use of a heat gun may be required to soften the door panel adhesive. Prior to removing the
outer door panel, use a sharp knife to cut the adhesive between the door shell and outer panel and the
intrusion beam.
Remove the outer panel sheet metal.

Using a flat-blade chisel or equivalent, remove the original panel.
Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange from
the door shell.
Remove any remaining adhesive from the door shell flange.
Installation
1. Prepare the door shell assembly.

Grind clean all mating surfaces.
Dress any tack welds.
2. Prepare the service replacement outer door panel.

Sand clean all the mating surfaces of the replacement panel.
Apply a mastic sound-deadener patch (obtain locally) to the inner side of the replacement panel.
For additional information, refer to Sound Deadeners and Insulators in this section.
3. NOTE: Hemming and alignment must be completed before the adhesive has begun to cure.
Apply metal bonding adhesive to the replacement panel hem flange and position on the door shell and
begin the hemming process.
Using a door panel installation tool or the hammer and dolly method, close the door hem flange
around the entire perimeter of the door and smooth any residual adhesive in the joints
4. Fit the door assembly to the vehicle and assure correct alignment with the adjoining panels.
5. WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected
the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of
the deepest shade providing adequate visibility are recommended. It is strongly recommended
Clamp the upper front portion of the door outer panel to the door shell and apply a MIG tack weld where
previously removed.
6. Remove the door assembly from the vehicle.
7. Apply flexible foam repair material between the door outer panel and the intrusion beam.
8. Sand and prime the flange area and apply a continuous bead of seam sealer to the entire door hem
flange perimeter.
9. Prime and paint the door flange area using a Ford approved paint system.
10. Apply rust inhibitor to the inside of the door assembly to all hem flange areas. For additional information,
refer to Restoring Corrosion Protection Following Repair in this section.
11. Install the door on the vehicle. For additional information, refer to Section 501-03 and refinish using a
Ford approved paint system.
12. Install the door latch and outer door handle. For additional information, refer to Section 501-14 .
13. Install the window glass. For additional information, refer to Section 501-11 .
14. Install a new door applique.

Frame Members — Front
Special Tool(s)
Heat Treatment Induction
Resistance Spot Welder
254-00001
Pro 230 MIG Welder

208-00030
Material
Item Specification
ZC-31-A
(aerosol)
Rust Inhibitor —
(aerosol)
Front Structure
NOTE: Right side fender reinforcements and apron shown, left side similar.
1 16C078 (RH)/ Fender bracket — mild steel
16C079 (LH)
2 16018 (RH)/ 16019 Fender reinforcement, outer — HSLA 350 steel
(LH)
3 16054 (RH)/ 16055 Fender apron — mild steel
(LH)
4 — Strut tower (part of 16054/16055) — HSLA 300
steel
5 54010A88 (RH)/ Frame rail, outer — Dual Phase Steel (DP) 600
54101A89 (LH) steel
6 17B749 (RH)/ Bumper mounting bracket — mild steel HSLA
17B750 (LH) 300 steel
7 — Bracket (part of 54010A88/54101A89) — mild
steel
8 — Cowl top support (part of 16054/16055) — mild
steel
9 — Brace (part of 54010A88/54101A89 — HSLA
300 steel
10 — Reinforcement (part of 54010A88/54101A89) —
Dual Phase Steel (DP) 600 steel
11 5410008 (RH)/ Frame rail, inner — Dual Phase Steel (DP) 600
5410009 (LH) steel

air bags
crash sensors
NOTICE: A frame rail sectioning kit is not available for this vehicle. Frame rail replacement must be
done at the factory seams. Failure to follow this direction will result in an incorrect repair and vehicle
energy management will be compromised.
1. Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure the
vehicle to determine if the body requires rough straightening and alignment. For dimensional information,
refer to Body in this section.
2. Remove the hood. For additional information, refer to Section 501-02 .
3. Remove the fender(s) from the affected side(s). For additional information, refer to Section 501-02 .
4. Remove the front bumper cover and reinforcement. For additional information, refer to Section 501-19 .
5. Remove the battery. For additional information, refer to Section 414-01 .
6. Remove the front strut from the affected side of the vehicle. For additional information, refer to Section
204-01 .
7. Remove the engine mount from the affected side of the vehicle. For additional information, refer to
Section 303-01 .
8. Remove the subframe. For additional information, refer to Section 502-00 .
9. Disconnect and position aside the Anti-Lock Brake System (ABS) sensor wire.
10. NOTE: Use care not to drill through to fender apron or A-pillar when removing the frame rail.
Carefully drill out the spot welds and remove the outer frame rail.
11. NOTE: Use care not to drill through to fender apron or A-pillar when removing the frame rail.
Carefully drill out the spot welds and remove the inner frame rail.
12. Dress any plug weld nuggets on the vehicle underbody structure resulting from inner or outer rail
removal.
Installation
1. NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds.
Apply a locally available weld-through primer only to the immediate weld locations of the inner and outer
frame rails.
2. Install and clamp the service replacement inner frame rail in place. Tack weld and verify correct
alignment of the frame rail.
3. NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds.
Install and clamp the service replacement outer frame rail in place.
Verify correct alignment of the outer frame rail.
4. Using a MIG welder or resistance spot welder, plug weld along the top and bottom seam of the service
replacement rails.
5. Use a dye penetrant or equivalent to determine if any cracks or large voids exist, grind out any defects
that exist and repair until the weld is free of defects.
Dress welds as necessary.
6. Apply corrosion protection. For additional information, refer to Restoring Corrosion Protection Following
Repair in this section.
7. MIG plug weld or resistance spot weld a new front bumper reinforcement mounting plate to the front
frame rail assembly.
8. Install the subframe. For additional information, refer to Section 502-00 .
9. Install the engine mount from the affected side of the vehicle. For additional information, refer to Section
303-01 .
10. Install the front strut. For additional information, refer to Section 204-01 .
11. Connect the Anti-Lock Brake System (ABS) sensor wire.
12. Install the battery. For additional information, refer to Section 414-01 .
13. Install the fender(s). For additional information, refer to Section 501-02 .
14. Install the front bumper cover and reinforcement. For additional information, refer to Section 501-19 .
15. Install the hood. For additional information, refer to Section 501-02 .
Frame Members — Rear
Special Tool(s)
Heat Treatment Induction
Resistance Spot Welder
254-00001
Pro 230 MIG Welder

208-00030
Material
Item Specification
ZC-31-A
(aerosol)
Rust Inhibitor —
(aerosol)
WARNING: Frame rail crush zones absorb crash energy during a collision and must be
replaced if damaged. Straighten damaged frame rails to correct frame dimensions prior to frame
member sectioning. Failure to follow these instructions may adversely affect frame rail
performance and may result in serious personal injury to vehicle occupant(s).

air bags
crash sensors
NOTICE: Because of component composition (Dual Phase Steel (DP) 600 steel) a frame rail
sectioning kit is not available for this vehicle. Frame rail replacement must be carried out by
replacement at the factory seams.
1. Position the vehicle on a frame repair rack following the manufacturer's recommendations.
Measure the vehicle to determine if the body requires rough straightening and alignment. For
dimensional information, refer to Body in this section.
2. Remove the rear bumper cover and reinforcement. For additional information, refer to section
Section 501-19 .
3. Remove the rear wheels. For additional information, refer to section Section 204-04 .
4. Remove the rear axle. For additional information, refer to section Section 204-02 .
5. LH side only. Remove the fuel fill assembly. For additional information, refer to section Section
310-01 .
6. NOTE: Use caution not to drill through the vehicle floor pan when removing spot welds.
NOTE: LH side shown. RH side similar.
Carefully remove the spot welds and the rear frame rail.
Installation
1. Dress all spot weld nuggets on the vehicle mating surfaces.
2. 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.
Drill plug weld holes in the replacement rear frame rail service part.
3. Apply a locally available weld-through primer to the immediate weld location only on the
replacement part and vehicle mating surfaces.
4. Install and clamp the service replacement rear frame rail in place and verify correct alignment of
the frame rail.
5. Using a MIG welder or resistance spot welder, plug weld the service replacement rail.
6. Apply corrosion protection. For additional information, refer to Restoring Corrosion Protection
Following Repair in this section.
7. Install a new rear bumper mounting plate.
8. LH side only. Install the fuel fill assembly. For additional information, refer to section Section 310-
01 .
9. Install the rear axle. For additional information, refer to section Section 204-02 .
10. Install the rear wheels. For additional information, refer to section Section 204-04 .
11. Install the rear bumper cover and reinforcement. For additional information refer to section
Section 501-19 .
Inner Body Reinforcing Panels
General Equipment
Material
Item Specification
ZC-31-A
(aerosol)
Rust Inhibitor —
(aerosol)
Seam Sealer —
TA-2
4-Door Sedan
NOTICE: Sectioning procedures can only be carried out on the outer body side panel. No sectioning
repairs can be carried out on inner reinforcement panels. Failure to follow these instructions may
compromise structural integrity of the vehicle.
NOTE: Refer to the steel repairability matrix chart in the Specifications portion of this section for specific
information regarding steel descriptions.
1 5424300 (RH)/ B-pillar inner— boron steel
5424301 (LH)
2 — Cowl side panel, inner (part of
5402038/5402039) — Dual Phase Steel (DP)
600 steel
3 5402038 (RH)/ Cowl side panel, inner — DP 350 steel
5402039 (LH)
4 5410116 (RH)/ Rocker panel reinforcement — DP 780 steel
5410117 (LH)
5 5402500 (RH)/ A-pillar reinforcement— boron steel
5402501 (LH)
6 54272A12 (RH)/ Door check mounting bracket— mild steel
54272A13 (LH)
7 5424382 (RH)/ B-pillar reinforcement— boron steel
5424383 (LH)
8 54513A06 (RH)/ Upper body reinforcement— HSLA 350 steel
54513A07 (LH)
9 5427790 (RH)/ Quarter panel and wheelhouse — HSLA 350
5427791 (LH) steel
10 5444822 (RH)/ Hinge — mild steel
5444823 (LH)
11 5445114 (RH)/ Luggage compartment drain trough — mild steel
5445115 (LH)
12 13A418A (RH)/ Rear lamp closing panel — mild steel
13A418B (LH)
13 54250A06 (RH)/ Support plate — mild steel
54250A07 (LH)
5-Door Hatchback
NOTICE: Sectioning procedures can only be carried out on the outer body side panel. No sectioning
repairs can be carried out on inner reinforcement panels. Failure to follow these instructions may
compromise structural integrity of the vehicle.
NOTE: Refer to the steel repairability matrix chart in the Specifications portion of this section for specific
information regarding steel descriptions.
1 5402038 (RH)/ Cowl side panel, inner — HSLA 350 steel
5402039 (LH)
2 5424300 (RH)/ B-pillar — boron steel
5424301 (LH)
5410117 (LH)
4 5402500 (RH)/ A-pillar reinforcement — boron steel
5402501 (LH)
5 54272A12 (RH)/ Door check mounting bracket — mild steel
54272A13 (LH)
6 5424382 (RH)/ B-pillar reinforcement — boron steel
5424383 (LH)
7 58513A06 (RH)/ Upper body reinforcement — HSLA 350 steel
58513A07 (LH)
8 5827790 (RH)/ Quarter panel and wheelhouse, inner — HSLA
5827791 (LH) 350 steel
9 54250A06 (RH)/ Support plate — mild steel
54250A07 (LH)
10 58613A63 (LH Bracket — mild steel
only)
11 5845114 Luggage compartment drain trough — mild steel
12 5845115 Luggage compartment drain trough — mild steel
13 — Quarter panel and wheelhouse reinforcement,
inner (part of 5827790/5827791 — HSLA 350
steel
Package Tray Assembly — 4-Door Sedan

1 5446774 Reinforcement — mild steel
2 5446506 Package tray — mild steel
4 13A418A Rear lamp closing panel — mild steel
5 5440320 Back panel — mild steel
7 13A418B Rear lamp closing panel — mild steel
Front Structure
NOTE: Right side fender reinforcements and apron shown, left side similar.

1 16C078 (RH)/ Fender bracket — mild steel
16C079 (LH)
2 16018 (RH)/ 16019 Fender reinforcement, outer — HSLA 350 steel
(LH)
3 16054 (RH)/ 16055 Fender apron — mild steel
(LH)
4 — Strut tower (part of 16054/16055) — HSLA 300
steel
5 54010A88 (RH)/ Frame rail, outer — Dual Phase Steel (DP) 600
54101A89 (LH) steel
6 17B749 (RH)/ Bumper mounting bracket — mild steel HSLA
17B750 (LH) 300 steel
7 — Bracket (part of 54010A88/54101A89) — mild
steel
8 — Cowl top support (part of 16054/16055) — mild
steel
9 — Brace (part of 54010A88/54101A89 — HSLA
300 steel
10 — Reinforcement (part of 54010A88/54101A89) —
Dual Phase Steel (DP) 600 steel
11 5410008 (RH)/ Frame rail, inner — Dual Phase Steel (DP) 600
5410009 (LH) steel
Underbody — Front Floor

1 5410776A (RH)/ Crossmember — DP 600 steel
5410776B (LH)
2 5862570 seat mounting bracket — Bake Hardened
Steel (BH) 210 steel
3 5410672 (RH)/ Crossmember - front, upper — DP 600 steel
5410673 (LH)
4 — Bracket (part of 5410672/5410673) — mild
steel
5 54111A46 Gusset (2 required) — HSLA 300 steel
6 54106A96 (RH)/ Floor side member — mild steel
54106A97 (LH)
7 5411135 Floor pan — mild steel
8 — Floor tunnel (part of 5411135) — HSLA 300
steel
9 2A697 Parking brake cable guide — mild steel
10 2L624 Parking brake cable reinforcement — mild
steel
11 54111K48 Reinforcement — DP 780 steel
12 5410062 Side member extension (2 required) — DP
780 steel
13 5402038 (RH)/ Cowl side panel, inner — DP 780 steel
5402039 (LH)
14 — Cowl side panel, inner (part of
5402038/5402039 — DP 600 steel
5410117 (LH)
16 58108K38 Crossmember — mild steel
Underbody — Rear Floor

1 — Brace (part of 5411215) — mild steel DP 600 steel
2 5447076 Bracket — mild steel
3 — Gusset — mild steel
4 — Brace (part of 5411215) — DP 600 steel
5 5411215 Floor pan — mild steel
6 — Reinforcement (part of 5411215) — HSLA 300
steel
7 — Reinforcement (part of 5411215) — HSLA 300
steel
8 — Bracket (part of 5411215) — mild steel
9 — Reinforcement (part of 5411215) — mild steel
12 — Bracket (part of 5411215) — HSLA 300 steel
13 5410125 Floor side member — HSLA 300 steel
14 2082 Bracket (2 required) — mild steel BH 210 steel
16 5410456 (RH)/ Side member — DP 600 steel
5410457 (LH)
17 9N077U (4-door)/ Fuel tank bracket — mild steel
9N077A (5-door)
18 17A750A Bumper mounting bracket — DP 600 steel
19 5410124 (4-door)/ Floor side member — DP 600 steel
5810124 (5-door)
20 — Reinforcement (part of 5410124/5810124) — BH
240 steel
21 — Bracket (part of 5410124/5810124) — HSLA 250
steel
22 — Reinforcement (part of
5410124/5410125/5810124/5810125) — BH 240
steel
23 4K338 Crossmember — HSLA 300 steel
24 17A750A Bumper mounting bracket — mild steel DP 600
steel
25 2082 Bracket — BH 210 steel
26 5410125 (4-door)/ Floor side member — DP 600 steel
5810125 (5-door)
27 — Reinforcement (part of 5410125/5810125) — DP
600 steel
28 — Bracket part of 5410125/5810125 — HSLA 250
steel

air bags
crash sensors
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect
operation of restraint devices. For additional restraints anchoring location information, refer to Section
501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to
WARNING: Do not carry out body side sectioning repairs in areas of laser welds. Factory laser
welds cannot be duplicated with conventional welding equipment and structural integrity may be
compromised. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise
structural integrity during a collision. Failure to follow these instructions may result in serious injury to
sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy®
module and related components. Failure to comply may result in accidental deployment or damage to
the Safety Canopy®. Refer to Section 501-20B . Failure to follow these instructions may result in
serious injury to technician or vehicle occupant(s).
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (MIG) plug
welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld
1. Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel
replacement. For additional information, refer to Sectioning Guidelines in this section.
2. NOTE: Observe prescribed welding procedures when carrying out repairs. For additional information,
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel
replacement. For additional information, refer to Sectioning Guidelines in this section.
3. When welding overlapping surfaces or substrates, apply a high quality weld-through primer between the
surfaces prior to welding.
Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture
intrusion. Water and moisture migrate to horizontal joints and corrosion tends to occur more
rapidly in these areas. Clean metal surfaces with metal surface prep or equivalent applying seam
sealer.
4. Proceed with refinish procedures following Ford-approved paint guidelines.
5. Apply corrosion protection as necessary to repair area.

Roof Panel — 4-Door Sedan
Special Tool(s)
Heat Gun
107-R0300
Heat Treatment Induction Resistance

Spot Welder
254-00001
Pro 230 MIG Welder

208-00030
Material
Item Specification
TA-1
Fusor® 121, or equivalent; obtain locally
Seam Sealer —
TA-2
Roof Panel — Exploded View

1 5450202B Roof panel with sunroof — mild steel
2 5450202A Roof panel without sunroof — mild steel
3 5403410 Windshield header panel — HSLA 350 steel
4 5451272 Roof bow without sunroof only — HSLA 350 steel
5 5842220 Rear roof rail — mild steel
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or
damaged vehicles. The use of such parts could lead to serious injury.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or
anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of
non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain
damage which is not visible.

air bags
crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by
skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair
procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company
engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural
repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or
non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any
crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by
Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and
corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative
structural component repair procedures and/or parts.
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and
skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing
adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear
flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Be sure to adequately protect all glass, exterior finish and interior trim to avoid surface
contamination from repair materials.
NOTE: The driver and passenger sides of the roof panel are laser skip-welded. Installation of a new roof panel will
employ a weld-bonding technique. The use of mechanical welding and chemical bonding are both part of the
installation technique.
1. Remove and discard the roof ditch mouldings.
2. Remove the windshield. For additional information, refer to Section 501-11 .
3. Remove the rear window. For additional information, refer to Section 501-11 .
5. Remove the side air curtains. For additional information, refer to Section 501-20B .
6. Remove the antenna. For additional information, refer to Section 415-00 .
7. Remove the sun roof (If equipped). For additional information, refer to Section 501-17 .
8. From inside the vehicle, leaving as much of the foam as possible intact, separate the Noise, Vibration and
Harshness (NVH) foam along the front and rear header panels and roof bow (if equipped) from the roof panel
using a flexible and sharp broad scraper or knife.
9. NOTICE: Drill through the outer panel sheet metal only to avoid damage to the header panel assembly.
NOTE: Note the location and quantity of the spot welds to assist in installation of the new roof panel.
Remove the windshield header panel spot welds.
Remove the rear header panel spot welds.

11. NOTICE: Drill through the outer panel sheet metal only to avoid damage to the body side panel
assembly.
Remove the roof ditch spot welds.
12. Remove the roof panel from the vehicle.

Installation
1. Using a suitable disc grinder, clean out any remaining seam sealer and paint along the roof ditch mating
surface.
2. Dress any spot weld nuggets in the roof ditch as well as the front and rear header panel mating surfaces.
3. Using the hammer and dolly method, straighten any damage caused to the mating surfaces on the vehicle
during panel removal.
4. Inspect the windshield header panel, roof bow and rear header panel. Repair or replace as required.
5. Position the service replacement roof panel on the vehicle.
6. Correctly align and index mark the positioning of the panel-to-vehicle and remove the panel.
7. NOTE: Spot welds can be replaced with MIG plug welds. Plug welds should equal resistance spot welds in
both location and quantity. Do not place a new spot or plug weld directly over an original weld location.
Prepare the roof panel for installation:

If Metal Inert Gas (MIG) plug welding, drill 8 mm (0.314 in) holes along the front and rear header panel
flanges.
If Squeeze-Type Resistance Spot Welding (STRW), remove the e-coat only in the exact locations for
spot welds along the front and rear header panels flanges.
8. Remove the e-coat on the roof ditch mating surface of the service replacement roof panel.
9. Apply a bead of metal bonding adhesive on the front and rear header panels and roof bow (if equipped) and to
the body side-to-roof panel flange area. Immediately reinstall the roof panel aligning it to the index marks made
during test fitting.
10. Make sure good contact is made with the adhesive. Clamp the roof panel on all sides and smooth out any
residual adhesive in the joints.
11. Resistance spot weld or MIG plug weld the roof panel to the front and rear header panels and allow the
adhesive to cure.
12. Inspect header panels and roof bow (if equipped) to roof panel adhesive mating surfaces. If good contact is not
apparent, apply flexible foam material for NVH purposes.
13. NOTE: Always use refinishing materials from a single paint manufacturer. Combining products from more than
one manufacturer may result in refinishing material incompatibility issues and potential void of warranty for
each product applied.
Sand and prime the roof ditch repair and apply a continuous bead of seam sealer to the roof ditch area joints.
14. Refinish the entire repair area using a Ford approved refinishing system.
15. Install the side air curtains. For additional information, refer to Section 501-20B .
16. Install the sun roof (if equipped). For additional information, refer to Section 501-17 .
17. Install the antenna. For additional information, refer to Section 415-00 .
19. Install the windshield and rear window. For additional information, refer to Section 501-11 .
20. Install new roof ditch mouldings.

Roof Panel — 5-Door Hatchback
Special Tool(s)
Heat Gun
107-R0300
Heat Treatment Induction Resistance

Spot Welder
254-00001
Pro 230 MIG Welder

208-00030
Material
Item Specification
Fusor® 121, or equivalent; obtain locally
TA-1
Seam Sealer —
TA-2
Roof Panel — Exploded View

Part
1 5850202A Roof panel with sunroof — mild steel
2 5850202B Roof panel without sunroof — mild steel
3 5403410 Windshield header panel — mild steel
4 5451272 Roof bow without sunroof only — mild steel High-Strength
Low Alloy (HSLA) 350 steel
5 5442220 Rear roof rail — mild steel
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or
damaged vehicles. The use of such parts could lead to serious injury.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or
anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of
non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain
damage which is not visible.

air bags
crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by
skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair
procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company
engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural
repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or
non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any
crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by
Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and
corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative
structural component repair procedures and/or parts.
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and
skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing
adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear
flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious
personal injury.
NOTICE: Be sure to adequately protect all glass, exterior finish and interior trim to avoid surface
contamination from repair materials.
NOTE: The driver and passenger sides of the roof panel are laser skip-welded. Installation of a new roof panel will
employ a weld-bonding technique. The use of mechanical welding and chemical bonding are both part of the
installation technique.
1. Remove the spoiler. For additional information, refer to Section 501-08 .
2. Remove and discard the roof ditch mouldings.
3. Remove the windshield. For additional information, refer to Section 501-11 .
4. Remove the rear luggage compartment lid. For additional information, refer to Section 501-03 .
6. Remove the side air curtains. For additional information, refer to Section 501-20B .
7. Remove the antenna. For additional information, refer to Section 415-00 .
8. Remove the sun roof (if equipped). For additional information, refer to Section 501-17 .
9. From inside the vehicle, leaving as much of the foam as possible intact, separate the Noise, Vibration and
Harshness (NVH) foam along the front and rear header panels and roof bow (if equipped) from the roof panel
using a flexible and sharp broad scraper or knife.
Remove the windshield header panel spot welds.
Remove the rear header panel spot welds.
12. Remove the roof ditch spot welds.

13. Remove the roof panel from the vehicle.
Installation
1. Using a suitable disc grinder, clean out any remaining seam sealer and paint along the roof ditch mating
surface.
2. Dress any spot weld nuggets in the roof ditch as well as the front and rear header panel mating surfaces.
3. Using the hammer and dolly method, straighten any damage caused to the mating surfaces on the vehicle
during panel removal.
4. Inspect the windshield header panel, roof bow and rear header panel. Repair or replace as required.
5. Position the service replacement roof panel on the vehicle.
6. Correctly align and index mark the positioning of the panel-to-vehicle and remove the panel.
7. NOTE: Spot welds can be replaced with Squeeze-Type Resistance Spot Welding (STRW) or Metal Inert Gas
(MIG) plug welds. Plug welds should equal resistance spot welds in both location and quantity. Do not place a
new spot or plug weld directly over an original weld location.
Prepare the roof panel for installation:

If MIG plug welding, drill 8 mm (0.314 in) holes along the front and rear header panel flanges.
If Squeeze-Type Resistance Spot Welding (STRW), remove the e-coat only in the exact locations for
spot welds along the front and rear header panels flanges.
8. Remove the e-coat on the roof ditch mating surface of the service replacement roof panel.
9. Apply a bead of metal bonding adhesive on the front and rear header panels and roof bow (if equipped) and to
the body side-to-roof panel flange area. Immediately reinstall the roof panel aligning it to the index marks made
during test fitting.
10. Resistance spot weld or MIG plug weld the roof panel to the front and rear header panels and allow adhesive to
cure.
11. Inspect header panels and roof bow (if equipped) to roof panel adhesive mating surfaces. If good contact is not
apparent, apply flexible foam material for NVH purposes.
12. NOTE: Always use refinishing materials from a single paint manufacturer. Combining products from more than
one manufacturer may result in refinishing material incompatibility issues and potential void of warranty for
each product applied.
Sand and prime the roof ditch repair and apply a continuous bead of seam sealer to the roof ditch area joints.
13. Refinish the entire repair area using a Ford approved refinishing system.
14. Install the antenna. For additional information, refer to Section 415-00 .
15. Install the side air curtains. For additional information, refer to Section 501-20B .
16. Install the sun roof (if equipped). For additional information, refer to Section 501-17 .
18. Install the windshield. For additional information, refer to Section 501-11 .
19. Install the rear luggage compartment lid. For additional information, refer to Section 501-03 .
20. Install new roof ditch mouldings.
21. Install the spoiler. For additional information, refer to Section 501-08 .
SECTION 502-00: Uni-Body, Subframe and Mounting System 2011 Fiesta Workshop Manual
Ball joint nuts 52 38 —
Engine roll restrictor bolt 70 52 —
Stabilizer bar link lower nuts 48 35 —
Steering shaft pinch bolt 32 24 —
Subframe brace bolts 48 35 —
Subframe forward bolts 60 44 —
Subframe rearward bolts a — — —
Tie-rod end nuts 55 41 —
Subframe and Mounting Systems
The front subframe is bolted to the body and is used to:
aid in structural support.

provide mounting surfaces for the steering system.
provide mounting surfaces for the front suspension lower control arms, the engine mounts and for
the front stabilizer bar.
Subframe — Front
Special Tool(s)
Powertrain Lift
300-OTC1585AE or equivalent
Remover, Tie-Rod End

211-001 (TOOL-3290-D)

1 W712486 Steering gear bolt (3 required) (install new)
2 5A262 Exhaust insulator
3 5019 Subframe assembly
4 W714343 Subframe rearward bolt (2 required) (install new)
5 5A104 Subframe brace (2 required)
6 W500233 Subframe brace bolts (4 required)
7 W714404 Subframe forward bolt (2 required)
8 W715185 Roll restrictor bolt
9 W520103 Stabilizer bar link lower nut (2 required) (install new)
10 W520203 Ball joint nut (2 required) (install new)
11 W709618 Ball joint bolt (2 required) (install new)
Removal
NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and
systems and their failure may result in major service expense. New parts must be installed where specified
with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure
correct retention of these parts.
1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-02 .
2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
3. Remove the pinch bolt and disconnect the steering shaft.

Discard the bolt.
4. Remove the front tires and wheels. For additional information, refer to Section 204-04 .
5. Remove the nuts and disconnect the lower stabilizer bar links.
6. Remove the bolts and disconnect the ball joints from the steering knuckles.
Discard the bolts.
7. Remove the nuts and disconnect the tie-rod ends from the steering knuckle.
Discard the nuts.
8. Remove the engine roll restrictor bolt from the subframe.
9. Disconnect the exhaust hanger.

10. Remove the bolts and subframe braces.
11. NOTE: This step is not necessary if the subframe assembly is replaced.
Mark the position of the subframe-to-frame mounting location at each mounting point on the frame rails on both
sides of the vehicle to aide in installation.
12. Position the Powertrain Lift under the subframe assembly.

13. Remove the forward and rearward subframe bolts.
1. Remove the forward bolts.
2. Remove the rearward bolts.
Discard the rearward bolts.
14. Carefully lower the subframe assembly from the vehicle.
Installation
1. Position the subframe to the vehicle and loosely install the 2 new rearward bolts and the forward bolts.
2. Remove the Powertrain Lift.
3. If installing the subframe that was previously removed, align the subframe to the locating marks made during
removal.
4. NOTE: RH and LH dimensions are identical. All measurements on center.
If installing a new subframe, measure for correct positioning of the subframe to vehicle underbody.
1. Location 1 — 260 mm (10.236 in).
2. Location 2 — 666 mm (26.22 in).
5. Tighten the subframe bolts.
1. Tighten the forward bolts to 60 Nm (44 lb-ft).
2. Tighten the new rearward bolts to 100 Nm (74 lb-ft).
Tighten the rearward bolts an additional 240 degrees.
6. Install the engine roll restrictor bolt.

7. Connect the exhaust hanger.

8. Install the subframe braces and bolts.
9. Connect the ball joints to the steering knuckles.

Install new bolts.
10. Connect the tie-rod ends to the steering knuckle.

Install new nuts.
11. Connect the lower stabilizer bar links and install the nuts.
12. Install the front tires and wheels. For additional information, refer to Section 204-04 .
13. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and
steering column shaft detachment or loss of steering control. Failure to follow this instruction may
result in serious injury to vehicle occupant(s).
Connect the steering shaft and install a new pinch bolt.

14. If installing a new subframe, check wheel alignment. For additional information, refer to Section 204-00 .
SECTION 303-00: Engine System — General Information 2011 Fiesta Workshop Manual
Material
Capacity
Dye-Lite® Gasoline Engine Oil — —
Leak Detection Dye
164-R3700 (Rotunda)
Motorcraft® SAE 5W-20 WSS- —
Premium Synthetic Blend Motor M2C945-A
Oil (US); Motorcraft® SAE 5W-
20 Super Premium Motor Oil
(Canada)
XO-5W20-QSP (US); CXO-
5W20-LSP12 (Canada); or
equivalent
Threadlock 262 WSK- —
TA-26 M2G351-A6
Description Nm lb-ft
Flywheel retaining bolts a — —
Engine
NOTICE: When repairing engines, all parts must be contamination free. If contamination/foreign
material is present when repairing an engine, premature engine failure may occur.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the appropriate
section in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to refinish it or install a new
component. Wear limits are provided as an aid to determine if the component can be refinished. A new
component must be installed when any component fails to meet specifications and cannot be refinished.
NOTE: This section contains information, steps and procedures that may not be specific to this engine.
This section covers general procedures and diagnosis and testing of the engine system, except for
exhaust emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
The engine incorporates the following features: Refer to the appropriate section in Group 303 for the
procedure.
Crankcase ventilation or breather system

Exhaust emission control system
Evaporative Emission (EVAP) control system
Some engines incorporate a fail-safe cooling system. Refer to the appropriate section in Group 303 for
the procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust
emission levels and must be maintained according to the maintenance schedule. Refer to the scheduled
Maintenance Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for
the procedure.
For complete vehicle and engine identification codes, refer to Section 100-01 .
Engine
Special Tool(s)
12 Volt Master UV Diagnostic
Inspection Kit
164-R0756 or equivalent (Leak
Detector)
Dial Indicator Gauge with

Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
EngineEAR
EngineEAR/ChassisEAR
Oil Pressure Gauge

303-088 (T73L-6600-A)
Vacuum/Pressure Tester

tool
Material
Item Specification
Dye-Lite® Gasoline Engine Oil —
Leak Detection Dye
164-R3700 (Rotunda)
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil (US); M2C945-A
Motorcraft® SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-
LSP12 (Canada); or equivalent
There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out
either Inspection and Verification — Engine Performance or Inspection and Verification — NVH.
Inspection and Verification — Engine Performance
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.

Mechanical
Engine coolant leaks
Engine oil leaks
Fuel leaks
Damaged or severely worn parts
Loose mounting bolts, studs and nuts
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
5. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground

tool.


418-00 .
If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble
Codes (CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern, go to the DTC Chart, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine .
Inspection and Verification — NVH
1. NVH symptoms should be identified using the diagnostic tools and techniques that are available.
For a list of these techniques, tools, an explanation of their uses and a glossary of common
terms, refer to Section 100-04 .
2. Verify the customer concern by operating the engine to duplicate the condition.
3. Check the engine oil level and check the oil for contamination. Low engine oil level or
contaminated oil are a common cause of engine noise. If the oil is contaminated, the source of
the contamination must be identified and repaired as necessary.

Mechanical
Loose mounting bolts, studs and nuts
Damaged or leaking powertrain mounts
Damaged or disconnected vacuum hoses
Obstruction of cooling fan
Obstruction of Front End Accessory Drive (FEAD)
Damaged or disconnected air intake components
5. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.

tool.


418-00 .
If the network test passes, retrieve and record continuous memory DTCs.
10. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
11. If the DTCs retrieved are related to the concern, go to the DTC Chart, refer to Section 419-10 .
12. If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise
concern is related to the engine. For vibration concerns and noise concerns such as powertrain
mounts, air intake system and starter, GO to Symptom Chart - NVH .
In some cases, a noise may be a normal characteristic of that engine type. In other cases the noise may
require further investigation. Comparing the noise to a similar year/model vehicle equipped with the
same engine will aid in determining if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the
location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope (the noise will always be
louder closer to the noise source) to isolate the location of the noise to one of the following:
Fuel injector(s)
Upper end of engine
Lower end of engine
Front of engine
Rear of engine
Fuel injector noise
A common source of an engine ticking noise can be related to the fuel injector(s). This is normal engine
noise that can be verified by listening to another vehicle. If the injector noise is excessive or irregular,
use the EngineEAR/ChassisEAR or stethoscope to isolate the noise to a specific fuel injector.
Upper end engine noise
A common source of upper end engine noise (ticking, knocking or rattle) include the camshaft(s) and
valve train. Upper end engine noise can be determined using the EngineEAR/ChassisEAR or
stethoscope on the valve cover bolts. If the noise is loudest from the valve cover bolts, then the noise is
upper end. The EngineEAR/ChassisEAR or stethoscope can be used to further isolate the noise to the
specific cylinder bank and cylinder. Removal of the valve covers will be required to visually inspect the
valve train to pinpoint the source of the noise.
Lower end engine noise
A common source of lower end engine noise (ticking or knocking) include the crankshaft, connecting rod
(s) and bearings. Lower end noises can be determined by using the oil pan or lower cylinder block. If the
noise is loudest from these areas, then the noise is lower end. If an engine noise is isolated to the lower
end, some disassembly of the engine may be required to inspect for damage or wear.
Front of engine noise
A common source of noise from the front of the engine (squeal, chirp, whine or hoot) is the Front End
Accessory Drive (FEAD) components. To isolate FEAD noise, carry out the Engine Accessory Test,
Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine.
Use the EngineEAR/ChassisEAR or stethoscope on the engine front cover to determine if the noise is
internal to the engine. Removal of the engine front cover may be necessary to inspect internal engine
components.
Rear of engine noise
A common source of noise from the rear of the engine (knocking) is the flywheel/flexplate. Inspection of
the flywheel/flexplate will be necessary.
If equipped, the Rear End Accessory Drive (READ) can also be a source of noise from the rear of the
engine (squeal or chirp). The READ consists of the coolant pump and belt.
Some engines have timing drive components at the rear of the engine and may be the source of noise
(ticking, knocking or rattle). Use the EngineEAR/ChassisEAR or stethoscope on the rear of the engine if
the noise is suspected to be internal to the engine. Some disassembly of the engine may be required to
inspect for damage or wear.
13. After the noise is localized, note the characteristics of the noise, including type of noise,
frequency and conditions when the noise occurs and GO to Symptom Chart - NVH .
Symptom Chart — Engine Performance
Symptom Chart — Engine Performance

Difficult Inoperative or Refer to the appropriate section
starting damaged ignition in Group 303 for the procedure.
system REFER to the Powertrain
Air or vacuum leak Control/Emissions Diagnosis
Inoperative or (PC/ED) manual.
damaged fuel system
Inoperative or
damaged starting
system
Damaged charging REFER to Section 414-00 .
system/battery
Burnt valve INSTALL a new cylinder head.
operation after the repair.
Worn piston INSTALL a new piston. TEST the
system for normal operation after
the repair.
Worn piston rings INSTALL new piston rings. TEST
the system for normal operation
after the repair.
Worn cylinder INSTALL a new cylinder block.
Damaged head INSTALL a new cylinder head
gasket gasket. TEST the system for
normal operation after the repair.
Inoperative or REFER to Section 303-03 .
damaged cooling
system
Fail-safe cooling REFER to the Powertrain
invoked (if equipped) Control/Emissions Diagnosis
(PC/ED) manual.
Poor idling Vacuum leaks Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
Inoperative or REFER to Section 303-07 .
damaged ignition
system
Inoperative or Refer to the appropriate section
damaged cooling in Group 303 for the procedure.
system
Inoperative or
damaged fuel system
(PC/ED) manual.
Incorrect valve ADJUST valve clearance.
clearance REFER to Section 303-01 . TEST
after the repair.
Incorrect valve-to- INSTALL a new cylinder head.
valve seat contact TEST the system for normal
Damaged head INSTALL a new cylinder head
gasket gasket. TEST the system for
Engine runs Inoperative or Refer to the appropriate section
rough damaged fuel system in Group 303 for the procedure.
Air or vacuum leaks
Inoperative or
damaged cooling
system
Inoperative or
damaged ignition
system
(PC/ED) manual.
Burnt or sticking INSTALL a new cylinder head.
valve TEST the system for normal
Weak or broken INSTALL a new valve spring.
valve spring TEST the system for normal
Carbon accumulation ELIMINATE carbon buildup.
in combustion TEST the system for normal
chamber operation after the repair.
Excessive oil Leaking oil REPAIR oil leakage. TEST the
consumption system for normal operation after
the repair.
Inoperative PCV REPAIR or INSTALL new
system components as necessary. TEST
after the repair.
Incorrect oil CHANGE oil to correct
specification.
Worn valve stem seal INSTALL a new valve stem seal.
Worn valve stem or INSTALL a new cylinder head.
valve guide TEST the system for normal
Sticking piston rings INSTALL new piston rings. TEST
after the repair.
Worn piston ring INSTALL a new piston and piston
groove pin. TEST the system for normal
Worn pistion or INSTALL a new piston or cylinder
cylinder block. TEST the system for
Oil in coolant Leaking head gasket INSPECT the engine
Damaged cylinder components. INSTALL new
block engine components as
Damaged cylinder necessary. Refer to the
head appropriate section in Group 303
for the procedure. TEST the
the repair.
Coolant in oil Leaking head gasket INSPECT the engine
Damaged cylinder components. INSTALL new
block engine components as
Damaged cylinder necessary. Refer to the
head appropriate section in Group 303
for the procedure. TEST the
the repair.
Insufficient Inoperative or Refer to the appropriate section
power damaged ignition in Group 303 for the procedure.
system
Air intake system
blockage
Lubrication system
blockage
Inoperative/blocked
or damaged fuel
system
Oil level too high DRAIN oil to correct level. TEST
after the repair.
Incorrect engine oil INSTALL correct specification
engine oil. TEST the system for
Excessive accessory Refer to the appropriate section
drive belt loading in Group 303 for the procedure.
Inoperative or
damaged cooling
system
(PC/ED) manual.
Damaged or plugged INSPECT exhaust system.
exhaust system
Incorrect tire size REFER to Section 204-00 .
Dragging brakes REFER to Section 206-00 .
Slipping transmission REFER to Section 307-11 .
Incorrect valve ADJUST valve clearance.
clearance REFER to Section 303-01 . TEST
after the repair.
Worn or damaged INSTALL a new valve tappet.
valve tappet TEST the system for normal
Damaged valve INSTALL a new cylinder head
guide assembly. TEST the system for
Compression normal operation after the repair.
leakage at valve seat
Seized valve stem
Weak or broken INSTALL a new valve spring.
valve spring TEST the system for normal
Worn or damaged INSTALL a new camshaft. TEST
cam the system for normal operation
after the repair.
Damaged head INSTALL a new head gasket.
gasket TEST the system for normal
Cracked or distorted INSTALL a new cylinder head
cylinder head assembly. TEST the system for
Damaged, worn or INSTALL a new piston ring(s).
sticking piston ring(s) TEST the system for normal
Worn or damaged INSTALL a new piston and piston
piston pin. TEST the system for normal
common terms, refer to Section 100-04 . Since it is possible that any one of multiple
systems may be the cause of the symptom, it may be necessary to use a process of
Drone type noise Powertrain mount CARRY OUT the
(s) Powertrain/Drivetrain Mount
Neutralizing procedure in this
normal operation after the
repair.
Drumming noise — Engine vibration CARRY OUT the
occurs inside the excites the body Powertrain/Drivetrain Mount
vehicle during idle resonances Neutralizing procedure in this
or high idle, hot or inducing interior section. TEST the system for
cold. Very low- noise normal operation after the
frequency repair.
drumming is very
rpm dependent
Engine drumming Powertrain mount CARRY OUT the
noise — (s) Powertrain/Drivetrain Mount
accompanied by Neutralizing procedure in this
vibration section. TEST the system for
repair.
Rattle — occurs at Powertrain mount CHECK the powertrain
idle or at light (s) mounts for damage.
acceleration from a INSTALL new mounts as
stop necessary. For engine,
For transaxle, REFER to
Section 307-11 . TEST the
system for normal operation
after the repair.
Whine/moan type Powertrain mount CHECK the powertrain
noise — pitch (s) mounts for damage.
increases or INSTALL new mounts as
changes with necessary. For engine,
vehicle speed REFER to Section 303-01 .
For transaxle, REFER to
after the repair.
Clunk — occurs Powertrain mount CHECK the
when shifting from (s) powertrain/drivetrain mounts
PARK or between for damage. INSTALL new
REVERSE and mounts as necessary. For
DRIVE engine, REFER to Section
303-01 . For transaxle,
Idle speed is too CHECK for the correct idle
high speed.
Accessory drive Accessory drive CARRY OUT the engine cold
bearing hoot — idler or tensioner soak procedure. REFER to
occurs at idle or pulley bearing is Section 100-04 .
high idle in cold experiencing PLACE the EngineEAR
temperatures of stick/slip between probe directly on the
approximately 4°C ball bearings and idler/tensioner center post or
(40°F) or colder at the bearing race bolt to verify which bearing is
the first start of the making the noise. INSTALL
day new parts as necessary.
Accessory drive Defective/worn or CARRY OUT the Engine
belt noise, squeal incorrect accessory Accessory Test. REFER to
or chirping drive belt Section 100-04 . INSPECT
Misaligned pulley(s) components and INSTALL
Pulley runout new parts as necessary.
Damaged or worn REFER to Section 303-05 .
accessory drive TEST the system for normal
component or idler operation after the repair.
Fluid contamination
of the accessory
drive belt or pulleys
Damaged or worn
accessory drive belt
tensioner
Damaged pulley
grooves
Clunking noise Coolant pump has CHECK the coolant pump for
excessive end play excessive end play.
or imbalance INSPECT the coolant pump
for imbalance with the drive
belt off. INSTALL a new
coolant pump as necessary.
Whine or moaning Air intake system CHECK the air cleaner and
noise ducts for correct fit.
INSPECT the air intake
system for leaks or damage.
REPAIR as necessary. TEST
Whistling noise — Air intake system CHECK the air intake ducts,
normally air cleaner, throttle body and
accompanied with vacuum hoses for leaks and
poor idle condition correct fit. REPAIR or
ADJUST as necessary.
Hissing noise — Vacuum leak USE the Ultrasonic Leak
occurs during idle Detector/EngineEAR to
or high idle that is locate the source. SCAN the
apparent with the air intake system from the
hood open inlet to each cylinder intake
port. DISCARD the leaking
parts, and INSTALL a new
component. TEST the
after the repair.
Vehicles with a Acceptable condition. Some
plastic intake plastic manifolds exhibit this
manifold noise, which is the effect of
the plastic manifold.
Grinding noise — Incorrect starter INSPECT the starter motor
occurs during motor mounting for correct mounting.
engine cranking REPAIR as necessary.
Starter motor CHECK the starter motor.
INSTALL a new starter motor
as necessary. REFER to
after the repair.
Incorrect starter INSPECT the starter motor
motor drive drive for wear or damage.
engagement INSTALL a new starter motor
as necessary. REFER to
after the repair.
INSPECT the flexplate for
wear or damage. INSTALL a
new flexplate as necessary.
Engine noise, front Damaged or CHECK for obvious signs of
of engine — separated damage or wobble during
knocking noise crankshaft operation. INSTALL new as
from lower front of pulley/damper necessary. REFER to
engine Section 303-01 . TEST the
after the repair.
Engine noise, front Timing drive REMOVE the accessory
of engine — components drive belt. REFER to Section
ticking, tapping or 303-05 .
rattling noise from USE the EngineEAR to
the front of the isolate the noise to the
engine engine front cover.
REMOVE the engine front
cover and INSPECT the
timing drive components.
INSTALL new parts as
necessary. REFER to
after the repair.
Engine noise, Fuel rail clip CHECK for loose or
upper end — damaged fuel rail clip(s).
ticking noise near REPAIR as necessary. TEST
the fuel rail and the system for normal
intake manifold operation after the repair.
Fuel injector USE the EngineEAR to
isolate the noisy injector(s).
INSTALL a new injector(s) as
necessary. REFER to
after the repair.
Engine noise, Worn or damaged REMOVE the spark plugs.
upper end — spark plugs INSPECT and INSTALL new
occurs mostly with as necessary. REFER to
a warm engine at Section 303-07 . TEST the
light/medium system for normal operation
acceleration after the repair.
Carbon Bore scope the cylinder.
accumulation in ELIMINATE carbon buildup.
combustion TEST the system for normal
chamber operation after the repair.
Engine noise, Low oil level CHECK the oil level. FILL as
upper end — necessary.
rattling noise from
the valve train.
Worse when the
engine is cold
Thin or diluted oil INSPECT the oil for
contamination. If the oil is
contaminated, CHECK for
the source. REPAIR as
necessary. CHANGE the oil
and filter. TEST the system
for normal operation after the
repair.
Low oil pressure CARRY OUT an oil pressure
test. If not within
specifications, REMOVE the
engine oil pan. REFER to
Section 303-01 . INSPECT
for a blocked oil pick up tube.
Worn valve train CARRY OUT the Valve Train
components Analysis Component Test in
this section. INSTALL new
parts as necessary. TEST
Worn valve guides CARRY OUT the Valve
Guide Inner Diameter
procedure in this section.
Excessive runout of CARRY OUT the Valve Seat
the valve seats on Inspection procedure in this
the valve face section.
Engine noise, Gasoline octane too VERIFY with customer the
upper end — low type of gasoline used.
pinging noise CORRECT as necessary.
Knock Sensor (KS) CHECK the KS . INSTALL a
operation new KS as necessary.
Incorrect spark CHECK the spark timing.
timing REPAIR as necessary. TEST
High operating INSPECT the cooling system
temperature for leaks. CHECK the coolant
level. REFILL as necessary.
CHECK the coolant for the
correct mix ratio. DRAIN and
REFILL as needed. VERIFY
the engine operating
temperature is within
specifications. REPAIR as
repair.
Spark plug CHECK the spark plugs.
INSTALL new spark plugs as
repair.
Catalytic converter Compare with a similar
vehicle for what is acceptable
noise.
Engine noise, lower Oil pump USE the EngineEAR to verify
end — ticking or the oil pump as the source of
knocking noise the noise at low rpm.
near the oil filter REPAIR as necessary.
adapter REFER to Section 303-01 .
Engine noise, lower Excessive CARRY OUT the Piston-to-
end — light clearance between Cylinder Bore Clearance
knocking noise, the piston and the procedure in this section.
also described as cylinder wall
piston slap. Noise
is most noticeable
when the engine is
cold with light to
medium
acceleration. The
noise disappears
as the engine
warms
Engine noise, lower Excessive CARRY OUT the Piston Pin
end — light double clearance between Bore Diameter and the
knock or sharp rap the piston and the Piston Pin Diameter
sound. Occurs piston pin procedures in this section.
mostly with a warm
engine at idle or
low speeds in
drive. Increases in
relation to engine
load. Associated
with a poor
lubrication history
Engine noise, lower Excessive CARRY OUT the Connecting
end — light clearance between Rod Bearing Journal-to-
knocking noise. the connecting rod Bearing Clearance procedure
The noise is most bearings and the in this section.
noticeable when crankshaft
the engine is warm.
The noise tends to
decrease when the
vehicle is coasting
or in NEUTRAL
Engine noise, lower Worn or damaged CARRY OUT the Crankshaft
end — deep crankshaft main Main Bearing Journal-to-
knocking noise. bearings Bearing Clearance procedure
The noise is most in this section.
noticeable when
the engine is warm,
at lower rpm and
under a light load
and then at float
Engine noise, rear Damaged CARRY OUT the Flexplate
of engine — flywheel/flexplate Inspection procedure in this
knocking noise at section.
rear of engine
Engine vibration — Excessive engine CARRY OUT the Engine
vibration felt at all pulley runout Accessory Test. REFER to
times Section 100-04 . INSTALL a
new engine pulley as
necessary. REFER to
after the repair.
Damaged or worn CARRY OUT the Engine
accessory Accessory Test. REFER to
component Section 100-04 . REPAIR or
INSTALL a new component
as necessary. TEST the
after the repair.
Engine vibration — Cylinder misfire Using the scan tool, CARRY
at idle, a low- OUT the cylinder power
frequency vibration balance and the relative
(5-20 Hz) or mild compression test. REPAIR
shake that is felt as necessary. REFER to
through the Section 303-01 . TEST the
seat/floorpan system for normal operation
after the repair.
Engine vibration — Powertrain mount CHECK the powertrain
is felt with (s) mounts for damage.
increases and INSTALL new mounts as
decreases in necessary. For engine,
engine rpm REFER to Section 303-01 .
For the transaxle, REFER to
after the repair.
Engine or INSPECT the
transmission powertrain/drivetrain for
grounded to correct clearances. REPAIR
chassis as necessary. TEST the
after the repair.
Engine vibration — Engine out-of- CARRY OUT the Neutral
increases intensity balance Engine Run-Up (NERU)
as the engine rpm Test. REFER to Section 100-
is increased 04 . TEST the system for
repair.
Engine vibration — Combustion CHECK the ignition system.
mostly at instability INSTALL new components
coast/neutral coast. as necessary. REFER to
Condition improves Section 303-07 . TEST the
with vehicle system for normal operation
acceleration after the repair.
Engine vibration or Worn or damaged INSPECT the spark plugs for
shudder — occurs spark plugs cracks, high resistance or
with light to broken insulators. INSTALL a
medium new spark plug(s) as
acceleration above necessary. REFER to
56 km/h (35 mph) Section 303-07 . TEST the
after the repair.
Plugged fuel REPAIR or INSTALL a new
injector injector as necessary.
Contaminated fuel INSPECT the fuel for
contamination. DRAIN the
fuel system and refill. REFER
to Section 310-00 .
Component Tests
The following component tests are used to diagnose engine concerns.

Engine Oil Leaks
NOTE: When diagnosing engine oil leaks, the source and location of the leak must be positively
identified prior to repair. If the vehicle is driven extensively between adding the fluorescent additive and
performing the leak test, fan air or wind can spread the leaking oil and make identifying the location of
the leak difficult.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and
flywheel with a suitable solvent to remove all traces of oil.
Engine Oil Leaks — Fluorescent Oil Additive Method
Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak
diagnosis.
1. Add 29.6 ml (1 oz) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of
0.95L (1 qt) engine oil and fill through the engine oil fill. Thoroughly premix the gasoline engine oil
dye or it will not have enough time to reach the crankcase, oil galleries and seal surfaces during
this particular 15 minute test. The additive must be mixed well with oil and added through the oil
fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in
the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark,
use 0.47L (1/2 qt).
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks
using the UV Leak Detector Kit. A clear bright yellow or orange area will identify the leak. For
extremely small leaks, several hours may be required for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks.
Remove oil as necessary if it registers above the full mark.
Leakage Points — Underhood
Examine the following areas for oil leakage:
Valve cover gaskets

Cylinder head gaskets
Oil cooler, if equipped
Oil filter adapter
Engine front cover
Oil filter adapter and filter body
Oil level indicator tube connection
Engine Oil Pressure (EOP) switch
Leakage Points — Under Engine, With Vehicle on Hoist
Oil pan gaskets

Oil pan sealer
Engine front cover gasket
Crankshaft front seal
Crankshaft rear oil seal
Oil filter adapter and filter body
Oil cooler, if equipped
Leakage Points — With Transmission and Flywheel Removed
Crankshaft rear oil seal

Rear main bearing cap parting line
Flexplate mounting bolt holes (with flexplate installed)
Pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected
when using the dye method.
Compression Test
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle until the engine is at normal operating
temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs.
2. Set the throttle plates in the wide-open position.
3. Install a compression gauge in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position,
and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and
record the highest reading. Note the approximate number of compression strokes necessary to
obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test — Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder is
at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart

Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
924 kPa 696 kPa 1,131 kPa 848 kPa 1,338 kPa 1,000 kPa 1,544 kPa 1,158 kPa
(134 psi) (101 psi) (164 psi) (123 psi) (194 psi) (146 psi) (224 psi) (168 psi)
1,007 kPa 758 kPa 1,214 kPa 910 kPa 1,420 kPa 1,062 kPa 1,627 kPa 1,220 kPa
1,110 kPa 834 kPa 1,324 kPa 993 kPa 1,631 kPa 1,145 kPa — —
(161 psi) (121 psi) (192 psi) (144 psi) (222 psi) (166 psi)
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford
specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check
on these cylinders.
Compression Test — Interpreting Compression Readings
1. If compression improves considerably, piston rings are worn or damaged.
2. If compression does not improve, valves are sticking or not seating correctly.
3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does
not increase compression, the head gasket may be leaking between cylinders. Engine oil or
coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the
lowest reading is within 75% of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing
the exact cause.
The leakage tester is inserted in the spark plug hole, the piston is brought up to Top Dead Center (TDC)
on the compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of
leakage. Leakage exceeding 20% 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 (TB). A leak at the exhaust valve can be heard at the tailpipe.
Leakage past the piston rings will be audible at the 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.
Excessive Engine Oil Consumption
Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and
pistons and rings. Determining the level of oil consumption may require testing by recording how much
oil is being added over a given set of miles.
Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy
loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent
the engine from reaching normal operating temperature. This prevents component clearances from
reaching specified operating ranges.
The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that
the concern is related to internal oil consumption, and not external leakage, which also consumes oil.
Verify there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption
can be tested.
A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances
and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances
and do not require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient
temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the
vehicle in the geographic region in which it is driven.
Basic Pre-checks
1. For persistent complaints of oil consumption, interview the customer to determine the oil
consumption characteristics. If possible, determine the brand and grade of oil currently in the oil
pan. Look at the oil filter or oil-change station tags to determine if Ford-recommended
maintenance schedules have been followed. Make sure that the oil has been changed at the
specified mileage intervals. If vehicle mileage is past the first recommended drain interval, the
OEM production filter should have been changed.
2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was
driven under the following conditions:
Extended idling or curbside engine operation
Stop-and-go traffic or taxi operation
Towing a trailer or vehicle loaded heavily
Frequent short trips (engine not up to normal operating temperature)
Excessive throttling or high engine-rpm driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under
Engine Oil Leaks in the Diagnosis and Testing portion of this section.
4. Inspect the crankcase ventilation system for:

disconnected hoses at the valve cover or TB .
loose or missing valve cover fill cap.
missing or incorrectly seated engine oil level indicator.
incorrect or dirty PCV valve.
a PCV valve grommet unseated in the valve cover (if so equipped).
5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder
head drainback wells. It can also increase oil pressure by restricting passages and reducing the
drainback capability of piston oil control rings. Sludge can result from either excessive water
ingestion in the crankcase or operation at extremely high crankcase temperatures.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air
to bypass into the air induction system. This can cause premature internal wear (engine dusting),
allowing oil to escape past rings, pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain
back. Ask the customer if this requirement has been followed. Adding oil without this wait period
can cause an overfill condition, leading to excessive oil consumption and foaming which may
cause engine damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube.
Remove the oil level indicator and record the oil level.
Detailed Pre-checks
1. Check the thermostat opening temperature to make sure that the cooling system is operating at
the specified temperature. If it is low, internal engine parts are not running at specified internal
operating clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as
an oil soaked condition on the plug. If a plug is saturated, a compression check may be
necessary at the conclusion of the oil consumption test.
Oil Consumption Test
Once all of the previous conditions are met, carry out an oil consumption test.
1. Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter. Make
sure the vehicle is positioned on a level surface. Refill the oil pan to a level one liter (quart) less
than the specified fill level, using manufacturer-specified oil.
2. Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 5-minute
drainback period and then record the oil level shown on the oil level indicator. Place a mark on
the backside of the oil level indicator noting the oil level location.
3. Add the final one liter (quart) to complete the normal oil fill. Restart the engine and allow it to idle
for 2 minutes. Shut the engine down.
4. After a 5-minute drainback period, record the location of the oil level again. Mark the oil level
indicator with the new oil level location. (Note: Both marks should be very close to the MIN-MAX
upper and lower limits or the upper and lower holes on the oil level indicator. These marks will
exactly measure the engine's use of oil, with a one quart differential between the new marks.)
Demonstrate to the customer that the factory-calibrated marks on the oil level indicator are where
the oil should fall after an oil change with the specified fill amount. Explain however, that this may
vary slightly between MIN-MAX or the upper and lower holes on the oil level indicator.
5. Record the vehicle mileage.
6. Advise the customer that oil level indicator readings must be taken every 320 km (200 mi) or
weekly, using the revised marks as drawn. Remind the customer that the engine needs a
minimum 5-minute drainback for an accurate reading and that the oil level indicator must be firmly
seated in the tube prior to taking the reading.
7. When the subsequent indicator readings demonstrate a full liter (quart) has been used, record the
vehicle mileage. The mileage driven should not be less than 2,414 km (1,500 mi). The drive cycle
the vehicle has been operated under must be considered when making this calculation. It may be
necessary to have the customer bring the vehicle in for a periodic oil level indicator reading to
closely monitor oil usage.
Post Checks, Evaluation and Corrective Action
1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The
cylinder compression test should be carried out with a fully charged battery and all spark plugs
removed. See the Compression Test Chart in this section for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the Compression Testing portion
of this section. 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.
3. A cylinder leak detection test can be carried out using a cylinder leakage tester. This can help
identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or
other related areas as the source of oil consumption.
NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil
use. A typical engine with normal oil consumption will exhibit a light tan to brown appearance. See Spark
Plug Analysis in this section for details. A single or adjoining, multiple cylinder leak can be traced by
viewing the tips.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost
limits and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were
eliminated in the original diagnosis, repeat the Oil Consumption Test as described above and
verify consumption results.
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 conducted. Subtract 4.0193 kPa (1 in-Hg) from the specified reading
for every 304.8 m (1,000 ft) of elevation above sea level.
The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle
is fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter.
Intake Manifold Vacuum Test — Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas.
Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge
readings, although helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.
1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
2. NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the engine
is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When
the throttle is suddenly released, the needle will snap back up to a higher than normal figure.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low
as 51 kPa (15 in-Hg) but will be relatively steady. Some oscillation is normal.
4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
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.
6. BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle

indicates one or more burned or warped valves. Insufficient valve clearance will also cause this
reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves
are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is
increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat
low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small
pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket
leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket
or warped cylinder head-to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may
be normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler,
kinked tailpipe or other 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.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the
system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster, the unit will not function correctly. Always fix vacuum leaks.
Oil Pressure Test
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure switch oil galley port.
3. Run the engine until normal operating temperature is reached.
4. Run the engine at the specified rpm and record the gauge reading.
5. The oil pressure should be within specifications; refer to the specification chart in the appropriate
engine section.
6. If the pressure is not within specification, check the following possible sources:
Insufficient oil
Oil leakage
Worn or damaged oil pump
Oil pump screen cover and tube
Excessive main bearing clearance
Excessive connecting rod bearing clearance
Chain tensioner leak
Valve Train Analysis
The following component tests are used to diagnose valve train concerns.
Valve Train Analysis — Engine Off — Valve Cover Removed
Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with
the static engine analysis as follows.
Valve Train Analysis — Camshafts and Valve Tappets
Check for broken or damaged parts.

Check for loose mounting bolts on camshaft caps.
Check for worn or damaged valve tappets.
Valve Train Analysis — Valve Springs — Valve Tappets Removed
Check for broken or damaged parts.
Valve Train Analysis — Valve Spring Retainer and Valve Spring Retainer Keys — Valve Tappets
Removed
Check for correct seating of the valve spring retainer key on the valve stem and in valve spring
retainer.
Check for correct seating on the valve stem.
Valve Train Analysis — Valves and Cylinder Head — Valve Tappets Removed
Check for plugged oil drain back holes.

Check for worn or damaged valve tips.
Check for missing or damaged valve stem seals or guide-mounted valve stem seal.
Check for missing or worn valve spring seats.
Valve Train Analysis — Camshaft Lobe Lift
Check the lift of each camshaft lobe in consecutive order and make a note of the readings.
1. Remove the spark plugs. Refer to Section 303-07 .
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the dial indicator is on
top of the camshaft lobe and on the same plane as the valve tappet.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer
bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
4. Zero the dial indicator. Continue to rotate the crankshaft until the high-lift point of the camshaft
lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original dial indicator reading, continue to rotate crankshaft until the
base circle is reached. The dial indicator reading should be zero. If zero reading is not obtained,
repeat Steps 1 through 6.
6. If the lift on any lobe is below specified service limits, install a new camshaft and valve tappets.
7. Install the spark plugs. Refer to Section 303-07 .

Sprockets
1. Inspect the sprockets for cracks and worn or chipped teeth.

Camshaft Bearing Journal Diameter
NOTE: Refer to the appropriate Section 303-01 for the specification.
1. Measure each camshaft journal diameter in 2 directions.

Camshaft Journal to Bearing Clearance — OHC Engines
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
Measure each camshaft bearing in 2 directions.

Subtract the camshaft journal diameter from the camshaft bearing diameter.
Camshaft End Play — OHC Engines
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
If camshaft end play exceeds specification after camshaft installation, install a new cylinder
head.
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
Camshaft Lobe Lift
Special Tool(s)
Dial Indicator Gauge with Holding
Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading to figure the camshaft lobe lift.
Camshaft Runout
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
Camshaft must be supported on the first and last camshaft bearing journal.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading.
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
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.
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
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.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.

Crankshaft End Play
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
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.
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. If the cylinder bore taper does not meet specification, bore the cylinder to the next
oversize limit.
Cylinder Bore Out-of-Round
1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.

Piston Inspection
Special Tool(s)
Scraper, Piston Ring Groove
303-D033 (D81L-6002-D) or
equivalent
NOTICE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage
can occur.
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.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
Make sure the oil ring holes are clean.
Piston Pin Bore Diameter
1. 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 within
specification.
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.
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a
piston.
1. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based
on their relative position within the range. A paint spot or specific size grade on a new piston
indicates the position within the size range.
Choose the piston with the correct paint color or specific size grade.
Refer to the appropriate section in Group 303 for the procedure.
Piston Ring End Gap
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The 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.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end
gap.
Piston Ring-to-Groove Clearance
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
Connecting Rod Cleaning
NOTICE: 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.
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.
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
Connecting Rod Bend
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
Connecting Rod Twist
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture.
Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals 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.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or
connecting rod bearing.
Connecting Rod to Crankshaft Side Clearance
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the
crankshaft. Verify the measurement is within specification.
Valve Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the
diameter is within specification.
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.
Valve Guide Inner Diameter
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 inside diameter of the valve guides in 2 directions at the top,
middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.
Valve Stem to Valve Guide Clearance
Special Tool(s)
Clearance Gauge, Valve Guide
303-004 (TOOL-6505-E) or
equivalent

Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide
clearance.
1. NOTE: If necessary, use a magnetic base.
Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture
and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial
Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve
stem-to-valve guide clearance.
Valve Spring Installed Length
1. Measure the installed length of each valve spring.

Valve Spring Free Length
1. Measure the free length of each valve spring.

Valve Spring Strength
Special Tool(s)
Pressure Gauge, Valve/Clutch
Spring
303-006 (TOOL-6513-DD) or
equivalent
1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.

Check valve angles.
Check margin width.
Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if
abnormalities are found.
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.
Depending on the engine, check the valve lash. Refer to General Procedures in Section
303-01.
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.

Flexplate Inspection
1. Inspect the flexplate for:

1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.
Cylinder Head Distortion
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil
and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm
(0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if
the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004
in) from end to end.
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the
sequence shown.
Cylinder Block Distortion
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in)
per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is
61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.
Cylinder Bore Cleaning
Material
Item Specification
LSP12 (Canada); or equivalent
1. NOTICE: If these procedures are not followed, rusting of the cylinder bores may occur.
Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores.

Use clean engine oil meeting Ford specification.
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
Exhaust Manifold Cleaning and Inspection
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-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.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm
(0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if
the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004
in) from end to end.
Using the Straightedge and a Feeler Gauge Set, 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.
Core Plug Replacement
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
All core plugs
1. NOTE: Cylinder block core plug shown, cylinder head core plug similar.
Use the Slide Hammer and a freeze plug remover to remove the core plug.
2. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the
plug.
Inspect the core plug bore for any damage that would interfere with the correct sealing of the
plug. If the core plug bore is damaged, bore for the next oversize plug.
Cup-type
3. NOTICE: Use care during this procedure so as not to disturb or distort the cup sealing
surface.
NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to
effectively seal the bore.
Coat the cup-type core plug and bore lightly with sealant and install the core plug using a freeze
plug installer.
Expansion-type
4. NOTICE: Do not contact the crown when installing an expansion-type core plug. This could
expand the plug before seating and result in leakage.
Coat the expansion-type core plug and bore lightly with sealant and install the core plug using a
freeze plug installer.
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.

Check for deposit build-up closing the gap between the electrodes. Deposits are caused by
oil or carbon fouling.
Install a new spark plug.
2. Check for oil fouling.

Check for wet, black deposits on the 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.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed
shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air
cleaner, too rich a fuel mixture or excessive idling.
Install new spark plugs.
4. Inspect for normal burning.
Check for light tan or gray deposits on the firing tip.
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.
6. Inspect for overheating, identified by white or light gray spots and a 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.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
Install new spark plugs.
Valve Tappet Inspection
1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident,
inspect the camshaft lobes and valves for damage. Install new components as necessary.
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate section and procedure for special instructions on loosening and
tightening mount fasteners.
100-02 .
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts
may occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the
same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.

SECTION 303-01: Engine — 1.6L 2011 Fiesta Workshop Manual
Material
Item Specification Fill Capacity
Gasket Maker WSK- —
TA-16 M2G348-A5
Motorcraft® Full Synthetic WSD- —
Manual Transmission M2C200-C
Fluid
XT-M5-QS
Motorcraft® Metal Surface — —
Prep
ZC-31-A
Motorcraft® SAE 5W-20 WSS- 4.05L (4.3 qt)
Premium Synthetic Blend M2C945-A includes filter
Motor Oil (US); change / 3.75L
Motorcraft® SAE 5W-20 (3.96 qt) without
Super Premium Motor Oil filter change
(Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12
(Canada)
Motorcraft® Specialty WSS- —
Orange Engine Coolant M97B44-D
VC-3-B (US); CVC-3-B
(Canada)
XG-4 and/or XL-5 B
Silicone Brake Caliper ESE- —
Grease and Dielectric M1C171-A
Compound
XG-3-A
Silicone Gasket and WSE- —
Sealant M4G323-A4
TA-30
Thread Sealant with PTFE WSK- —
M2G350-A2
TA-24
Item Specification
Engine
Displacement 1.6L
No. of cylinders 4
Bore/stroke 79.0/81.4 mm (3.11/3.20 in)
Firing order 1-3-4-2
Oil pressure (hot @ 800 rpm) 100 kPa (14.5 psi)
Oil pressure (hot @ 2,000 rpm) 200 kPa (29.0 psi)
Compression ratio 11:1
Engine weight — (with flexplate) 81.0 kg (178.6 lb)
Engine and transaxle weight — 157.2 kg (346.6 lb)
automatic transaxle
Engine weight — (with flywheel) 90.5 kg (199.5 lb)
Engine and transaxle weight — manual 166.6 kg (367.5 lb)
transaxle
Cylinder Block
Cylinder bore diameter 79.005-79.025 mm (3.110-3.111 in)
Cylinder bore maximum out-of-round 0.008 mm (0.0003 in)
Main bearing bore diameter 54.000-54.018 mm (2.126-2.127 in)
Head gasket surface flatness 0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general)
(0.0019 in/7.87 x 7.87)
Piston
Piston diameter (single grade) 78.977 - 78.991 mm (3.1093 - 3.1099 in)
Piston-to-cylinder bore clearance 0.0135 - 0.0485 mm (0.0005 - 0.0019 in)
Ring groove width — top 1.23-1.25 mm (0.048-0.049 in)
Ring groove width — 2nd 1.52-1.54 mm (0.059-0.060 in)
Ring groove width — oil 2.01-2.03 mm (0.079-0.080 in)
Piston skirt coating thickness Tin Plating
Piston Pin
Diameter 17.996-18.000 mm (0.7085-0.7086 in)
Length 51.0-51.3 mm (2.00-2.01 in)
Piston-to-pin clearance 0.012-0.020 mm (0.0005-0.0008 in)
Pin-to-rod clearance Press fit
Cylinder Head
Cylinder head flatness 0.1 mm (0.003 in) overall
Valve lift @ zero lash (exhaust) 8.6 mm (0.338 in)
Valve lift @ zero lash (intake) 8.7 mm (0.342 in)
Valve guide diameter 6.000-6.030 mm (0.242-0.244 in)
Valve seat width — intake/exhaust 1 mm ± 0.15 mm (0.039 in ± 0.006 in)
Valve seat angle 45 degrees
Valve seat runout 0.029 mm (0.001 in)
Valve tappet bore diameter 28.8-29.2 mm (1.13-1.15 in)
Cam bore diameter 25.0-25.03 mm (0.98-.099 in)
Valve
Valve head diameter — intake 30.1 mm ± 0.15 mm (1.18 in ± 0.006 in)
Valve head diameter — exhaust 24.1 mm ± 0.15 mm (0.95 in ± 0.006 in)
Valve stem diameter — intake 5.968 mm ± 0.0075 mm (0.235 in ± 0.0003 in)
Valve stem diameter — exhaust 5.958 mm ± 0.0075 mm (0.234 in ± 0.0003 in)
Valve stem-to-guide clearance — intake 0.0245-0.0695 mm (0.0010-0.0027 in)
Valve stem-to-guide clearance — 0.0295-0.0745 mm (0.0011-0.003 in)
exhaust
Valve face runout 0.03 mm (0.001 in)
Valve face angle 44.5 degrees ± 0.15 mm (0.005 in)
Valve Spring — Compression Pressure
Intake and exhaust (installed) 180 N ± 11 N
Intake (valve open) 8.9 mm (0.35 in) of 320 N ± 20 N
lift
Exhaust (valve open) 8.94 mm (0.351 in) 320 N ± 20 N
of lift
Free length 48.7 mm ± 0.8 mm (1.92 in ± 0.031 in)
Assembled height 35.60 mm (1.401 in)
Crankshaft
Main bearing journal diameter 47.980-48.000 mm (1.888-1.889 in)
Production repair 47.730-47.750 mm (1.878-1.879 in)
Main bearing clearance 0.024-0.044 mm (0.0009-0.0017 in)
Connecting rod journal diameter 43.980-44.000 mm (1.731-1.732 in)
Production repair 43.730-43.750 mm (1.721-1.722 in)
End play 0.2-0.43 mm (0.008-0.017 in)
Rings
Width — top 1.19-1.23 mm (0.0468-0.0484 in)
Width — 2nd 1.495-1.53 mm (0.059-0.060 in)
Width — oil 2 mm (0.078 in)
Ring gap (in bore) — top 0.16-0.26 mm (0.0062-0.0102 in)
Ring gap (in bore) — 2nd 0.7-0.9 mm (0.0275-0.0295 in)
Ring gap (in bore) — oil 0.2-0.9 mm (0.0078-0.0295 in)
Valve Tappet
Diameter 27.965-27.980 (1.100-1.101 in)
Tappet-to-valve clearance — intake 0.17-0.23 mm (0.007-0.009 in)
Tappet-to-valve clearance — exhaust 0.31-0.37 mm (0.012-0.015 in)
Tappet-to-bore clearance 0.020-0.065 mm (0.0008-0.0025 in)
Camshaft
End play 0.07-0.20 mm (0.003-0.008 in)
Lobe lift — intake 8.9 mm (0.35 in)
Lobe lift — exhaust 8.94 mm (0.351 in)
Runout (1) a 0.02 mm (0.0008 in)
Thrust clearance 30.960-30.980 mm (1.21-1.22 in)
Journal diameter 24.97 mm ± 0.01 mm (0.98 in ± 0.0004 in)
Journal-to-bore clearance 0.020-0.070 mm (0.0008-0.0027 in)
Connecting Rod
Running clearance 0.024-0.044 mm (0.0009-0.0017 in)
Bearing clearance 0.024-0.044 mm (0.0009-0.0017 in)
Bearing thickness (grade 1) 1.499-1.506 mm (0.0590-0.0592 in)
Crank bore diameter 47.025-47.045 mm (1.851-1.852 in)
Pin bore diameter 17.965-17.985 mm (0.7072-0.7080 in)
Length (center to center) 137 mm (5.393 in)
a No. 3 Journal — Supported by No. 1 and No. 5 journals.
Accessory drive belt idler pulley bracket bolts (without A/C only) 24 18 —
Accessory drive belt splash shield bolts 9 — 80
A/C compressor bolts and stud bolt 25 18 —
A/C line bracket nut 9 — 80
Battery tray bolts 10 — 89
Battery tray bracket nuts 10 — 89
Bellhousing-to-engine bolts 48 35 —
Block heater nut 3 — 27
Camshaft bearing caps a — — —
Camshaft phaser and sprocket bolts — Exhaust a — — —
Camshaft phaser and sprocket bolts — Intake a — — —
Camshaft phaser and sprocket plugs 16 — 142
Camshaft Position (CMP) bolts 9 — 80
Camshaft trigger wheel bolts 21 15 —
Catalytic converter bracket-to-catalytic converter bolts 25 18 —
Catalytic converter bracket-to-engine bolts 50 37 —
Catalytic converter-to-cylinder head studs 17 — 150
Catalytic converter heat shield bolts 10 — 89
Catalytic converter nuts and bolt a — — —
Catalytic converter-to-muffler bolts 48 35 —
Clutch pressure plate a — — —
Connecting rod cap bolts a — — —
Coolant outlet bolts 19 — 168
Coolant outlet bracket nut and bolt 6 — 53
Coolant pump bolts a — — —
Coolant pump pulley bolts 20 — 177
Crankshaft rear seal bolts a — — —
Crankshaft Position (CKP) sensor bolts 8 — 71
Crankshaft pulley bolt a — — —
Crankcase vent oil separator bolts 9 — 80
Cylinder head bolts a — — —
Engine ground wire bolt 10 — 89
Engine lifting eye bolts — LH 19 — 168
Engine mount bolts 48 35 —
Engine mount bracket bolts a — — —
Engine mount nuts a — — —
Engine mount studs 8 — 71
Engine Oil Pressure (EOP) switch 18 — 159
Engine plug bolt 20 — 177
Engine-to-bellhousing bolts 48 35 —
Evaporative Emission (EVAP) canister purge valve bolt 9 — 80
Flexplate bolts a — — —
Flexplate-to-clutch nuts a — — —
Flywheel bolts a — — —
Fuel rail bolts 11 — 97
Halfshaft bracket lower bolts 24 18 —
Halfshaft bracket upper bolt 48 35 —
Heated Oxygen Sensor (HO2S) electrical connector bracket nut 8 — 71
Ignition coil screws 6 — 53
Intake manifold bolts 18 — 159
Main bearing beam bolts a — — —
Knock Sensor (KS) 20 — 177
Oil cooler bolt 56 41 —
Oil filter 15 — 133
Oil level indicator tube screw 4 — 35
Oil pan drain plug 28 21 —
Oil pan bolts a — — —
Oil pan-to-bellhousing bolts 48 35 —
Oil pump bolts a — — —
Oil pump screen and pickup tube bolts 9 — 80
PCM cover bolt 5.4 — 47.8
Positive battery cable nut 10 — 89
Selector lever cable bolt 10 — 89
Selector lever cable bracket bolts 25 18 —
Spark plugs 15 — 133
Starter motor bolts 48 35 —
Starter motor electrical terminals nuts 10 — 89
Thermostat housing bolts a — — —
Timing belt cover backplate bolts 9 — 80
Timing belt cover bolts — Lower 9 — 80
Timing belt cover bolts — Upper 9 — 80
Timing belt tensioner bolt 25 18 —
Transaxle fill plug 35 26 —
Transaxle support insulator bolts 90 66 —
Transaxle support insulator nuts 125 92 —
Transaxle roll-restrictor bolts 70 52 —
Valve cover retainers a — — —
Variable Camshaft Timing (VCT) bridge bolts a — — —
VCT solenoid bolts 8 — 71
Windage tray bolts 9 — 80
Engine
The 1.6L 4-cylinder engine has the following features:
Dual overhead camshaft

Four valves per cylinder
Sequential Multi-Port Fuel Injection (SFI)
Aluminum cylinder head
Aluminum cylinder block
Twin independent Variable Camshaft Timing (VCT) system
The 1.6L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses an ignition
coil and spark plug wires. The cylinder block is made of aluminum and the bearing caps are integrated
into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the
transmission to provide greater strength. The camshafts are mounted in the cylinder head and act
against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder
head by one timing belt. The belt is driven by a sprocket that is located on the crankshaft. The piston
assembly is an aluminum piston with a sinter forged carbon steel connecting rod. The oil pump is driven
by the crankshaft.
Engine Identification
Always refer to these labels when installation of new parts is necessary or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
make sure the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions.
Engine Code Information Label
The engine code information label, located on the front side of the timing cover, contains the following:
Item Description
1 Engine part number
2 Derivative of build
3 Bar code
4 Engine build date and time
5 Engine displacement
6 Engine build date (YYMMDD)
7 Bar code
8 Plant code (Taubate)
Engine Cylinder Identification

Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine are
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated
fuel injectors:
are mounted in the cylinder head.

meter fuel into the air intake stream in accordance with engine demand.
are positioned so that their tips direct fuel just ahead of the engine intake valves.
supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
Twin Independent Variable Camshaft Timing (VCT) System
The twin independent VCT system allows variable control of intake valve closing which optimizes
combustion at full load providing improved power and low speed torque (broadening the torque curve)
which enables variable valve overlap which provides better fuel economy and emissions and provides
optimized cold start operation with improved exhaust emissions.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake
manifold.
Lubrication System
The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
Oil is pumped through the oil filter on the left front side of the cylinder block and is cooled by an oil
cooler.
Oil enters the main gallery where it is distributed to the crankshaft main journals and to the
cylinder head.
From the main journals, the oil is routed through cross-drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings
and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as
well as the entire connecting rod, piston and piston ring assembly.
Engine
Refer to Section 303-00 for basic mechanical concerns or refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability concerns.
Valve Clearance Check
1. Remove the valve cover. For additional information, refer to Valve Cover in this section.
2. Remove the 4 spark plugs. For additional information, refer to Section 303-07 .
3. Remove the 2 bolts and accessory drive belt splash shield.

4. NOTE: Turn the engine clockwise only, and use the crankshaft bolt only.
NOTE: Measure each valve's clearance at base circle, with the lobe pointed away from the
tappet, before removing the camshafts. Failure to measure all clearances prior to removing the
camshafts will necessitate repeated removal and installation and wasted labor time.
Use a feeler gauge to measure each valve's clearance and record its location.
5. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For
example, a tappet with the number 0.650 has the thickness of 3.650 mm.
NOTE: The nominal clearance is 0.20 mm (0.0079 in) for intake and 0.34 mm (0.0133 in) for
exhaust.
NOTE: The acceptable clearances after being fully installed is 0.17-0.23 mm (0.007-0.009 in) for
intake and 0.31-0.37 mm (0.012-0.015 in) for exhaust.
Select tappets using this formula: tappet thickness = measured clearance + the existing tappet
thickness - nominal clearance.
Select the closest tappet size to the ideal tappet thickness available and mark the installation
location.
6. If any tappets do not measure within specifications, install new tappets in these locations. For
additional information, refer to Valve Train Components — Exploded View and Valve Tappets in
this section.
IN-VEHICLE REPAIR Procedure revision date: 04/19/2011
Intake Manifold
Intake Manifold (View 1 of 2)
Part
1 — Throttle Body (TB) electrical connector (part of 12A581)
2 — TB wiring harness retainer (part of 12A581)
3 W500213 Evaporative Emission (EVAP) canister purge valve bolt -
9 Nm (80 lb-in)
4 9C490 Brake booster vacuum tube
5 9C047 EVAP canister purge valve tube
6 — Knock Sensor (KS) electrical connector (part of 12A581)
7 — Wiring harness retainer (part of 12A581) (2 required)
Intake Manifold (View 2 of 2)
NOTE: Refer to the on-line Workshop Manual to view this illustration as an interactive exploded view, requires
Adobe® Acrobat® 8.0 or higher.
NOTE: Refer to the on-line Workshop Manual to learn about using an Interactive Illustration.
1 6N664 PCV hose
2 W500117 Intake manifold bolt - 18 Nm (159 lb-in)
3 W500112 Intake manifold bolt (7 required) - 18 Nm (159 lb-in)
4 9424 Intake manifold
5 9439 Intake manifold gasket (4 required)
Removal
1. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 .
2. Disconnect the crankcase vent tube from the valve cover.

Detach the 2 crankcase vent tube retainers.
3. Remove the fuel rail. For additional information, refer to Section 303-04 .
4. Remove the generator. For additional information, refer to Section 414-00 .
5. Remove the screw and the oil level indicator and tube.
Inspect and replace the O-ring seal, if necessary.
6. Disconnect the Throttle Body (TB) electrical connector.

Detach the wiring harness retainer from the TB .
7. Disconnect the PCV hose from the intake manifold.
8. Remove the bolt for the Evaporative Emission (EVAP) canister purge valve.
9. Disconnect the brake booster vacuum tube from the intake manifold.
10. Disconnect the EVAP canister purge valve tube from the intake manifold and position the EVAP canister
purge valve aside.
11. Detach the Knock Sensor (KS) electrical connector from the bottom of the intake manifold.
Detach the 2 wiring harness retainers from the bottom of the intake manifold.
12. Remove the 7 bolts for the intake manifold.
Installation
NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve
or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new
intake manifold. Failure to follow these instructions can result in engine damage.
1. Inspect and install new intake manifold gaskets, if necessary.
2. Install the intake manifold and the 7 bolts.

3. Attach the KS electrical connector to bottom of the intake manifold.
Attach the 2 wiring harness retainers to the bottom of the intake manifold.
4. Position and connect the EVAP canister purge valve tube to the intake manifold.
5. Connect the brake booster vacuum tube to the intake manifold.

6. Install the bolt for the EVAP canister purge valve.
7. Connect the PCV hose to the intake manifold.
8. Connect the TB electrical connector.

Attach the wiring harness retainer to the TB .
9. NOTE: Lubricate the O-ring seal with clean engine oil.
Install the oil level indicator and tube and the screw.
10. Install the generator. For additional information, refer to Section 414-00 .
11. Install the fuel rail. For additional information, refer to Section 303-04 .
12. Connect the crankcase vent tube to the valve cover.

Attach the 2 crankcase vent tube retainers.
13. Install the air cleaner outlet tube. For additional information, refer to Section 303-12 .
Valve Cover
Part
1 — Exhaust Camshaft Position (CMP) sensor electrical
2 — Intake CMP sensor electrical connector (part of 12A581)
3 6A664 Crankcase vent tube
4 W520412 Heated Oxygen Sensor (HO2S) connector bracket nut -
8 Nm (71 lb-in)
5 14A163 HO2S connector bracket
6 — Wiring harness retainer (part of 12A581) (2 required)
7 — Valve cover bolt (8 required) (part of 6M293) - 9 Nm (80
lb-in)
8 — Valve cover stud bolt (4 required) (part of 6M293) - 9 Nm
(80 lb-in)
9 6582 Valve cover
10 6584 Valve cover gasket
Removal
NOTICE: 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.
NOTICE: 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.
1. Remove the 2 Variable Camshaft Timing (VCT) oil control solenoids. For additional information, refer to
Section 303-14 .
2. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.
3. Remove the spark plug wires. For additional information, refer to Section 303-07 .
5. Remove the nut and the Heated Oxygen Sensor (HO2S) electrical connector bracket.
6. Detach all the wiring harness retainers from the valve cover.
7. Loosen the 12 retainers and remove the valve cover.

Discard the gasket.
Installation
1. Using a new gasket, install the valve cover and tighten the retainers in sequence shown.
2. Attach all the wiring harness retainers to the valve cover.
3. Install the Heated Oxygen Sensor (HO2S) electrical connector bracket and nut.
5. Install the spark plug wires. For additional information, refer to Section 303-07 .
6. Connect the Camshaft Position (CMP) sensor electrical connectors.

7. Install the 2 Variable Camshaft Timing (VCT) oil control solenoids. For additional information, refer to
Section 303-14 .
Crankshaft Pulley and Crankshaft Front Seal — Exploded View

1 6A340 Crankshaft pulley bolt
2 6312 Crankshaft pulley
3 W500215 Lower timing belt cover bolt (3 required)
4 6019 Lower timing belt cover
5 6306 Crankshaft sprocket gear
6 6700 Crankshaft front seal
removal.
Crankshaft Pulley
Special Tool(s)
Engine Support Bar
303-F072
Lifting Bracket, Engine

303-050 (T70P-6000)
Pin, Crankshaft Top Dead

Center (TDC)
303-748
Tool, Variable Camshaft Timing

(VCT) Alignment
303-1097
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Material
Item Specification
LSP12 (Canada)
Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special
tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft.
Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft
and camshafts must be locked in place by the special service tools, otherwise severe engine
damage can occur.
NOTICE: 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.
100-02 .
2. Remove the upper and lower cowl panel grilles. For additional information, refer to Section 501-
02 .
3. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 .
4. Remove the 2 bolts and accessory drive belt splash shield.
5. Loosen the 4 coolant pump bolts.
7. Release the 2 tabs and position the degas bottle aside.

8. Using a floor jack and a block of wood, support the engine.
9. NOTICE: The engine mount studs must be held while removing the engine mount nuts or
damage to the powertrain may occur.
NOTE: Do not loosen the engine mount center bolt or the engine may become improperly
positioned.
Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine
mount nuts.
10. Remove the 3 bolts and the engine mount.

11. Remove the 4 bolts and coolant pump pulley.
12. Remove the 1 engine mount stud.
13. Remove the 9 bolts and the timing belt cover.

14. Remove the 3 bolts and the engine mount bracket.
15. Using an engine mount bracket bolt, install the Engine Lifting Bracket.
16. Install the Engine Support Bar and support the engine.
17. Remove the floor jack and block of wood.
18. NOTICE: Only rotate the crankshaft in a clockwise direction.
Using the crankshaft pulley bolt, turn the crankshaft clockwise until the markings on the camshaft
phaser and sprockets are at the 11 o'clock position as shown.
19. Remove the engine plug bolt.

20. NOTE: The Crankshaft Top Dead Center (TDC) Timing Pin will contact the crankshaft and
prevent it from turning past TDC . However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft
pulley removal and installation.
Install the Crankshaft TDC Pin.
21. NOTE: Only rotate the crankshaft clockwise direction.
Rotate the crankshaft until it contacts Crankshaft TDC Pin.
22. Using the Strap Wrench, remove the crankshaft pulley bolt and the crankshaft pulley.
Discard the crankshaft pulley bolt.
23. Install the VCT Alignment Tool.
Installation
1. Install the crankshaft pulley and the new bolt.

The final torque of the crankshaft will be completed in following steps.
2. Remove the Crankshaft TDC Timing Pin.

3. Remove the VCT Alignment Tool.
4. Tighten the crankshaft bolt in the following 3 stages.

1. Stage 1: Using the Strap wrench, tighten an additional 90 degrees.
2. Stage 2: Wait for 10 seconds.
Rotate the crankshaft about 1 3/4 turns.

6. Install the Crankshaft TDC Timing Pin.
Rotate the crankshaft until it stops against the Crankshaft TDC Timing Pin.
8. NOTE: The special tool can only be installed if the valve timing is correct.
Install the VCT Alignment Tool.

If the special tool cannot be installed, repeat the adjustment according to the preceding
steps.
11. Install the engine plug bolt.

13. Remove the Engine Support Bar.
14. Remove the bolt and the Engine Lifting Bracket.

15. Install the engine mount bracket and the 3 bolts finger tight.
1. Tighten the 2 bolts to 55 Nm (41 lb-ft).
2. Tighten the bolt to 55 Nm (41 lb-ft).
16. Install the timing belt cover and the 9 bolts.

17. Install the coolant pump pulley and the 4 bolts finger tight.
18. Install the 1 engine mount stud finger tight.
19. NOTICE: The 2 engine mount studs must be torqued or damage to the powertrain may
occur.
Torque the 2 engine mount studs before installing the engine mount nuts.
20. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly
positioned.
Install the engine mount and the 2 nuts.

Tighten the 2 nuts to 80 Nm (59 lb-ft).
21. Install the 3 engine mount bolts.
22. Position the degas bottle on the 2 retainer tabs.
24. Tighten the 4 coolant pump bolts to 20 Nm (177 lb-in).

25. Install the accessory drive belt splash shield and the 2 bolts.
26. Install the RH front wheel and tire. For additional information, refer to Section 204-04 .
27. Install the upper and lower cowl panel grilles. For additional information, refer to Section 501-02 .
Crankshaft Front Seal
Special Tool(s)
Installer, Crankshaft Vibration
Damper
303-175 (T82L-6316-B)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Replacer, Front Crankshaft Seal
303-420 (T92P-6701-BH)
Remover, Input Shaft Oil Seal

308-375
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the timing belt. For additional information, refer to Timing Belt in this section.
2. Remove the crankshaft sprocket gear.

3. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the crankshaft front oil seal.
Installation
1. NOTE: Lubricate the oil seal with clean engine oil.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Front
Crankshaft Seal Replacer, install the crankshaft front oil seal.
2. Install the crankshaft sprocket gear.

3. Install the timing belt. For additional information, refer to Timing Belt in this section.
Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View
Part
1 6379 Flexplate bolt (6 required)
2 6375 Flexplate
3 6379 Flywheel bolt (6 required)
4 6375 Flywheel
5 W500213 Crankshaft rear oil seal with retainer plate bolt (6
required)
6 6K301 Crankshaft rear oil seal with retainer plate
removal.
Flexplate
Special Tool(s)
Tool, Flywheel Holding
303-103
Removal
1. Remove the automatic transaxle. For additional information, refer to Section 307-11 .
2. Remove the 6 bolts and the flexplate.

Discard the bolts.
Installation
1. Align the flexplate and crankshaft using the dowel pin location hole and install the new bolts finger
tight.
2. Install the Flywheel Holding Tool.

3. Tighten the bolts in the sequence shown in 2 stages:
Stage 1: Tighten to 30 Nm (22 lb-ft).
Stage 2: Tighten an additional 80 degrees.
4. Install the automatic transaxle. For additional information, refer to Section 307-11 .
Flywheel
Special Tool(s)
303-103
Removal
1. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01 .
2. Remove the 6 bolts and the flywheel.

Discard the bolts.
Installation
1. Align the flywheel and crankshaft using the dowel pin location hole and install the new bolts finger
tight.

4. Install the clutch disc and pressure plate. For additional information, refer to Section 308-01 .
Crankshaft Rear Seal
Removal
1. Remove the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this
section.
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
3. Remove the 6 bolts and the crankshaft rear seal.
4. Clean the sealing surface of the crankshaft rear seal and crankshaft.
Installation
1. NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed
after installation.
NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on
the crankshaft.
NOTE: Do not lubricate the new crankshaft rear seal.
Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft
rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear
seal meets the cylinder block.
Install the 6 bolts and tighten in sequence shown in 2 stages.
Stage 1: Tighten bolts 1 through 6 to 4 Nm (35 lb-in).
2. Remove the alignment sleeve taking care not to touch the sealing lip.
3. Install the oil pan. For additional information, refer to Oil Pan in this section.
4. Install the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this
section.
Timing Belt Cover

1 W714914 Coolant pump pulley bolt (3 required)
2 8509 Coolant pump pulley
3 W500215 Upper and lower timing belt cover bolt (12 required)
4 W500303 Upper timing belt cover bolt
5 6019 Upper timing belt cover
7 W702251 Timing belt cover backplate bolt (4 required)
8 6019 Timing belt cover backplate
Removal
All timing belt covers
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
Upper timing belt cover
2. Loosen the 4 coolant pump pulley bolts.

3. Remove the accessory drive belt. For additional information, refer to Section 303-05 .
4. Remove the engine mount. For additional information, refer to Engine Mount in this section.
7. Remove the 9 bolts and the upper timing belt cover.

Lower timing belt cover
8. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
9. Remove the 3 bolts and the lower timing belt cover.
Timing belt cover backplate
12. Remove the engine mount. For additional information, refer to Engine Mount in this section.

15. Remove the 9 bolts and the upper timing belt cover.
16. Remove the 4 bolts and the timing belt cover backplate.
Installation
Timing belt cover backplate
1. Install the timing belt cover backplate and the 4 bolts.

2. Install the upper timing belt cover and the 9 bolts.

4. NOTICE: The 2 engine mount studs must be torqued or damage to the powertrain may occur.
5. Install the coolant pump pulley and the 4 bolts.
Do not torque at this time.
6. Install the engine mount. For additional information, refer to Engine Mount in this section.
7. Install the accessory drive belt. For additional information, refer to Section 303-05 .
8. Tighten the 4 coolant pump pulley bolts to 20 Nm (177 lb-in).
Lower timing belt cover
9. Install the lower timing belt cover and the 3 bolts.

10. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
Upper timing belt cover
11. Install the upper timing belt cover and the 9 bolts.
Do not torque at this time.
15. Install the engine mount. For additional information, refer to Engine Mount in this section.
17. Tighten the 4 coolant pump pulley bolts to 20 Nm (177 lb-in).

Timing Belt
Special Tool(s)
(VCT) Alignment
303-1097

1 W500215 Lower timing belt cover bolt (3 required)
3 6268 Timing belt

5. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all
times when handling the tensioner. Failure to follow this instruction may result in personal injury.
Remove the timing belt.

1. Rotate the timing belt tensioner clockwise.
2. Align the 2 holes on the tensioner and install a small screwdriver or holding pin.
Installation
1. Install the timing belt in the sequence shown.

Remove the timing belt tensioner holding tool.

Timing Drive Components
Special Tool(s)
(VCT) Alignment
303-1097
Alignment Plate, Camshaft

303-376B

1 6268 Timing belt
3 6A340 Timing belt tensioner bolt
4 6K254 Timing belt tensioner
5 W710954 Intake camshaft phaser and sprocket plug and seal
6 6279 Intake camshaft phaser and sprocket bolt
7 6256 Intake camshaft phaser and sprocket
8 W710954 Exhaust camshaft phaser and sprocket plug and seal
9 6279 Exhaust camshaft phaser and sprocket bolt
10 6256 Exhaust camshaft phaser and sprocket
Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools.
The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any
repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must
be locked in place by the special service tools, otherwise severe engine damage can occur.

8. Remove the bolt and the timing belt tensioner.

10. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the
camshafts from turning.
Remove the 2 camshaft phaser and sprocket plugs.
Remove the 2 bolts and the camshaft phaser and sprockets.
Installation
1. Loosen the 2 bolts for the LH engine lift eye.
2. Install the Camshaft Alignment Plate into the end of the camshafts.
NOTE: The timing marks of the camshaft phaser and sprocket must be at the 12 o'clock position.
Install the 2 camshaft phaser and sprockets, bolts and the VCT Alignment Tool.
Tighten the 2 bolts to 25 Nm (18 lb-ft).
5. Remove the Camshaft Alignment Plate.

Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.
Install the Camshaft Alignment Plate into the end of the camshafts.

If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
Install the 2 camshaft phaser and sprocket plugs.

12. Install the timing belt tensioner and the bolt.
Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a
small screwdriver or holding pin.


19. Tighten the 2 bolts for the LH engine lift eye.

19 Nm (168 lb-in).
20. Install the valve cover. For additional information, refer to Valve Cover in this section.
Camshaft Phaser and Sprocket
Special Tool(s)
303-376B

(VCT) Alignment
303-1097

Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools.
The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any
repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must
be locked in place by the special service tools, otherwise severe engine damage can occur.
3. Remove the timing belt. For additional information, refer to Timing Belt in this section.

Installation
1. Loosen the 2 bolts for the LH engine lift eye.
2. NOTICE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon
to align the camshafts.
Install the 2 camshaft phaser and sprocket, bolts and the VCT Alignment Tool.
Tighten the 2 camshaft phaser and sprocket bolts an additional 75 degrees.





13. Install the timing belt. For additional information, refer to Timing Belt in this section.
14. Tighten the 2 bolts for the LH engine lift eye.

15. Install the valve cover. For additional information, refer to Valve Cover in this section.
Valve Train Components — Exploded View
Part
1 W706225 Camshaft cap bolt (16 required)
2 W710294 Variable Camshaft Timing (VCT) bridge bolt (2
required)
3 W710295 VCT bridge bolt (2 required)
4 6K292 Camshaft oil seal (2 required)
5 — VCT bridge (part of 6049)
6 W708317 VCT bridge O-ring seal
7 — Camshaft cap (8 required) (part of 6049)
8 6250 Exhaust camshaft
9 — Exhaust camshaft trigger wheel (part of 6250)
10 — Exhaust camshaft trigger wheel bolt (part of 6250)
11 6250 Intake camshaft
12 — Intake camshaft trigger wheel (part of 6250)
13 — Intake camshaft trigger wheel bolt (part of 6250)
14 6500 Valve tappet (16 required)
15 6518 Valve collet (16 required)
16 6514 Valve spring retainer (16 required)
17 6513 Valve spring (16 required)
18 6571 Valve seal (16 required)
removal.
Camshafts
Special Tool(s)
Installer, Camshaft Seal
303-1532

308-375
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
LSP12 (Canada)
Gasket Maker WSK-
TA-16 M2G348-A5
Removal
material (including any material created while cleaning gasket surfaces) that enters the oil
NOTICE: Do not rotate the camshafts unless instructed to in this procedure. Rotating the
camshafts or crankshaft with timing components loosened or removed can cause serious
damage to the valves and pistons.
1. Remove the camshaft phaser and sprockets. For additional information, refer to Camshaft Phaser
and Sprocket in this section.
2. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the 2 camshaft oil seals.
3. NOTE: Note the position of each component before removal.
Remove the bolts for the camshaft bearing caps and Variable Camshaft Timing (VCT) bridge in
the sequence shown.
Inspect and replace the VCT bridge O-ring seal, if necessary.
4. NOTICE: Do not pry on camshafts when removing or damage to the camshafts may occur.
Remove the 2 camshafts from the cylinder head.
5. If necessary, remove the 2 bolts and the camshaft trigger wheels.

Installation
1. If removed, install the camshaft trigger wheels and the 2 bolts.

2. NOTE: Lubricate the camshafts with clean engine oil.
Install the camshafts as shown.
3. Install the VCT bridge O-ring seal.

4. NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker to the
cylinder head.
Apply a 1.5 mm (0.059 in) bead of gasket maker to the cylinder head as shown.
5. NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their
original locations or damage to the engine may occur.
NOTE: Apply clean engine oil to the bearing surfaces of the camshaft bearing caps and the VCT
bridge.
Install the camshaft bearing caps, VCT bridge and the bolts finger tight.
6. Tighten the bolts in the sequence shown in 6 stages.

Stage 1: Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and
the VCT bridge are seated against the cylinder head.
Stage 4: Tighten bolts 1 through 16 an additional 45 degrees.
Stage 5: Tighten bolts 17 and 19 an additional 70 degrees.
7. If the cylinder head, camshafts or valve tappets were replaced, check the valve clearance. For
additional information, refer to Valve Clearance Check in this section.
8. Using the Camshaft Seal Installer, install the 2 camshaft oil seals.
9. Install the camshaft phaser and sprocket. For additional information, refer to Camshaft Phaser
and Sprocket in this section.
Valve Springs
Special Tool(s)
Compressor, Valve Spring
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1418
Material
Item Specification
LSP12 (Canada)
XG-4 and/or XL-5 B
Removal
100-02 .
2. Remove the camshafts. For additional information, refer to Camshafts in this section.
3. Remove the ignition coil. For additional information, refer to Section 303-07 .
4. Remove the 2 bolts and the LH engine lift eye.

5. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets
to make sure they are assembled in their original positions.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For
Remove and inspect the valve tappets. For additional information, refer to Section 303-00 .
6. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can
occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing
the spark plugs.
Remove the 4 spark plugs.
7. NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the
compressed air from the cylinder until the valve spring, valve spring retainer and valve
collet is installed. Any loss of air pressure will allow the valve to fall into the cylinder.
Connect the compressed air supply to the No. 1 cylinder.
8. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
Using the Valve Spring Compressors, compress the valve spring and remove the valve
collet, using some multi-purpose grease and a small screwdriver.
Remove the valve spring retainer and the valve spring.
9. Repeat the appropriate removal steps for all of the other cylinders.
Installation
1. NOTE: Check the seating of the valve collet.
Using the Valve Spring Compressors, install the valve spring.

Insert the valve spring and the valve spring retainer.
Compress the valve spring and install the valve collet using some multi-purpose grease
and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate installation steps for all of the other cylinders.
4. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can
occur to the cylinder head or spark plug.
Install the 4 spark plugs.

5. Coat the valve tappets with clean engine oil and install them in the cylinder head in their original
position.
6. Install the camshafts. For additional information, refer to Camshafts in this section.
7. Install the LH engine lift eye and the 2 bolts.

8. Install the ignition coil. For additional information, refer to Section 303-07 .
Valve Seals
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the valve springs. For additional information, refer to Valve Springs in this section.
2. NOTE: Use valve stem seal pliers (such as Snap-on® YA-8230 or equivalent).
Using valve stem seal pliers, remove and discard the valve seals.
Installation
1. Install the valve stem seal installation sleeve.

2. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
Using valve stem seal pliers, install the valve seals.
3. Install the valve springs. For additional information, refer to Valve Springs in this section.
Valve Tappets
Material
Item Specification
LSP12 (Canada)
100-02 .
2. Remove the camshafts. For additional information, refer to Camshafts in this section.

Coat the valve tappets with clean engine oil prior to installation.
Cylinder Head
Special Tool(s)
Engine Support Bar
303-F072
Lifting Bracket, Engine

303-050 (T70P-6000)
Material
Item Specification
LSP12 (Canada)
ZC-31-A
1 6065 Cylinder head bolt (10 required)
2 6049 Cylinder head
3 6051 Cylinder head gasket
Removal
2. Release the fuel system pressure. For additional information, refer to Section 310-00 .
3. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
4. Remove the Air Cleaner (ACL) outlet tube. For additional information, refer to Section 303-12 .
5. Remove the Heated Oxygen Sensor (HO2S). For additional information, refer to Section 303-14 .
6. Drain the engine cooling system. For additional information, refer to Section 303-03 .
7. Drain the engine oil.

Install the drain plug.
8. Remove and discard the engine oil filter.
9. Remove the Catalyst Monitor Sensor (CMS). For additional information, refer to Section 303-14 .
10. Remove the 2 catalytic converter-to-muffler nuts and separate the catalytic converter from the muffler.
Discard the gasket.
11. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these
instructions may cause damage to the flexible pipe.
Support the exhaust flexible pipe with a support wrap or suitable splint.
12. Remove the 4 bolts and the lower catalytic converter bracket.
13. Remove the 4 bolts and the catalytic converter heat shield.
14. Remove the 4 catalytic converter nuts and bolt.
Discard the 4 nuts and bolt.
15. Position the catalytic converter back and secure with mechanic wire.
Discard the catalytic converter gasket.
16. If equipped, disconnect the block heater electrical connector.
17. Remove the 4 catalytic converter studs and discard.
18. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer to
Section 310-00 .
19. Disconnect the 4 fuel injector electrical connectors.

Detach the wiring harness retainer from the TB .
22. Disconnect the PCV hose from the intake manifold.
23. Remove the bolt for the Evaporative Emission (EVAP) canister purge valve.
25. Disconnect the EVAP canister purge valve tube from the intake manifold and position the EVAP canister
purge valve aside.
26. Detach the Knock Sensor (KS) electrical connector from the bottom of the intake manifold.
Detach the 2 wiring harness retainers from the bottom of the intake manifold.
27. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
28. Remove the 2 lower bolts for the intake manifold.
30. Disconnect the ignition coil electrical connector and remove the 4 screws and the ignition coil.
31. Detach the fuel tube retainer from the coolant outlet bracket.
Detach the 2 wiring harness retainers and the coolant hose retainer from the coolant outlet
bracket.
32. If equipped with a manual transaxle, remove the transaxle shift cables from the clip.
33. Remove the nut, bolt and the bracket from the coolant outlet.
34. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
35. Disconnect the 2 coolant hoses from the coolant outlet.

36. Disconnect the coolant return hose from the cylinder head.
38. Remove the Engine Support Bar.
39. Remove the bolt and the Engine Lifting Bracket.

40. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head
bolts.
Remove the 10 cylinder head bolts in the sequence shown.

Remove the cylinder head.
Discard the cylinder head bolts and gasket.
41. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion
and the cylinder block distortion. For additional information, refer to Section 303-00 .
Installation
1. NOTICE: 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.
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 surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of gasket material with a plastic scraper.
2. Apply metal surface prep, following package directions, to remove any 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.
2. NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head gasket, cylinder head and 10 new bolts. Tighten the bolts in the sequence
shown in 4 stages:
Stage 1: Tighten to 5 Nm (44 lb-in).
3. Using a engine mount bracket bolt, install the Engine Lifting Bracket.
4. Install the Engine Support Bar and support the engine.
5. Remove the floor jack and block of wood.

6. Connect the coolant return hose to the cylinder head.
7. Connect the 2 coolant hoses to the coolant outlet.
8. Connect the ECT sensor electrical connector.
9. Install the coolant outlet bracket, nut and the bolt.

10. If equipped with a manual transaxle, install the transaxle shift cables to the clip.
11. Attach the fuel tube retainer to the coolant outlet bracket.
Attach the 2 wiring harness and coolant hose retainers to the coolant outlet bracket.
12. Install the ignition coil, 4 screws and connect the ignition coil electrical connector.
14. Install the 2 lower bolts for the intake manifold.

15. Install the valve tappets. For additional information, refer to Valve Tappets in this section.
16. Attach the KS electrical connector to bottom of the intake manifold.

Attach the 2 wiring harness retainers to the bottom of the intake manifold.
17. Position and connect the EVAP canister purge valve tube to the intake manifold.
19. Install the bolt for the EVAP canister purge valve.
20. Connect the PCV hose to the intake manifold.
22. Connect the TB electrical connector.

Attach the wiring harness retainer to the TB .
23. Connect the 4 fuel injector electrical connectors.
24. Connect the fuel tube spring lock couplings to the fuel rail. For additional information, refer to Section
310-00 .
25. Install the 4 new catalytic converter studs.

26. If equipped, connect the block heater electrical connector.
27. Using a new gasket, position the catalytic converter and install the 4 new nuts and bolt finger tight.
28. NOTICE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until
reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.
Tighten the bolt and 4 nuts in the sequence shown, in 3 stages.

Stage 1: Tighten all fasteners in sequence to 20 Nm (177 lb-in).
Stage 2: Tighten all fasteners in sequence to 40 Nm (30 lb-ft).
29. Install the catalytic converter heat shield and the 4 bolts.
30. Install the lower catalytic converter bracket and the 4 bolts and tighten in sequence shown.
1. Tighten the catalytic converter bracket-to-engine block bolts to 50 Nm (37 lb-ft).
2. Tighten the catalytic converter bracket-to-catalytic converter bolts to 25 Nm (18 lb-ft).
Remove the support for the exhaust flexible pipe.
32. Using a new gasket, position the catalytic converter to the muffler and install the 2 catalytic converter
nuts.
33. Install the CMS . For additional information, refer to Section 303-14 .
34. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.

35. Install the HO2S . For additional information, refer to Section 303-14 .
36. Install the ACL outlet tube. For additional information, refer to Section 303-12 .
37. Connect the battery ground cable. For additional information, refer to Section 414-01 .
38. Fill the engine with clean engine oil.
39. Fill the engine cooling system. For additional information, refer to Section 303-03 .
Engine Lubrication Components — Exploded View
Oil Filter, Oil Cooler and Engine Oil Pressure (EOP) Switch
Part
1 — Engine Oil Pressure (EOP) switch electrical connector
(part of 12A522)
2 9278 EOP switch
3 8K276 Oil cooler coolant hose
4 18472 Oil cooler coolant hose
5 6731 Oil filter
6 6L626 Oil cooler mounting bolt
7 6A642 Oil cooler
8 6L621 Oil cooler gasket
Oil Pan, Oil Pump and Oil Pump Screen and Pickup Tube
NOTE: Automatic transaxle shown, manual transaxle similar.

1 6730 Oil pan drain plug
2 W500225 Oil pan bolt (13 required)
3 W701069 Oil pan bolt (4 required)
4 6675 Oil pan
5 W703311 Oil pump screen and pickup tube bolt (3 required)
6 6622 Oil pump screen and pickup tube
7 6626 Oil pump screen and pickup tube O-ring seal
8 W500300 Oil pump bolt (2 required)
11 6600 Oil pump
12 6659 Oil pump gasket
removal.
Oil Cooler
Material
Item Specification
LSP12 (Canada)
Motorcraft® Specialty Orange WSS-
Engine Coolant M97B44-D
VC-3-B (US); CVC-3-B (Canada)
100-02 .
Remove the engine oil filter and discard.

3. Using hose clamp pliers, clamp the 2 oil cooler coolant hoses and remove the 2 coolant hoses
from the oil cooler.
4. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns
exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical
concerns, refer to Section 303-00 .
Remove the oil cooler mounting bolt and the oil cooler.
Inspect the oil cooler gasket, replace if necessary.

Inspect and adjust the coolant level in the degas bottle.
Engine Oil Pressure (EOP) Switch
Material
Item Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24
100-02 .
2. Disconnect the EOP switch electrical connector.
3. Remove the EOP switch.


Apply thread sealant to the EOP switch threads.
Oil Pan
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Removal
100-02 .

Install the drain plug.
5. Remove the 17 bolts from the oil pan.
6. Using the 3 pry pads (2 shown), remove the oil pan.

Installation
1. NOTICE: 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 traces of sealant.
Clean and inspect all mating surfaces using silicone gasket remover.
2. Install 2 M8x20 studs for oil pan alignment.
3. NOTE: The oil pan must be installed within 5 minutes of applying the sealant.
NOTE: If the oil pan is not secured within 5 minutes of sealant application, the sealant must be
removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign
of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure can cause future oil
leakage
Apply a 3.5 mm (0.137 in) bead of sealant to the oil pan.

4. Install the oil pan using the 2 studs for alignment.
5. Install 15 bolts finger tight and remove the 2 alignment studs and install the remaining 2 bolts
finger tight.
6. Tighten the oil pan bolts in the following sequence in 3 stages.

Stage 1: Tighten bolts 1 through 4 to 48 Nm (35 lb-ft).


Oil Pump Screen and Pickup Tube
100-02 .
2. Remove the engine oil pan. For additional information, refer to Oil Pan in this section.
3. Remove the 3 bolts and the oil pump screen and pickup tube.

Oil Pump
Removal
1. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
Inspect and replace the oil pump screen and pickup tube O-ring seal, if necessary.
5. Remove the 8 bolts and the oil pump.

Remove and discard the oil pump gasket.
Installation
1. Install a new gasket, the oil pump and the 8 bolts in their original position and tighten in sequence
shown in 2 stages.
2. Install the oil pump screen and pickup tube and 3 bolts.

4. Install the oil pan. For additional information, refer to Oil Pan in this section.
5. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
Oil Level Indicator and Tube
Material
Item Specification
LSP12 (Canada)

1 6750 Oil level indicator
2 W709843 Oil level indicator tube screw
3 6754 Oil level indicator tube
4 W701261 O-ring seal
1. Remove the oil level indicator.
2. Remove the oil level indicator tube screw.

3. Remove the oil level indicator tube.

To install, lubricate the O-ring seal with clean engine oil.
Engine Mount

1 W520214 Engine mount nut (2 required)
2 W706408 Engine mount bolt (3 required)
3 6038 Engine mount
Removal
2. Using a floor jack and a wooden block, support the engine.

3. NOTICE: The engine mount studs must be held while removing the engine mount nuts or damage
to the powertrain may occur.
NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.
Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount
nuts.
Installation
1. NOTICE: The engine mount studs must be torqued or damage to the powertrain may occur.
Torque the engine mount studs before installing the engine mount.
2. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.


4. Position the degas bottle on the 2 retainer tabs.

REMOVAL Procedure revision date: 01/14/2011
Engine — Automatic Transaxle
Special Tool(s)
2,200# Floor Crane, Fold Away
300-OTC1819E
Powertrain Lift
300-OTC1585AE
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Adjustable Grip Arm, 1735A

014-00001
All vehicles
100-02 .
3. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section
303-12 .

Detach the 2 crankcase vent tube retainers and remove the tube.
5. Remove the positive battery cable cover.
7. Remove the nut and cable from the positive battery cable terminal.
8. Remove the bolt and the PCM cover.

9. Disconnect the 3 PCM electrical connectors.
10. Remove the 3 bolts and the battery tray.
11. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.
12. Remove the selector lever cable bolt, 3 battery tray nuts and the battery tray bracket.
Detach the 2 wiring harness retainers from the battery tray bracket.
13. Disconnect the engine harness electrical connector.
14. Disconnect the brake booster vacuum hose.

15. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer
to Section 310-00 .
16. Detach the fuel tube from the coolant outlet bracket retainer.
19. Remove the degas bottle. For additional information, refer to Section 303-03 .
20. Disconnect the selector lever cable from the control lever.
21. Detach the wiring harness retainer from the selector lever cable bracket.
22. Remove the 2 selector lever cable bracket bolts from the transaxle and position the selector lever
cable and bracket aside.
23. Remove the cooling fan motor and shroud. For additional information, refer to Section 303-03 .
24. Disconnect the 2 coolant hoses from the engine oil cooler.
Detach the oil cooler hose retainer from the upper radiator hose.
26. Disconnect the lower heater hose from the heater core.
27. Detach the coolant hose retainer from the coolant outlet bracket.
28. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling near the bulk head.
For additional information, refer to Section 310-00 .
29. Disconnect the upper radiator hose from the engine.
30. Disconnect the lower radiator hose and coolant hose from the thermostat housing.
31. Remove the bolt and position the engine ground wire aside.
32. Drain the transmission. For additional information, refer to Section 307-11 .
33. Remove the RH and LH halfshafts. For additional information, refer to Section 205-04 .
34. Remove the 3 bolts and the halfshaft bracket.
Vehicles with A/C
35. Disconnect the A/C compressor electrical connector.

36. Remove the nut and position the A/C line bracket aside.
37. Disconnect the A/C pressure transducer electrical connector.

Detach the wiring harness retainer.
38. Detach the wiring harness retainer from the lower A/C compressor bracket.
39. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of
mechanic's wire.
Vehicles without A/C
40. Remove the 3 bolts and the accessory drive belt idler pulley bracket.
All vehicles
42. Remove the 2 catalytic converter-to-muffler nuts and separate.

Discard the gasket.
Discard the bolt and 4 nuts.
48. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust
manifold cleaning and inspection in Section 303-00 .

Install the drain plug and tighten to 28 Nm (21 lb-ft).

52. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine to the lift table.
53. Remove the 2 bolts and the transaxle roll restrictor.
positioned.
mount nuts.
56. Remove the 2 bolt, 2 nuts and the transaxle support insulator.
57. Lower the engine and transaxle assembly from the vehicle.

59. Detach the 2 wiring harness retainers from the coolant outlet bracket.
60. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
61. Detach the HO2S sensor electrical connector pin-type retainer from the bracket.
63. Detach and disconnect the LH Knock Sensor (KS) electrical connector.
64. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
Detach the 2 wiring harness retainers.
Detach the wiring harness retainers from the valve cover stud bolts.
66. Disconnect the EVAP canister purge valve electrical connector.

Detach the 2 wiring harness retainers from the TB .
68. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
69. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
Detach the wiring harness retainer from the engine block.
70. Disconnect the RH KS electrical connector.

Detach the 2 wiring harness retainers from the intake manifold.
71. Remove the 2 nuts and disconnect the starter motor electrical terminals.
72. Remove the 3 bolts (2 shown) and the starter motor.
73. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts
and bracket.
74. Remove the clutch nut access cover.
75. NOTICE: Rotate the engine in a clockwise direction only or engine damage may occur.
NOTE: Mark one stud and the flexplate for installation reference.
Remove the 6 flexplate-to-clutch nuts and discard.
76. NOTE: Lower the engine to within a few inches of the floor.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle assembly from the lift
table.
77. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.
78. Remove and discard the engine-to-transaxle separator plate.

Engine — Manual Transaxle
Special Tool(s)
300-OTC1819E
Powertrain Lift
300-OTC1585AE
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent

014-00001
All vehicles
100-02 .
3. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section
303-12 .

Detach the 2 crankcase vent tube retainers and remove the tube.
5. Remove the positive battery cable cover.
7. Remove the nut and cable from the positive battery cable terminal.

10. Remove the 3 bolts and the battery tray.
11. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.
12. Remove the 3 battery tray nuts and the battery tray bracket.
Detach the 2 wiring harness retainers from the battery tray bracket.
13. Disconnect the engine harness electrical connector.
14. Disconnect the brake booster vacuum hose.

15. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer
to Section 310-00 .
16. Detach the fuel tube from the coolant outlet bracket retainer.
19. Remove the degas bottle. For additional Information, refer to Section 303-03 .
20. Release the 7 retainers (2 shown) and remove the gearshift cable cover.
21. Remove the gearshift cables.
1. Using a suitable tool, lightly pry the gearshift cables off the transaxle shift control levers.
2. Remove the gearshift cable by pulling the lower part of abutment down and removing from
the brackets.
23. Disconnect the 2 coolant hoses from the engine oil cooler.
Detach the oil cooler hose retainer from the upper radiator hose.
25. Disconnect the lower heater hose from the heater core.
26. Detach the coolant hose retainer from the coolant outlet bracket.
27. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling near the bulk head.
28. Disconnect the upper radiator hose from the engine.

29. Disconnect the lower radiator hose and coolant hose from the thermostat housing.
30. WARNING: Carefully read cautionary information on product label. For EMERGENCY
products call: 1-800-959-3673. For additional information, consult the product Material
Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface
may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the
surface with water.
Remove the clip and disconnect the clutch hydraulic hose.
31. Detach the clutch hydraulic hose from the transaxle retainer.
32. Remove the bolt and position the engine ground wire aside.
33. Remove the RH and LH halfshafts. For additional information, refer to Section 205-04 .
34. Remove the 3 bolts and the halfshaft bracket.

Vehicles with A/C
35. Disconnect the A/C compressor electrical connector.
36. Remove the nut and position the A/C line bracket aside.
Detach the wiring harness retainer.
38. Detach the wiring harness retainer from the lower A/C compressor bracket.
39. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of
mechanic's wire.
All vehicles
42. Remove the 2 catalytic converter-to-muffler nuts and separate.

Discard the gasket.

Discard the bolt and 4 nuts.
48. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust
manifold cleaning and inspection in Section 303-00 .

Install the drain plug and tighten to 28 Nm (21 lb-ft).
52. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine to the lift table.
53. Remove the bolt for the transaxle roll restrictor.
positioned.
mount nuts.

56. Remove the 2 bolt, 2 nuts and the transaxle support insulator.
57. Lower the engine and transaxle assembly from the vehicle.
59. Detach the 2 wiring harness retainers from the coolant outlet bracket.
60. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
61. Detach the HO2S sensor electrical connector pin-type retainer from the bracket.

63. Detach and disconnect the LH Knock Sensor (KS) electrical connector.
64. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
Detach the 2 wiring harness retainers.

Detach the wiring harness retainers from the valve cover stud bolts.
66. Disconnect the EVAP canister purge valve electrical connector.

Detach the 2 wiring harness retainers from the TB .
68. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

69. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
Detach the wiring harness retainer from the engine block.
70. Disconnect the RH KS electrical connector.

Detach the 2 wiring harness retainers from the intake manifold.
71. Remove the 2 nuts and disconnect the starter motor electrical terminals.
72. Remove the 3 bolts (2 shown) and the starter motor.
73. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts
and bracket.
74. NOTE: Lower the engine to within a few inches of the floor.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle assembly from the lift
table.
75. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.
DISASSEMBLY Procedure revision date: 01/14/2011
Engine
Special Tool(s)
Engine Stand
Installer, Connecting Rod

303-462 (T94P-6136-AH)
Pin, Crankshaft Top Dead

Center (TDC)
303-748

308-375
Slide Hammer
100-001 (T50T-100-A)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

(VCT) Alignment
303-1097
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special
tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft.
Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft
and camshafts must be locked in place by the special service tools, otherwise severe engine
damage can occur.
material, including any material created while cleaning gasket surfaces that enters the oil
passages, coolant passages or the oil pan, can cause engine failure.
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this
section.
Vehicles with manual transaxle
1. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not
held when the bolts are removed. Failure to follow this instruction may result in serious
personal injury.
NOTE: Loosen the clutch pressure plate retaining bolts evenly, by two turns at a time.
Remove and discard the 6 clutch pressure plate retaining bolts, remove the clutch disc and
pressure plate.
2. Remove the bolts and the flywheel.

Discard the bolts.
Vehicles with automatic transaxle
3. Remove the bolts and the flexplate.

Discard the bolts.
All vehicles
4. Mount the engine on a Engine Stand.
5. Disconnect the Evaporative Emission (EVAP) canister purge valve tube from the intake manifold.
7. Detach the EVAP tube and coolant tube from the coolant outlet bracket retainer.
8. Remove the bolt for the EVAP canister purge valve and remove the brake booster vacuum tube
and EVAP canister purge valve as an assembly.
9. Remove the 4 spark plug wires.
10. Disconnect the coolant hose from the coolant outlet.
11. Disconnect the coolant return hose from the cylinder head.
Detach the coolant tube from the fuel rail retainers.
12. Remove the nut, bolt and the bracket from the coolant outlet.
13. Remove the 4 bolts and the coolant outlet and ignition coil assembly.
Inspect and replace the gasket, if necessary.
14. Remove the 2 bolts and the engine lift eye.

16. If equipped, remove the engine block heater.
17. Remove the 2 bolts and the fuel rail assembly.

18. Remove the 4 fuel injector clips and the 4 fuel injectors.
19. Remove and discard the 8 fuel injector O-ring seals.
20. Detach the Knock Sensor (KS) from the bottom of the intake manifold.
21. Remove the 7 bolts and the intake manifold.
Disconnect the PCV hose from the intake manifold.
22. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the bolt and the oil cooler.

Discard the oil cooler.
23. Remove the 4 bolts and the thermostat housing

24. Remove the thermostat from the engine block.
Inspect the thermostat seal and replace, if necessary.
25. NOTE: Mark the location of the 2 KS for installation.
Remove the 2 bolts and the 2 KS .
26. Remove the bolts and the crankcase vent oil separator.
27. Remove the Engine Oil Pressure (EOP) switch.
28. Remove the bolt and the Crankshaft Position (CKP) sensor.
29. Remove the 2 bolts and the Variable Camshaft Timing (VCT) oil control solenoids.
30. Remove the nut and the Heated Oxygen Sensor (HO2S) electrical connector bracket.
31. Loosen the 12 retainers and remove the valve cover.

Discard the gasket.


35. Remove the 3 bolts and the engine mount bracket.
36. NOTICE: Only rotate the crankshaft in a clockwise direction.
Using the crankshaft pulley bolt, turn the crankshaft clockwise until the markings on the camshaft
phaser and sprockets are at the 11 o'clock position as shown.
38. NOTE: The Crankshaft Top Dead Center (TDC) Timing Pin will contact the crankshaft and
prevent it from turning past TDC . However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft
pulley removal and installation.
Rotate the crankshaft until it contacts the Crankshaft TDC Pin.

40. Using the Strap Wrench, remove the crankshaft pulley bolt and the crankshaft pulley.
Discard the crankshaft pulley bolt.

43. WARNING: The timing belt tensioner spring is under load. Extra care must be taken
at all times when handling the tensioner. Failure to follow this instruction may result in
personal injury.


46. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the crankshaft front oil seal.
48. Remove the 6 bolts and the coolant pump.

Discard the gasket.
49. Remove the 4 spark plugs.

53. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the 2 camshaft oil seals.
54. NOTE: Note the position of each component before removal.
Remove the bolts for the camshaft bearing caps and VCT bridge in the sequence shown.
55. Remove the VCT bridge O-ring seal.
Inspect and replace the VCT bridge O-ring seal, if necessary.
56. NOTICE: Do not pry on camshafts when removing or damage to the camshafts may occur.
Remove the 2 camshafts from the cylinder head.
57. If necessary, remove the 2 bolts and the camshaft trigger wheels.
59. Remove the Crankshaft TDC Pin.
60. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the
cylinder head bolts.
Remove the 10 cylinder head bolts in the sequence shown.

Remove the cylinder head.
Discard the cylinder head bolts and gasket.
61. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
62. Remove the cylinder head alignment dowels.
63. Remove the 13 bolts from the oil pan.
64. Using the pry pads, remove the oil pan.

65. Remove the 6 bolts and the crankshaft rear seal.
67. Remove the 4 bolts and the windage tray.

68. NOTE: Mark the location of the 3 different length bolts.
Remove the 8 bolts and the oil pump.

Discard the gasket.
69. 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
manufacturer's instructions.
70. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in
numerical order for correct orientation for reassembly.
Remove the bolts and the connecting rod cap.
71. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
72. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine
block.
73. NOTE: Mark the position of the parts, so they can be installed in their original positions.
Remove the connecting rod bearings from the connecting rod and cap.
74. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct
orientation for reassembly.
Remove the 10 bolts in the sequence shown and the main bearing beam.
75. NOTE: If the main bearings are being reused, mark them in order for correct orientation and
reassembly.
Remove the main bearings from the main bearing beam.

76. Remove the crankshaft from the engine block.
77. NOTE: If the main bearings are being reused, mark them in order for correct orientation and
reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
78. Inspect the cylinder block and main bearing beam.
79. Inspect the pistons and connecting rods. For additional information, refer to Section 303-00 .
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 11/11/2010
Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1418
Material
Item Specification
LSP12 (Canada)
XG-4 and/or XL-5 B
Cylinder Head (View 1 of 2)

1 W704043 Fuel rail bolt (2 required) - 11 Nm (97 lb-in)
2 9D280 Fuel rail assembly
3 W500117 Intake manifold bolt - 18 Nm (159 lb-in)
4 W500112 Intake manifold bolt (4 required) - 18 Nm (159 lb-in)
6 9439 Intake manifold gasket (4 required)
Cylinder Head (View 2 of 2)

Part
1 W714169 Coolant outlet bolt - 19 Nm (168 lb-in)
2 — Coolant outlet bolt (part of 8K556) (2 required) - 19 Nm
(168 lb-in)
3 W713019 Coolant outlet stud bolt - 19 Nm (168 lb-in)
4 8K556 Coolant outlet
5 — Coolant outlet gasket (part of 8K556)
6 W500223 Lift eye bolt (2 required) - 19 Nm (168 lb-in)
7 — Lift eye bracket
8 12405 Spark plug (4 required)
9 6518 Intake valve collet (16 required)
10 6514 Intake valve spring retainer (8 required)
11 6513 Intake valve spring (8 required)
12 6571 Intake valve seal (8 required)
13 6507 Intake valve (8 required)
14 6518 Exhaust valve collet (16 required)
15 6514 Exhaust valve spring retainer (8 required)
16 6513 Exhaust valve spring (8 required)
17 6571 Exhaust valve seal (8 required)
18 6505 Exhaust valve (8 required)
Disassembly
NOTE: If the components are to be reinstalled, mark the location of the components removed, they must be
installed in the same location.
1. Remove the 2 bolts and the fuel rail and injectors as an assembly.
2. Remove the 4 fuel injector clips and the 4 fuel injectors.
3. Remove and discard the 8 fuel injector O-ring seals.
4. Remove the 5 bolts and the intake manifold.
5. Remove the 2 bolts and the LH engine lift eye.
6. Remove the 3 bolts, stud bolt and the coolant outlet.

Discard the gasket.
7. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur
to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
Remove the 4 spark plugs.
8. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.
Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets,
the valve spring retainers and the valve springs.
9. Inspect the valve springs. For additional information, refer to Section 303-00 .
10. NOTE: Note the location of the valves if they are to be reused
Remove the valves.
11. Inspect the valves. For additional information, refer to Section 303-00 . Install new parts, as necessary.
12. NOTE: Use a valve stem seal pliers (such as Snap-on® YA-8230 or equivalent).
Using valve stem seal pliers, remove and discard the valve seals.
Assembly
1. NOTE: If installing the original valves, make sure the valves are installed in the same position from which
they were removed. Coat the valve stems with clean engine oil.
Install the valves.
2. Install the valve stem seal installation sleeve.
3. NOTE: Lubricate the valve stem, guides and valve stem seals with clean engine oil prior to installation.
Using valve stem seal pliers, install the valve seals.
4. NOTE: Check the seating of the valve collet.
Using the Valve Spring Compressors, install the valve spring.

Insert the valve spring and the valve spring retainer.
Compress the valve spring and install the valve collet using some multi-purpose grease and a
small screwdriver.
5. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur
to the cylinder head or spark plug.
Install the 4 spark plugs.

6. Using a new gasket, install the coolant outlet, 3 bolts and the stud bolt.

8. Inspect and install new intake manifold gaskets if necessary.

10. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-
rings may cause the fuel system to leak. Do not reuse the O-ring seals.
Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.
11. Install the 4 fuel injectors and the 4 fuel injector clips into the fuel rail.
12. Install the fuel rail and fuel injectors as an assembly and install the 2 bolts.
Piston
Material
Item Specification
LSP12 (Canada)

1 — Piston compression upper ring (part of 6148)
2 — Piston compression lower ring (part of 6148)
3 — Piston oil control upper segment ring (part of 6148)
4 — Piston oil control spacer (part of 6148)
5 — Piston oil control lower segment ring (part of 6148)
6 6135 Piston pin
7 6108 Piston
8 6200 Connecting rod
Disassembly
1. Remove the connecting rod bearings from the connecting rod and cap.
2. Remove the piston rings from the piston.

Discard the piston rings.
3. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
NOTE: Use a portable multipurpose press (such as OTC® 5180 or equivalent).
Using the portable multipurpose press, press the piston pin out of the connecting rod and piston
assembly.
4. Separate the piston from the connecting rod.
5. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 .
Assembly
1. NOTE: Lubricate all parts with clean engine oil.
Gradually heat the pin bore side of the connecting rod to approximately 300°C (572°F).
2. Align the piston-to-connecting rod orientation marks, and immediately install the piston pin.
3. Using the portable multipurpose press, press the piston pin into the piston and connecting rod assembly.
4. NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper
side.
Install the piston rings.
5. Make sure the ring gaps (oil spacer — A, oil ring — B, compression ring — C) are correctly spaced
around the circumference of the piston.
ASSEMBLY Procedure revision date: 04/19/2011
Engine
Special Tool(s)
303-376B

Fixture
100-002 (TOOL-4201-C)
Installer, Camshaft Seal

303-1532
Installer, Connecting Rod

303-462 (T94P-6136-AH)
Installer, Crankshaft Vibration Damper

303-175 (T82L-6316-B)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Pin, Crankshaft Top Dead Center

(TDC)
303-748
Replacer, Front Crankshaft Seal

303-420 (T92P-6701-BH)
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
303-103
Tool, Variable Camshaft Timing (VCT)

Alignment
303-1097
Material
Item Specification
Gasket Maker WSK-
TA-16 M2G348-A5
ZC-31-A
Motorcraft® SAE 5W-20 Super Premium
Motor Oil (Canada)
LSP12 (Canada)
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Thread Sealant with PTFE WSK-
TA-24 M2G350-A2
Upper Engine
Part
1 12A581 Engine wiring harness
2 12259 Spark plug wire (4 required)
3 14A163 Heated Oxygen Sensor (HO2S) connector bracket
4 6B288 Camshaft Position (CMP) sensor (2 required)
6 6766 Oil fill cap
7 6582 Valve cover
8 W706225 Camshaft cap bolt (16 required)
9 — Camshaft cap (8 required) (part of 6049)
10 — Variable Camshaft Timing (VCT) bridge bolt (2 required)
(part of 6049)
11 — VCT bridge bolt (2 required) (part of 6049)
12 — VCT bridge (part of 6049)
13 W700279 Camshaft trigger wheel bolt (2 required) (part of 6250)
14 6M265 Camshaft trigger wheel (2 required) (part of 6250)
15 6250 Exhaust camshaft
16 6250 Intake camshaft
17 6500 Valve tappet (16 required)
18 6518 Valve collet (16 required)
19 6514 Valve spring retainer (16 required)
20 6513 Valve spring (16 required)
21 6571 Valve seal (16 required)
22 9D280 Fuel rail
23 9F593 Fuel injector (4 required)
24 9C995 Fuel injector clip (4 required)
25 9C047 Evaporative Emission (EVAP) tube
26 12029 Ignition coil
27 — Lift eye bracket
28 12A648 Engine Coolant Temperature (ECT) sensor
29 8K556 Coolant outlet
30 6051 Cylinder head gasket
32 W703540 Catalytic converter stud bolt (4 required)
33 9448 Catalytic converter gasket
34 5G232 Catalytic converter
35 W500634 Catalytic converter bolt
36 9N454 Catalytic converter heat shield
Timing Drive

1 6268 Timing belt
3 00812 Timing belt tensioner bolt
4 6K254 Timing belt tensioner
Lower Engine

1 6A340 Crankshaft pulley bolt
4 8501 Coolant pump
5 6019 Upper timing belt cover
6 6019 Timing belt cover backplate
7 6038 Engine mount bracket
9 6700 Crankshaft front seal
10 6600 Oil pump
11 6148 Piston ring (5 required)
12 6108 Piston (4 required)
13 6135 Piston pin (4 required)
14 6200 Connecting rod (4 required)
15 6211 Upper connecting rod bearing (4 required)
16 6337 Upper main bearing
17 6333 Upper main bearing (4 required)
18 6C315 Crankshaft Position (CKP) sensor
19 6303 Crankshaft
20 6211 Lower connecting rod bearing (4 required)
21 6200 Connecting rod cap (4 required)
22 6200 Connecting rod cap bolt (8 required)
23 6333 Lower main bearing (4 required)
24 6333 Wider lower main bearing
25 — Lower crankshaft main bearing beam (part of 6010)
26 6687 Windage tray
27 6622 Oil pump screen and pickup tube
28 6675 Oil pan
29 6010 Engine block
30 6K301 Crankshaft rear oil seal with retainer plate
31 6375 Flexplate/Flywheel
32 6754 Oil level indicator tube
33 12A699 LH Knock Sensor (KS)
34 12A699 RH KS
36 9E926 Throttle Body (TB)
37 8575 Thermostat
38 8592 Thermostat housing
39 6A785 Crankcase vent oil separator
40 6A642 Oil cooler
41 6L626 Oil cooler mounting bolt
42 6731 Oil filter
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly
cleaned and 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.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block,
crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the
engine components will require replacement. For additional information, refer to Section 303-00 .
All vehicles
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest
diameter for each journal.
2. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear
face of the engine block and install the original main bearing beam bolts finger tight.
3. Tighten the 10 original main bearing beam bolts in the sequence shown in 2 stages.
4. Measure each crankshaft block main bearing bore diameter.

5. Using the chart, select the crankshaft main bearings.
6. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2
stages.
7. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
Remove the bolts and the connecting rod cap.
Discard the connecting rod cap bolts.
8. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the
smallest measurement for each connecting rod journal.
9. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
10. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for
reassembly.
Remove the 10 bolts in the sequence shown and the main bearing beam.
Discard the main bearing beam bolts.
11. 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.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted
during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in
the cylinder block.
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted
during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the
main bearing beam.
13. NOTE: Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

14. Lubricate the 10 main bearing beam side fit surfaces and the 5 main bearing beam bearings with clean engine
oil.
15. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear
face of the engine block.
16. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the
cylinder block before tightening the main bearing beam bolts.
Install and tighten the 10 new main bearing beam bolts.

Tighten the bolts in the sequence shown in 2 stages.
17. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
Position the crankshaft to the rear of the cylinder block.
Zero the Dial Indicator Gauge with Holding Fixture.
Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the
specified range, install new parts as necessary.
18. Make sure the dimple in the piston faces the front of the engine.
19. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push
the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean
engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod
assemblies.
When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60
degrees apart from each other and a minimum of 90 degrees from the expander gap.
The position of the upper and lower compression ring gaps are not controlled for installation.
20. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or
engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then
rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and
3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Install the connecting rod caps and the new bolts and tighten the bolts in 3 stages.
Stage 2: Wait 2 seconds.
21. Install the Crankshaft Top Dead Center (TDC) Timing Pin and rotate the crankshaft slowly clockwise until the
crankshaft balance weight is up against the Crankshaft TDC Timing Pin. The engine is now at TDC .
22. Install a new gasket, the oil pump and the 8 bolts in their original position and tighten in sequence shown in 2
stages.
23. Install the windage tray and the 4 bolts.

24. Install the oil pump screen and pickup tube and 3 bolts.
25. NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.
NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.
NOTE: Do not lubricate the new crankshaft rear seal.
Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the
alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block.
Install the 6 bolts and tighten in sequence shown in 2 stages.
26. Remove the alignment sleeve taking care not to touch the sealing lip.
27. NOTICE: 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 all oil pan mating surfaces.
28. Install 2 M8x20 studs for oil pan alignment.
29. NOTE: The oil pan must be installed within 5 minutes of applying the sealant.
NOTE: If the oil pan is not secured within 5 minutes of sealant application, the sealant must be removed and
the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 5 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3.5 mm (0.137 in) bead of sealant to the oil pan.
30. Install the oil pan using the 2 studs for alignment.
31. Install 11 bolts finger tight and remove the 2 alignment studs and install the remaining 2 bolts finger tight.
32. Tighten the oil pan bolts in the following sequence in 2 stages.
33. NOTICE: 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.
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 surface of both the cylinder head and the cylinder block in the
following sequence.
1. Apply metal surface prep, following package directions, to remove any 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.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
34. Install the cylinder head alignment dowels.

Dowels must be fully seated in the cylinder block.
35. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be
installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Install the cylinder head gasket, cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 4
stages:
Stage 4: Turn 75 degrees.
36. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
37. If removed, install the camshaft trigger wheels and the 2 bolts.
38. NOTE: Lubricate the camshafts with clean engine oil.
Install the camshafts as shown.

39. Install the Variable Camshaft Timing (VCT) bridge O-ring seal.
40. NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker to the cylinder head.
Apply a 1.5 mm (0.059 in) bead of gasket maker to the cylinder head as shown.
41. NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their original
locations or damage to the engine may occur.
NOTE: Apply clean engine oil to the bearing surfaces of the camshaft bearing caps and the VCT bridge.
Install the camshaft bearing caps, VCT bridge and the bolts finger tight.
42. Tighten the bolts in the sequence shown in 6 stages.
Stage 1: Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT
bridge are seated against the cylinder head.
Stage 4: Tighten bolts 1 through 16 an additional 45 degrees.
43. If the cylinder head, camshafts or valve tappets were replaced, check the valve clearance. For additional
information, refer to Valve Clearance Check in this section.
44. Using the Camshaft Seal Installer, install the 2 camshaft oil seals.
45. NOTICE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to
align the camshafts.
46. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts
from turning.
Install the 2 camshaft phaser and sprocket, bolts and the VCT Alignment Tool.

from turning.
Tighten to 2 camshaft phaser and sprocket bolts an additional 75 degrees.

from turning.

56. Install the 4 spark plugs.

57. Using a new gasket, install the coolant pump, 6 bolts and tighten in sequence shown in 2 stages.
58. Install the timing belt tensioner and the bolt.

Rotate the timing belt tensioner clockwise and align the 2 holes on the tensioner and install a small
screwdriver or holding pin.
59. NOTE: Lubricate the oil seal with clean engine oil.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Front Crankshaft Seal
Replacer, install the crankshaft front oil seal.
63. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times
when handling the tensioner. Failure to follow this instruction may result in personal injury.
65. Install the crankshaft pulley and the new bolt.
The final torque of the crankshaft will be completed in following steps.
68. Tighten the crankshaft bolt in the following 3 stages.

2. Stage 2: Wait for 10 seconds.
Rotate the crankshaft about 1 3/4 turns.
70. Install the Crankshaft TDC Timing Pin.
Rotate the crankshaft until it stops against the Crankshaft TDC Timing Pin.

If the special tool cannot be installed, repeat the adjustment according to the preceding steps.

76. Install the engine mount bracket and the 3 bolts finger tight.
1. Tighten the 2 bolts to 55 Nm (41 lb-ft).
2. Tighten the bolt to 55 Nm (41 lb-ft).
77. Install the timing belt cover and the 9 bolts.

81. Using a new gasket, install the valve cover and tighten the retainers in sequence shown.
82. Install the Heated Oxygen Sensor (HO2S) electrical connector bracket and the nut.
83. NOTE: Lubricate the O-ring seals with clean engine oil.
Install the VCT oil control solenoids and the 2 bolts.

84. Install the Crankshaft Position (CKP) sensor and the bolt.
85. NOTE: Apply thread sealant to the Engine Oil Pressure (EOP) switch threads.
Install the EOP switch.

86. Install the crankcase vent oil separator and the bolts.
87. Install the RH Knock Sensor (KS) at the 2 o'clock position and the LH KS at the 11 o'clock position and install
the bolts.
88. Install the thermostat and seal in the engine block.
89. Install the gasket, thermostat housing and the 4 bolts finger tight. Tighten the bolts in sequence shown in 2
stages.
90. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Install the new oil cooler and the bolt.

91. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve
or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new
intake manifold. Failure to follow these instructions can result in engine damage.
Inspect and install new intake manifold gaskets if necessary.

Connect the PCV hose to the intake manifold.
93. Attach the KS electrical connector to the intake manifold.

94. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings
may cause the fuel system to leak. Do not reuse the O-ring seals.
Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.
95. Install the 4 fuel injectors and the 4 fuel injector clips into the fuel rail.
96. Install the fuel rail and fuel injectors as an assembly and install the 2 bolts.
97. If equipped, position the block heater and finger-tighten the nut, making sure the block heater electrical
connector points to the 8 o'clock position.
Tighten the nut to 3 Nm (27 lb-in).

100. Install the ignition coil and coolant outlet assembly and the 4 bolts.
101. Install the coolant outlet bracket, nut and the bolt.
102. Connect the coolant return hose to the cylinder head.

Attach the coolant tube to the fuel rail retainers.
103. Connect the coolant hose to the coolant outlet.
104. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
Install the 4 spark plug wires.
105. Install the Evaporative Emission (EVAP) canister purge valve and the bolt.
106. Attach the EVAP tube and coolant tube to the coolant outlet bracket retainer.
108. Connect the EVAP canister purge valve tube to the intake manifold.
109. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
Vehicles with automatic transaxle
110. Align the flexplate and crankshaft using the dowel pin location hole and install the new bolts finger tight.

Vehicles with manual transaxle
113. Align the flywheel and crankshaft using the dowel pin location hole and install the new bolts finger tight.

116. NOTICE: Be sure the clutch is installed correctly in the pressure plate. The side of the clutch marked
gearbox side faces the pressure plate fingers. Failure to install the clutch plate will damage the clutch
assembly during installation on the flywheel.
NOTICE: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in
solvent or damage may occur.
Position the clutch disc on the clutch pressure plate with the side of the clutch marked gearbox side facing the
pressure plate fingers. Using a suitable clutch aligner, centralize the clutch disc to the clutch pressure plate.
117. NOTE: Use a clutch disc aligner (such as OTC® Clutch Alignment Tool Set 4528 or equivalent).
Using a clutch disc aligner, position the clutch disc and clutch pressure plate on the flywheel. Install the 6 new
clutch pressure plate-to-flywheel bolts.
Tighten the bolts evenly two turns at a time in the pattern shown.
INSTALLATION Procedure revision date: 01/14/2011
Engine — Automatic Transaxle
Special Tool(s)
300-OTC1819E
Powertrain Lift
300-OTC1585AE
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent

014-00001
Material
Item Specification
LSP12 (Canada)
All vehicles
1. NOTICE: Use caution not to damage the engine-to-transaxle separator plate or damage can
occur.
Install the new engine-to-transaxle separator plate.

2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together.
Install the 6 engine-to-bellhousing bolts.
3. Using the Floor Crane and Spreader Bar, raise the engine and transaxle assembly onto the lift
table.
4. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine and transaxle assembly to
the lift table.
5. NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.
NOTICE: Tighten the flexplate-to-clutch nuts in a star pattern or transaxle damage can
occur.
NOTE: Using a magnetic socket will help ensure ease of installation. If the nuts are dropped in
the clutch housing, the transaxle will have to be removed to retrieve them.
Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.
Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).
Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).
6. Install the flexplate-to-clutch nut access cover.
7. Install the 2 upper bellhousing-to-engine bolts and bracket.

Attach the wiring harness pin-type retainer to the bracket.
8. Install the starter motor and the 3 bolts (2 shown).
Install the 3 bolts finger-tight.
Tighten the 2 upper bolts to 48 Nm (35 lb-ft).
Tighten the lower bolt to 48 Nm (35 lb-ft).
9. Connect the starter motor electrical terminals and install the 2 nuts.
10. Connect the RH Knock Sensor (KS) electrical connector.

Attach the 2 wiring harness retainers to the intake manifold.
11. Connect the Engine Oil Pressure (EOP) switch electrical connector.
Attach the wiring harness retainer to the engine block.
12. Connect the Crankshaft Position (CKP) sensor electrical connector.
13. Connect the Throttle Body (TB) electrical connector.

Attach the 2 wiring harness retainers to the TB .
14. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.

Attach the 2 wiring harness retainers to the valve cover stud bolts.
16. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
Attach the 2 wiring harness retainers.
17. Connect and attach the LH KS electrical connector.
18. Connect the 2 Camshaft Position (CMP) sensor electrical connectors.
19. Attach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer to the
bracket.
20. Connect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
21. Attach the 2 wiring harness retainers to the coolant outlet bracket.

23. NOTICE: The engine mount studs must be torqued or damage to the powertrain may
occur.
Torque the engine mount studs before installing the engine mount nuts.
24. Using the lift table, position the engine and transaxle assembly in the vehicle.
25. Align the transaxle support insulator, install and tighten the 2 nuts and 2 bolts.
positioned.

27. Lower the powertrain to the installed position.

29. Install the transaxle roll restrictor and the 2 bolts.


32. NOTICE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments
until reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.

33. Position the catalytic converter heat shield and install the 4 bolts.
36. Using a new gasket, position the catalytic converter to the muffler and install the 2 catalytic
converter nuts.
37. Install the Catalyst Monitor Sensor (CMS). For additional information, refer to Section 303-14 .
38. Install the accessory drive belt idler pulley bracket and the 3 bolts.
Vehicles with A/C
39. Position the A/C compressor and install the 2 bolts and stud bolt.
40. Attach the wiring harness retainer to the lower A/C compressor bracket.
41. Connect the A/C pressure transducer electrical connector.

Attach the wiring harness retainer.
42. Position the A/C line bracket and install the nut.
43. Connect the A/C compressor electrical connector.
All vehicles
44. Install the halfshaft bracket and the 3 bolts and tighten in sequence shown.
1. Tighten the top bolt to 48 Nm (35 lb-ft).
2. Tighten the 2 bottom bolts to 24 Nm (18 lb-ft).
45. Install the RH and LH halfshafts. For additional information, refer to Section 205-04 .
46. Position the engine ground wire and install the bolt.
47. Connect the lower radiator hose and coolant hose to the thermostat housing.
48. Connect the upper radiator hose to the engine.
49. Connect the EVAP tube quick connect coupling near the bulk head. For additional information,
50. Attach the coolant hose retainer to the coolant outlet bracket.
51. Connect the lower heater hose to the heater core.
53. Position the selector lever cable and bracket and install the 2 bolts.
54. Attach the wiring harness retainer to the selector lever cable bracket.
55. Connect the selector lever cable to the control lever.
56. Connect the 2 coolant hoses to the engine oil cooler.

Attach the oil cooler hose retainer to the upper radiator hose.
57. Install the cooling fan motor and shroud. For additional information, refer to Section 303-03 .
59. Attach the fuel tube to the coolant outlet bracket retainer.
60. Connect the fuel tube spring lock couplings to the fuel rail. For additional information, refer to
Section 310-00 .
61. Connect the brake booster vacuum hose.
62. Connect the engine harness electrical connector.

63. Install the battery tray bracket, 3 battery tray nuts and the selector lever cable bolt.
Attach the 2 wiring harness retainers to the bottom of the battery tray bracket.
Tighten nuts and bolt to 10 Nm (89 lb-in).
64. Attach the 2 positive battery cable wire harness retainers to battery tray bracket.
65. Install the battery tray and the 3 bolts.

66. Connect the 3 PCM electrical connectors.
67. Install the PCM cover and the bolt.

Tighten to 5.4 Nm (47.8 lb-in).
68. Connect the cable and nut to the positive battery cable terminal.
70. Install the positive battery cable cover.

Attach the crankcase vent tube to the 2 retainers.
72. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-
12 .
74. Install the degas bottle. For additional information, refer to Section 303-03 .
75. Fill the and bleed cooling system. For additional information, refer to Section 303-03 .
76. Fill the transaxle with transmission fluid. For additional information, refer to Section 307-11 .
77. Adjust the selector lever cable. For additional information, refer to Section 307-05 .
Engine — Manual Transaxle
Special Tool(s)
300-OTC1819E
Powertrain Lift
300-OTC1585AE
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent

014-00001
Material
Item Specification
Motorcraft® Full Synthetic Manual WSD-
Transmission Fluid M2C200-C
XT-M5-QS
LSP12 (Canada)
All vehicles
1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together.
Install the 6 engine-to-bellhousing bolts.
2. Using the Floor Crane and Spreader Bar, raise the engine and transaxle assembly onto the lift
table.
3. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine and transaxle assembly to
the lift table.
4. Install the 2 upper bellhousing-to-engine bolts and bracket.
Attach the wiring harness pin-type retainer to the bracket.
5. Install the starter motor and the 3 bolts (2 shown).

Install the 3 bolts finger-tight.
Tighten the 2 upper bolts to 48 Nm (35 lb-ft).
Tighten the lower bolt to 48 Nm (35 lb-ft).
6. Connect the starter motor electrical terminals and install the 2 nuts.
7. Connect the RH Knock Sensor (KS) electrical connector.
Attach the 2 wiring harness retainers to the intake manifold.
8. Connect the Engine Oil Pressure (EOP) switch electrical connector.

Attach the wiring harness retainer to the engine block.
9. Connect the Crankshaft Position (CKP) sensor electrical connector.

10. Connect the Throttle Body (TB) electrical connector.
Attach the 2 wiring harness retainers to the TB .
11. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.

Attach the wiring harness retainers to the valve cover stud bolts.
13. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
Attach the 2 wiring harness retainers.
14. Connect and attach the LH KS electrical connector.
15. Connect the 2 Camshaft Position (CMP) sensor electrical connectors.

16. Attach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer to the
bracket.
17. Connect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
18. Attach the 2 wiring harness retainers to the coolant outlet bracket.
20. NOTICE: The engine mount studs must be torqued or damage to the powertrain may
occur.
Torque the engine mount studs before installing the engine mount nuts.
21. Using the lift table, position the engine and transaxle assembly in the vehicle.
22. Align the transaxle support insulator, install and tighten the 2 nuts and 2 bolts.
positioned.

24. Lower the powertrain to the installed position.

26. Install the transaxle roll restrictor bolt.



30. Position the catalytic converter heat shield and install the 4 bolts.
33. Using a new gasket, position the catalytic converter to the muffler and install the 2 catalytic
converter nuts.
35. Install the accessory drive belt idler pulley bracket and the 3 bolts.
Vehicles with A/C
36. Position the A/C compressor and install the 2 bolts and stud bolt.
37. Attach the wiring harness retainer to the lower A/C compressor bracket.
38. Connect the A/C pressure transducer electrical connector.
Attach the wiring harness retainer.
39. Position the A/C line bracket and install the nut.
40. Connect the A/C compressor electrical connector.

All vehicles
41. Install the halfshaft bracket and the 3 bolts and tighten in sequence shown.
1. Tighten the top bolt to 48 Nm (35 lb-ft).
2. Tighten the 2 bottom bolts to 24 Nm (18 lb-ft).
42. Install the RH and LH halfshafts. For additional information, refer to Section 205-04 .
43. Position the engine ground wire and install the bolt.
44. Attach the clutch hydraulic hose to the transaxle retainer.
surface with water.
Connect the clutch hydraulic hose and install the clip.
46. Connect the lower radiator hose and coolant hose to the thermostat housing.
47. Connect the upper radiator hose to the engine.
48. Connect the EVAP tube quick connect coupling near the bulk head. For additional information,
49. Attach the coolant hose retainer to the coolant outlet bracket.
50. Connect the lower heater hose to the heater core.
52. Connect the 2 coolant hoses to the engine oil cooler.

Attach the oil cooler hose retainer to the upper radiator hose.
53. Install the cooling fan motor and shroud. For additional information, refer to Section 303-03 .
54. Install the gearshift cables.

1. Attach the gearshift cables to the transaxle gearshift control levers.
2. Install the gearshift cable by pulling the lower part of abutment down and installing them in
the brackets.
56. Attach the fuel tube to the coolant outlet bracket retainer.
57. Connect the fuel tube spring lock couplings to the fuel rail. For additional information, refer to
Section 310-00 .
58. Connect the brake booster vacuum hose.
59. Connect the engine harness electrical connector.
60. Install the battery tray bracket and the 3 battery tray nuts.
Attach the 2 wiring harness retainers to the bottom of the battery tray bracket.
Tighten nuts and bolt to 10 Nm (89 lb-in).
61. Attach the 2 positive battery cable wire harness retainers to battery tray bracket.


64. Install the PCM cover and the bolt.
65. Install the cable and nut to the positive battery cable terminal.
67. Install the positive battery cable cover.

Attach the crankcase vent tube to the 2 retainers.
69. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-
12 .
71. Install the degas bottle. For additional information, refer to Section 303-03 .
72. Fill the and bleed cooling system. For additional information, refer to Section 303-03 .
73. NOTE: Before removing, clean the area around the fill plug.
Remove the fill plug and using a fluid suction gun, fill the transaxle with manual transmission fluid
until fluid level is 0.0-5.0 mm (0.0-0.2 in) below the lower edge of the fill hole.
Install the fill plug and tighten to 35 Nm (26 lb-ft).
74. Bleed the clutch hydraulic system. For additional information, refer to Section 308-00 .
75. Adjust the gearshift cables. For additional information, refer to Section 308-00 .
76. Install the gearshift cable cover and attach the 7 retainers (2 shown).
SECTION 303-03: Engine Cooling 2011 Fiesta Workshop Manual
Material
Capacity
Motorcraft® Metal Surface — —
Prep
ZC-31-A
Motorcraft® Premium Cooling ESR-M14P7-A —
System Flush
VC-1
Motorcraft® Specialty Orange WSS-M97B44- 5.5L (5.8
Engine Coolant D qt)
VC-3-B (US); CVC-3-B
(Canada)
Item Specification
Pressure Tests
Complete cooling system maximum pressure 138 kPa (20 psi)
Pressure relief cap 145-159 kPa (21-23 psi)
Radiator (out of vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures
Thermostat starts to open 82°C (180°F)
Thermostat fully open 97°C (207°F)
A/C compressor bolts and studbolt 24 18 —
A/C tube bracket nut 10 — 89
Accessory drive belt idler pulley bracket bolts 24 18 —
Block heater a 3 — 27
Coolant connection bolts 10 — 89
Coolant pump bolts b — — —
Coolant pump pulley bolts 20 — 177
Engine mount bolts 48 35 —
Engine mount nuts 80 59 —
Engine mount studs 8 — 71
Engine plug bolt 20 — 177
Timing belt cover bolts 9 — 80
Timing belt tensioner bolt 20 — 177
a V-lock design only. Do not install or reinstall a split ring design block heater. Refer to the procedure.
b Refer to the procedure.
Engine Cooling
NOTICE: The engine cooling system is filled with Motorcraft® Specialty Orange Engine Coolant.
Do not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft®
Specialty Orange Engine Coolant. Failure to follow these instructions may damage the engine or
cooling system.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color
from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color
change does not indicate the engine coolant has degraded nor does it require the engine coolant to be
drained, the system to be flushed, or the engine coolant to be replaced.
The cooling system components include the:
radiator
cooling fan motor and shroud
degas bottle
radiator drain valve
coolant pump
thermostat housing
block heater (if equipped)
The engine uses a cold side thermostat. This means the thermostat is located at the lower radiator hose
connection to the engine, where coolant enters the engine after being cooled by the radiator. During
initial warm-up, the cooler coolant from the radiator quickly closes the thermostat after the warm coolant
in the engine opens the thermostat slightly. The thermostat opens and closes several times before the
coolant coming from the radiator is warm enough to allow the thermostat to remain open. The engine
must run much longer than a vehicle with a hot side thermostat before the thermostat remains fully
opened.
Engine coolant provides freeze protection, boil protection, corrosion protection and cooling efficiency to
the engine and cooling components. In order to obtain these protections, maintain the engine coolant at
the correct concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. A coolant
concentration of 50% will provide freeze point protection down to -37°C (-34°F).
To maintain the integrity of the coolant and the cooling system:
Add Motorcraft® Specialty Orange Engine Coolant or equivalent meeting Ford specification WSS-
M97B44-D (orange color).
Do not add or mix with any other engine coolant. Mixing coolants degrades the coolant corrosion
protection.
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.
Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles
originally equipped with Motorcraft® Specialty Orange Engine Coolant since a Ford-approved
recycling process is not yet available.
Engine Cooling
Special Tool(s)
3-Way HD Antifreeze Coolant
Test Kit
Coolant/Battery Refractometer
ROB75240 or equivalent
D-Gas Adapter
300-OTC014-R1068 or
equivalent
Radiator Tester
STN12270 or equivalent
UView® Combustion Leak

Tester
UVU560000-R

hardware or equivalent scan
tool
Material
Item Specification
Motorcraft® Specialty Orange WSS-M97B44-
Engine Coolant D
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump.
Coolant is sent from the coolant pump through the engine block and cylinder heads. A separate circuit
from the engine also feeds the heater core with coolant. The coolant pump is operated by engine
rotation through a pulley which is driven by the accessory drive belt to circulate the coolant. The coolant
thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant
flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened,
coolant flows through the radiator circuit to transfer engine generated heat to the outside air.
The degas bottle removes air from the cooling system, allows for coolant expansion and system
pressurization, replenishes coolant to the cooling system and serves as the location for service fill.
The cooling fan draws air through the radiator to help cool the system coolant as it passes through the
radiator.
The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation.
The monitor executes once per drive cycle and has a monitor run duration of 300-800 seconds. If a
malfunction occurs, DTC P0125 or P0128 is set, and the Malfunction Indicator Lamp (MIL) is illuminated.
injury.
Always fill the cooling system with the manufacturer's specified coolant. Chemically flush the
cooling system if a non-specified coolant has been used. Refer to Cooling System Flushing in
this section. Failure to follow these instructions may damage the engine or cooling system.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no radiator cap.
2. Visually check the engine coolant level at the degas bottle when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system DTCs retrieved. Refer to the PCM DTC chart in this section for DTC
descriptions.
5. NOTE: Take note of any coolant odor or steam coming from cooling system components.
If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved,
verify the customer concern by operating the engine to duplicate the condition.
6. Visually inspect for obvious signs of any mechanical or electrical damage.

Leaks or weeps at: Inoperative or damaged:
Hoses Electric cooling fan
Tubes Wiring, connectors, relays or
Clamp joints modules
Gaskets Cylinder Head Temperature
O-rings (CHT) sensor
Thermostat coolant connection Vehicle Speed Sensor (VSS)
Radiator
Pressure relief cap
Coolant pump
Oil cooler (may leak internally or externally)
Heater core (wet floor or coolant odor in
vehicle)
Degas bottle
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)
Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat coolant connection
Radiator
Pressure relief cap
Cooling fan
Coolant pump
Oil cooler
Degas bottle
Restricted airflow through the A/C
condenser/radiator
Drive belt loose, worn or installed incorrectly
Broken or weak drive belt tensioner
Excessive white or light gray exhaust smoke (may
have burnt coolant odor)
Coolant in engine oil
Engine oil in coolant
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.
Test the system for normal operation.
8. Inspect the coolant condition.

1. Inspect the coolant color.
Discoloration may indicate that incorrect coolant may have been added to the
system. Use of incorrect (green or yellow in color) coolant degrades the corrosion
protection of Motorcraft® Specialty Orange Engine Coolant. Addition of Motorcraft®
Specialty Green Engine Coolant may cause the color to appear to be a murky
green-brown color. The addition of Motorcraft® Premium Gold Engine Coolant,
however, may not change the color or appearance of the orange colored coolant.
Detection of contamination with Motorcraft® Premium Gold Engine Coolant is
determined by the presence of nitrite. If contamination with Motorcraft® Premium
Gold Engine Coolant is suspected, test the coolant with the 3-Way HD Antifreeze
Coolant Test Kit. Follow the directions on the packaging. If the incorrect coolant has
been added to the cooling system, flush the system and refill with the correct
mixture of distilled water and Motorcraft® Specialty Orange Engine Coolant. Refer
to Cooling System Flushing in this section.
A darker orange with the presence of debris could indicate a commercially available
stop leak may have been used and could result in loss of coolant flow to critical
parts of the engine. If sediment is present, flush the system and refill with the correct
A light or reddish brown color indicates that rust may be present in the cooling
system. Flush the system and refill with the correct mixture of distilled water and
Motorcraft® Specialty Orange Engine Coolant. Refer to Cooling System Flushing in
this section.
An iridescent sheen on top of the coolant could indicate a trace of oil is entering the
system. For engine diagnosis, refer to Section 303-00 . Flush the system and refill
with the correct mixture of distilled water and Motorcraft® Specialty Orange Engine
Coolant. Refer to Cooling System Flushing in this section.
A milky brown color may indicate that engine oil is entering the cooling system.
Pressure test the cooling system. Refer to component tests in this section. If engine
oil is suspected, the cause of the leak may be internal to the engine. For engine
diagnosis, refer to Section 303-00 . Flush the system and refill with the correct
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the Coolant/Battery Refractometer. The freezing point should be in the range of
-50°C to -26°C (-58°F to -15°F). If the vehicle is driven in cold climates less than -37°C (-
34°F), it may be necessary to increase the coolant concentration to get adequate freeze
protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water.
Maximum coolant concentration is 60/40 for cold weather areas.
Minimum coolant concentration is 40/60 for warm weather areas.
3. Adjust coolant range and level if necessary:
If coolant is low, add specified coolant mixture only.
If the engine coolant tests too weak, remove some of the engine coolant and add
undiluted engine coolant until the readings are within acceptable levels.
If the engine coolant tests strong, remove some of the engine coolant and add
distilled water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the
system for normal operation before proceeding to the next step.

tool.

418-00 .
Codes (CMDTCs).
14. Clear the continuous DTCs and carry out the self-test diagnostics PCM.
15. If the DTCs recovered are related to the concern, go to the PCM DTC Chart. For all other PCM
DTCs, refer to Section 303-14 .
DTC Chart
PCM DTC Chart

P0125 Insufficient Coolant Temp For Closed Loop GO to Pinpoint Test C .
Fuel Control
P0128 Coolant Thermostat (Coolant Temp Below GO to Pinpoint Test C .
Thermostat Regulating Temperature)
P0480 Fan 1 Control Circuit REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
P0481 Fan 2 Control Circuit REFER to the Powertrain
manual.
P0691 Fan 1 Control Circuit Low REFER to the Powertrain
manual.
P0692 Fan 1 Control Circuit High REFER to the Powertrain
manual.
P0693 Fan 2 Control Circuit Low REFER to the Powertrain
manual.
P0694 Fan 2 Control Circuit High REFER to the Powertrain
manual.
All Other — REFER to Section 303-14 .
PCM DTCs
Symptom Chart
Symptom Chart
Loss of coolant Coolant hoses or tubes GO to Pinpoint Test A .
Hose clamps
Coolant pump O-ring
seal or gasket
Thermostat O-ring seal
or gasket
Thermostat coolant
connection
Radiator
Degas bottle
Pressure relief cap
Coolant pump leaking
from weep hole
Oil cooler (may leak
internally or externally)
Heater core
Engine gaskets (may
leak internally or
externally)
Cylinder block core
plugs
Block heater (if
equipped)
The engine Low coolant level GO to Pinpoint Test B .
overheats External engine coolant
leak
Airlock in system
Pressure relief cap
installation
Restricted airflow
through the A/C
condenser/radiator
Internal engine coolant
leak
Coolant
condition/concentration
Accessory drive
components
Non-OEM engine
enhancement
components
Electric cooling fan
Radiator
Thermostat
Engine Coolant
Temperature (ECT)
sensor
ECT gauge
Coolant pump
Coolant flow restriction
The engine does Low coolant level GO to Pinpoint Test C .
not reach normal Thermostat
operating Electric cooling fan
temperature always on
ECT gauge
The block heater Block heater power CHECK continuity in all 3
does not operate cable power cable circuits. If any
correctly circuit measures more
than 5 ohms, INSTALL a
new power cable.
Block heater CHECK the resistance of
the block heater. If the
resistance does not
measure between 12.5
and 17 ohms, INSTALL a
new block heater.
The electric Wiring REFER to the Powertrain
cooling fan is Relays Control/Emissions
inoperative in Fuses Diagnosis (PC/ED)
one or more Fan control module manual.
speeds or does Cooling fan motor
not operate Cooling fan resistor
correctly
The electric Wiring REFER to the Powertrain
cooling fan stays Relays Control/Emissions
on all the time Diagnosis (PC/ED)
manual.
Noisy electric Foreign material REMOVE the foreign
cooling fan contamination material from the cooling
operation Fan motor fan and shroud. TEST the
system for normal
operation. If still noisy,
INSTALL a new cooling
fan assembly.
Fan blade detached from INSTALL a new cooling
fan motor fan assembly.
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Normal Operation
The engine cooling system is a closed system providing for coolant expansion and contraction as well as
changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses
and clamps contain coolant within the cooling system and keep other fluids and contaminants from
entering the cooling system.
Coolant loss can be attributed to external or internal leaks anywhere within the cooling system.

Coolant hoses or tubes
Hose clamps
Thermostat coolant connection O-ring seal or gasket
Thermostat coolant connection
Coolant pump gasket
Radiator
Pressure relief cap
Coolant pump
Oil cooler (may leak internally or externally)
Heater core
Engine gaskets (may leak internally or externally)
Degas bottle
Engine Coolant Temperature (ECT) sensor
PINPOINT TEST A: LOSS OF COOLANT
injury.

A1 CARRY OUT INSPECTION AND VERIFICATION
Carry out the Inspection and Verification procedure in Yes
this section. REPAIR as needed. TEST the
Were any concerns found? system for normal operation.
No
GO to A2 .
A2 CHECK THE ENGINE COOLANT LEVEL
NOTE: Allow the engine to cool before checking the Yes

engine coolant level. GO to A3 .
Ignition OFF. No
Visually inspect the engine coolant level at the degas ADJUST the engine coolant level
bottle. as necessary. GO to A3 .
Is the engine coolant level within specifications?
A3 PRESSURE TEST THE ENGINE COOLING SYSTEM
Pressure test the engine cooling system. Refer to Yes
Component Tests, Cooling System Pressure Test in this REPAIR or INSTALL new
section. components. TEST the system
Does the engine cooling system leak externally? for normal operation.
No
GO to A4 .
A4 CHECK THE ENGINE COOLANT FOR AN INTERNAL
LEAK
Inspect the engine coolant in the coolant expansion tank Yes
for signs of engine oil. GO to Section 303-00 for engine
Is engine oil evident in the coolant? diagnosis.
No
GO to A5 .
A5 CHECK THE ENGINE OIL FOR COOLANT
Remove the oil level indicator from the engine. Yes
Is coolant evident in the oil? GO to Section 303-00 for engine
diagnosis.
No
GO to A6 .
A6 CHECK THE COOLING SYSTEM FOR COMBUSTION
GASES
NOTE: Use UView® Combustion Leak Tester part Yes
number UVU560000-R or equivalent. GO to Section 303-00 for engine
Using a cooling system combustion gas leak tester, diagnosis.
following the instructions supplied with the tester, check
the coolant for combustion gases. No
Are combustion gases present? The cooling system is
operational.
Pinpoint Test B: The Engine Overheats
Normal Operation
The engine cooling system maintains the engine temperature during operation. Correct coolant flow
through the engine, radiator and remainder of cooling system passages and components is essential to
maintaining a correct engine temperature.
from the engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation
through a pulley driven by the accessory drive belt circulates the coolant. The coolant thermostat is a
control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the
radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through
the radiator circuit to transfer engine-generated heat to the outside air.
Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow
at the correct rate, the inability to transfer heat from the engine through the coolant (including low
coolant) or an inability to transfer engine-generated heat to the outside air through the radiator.

Low coolant level
External engine coolant leak
Airlock in system
Pressure relief cap installation
Restricted airflow through the A/C condenser/radiator
Internal engine coolant leak
Coolant condition/concentration
Accessory drive components
Non-OEM engine enhancement components
Electric cooling fan
Radiator
Thermostat
Engine Coolant Temperature (ECT)
ECT gauge
Coolant pump
Coolant flow restriction
PINPOINT TEST B: THE ENGINE OVERHEATS
injury.

B1 CARRY OUT INSPECTION AND
VERIFICATION
Carry out the Inspection and Verification Yes
procedure in this section. REPAIR as needed. TEST the system for
Were any concerns found? normal operation.
No
GO to B2 .
B2 CHECK FOR AN AIRFLOW
OBSTRUCTION
Check the radiator or A/C condenser for Yes
an external obstruction such as leaves or REMOVE the obstruction. TEST the system for
cardboard. normal operation.
Is an obstruction present?
No
GO to B3 .
B3 CHECK THE ENGINE COOLANT LEVEL
NOTE: Allow the engine to cool before Yes

checking the coolant level. GO to B4 .
Ignition OFF. No
Visually check the engine coolant level in ADJUST the engine coolant level as necessary.
the coolant expansion tank. GO to B4 .
Is the engine coolant level within
specification?
B4 PRESSURE TEST THE ENGINE
COOLING SYSTEM
Pressure test the engine cooling system. Yes
Refer to Component Tests, Cooling REPAIR or INSTALL new components. TEST
System Pressure Test in this section. the system for normal operation.
Does the engine cooling system leak
externally? No
GO to B5 .
B5 CHECK THE ENGINE COOLANT FOR AN
INTERNAL LEAK
Inspect the engine coolant in the coolant Yes
expansion tank for signs of engine oil. GO to Section 303-00 for engine diagnosis.
Is engine oil evident in the coolant?
No
GO to B6 .
B6 CHECK THE ENGINE OIL FOR COOLANT
Remove the oil level indicator from the Yes
engine. GO to Section 303-00 for engine diagnosis.
Is coolant evident in the oil?
No
GO to B7 .
B7 CHECK THE COOLING SYSTEM FOR
COMBUSTION GASES
NOTE: Use UView® Combustion Leak Yes
Tester part number UVU560000-R or GO to Section 303-00 for engine diagnosis.
equivalent.
Using a cooling system combustion gas No
leak tester, following the instructions GO to B8 .
supplied with the tester, check the coolant
for combustion gases.
Are combustion gases present?
B8 CHECK COOLANT CONDITION
Check the coolant for dirt, rust or Yes
contamination and check the coolant GO to B9 .
concentration.
Is the coolant condition OK? No
FLUSH the engine cooling system. REFER to
Cooling System Flushing in this section. TEST
B9 CHECK THE ELECTRIC COOLING FAN
OPERATION
Start the engine. Yes
Place the climate control function selector GO to B10 .
in the MAX A/C position and the blower
motor switch in the HI position. No
Did the electric cooling fan operate? DIAGNOSE the electric cooling fan operation.
REFER to Powertrain Control/Emissions
B10 CHECK THE COOLANT PUMP
OPERATION
Allow the engine to run for 30 minutes. GO to B11 .
Place the climate control function selector
in the MAX HEAT position. Feel the No
heater outlet hose. INSTALL a new coolant pump. TEST the
Is the heater outlet hose hot? system for normal operation.
B11 CHECK THE THERMOSTAT
OPERATION
Allow the engine to run for 30 minutes. CHECK the ECT gauge operation. REFER to
Feel the lower radiator hose. Section 413-01 .
Is the lower radiator hose hot?
No
GO to B12 .
B12 VISUALLY INSPECT THE
THERMOSTAT
Carry out the Thermostat Visual Yes
Inspection in the Component Tests INSTALL a new thermostat. TEST the system
portion of this section. for normal operation.
Is the thermostat damaged?
No
INSTALL a new thermostat. TEST the system
for normal operation. If the engine still
overheats, INSTALL a new radiator. TEST the
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Normal Operation
The engine cooling system maintains engine temperature during operation. Correct coolant flow through
the engine, radiator and remainder of cooling system passages and components is essential to
maintaining a correct engine temperature.
from the engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation
through a pulley driven by the accessory drive belt, circulates the coolant. The coolant thermostat is a
control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the
radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through
the radiator circuit in order to transfer engine generated heat to the outside air.
Concerns of engine inability to reach normal operating temperature typically occur when the rate of
coolant flow through some coolant circuits (radiator, heater core) is more than expected given the
conditions, or when the electric cooling fan operates all of the time. Heat is not allowed to build in the
engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil
cooler. In addition, perceived concerns that the engine does not reach normal operating temperature can
be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the
heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect
engine temperature gauge indication.
DTC P0125 (Insufficient Coolant Temp for Closed Loop Fuel Control) — Indicates the Engine
Coolant Temperature (ECT) sensor has not achieved the required temperature level to enter
closed loop operating conditions within a specified amount of time after starting the engine.
DTC P0128 (Coolant Thermostat [Coolant Temp Below Thermostat Regulating Temperature]) —
Indicates that the thermostat monitor has not achieved the required engine operating temperature
within a specified amount of time after starting the engine.

Low coolant level
Thermostat
ECT indicator system (gauge)
Engine cooling fan always on
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
injury.

C1 CARRY OUT
INSPECTION AND
VERIFICATION
Carry out the Yes
Inspection and REPAIR as needed. TEST the system for normal operation.
Verification procedure
in this section. No
Were any concerns GO to C2 .
found?
C2 CHECK FOR DTCs
P0125 or P0128
Check for DTC P0125 Yes
or P0128. GO to C3 .
Is DTC P0125 or
P0128 present? No
The cooling system is operational. If an inoperative ECT gauge is
suspected, CHECK the ECT gauge operation. REFER to Section
413-01 . If an inoperative climate control system is suspected,
CHECK the climate control system operation. REFER to Section
412-00 . If any other DTCs are retrieved, REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
C3 CHECK THE
ELECTRIC COOLING FAN
OPERATION
Allow the engine to Yes
cool. DIAGNOSE the electric cooling fan operation. REFER to the
Make sure the A/C Powertrain Control/Emissions Diagnosis (PC/ED) manual.
switch is OFF.
Start the engine. No
Check the electric GO to C4 .
cooling fan.
Is the electric
cooling fan on all the
time?
C4 CHECK THE
COOLANT LEVEL
NOTE: Allow the Yes
engine to cool before INSTALL a new thermostat. TEST the system for normal operation.
checking the coolant
level. No
Visually check the GO to Pinpoint Test A to diagnose a coolant leak.
engine coolant level in
the coolant expansion
tank.
Is the engine coolant
level within
specification?
Component Tests
Cooling System Pressure Test
injury.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no radiator cap.
1. Turn the engine OFF.
2. Check the engine coolant level. Adjust the coolant level as necessary.
3. Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator
Tester to the quick connect fitting of the D-Gas Adapter.
4. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section or cooling system components may be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an incorrect pressure reading
results.
Slowly press the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained. If the pressure reading exceeds the
maximum cap pressure listed in the specifications table, install a new pressure relief cap.
5. If the system does not hold pressure, remove the pressure relief cap and wash it in clean water to
dislodge all of the foreign material from the gasket. Check the sealing surface in the filler neck of
the degas bottle for nicks or cuts. Use fine sandpaper or emery cloth to remove nicks and cuts.
Place a shop cloth in the filler neck to prevent debris from falling into the degas bottle. If nicks or
cuts are too deep to remove, install a new degas bottle. Install the pressure relief cap.
6. Pressurize the engine cooling system as described in Step 4. Observe the gauge reading for
approximately 2 minutes. Pressure should not drop during this time. If the pressure drops, inspect
for leaks and repair as necessary.
7. If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new
pressure relief cap and retest the system.
8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak
may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant.
Refer to Section 303-00 to diagnose the engine.
9. Release the system pressure by loosening the pressure relief cap. Check the coolant level and
adjust as necessary.
Thermostat
A new thermostat should be installed only after the following tests and checks have been carried out:
Pinpoint Test A, B or C
Thermostat Visual Inspection
Thermostat Visual Inspection
1. Remove the thermostat.
2. Examine the thermostat for signs of damage including:

Valve not fully seated (light visible through the valve)
Foreign material lodged in the main valve
Bent or broken frame or flange
Bent or broken spring
Bent or broken valve or valve stem
Wax leaking from wax reservoir or a bulge in the reservoir
Any other damage or distortion
3. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using
hot water or other heat sources. This method is not an accurate means to test the function of the
thermostat and may damage the thermostat.
If damage is found during the inspection, remove any foreign material or broken pieces and install
a new thermostat.
4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to
the Symptom Chart for further instructions.
Radiator Leak Test, Removed From Vehicle
NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage
aluminum radiators.
NOTE: Clean the radiator before leak testing to avoid contamination of tank.
Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the
Specifications.
Cooling System Draining, Filling and Bleeding
Special Tool(s)
Airlift Cooling System Tester
UVU550000 or equivalent
Material
Item Specification
Engine Coolant D
Draining
100-02 .
2. WARNING: Always allow the engine to cool before opening the cooling system. Do
not unscrew the coolant pressure relief cap when the engine is operating or the cooling
system is hot. The cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly. Failure to follow these instructions may result
NOTICE: The coolant must be recovered in a suitable, clean container for reuse. If the
coolant is contaminated, it must be recycled or disposed of correctly. Using contaminated
coolant may damage the engine or cooling system components.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may
change color from orange to pink or light red. As long as the engine coolant is clear and
uncontaminated, this color change does not indicate the engine coolant has degraded nor does it
require the engine coolant to be drained, the system to be flushed, or the engine coolant to be
replaced.
Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn
counterclockwise. When the pressure has been released, remove the pressure relief cap.
3. Place a suitable container below the lower radiator hose.

Release the clamp, disconnect the lower radiator hose from the radiator and allow the
coolant to drain.
Filling and Bleeding with a Vacuum Cooling System Filler
Always fill the cooling system with the manufacturer's specified coolant. If a non-specified
coolant has been used the cooling system must be chemically flushed. Refer to Cooling System
Flushing in this section. Failure to follow these instructions may damage the engine or cooling
system.
NOTICE: Engine coolant provides freeze protection, boil 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 coolant
expansion tank.
Add Motorcraft® Specialty Orange Engine Coolant or equivalent meeting Ford

specification WSS-M97B44-D (orange color).
Do not add or mix with any other type of engine coolants. Mixing coolants degrades the
coolant's corrosion protection.
Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
originally equipped with Motorcraft® Specialty Orange Engine Coolant since a Ford-
approved recycling process is not yet available.
1. Connect the lower radiator hose to the radiator and position the clamp.
2. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed
the cooling system.
Recommended coolant concentration is 50/50 ethylene glycol to distilled water.
For extremely cold climates (less than -37°C [-34°F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%.
A coolant concentration of 60% will provide freeze point protection down to -50°C (-
58°F).
Engine coolant concentration above 60% will decrease the overheat protection
characteristics of the engine coolant and may damage the engine.
For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
15°F).
Engine coolant concentration below 40% will decrease the corrosion and freeze
protection characteristics of the engine coolant and may damage the engine.
Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine
coolant and distilled water for optimum cooling system and engine protection.
Filling and Bleeding without a Vacuum Cooling System Filler
Always fill the cooling system with the manufacturer's specified coolant. If a non-specified
coolant has been used the cooling system must be chemically flushed. Refer to Cooling System
Flushing in this section. Failure to follow these instructions may damage the engine or cooling
system.
NOTICE: Engine coolant provides freeze protection, boil 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 coolant
expansion tank.
Add Motorcraft® Specialty Orange Engine Coolant or equivalent meeting Ford

specification WSS-M97B44-D (orange color).
Do not add or mix with any other type of engine coolants. Mixing coolants degrades the
coolant's corrosion protection.
Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
originally equipped with Motorcraft® Specialty Orange Engine Coolant since a Ford-
approved recycling process is not yet available.
1. Connect the lower radiator hose to the radiator and position the clamp.
2. Fill the radiator through the degas bottle until the coolant level is at the max fill line on the degas
bottle.
Recommended coolant concentration is 50/50 ethylene glycol to distilled water.
For extremely cold climates (less than -37°C [-34°F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%.
58°F).
Engine coolant concentration above 60% will decrease the overheat protection
characteristics of the engine coolant and may damage the engine.
For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
15°F).
Engine coolant concentration below 40% will decrease the corrosion and freeze
protection characteristics of the engine coolant and may damage the engine.
Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine
coolant and distilled water for optimum cooling system and engine protection.
3. Install the pressure relief cap.
4. NOTICE: If the engine overheats or the fluid level in the coolant expansion tank drops
below the min fill line, allow the engine to cool. Once engine is cool, add coolant to the
coolant expansion tank to the max fill line. Failure to follow these instructions may
damage the engine.
Start the engine, run and hold at 2,500 rpm for 15 minutes.
damage the engine.
Increase the engine speed to 5,000 rpm and then decrease to idle. Repeat six times.
damage the engine.
Increase the engine speed to 4,000 rpm for ten seconds, then return the engine speed to 2,500
rpm and hold for another ten minutes.
7. Decrease the engine speed to idle, shut the engine off and allow to cool.
8. Check the engine and cooling system for any leaks.
9. Check the coolant level in the degas bottle and fill as necessary.
Cooling System Flushing
Special Tool(s)
Drain Kit
164-R3662
Flush Kit
Pro Flush and Fill

Material
Item Specification
Motorcraft® Premium Cooling ESR-M14P7-
System Flush A
VC-1
1. WARNING: Always allow the engine to cool before opening the cooling system. Do
not unscrew the coolant pressure relief cap when the engine is operating or the cooling
system is hot. The cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly. Failure to follow these instructions may result
Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and
Bleeding in this section.
2. Remove the thermostat. For additional information, refer to Thermostat in this section.
3. Install the coolant hose connection without the thermostat.

Tighten the bolts to 10 Nm (89 lb-in).
4. NOTE: Refer to the cooling system Pro Flush and Fill operating instructions for specific vehicle
hook-up.
Use cooling system Pro Flush and Fill, Flush Kit and Drain Kit to flush the cooling system.
Use Motorcraft® Premium Cooling System Flush. Follow the directions on the packaging.
5. Install the thermostat. For additional information, refer to Thermostat in this section.
6. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and
Thermostat

1 W527338 Lower radiator hose clamp
2 8286 Lower radiator hose
3 W527314 Oil cooler hose clamp
4 8K276 Oil cooler hose
5 W500214 Coolant connection bolt (4 required)
6 8592 Coolant connection
7 8255 Thermostat O-ring seal (part of 8575)
8 8575 Thermostat
9 6840 Coolant connection gasket (part of 8592)
Removal
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and
3. Release the clamp and disconnect the lower radiator hose from the coolant connection.
4. Release the clamp and disconnect the oil cooler hose from the coolant connection.
5. Remove the 4 bolts, the coolant connection and the gasket.

Discard the gasket.
6. Remove the thermostat and the O-ring seal.
Discard the O-ring seal.
Installation
1. Position the thermostat and an new O-ring seal.

Position the thermostat with the weep hole at the 12 o'clock position.
2. Position a new gasket, the coolant connection and install the 4 bolts finger tight. Tighten the bolts in the
sequence shown in 2 stages.
3. Connect the oil cooler hose to the coolant connection and position the clamp.
4. Connect the lower radiator hose to the coolant connection and position the clamp.
6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding in this section.
Coolant Pump
Special Tool(s)
Pin, Crankshaft Top Dead Center
(TDC)
303-748
Tool, Timing Belt Holding

303-1556

1 W713043 Coolant pump bolt (6 required)
2 8501 Coolant pump
3 8507 Coolant pump gasket
Removal
All vehicles
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in
this section.

Vehicles with A/C
4. Remove the 2 bolts, the studbolt, position the A/C compressor aside and support it with a length of mechanic's
wire.
All vehicles

7. NOTE: The Crankshaft Top Dead Center (TDC) Pin will contact the crankshaft and prevent it from turning past
TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must
remain at the TDC position during the coolant pump removal and installation.
8. NOTE: Only rotate the crankshaft in the clockwise direction.
Rotate the crankshaft until it stops against the Crankshaft TDC Pin.
Vehicles with A/C
9. Remove the nut and position the A/C bracket aside.

All vehicles
11. NOTICE: Use a wooden block to protect the oil pan when supporting the engine
Using a floor jack and a block of wood, support the engine.
12. NOTICE: Hold the engine mount studs while removing the engine mount nuts or the powertrain may be
damaged.
NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.
Using the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount nuts.
14. Remove the 4 bolts and the coolant pump pulley.

17. NOTICE: Do not rotate the crankshaft while installing the special tool or the engine may be damaged.
Hold the timing belt in position.

1. Install the Timing Belt Holding Tools in 3 places as shown.
2. Mark the position of the timing belt for assembly reference.
18. Release the timing belt tension.

Discard the bolt.
20. Remove the 6 bolts, the coolant pump and the gasket.
Discard the gasket.
Installation
All vehicles
1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
2. Install a new gasket, the coolant pump and the 6 bolts.
Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
3. Position the timing belt tensioner and install a new bolt.

4. Make sure the timing belt is in the position noted during removal.
5. Remove the timing belt tensioner holding tool.
6. Remove the Timing Belt Holding Tools.

1. Make sure the timing belt is in the position noted during removal.
2. Remove the 3 Timing Belt Holding Tools.
7. Remove the Crankshaft TDC Pin.

9. Position the timing belt cover and install the 9 bolts.

10. Position the coolant pump pulley and install the 4 bolts finger tight.
12. NOTICE: The 2 engine mount studs must be tightened to specification or the powertrain may be
damaged.
Tighten the 2 engine mount studs to specification before installing the engine mount nuts.
13. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.
Position the engine mount and install the 2 nuts.

14. Install the 3 engine mount bolts finger tight.
15. Remove the jack and the wood block.
16. Tighten the 3 engine mount bolts.

17. Install the degas bottle.
Vehicles with A/C
18. Position the A/C bracket and install the nut.

19. Position the A/C compressor and install the 2 bolts and the studbolt.
20. Position the accessory drive belt idler pulley bracket and install the 3 bolts.
All vehicles
22. Tighten the 4 coolant pump pulley bolts.

23. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and
Radiator and Cooling Fan — Exploded View
Cooling Fan Motor and Shroud

1 14A464 Cooling fan electrical connector (part of 14K021)
2 14A169 Cooling fan wiring harness retainer (part of 14K021)
3 8C607 Cooling fan motor and shroud
Radiator and Hoses

1 8B069 Radiator mounting bracket (2 required)
2 8124A Upper radiator insulator (2 required)
3 W527317 Upper radiator hose clamp
4 8B274 Upper radiator hose
5 W527317 Lower radiator hose clamp
6 8286 Lower radiator hose
7 8005 Radiator
8 8124B Lower radiator insulator (2 required)
removal.
Radiator
Removal
All vehicles
1. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor
and Shroud in this section.
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and
3. Release the clamp and disconnect the upper radiator hose from the radiator.
4. Remove the trim pushpin on the LH side of the grille.
5. Remove the 2 radiator clips and the 2 rubber grommets.
Vehicles with A/C
6. Release the 2 A/C condenser condenser clips from the radiator and push the radiator up and the
A/C condenser down to detach the condenser from the radiator.
All vehicles
7. Tilt the top of the radiator toward the engine, lift the radiator off the radiator supports and remove
the radiator.
Installation
Vehicles with A/C
1. Position the radiator in the vehicle, slide the A/C condenser into the top slots on the radiator and
clip the A/C condenser to the bottom of the radiator.
2. Position the radiator and A/C condenser assembly on the radiator supports.

3. Position the radiator on the radiator supports.
All vehicles
4. Install the 2 rubber grommets and the 2 radiator clips.
5. Install the trim pushpin on the LH side of the grille.
6. Connect the upper radiator hose and position the clamp.
7. Install the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor
and Shroud in this section.
8. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding in this section.
Cooling Fan Motor and Shroud
1. Remove the air cleaner. For additional information, refer to Section 303-12 .
2. Detach the transmission vent hose from the cooling fan and shroud.
3. Detach the upper 2 wiring harness pushpins from the cooling fan shroud.
4. Release the 2 cooling fan shroud clips.
5. Detach the lower 2 wiring harness pushpins from the cooling fan shroud and disconnect the cooling
fan electrical connector.
6. Remove the cooling fan and shroud.

Block Heater
Material
Item Specification
ZC-31-A
Motorcraft® Specialty Orange Engine WSS-M97B44-
Coolant D
Split Ring Design

1 6B018 Block heater wiring harness
2 6A051 Block heater
V-Lock Design
1 6B018 Block heater wiring harness
2 — Block heater retaining nut (part of 6A051) 3 Nm (27 lb-in)
3 6A051 Block heater
Removal
All vehicles
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in
this section.
2. Disconnect the block heater electrical connector.
Vehicles equipped with a split ring design block heater
3. NOTE: Use a 1 1/4 in, 12-point flare nut crowfoot wrench (such as Snap-on® stock number AN850820B, or
equivalent) to remove the block heater.
Remove the block heater.

Vehicles equipped with a V-lock design block heater
4. Remove the block heater retaining nut and the block heater, then remove the V-lock and the threaded rod.
Installation
NOTE: Install only a V-lock design block heater.
1. Clean the engine block mating surface with Motorcraft® Metal Surface Prep. Follow the directions on the
packaging.
2. Position the block heater and finger-tighten the nut, making sure the block heater electrical connector points to
the 8 o'clock position.
3. Tighten the block heater nut.

4. NOTICE: Route the block heater power cable away from hot or rotating components, or the cable can
be damaged.
Connect the electrical connector.
5. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and
Degas Bottle
Material
Item Specification
Engine Coolant D

1 W520412 A/C tube bracket nut
2 19D626 A/C tube bracket
3 8100 Pressure relief cap
4 W527311 Degas bottle-to-engine hose clamp
5 8K276 Degas bottle-to-engine hose
6 8B081 Engine-to-degas bottle hose
7 8A080 Degas bottle
1. Remove the A/C tube bracket nut and detach the bracket from the stud.
2. WARNING: Always allow the engine to cool before opening the cooling system. Do not
injury.
Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn
counterclockwise. When the pressure has been released, remove the pressure relief cap.
3. Using hose pinch pliers, clamp the degas bottle-to-engine hose.
4. Using a suitable suction device, siphon the coolant from the degas bottle.
5. Squeeze the tabs and disconnect the engine-to-degas bottle hose.
6. Release the 2 clips and lift the degas bottle hose to access the degas bottle-to-engine hose.
7. Release the clamp, disconnect the degas bottle-to-engine hose and remove the degas bottle.
9. Fill the degas bottle with a 50/50 mixture of Motorcraft® Specialty Orange Engine Coolant and distilled
water.
SECTION 303-04: Fuel Charging and Controls — 1.6L 2011 Fiesta Workshop Manual
Material
Capacity
Oil (US); Motorcraft® SAE 5W-20
Super Premium Motor Oil
(Canada)
5W20-LSP12 (Canada)
Fuel Pump (FP) control module nuts 5 44
Fuel rail bolts 11 97
Throttle Body (TB) bolts 8 71
Fuel Charging and Controls
Sequential Multi-Port Fuel Injection (SFI)
System Overview
The fuel charging and controls system is:
a Sequential Multi-Port Fuel Injection (SFI) system.

Pulse Width Modulated (PWM).
Mass Air Flow (MAF) sensor controlled.
Component List
The fuel charging and controls system consists of the:
Throttle Body (TB)

fuel injectors
fuel rail
Fuel Pump (FP) control module
System Components
Throttle Body (TB)
The TB :
controls air supply to the intake manifold by electronically positioning the throttle plate.
is not adjustable.
cannot be cleaned.
Fuel Injectors
The fuel injectors:
NOTICE: Handle the fuel injectors and fuel rail with extreme care to prevent damage to sealing
areas and sensitive fuel-metering orifices.
are electronically operated by the PCM.

atomize the fuel as the fuel is delivered.
each have an internal solenoid that opens a needle valve, injecting fuel into the intake port in the
cylinder head.
are deposit resistant.
Fuel Rail
The fuel rail receives fuel from the fuel supply tube and delivers fuel to the fuel injectors
NOTICE: Handle the fuel injectors and fuel rail with extreme care to prevent damage to sealing
areas and sensitive fuel-metering orifices.
Fuel Pump (FP) Control Module
The FP control module is electronically operated by the PCM and controls voltage to the FP depending
on engine load.
System Operation
Fuel is metered into each intake port in a sequential firing order. Fuel injectors pulse to follow engine
firing order, in accordance with engine demand on a tuned intake manifold.
The basic fuel requirement of the engine is determined from the data supplied to the PCM by the MAF
sensor. The MAF sensor measures the amount of air being drawn into the engine.
The various sensors detect any changes in the operating conditions and send signals to the PCM. This
permits the PCM to control the opening duration (pulse width) of the fuel injectors and maintain optimum
exhaust emission control and engine performance for all operating conditions.
Fuel Charging and Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

Throttle Body
Part
1 — Electronic throttle control electrical connector (part of
12A581)
2 W708972 Throttle Body (TB) bolt (4 required)
3 9E926 TB
4 9E936 TB gasket
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
2. Disconnect the electronic throttle control electrical connector.
3. Remove the 4 bolts and the Throttle Body (TB).

Remove and discard the TB gasket.

Install a new TB gasket.
5. If the TB was replaced, turn the key ON without cranking the engine for 1 minute to allow the PCM to
learn the adaptive table values for the new TB .
Fuel Rail and Fuel Injector — Exploded View
Part
1 6582 Valve cover
2 6A664 Valve cover vent hose
3 9F593 Fuel injector (4 required)
4 — Fuel injector electrical connector (4 required) (part of
12A581)
5 9C995 Fuel injector clip (4 required)
6 W704043 Fuel rail bolt (2 required)
7 9229 Fuel injector O-ring seals (2 required per injector)
8 9D280 Fuel rail
9 — Fuel tube-to-fuel rail spring lock coupling (part of
9L291)
10 00817 Degas bottle vent hose clip
11 8B081 Degas bottle vent hose
removal.
Fuel Rail
Material
Item Specification
LSP12 (Canada)
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue
may ignite when the engine is returned to operation. Failure to follow this instruction may result
personal injury.
NOTE: Refer to the on-line Workshop Manual to view this illustration as an interactive exploded view,
requires Adobe® Acrobat® 8.0 or higher.
NOTE: Refer to the on-line Workshop Manual to learn about using an Interactive Illustration.
3. Disconnect the valve cover vent hose from the valve cover and position the hose out of the way.
4. Disconnect the degas bottle vent hose from the two clips on the fuel rail.
5. Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to
Section 310-00 .
7. Remove the 2 bolts, the fuel rail and the 4 injectors.

8. NOTICE: Use O-ring seals that are made of special fuel resistant material. Use of ordinary
O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
Remove the fuel injector retaining clips and the fuel injectors.
Remove and discard the O-ring seals.
9. NOTE: Install new O-ring seals and lubricate them with clean engine oil.

Fuel Injectors
1. The fuel injectors are serviced with the fuel rail. For additional information, refer to Fuel Rail and
Fuel Injector — Exploded View and Fuel Rail in this section.
Fuel Pump Control Module
Part
1 — Fuel Pump (FP) control module electrical connector
(part of 14A005)
2 9D370 FP control module
3 W711330 FP control module nut (2 required)
1. Remove the LH front seat. For additional information, refer to Section 501-10 .
2. Remove the scuff plate trim panel and the cowl side trim panel. For additional information, refer to
Section 501-05 .
3. NOTE: The Fuel Pump (FP) control module is located on the rear surface of the LH front seat mount.
Disconnect the FP control module electrical connector.
4. NOTICE: Do not overtighten the fasteners or damage to the module may occur.
Remove the 2 FP control module nuts.


SECTION 303-05: Accessory Drive 2011 Fiesta Workshop Manual
Accessory drive belt idler pulley bolt (without A/C only) 24 18 —
Accessory drive belt idler pulley bracket bolt (without A/C only) 24 18 —
Accessory drive belt splash shield bolts 9 — 80
Accessory Drive
The accessory drive:
has a single serpentine drive belt with 6 ribs.

is not adjustable.
The accessory drive system provides power to operate components which power other systems. These could
include components such as the generator and A/C compressor. Each of these components is equipped with a
pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft
pulley. To maintain correct operation of this system, it is critical that the correct length drive belt be installed.
The pulleys must also be correctly aligned and kept clean.
Accessory Drive Belt Routing
With A/C

3 10344 Generator pulley
4 6C301 Accessory drive belt
5 19D784 A/C compressor pulley
Without A/C
3 10344 Generator pulley
5 6C344 Accessory drive belt Idler pulley
Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any
fluids or belt dressing applied to them as damage to the belt material and tensioner damping
mechanism may occur.
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical damage.

Mechanical
Drive belt cracking/chunking/wear
Belt/pulley contamination
Incorrect accessory drive belt
Incorrectly routed accessory drive belt
Pulley misalignment or excessive pulley runout
Loose or mislocated hardware
Loose accessory drive belt
Damaged pulleys
3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, A/C slugging noise, power steering cavitations at low
temperatures, Variable Camshaft Timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
5. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard, install a new belt.
V-Ribbed Serpentine Belt With Piling

NOTE: Piling is an excessive buildup in the V-grooves of the belt.
6. The condition of the V-ribbed drive belt should be compared against the illustration and
appropriate action taken.
1. Small scattered deposits of rubber material. This is not a concern, therefore, installation of
a new belt is not required.
2. Longer deposit areas building up to 50% of the rib height. This is not considered a
durability concern, but it can result in excessive noise. If noise is apparent, install a new
belt.
3. Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt.
8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart .
Symptom Chart
Symptom Chart
Accessory drive Accessory drive INSPECT the accessory drive
belt cracking (over belt belt. REFER to Inspection
15 cracks in a rib and Verification in this
over a distance of section. INSTALL a new
100 mm [4.0 in]) accessory drive belt as
necessary.
Accessory drive Accessory drive INSPECT the accessory drive
belt chunking belt belt. REFER to Inspection
and Verification in this
section. INSTALL a new
accessory drive belt as
necessary.
Damaged pulley INSPECT the accessory drive
grooves belt pulley grooves for
damage. INSTALL a new
pulley or component as
necessary.
Accessory drive Defective/worn or REFER to Component Tests,
belt noise, squeal, incorrect accessory Drive Belt — Noise/Flutter in
chirping or flutter drive belt this section. REPAIR or
Misaligned pulley INSTALL new parts as
(s) necessary.
Pulley runout
Damaged or worn
accessory drive
component or idler
Fluid
contamination of
accessory drive
belt or pulleys
necessary.
Accessory drive CHECK the accessory drive
component failure components. INSTALL new
components as necessary.
Accessory drive INSPECT the accessory drive
belt idler pulley belt idler pulley for freedom of
bearing failure rotation and damage.
INSTALL a new accessory
drive belt idler pulley as
necessary.
Premature Defective or REFER to Component Tests,
accessory drive incorrect accessory Drive Belt — Noise/Flutter
belt wear drive belt and Drive Belt — Incorrect
Misaligned pulley Installation in this section.
(s) REPAIR or INSTALL new
Pulley runout parts as necessary.
Damaged
accessories
Incorrectly installed
drive belt
Fluid
contamination
necessary.
Component Tests
Drive Belt — Noise/Flutter
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any
fluids or belt dressing applied to them as damage to the belt material and tensioner damping
mechanism may occur.
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area with
a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction
or at an angle to the straightedge.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an
accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start up and shut down or during very rapid engine
acceleration and decelerations, such as:
Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic
transmissions.
WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions.
These special short-term transient events are expected, and are due to the higher system inertias
required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring
drive belt squeal can occur:
if the A/C discharge pressure goes above specifications:

the A/C system is overcharged.
the A/C condenser core airflow is blocked.
the A/C anti-slugging strategy executes after a long hot heat soak.
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 or idler pulley(s) 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 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.
Install a new accessory drive belt if the drive belt is worn or damaged.
Drive Belt — Incorrect Installation
NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks
incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt.
Incorrect Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory
drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the
accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists,
proceed with the following:
Visually check the accessory drive belt tensioner for damage and wear, especially the mounting
pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions will result in chirp and squeal noises.
With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
Check all accessories, mounting brackets and the accessory drive belt tensioner for any
interference that would prevent the component from mounting correctly. Correct any interference
condition and recheck the accessory drive belt tracking.
Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware
to specification. Recheck the accessory drive belt tracking.
Front End Accessory Drive (FEAD) — Exploded View
Part
2 W709601 Accessory drive belt idler pulley (without A/C only)
3 8687 Accessory drive belt idler pulley washer (without A/C
only)
4 6C344 Accessory drive belt idler pulley (without A/C only)
5 W500311 Accessory drive belt idler pulley bracket bolt (without
A/C only) (3 required)
6 8680 Accessory drive belt idler pulley bracket (without A/C
only)

Accessory Drive Belt
Removal
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys be
lubricated as potential damage to the belt material and tensioner damping mechanism will occur.
Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
100-02 .
2. Remove the 2 bolts and the accessory drive belt splash shield.
3. Cut and discard accessory drive belt.
Installation
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys be
lubricated as potential damage to the belt material and tensioner damping mechanism will occur.
Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
NOTICE: Only rotate the crankshaft clockwise or damage to the engine can occur.
1. Remove and discard the bolt. Install the stud bolt supplied with the new accessory drive belt.
Tighten the stud bolt to 9 Nm (80 lb-in).
2. Rotate the crankshaft clockwise until the designated hole is at the 5 o'clock position.
3. Install the tools supplied with the new accessory drive belt as shown.
Install the supplied nut finger tight.
4. NOTE: Without A/C shown, with A/C similar.
Position the accessory drive belt onto the coolant pump, generator and idler pulleys as shown.
5. NOTE: After installation, verify the accessory drive belt is correctly seated on all of the pulleys.
Rotate the crankshaft clockwise 1 full rotation.

6. Remove the nut and the special tools. Leave the stud bolt installed.
7. NOTE: With A/C shown, without A/C similar.
Verify the accessory drive belt is correctly seated on all of the pulleys.
8. Position the accessory drive belt splash shield and install the 2 bolts.
SECTION 303-06: Starting System 2011 Fiesta Workshop Manual
Starter motor bolts 48 35 —
Starter motor solenoid battery cable nut 10 — 89
Starter motor solenoid wire nut 10 — 89
Starting System
The starting system consists of the following:
Without Intelligent Access

Battery
Battery cables
Ignition switch
Starter motor
Starter relay (located in the Battery Junction Box (BJB)
PCM (located in the engine compartment attached to the battery tray)
Transmission Range (TR) sensor (automatic transaxle-equipped vehicles) (located on the transaxle)
Clutch Pedal Position (CPP) switch (manual transmission-equipped vehicles) (located on the clutch pedal)
Transmission Control Module (TCM) (located on the transaxle)
Integrated Keyhead Transmitters (IKTs)
With Intelligent Access

Battery
Battery cables
Start/stop switch
Starter motor
Starter relay (located in the BJB
PCM (located in the engine compartment attached to the battery tray)
Brake pedal switch (automatic transaxle)
TR sensor (automatic transaxle-equipped vehicles) (located on the transaxle)
CPP switch (manual transmission-equipped vehicles) (located on the clutch pedal)
TCM (located on the transaxle)
Intelligent Access (IA) key
Remote Function Actuator (RFA) module
Starting System
Special Tool(s)
Flex Probe Kit

Test Light
SGT27000 or equivalent 250-
300 mA incandescent bulb test
lamp

tool
Principles of Operation — Without Intelligent Access (IA)
NOTE: This vehicle is equipped with Passive Anti-Theft System (PATS) that disables the engine if an
unprogrammed PATS key is used or an invalid PCM ID is received. PATS is controlled by the Instrument
Panel Cluster (IPC). If there is a PATS concern that caused the engine to be disabled, the anti-theft light
flashes rapidly in the IPC . Refer to Section 419-01B to diagnose a PATS concern.
The starting system is electronically controlled by the PCM. The PCM receives the following inputs:
Correctly coded ignition key from the IPC

Clutch pedal applied from the Clutch Pedal Position (CPP) switch (vehicles equipped with manual
transaxle)
Transaxle in PARK or NEUTRAL from the Transmission Range (TR) sensor (vehicles equipped
with automatic transaxle)
Request to start the engine, ignition switch in the START position
Under normal operation when the ignition is turned to the START position the IPC generates a key
verification message. It sends this message to the PATS transceiver. The transceiver reads the key and
sends a key verification message back to the IPC . If the message received does not match the key
verified in the IPC memory, the engine will not crank and start. Once the IPC determines the correct
programmed key was used to START the vehicle, the IPC sends the PCM a request to crank and start
the engine. When the PCM receives the message, it generates a response and sends it back to the
IPC . If the response from the PCM does not match the response in the IPC memory, PATS is not
enabled and the engine does not crank. If both the key verification and PCM ID pass, PATS is enabled.
The PCM recognizes the correct electronically coded passive key and provides voltage and ground to
the starter relay coil. The starter relay coil is energized causing the relay contacts to close providing
voltage to the starter solenoid, allowing the starter motor to crank and start the engine. The PCM
disengages the starter once an engine rpm threshold is reached, a set crank time is exceeded or the
ignition is turned OFF. For additional information, refer to Section 419-01B .
Vehicles equipped with an automatic transaxle have a TR sensor. The TR sensor prevents operation of
the starter unless the transaxle is in NEUTRAL or PARK.
Vehicles equipped a manual transaxle have a CPP switch. The CPP switch prevents operation of the
starter unless the clutch pedal is fully pressed.
Principles of Operation — With Intelligent Access (IA)
NOTE: This vehicle is equipped with Passive Anti-Theft System (PATS) that disables the engine if an
unprogrammed PATS key is used or an invalid PCM ID is received. PATS is controlled by the Remote
Function Actuator (RFA) module. If there is a PATS concern that caused the engine to be disabled, the
anti-theft light flashes rapidly in the Instrument Panel Cluster (IPC). Refer to Section 419-01B to
diagnose a PATS concern.
The Intelligent Access (IA) starting system is electronically controlled by the RFA module which acts as
the PATS control function. The RFA module receives the following inputs:
Correctly coded ignition key from PATS

Clutch pedal applied input from the Clutch Pedal Position (CPP) switch (vehicles equipped with
manual transaxle)
Transaxle in PARK or NEUTRAL from the Transmission Control Module (TCM) (vehicles
equipped with automatic transaxle)
Request to start the engine, start/stop switch is pushed
Brake pedal applied input (automatic transaxle)
During a start event, the start/stop button is pushed in combination with either the brake or clutch pedal
input. The RFA module receives a request to start the engine. The RFA module recognizes the correct
electronically coded passive key and provides voltage to the starter relay coil and signals the PCM. The
PCM recognizes the correct inputs and provides ground to energize the relay coil and close the relay
contacts. The starter relay contacts close, providing voltage to the starter solenoid, allowing the starter to
crank and start the engine. The PCM disengages the starter once an engine rpm threshold is reached, a
set crank time is exceeded or the stop/start button is pressed indicating an engine shutdown request.
Vehicles equipped with an automatic transaxle have a TR sensor. The TR sensor prevents operation of
the starter unless the transaxle is in NEUTRAL or PARK.
Vehicles equipped a manual transaxle have a CPP switch. The CPP switch prevents operation of the
starter unless the clutch pedal is fully pressed.
NOTE: Make sure the anti-theft system is functioning correctly before carrying out a logical starting
system diagnosis. Address anti-theft system concerns before continuing. Refer to Section 419-01B .
2. Remove the accessory drive belt. Refer to Section 303-05 . Verify the crankshaft and each of the
components driven by the accessory drive belt rotate and are not seized or damaged.

Starter motor Battery
Starter motor bolts Battery cables
IA key (with Intelligent High-current Battery Junction Box (BJB) mega fuse 1
access) (450A)
Start/stop button (with IA ) BJB fuse 11(30A)
Starter relay
PATS

tool.
7. For vehicles without Intelligent Access, if the scan tool does not communicate with the vehicle:
8. For vehicles with Intelligent Access, if the scan tool does not communicate with the vehicle:
verify the ignition is in the ON mode.
the air bag warning indicator prove-out (other indicators may NOT prove ignition is
ON) confirms ignition ON. If ignition does not turn ON, refer to Section 211-05 to
diagnose no power in RUN.
refer to Section 418-00 , to diagnose no response from the PCM.

418-00 .
If the network test passes, proceed with module self-test diagnostics.
10. Carry out the self-test diagnostics for the Transmission Control Module (TCM) (if equipped), RFA
module (if equipped) and the PCM.
11. If the DTCs retrieved are related to the concern, go to DTC Charts.
DTC Chart
PCM DTC Chart

P0617:12 Starter Relay Circuit High: Circuit Short To GO to Pinpoint Test C .
Battery
P0850:00 Park / Neutral Switch Input Circuit: No Sub For vehicles without Intelligent Access (IA),
Type Information GO to Pinpoint Test A .
For vehicles with IA , GO to Pinpoint Test

B.
P0851:00 Park / Neutral Switch Input Circuit Low: No For vehicles without IA , GO to Pinpoint
Sub Type Information Test A .
For vehicles with IA , GO to Pinpoint Test

B.
All other — REFER to Section 303-14 .
DTCs
Transmission Control Module (TCM) DTC Chart

P0706:00 Transmission Range Sensor A Circuit Range/Performance: No REFER to Section
Sub Type Information 307-11 .
P0707:00 Transmission Range Sensor A Circuit Low: No Sub Type REFER to Section
Information 307-11 .
P0708:00 Transmission Range Sensor A Circuit High: No Sub Type REFER to Section
P0709:00 Transmission Range Sensor A Circuit Intermittent: No Sub Type REFER to Section
P2801:00 Transmission Range Sensor B Circuit Range/Performance: No REFER to Section
Sub Type Information 307-11 .
P2802:00 Transmission Range Sensor B Circuit Low: No Sub Type REFER to Section
P2803:00 Transmission Range Sensor B Circuit High: No Sub Type REFER to Section
P2804:00 Transmission Range Sensor B Circuit Intermittent: No Sub Type REFER to Section
All other — REFER to Section
DTCs 307-11
P0615:12 Starter Relay Circuit: Circuit Short to Battery GO to Pinpoint Test C .
P1708:62 Clutch Switch Circuit: Signal Compare Failure GO to Pinpoint Test B .
All other DTCs — REFER to Section 419-01B .
Symptom Chart
Symptom Chart
The engine Fuse GO to Pinpoint Test A .
does not Battery
crank — Battery cables
without Passive Anti-
Intelligent Theft System
Access (IA) (PATS)
Starter motor
Wiring, terminals
or connectors
PCM
Starter relay
Ignition switch
Transmission
Range (TR)
sensor (automatic
transaxle only)
Transmission
Control Module
(TCM) (automatic
transaxle only)
CPP switch
(manual transaxle
only)
The engine Fuse GO to Pinpoint Test B .
does not Battery
crank — with Battery cables
Intelligent PATS
Access (IA) Starter motor
Wiring, terminals
or connectors
PCM
Remote Function
Actuator (RFA)
module
Starter relay
Start/stop switch
Brake switch
input
TCM (automatic
transaxle only)
CPP switch
(manual transaxle
only)
Unusual Starter motor GO to Pinpoint Test D .
starter noise Starter motor
mounting
Flywheel or
flexplate ring gear
Starter motor
engagement
The engine Battery CARRY OUT the Starter Motor
cranks slowly Starter motor Component Test.
Circuitry
The starter Starter motor INSPECT the flywheel/flexplate ring
spins but the gear for missing teeth. CHECK the
engine does starter motor for correct mounting. If
not crank concern persists, INSTALL a new
starter motor. REFER to Starter
Motor in this section. TEST the
Pinpoint Tests
Pinpoint Test A: The Engine Does Not Crank — Without Intelligent Access
Refer to Wiring Diagrams Cell 20 , Starting System for schematic and connector information.
Normal Operation
Under normal operation the ignition switch is turned to the START position, the PCM receives a request
to start the engine. The PCM receives a signal from theTransmission Control Module (TCM) that the
vehicle is in PARK or NEUTRAL as determined by the TR sensor (vehicles equipped with an automatic
transaxle) or from the Clutch Pedal Position (CPP) switch indicating the clutch pedal is fully pressed
(vehicles equipped with manual transaxle). The PCM supplies voltage and ground to energize the starter
relay coil. The energized coil causes the starter relay contacts to close. This allows voltage to be
supplied from Battery Junction Box (BJB) fuse 11 (30A) to the starter solenoid. The starter solenoid is
grounded at the starter. Energizing the starter solenoid closes the solenoid contacts allowing voltage
directly from the battery to the starter, engaging the starter drive into the ring gear causing the engine to
crank and start. The PCM disengages the starter once an engine rpm threshold is reached, a set crank
time is exceeded or the ignition is turned OFF.
DTC P0850:00 (Park/Neutral Switch Input Circuit: No Sub Type Information) — sets when the
message from the P/N_SW CLUTCH 2 circuit is invalid causing a mismatch with the High Speed
Controller Area Network (HS-CAN) message from the TCM .
DTC P0851:00 (Park/Neutral Switch Input Circuit Low: No Sub Type Information) — sets when
the PCM detects a short to ground on the P/N_SW/CLUTCH 2 circuit.

Battery
Battery cables
Passive Anti-Theft System (PATS)
Ignition switch
Fuse
Starter motor
Starter relay
PCM
TCM (automatic transaxle)
Clutch Pedal Position (CPP) switch (manual transaxle only)
PINPOINT TEST A: THE ENGINE DOES NOT CRANK — WITHOUT INTELLIGENT ACCESS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the
correct probe adapter(s) may damage the connector.
Result / Action to
Test Step
Take
A1 CHECK THE BATTERY
Check the battery condition and state of charge. Refer to Yes
Diagnosis and Testing in Section 414-01 . GO to A2 .
Is the battery OK?
No
CHARGE or INSTALL a
new battery as
necessary. REFER to
Section 414-01 . TEST
operation.
A2 RETRIEVE DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: PCM — For IPC DTCs, REFER
Self-Test. to Section 413-01 .
Enter the following diagnostic mode on the scan tool: IPC — Self-
Test. For all TCM DTCs,
Enter the following diagnostic mode on the scan tool: TCM — REFER to Section 307-
Self-Test. 11 .
Were DTCs retrieved on-demand during self-test?
For PCM DTC
P0617:12, GO to
Pinpoint Test C . For
PCM DTC P0850:00,
GO to A4 . For DTC
P0851:00, GO to A7 .
For all other PCM
DTCs, REFER to
Section 303-14 .
No
For automatic transaxle,
GO to A3 . For manual
transaxle, GO to A9 .
A3 CHECK THE PCM TRANSMISSION PARK OR NEUTRAL RANGE
SWITCH (TRP/N) PID
— PCM. GO to A10 .
While observing the TRP/N PID, place the gear selector in
NEUTRAL and then PARK. No
Does the PID indicate YES with the gear selector in NEUTRAL GO to A4 .
or PARK?
A4 CHECK THE P/N_SW/CLUTCH 2 CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: PCM C175B. REPAIR circuit CE903
Disconnect: TCM C1750A. (BU/OG). CLEAR the
Ignition ON. DTCs. REPEAT the
Measure the voltage between PCM C175B-7, circuit CE903 self-test. TEST the
(BU/OG), harness side and ground. system for normal
operation.
No
GO to A5 .

A5 CHECK THE P/N_SW/CLUTCH 2 CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between PCM C175B-7, circuit CE903 GO to A6 .
(BU/OG), harness side and TCM C1750A-39, circuit CE903
(BU/OG), harness side. No
REPAIR circuit CE903
(BU/OG). CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.

A6 CHECK THE TCM TRANSMISSION RANGE INPUT ALLOWING
ENGINE START (TR_CRANK) AND PCM TRANSMISSION PARK OR
NEUTRAL RANGE SWITCH (TRP/N) PIDs
Connect: PCM C175B. Yes
Connect: TCM C1750A. The system is operating
Ignition ON. correctly at this time.
Enter the following diagnostic mode on the scan tool: DataLogger The concern may have
— TCM . been caused by a loose
While observing the TR_CRANK PID, place the gear selector in or corroded connector.
NEUTRAL and then PARK. CLEAR the DTCs.
Enter the following diagnostic mode on the scan tool: DataLogger REPEAT the self-test.
— PCM. TEST the system for
While observing the TRP/N PID, place the gear selector in normal operation.
NEUTRAL and then PARK.
Do the PIDs indicate YES with the gear selector position in No
NEUTRAL or PARK? If the concern is with
TRP/N PID, INSTALL a
new PCM. REFER to
operation.
If the concern is with

TR_CRANK PID,
INSTALL a new TCM .
A7 CHECK FOR DTC WITH TCM DISCONNECTED
Ignition OFF. Yes
Disconnect: TCM C1750A. GO to A8 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: PCM — No
Self-Test. INSTALL a new TCM .
Was DTC P0851:00 retrieved on-demand during self-test? REFER to Section 307-
11 . CLEAR the DTCs.
TEST the system for
normal operation.
A8 CHECK THE P/N_SWITCH CLUTCH 2 CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF. Yes
Disconnect: PCM C175B. INSTALL a new PCM.
Measure the resistance between PCM C175B-7, circuit CE903 REFER to Section 303-
(BU/OG), harness side and ground. 14 . TEST the system
No
(BU/OG). CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.

A9 CHECK THE PCM CLUTCH PEDAL AT OR NEAR BOTTOM OF
TRAVEL (CPP_BOT) PID
While observing the CPP_BOT PID, fully disengage the clutch.
Does the PID change from NO to YES? No
GO to A23 .
A10 CHECK THE PCM STARTER RELAY ENABLE (STRT_RLY) PID
NOTE: For manual transaxle, fully disengage the clutch.
Monitor the STRT_RLY PID while holding the key in the START No
position. GO to A21 .
Does the PID change from DISENGAGED to ENGAGED?
A11 CHECK THE STARTER RELAY
Swap the starter relay with a known good relay and attempt to Yes
crank the engine. INSTALL a new starter
Does the engine crank? relay. TEST the system
No
GO to A12 .
A12 CHECK THE VOLTAGE TO THE STARTER RELAY
Ignition OFF. Yes
Disconnect: Starter Relay. GO to A13 .
Measure the voltage between Battery Junction Box (BJB) starter
relay cavity pin 3, circuit SBB11 (BU/RD), harness side and No
ground. VERIFY BJB fuse 11
(30A) is OK. If OK,
(BU/RD) for an open. If
not OK, REFER to the
Wiring Diagrams
system for normal
operation.

A13 CHECK THE STARTER MOTOR OPERATION AT THE
STARTER RELAY
Ignition OFF. Yes
With the transaxle in PARK or NEUTRAL, connect one end of a GO to A19 .
fused jumper wire to BJB starter relay cavity 3, circuit SBB11
(BU/RD) and momentarily connect the other end of the fused No
jumper wire to BJB starter relay cavity 5, circuit CDC26 (GY/OG). GO to A14 .
Did the starter engage and the engine crank?
A14 CHECK THE BATTERY GROUND CABLE
Measure the voltage between the positive battery post and the Yes
battery ground cable connection at the engine. GO to A15 .
No
CARRY OUT the
Starter Motor — Ground
Circuit Test. REFER to
Component Test in this
section. TEST the
system for normal
operation.

A15 CHECK THE STARTER MOTOR GROUND
starter motor case. GO to A16 .
No
CLEAN the starter
motor mounting flange
and make sure the
starter motor is correctly
mounted. TEST the
system for normal
operation.

A16 CHECK THE VOLTAGE TO THE STARTER MOTOR
Measure the voltage between starter solenoid C197A, circuit Yes
SBF01 (RD) and ground. GO to A17 .
No
INSTALL a new positive
battery cable. REFER
to Section 414-01 .
TEST the system for
normal operation.

A17 CHECK THE STARTER MOTOR
Connect one end of a fused jumper wire to starter solenoid Yes
C197A, circuit SBF01 (RD) and momentarily connect the other GO to A18 .
end of the fused jumper wire to starter solenoid C197B, circuit
CDC26 (GY/OG). No
INSTALL a new starter
motor. REFER to
Starter Motor in this
section. TEST the
system for normal
operation.

A18 CHECK FOR START INPUT AT THE STARTER
Connect: Starter Relay. Yes
Disconnect: Starter Solenoid C197B. CLEAN the starter
Measure the voltage between the starter solenoid C197B-1, circuit solenoid "S" terminal
CDC26 (GY/OG) and ground, while holding the key in the START and connector. CHECK
position. the wiring and the
starter motor for a loose
or intermittent
connection. TEST the
system for normal
operation.
No
REPAIR circuit CDC26
(GY/OG) for an open.
TEST the system for
normal operation.

A19 CHECK THE PCM START CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: PCM C175B. GO to A20 .
Disconnect: Starter Relay.
Disconnect: IPC C220. No
Disconnect: ACM C240A (Vehicles Built After 1/14/2011). REPAIR the affected
Measure the resistance between PCM C175B, harness side and circuit for a short to
ground, using the following chart. ground. TEST the
system for normal
PCM Connector Circuit operation.
C175B-24 CDC12 (YE)

C175B-22 CDC54 (WH/GN)

A20 CHECK THE PCM START CIRCUITS FOR AN OPEN
Measure the resistance between PCM C175B, harness side and Yes
BJB starter relay cavity, using the following chart. INSTALL a new PCM.
PCM Connector Circuit BJB 14 . TEST the system
C175B-24 CDC12 (YE) BJB starter relay cavity 2
No
C175B-22 CDC54 (WH/GN) BJB starter relay cavity 1
REPAIR the affected
circuit for an open.
TEST the system for
normal operation.

A21 CHECK THE START CIRCUIT FOR VOLTAGE AT THE PCM
Disconnect: PCM C175B. Yes
Measure the voltage between PCM C175B-9, circuit CDC35 INSTALL a new PCM.
(BU/WH) and ground, while holding the key in the START REFER to Section 303-
position. 14 . TEST the system
No
GO to A22 .

A22 CHECK THE IGNITION SWITCH
Carry out the Ignition Switch Component Test. Yes
Refer to Wiring Diagrams Cell 149 for component testing. (BU/WH) for an open.
TEST the system for
normal operation.
Did the ignition switch pass the component test?
No
INSTALL a new ignition
switch. REFER to
operation.
A23 CHECK THE CPP SWITCH CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: CPP Switch C257. GO to A24 .
Disconnect: PCM C175B.
Measure the resistance between CPP switch C257-1, circuit No
CE903 (BU/OG), harness side and PCM C175B-7, circuit CE903 REPAIR circuit CE903
(BU/OG), harness side. (BU/OG) for an open.
TEST the system for
normal operation.

A24 CHECK THE CPP GROUND CIRCUIT FOR AN OPEN
Measure the resistance between CPP switch C257-2, circuit Yes
GD187 (BK/GN), harness side and ground. GO to A25 .
No
(BK/GN) for an open.
TEST the system for
normal operation.

A25 CHECK THE CPP SWITCH
Connect: CPP Switch C257. Yes
Measure the resistance between PCM C175B-7, circuit CE903 INSTALL a new PCM.
(BU/OG), harness side and ground while depressing the clutch REFER to Section 303-
pedal. 14 . TEST the system
No
INSTALL a new CPP
switch. REFER to
operation.
Pinpoint Test B: The Engine Does Not Crank — With Intelligent Access (IA)
Normal Operation
Under normal operation the start/stop switch, when pushed in combination with pressing either the brake
or clutch pedal (depending upon transaxle), provides the Remote Function Actuator (RFA) module a
request to start the engine. The RFA module and PCM receive a signal from the Transmission Control
Module (TCM) that the vehicle is in PARK or NEUTRAL (vehicles equipped with an automatic transaxle)
or from the Clutch Pedal Position (CPP) switch when the clutch pedal is fully pressed (vehicles equipped
with manual transaxle). The RFA module supplies voltage to the starter relay coil and signals the PCM
to provide ground to the relay coil. The energized coil causes the starter relay contacts to close. This
allows voltage to be supplied from Battery Junction Box (BJB) fuse 11 (30A) to the starter solenoid. The
starter solenoid is grounded at the starter. Energizing the starter solenoid closes the solenoid contacts
allowing voltage directly from the battery to the starter, engaging the starter drive into the ring gear
causing the engine to crank and start. The PCM disengages the starter once an engine rpm threshold is
reached, a set crank time is exceeded or the stop/start button is pressed indicating engine shut down.
DTC P0850:00 (Park/Neutral Switch Input Circuit: No Sub Type Information) — sets when the
message from the P/N_SW CLUTCH 2 circuit is invalid causing a mismatch with the High Speed
Controller Area Network (HS-CAN) message from the TCM .
DTC P0851:00 (Park/Neutral Switch Input Circuit Low: No Sub Type Information) — sets when
the PCM detects a short to ground on the P/N_SW/CLUTCH 2 circuit.
DTC P1708:62 (Clutch Switch Circuit: Signal Compare Failure) — sets when the clutch switch
input to the RFA module indicates the clutch pedal is pressed but the Medium Speed Controller
Area Network (MS-CAN) message transmitted by the Instrument Panel Cluster (IPC) module
indicates the clutch pedal is not pressed.

Battery
Battery cables
Start/stop switch
Cruise control deactivation switch
Fuses
PATS
Starter motor
Starter relay
PCM
Clutch Pedal Position (CPP) switch (manual transaxle only)
RFA module
PINPOINT TEST B: THE ENGINE DOES NOT CRANK — WITH INTELLIGENT ACCESS (IA)
Result / Action to
Test Step
Take
B1 CHECK THE BATTERY
Check the battery condition and state of charge. Refer to Yes
Diagnosis and Testing in Section 414-01 . GO to B2 .
Is the battery OK?
No
CHARGE or INSTALL
a new battery as
necessary. REFER to
operation.
B2 CHECK FOR KEY NOT DETECTED
NOTE: There are certain areas inside the vehicle where the IA key Yes
may not be detected and the message center displays KEY NOT REFER to Section 419-
DETECTED. If the IA key is in the far outside edges of the interior 01B to diagnose KEY
(like in a door map pocket or above a sun visor) it might not be NOT DETECTED is
detected. Move the IA key to a different location and try to crank displayed.
the vehicle again.
No
Check the Front Control/Display Interface Module (FCDIM) while GO to B3 .
pressing the start/stop switch.
Is KEY NOT DETECTED displayed?
B3 CHECK THE IPC OPERATION
Observe the Instrument Panel Cluster (IPC) operation while Yes
pressing the start/stop switch. GO to B5 .
Do some indicators in the IPC illuminate?
No
GO to B4 .
B4 CHECK FOR COMMUNICATION WITH THE SCAN TOOL
Refer to Inspection and Verification in Section 418-00 , and follow Yes
the procedure to establish a session with the vehicle. REFER to Section 211-
Does the RFA module pass the network test? 05 to diagnose no
power in RUN.
No
00 to diagnose no
communication with the
RFA module or PCM.
B5 RETRIEVED DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: PCM — Self- For RFA module DTC
Test. P1708:62, GO to B33 .
Enter the following diagnostic mode on the scan tool: RFA module For RFA module DTC
— Self-Test. P0615:12, GO to
Enter the following diagnostic mode on the scan tool: TCM — Self- Pinpoint Test C . For all
Test. other RFA module
Enter the following diagnostic mode on the scan tool: PCM — Self- DTCs, REFER to
Test. Section 419-01B .
Were DTCs retrieved on-demand during self-test?
For PCM DTC
P0617:12, GO to
Pinpoint Test C . For
PCM DTC P0850:00,
GO to B10 . For DTC
P0851:00, GO to B13 .
For all other PCM
DTCs, REFER to
Section 303-14 .
For all TCM DTCs,

11 .
No
For automatic
transaxle, GO to B6 .
For manual transaxle,

GO to B15 .
B6 CHECK THE RFA MODULE BRAKE SWITCH (BRAKE_SW) PID
— RFA module. GO to B9 .
While observing the BRAKE_SW PID, apply the brake pedal.
Does the PID change from OFF to ON? No
GO to B7 .
B7 CHECK THE CRUISE CONTROL DEACTIVATION CIRCUIT TO
THE RFA MODULE FOR A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: IPC C220. GO to B8 .
Disconnect: RFA module C3503B.
Disconnect: Cruise Control Deactivation Switch C278. No
Measure the resistance between RFA module C3503B-21, circuit REPAIR circuit CCA29
CCA29 (GN/BU), harness side and ground. (GN/BU). TEST the
system for normal
operation.

B8 CHECK THE BRAKE SWITCH
Connect: Cruise Control Deactivation Switch C278. Yes
Measure the resistance between RFA module C3503B-21, circuit INSTALL a new RFA
CCA29 (GN/BU) and ground while applying the brake pedal. module. REFER to
operation.
No
INSTALL a new cruise
control deactivation
switch. REFER to
operation.

B9 CHECK THE PCM TRANSMISSION P/N SWITCH (TRN/P) PID
— PCM . GO to B16 .
While observing the TRP/N PID, place the gear selector in
NEUTRAL and then PARK. No
Does the PID indicate YES with the gear selector in NEUTRAL GO to B10 .
or PARK?
B10 CHECK THE P/N_SW/CLUTCH 2 CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: PCM C175B. REPAIR circuit CE903
Disconnect: TCM C1750A. (BU/OG). CLEAR the
Ignition ON. DTCs. REPEAT the
Measure the voltage between PCM C175B-7, circuit CE903 self-test. TEST the
(BU/OG), harness side and ground. system for normal
operation.
No
GO to B11 .

B11 CHECK THE P/N_SW/CLUTCH 2 CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between PCM C175B-7, circuit CE903 GO to B12 .
(BU/OG), harness side and TCM C1750A-39, circuit CE903
(BU/OG). CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
B12 CHECK THE TCM TRANSMISSION RANGE INPUT ALLOWING
ENGINE START (TR_CRANK) AND PCM TRANSMISSION PARK OR
NEUTRAL RANGE SWITCH (TRP/N) PIDs
Connect: PCM C175B. Yes
Connect: TCM C1750A. The system is
Ignition ON. operating correctly at
Enter the following diagnostic mode on the scan tool: DataLogger this time. The concern
— TCM . may have been caused
While observing the TR_CRANK PID, place the gear selector in by a loose or corroded
PARK and then NEUTRAL. connector. CLEAR the
Enter the following diagnostic mode on the scan tool: DataLogger DTCs. REPEAT the
— PCM. self-test. TEST the
While observing the TRP/N PID, place the gear selector in PARK system for normal
and then NEUTRAL. operation.
Do the PIDs indicate YES with the gear selector in NEUTRAL
or PARK? No
TRP/N PID, INSTALL a
new PCM. REFER to
the system for correct
operation.

TR_CRANK PID,
INSTALL a new TCM .
B13 CHECK FOR A DTC WITH THE TCM DISCONNECTED
Ignition OFF. Yes
Disconnect: TCM C1750A. GO to B14 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: PCM — Self- No
Test. INSTALL a new TCM .
Was DTC P0851:00 retrieved on-demand during self-test? REFER to Section 307-
11 . CLEAR the DTCs.
TEST the system for
normal operation.
GROUND
Ignition OFF. Yes
Disconnect: PCM C175B. INSTALL a new PCM.
Measure the resistance between PCM C175B-7, circuit CE903 REFER to Section 303-
(BU/OG), harness side and ground. 14 . TEST the system
No
(BU/OG). CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.

B15 CHECK THE PCM CLUTCH PEDAL AT OR NEAR BOTTOM OF
TRAVEL (CPP_BOT) PID
— PCM. GO to B16 .
While observing the CPP_BOT PID, fully disengage the clutch.
Does the PID change from NO to YES? No
GO to B30 .
B16 CHECK THE PCM STARTER RELAY ENABLE (STRT_RLY) PID
— PCM. GO to B17 .
NOTE: For manual transaxle, fully disengage the clutch.
Monitor the STRT_RLY PID while pressing the start/stop switch No
and the brake or clutch pedal. REFER to Section 211-
Does the PID change from DISENGAGED to ENGAGED? 05 to diagnose the no
power in start concern.
B17 CHECK THE STARTER RELAY
Swap the starter relay with a known good relay and attempt to Yes
crank the engine. INSTALL a new starter
Does the engine crank? relay. TEST the system
No
GO to B18 .
B18 CHECK THE VOLTAGE TO THE STARTER RELAY
Ignition OFF. Yes
Disconnect: Starter Relay. GO to B19 .
Measure the voltage between Battery Junction Box (BJB) starter
relay cavity 3, circuit SBB11 (BU/RD), harness side and ground. No
VERIFY BJB fuse 11
(30A) is OK. If OK,
(BU/RD) for an open. If
Wiring Diagrams
system for normal
operation.
B19 CHECK THE STARTER MOTOR OPERATION AT THE
STARTER RELAY
Ignition OFF. Yes
With the transaxle in PARK or NEUTRAL, connect one end of a GO to B25 .
fused jumper wire to BJB starter relay cavity 3, circuit SBB11
(BU/RD) and momentarily connect the other end of the fused No
jumper wire to BJB starter relay cavity 5, circuit CDC26 (GY/OG). GO to B20 .
B20 CHECK THE BATTERY GROUND CABLE
battery ground cable connection at the engine. GO to B21 .
No
CARRY OUT the
Starter Motor —
Ground Circuit Test.
REFER to Component
Test in this section.
TEST the system for
normal operation.

B21 CHECK THE STARTER MOTOR GROUND
starter motor case. GO to B22 .
No
CLEAN the starter
motor mounting flange
and make sure the
starter motor is
correctly mounted.
TEST the system for
normal operation.

B22 CHECK THE VOLTAGE TO THE STARTER MOTOR
Measure the voltage between starter solenoid C197A-1, circuit Yes
SBF01 (RD) and ground. GO to B23 .
No
INSTALL a new
positive battery cable.

B23 CHECK THE STARTER MOTOR FOR CORRECT OPERATION
Connect one end of a fused jumper wire to starter solenoid Yes
C197A-1, circuit SBF01 (RD) and momentarily connect the other GO to B24 .
end of the fused jumper wire to starter solenoid C197B, circuit
CDC26 (GY/OG). No
motor. REFER to
Starter Motor in this
section. TEST the
system for normal
operation.

B24 CHECK FOR START INPUT AT THE STARTER
Connect: Starter Relay. Yes
Disconnect: Starter Solenoid C197B. CLEAN the starter
Measure the voltage between the starter solenoid C197B-1, circuit solenoid "S" terminal
CDC26 (GY/OG) and ground, while pressing the start/stop switch and connector. CHECK
and the brake or clutch pedal. the wiring and the
starter motor for a
loose or intermittent
connection. TEST the
system for normal
operation.
No
TEST the system for
normal operation.

B25 CHECK THE RFA MODULE STARTER REQUEST CIRCUIT FOR
VOLTAGE
Measure the voltage between BJB starter relay cavity 1, circuit Yes
CDC54 (WH/GN), harness side and ground while pressing the GO to B28 .
start/stop switch and the brake or clutch pedal.
No
GO to B26 .

A SHORT TO GROUND
Disconnect: IPC C220. Yes
Disconnect: RFA C3503C. GO to B27 .
Disconnect: ACM C240A (Vehicles Built After 1/14/2011).
Measure the resistance between BJB starter relay cavity 1, circuit No
CDC54 (WH/GN), harness side and ground. REPAIR circuit CDC54
(WH/GN). TEST the
system for normal
operation.

AN OPEN
Measure the resistance between BJB starter relay cavity 1, circuit Yes
CDC54 (WH/GN), harness side and RFA module C3503C-6. INSTALL a new RFA
module. REFER to
operation.
No
(WH/GN). TEST the
system for normal
operation.
B28 CHECK THE PCM STARTER CONTROL CIRCUIT
Connect a 12-volt test light between BJB starter relay cavity 1, Yes
circuit CDC54 (WH/GN) and BJB starter relay cavity 2, circuit INSTALL a new starter
CDC12 (YE), then press the brake or clutch pedal and press the relay. TEST the system
start/start switch. for normal operation.
No
GO to B29 .
Does the test light illuminate?
B29 CHECK THE STARTER CONTROL CIRCUIT FOR AN OPEN
Measure the resistance between BJB starter relay cavity 2, circuit INSTALL a new PCM.
CDC12 (YE), harness side and PCM C175B-24, circuit CDC12 REFER to Section 303-
(YE), harness side. 14 . TEST the system
No
(YE). TEST the system
B30 CHECK THE P/N_SW/CLUTCH 2 CIRCUIT FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: CPP Switch C257. GO to B31 .
Disconnect: RFA Module C3503B.
Disconnect: PCM C175B. No
Measure the resistance between: REPAIR circuit CE903
CPP switch C257-1, circuit CE903 (BU/OG), harness side (BU-OG). CLEAR the
and PCM C175B-7, circuit CE903 (BU/OG), harness side. DTCs. REPEAT the
PCM C175B-7, circuit CE903 (BU/OG), harness side and self-test. TEST the
ground. system for normal
operation.
Is the resistance greater than 10,000 ohms between the PCM

and ground; and less than 5 ohms between the PCM and CPP
switch?
B31 CHECK THE CPP GROUND CIRCUIT FOR AN OPEN
GD187 (BK/GN), harness side and ground. GO to B32 .
No
CLEAR DTCs.
TEST the system for
normal operation.

B32 CHECK THE CPP SWITCH
Connect: CPP Switch C257. Yes
Measure the resistance between PCM C175B-7, circuit CE903 INSTALL a new PCM.
(BU/OG), harness side and ground while pressing the clutch REFER to Section 303-
pedal. 14 . TEST the system
No
INSTALL a new CPP
switch. REFER to
Section 303-14 .
CLEAR the DTCs.
TEST the system for
normal operation.

VOLTAGE
Ignition OFF. Yes
Disconnect: CPP Switch C257. REPAIR circuit CE903
Disconnect: RFA Module C3503B. (BU-OG). CLEAR the
Disconnect: PCM C175B. DTCs. REPEAT the
Ignition ON. self-test. TEST the
Measure the voltage between PCM C175B-7, circuit CE903 system for normal
(BU/OG), harness side and ground. operation.
No
GO to B34 .
B34 CHECK THE P/N_SW/CLUTCH 2 INPUT CIRCUIT FOR AN
OPEN BETWEEN THE PCM AND RFA MODULE
Ignition OFF. Yes
Measure the resistance between RFA module C3503B-17, circuit GO to B35 .
CE903 (BU/OG), harness side and PCM C175B-7, circuit CE903
(BU/OG). CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.

B35 CHECK THE PCM CLUTCH PEDAL AT OR NEAR BOTTOM OF
TRAVEL (CPP_BOT) AND RFA MODULE CLUTCH SWITCH
(CLUTCH_SW) PIDs
Ignition OFF. Yes
Connect: CPP Switch C257. The system is
Connect: RFA Module C3503B. operating correctly at
Connect: PCM C175B. this time. The concern
Ignition ON. may have been caused
Enter the following diagnostic mode on the scan tool: by a loose or corroded
DataLogger— PCM. connector. TEST the
While observing the CPP_BOT PID, fully engage and disengage system for normal
the clutch pedal. operation.
DataLogger— RFA module. No
While observing the CLUTCH_SW PID, fully engage and If the concern is with
disengage the clutch. CPP_BOT PID,
Do both PIDs agree with the clutch pedal position? INSTALL a new PCM.
14 .

CLUTCH _SW PID,
INSTALL a new RFA
module. REFER to
operation.
Pinpoint Test C: DTC P0615:12 or P0617:12
Normal Operation — (Without Intelligent Access)
When the ignition is turned to the START position, the PCM receives a request to start the engine and
supplies voltage to the starter relay coil. The PCM monitors the start request circuit for faults. If voltage
is detected on the start request circuit and the starter relay is not in an active state, the PCM sets a DTC.
DTC P0617:12 (Starter Relay Circuit High: Circuit Short to Battery) — sets when the PCM detects
excessive current on the starter relay circuit and the output is not activated.
Normal Operation — With Intelligent Access (IA)
When the start/stop switch is pressed and released along with either the brake pedal (vehicles equipped
with automatic transaxle) or Clutch Pedal Position (CPP) switch (vehicles equipped with manual
transaxle) input, the Remote Function Actuator (RFA) module receives a request from the Intelligent
Access (IA) key to start the engine. The RFA module then supplies voltage to the starter relay coil. The
RFA module monitors the start request circuit for faults. If voltage is detected on the start request circuit
and the starter relay is not in an active state, the RFA module sets a DTC.
DTC P0615:12 (Starter Relay Circuit High: Circuit Short to Battery) — sets when the RFA module
detects current output above threshold on the starter relay circuit and the output is not activated.

RFA module
PCM
Starter relay
PINPOINT TEST C: DTCs P0615:12 OR P0617:12

C1 RETRIEVE DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: PCM — GO to C2 .
Self-Test (vehicles without IA ).
Enter the following diagnostic mode on the scan tool: Self No
Test — RFA Module (vehicles equipped with IA ). The system is operating
Are DTCs present on-demand during self-test? correctly at this time. The
test.
C2 CHECK THE STARTER REQUEST CIRCUIT FOR A SHORT

TO VOLTAGE
Ignition OFF. Yes
Disconnect: Starter Relay. REPAIR circuit CDC54
Disconnect: ACM C240A (Vehicles Built After 1/14/2011). (WH/GN). CLEAR the DTCs.
Disconnect: RFA module C3503C or PCM C175B. REPEAT the self-test.
Ignition ON.
Measure the voltage between BJB starter relay cavity 1, No
circuit CDC54 (WH/GN), harness side and ground. GO to C3 .

C3 CHECK THE STARTER RELAY
Swap the starter relay with a known good relay. Yes
Enter the following diagnostic mode on the scan tool: Self For vehicles without IA ,
Test — RFA module or PCM. INSTALL a new PCM.
Was RFA DTC P0615:12 or PCM DTC P0617:12 retrieved REFER to Section 303-14 .
on-demand during self-test? CLEAR the DTCs. REPEAT
the self-test.
For vehicles with IA

INSTALL a new RFA
module. REFER to Section
419-10 . CLEAR the DTCs.
No
relay. CLEAR the DTCs.
Pinpoint Test D: Unusual Starter Noise

Normal Operation
Correct starter operation relies on correct mounting of the starter to the engine, alignment of the starter
ring gear to the flywheel or flexplate and correct functioning of the starter assembly (internal gears,
bearings).

Starter motor
Starter motor mounting
Starter motor engagement
Flywheel or flexplate ring gear
PINPOINT TEST D: UNUSUAL STARTER NOISE

D1 CHECK THE STARTER MOTOR MOUNTING
Inspect the starter motor mounting bolts for looseness. Yes
Is the starter motor mounted correctly? GO to D2 .
No
INSTALL the starter motor
correctly. REFER to Starter
D2 CHECK FOR ENGINE NOISE
Ignition OFF. Yes
Connect a remote starter switch between the starter GO to D3 .
solenoid "B" and "S" terminals.
No
continue the diagnosis.
Engage the starter motor and verify the noise is due to

the starter operation.
Is the noise due to the starter motor engagement?
D3 CHECK FOR UNUSUAL WEAR
Remove the starter motor. Refer to Starter Motor in this Yes
Inspect the ring gear for damaged or worn teeth. flexplate/flywheel ring gear.
Is the noise due to ring gear tooth damage? EXAMINE the starter pinion
teeth. If damaged, INSTALL a
new starter motor. REFER to
Starter Motor in this section.
operation.
No
INSTALL a new starter motor.
REFER to Starter Motor in this
section.
Component Tests
Always make the Fluke 77-IV Digital Multimeter connections at the component terminal rather than at
the wiring end connector. Making a connection at the wiring end connector could result in false readings
because the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor — Feed Circuit Test
1. Make sure the battery is fully charged. Carry out the battery condition test. Refer to Diagnosis and
Testing in Section 414-01 .
2. Connect a remote starter switch between the starter solenoid "S" terminal and the battery positive
(+) terminal.
3. Connect the Fluke 77-IV Digital Multimeter positive lead to the battery positive (+) post. Connect
the negative lead to the "M" terminal.
4. Engage the remote starter switch. Read and record the voltage. The voltage reading should be
0.5 volt or less.
5. If the voltage reading is 0.5 volt or less, go to the Starter Motor — Ground Circuit Component
Test.
6. If the voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the
connections, the positive battery cable or in the starter solenoid. Move the Fluke 77-IV Digital
Multimeter negative lead to the starter solenoid "B" terminal and repeat the test. If the voltage
reading at the "B" terminal is lower than 0.5 volt, the concern is either in the connections at the
starter solenoid or in the solenoid contacts.
7. Remove the cables from solenoid "B", "S" and "M" terminals. Clean the cables and connections
and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop
reading is still greater than 0.5 volt when checked at the "M" terminal and less than 0.5 volt when
checked at the "B" terminal, the concern is in the solenoid contacts. Install a new starter motor.
8. If the voltage reading taken at the solenoid "B" terminal is still greater than 0.5 volt after cleaning
the cables and the connections at the solenoid, the concern is either in the positive (+) battery
cable connection or in the positive battery cable itself. Clean the positive (+) battery cable
connection. If this does not solve the problem, install a new positive battery cable. Refer to
Section 414-01 .
Starter Motor — Ground Circuit Test
A no or slow crank condition can be caused by excessive resistance in the ground or return portion of
the cranking circuit. Check the voltage drop in the ground circuit as follows:
1. Connect the Fluke 77-IV Digital Multimeter positive lead to the starter motor housing (make sure
the connection is clean and free of rust or grease). Connect the negative lead to the negative (-)
battery terminal.
2. Engage the remote starter switch and crank the engine. Read and record the voltage reading.
The reading should be 0.5 volt or less.
3. If the voltage is greater than 0.5 volt, clean the negative cable connections at the battery, the
body ground connections and the starter ground connections. Retest.
4. If the voltage is greater than 0.5 volt, install a new negative battery cable. If the voltage reading is
less than 0.5 volt and the engine still does not crank or cranks slowly, install a new starter motor.
Starter Motor

1 W704141 Starter solenoid wire nut
2 W701596 Starter solenoid battery cable nut
3 14A240 Starter motor solenoid wire harness terminal cover
4 W702042 Starter motor bolt (if equiped with IB5 transmission)
4 W500132 Starter motor bolt (if equiped with DPS6 transmission)
5 W500125 Starter motor bolt (if equiped with IB5 transmission)
5 W709638 Starter motor bolt (if equiped with DPS6 transmission)
6 11000 Starter motor
WARNING: Always disconnect the battery ground cable at the battery before disconnecting the
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can
quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
3. Remove the starter solenoid wire nut.

4. Remove the starter solenoid battery cable nut and the starter motor solenoid wire harness terminal
cover.
5. Remove the bolts and the starter motor.


SECTION 303-07: Engine Ignition — 1.6L 2011 Fiesta Workshop Manual
Material
Capacity
Silicone Brake Caliper Grease ESE-M1C171- —
and Dielectric Compound A
XG-3-A
Item Specification
Base ignition timing (not adjustable) 10 degrees before Top Dead Center (TDC)
Firing order 1-3-4-2
Spark plug CYFS12YEC
Spark plug gap 0.7-0.8 mm
(0.027-0.032 in)
Coil mounting bolts 6 53
Spark plugs 15 133
Engine Ignition
The Electronic Ignition (EI) system consists of the:
ignition coil
spark plug wires
spark plugs
The ignition coil is controlled by the PCM and fires 2 spark plugs simultaneously.
The spark plug wires carry high voltage pulses from the ignition coil to the spark plugs.
The spark plug ignites the fuel and air mixture.
Coil Terminal-to-Cylinder Relationship

Engine Ignition
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the
ignition system.
Engine Ignition Components — Exploded View

1 12280 Spark plug wire (4 required)
3 — Ignition coil electrical connector (part of 14A464)
4 W713210 Ignition coil bolt (4 required)
5 12029 Ignition coil
removal.
Ignition Coil
Material
Item Specification
Silicone Brake Caliper Grease ESE-M1C171-
XG-3-A
1. NOTICE: Spark plug wires must be connected correctly. For additional information, refer to
the Coil Terminal-to-Cylinder Relationship illustration in the Description and Operation,
Engine Ignition portion of this section. Failure to follow this instruction may result in poor
engine performance.
NOTICE: Do not pull on the spark plug wire as it may separate from the spark plug wire
connector inside the spark plug wire boot.
Disconnect the spark plug wires from the ignition coil by slightly twisting while pulling upwards.
2. Disconnect the ignition coil electrical connector.
3. Remove the 4 ignition coil bolts.

4. Remove the ignition coil.
5. NOTE: Wipe the coil towers with a clean cloth dampened with soap and water. Remove any soap
film and dry with compressed air. Inspect for cracks, carbon tracking and dirt.

Apply silicone dielectric compound to the inside of the spark plug wire boots prior to
installation.
Spark Plugs
Material
Item Specification
XG-3-A
1. Detach the spark plug wire if routed through another spark plug wire.
engine performance.
Disconnect the spark plug wires from the spark plugs by slightly twisting while pulling upwards.
3. NOTE: Remove any foreign material with compressed air.

Remove the spark plugs.
4. Inspect the spark pugs. For additional information refer to the Spark Plug Inspection procedure in
Section 303-00 .
5. Check and adjust the spark plug gap as necessary.

Apply silicone dielectric compound to the locations shown.
Spark Plug Wires
Material
Item Specification
XG-3-A
1. Detach the spark plug wire if routed through another spark plug wire.
engine performance.
Disconnect the spark plug wires from the spark plugs by slightly twisting while pulling upwards.
3. Disconnect the spark plug wires from the ignition coil by slightly twisting while pulling upward.
4. Remove the spark plug wires.
5. NOTE: Wipe the coil towers with a clean cloth dampened with soap and water. Remove any soap
film and dry with compressed air. Inspect for cracks, carbon tracking and dirt.

Apply silicone dielectric compound to the locations shown.
SECTION 303-08: Engine Emission Control 2011 Fiesta Workshop Manual
Crankcase vent oil separator bolts 9 80
Engine Emission Control
Crankcase Ventilation
System Overview
NOTE: The vehicle emission vacuum routing diagrams are contained in the Description and Operation
subsection of Evaporative Emissions. Refer to Section 303-13 .
NOTE: Do not permanently remove or render inoperative any part of the vehicle emission control system
including related hardware. Failure to comply may violate applicable state and federal laws.
The crankcase ventilation system gathers blow-by vapors from the crankcase and returns them to the
intake manifold and air cleaner for combustion.
Component List
The crankcase ventilation system consists of the following components:
a crankcase vent oil separator located on the engine block

a valve cover vent hose connected to the air cleaner
a crankcase vent oil separator hose connected to the intake manifold
a crankcase pressure regulator located inside the crankcase vent oil separator housing
System Components
The crankcase vent oil separator removes vaporized oil from the blow-by vapors and returns the
separated oil to the crankcase.
The crankcase pressure regulator controls the return of the blow-by pressure to the intake manifold
through the crankcase vent oil separator hose.
The valve cover vent hose vents excessive crankcase pressure to the air cleaner and allows fresh air
into the crankcase to prevent premature degradation of the engine oil.
System Operation
During high intake manifold vacuum situations the blow-by pressure flows through the crankcase
pressure regulator and is returned to the intake manifold through the crankcase vent oil separator hose.
During low intake manifold vacuum situations the crankcase pressure regulator restricts flow to the
intake manifold causing blow-by pressure to flow through the valve cover vent hose to the air cleaner.
Engine Emission Control

Crankcase Vent Oil Separator
NOTICE: Clean and inspect the crankcase vent oil separator for damage prior to installation. The
crankcase vent oil separator gasket cannot be reused and must be replaced prior to installation
of the crankcase vent oil separator.
1. Remove the intake manifold. For additional information, refer to Section 303-01 .
2. Remove the crankcase vent oil separator hose.
3. Remove the 7 bolts and the crankcase vent oil separator.

Remove and discard the crankcase vent oil separator gasket.

1. Install a new crankcase vent oil separator gasket.
2. Tighten the 7 crankcase vent oil separator bolts to 9 Nm (80 lb-in).
Positive Crankcase Ventilation (PCV) System Components — Exploded View
Valve Cover Vent Hose

1 6582 Valve cover
2 6A664 Valve cover vent hose
3 — Valve cover vent hose clip (part of 6A664)
4 9600 Air cleaner
Crankcase Vent Oil Separator

1 — Crankcase vent oil separator gasket
2 6A785 Crankcase vent oil separator
3 6N664 Crankcase vent oil separator hose
4 W500214 Crankcase vent oil separator bolt (7 required)
removal.
SECTION 303-12: Intake Air Distribution and Filtering 2011 Fiesta Workshop Manual
Air Cleaner (ACL) cover screws 2 18
ACL outlet pipe clamps 3 27
Intake Air Distribution and Filtering
The air intake system consists of the following:
Air Cleaner (ACL)

ACL element
Mass Air Flow (MAF) sensor
ACL outlet pipe
The air intake system:
cleans intake air with an ACL element.

measures airflow with a MAF sensor.
The ACL contains an ACL element made of treated, pleated paper. A new ACL element must be
installed periodically as scheduled. Engine performance and fuel economy are adversely affected when
maximum restriction of the ACL element is reached.
Intake Air Distribution and Filtering

Intake Air System Components — Exploded View
Part
1 — Mass Air Flow (MAF) sensor electrical connector (part
of 12A522)
2 6A664 Crankcase ventilation tube
3 9C490 Brake booster vacuum tube assembly
4 — Air Cleaner (ACL) outlet pipe clamp (2 required) (part of
9R504)
5 9A624 ACL outlet pipe
6 W745236 ACL cover screw (4 required)
7 — ACL cover (part of 9600)
8 9601 ACL element
9 9600 ACL assembly
removal.
SECTION 303-13: Evaporative Emissions 2011 Fiesta Workshop Manual
Evaporative Emission (EVAP) canister nuts 7 62
EVAP canister purge valve bolt 9 80
Natural vacuum leak detection module nut 7 62
Evaporative Emissions
The Evaporative Emission (EVAP) system consists of the:
EVAP canister.
EVAP canister purge valve.
fuel tank.
fuel vapor tubes
natural vacuum leak detection module.
The EVAP system:
prevents hydrocarbon emissions from reaching the atmosphere.

stores fuel vapors in the EVAP canister that are generated during vehicle operation hot soak or vehicle
refueling, until they can be consumed by the engine during normal engine operation.
routes the stored fuel vapors to the engine during engine operation.
The fuel vapors are routed:
to the EVAP canister through a vapor tube.

to the engine when the EVAP canister purge valve is opened.
The EVAP canister:
is located under the rear of the vehicle.

contains activated carbon.
stores fuel vapors.
The EVAP canister purge valve:
is normally closed.
regulates the purging of the EVAP canister.
The natural vacuum leak detection module:
completes a series of checks to confirm the integrity of the enhanced EVAP system components in the
engine running state and the ignition OFF state.
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for additional information on the EVAP
system.
Vehicle Emission Vacuum Routing

1 6A666 PCV valve
3 9C047 Evaporative Emission (EVAP) canister purge valve
4 6582 Valve cover
5 9R504 Air Cleaner (ACL) outlet tube
6 9D653 EVAP canister
7 9G297 Fresh air hose
8 9A228 Natural vacuum leak detection module
9 9034 Fuel tank filler pipe
10 9002 Fuel tank
Evaporative Emissions

Evaporative Emission System Leak Test
Special Tool(s)
VACUTEC Smoke Machine Fuel
EVAP Emissions System Tester
2. Disconnect the natural vacuum leak detection module hose from the carbon canister.
3. Connect the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester to the carbon canister port, use
a suitable adapter hose. For additional information refer to the manufacturer's instructions.
4. NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter into the Easy Fuel TM (capless) fuel tank filler pipe assembly.
5. NOTE: Direct smoke to the carbon canister port only. Smoke directed towards the natural vacuum leak
detection module or filter may cause damage and/or restrict vapor lines
Introduce smoke from the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester into the EVAP
system and verify that smoke is exiting the fuel tank filler pipe neck area. For additional information, refer to the
manufacturer's instructions.
6. Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe neck area.
7. Continue to enter smoke into the system for 60 seconds to obtain pressure.
8. Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while checking
for exiting smoke.
9. Use the halogen light provided with the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester to
follow the EVAP system path and look for smoke exiting at the source of the leak(s).
10. If smoke is observed at:

the capless fuel fill insert, clean capless insert (per SSM 21018). If leak persists, replace the fuel filler
pipe assembly.
a vapor tube joint, disconnect and reconnect the components. If leak persists, replace both components
that make up the joint.
11. NOTE: If the vehicle fails the IDS leak verification test but a leak cannot be found using the smoke machine,
replace the natural vacuum leak detection module and fresh air hose assemblies.
After smoke testing is completed, reconnect the natural vacuum leak detection module vapor hose to the
carbon canister.
12. Re-run the IDS leak verification test to confirm the source of the leak has been corrected.
Evaporative Emission (EVAP) System Components — Exploded View
Evaporative Emission (EVAP) Canister Purge Valve
Part
1 9C047 Evaporative Emission (EVAP) canister purge valve
2 — Intake manifold fitting (part of 9424)
3 9L291 Fuel vapor tube
4 — EVAP canister purge valve electrical connector (part of
12B581)
5 W700475 Wiring harness retainer (part of 12B581)
6 — Vacuum hose retainer (part of 19048)
7 W500213 EVAP canister purge valve bolt
Evaporative Emission (EVAP) Canister
NOTE: Five door vehicle shown, four door vehicle similar.

1 W707142 Evaporative Emission (EVAP) canister nut (3 required)
2 — EVAP hose (part of 9A228)
3 9B033 Fuel vapor tube (to fuel tank)
4 9B337 Fuel vapor tube (to canister purge valve)
Natural Vacuum Leak Detection Module

Part
1 9J279 Natural vacuum leak detection module
2 W707142 Natural vacuum leak detection module nut
3 — Natural vacuum leak detection module electrical
Evaporative Emission (EVAP) Fresh Air Hose
NOTE: The LH wheel liner must be positioned aside to access the fresh air hose.
NOTE: Press the release tab to disengage the fresh air hose from the fuel filler pipe bracket.
2 W715398 Fresh air hose retainer
3 — Hose retainer (part of 9A228)
4 9J279 Natural vacuum leak detection module
5 — Fresh air hose release tab (part of 9G297)
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
NOTE: After installing an Evaporative Emission (EVAP) canister or Evaporative Emission (EVAP) canister
purge valve, carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test in this section.
removal.
SECTION 303-14: Electronic Engine Controls 2011 Fiesta Workshop Manual
Material
Capacity
High Temperature Nickel Anti- — —
Seize Lubricant
XL-2
(Canada)
5W20-LSP12 (Canada)
Penetrating and Lock Lubricant — —
(US); Penetrating Fluid (Canada)
Camshaft Position (CMP) sensor 8 71
Catalyst Monitor Sensor (CMS) a — —
CMS electrical connector heat shield screw — —
Crankshaft Position (CKP) sensor a 8 71
Cylinder Head Temperature (CHT) sensor 12 106
Heated Oxygen Sensor (HO2S) a — —
Knock Sensor (KS) 20 177
Mass Air Flow (MAF) sensor screw 5 44
PCM bolt 5.4 47.8
PCM cover bolt 5.4 47.8
Variable Camshaft Timing (VCT) oil control solenoid 8 71
a Refer to the procedure for the specification.
Electronic Engine Controls
The electronic engine controls consist of the following:
PCM
Camshaft Position (CMP) sensor (2 required)
Clutch Pedal Position (CPP) switch (manual transmission only)
Crankshaft Position (CKP) sensor
Mass Air Flow (MAF) sensor
Heated Oxygen Sensor (HO2S)
Catalyst Monitor Sensor (CMS)
Knock Sensor (KS) (2 required)
Engine Coolant Temperature (ECT) sensor
Variable Camshaft Timing (VCT) oil control solenoid (2 required)
The PCM:
accepts input from various engine sensors and generates output signals to control fuel injection,
ignition and emissions.
The CMP sensor:
sends the PCM a signal indicating camshaft position used for fuel synchronization.
The CPP sensor:
sends a signal through the instrument cluster to the PCM. The PCM needs this signal to improve
engine running performance during gear changes.
The CKP sensor:
sends the PCM a signal indicating crankshaft position.
The MAF sensor:
uses a hot-film element to measure the amount of air entering the engine.
The HO2S :
creates a voltage signal dependent on exhaust oxygen content.

provides feedback information to the PCM used to calculate fuel delivery.
The CMS :
monitors oxygen content after it flows through the catalytic converter.

provides a voltage to the PCM used to calculate catalytic converter integrity.
The KS :
is used to detect engine detonation.

sends a voltage signal to the PCM.
The ECT sensor:
sends the PCM a signal indicating engine coolant temperature.

voltage decreases as coolant temperature increases.
The VCT oil control solenoid:
is an electronic solenoid that actuates the flow of oil to the variable camshaft. Once the PCM
transmits a signal, the solenoid moves a valve spool, directing oil into the camshaft phaser cavity.
This action changes valve timing by either inducing an advance or retard condition. The camshaft
is, thereby repositioned in relation to crankshaft timing and allows for optimum engine
performance and lower emissions
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for additional information on
electronic engine control components.
Electronic Engine Controls
DTC Charts
PCM DTC Chart

DTC Description Action to Take
P0125:00 Insufficient Coolant Temp For Closed Loop Fuel REFER to Section 303-03 .
Control: No Sub Type Information
P0128:00 Coolant Thermostat (Coolant Temp Below REFER to Section 303-03 .
Thermostat Regulating Temperature): No Sub Type
Information
P0504:00 Brake Switch A/B Correlation: No Sub Type REFER to Section 419-03 .
Information
P0531:2F A/C Refrigerant Pressure Sensor A Circuit REFER to Section 412-00 .
Range/Performance: Signal Erratic
P0532:16 A/C Refrigerant Pressure Sensor A Circuit Low: REFER to Section 412-00 .
Circuit Voltage Below Threshold
P0533:17 A/C Refrigerant Pressure Sensor A Circuit High: REFER to Section 412-00 .
Circuit Voltage Above Threshold
P0578:00 Cruise Control Multi-Function Input A Circuit Stuck: REFER to Section 419-03 .
No Sub Type Information
P0579:00 Cruise Control Multi-Function Input A Circuit REFER to Section 419-03 .
Range/Performance: No Sub Type Information
P0617:12 Starter Relay Circuit High: Circuit Short To Battery REFER to Section 303-06 .
P0645:13 A/C Clutch Relay Control Circuit: Circuit Open REFER to Section 412-00 .
P0646:11 A/C Clutch Relay Control Circuit Low: Circuit Short REFER to Section 412-00 .
To Ground
P0647:12 A/C Clutch Relay Control Circuit High: Circuit Short REFER to Section 412-00 .
To Battery
P065B:09 Generator Control Circuit Range/Performance: REFER to Section 414-00 .
Component Failure
P065C:09 Generator Mechanical Performance: Component REFER to Section 414-00 .
Failure
P0833:00 Clutch Pedal Switch B Circuit: No Sub Type REFER to Section 419-03 .
Information
P0850:00 Park / Neutral Switch Input Circuit: No Sub Type REFER to Section 303-06 .
Information
P0851:00 Park / Neutral Switch Input Circuit Low: No Sub REFER to Section 303-06 .
Type Information
P0A3B:19 Generator Over Temperature: Component Failure REFER to Section 414-00 .
P162D:00 Internal Control Module Cruise Control REFER to Section 419-03 .
Performance: No Sub Type Information
P1794:16 Battery Voltage Circuit: Circuit Voltage Below REFER to Section 414-00 .
Threshold
P1794:17 Battery Voltage Circuit: Circuit Voltage Above REFER to Section 414-00 .
Threshold
U0120:88 Lost Communication with Starter/Generator Control REFER to Section 414-00 .
Module: Bus Off
U0167:00 Lost Communication With Vehicle Immobilizer REFER to Section 419-01B .
Control Module: No Sub Type Information
U0426:00 Invalid Data Received From Vehicle Immobilizer REFER to Section 419-01B .
Control Module: No Sub Type Information
U0469:09 Invalid Data Received From Starter/Generator REFER to Section 414-00 .
Control Module: Component Failure
U3003:16 Battery Voltage: Circuit Voltage Below Threshold REFER to Section 414-00 .
U3003:17 Battery Voltage: Circuit Voltage Above Threshold REFER to Section 414-00 .
All Other — REFER to Powertrain
DTCs Control/Emissions Diagnosis
(PC/ED) manual.
Engine Control Components — Exploded View
Material
Item Specification
High Temperature Nickel Anti-Seize —
Lubricant
XL-2
LSP12 (Canada)
Penetrating and Lock Lubricant (US); —
Penetrating Fluid (Canada)
Camshaft Position (CMP) Sensor
NOTE: Lubricate the O-ring seals with clean engine oil.
Part
1 — Camshaft Position (CMP) sensor electrical connector
(part of 12B581) (2 required)
2 W702251 CMP sensor bolt (2 required)
3 12K073 CMP sensor (2 required)
Crankshaft Position (CKP) Sensor

Part
1 — Crankshaft Position (CKP) sensor electrical connector
(part of 12B581)
2 W702251 CKP sensor bolt
3 6C315 CKP sensor
Mass Air Flow (MAF) Sensor
Part
1 — Mass Air Flow (MAF) sensor electrical connector (part of
12B581)
2 — MAF sensor screw (2 required)
3 12B579 MAF sensor
Heated Oxygen Sensor (HO2S) Sensor
NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to assist in removal.
NOTE: Apply anti-seize to the threads of the HO2S prior to installing.
NOTE: The correct torque wrench setting must be calculated when using a commercially available exhaust gas
sensor socket to install the HO2S . Refer to the Torque Wrench Adapter Formulas in the Appendix.
Part
1 — Heated Oxygen Sensor (HO2S) electrical connector
(part of 9G444)
2 9G444 HO2S
Catalyst Monitor Sensor (CMS)
NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to assist in removal.
NOTE: Apply anti-seize to the threads of the CMS prior to installing.
NOTE: The correct torque wrench setting must be calculated when using a commercially available exhaust gas
sensor socket to install the CMS . Refer to the Torque Wrench Adapter Formulas in the Appendix.
Part
1 W705981 Catalyst Monitor Sensor (CMS) electrical connector heat
shield screw (manual transmission only)
2 14A163 CMS electrical connector heat shield (manual
transmission only)
3 — CMS electrical connector (part of 12B581)
4 9F472 CMS
Knock Sensor (KS)
NOTICE: The RH Knock Sensor (KS) must be installed in the 2 o'clock position and the LH KS must be
installed in the 11 o'clock position. Failure to follow these instructions may result in damage to the
engine.
NOTE: The intake manifold must be removed to access the KS . For additional information, refer to Section
303-01 .
Part
1 — RH Knock Sensor (KS) electrical connector (part of
12B581)
2 W500225 RH KS bolt - 20 Nm (177 lb-in)
3 12A699 RH KS
4 W500225 LH KS bolt - 20 Nm (177 lb-in)
5 12A699 LH KS
6 — LH KS electrical connector (part of 12B581)
Engine Coolant Temperature (ECT) Sensor
NOTE: Drain the engine cooling system prior to removal of the ECT sensor.
NOTE: Fill and bleed the engine cooling system after installing the ECT sensor.
NOTE: The ignition coil must be removed to access the ECT sensor. For additional information, refer to Section
303-07 .
Part
1 — Engine Coolant Temperature (ECT) sensor electrical
connector (part of 12B581)
2 W703355 ECT sensor retaining clip
3 12A648 ECT sensor
— Engine Coolant Temperature (ECT) sensor O-ring seal
(part of 12A648)
Variable Camshaft Timing (VCT) Oil Control Solenoid
NOTE: Intake solenoid shown, exhaust solenoid similar.
NOTE: Lubricate the O-ring seals with clean engine oil.

Part
1 — LH Variable Camshaft Timing (VCT) oil control solenoid
electrical connector
2 W500011 VCT oil control solenoid bolt (2 required)
3 6L713 VCT oil control solenoid (2 required)
Clutch Pedal Position (CPP) Switch
Part
1 — Clutch Pedal Position (CPP) switch electrical connector
(part of 14290)
2 11A152 CPP switch
removal.
Powertrain Control Module (PCM)

1 — PCM electrical connector (3 required)
2 12C514 PCM cover
3 12A650 PCM
4 W700005 PCM cover bolt - 5.4 Nm (47.8 lb-in)
3 W700005 PCM bolt - 5.4 Nm (47.8 lb-in)
Removal
1. NOTE: PCM installation DOES NOT require new keys or programming of keys, only a Parameter Reset
of the Passive Anti-Theft System (PATS).
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section 418-01 .
4. Remove the bolt and the PCM.
Installation
1. NOTICE: The PCM and PCM cover can be easily damaged by excessive fastener torque. Do not
exceed 5.4 Nm (47.8 lb-in).
Position the PCM and install the bolt.

3. NOTICE: The PCM and PCM cover can be easily damaged by excessive fastener torque. Do not
exceed 5.4 Nm (47.8 lb-in).
Position the PCM cover and install the bolt.

4. NOTE: If the Programmable Module Installation (PMI) procedure was not successful in downloading the
data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and the oil
life cannot be determined through service history or customer interview, it is recommended the vehicle
engine oil and filter be changed and the oil change minder reset.
Restore the module configuration. Carry out the module configuration restore steps of the Programmable
Module Installation (PMI) procedure. For additional information, refer to Section 418-01 .
5. Reprogram the PATS . Carry out the Parameter Reset procedure. For additional information, refer to
Section 419-01B .
SECTION 204-00: Suspension System — General Information 2011 Fiesta Workshop Manual
Alignment Specifications
NOTE: All alignment specifications are with the vehicle fuel tank full.
Thrust
Item LH RH Split Angle
Front
Camber a -0.70° ± -0.70° ± 0.00° ± —
0.75° 0.75° 0.75°
Caster a 3.37° ± 3.37° ± 0° ± 0.75° —
0.75° 0.75°
Toe @ curb ride height (positive value is toe in, — — 0.15° ± —
negative value is toe out) 0.35°
Rear
Camber a -1.52° ± -1.52° ± — —
0.75° 0.75°
Only total toe defined — — 0.31° ± 0° ± 0.50°
0.30°
a Nominal setting (reference only) no adjustment
Item Specification
Ball Joint Deflection
Lower 0-0.2 mm (0-0.008 in)
Ride Height
Front 15 mm (0.59 in) ±
9 mm (0.354 in)
Rear 39 mm (1.535 in) ±
9 mm (0.354 in)
Tie-rod end jam nut 85 63
Wheel Alignment Angles
Camber
NOTE: Wheel alignment angles can be affected by subframe position. Subframe alignment may be
necessary if wheel alignment cannot be achieved.
Negative and Positive Camber
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. The camber setting is not adjustable.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and
lower ball joint), when viewed from the side. The caster specifications in this section will give the vehicle
the best directional stability characteristics when loaded and driven. The caster setting is not related to
tire wear. The caster setting is not adjustable.
Item Description
1 True vertical
2 Positive caster angle
3 Strut centerline
4 Pivot centerline
A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate
procedure on this vehicle.
Toe
Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting affects tire wear and directional stability.
Incorrect Thrust Angle (Dogtracking)

Item Description
1 Vertical 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.
Shimmy
Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and experienced by the driver as small rotational oscillations of the steering wheel. For wheel
and tire diagnosis, refer to Section 204-04 .
Poor Returnability/Sticky Steering
Poor returnability and sticky steering are used to describe the poor return of the steering wheel to center
after a turn or steering correction.
Drift/Pull
Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the
vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead
path and requires constant steering input in the opposite direction to counteract the effect.
Drift/pull may be induced by conditions external to the vehicle (wind or road crown).
Suspension System
1. Road test the vehicle.

If any suspension alignment or ride height concerns are present, GO to Symptom Chart -
Suspension System .
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are
present, GO to Symptom Chart - NVH .
2. Inspect the tires.

Check the tire pressures with all normal loads in the vehicle and the tires cold. Refer to the
Vehicle Certification (VC) label.
Verify that all tires are sized to specification. Refer to the VC label.
Inspect the tires for incorrect wear and damage. Install new tires as necessary.
3. Inspect the chassis and underbody.

Remove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment.

Check for aftermarket changes to the steering, suspension, and wheel and tire components (such
as competition or heavy duty). The specifications shown in this manual do not apply to vehicles
equipped with aftermarket equipment.

Mechanical
Front or rear suspension components
Suspension fastener(s)
Incorrect spring usage
Spring(s)
Shock absorber(s)
Strut(s)
Suspension bushing(s)
Steering system components
Subframe
Wheel bearing and wheel hub(s)
Tires
Non-OEM parts or modifications
5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before
6. If the fault is not visually evident, or GO to Symptom Chart - NVH .
Symptom Chart — Suspension System
Symptom Chart — Suspension System

Vehicle drifts/pulls Unevenly loaded GO to Pinpoint Test A .
or overloaded
vehicle
Tires/tire pressure
Alignment is not
within
specification
Brake drag
Steering
components
Subframe
misalignment
Wander Overloaded, NOTIFY the customer of incorrect
unevenly or vehicle loading.
incorrectly loaded
vehicle
Ball joint(s) INSPECT the ball joints. REFER to
the Ball Joint Inspection component
test in this section.
Damaged or INSTALL a new front strut mount
missing front strut bearing(s) as necessary. REFER to
mount bearing(s) Section 204-01 .
Loose, worn or INSPECT the wheel bearings.
damaged front INSTALL new wheel bearings as
wheel bearing(s) necessary.
Loose, worn or INSTALL new suspension
damaged component(s) as necessary. REFER
suspension to Section 204-01 for front
component(s) suspension or Section 204-02 for
rear suspension.
Loose suspension INSPECT the suspension fasteners.
fasteners TIGHTEN to specification. REFER to
Section 204-01 for front suspension
or Section 204-02 for rear
suspension.
Steering INSPECT the steering system.
components INSTALL new components as
necessary. REFER to Section 211-
00 .
Wheel alignment ADJUST as necessary. REFER to
(excessive total Toe Adjustment — Front in this
front toe out) section.
Front bottoming or Worn, damaged MEASURE the ride height. REFER
riding low or incorrect to Ride Height Measurement in this
springs section. INSTALL new springs as
01 .
Worn front strut(s) INSTALL new struts as necessary.
Abnormal/incorrect Incorrect tire ADJUST the tire pressure. REFER
tire wear pressure (rapid to the Vehicle Certification (VC)
center rib or inner label. REFER to Diagnosis and
and outer edge Testing for further tire wear
wear) diagnosis.
Incorrect tire REFER to Section 100-03 .
rotation intervals
High-speed REFER to Section 204-04 Diagnosis
cornering and Testing for further tire wear
Excessive front or diagnosis.
rear toe (inner or
outer edge wear)
Excessive
negative or
positive camber
(inner or outer
edge wear)
Front or rear INSPECT the front and rear
suspension suspension system. REPAIR or
components INSTALL new suspension
components as necessary. REFER
to Section 204-01 for front
suspension or Section 204-02 for
rear suspension.
Sticky steering, Damaged or worn INSTALL a new front strut mount
poor returnability front strut mount bearing(s) as necessary. REFER to
bearing(s) Section 204-01 .
Binding ball joints REFER to the Ball Joint Inspection
component test in this section.
02 for steering system diagnosis.
Steering wheel off- Unequal front or CHECK the wheel alignment.
center rear toe setting REFER to Toe Adjustment — Front
(side-to-side) in this section. ADJUST as
necessary.
00 .
Sway or roll Overloaded, NOTIFY the customer of incorrect
unevenly or vehicle loading.
incorrectly loaded
vehicle
Loose wheel nut TIGHTEN the wheel nut(s) to
(s) specification. REFER to Section
204-04 .
Strut(s) or shock INSTALL new struts or shock
absorber(s) absorbers as necessary. REFER to
Section 204-01 for front suspension
or Section 204-02 for rear
suspension.
Loose stabilizer TIGHTEN the bolts to specification.
bracket-to-frame REFER to Section 204-01 .
bolts
Worn stabilizer INSTALL new stabilizer bar
bar bushings or bushings or links as necessary.
links REFER to Section 204-01 .
Damaged or INSTALL a new stabilizer bar as
broken stabilizer necessary. REFER to Section 204-
bar 01 .
Worn spring(s) INSTALL new springs as necessary.
REFER to Section 204-01 for front
suspension or Section 204-02 for
rear suspension.
Vehicle leans to Unevenly loaded NOTIFY the customer of incorrect
one side or overloaded vehicle loading.
vehicle
Front or rear INSPECT the front and rear
suspension suspension systems. INSTALL new
components suspension components as
01 for front suspension or Section
204-02 for rear suspension.
Incorrect drive MEASURE the ride height. REFER
axle(s) ride to Ride Height Measurement in this
height. Side-to- section. INSPECT the front and rear
side lean out of suspension systems. REPAIR or
specification INSTALL new components as
01 for front suspension or Section
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For
a list of these tools, an explanation of their uses and a glossary of common terms, refer to
Section 100-04 . Since it is possible any one of multiple systems may be the cause of a
symptom, it may be necessary to use a process of elimination type of diagnostic approach
to pinpoint the responsible system. If this is not the causal system for the symptom, refer
back to Section 100-04 for the next likely system and continue diagnosis.
Squeak or grunt — noise Front or rear INSPECT the front or rear
from the suspension suspension suspension. INSTALL new
components components as necessary.
REFER to Section 204-01 for
front suspension or Section
Clunk — noise from the Loose front INSPECT for loose nuts or
front suspension, occurs suspension bolts. TIGHTEN to
in and out of turns specifications. REFER to
Section 204-01 for front
suspension or Section 204-02
for rear suspension.
Clunk — noise from the Loose rear INSPECT for loose or
rear suspension, occurs suspension damaged rear suspension
when shifting from components components. REPAIR or
REVERSE to DRIVE INSTALL new components as
necessary. REFER to Section
204-02 .
Click or pop — noise from Worn or damaged CARRY OUT a ball joint
the front suspension. ball joint(s) inspection. INSTALL new ball
More noticeable over joint(s) or control arm(s) as
rough roads or over necessary. REFER to Section
bumps 204-00 .
Front suspension noise Front suspension INSPECT the front
— a squeak, creak or components suspension. INSTALL new
rattle noise. Occurs Loose or damaged components as necessary.
mostly over bumps or front struts, shock REFER to Section 204-01 .
while turning absorber(s) or
shock absorber
bushing(s)
Damaged spring or
spring mount(s)
Damaged or worn
control/radius arm
bushing(s)
Worn or damaged
stabilizer bar
bushings or link(s)
Worn or damaged
upper strut mount
bearing(s)
Rear suspension noise — Loose or damaged INSPECT the rear
a squeak, creak or rattle rear shock suspension. INSTALL new
noise. Occurs mostly over absorber(s) or components as necessary.
bumps or rough roads shock absorber REFER to Section 204-02 .
bushing(s)
Damaged spring or
spring mount(s)
Damaged or worn
control arm
bushing(s)
Worn or damaged
stabilizer bar
bushing(s) or link
(s)
Shudder — occurs during Incorrect ride REFER to Section 205-00 for
acceleration from a slow height causing driveline angle diagnosis.
speed or stop incorrect driveline
angle
Shimmy Loose wheel nut(s) TIGHTEN the nut(s) to
specification. REFER to
Section 204-04 .
Loose front TIGHTEN the fastener(s) to
suspension specification. REFER to
fastener(s) Section 204-01 .
Loose front wheel INSPECT the front wheel
bearing(s) bearing(s). INSTALL new
bearing(s) as necessary.
Strut(s) or shock INSTALL new struts or shock
absorber(s) absorbers as necessary.
front suspension or Section
Shimmy — most Excessive positive INSPECT the front
noticeable on caster suspension. REFER to
coast/deceleration. Also Section 204-01 in this section.
hard steering condition REPAIR or INSTALL new
suspension components as
necessary.
Rough/harsh ride Incorrect tire ADJUST the tire pressure.
pressure REFER to the VC label.
Low ride height MEASURE the ride height.
REFER to Ride Height
Measurement in this section.
INSTALL new springs as
204-01 for front suspension or
Section 204-02 for rear
suspension.
Loose, worn or INSTALL new suspension
damaged component(s) as necessary.
suspension REFER to Section 204-01 for
component(s) front suspension or Section
Pinpoint Tests
Pinpoint Test A: Vehicle Drifts/Pulls

Unevenly loaded vehicle
Tire pressure
Tire forces
Brake drag
Incorrect vehicle alignment
Steering system
PINPOINT TEST A: VEHICLE DRIFTS/PULLS

A1 CHECK FOR UNEVENLY LOADED VEHICLE
Visually check the vehicle for an uneven loading condition. Yes
Is the vehicle unevenly loaded? ADVISE the customer of
uneven loading condition.
No
GO to A2 .
A2 CHECK THE TIRE PRESSURES AND TIRE CONDITIONS
Check the tire pressures. Refer to the VC label located on the driver Yes
door jamb. Check the tires for uneven/abnormal wear. Refer to GO to A3 .
Diagnosis and Testing —Wheels and Tires in Section 204-04 .
Are the tire pressures and tire conditions OK? No
ADJUST the tire pressures
to the specified pressure or
INSTALL new tires as
necessary.
A3 ISOLATE TIRE DRIFT/PULL CONDITION
NOTE: It is important to determine if tire forces are the cause of a Yes
drift/pull condition. Changing the position of the wheel and tire If the vehicle drifts/pulls in
assemblies on the vehicle may correct a pull/drift condition. A tire or the opposite direction, tire
tires that are causing a drift/pull should not be removed from service forces are causing the
unless it has been determined that the tire(s) are worn beyond drift/pull. ROTATE the wheel
specification. Refer to Diagnosis and Testing — Wheels and Tires in and tire assemblies front-to-
Section 204-04 rear. REFER to Section 204-
Cross the front wheel and tire assemblies from left-to-right. Refer to 04 . If the vehicle drifts/pulls
Section 204-04 . in the same direction, GO to
Does the vehicle drift/pull? A4 .
No
Tire forces were causing the
drift/pull and the concern
has been corrected.
A4 CHECK SUBFRAME ALIGNMENT
NOTE: RH and LH dimensions are identical. All measurements on Yes
center. GO to A5 .
Using the following measurements, check the subframe alignment.
Location 1 — 260 mm (10.236 in). No
Location 2 — 666 mm (26.22 in). REMOVE and DISCARD the
2 rearward subframe bolts.
LOOSEN the 2 forward
subframe bolts. Using the
measurements listed above,
ALIGN the subframe.
TIGHTEN the 2 forward
subframe bolts to 60 Nm (44
lb-ft). TIGHTEN the 2 new
rearward subframe bolts to
100 Nm (74 lb-ft). TIGHTEN
the 2 new rearward
subframe bolts an additional
240 degrees.
Vehicle wheel alignment

must be reset after the
subframe is moved.
ADJUST the alignment as
necessary. REFER to
General Procedures in this
section.
Is the subframe aligned correctly?

A5 CHECK FOR BRAKE DRAG
Spin all four wheel and tire assemblies by hand and check for brake Yes
drag. GO to A6 .
Do the wheels spin freely?
No
diagnose brake drag
condition.
A6 CHECK THE WHEEL ALIGNMENT
Using alignment equipment and the manufacturer's instructions, Yes
check the wheel alignment. ADJUST the alignment as
Is the wheel alignment out of specification? necessary. REFER to
General Procedures in this
section.
No
diagnose steering system
drift/pull/wander condition.
Component Tests
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Install a new wheel bearing as
necessary.
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.
3. Inspect the ball joint and ball joint boot for damage.
If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. Refer to Section
204-01 .
4. NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or suspension
components while checking for relative movement. Suspension damage may occur. The use of
tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
Inspect the ball joint for relative movement by 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.
If relative movement is found, continue with Step 5.
5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis (center line) of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower
control arm and the wheel knuckle or ball joint stud.
6. Measure the ball joint deflection while an assistant pushes up and pulls down on the lower control arm,
by hand.
If the deflection exceeds the specification, a new ball joint must be installed. Refer to Section 204-
01 .
If the deflection meets the specification, no further action is required.
Ride Height Measurement
Front Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the
correct pressure. Vehicle should have a full tank of fuel.
1. Position the surface gauge on the same flat, level surface, adjust the gauge arm until the scriber
point is located in the center of the lower arm forward bolt.
Lock the surface gauge in this position.
2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 2).
3. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface
and adjust the gauge arm until the scriber point is located in the center of the ball joint bolt.
Lock the surface gauge in this position.
4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 3).
5. Subtract measurement 3 from measurement 2 to obtain the front ride height.

Refer to Specifications in this section.
Rear Ride Height Measurement

Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the
correct pressure. Vehicle should have a full tank of fuel.
1. Measure the distance between the flat level surface and the forward lower arm inboard bolt
(measurement 2).
2. Measure the distance between the flat level surface and the center of the forward lower arm
outboard bolt (measurement 3).
3. Subtract measurement 3 from measurement 2 to obtain the rear ride height.

Refer to Specifications in this section.
Toe Adjustment — Front
1. Using a suitable steering wheel holding device, lock the steering wheel in the straight ahead
position.
2. Using alignment equipment and the manufacturer's instructions, measure the toe.
3. Loosen the tie-rod end jam nuts.
4. Rotate the tie rods as necessary to adjust the toe setting.
5. Tighten the tie-rod end jam nuts to 85 Nm (63 lb-ft).

6. Recheck the toe settings, adjust as necessary.
SECTION 204-01: Front Suspension 2011 Fiesta Workshop Manual
Ball joint nut 52 38 —
Brake caliper guide pin bolts 28 21 —
Brake flexible hose bracket bolt 26 19 —
Lower arm forward bolt a — — —
Lower arm rearward bolt a — — —
Stabilizer bar bracket bolts 48 35 —
Stabilizer bar link nuts 48 35 —
Strut rod nut 48 35 —
Strut upper nuts 30 22 —
Tie-rod end nut 53 39 —
Wheel hub nut 255 188 —
Wheel knuckle-to-strut nuts a — — —
Wheel speed sensor bolt 9 — 80
Front Suspension
The front suspension consists of the following components:
Lower arms
Stabilizer bar, bushings and links
Strut and spring assemblies
Wheel bearings
Wheel hubs
Wheel knuckles
Wheel studs
The front suspension utilizes a MacPherson strut system. This suspension system incorporates a strut
assembly that takes the place of the upper arm and ball joint. The strut performs the function of a shock
absorber and is encompassed by a coil spring. The strut and spring assembly carries the sprung weight
of the vehicle and is also the pivot point for the steering knuckle. This system uses a lower control arm
and ball joint for the lower (unloaded) pivot point of the steering knuckle.
Wheel Bearing
Special Tool(s)
Installer, Wheel Hub Bearing Cup
205-147
Pinion Bearing Cone Remover

205-D0002 (D79L-4621-A) or
equivalent
Remover/Installer, Wheel Hub Cup

204-020
Step Plate
205-117
1 1104 Wheel hub
2 7059 Snap ring
3 1215 Wheel bearing
4 2K005LH/ 2K004RH Brake disc shield
5 3K186 LH/ 3K185 RH Wheel knuckle
Removal
NOTICE: When the wheel hub is pressed from the bearing, the bearing inner race will come out with the
hub. Never try to install the race back into the bearing. Always install a new bearing.
NOTICE: Make sure to keep the knuckle level and supported during pressing operations, or damage to
the knuckle can occur. Support the knuckle as close to the bearing bore as possible. Do not use
knuckle extremities as supports.
NOTE: If removing the wheel hub, the wheel bearing must be replaced.
NOTE: The Anti-Lock Brake System (ABS) tone ring is part of the wheel bearing assembly.
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.
2. Using the Step Plate and a suitable press, remove the wheel hub from the wheel bearing.
3. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle
after removing the wheel hub.
Using the Pinion Bearing Cone Remover and a suitable press, remove the inner wheel bearing race from
the wheel hub.
4. Remove the snap ring.

5. Using the Wheel Hub Cup Remover/Installer and a suitable press, remove the outer wheel bearing race
from the wheel knuckle.
Installation
NOTE: Install the wheel bearing with the pink colored wheel speed sensor ring facing towards the transmission
side.
1. Using the Wheel Hub Bearing Cup Installer and a suitable press, install the wheel bearing into the wheel
knuckle.
2. Install the snap ring.
3. NOTICE: The wheel bearing inner race must be supported during hub installation. Failure to do
so will damage the bearing.
Using the Wheel Hub Bearing Cup Installer, Step Plate and a suitable press, install the wheel hub into
the wheel bearing.
4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.
Wheel Studs
Special Tool(s)
211-001 (TOOL-3290-D)

1 1107 Wheel stud
Removal
1. NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts
must be installed with the same part numbers or equivalent part, if replacement is
necessary. Do not use a replacement part of lesser quality or substitute design. Torque
values must be used as specified during reassembly to make sure correct retention of
these parts.
NOTE: Make sure the steering wheel is in the UNLOCKED position.

Remove the brake disc. For additional information, refer to Section 206-03 .
2. Using the Tie-Rod End Remover, remove the wheel stud.
Installation
1. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the
hub flange.
Position the wheel stud in the flange, making sure the serrations on the stud line up with the
serrations in the flange. Install the washers and a wheel nut.
2. NOTICE: Do not use power tools to install the wheel stud or damage to the flange may
occur.
Tighten the wheel nut until the stud is seated against the hub flange.
3. Remove the wheel nut and the washers. Discard the wheel nut.
4. Install the brake disc. For additional information, refer to Section 206-03 .
Lower Arm

1 W703432 Rear lower arm bolt
2 3079 LH / 3078 RH Lower arm
3 W709618 Ball joint bolt
4 W520203 Ball joint nut
5 W703432 Forward lower arm bolt
Removal
NOTICE: Suspension fasteners are critical parts that affect performance of vital components and
systems. Failure of these fasteners may result in major service expense. Use the same or equivalent
parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design.
Tighten fasteners as specified.
NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage
to the ball joint seal may occur.
NOTICE: Tighten suspension bushing fasteners with the weight of the vehicle resting on the wheel and
tires or incorrect clamp load and bushing damage may occur.
NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle.
Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower
control arm body opening.
2. Remove and discard the ball joint nut and bolt. Using a pry bar, separate the ball joint stud from the
wheel knuckle.
3. Remove and discard the forward and rear lower arm bolts and remove the lower arm.
Installation
NOTE: Do not tighten the forward and rear lower arm bolts at this time.
1. Position the lower arm and loosely install the new forward and rear bolts.
2. Insert the ball joint stud into the wheel knuckle and install the new ball joint bolt and nut.
3. Install the wheel and tire. For additional information, refer to Section 204-04 .
4. Lower the hoist so the weight of the vehicle is resting on the wheels and tires.
5. Tighten the new forward and rear lower arm bolts in 2 stages
6. Check and, if necessary, align the front end. For additional information, refer to Section 204-00 .
Stabilizer Bar
Special Tool(s)
Remover, Tie Rod End
211-001 (Tool-3290-D)
General Equipment
Transmission Jack

1 5482 Stabilizer bar
2 5484 Stabilizer bar bushing (2 required)
3 5486 Stabilizer bar bushing bracket (2 required)
4 W500032 Stabilizer bar bracket bolt (4 required)
Removal
NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and
systems and their failure may result in major service expense. New parts must be installed with the same part
numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to make sure correct retention
of these parts.
1. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
2. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected or
damage to the clockspring may result. If there is evidence that the steering column shaft has rotated,
remove and recenter the clockspring. For additional information, refer to Section 501-20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering column shaft
from the steering gear.
4. Remove and discard the 2 outer tie rod nuts.
5. Using the Tie Rod End Remover, separate the outer tie rods from the wheel knuckles.
6. Remove and discard the 2 stabilizer bar link-to-stabilizer bar nuts and disconnect the stabilizer bar links from
the stabilizer bar.
7. Remove the 2 subframe brace-to-body bolts.

8. Disconnect the exhaust isolator.
9. Remove the engine roll restrictor bolt.
10. Support the front subframe using a suitable transmission jack.
11. Mark the position of the subframe-to-frame mounting location at each mounting point on the vehicle frame rails
to aide in installation.
12. Remove the 4 subframe bolts and discard the 2 rearward bolts.
13. Lower the front subframe approximately 155 mm (6.102 in).
14. Remove the stabilizer bar bracket bolts and brackets.

Discard the bolts.
15. Remove the stabilizer bar bushings.
16. Remove the stabilizer bar.
Installation
NOTICE: The stabilizer bar bushings must be positioned correctly with the slit in the bushing toward the rear
of the vehicle or damage to the bushings may occur.
1. Position the stabilizer bar with the bushings installed with the slit in the bushing toward the rear of the vehicle.
2. Position the stabilizer bar brackets and install the new bolts.
3. Raise the subframe and loosely Install the 4 subframe bolts.
4. Align the subframe to the locating marks made during removal.

Measure for correct positioning of the subframe to vehicle underbody.

1. Location 1 — 260 mm (10.236 in)
2. Location 2 — 666 mm (26.22 in)

Tighten the rearward bolts an additional 240°.
7. Position the engine roll restrictor and install the engine roll restrictor bolt.
8. Connect the exhaust isolator.

9. Install the 2 subframe brace-to-body bolts.
10. Position the stabilizer bar links and install the 2 new stabilizer bar link-to-stabilizer bar nuts.
11. Position the outer tie rods and install the new 2 outer tie rod nuts.
Connect the steering column shaft and install a new steering column shaft-to-steering gear bolt.
13. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .
Wheel Knuckle
Special Tool(s)
Installer, Halfshaft
204-161 (T97P-1175-A)
Remover, Front Wheel Hub

205-D070 (D93P-1175-B) or
equivalent

211-001 (TOOL-3290-D)
1 W709618 Ball joint bolt
2 W520203 Ball joint nut
3 3K186 LH / 3K185 RH Wheel knuckle and hub assembly
4 W713640 Wheel hub nut
5 2C204 Wheel speed sensor
6 W520204 Tie-rod end nut
7 W500011 Wheel speed sensor bolt
8 W709618 Wheel knuckle-to-strut bolt (2 required)
9 W520203 Wheel knuckle-to-strut nut (2 required)
Removal
NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. Tighten the nut to
specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the
wheel bearing is loaded with the weight of the vehicle applied.
NOTICE: Install and tighten the new wheel hub nut to specification in a continuous rotation. Always
install a new wheel hub nut after loosening or when not tightened to specification in a continuous
rotation or damage to the component may occur.
NOTE: Apply the brake to prevent the halfshaft from rotating while loosening the wheel hub nut.
2. Remove and discard the wheel hub nut.
3. Remove the brake flexible hose bracket bolt and disconnect the brake flexible hose from the strut and
spring assembly.
NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose can
occur.
4. Remove the 2 brake caliper anchor plate bolts and position the brake caliper assembly aside.
Support the brake caliper assembly using mechanic's wire.
5. Remove the brake disc.
6. If equipped with Anti-Lock Brake System (ABS), remove the wheel speed sensor bolt and position the
wheel speed sensor aside.
NOTICE: Do not remove the tie-rod end nut or damage to the tie-rod end may occur.
7. Loosen the tie-rod end nut.
8. Using the Tie-Rod End Remover, detach the tie-rod end from the wheel knuckle.
Remove and discard the tie-rod end nut.
NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle.
Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower
arm body opening.
NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage
to the ball joint seal may occur.
9. Remove and discard the ball joint nut and bolt. Using a pry bar, separate the ball joint stud from the
wheel knuckle.
10. NOTICE: Do not bend the inner joint more than 18 degrees or the outer joint more than 45
degrees. Damage to the halfshaft will occur.
Using the Front Wheel Hub Remover, press the halfshaft from the wheel hub and detach the halfshaft
from the wheel hub
Support the halfshaft.
11. Remove and discard the wheel knuckle-to-strut nuts and bolts.
12. Remove the wheel knuckle.

If necessary, remove the wheel bearing and hub. For additional information, refer to Wheel
Bearing in this section.
Installation
1. Position the wheel knuckle and install new wheel knuckle-to-strut bolts and nuts.
Tighten to 80 Nm (59 lb-ft) and then tighten an additional 90 degrees.
2. Insert the halfshaft into the wheel hub.
3. Insert the ball joint stud into the wheel knuckle and install the new ball joint bolt and nut.
4. Attach the tie-rod end to the wheel knuckle and install a new tie-rod end nut.
5. If equipped with ABS , position the wheel speed sensor and install the wheel speed sensor bolt.
6. Install the brake disc.
7. Position the brake caliper assembly and install the 2 brake caliper anchor plate bolts.
8. Using the Halfshaft Installer, install the halfshaft into the wheel hub.
9. Connect the brake flexible hose to the strut and spring assembly and install the brake flexible hose
bracket bolt.
10. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. Tighten the nut to
specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if
the wheel bearing is loaded with the weight of the vehicle applied.
NOTICE: Install and tighten the new wheel hub nut to specification in a continuous rotation.
Always install a new wheel hub nut after loosening or when not tightened to specification in a
continuous rotation, or damage to the components may occur.
NOTE: Apply the brake to prevent the halfshaft from rotating while tightening the wheel hub nut.
Install a new wheel hub nut.

Strut and Spring Assembly

1 W520214 Wheel knuckle-to-strut nut (2 required)
2 W500742 Wheel knuckle-to-strut bolt (2 required)
3 W713760 Stabilizer bar link upper nut
4 W715409 Strut upper nut (3 required)
5 18124 Strut and spring assembly
6 W500222 Brake hose bracket to strut bolt
NOTICE: Suspension fasteners are critical parts because they affect performance of vital components
and systems and their failure may result in major service expense. New parts must be installed with the
same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure correct retention of these parts.
NOTICE: Support the strut and spring assembly to prevent damage.
NOTE: Drivers side only
2. Position aside the brake fluid reservoir (main container).

3. Position aside the air conditioner hose support bracket.
4. Remove and discard the 3 strut and spring assembly upper mount nuts.
To install, tighten the new nuts to 30 Nm (22 lb-ft).
5. Disconnect the wheel speed sensor harness from the strut and spring assembly bracket.
6. Remove the stabilizer bar link upper nut and detach the link from the strut.
Discard the nut.
To install, tighten the new nut to 55 Nm (41 lb-ft).
7. Remove the brake flexible hose bracket bolt and disconnect the hose from the strut and spring
assembly.
8. Remove the wheel knuckle-to-strut nuts, bolts and the strut and spring assembly.
Discard the wheel knuckle-to-strut nuts and bolts.
To install, tighten the new wheel knuckle-to-strut nuts to 80 Nm (59 lb-ft) and then tighten an
additional 90 degrees.
9. NOTE: Insert LH knuckle-to-strut bolts from the knuckle arm side.
Insert RH knuckle-to-strut bolts from the brake caliper side.
10. Check and, if necessary, align the front end. For additional information, refer to Section 204-00 .
Strut and Spring Assembly
Material
Item Specification
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A

1 5349 Dust boot
2 3020 Jounce bumper
3 18198 Spring upper seat and bearing assembly
4 18183 Upper mount
5 W708922 Strut rod nut
6 5310 Spring
7 18124 Strut assembly
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
and systems and their failure can result in major service expense. A new part 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.
NOTICE: When installing a suitable spring compressor, use care not to damage the spring coating.
1. Remove the strut and spring assembly. For additional information, refer to Strut and Spring Assembly in
this section.
WARNING: Do not attempt to disassemble the shock absorber and spring assembly without using
a spring compressor. Assemblies are under extreme load. Failure to follow this instruction may result
WARNING: The coil spring is under extreme load. Care must be taken at all times when removing
or installing a loaded spring. Failure to follow this instruction may result in serious personal injury.
2. Using a suitable coil spring compressor, compress the spring.
3. NOTE: Use the hex-holding feature to prevent the strut rod from rotating while removing the nut.
Carefully remove and discard the strut rod nut.

To install, tighten the new nut to 48 Nm (35 lb-ft).
4. Remove the upper mount, spring upper seat and bearing assembly and the dust boot.
5. Remove the strut and jounce bumper.
6. Carefully remove the spring from the spring compressor.
7. NOTICE: Make sure the upper mount is correctly seated before assembly or damage to the upper
mount may occur.
NOTICE: Make sure the spring is installed with the flat surface facing up and with the spring end
correctly positioned against the spring seat (color code at the bottom). This is to prevent spring
seat damage and incorrect spring position.
NOTE: During assembly, apply the specified silicone brake grease to the strut rod and the top and sides
of the outermost part of the dust boot.
To assemble, reverse the disassembly procedure.

SECTION 204-02: Rear Suspension 2011 Fiesta Workshop Manual
Brake tube fitting 18 — 159
Shock absorber lower bolt 115 85 —
Shock absorber upper bolt 25 18 —
Trailing arm bolts a — — —
Wheel speed sensor bolt 9 — 80
Wheel hub and bearing assembly bolts a — — —
a Refer to the procedure for specification.
Rear Suspension
The rear suspension consists of the following components:
Twist-beam axle (torsionally rigid axle)

Coil springs
Shock absorbers
Wheel bearing and wheel hub assemblies
Wheel studs
If compression takes place on both wheels evenly (for example when a load is placed on the vehicle),
the whole axle unit swivels evenly in the rubber-metal bearings. If only one wheel is compressed, the
cross-beam twists (undergoes torsion) and acts as a stabilizer. This minimizes track and toe changes.
Axle
Part
1 W713343 Shock absorber lower bolt (2 required)
2 W520214 Trailing arm nut (2 required)
3 — Front parking brake cable-to-RH rear parking brake
cable union (part of 2A635) (2 required)
4 W500553 Trailing arm bolt (2 required)
5 — Anti-Lock Brake System (ABS) connector (part of 2B372)
(2 required)
6 W700936 Clip (2 required)
7 — Brake tube fitting (part of 2267)
8 5596 Bracket assembly (2 required)
9 W708508 Bracket-to-frame bolts (6 required)
10 W520413 Parking brake cable bracket nut (2 required)
Removal
2. Remove the parking brake adjustment nut retaining clip.
3. Loosen the parking brake adjustment nut 5 turns.
5. Disconnect both parking brake actuation lever cables.

6. NOTE: RH side shown, LH side similar.
Compress the clips and pull both parking brake cables through the mounting brackets.
7. NOTE: Cap the brake tube connections to prevent fluid loss.
Disconnect the rear brake tube fittings from the rear brake hoses and remove the clips.
8. Remove the wheel bearing and wheel hub assemblies. For additional information, refer to Wheel Bearing
and Wheel Hub .
9. Using a suitable jackstand, support the rear axle assembly.
10. Remove and discard the 2 shock absorber lower bolts.

11. Remove the 2 parking brake cable bracket nuts.
12. Remove the 6 bracket-to-frame bolts and remove the axle assembly

Bleed the brake wheel cylinders. For additional information, refer to Component Bleeding in
Section 206-00 .
Wheel Bearing and Wheel Hub
Part
1 W711918 Wheel bearing and wheel hub assembly bolt (4
required) (install new)
2 1109 Wheel bearing and wheel hub assembly
Removal
1. Remove the brake drum. For additional information, refer to Section 206-02 .
2. Remove the wheel speed sensor bolt and remove the wheel speed sensor.
3. Remove the wheel bearing and wheel hub assembly.
Remove and discard the 4 wheel bearing and wheel hub assembly bolts.
Remove the wheel bearing and wheel hub assembly.
Installation
1. Install the wheel bearing and wheel hub assembly with 4 new bolts in the sequence shown.
1. Tighten all 4 bolts to 65 Nm (48 lb-ft).
2. Loosen each bolt 90 degrees.
3. Tighten each bolt to 65 Nm (48 lb-ft) using the sequence shown.
2. Install the wheel speed sensor and install the wheel speed sensor bolt.
3. Install the brake drum. For additional information, refer to Section 206-02 .
Wheel Studs
Special Tool(s)
211-001 (TOOL-3290-D)

1 1107 Wheel stud
make sure of correct retention of these parts.
1. Remove the brake drum. For additional information, refer to Section 206-02 .
NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result.
2. Using the Tie-Rod End Remover, remove the wheel stud.

3. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations.
Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange.
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by
the original wheel stud.
Place approximately 4 washers over the outside end of the wheel stud and thread a standard
wheel nut onto the wheel stud with the flat side against the washers.
Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub
flange.
4. Remove the wheel nut and washers.
5. Install the brake drum. For additional information, refer to Section 206-02 .
Shock Absorber

1 18125 Shock absorber
2 W713343 Shock absorber lower bolt
3 W708828 Shock absorber upper bolt (2 required)
Removal
1. Using a suitable jackstand, support the rear axle.
2. Remove and discard the two shock absorber upper bolts.

To install, tighten the new bolts to 25 Nm (18 lb-ft).
3. Remove and discard the shock absorber lower bolt and remove the shock absorber.
To install, tighten the new bolt to 115 Nm (85 lb-ft).
4. NOTICE: Tighten the shock absorber lower bolt while the suspension is at curb height or bushing
damage and incorrect clamp load may occur.

Spring

1 5560 Spring
2 — Spring compressor
WARNING: The coil spring is under extreme load. Care must be taken at all times when
removing or installing a loaded spring. Failure to follow this instruction may result in serious
personal injury.
1. Using a suitable spring compressor, compress the spring.
2. Remove the spring.
3. NOTICE: Make sure the upper spring seat is installed, and the spring ends butt correctly
against the upper and lower spring seats.

Trailing Arm Bushing
Special Tool(s)
Installer, Spindle/Axle Shaft
205-199
Installer, Front Wheel Spindle Oil

Seal
205-353
Installer, Input Shaft Bearing

308-062

1 5A638 Trailing arm bushing
Removal
2. Using a suitable jackstand, support the rear axle assembly.
3. Remove the 2 parking brake cable bracket bolts.

To Install, tighten to 24 Nm (18 lb-ft).
4. Remove the 6 axle bracket-to-frame bolts and remove the axle assembly.
5. Lower the subframe and remove the 2 trailing arm bolts.

To install, tighten to 80 Nm (59 lb-ft) then tighten an additional 120 degrees.
6. Using the special tools, remove the trailing arm bushing.

Installation
1. Using the special tool, install the trailing arm bushing.

SECTION 204-04: Wheels and Tires 2011 Fiesta Workshop Manual
Material
Capacity
Seize Lubricant
XL-2
Motorcraft® Wheel and Tire — —
Cleaner
ZC-37-A
Item Specification
Tire Inflation
Tires See Safety Certification Label on driver door jamb
Wheel Weights
Wheel weight Use a wheel weight manufacturer's rim gauge to determine the correct wheel weight
type application
Valve stem-to-Tire Pressure Monitoring System (TPMS) sensor screw 1.5 13
Wheel nuts a — —
Wheels And Tires
Safety Precautions
WARNING: Always match the tire size to the wheel size during assembly. Incorrect
matching can result in tire bead damage or tire separation from the wheel. Failure to follow this
instruction may result in serious personal injury to technician or vehicle occupant(s).
WARNING: Before servicing any tire, ask the customer if anyone injected a tire sealant into
the tire. Tire sealants may be flammable and can burn or explode if exposed to an ignition
source. Failure to follow this instruction may result in serious personal injury.
WARNING: Replacement wheels must be equivalent to the original equipment wheels in:
load carrying capacity.

diameter, width and offset.
pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or
greater than that axle's gross axle weight rating (GAWR) identified on the vehicle's Safety
Compliance Certification label. All other specifications should be evaluated by measurement of
both the original wheel and the replacement wheel. If specifications are not equivalent, the safety
and handling of the vehicle may be degraded, which may result in serious injury to the vehicle
occupant(s).
WARNING: Never use wheels different than the original equipment. Additionally, never use
wheel nuts different than the original equipment. Failure to follow these instructions may result
in damage to the wheel or mounting system. This damage could cause the wheel to come off
while the vehicle is being driven, which could result in serious personal injury or death to vehicle
occupant(s).
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
WARNING: Keep eyes away from valve stem when deflating tires. Reduce air pressure in
tire as much as possible by pushing in valve core plunger prior to removing the core. Escaping
air can carry particles that can injure the eyes. Failure to follow these instructions may result in
WARNING: Only use replacement tires that are the same size, load index, speed rating and
type (such as P-metric versus LT-metric or all-season versus all-terrain) as those originally
provided by Ford. The recommended tire and wheel size may be found on either the Safety
Compliance Certification Label or the Tire Label, which is located on the B-pillar or edge of the
driver's door. If the information is not found on these labels, consult a Ford dealer. Use of any
tire or wheel not recommended by Ford can affect the safety and performance of the vehicle,
which could result in an increased risk of loss of vehicle control, vehicle rollover, personal injury
and death. Additionally, the use of non-recommended tires and wheels could cause steering,
suspension, axle or transfer case/power transfer unit failure.
NOTICE: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong
detergents or damage to the wheel finish may occur. Use Wheel and Tire Cleaner ZC-27-A or -B
or equivalent.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including
full-rated load capacity when inflated to recommended inflation pressures.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
To equalize tire wear, rotate the tires at recommended intervals.
Tire Pressure Monitoring System (TPMS)
NOTE: The Tire Pressure Monitor (TPM) module is identified by the scan tool as the Vehicle Security
Module (VSM).
The TPMS includes:
the TPM / VSM , a stand alone receiver located in the driver's side luggage compartment (4-
door), or in the driver's side cargo area (5-door).
four tire pressure sensors.
TPM / VSM
The TPM / VSM contains the TPMS functionality. Refer to Tire Pressure Monitoring System in Diagnosis
and Testing for TPMS fault diagnosis and repair.
The TPM / VSM compares the information of each tire pressure sensor transmission against a pressure
limit. If the TPM / VSM determines that the tire pressure has fallen below the minimum pressure the
TPM / VSM communicates this to the Instrument Panel Cluster (IPC) on the vehicle communication
network.
Tire Pressure Monitoring System (TPMS) Pressure Sensor
The TPM / VSM uses tire pressure sensors to monitor the tire pressure in the 4 road tires. The tire
pressure sensors transmit radio frequency signals to the TPM / VSM approximately once every 60
seconds when the vehicle speed exceeds 32 km/h (20 mph).
The tire pressure sensors are battery operated and mounted on the valve stem.
The IPC illuminates the TPMS indicator when it receives a message from the TPM / VSM .
For additional Information, refer to Section 413-01 for diagnosis and repair of the IPC .
Wheels And Tires
Special Tool(s)
Digital Tire Gauge
204-354
Hunter Road Force® Wheel

Balancer
GSP9700 Series
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent,
GO to Symptom Chart - NVH .
To maximize tire performance, inspect for signs of incorrect inflation and uneven wear, which may
indicate a need for balancing, rotation or front suspension alignment.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
Replacement tires must follow the recommended:
tire sizes.
speed rating.
load range.
tire construction type.
The use of any other tire/wheel size, load range or type can seriously affect:
ride.
handling.
speedometer/odometer calibration.
vehicle ground clearance.
tire clearance between the body and chassis.
wheel bearing life.
braking performance.
New wheels need to be installed when the vehicle wheels:
are bent.
are cracked.
are dented.
are heavily corroded.
are leaking.
have elongated wheel hub bolt holes.
have excessive lateral or radial runout.
It is mandatory to use only the tire sizes recommended on the tire label located on the driver door or
door pillar attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability and
require changing the speedometer calibration. Make sure wheel size and offsets match those
recommended for the tire in use.
1. Inspect the tires for signs of uneven wear. Refer to the following descriptions to identify the type
of wear and GO to Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
2. Check the tires for:

cuts.
stone bruises.
abrasions.
blisters.
embedded objects.
3. Check the valve stems for:

cracks.
cuts.
Install a new valve stem when damage is found or anytime a new tire is installed.
4. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the
indicator bands become less than 2/32 inch.
Tire Wear
Tire wear is commonly defined as a loss of tread depth. Tire tread wear occurs due to friction with the
contact surface (road/pavement). The tread should wear down uniformly all the way around the
circumference of the tire and all the way across the tread face. When this does not occur, the tire may
have abnormal/incorrect wear.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are many
factors (driving style, road surfaces, type of vehicle, type of tire) that can affect tire wear, there is no
absolute mileage expectation for a normal wear condition. A tire is considered worn-out when the tread
has worn to the level of the tread-wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread and that
creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving style
(aggressive, passive), climate (hot, cold), road conditions, vehicle loading and maintenance (correct tire
pressure, rotation intervals and balance). It is important to determine the root cause of wear on a vehicle
before carrying out repair. Tires exhibiting abnormal/incorrect tire wear may still be serviceable provided
that the minimum tread depth is greater than 2/32 inch and the tire is not causing a vehicle performance
(noise/vibration) concern.
Some abnormal/incorrect wear patterns look the same all the way around the tread of the tire, other
wear patterns are not consistent and can occur in various spots on the tread area. The underlying
causes of the 6 wear categories are different. Refer to the following descriptions to identify the type of
wear and GO to Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive
toe out and/or excessive negative camber. If the tread depth of the outer shoulder is at least 50%
greater than the tread depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear. To
determine whether tires have this type of wear, visually inspect the tires. In some instances, it may be
necessary to measure the tread depth of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Outer Edge/Shoulder Wear
Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by excessive
toe in and/or excessive positive camber. If the tread depth of the inner shoulder is at least 50% greater
than the tread depth of the outer shoulder, the tire is experiencing outer edge/shoulder wear. To
determine whether tires have this type of wear, visually inspect the tires. In some instances, it may be
necessary to measure the tread depth of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire. To
determine whether tires have this type of wear, visually inspect the tires in both the inside and outside
shoulder ribs. In some instances, it may be necessary to measure the difference in tread depth of
leading versus trailing edge of each lug in the inside and outside shoulder rib.
Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To
determine whether tires have this type of wear, visually inspect the tires to determine if the wear pattern
runs diagonally across the tread and around the circumference of the tire. In some instances, the
difference in tread depth along the diagonal wear pattern may need to be measured.
Symptom Chart — Tire Wear
Symptom Chart — Tire Wear
NOTE: For suspension system and additional alignment diagnosis, refer to Section
204-00 .
Inner Excessive toe out GO to Pinpoint Test A .
edge/shoulder and/or negative
wear camber
Incorrect wheel and GO to Pinpoint Test A .
tire assembly rotation
intervals
High-speed cornering GO to Pinpoint Test A .
Outer Excessive toe in GO to Pinpoint Test B .
edge/shoulder and/or positive
wear camber
Incorrect wheel and GO to Pinpoint Test B .
tire assembly rotation
intervals
High-speed cornering GO to Pinpoint Test B .
Heel/toe wear Excessive toe in/out ROTATE the wheel and tire
Incorrect wheel and assemblies. CHECK the
tire assembly rotation alignment, ADJUST as
intervals necessary.
Diagonal wear Excessive toe in/out GO to Pinpoint Test C .
Incorrect tire rotation GO to Pinpoint Test C .
intervals
Loose, worn or REFER to Section 204-00 .
damaged suspension
components
Wobble or Bent wheel INSTALL a new wheel as necessary.
shimmy
Damaged tire INSTALL a new tire as necessary.
Loose wheel TIGHTEN to specification.
nuts
High-speed Tires/wheels REFER to Wheel and Tire Runout
shake Component Tests in this section.
Vehicle Tires/wheels REFER to Wheel and Tire Runout
vibration Component Tests in this section.
Pinpoint Tests
For a description of the various tire wear patterns, refer to Inspection and Verification.
Pinpoint Test A: Inner Edge/Shoulder Wear

Excessive toe out
Incorrect wheel and tire rotation
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR

A1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or similar Yes
tool, measure the inside ROTATE the wheel and tire assemblies.
edge/shoulder tread depth.
Is the tread depth greater than CHECK and ADJUST the toe to nominal +0.15
2/32 inch? degrees (toe in). CHECK and ADJUST caster and
camber to nominal. REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK and ADJUST the toe
to nominal. CHECK and ADJUST caster and camber
to nominal. REFER to Section 204-00 .
Pinpoint Test B: Outer Edge/Shoulder Wear

Excessive toe in
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR

B1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or similar Yes
tool, measure the outside ROTATE the wheel and tire assemblies.
edge/shoulder tread depth.
Is the tread depth greater than 2/32 CHECK and ADJUST the toe to nominal -0.15
inch? degrees (toe out). CHECK and ADJUST caster and
camber to nominal. REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK and ADJUST the toe
to nominal. CHECK and ADJUST caster and camber
to nominal. REFER to Section 204-00 .
Pinpoint Test C: Diagonal Wear

Excessive toe in/out
Incorrect tire inflation
Loose, worn or damaged suspension components
PINPOINT TEST C: DIAGONAL WEAR

C1 MEASURE THE
TREAD DEPTH
Using a tread depth Yes
gauge or similar If no performance concerns (noise/vibration) are present, the tire can
tool, measure the remain in service. CHECK the air pressure in the tires, ADJUST as
tread depth of the necessary. ROTATE the wheel and tire assemblies. INSPECT for
wear pattern. loose, worn or damaged suspension components. INSTALL new
Is the tread depth components as necessary. CHECK the alignment and ADJUST as
greater than 2/32 necessary. REFER to Section 204-00 .
inch?
No
INSTALL a new tire(s). CHECK the air pressure in the tires, ADJUST
as necessary. ROTATE the wheel and tire assemblies. INSPECT for
loose, worn or damaged suspension components. INSTALL new
components as necessary. CHECK the alignment and ADJUST as
necessary. REFER to Section 204-00 .
Component Tests
Radial Runout
Radial runout is the egg-shaped deviation from a perfect circle and is measured perpendicular to the
circumference. On a wheel and tire assembly, this means measuring the center tire tread rib. The center
rib is indicative of the condition of the tire as a whole. Total runout is the difference between the
maximum-to-minimum gauge reading. The high spot is the location of maximum runout.
Item Description
1 High spot
2 Low spot
Loaded Runout Measurement (Hunter Road Force® 9700 Series Wheel Balancer)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200
mi). Some initial tire/wheel vibration issues (such as flat spotting) may correct themselves after the tires
have been in service for 320 km (200 mi).
This procedure is intended to assist with the diagnosis of wheel and tire assembly runout and/or force
variation issues.
The Hunter Road Force® 9700 Series Wheel Balancer measures the wheel and tire assembly's loaded
runout and the tire's radial spring rate. The balancer then converts the runout into pounds of force
(termed as Road Force®). Measuring loaded runout (Road Force®) is more effective than measuring
unloaded runout using a dial indicator.
1. Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires.
2. Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section.
3. NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the Vehicle
Certification (VC) label.
4. NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
NOTE: The wheel balancer inflation station must be turned OFF for tires with inflation pressures
of 414 kPa (60 psi) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS
website.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. Measure the Road Force®.

Temporarily mark the high spot and the Road Force® value on the sidewall of the tire. If
the wheel and tire assembly Road Force® value is greater than 9 kg (20 lb), carry out the
Match Mounting procedure to optimize the wheel and tire assembly.
If the wheel and tire assembly Road Force® value is 9 kg (20 lb) or less, permanently mark
the high spot and the Road Force® value on the inward sidewall of the tire for reference
during future wheel and tire service. Balance the assembly and install the wheel and tire on
the vehicle using the Wheel-to-Hub Optimization procedure.
Runout Measurement (Dial Indicator)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200
mi). Some initial tire/wheel vibration issues (such as flat spotting) will correct themselves after the tires
have been in service for 320 km (200 mi).
NOTE: Loaded run-out measurements are the preferred method for verifying tire serviceability. While a
dial indicator can be used to optimize the position of the tire on the wheel, the unloaded run-out
measurement cannot accurately determine if the tire should be removed from service.
The following procedures should be used if normal diagnostics leads to a potential runout issue.
Some vehicles may exhibit a wheel and tire vibration caused by excessive runout. Radial runout
measurements can be taken using a dial indicator and should be measured with the wheel and tire
assembly mounted on a suitable wheel balancer. The dial indicator should be mounted securely to
eliminate gauge movement when measuring runout.
1. NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the VC label.
2. Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires.
3. Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section.
4. NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS
website.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. NOTE: Masking tape can be applied on the center tread rib to allow for a smoother measuring
surface. Some fluctuation of the gauge reading is expected. Observe the overall sweep of the
gauge from the highest to the lowest spot on the tire.
Position a suitable dial indicator and stand with the dial indicator on the center tread rib.
Rotate the wheel and tire assembly (or wheel) to locate the low spot.
Adjust the runout gauge to read 0.
Rotate the wheel and tire assembly one complete revolution to make sure that the low spot
has been found and that the dial indicator returns to a 0 reading.
6. While slowly and constantly rotating the wheel and tire assembly (or wheel), measure the radial
runout.
Note the variance (runout) from 0 on the dial of the gauge.
If the runout reading of a wheel and tire assembly is greater than 1.14 mm (0.045 in),
locate and temporarily mark the high spot and runout reading on the sidewall of the tire
and carry out the Match Mounting procedure to optimize the wheel and tire assembly.
If the runout reading of a wheel and tire assembly is 1.14 mm (0.045 in) or less,
permanently mark the high spot and the runout reading on the inward sidewall of the tire
for reference during future wheel and tire service. Balance the assembly and install the
wheel and tire on the vehicle using the Wheel-to-Hub Optimization procedure.
Match Mounting
NOTE: Road Force® values in illustrations are shown in pounds.
Match mounting is a technique used to reduce radial runout or road force on wheel and tire assemblies.
Excessive runout is a source of ride quality complaints and match mounting can be used to minimize the
runout. Match mounting can be accomplished by changing the position of the tire on the wheel.
1. Position the wheel and tire assembly on a tire machine and put a reference mark on the tire
sidewall at the valve stem position.
Item Description
1 Valve stem
2 Reference mark
2. NOTICE: For vehicles equipped with a Tire Pressure Monitoring System (TPMS), the
sensor may be damaged by incorrect tire mounting or dismounting. Dismount the tire from
the wheel as instructed in the Disassembly and Assembly procedure. Failure to follow
these instructions may result in TPMS component damage.
NOTE: Always make sure that the final high spot and measurement values are permanently
marked on the inward sidewall of the tire for reference during future wheel and tire service.
Using a suitable tire machine, separate the tire beads from the wheel.
Lubricate the tire beads using a suitable fast drying, corrosion inhibiting tire bead lubricant.
Position the tire 180 degrees (half-way around) on the rim so the valve stem reference
mark is now opposite the valve stem.
3. Re-inflate the wheel and tire assembly to the specified air pressure and measure the assembly
again using a suitable dial indicator or Hunter Road Force® 9700 Series Wheel Balancer. Mark
the second high spot on the tire.
If the runout or Road Force® is reduced to within specifications, the concern has been
resolved. Balance the assembly and install on the vehicle using the Wheel-to-Hub
Optimization procedure.
4. If the second runout or Road Force® measurement is still not within specification and both high
spots are close to each other (within 101.6 mm [4 in]), the root cause is probably the tire (the high
spot followed the tire).
To be SURE that the tire is causing the high runout, it is necessary to have 2 runout or
Road Force® measurements that are not within specification and the high spots must be in
approximately the same location on the tire's sidewall. If the tire is the cause, install a new
tire, balance the assembly and install on the vehicle using the Wheel-to-Hub Optimization
procedure.
If the second high spot is not within 101.6 mm (4 in) of the first high spot, proceed to the
next step.
Item Description
1 First high spot on the tire
2 Second high spot on the tire
5. If the second high spot is still above specification and is within 101.6 mm (4 in) of being opposite
the first high spot on the wheel, the root cause is probably the wheel (the high spot followed the
wheel). Dismount the tire from the wheel, mount the wheel on a balancer and check the wheel
runout. If the wheel runout exceeds 1.14 mm (0.045 in), install a new wheel, balance the
assembly and install on the vehicle using the Wheel-to-Hub Optimization procedure.
Item Description
6. NOTE: If the second high spot did not follow the wheel or the tire and the runout is still not within
specification, improvements may be made by rotating the tire 90 degrees (one-fourth turn).
Draw an arrow on the tire sidewall from the second high spot towards the first high spot (in the
shortest direction).
Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth turn) in
the direction of the arrow.
Item Description
Wheel-to-Hub Optimization
Wheel-to-hub optimization is important. Clearance between the wheel and hub can be used to offset or
neutralize the Road Force® or run-out of the wheel and tire assembly. For every 0.001 inch of wheel-to-
hub clearance, the Road Force® can be affected between 1 and 3 pounds depending on the tire
stiffness.
NOTE: The example below illustrates how the clearance between the wheel and the hub can be used to
offset the high spot of radial run-out or Road Force®. Following the procedure will make sure of the best
optimization.
1. Position the wheel and tire assembly on the vehicle so that the high spot location of radial run-out
or Road Force® is at the 6 o'clock position and install the wheel nuts by hand until snug.
2. NOTE: Do not allow the full weight of the vehicle to rest on the tires while tightening the wheel
nuts.
Lower the vehicle until the tires make contact with the ground, slightly loading the suspension.
Tighten the wheel nuts as described in Wheel and Tire in this section.
Tire Pressure Monitoring System
Special Tool(s)
Activation Tool, Tire Pressure
Monitor
204-363, or Customer Activation
Tool, Tire Pressure Monitor 8C2T-
1AZ03-AA
Digital Tire Pressure Gauge

204-354
Flex Probe Kit



scan tool
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the
battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the
correct procedures for hazardous material disposal. Failure to follow these instructions may result in
NOTE: The Tire Pressure Monitor (TPM) module is identified by the scan tool as the Vehicle Security Module
(VSM).
The Tire Pressure Monitoring System (TPMS) uses tire pressure sensors located in the wheels to monitor the
tire pressure of all 4 tires (there is no sensor in the spare tire). Each sensor has a unique identifier that is
transmitted to the TPMS receiver during system training. The TPM / VSM retains these identifiers in memory
and associates them with a vehicle position based on the training order. The sensors transmit tire pressure
information to the TPM / VSM via radio frequency signals once every 60 seconds when vehicle speed exceeds
32 km/h (20 mph), or once every 6 hours when stationary. The TPM / VSM function compares tire pressure
information against a low-pressure limit. If it determines the tire pressure has fallen below this limit, the TPM /
VSM sends a message requesting illumination of the TPMS indicator to the Instrument Panel Cluster (IPC) over
the Medium Speed Controller Area Network (MS-CAN) bus. The IPC illuminates the TPMS indicator when
commanded by the TPM / VSM .
Radio Frequency Interference (RFI) can create intermittent TPMS issues that are difficult to diagnose. RFI can
be caused by the addition of aftermarket equipment that blocks the TPMS sensor transmissions from getting to
the Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM). Devices causing RFI can prevent the module
from communicating with any of the 4 tire pressure sensors.
Tire Pressure Monitoring System (TPMS) Indicator
The TPMS indicator may display faults that cannot be resolved by the customer. Treat these messages as
TPMS DTCs or symptoms that must be serviced.
Tire Pressure Monitoring System (TPMS) Indicator Is On Continuously from Key ON.
The TPMS indicator is illuminated continuously when the ignition is turned to the ON position and any of the tire
pressures are low. A DTC is not present for this condition and the TPMS status PID: TP_STAT equals LOW.
When this condition exists, the tire pressure must be adjusted in all tires to the recommended cold pressure as
noted on the Vehicle Certification (VC) label. GO to Symptom Chart .
Ambient Temperature Change and Tire Pressure
NOTICE: Do not inflate tires more than maximum tire pressure stamped on the tire sidewall. Premature
tire wear or damage to the tire may result.
Tire pressures fluctuate with temperature changes. For this reason, set tire pressures to specification when
tires are at outdoor ambient temperatures. If the vehicle is allowed to warm up to shop temperatures, and the
outside temperature is less than shop temperature, adjust the tire inflation pressure accordingly.
If the tires are inflated to specification at shop 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 illuminate the TPMS indicator.
As the ambient temperature decreases by 6°C (10°F), tire pressure decreases 7 kPa (1 psi). Adjust the tire
pressure by 7 kPa (1 psi) for each 6°C (10°F) ambient temperature drop as necessary to maintain tire pressure
as specified on the Vehicle Certification (VC) label. Refer to the following tables to adjust the tire pressure
indoors for colder outside temperatures.
Tire Pressure Monitoring System (TPMS) Indicator Flashes For 70 seconds From Key ON And Then
Remains On Continuously
The TPMS indicator flashes for 70 seconds and then remains on continuously if the TPMS is malfunctioning.
The TP_STAT PID can be used to determine why the TPMS indicator is flashing.
Tire Pressure Monitoring System (TPMS) PID Definitions
TPM / VSM Status PID
The TPM / VSM monitors the TPMS status. The TPMS status can be monitored using the scan tool PID
TP_STAT. The PID has 4 valid states:
1. TP_STAT = SENSOR FAULT.

SENSOR FAULT is displayed if the TPM / VSM has not heard from 1 to 3 TPMS sensors for 20
minutes when the vehicle speed is above 32 km/h (20 mph).
2. TP_STAT = SYSTEM FAULT.

SYSTEM FAULT is displayed if the TPM / VSM does not receive a signal transmission from all 4
TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).
3. TP_STAT = LOW.
LOW is displayed if the TPM / VSM has detected that at least 1 TPMS sensor is reporting low tire
pressure.
4. TP_STAT = ACTIVE.
ACTIVE is displayed if the TPMS is functioning normally.
TPMS Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event PIDs to store detailed information about the last 5 times the
TPMS indicator was illuminated. These PIDs can be used to acquire more information about a particular TPMS
event.
EVT1_IGN through EVT5_IGN
The number of key cycles since the TPMS indicator was illuminated. This PID cycles from zero to 255 and then
starts over from zero again. Use this PID to determine how long ago a TPMS event occurred and the time (in
key cycles) between events.
EVT1_TLOC through EVT5_TLOC
This is the last programmed location for the sensor causing each TPMS event. Due to tire rotation, the sensor
may no longer be at the location indicated. It is suggested that all the PIDs be recorded, the system retrained,
and the sensor identifier PIDs be used to pinpoint the actual location of each sensor.
EVT1_PSI through EVT5_PSI
This is the tire pressure associated with each TPMS indicator event. This can be used to identify the TPMS
events that were due to low pressure and to determine when a sensor is transmitting inaccurate tire pressure.
EVT1_STAT through EVT5_STAT
Describes the warning status of each TPMS event by using the information received from the TPMS status
(TP_STAT) PID. If there is a communication issue, the status could be NORMAL.
UNKNOWN
NORMAL (normal operation)
LOW (low pressure event)
FAULT (sensor fault or system fault)
EVT1_TxID through EVT5_TxID
This is the unique identifier of the sensor involved in each TPMS event. EVT1 is the most recent event that
triggered the TPMS indicator.
Wheel Rotation and Sensor Training Techniques
Moving a Problem Sensor/Wheel to a Different Position
If a sensor in a certain location has caused several events, yet the sensor trains and seems to operate
normally, moving that particular sensor/wheel to a different location on the vehicle can isolate the issue to a
certain sensor/wheel location. Carry out a road test following sensor/wheel relocation to attempt to recreate the
fault. This determines whether the fault followed the sensor or remained in the original sensor location.
Training Sensors in a Different Order
This is a technique to get past a left front sensor that may not be responding to determine if the remaining
sensors train to the module. This can help save time determining if other sensors are having issues or if the
module is experiencing training difficulties with a certain location.
NOTE: Training known good sensors from another vehicle cannot differentiate between a faulted module and
RFI .
Training Known Good Sensors From Another Vehicle
Use this technique to differentiate between a sensor fault and a module fault. If neither the originally installed
sensors nor the known good sensors can be trained, then a module fault or RFI concern is present. See items
that cause RFI , below. Do not replace the original sensors.
Items That Cause RFI
Non-OEM Equipment
The following equipment has been found to cause RFI :
Video equipment has been found to cause RFI especially when the video and power supply lines are
near the TPMS .
Car alarms (even those installed by dealerships) can create enough RFI to cause the TPMS to
malfunction or lose considerable range. These car alarms can sometimes be difficult to locate, as they
are usually hidden somewhere out of the way.
Many different in-vehicle cell phone chargers have been found to cause considerable RFI . The vehicles
with the power point closest to the TPM / VSM are the most affected. It must be noted that most cell
phone chargers do not produce high levels of RFI all of the time. This depends on the state of charge of
the cell phone battery. The phone must be almost completely discharged in some cases.
Power supplies and DC/AC inverters typically create significant RFI . Most consumer grade equipment
has very little filtering or shielding.
OEM Modules
In some cases, the RFI may actually be caused by a module or ground on the vehicle. A poor ground or loose
ground shield can disable the system. Modules that have microcontrollers using clock circuits to create the
timing pulses for the microprocessor may radiate RFI .
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source
This can be a way to determine the cause of an issue well before the sensors and module are replaced with
little or no affect on the system performance. Since this takes more up-front work, it relies on working with the
customer to determine what equipment was being used at the time of the event.
Options for Eliminating Intermittent TPMS Conditions Caused by RFI
If an OEM component or customer device is causing an RFI issue, the device can be replaced.
If a phone charger is causing an RFI issue, the customer should consult with their cell phone provider to
acquire a different phone charger.
If a device such as an dealer-installed alarm is causing an RFI issue, the device could be moved to
another location on the vehicle. In the case of a portable device, the power cord could be moved to
another power point location.
In summary, if the RFI source is present and cannot be moved or replaced, the intermittent issue remains. The
TPMS system must accept RFI and the unwanted system operation it can cause.
1. Keep the following items in mind when diagnosing any TPMS related issue:
The tire pressure sensors are not designed to be used with aftermarket wheels. The use of run-
flat tires (tires with steel body cord plies in the tire sidewall) that are not originally equipped, may
block the TPMS signal and are not recommended.
Non-OEM modifications made to the vehicle may result in false TPMS warnings.
Swapping wheels on vehicles with the same TPMS sensors sets a fault if the sensors are not
trained. Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section.
The tire pressure calibrations in the TPM / VSM for the system cannot be changed to use lower
tire pressures than those listed on the Vehicle Certification (VC) label.
Certain non-OEM electronic equipment may cause RFI and false TPMS warnings. To aid in
diagnosis, obtain information from the owner regarding any equipment that has been added or
was in use at the time the TPMS fault occurred.
It may be necessary to disconnect any electronic add-on equipment to verify its impact on TPMS
operation. For intermittent cases, it may be necessary to ask the customer to provide portable
electronic equipment to verify its impact on the system.

Low tire pressure Wiring, terminals or connectors
Tire Pressure Monitoring System (TPMS) Electrical connectors
sensor damaged or missing TPM / VSM missing or damaged
Spare tire installed as a road wheel Aftermarket electronic accessories (in-car chargers
Incorrect TPMS sensor installed or supplies, DC/AC inverters, video screens, car
TPMS sensor installed incorrectly alarms)
Non-OEM wheels installed (aftermarket
rims)
Non-OEM equipped run-flat tires installed
Other non-OEM modifications (roll cages,
service barriers, part racks, ladder racks)
5. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground from the



00 .
If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the TPM / VSM module.
9. If the DTCs retrieved are related to the concern, go to the TPM / VSM DTC Chart. For all other DTCs,
refer to the Master DTC Chart in Section 419-10 .
DTC Charts
Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) DTC Chart
B106A TPMS Sensor GO to Pinpoint Test D .
Pressure Range Bit
Incorrect State
B106B Tire Pressure Sensor DTC B106B can be set during TPM / VSM configuration. If DTC B106B was
Low Battery set during configuration, DISREGARD the DTC. If DTC B106B was not set
during configuration. GO to Pinpoint Test D .
B106E Solid State Driver GO to Pinpoint Test E .
Disabled Due To
Short Circuit
B106F Module Disabled GO to Pinpoint Test E .
Due To External
Fault
B1217 Horn Relay Coil If the horn sounds continuously, REFER to Section 413-06 .
Circuit Failure
If the horn does not sound continuously, GO to Pinpoint Test E .
B1218 Horn Relay Coil GO to Pinpoint Test E .
Circuit Short to VBatt
B1317 Battery Voltage High GO to Pinpoint Test F .
B1342 ECU Is Faulted NOTE: If other DTCs are present, REPAIR them before installing a new
component.
CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL
a new module. REFER to Tire Pressure Monitoring System (TPMS) Module —
4-Door Sedan or Tire Pressure Monitoring System (TPMS) Module — 5-Door
Hatchback in this section. TEST the system for normal operation.
B1359 Ignition Run/Acc GO to Pinpoint Test G .
Circuit Failure
B1363 Ignition Start Circuit GO to Pinpoint Test G .
Failure
B2477 Module Configuration Only present in a new or reconfigured module. To configure the TPM / VSM
Failure REFER to Tire Pressure Monitoring System (TPMS) Module — 4-Door Sedan
or Tire Pressure Monitoring System (TPMS) Module — 5-Door Hatchback in
B2868 Left Front Tire Only present in a new or reconfigured module. To configure the TPM / VSM
Pressure Sensor REFER to Tire Pressure Monitoring System (TPMS) Module — 4-Door Sedan
Fault or Tire Pressure Monitoring System (TPMS) Module — 5-Door Hatchback in
B2869 Right Front Tire Only present in a new or reconfigured module. To configure the TPM / VSM
this section.
B2870 Right Rear Tire Only present in a new or reconfigured module. To configure the TPM / VSM .
B2871 Left Rear Tire Only present in a new or reconfigured module. To configure the TPM / VSM .
B2872 Tire Pressure Sensor If DTC B287A is also present, GO to Pinpoint Test K .
Fault
Otherwise, GO to Pinpoint Test J .
B287A Tire Pressure GO to Pinpoint Test K .
System Fault
C2780 ECU in Manufacturer To configure the TPM / VSM REFER to Tire Pressure Monitoring System
Sub-state (TPMS) Module — 4-Door Sedan or Tire Pressure Monitoring System (TPMS)
Module — 5-Door Hatchback in this section. TEST the system for normal
operation.
U0155 Lost Communication GO to Pinpoint Test L .
With Instrument
Panel Cluster
U2023 Fault Received From RETRIEVE and REPAIR all non-network DTCs in the IPC . REFER to Section
External Node 413-01 .
U2050 No Application CONFIGURE the TPM / VSM . REFER to Programmable Module Installation
Present (PMI) in Section 418-01 . CARRY OUT the TPM / VSM self-test. If DTC U2050
returns, INSTALL a new TPM / VSM . REFER to Tire Pressure Monitoring
System (TPMS) Module — 4-Door Sedan or Tire Pressure Monitoring System
(TPMS) Module — 5-Door Hatchback in this section. TEST the system for
normal operation.
Symptom Chart
Symptom Chart
NOTE: 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.
Tire Pressure Tire pressure not GO to Pinpoint Test I .
Monitoring System set to specifications
(TPMS) indicator listed on the Vehicle
ON continuously Certification (VC)
from key ON with label
no related DTCs
present
TPMS indicator TPMS sensor(s) not RETRIEVE the DTCs. FOLLOW
flashes for 70 trained to the TPM / diagnostics for the DTCs present.
seconds from key VSM REFER to DTC Charts in this
ON and then TPMS sensor(s) not section.
remains on installed
continuously Spare tire in use or
road wheel missing
for extended
duration
Incorrect TPMS
sensor installed
Network
communication
concern
TPM / VSM
The TPMS does not Stoplamp switch GO to Pinpoint Test H .
enter sensor open circuitry
training mode when Vehicle
using the TPMS communication
sensor training network
procedure TPM / VSM
The Tire Pressure TPMS sensor(s) RETRIEVE and RECORD DTCs.
Monitoring System Vehicle REFER to Tire Pressure
(TPMS) enters communication Monitoring System (TPMS) DTC
sensor training issue Chart in this section.
mode but one or TPM / VSM
more sensors do
not train and DTCs
are present
The Tire Pressure TPMS sensor(s) TRAIN all 4 tire pressure sensors.
Monitoring System Attempting to install REFER to Tire Pressure
(TPMS) enters a banded TPMS Monitoring System (TPMS) Sensor
sensor training sensor that is not Training in this section.
mode but one or compatible with a If a sensor does not respond to the
more sensors do valve stem mounted Tire Pressure Monitor Activation
not train and no sensor Tool, MOVE the vehicle to rotate
DTCs are present the wheels at least one-fourth of a
turn and ATTEMPT to activate the
same sensor again. If the sensor
still does not respond, ATTEMPT
to activate the same sensor again
using the customer activation tool
(if available). If the sensor still fails
to train, ATTEMPT to train the
sensor with the vehicle doors
open.
If the sensor(s) fails to train a
second time, INSTALL a new
sensor(s). REFER to Tire Pressure
Monitoring System (TPMS) Sensor
in this section.
Pinpoint Tests
Pinpoint Test D: DTCs B106A, B106B
Normal Operation
If there is a fault in the Tire Pressure Monitoring System (TPMS), such as a damaged or missing sensor(s),
damaged module or a communication issue within the vehicle, DTCs are set in the Tire Pressure Monitor
(TPM)/Vehicle Security Module (VSM). The TPMS warning indicator flashes for 70 seconds and then remains
on continuously when the ignition switch is turned to the ON position.
DTC B106A (TPMS Sensor Range Bit Incorrect State) — sets if an attempt has been made to train a
non-compatible sensor.
DTC B106B (Tire Pressure Sensor Low Battery) — sets if an attempt has been made to train a tire
pressure sensor(s) with a low battery. This DTC can also set in the Tire Pressure Monitor (TPM)/Vehicle
Security Module (VSM) during configuration.

Non-compatible sensor
Tire pressure sensor battery
Tire pressure sensor(s)
PINPOINT TEST D: DTCs B106A, B106B

D1 DETERMINE WHICH SENSOR
HAS A LOW BATTERY OR IS
NON-COMPATIBLE
Train all 4 tire pressure Yes
sensors. Refer to Tire CLEAR the DTCs. REPEAT the self-test. VERIFY system
Pressure Monitoring System operation.
(TPMS) Sensor Training in
this section. No
Did all of the tire pressure Before installing a new sensor(s) : If a sensor does not respond
sensors transmit correctly to the Tire Pressure Monitor Activation Tool, MOVE the vehicle to
and did the horn sound ROTATE the wheels at least one-fourth of a turn and ATTEMPT to
when each tire pressure ACTIVATE the same sensor again. If the sensor still does not
sensor transmitted to the respond, ATTEMPT to ACTIVATE the same sensor again using the
TPM / VSM ? customer activation tool (if available). If the sensor still fails to train,
ATTEMPT to TRAIN the sensor with the vehicle doors open.
If the sensor(s) fails to train a second time, INSTALL a new tire

pressure sensor(s). REFER to Tire Pressure Monitoring System
(TPMS) Sensor in this section.
Pinpoint Test E: DTCs B106E, B106F, B1217 and B1218
Refer to Wiring Diagrams Cell 118 , Tire Pressure Monitoring System (TPMS) for schematic and connector
information.
Normal Operation
The Tire Pressure Monitoring System (TPMS) uses the horn as a feedback signal during TPMS sensor training
and activation by sending a ground signal to the Body Control Module (BCM). When the BCM receives this
ground signal it activates the horn relay and sounds the horn.
The TPMS monitors the circuit for shorts to voltage, ground and opens. If one of these conditions is detected,
the appropriate DTC sets.
The TPM / VSM utilizes a Field-Effect Transistor (FET) (in place of a fuse) to protect itself during a short circuit
condition, the FET is also known as a solid state driver. The FET is only designed to withstand a certain amount
of use.
The TPMS keeps track of how many times DTC B106E is set and once that counter reaches a predetermined
number (based off of FET durability) DTC B106F (and usually B1342) set. DTCs B1217, B1218 and/or B106E
also set along with B106F. The only way to clear B106F is by installing a new Tire Pressure Monitor
(TPM)/Vehicle Security Module (VSM). Repair the circuit conditions that set DTCs B1217, B1218 and/or B106E
before installing a new TPM / VSM .

• B1217 — Horn Relay Coil This DTC sets when the TPMS detects an open or a short to ground on horn
Circuit Failure control circuit. A short to ground on the horn control circuit causes the horn to
sound continuously.
• B1218 — Horn Relay Coil This DTC sets when the TPMS detects a short to battery voltage.
Circuit Short to VBatt
• B106E — Solid State Driver This DTC sets when the TPMS has protected the horn control circuit and the
Disabled Due to Short Circuit horn driver has been deactivated until the vehicle is serviced.
• B106F — Module Disabled This DTC sets when DTC B106F indicates the horn control driver has
Due to External Fault reached the end of its life expectancy and has been permanently disabled.

TPM / VSM
BCM module
PINPOINT TEST E: DTCs B106E, B106F, B1217 AND B1218
Result / Action to
Test Step
Take
E1 CHECK THE HORN OPERATION
NOTICE: If DTC B106F is present, correct the fault condition prior to Yes
installing a new Tire Pressure Monitor (TPM)/Vehicle Security Module GO to E2 .
(VSM). Failure to correct the fault condition first may cause damage to
the new TPM / VSM , resulting in a repeat repair. No
GO to Section
Push the horn pad. 413-06 to
Does the horn sound? diagnose the horn.
E2 CHECK THE HORN CIRCUIT FUNCTION
NOTICE: If the jumper wire fails, refer to the Wiring Diagrams Manual to Yes
identify the possible causes of the circuit short. After the repair: If no REMOVE the
DTCs are present, test the system for normal operation. If DTC B106E is jumper wire. GO to
present, Clear the DTCs and repeat the self-test (required to enable the E3
horn driver if DTC B106E is present). Test the system for normal
operation. If DTC B106F is present, install a new TPM / VSM . Refer to No
Tire Pressure Monitoring System (TPMS) Module — 4-Door Sedan or REMOVE the
Tire Pressure Monitoring System (TPMS) Module — 5-Door Hatchback in jumper wire.
this section. Test the system for normal operation. REPAIR circuit
CRH03 (BN) for an
Ignition OFF. open circuit.
Disconnect: TPM / VSM C4321B. CLEAR the DTCs
Ignition ON. and REPEAT the
Connect a fused jumper wire between the TPM / VSM , C4321B-9 CRH03 self-test.
(BN), harness side and ground.
Does the horn sound?

E3 CHECK FOR CORRECT TPMS OPERATION
Disconnect all the TPM / VSM electrical connectors. Yes
Check the connectors for: INSTALL a new
corrosion. TPM / VSM .
pushed-out pins. REFER to Tire
spread terminals. Pressure
Connect all the TPM / VSM connectors and make sure that they are seated Monitoring System
correctly. (TPMS) Module —
Is the concern still present? 4-Door Sedan or
Tire Pressure
Monitoring System
(TPMS) Module —
5-Door Hatchback
in this section.
TEST the system
for normal
operation.
No
The system is
operating correctly
at this time. The
concern may have
been caused by a
loose or corroded
connector. CLEAR
the DTCs.
REPEAT the self-
test.
Pinpoint Test F: DTC B1317
information.
Normal Operation
The Tire Pressure Monitoring System (TPMS) monitors the voltage from the battery to determine if it exceeds
specific thresholds. DTC B1317 sets in continuous memory if the TPMS detects battery voltage above 16 volts.
DTC B1317 (Battery Voltage High) — sets if the voltage supplied to the Tire Pressure Monitor
(TPM)/Vehicle Security Module (VSM) exceeds 16 volts during the TPM / VSM self-test or normal
operation, with vehicle speed greater than 5 km/h (3 mph).

Charging system concern
TPM / VSM
PINPOINT TEST F: DTC B1317
NOTE: DTC B1317 can be set if the vehicle has been recently jump started or the battery has been recently
charged. The battery may become discharged due to excessive load(s) on the charging system from
aftermarket accessories or if the battery has been left unattended with the accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.

F1 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON. REFER to Section 414-00
Enter the following diagnostic mode on the scan tool: VSM Self-Test. to diagnose the charging
Is DTC B1317 present? system. CLEAR all
Continuous Memory
Diagnostic Trouble Codes
(CMDTCs). TEST the
system for normal
operation.
No
GO to F2 .
F2 CHECK BATTERY CONDITION
Ignition OFF. Yes
Refer to Section 414-01 and carry out the battery condition test. If the battery passed the
Does the battery pass the condition test? condition test but required
Section 414-00 . CLEAR
all CMDTCs . TEST the
system for normal
operation. If the battery
passed the condition test
and did not require a
recharge, GO to F3 .
No
CLEAR all CMDTCs .
TEST the system for
normal operation.
F3 CHECK THE CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine rpm to increase above 2,000 rpm Yes
while performing this step or the generator may self-excite and result GO to F4
in default charging system output voltage. If engine rpm has gone
above 2,000 rpm, shut the vehicle off and restart the engine before No
performing this step. REFER to Section 414-00
to diagnose battery and
Start the engine. charging system. TEST
Measure the voltage of the battery: the system for normal
Turn off all accessories and run the engine at 1,500 rpm for a operation.
minimum of 2 minutes.
Is the battery voltage between 13-15.2 volts?

F4 CHECK FOR CORRECT TPMS OPERATION
Check the connectors for: INSTALL a new TPM /
corrosion. VSM . REFER to Tire
pushed-out pins. Pressure Monitoring
spread terminals. System (TPMS) Module
Connect all the TPM / VSM connectors and make sure that they are — 4-Door Sedan or Tire
seated correctly. Pressure Monitoring
Is the concern still present? System (TPMS) Module
— 5-Door Hatchback in
this section. TEST the
system for normal
operation.
No
corroded connector.
CLEAR the DTCs.
Pinpoint Test G: DTCs B1359 and B1363
information.
Normal Operation
The Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) receives voltage from the Central Junction
Box (CJB).
DTC B1359 (Ignition Run/Acc Circuit Failure) — sets if the TPMS detects that the RUN/ACC input is
open or shorted to ground. This DTC also sets set if the self-test is performed with the ignition in the OFF
or ACC positions.
DTC B1363 (Ignition Start Circuit Failure) — sets if the TPMS detects that the RUN/START input is open
or shorted to ground. This DTC also sets set if the self-test is performed with the ignition in the OFF or
ACC positions.

Fuse(s)
TPM / VSM
Ignition switch
PINPOINT TEST G: DTCs B1359 and B1363

G1 CHECK VOLTAGE TO THE TPM / VSM
Ignition In ACC. Yes
Disconnect: TPM / VSM C4321A. GO to G2
Ignition ON.
Measure the voltage between the TPM / VSM C4321A-20, No
circuit CBP26 (BU/WH), harness side and ground. VERIFY the CJB fuses 26 (7.5A)
and 23 (10A) are OK. If OK,
REPAIR open in circuit CBP26
(BU/WH) or circuit CBP23 (BN/YE).
possible causes of the short circuit.
Measure the voltage between the TPM / VSM C4321A-23,

circuit CBP23 (BN/YE), harness side and ground.

G2 CHECK FOR CORRECT TPMS OPERATION
Check the connectors for: INSTALL a new TPM / VSM .
corrosion. REFER to Tire Pressure Monitoring
pushed-out pins. System (TPMS) Module — 4-Door
spread terminals. Sedan or Tire Pressure Monitoring
Connect all the TPM / VSM connectors and make sure that System (TPMS) Module — 5-Door
they are seated correctly. Hatchback in this section. TEST the
Is the concern still present? system for normal operation.
No
The system is operating correctly at
this time. The concern may have
been caused by a loose or corroded
connector. CLEAR the DTCs.
Pinpoint Test H: The Tire Pressure Monitoring System (TPMS) Does Not Enter Sensor Training Mode
When Using the TPMS Sensor Training Procedure
Normal Operation
For the TPMS to enter TPMS sensor training mode, the TPM / VSM must receive valid inputs from the
stoplamp switch (OFF-ON-OFF) and it must receive valid Vehicle Speed Sensor (VSS) input (0 km/h [0 mph]).
The TPM / VSM also monitors the ignition switch status (both OFF and RUN). Refer to Tire Pressure Monitoring
System (TPMS) Sensor Training in this section for the complete sensor training procedure.

Stoplamp switch state
TPM / VSM
PINPOINT TEST H: TPM / VSM DOES NOT ENTER SENSOR TRAINING MODE WHEN USING THE TPMS
TRAINING PROCEDURE

H1 RETRIEVE THE RECORDED DTCs
FROM THE SELF-TEST
Ignition ON. Yes
Enter the following diagnostic mode GO to the TPM / VSM DTC chart in this section.
on the scan tool: VSM Self-Test.
Are there any TPM / VSM DTCs No
present? GO to H2
H2 CHECK THE TPMS BRAKE ON/OFF
(BOO_INPUT) PID
on the scan tool: VSM DataLogger. GO to H3 .
Monitor the BOO_INPUT PID
( TPMS receives the brake pedal No
information from the Instrument REFER to Section 417-01 to continue diagnosis of the
Panel Cluster (IPC)). stoplamps.
Press and release the brake pedal
while monitoring the PID.
Do the brake pedal PID values
match the brake pedal positions?
H3 CHECK THE TPMS VEHICLE
SPEED SENSOR (VSS) PID
Monitor the VSS PID ( TPMS Yes
receives vehicle speed from the GO to H4 .
IPC ).
Is the vehicle speed less than 5 No
km/h (3 mph)? REFER to Section 413-01 continue diagnosis of the vehicle
speed.
H4 CHECK FOR CORRECT TPMS
OPERATION
Disconnect all the TPM / VSM Yes
electrical connectors. The TPMS sensors may not be present. DISMOUNT the
Check the connectors for: tire. REFER to Wheel and Tire in this section. VERIFY that
corrosion. the sensors are present and mounted to the wheels. If
pushed-out pins. missing, INSTALL new TPMS sensors.
spread terminals.
Connect all the TPM / VSM If the TPMS sensors are present, INSTALL a new TPM /
connectors and make sure that they VSM . REFER to Tire Pressure Monitoring System (TPMS)
are seated correctly. Module — 4-Door Sedan or Tire Pressure Monitoring
Attempt to train the TPMS sensors System (TPMS) Module — 5-Door Hatchback in this
again. Refer to Tire Pressure section. TEST the system for normal operation.
Monitoring System (TPMS) Sensor
Training in this section. No
Is the concern still present? The system is operating correctly at this time. The concern
may have been caused by a loose or corroded connector.
CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test I: TPMS Indicator On Continuously From Key ON With No Related DTCs Present
Normal Operation
The TPMS function compares each tire pressure sensor transmission against a low pressure limit. If the
pressure falls below this limit, the Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) communicates
this on the Medium Speed Controller Area Network (MS-CAN) to the Instrument Panel Cluster (IPC). The IPC
illuminates the TPMS indicator.

Low tire pressure
Spare tire in use
Stuck TPMS sensor
PINPOINT TEST I: TPMS INDICATOR ON CONTINUOUSLY FROM KEY ON WITH NO TPMS RELATED
DTCs PRESENT IN THE TPM / VSM

I1 DETERMINE TPMS SYSTEM STATUS (TP_STAT) PID
Enter the following diagnostic mode on the scan tool: VSM
DataLogger. No
Read and record the TP_STAT PID. IF TP_STAT = SENSOR FAULT, GO
Is the TPMS system status LOW? to Pinpoint Test J .
IF TP_STAT = SYSTEM FAULT, GO

to Pinpoint Test K .
IF TP_STAT = SYSTEM ACTIVE, the

TPMS system is working as designed
at this time. If an issue was reported
by the customer, REFER to the
symptom chart in this section.
I2 CHECK LOW PRESSURE DETECTED
NOTE: The spare tire is not programmable even if it is Yes
equipped with a TPMS sensor. If a damaged road wheel is REPAIR and REMOUNT the wheel to
located in the trunk, the sensor may still be recognized by the vehicle. REFER to Wheel and Tire
the TPM / VSM as low. Make sure the spare tire is not in this section. ADJUST tire pressures
currently in use. To restore TPMS functionality, repair the to the required pressure as defined on
damaged road wheel and re-mount it to the vehicle. the Vehicle Certification (VC) label
located in the driver door jam.
Check spare tire location.
Is the spare tire in use? No
GO to I3 .
I3 CHECK FOR LOW TIRE PRESSURE
Using the Digital Tire Gauge, measure and record the tire Yes
pressure in all 4 road tires. The system is functioning normally.
Adjust the pressure for those found to be below the INFORM the customer that correct tire
specification listed on the VC label. pressure maintenance is a customer
Activate each sensor at least twice with the training tool or responsibility and the details are
customer activation tool to make sure the module gets the provided in the Owner's Literature.
latest tire pressure data. Refer to Tire Pressure Monitoring
System (TPMS) Sensor Activation or drive the vehicle for No
at least 2 minutes above 32 km/h (20 mph) to clear the GO to I4 .
low pressure warning. Do not train the sensors at this
time.
Has the TPMS indicator gone out?
I4 CHECK FOR STUCK TPMS SENSOR
Read and record the following PIDs: Yes
LF_PRES The system is functioning normally.
RF_PRES
LR_PRES No
RR_PRES INSTALL a new TPMS sensor(s).
Using the Digital Tire Gauge, measure the actual tire REFER to Tire Pressure Monitoring
pressures. System (TPMS) Sensor in this section.
Compare the tire pressure PIDs with the actual tire
pressures.
Do the compared tire pressure values match within ±
5 psi and has the TPMS indicator gone out?
Pinpoint Test J: DTC B2872
Normal Operation
If there is a concern with 1, 2 or 3 TPMS sensors, the TPMS sets DTC B2872. The TPMS indicator flashes for
70 seconds from key ON and then remains ON continuously. This symptom occurs when the Tire Pressure
Monitor (TPM)/Vehicle Security Module (VSM) does not hear from a sensor or is incapable of hearing a sensor
(s) for 20 minutes.
DTC B2872 (Tire Pressure Sensor Fault) — sets if the TPMS has been unable to communicate with 1 or
more sensors (up to 3) for more than 20 minutes.

TPMS sensors not trained to the TPMS
TPMS sensors not transmitting / damaged
TPMS sensors missing
Incorrect TPMS sensor installed
Spare tire in use
Radio Frequency Interference (RFI)
PINPOINT TEST J: DTC B2872
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors go into "sleep mode" to
conserve battery power. It becomes necessary to wake them up so that they transmit the latest tire pressure
information to the TPM / VSM . Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation in this
section.

J1 CHECK TPMS SENSOR IDENTIFIERS AND FOR SPARE
TIRE USE
NOTE: Make sure that all aftermarket electronic Yes

equipment has been disconnected (if possible) and that REPAIR and REMOUNT the wheel to
the customer has been questioned about the kinds of the vehicle. REFER to Wheel and Tire
electronic equipment they may have been using in the in this section. ADJUST the tire
vehicle when this issue was identified. pressure to the required pressure as
specified on the Vehicle Certification
Connect the scan tool. (VC) label located in the driver door
NOTE: A spare tire cannot be programmed to the jam.
vehicle, even if equipped with a TPMS sensor. If a
damaged road wheel is located in the trunk and the No
TPM / VSM cannot communicate with it, or if the GO to J2 .
damaged wheel has been dropped off at a dealership or
repair shop, the TPM / VSM sets a TPMS sensor fault.
Ignition ON.
VSM DataLogger.
Read and record the following PIDs:
Left Front Tire Transmitter Identifier (LF_ID)
Right Front Tire Transmitter Identifier (RF_ID)
Left Rear Tire Transmitter Identifier (LR_ID)
Right Rear Tire Transmitter Identifier (RR_ID)
Is the spare tire in use?
J2 CARRY OUT TPMS SENSOR TRAINING
Training the TPMS sensors. Refer to Tire Pressure Yes
Monitoring System (TPMS) Sensor Training in this GO to J3 .
section.
Did all the sensors train? No
GO to J4 .
J3 COMPARE THE SENSOR IDENTIFIERS BEFORE AND
AFTER SENSOR TRAINING
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Sensor identifiers that did not match
VSM DataLogger. were mounted to the vehicle without the
Read and record the following PIDs: required sensor training. Sensor
Left Front Tire Transmitter Identifier (LF_ID) training in the previous step has
Right Front Tire Transmitter Identifier (RF_ID) corrected the condition.
Right Rear Tire Transmitter Identifier (RR_ID) No
Compare the recorded transmitter identifier PID readings REFER to Tire Pressure Monitoring
taken before sensor training with the readings taken after System (TPMS) PID Definitions in this
sensor training. section for more information on
Did all the sensors match? repairing intermittent conditions .
J4 SENSOR(S) NOT RESPONDING TO TRAINING
NOTE: Sensor(s) that fail to train may be broken, Yes
missing, effected by RFI or the wrong sensor(s) may be The system is functioning normally.
installed.
Dismount tire and inspect the suspect TPMS sensor(s). No
Install a new sensor(s) as necessary. Refer to Tire REFER to Tire Pressure Monitoring
Pressure Monitoring System (TPMS) Sensor in this System (TPMS) principles of operation
section. in this section for additional information
Retrain the TPMS sensors. Refer to Tire Pressure on training sensors.
Monitoring System (TPMS) Sensor Training in this
section.
Did all the tire pressure sensors transmit to the
TPM / VSM ?
Pinpoint Test K: DTCs B2872, B287A
NOTE: If the vehicle has been stationary for more then 30 minutes, the sensors go into sleep mode to conserve
battery power. It becomes necessary to wake them up to transmit the latest tire pressure information to the Tire
Pressure Monitoring System (TPMS). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation in
this section.
Normal Operation
The TPMS normally receives a response from all 4 sensors, if the Tire Pressure Monitor (TPM)/Vehicle Security
Module (VSM) does not receive a response from one or more sensors, the TPMS system sets DTCs B2872
and B287A. When no response is received from all four sensors, the TPMS indicator flashes for 70 seconds
from key ON and then remains ON continuously.
DTC B2872 (Tire Pressure Sensor Fault) — sets if the Tire Pressure Monitor (TPM)/Vehicle Security
Module (VSM) has been unable to communicate with 1 or more sensors (up to 3) for more than 20
minutes.
DTC B287A (Tire Pressure System Fault) — sets if the TPM / VSM has been unable to communicate
with all 4 sensors for more than 20 minutes.
TP_STAT = SYSTEM FAULT is displayed if the TPM / VSM does not receive a signal transmission from
all 4 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).

TPMS sensors not trained to the TPM / VSM
TPMS sensors missing
Incorrect TPMS sensor installed
TPMS
Radio Frequency Interference (RFI)
PINPOINT TEST K: DTCs B2872, B287A
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors go into sleep mode" to
conserve battery power. It is necessary to wake them up to transmit the latest tire pressure information to the
TPM / VSM . Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation in this section.

K1 CHECK TPMS SENSOR IDENTIFIERS (IDs) AND
CARRY OUT TPMS SENSOR TRAINING PROCEDURE

equipment has been disconnected (if possible) and that GO to K2 .
the customer has been questioned about the kinds of
electronic equipment they may have been using in the No
vehicle when this issue was identified. GO to K3 .
Connect the scan tool.

Ignition ON.
VSM DataLogger.
Train the TPMS sensors. Refer to Tire Pressure
section.
Ignition ON.
VSM DataLogger .
Did all the sensors train?
K2 COMPARE THE SENSOR IDENTIFIERS BEFORE AND
AFTER SENSOR TRAINING
Read and record the following PIDs: Yes
Left Front Tire Transmitter Identifier (LF_ID) If all the sensors trained, REFER to Tire
Right Front Tire Transmitter Identifier (RF_ID) Pressure Monitoring System (TPMS)
Left Rear Tire Transmitter Identifier (LR_ID) principles of operation in this section for
Right Rear Tire Transmitter Identifier (RR_ID) additional Information on training
Compare the recorded PID readings taken before sensor sensors.
training with the readings taken after sensor training.
Did all the sensors match? No
Any sensor identifiers that do not match
were mounted to the vehicle without the
required sensor training. REFER to Tire
Pressure Monitoring System (TPMS)
Sensor Training in this section.
K3 SENSOR(S) NOT RESPONDING TO TRAINING
NOTE: Sensor(s) that won't train may be broken, Yes
missing, or the wrong sensor(s) may be installed. The system is functioning normally.
Dismount tire and inspect the suspect TPMS sensor(s).
Install a new sensor(s) as necessary. Refer to Tire No
Pressure Monitoring System (TPMS) Sensor in this GO to K4 .
section.
Retrain the TPMS sensors. Refer to Tire Pressure
section.
Did all the TPMS sensors transmit to the TPM /
VSM ?
K4 CHECK TPMS SYSTEM OPERATION
Check the connectors for: GO to K5 .
corrosion.
pushed-out pins. No
spread terminals. The system is operating correctly at this
Connect all the TPM / VSM connectors and make sure time. The concern may have been
that they are seated correctly. caused by a loose or corroded
Attempt to train the TPMS sensors again. Refer to Tire connector. CLEAR the DTCs. REPEAT
Pressure Monitoring System (TPMS) Sensor Training in the self-test.
this section.
K5 CHECK TPM / VSM

equipment has been disconnected (if possible) and that If the concern and/or DTCs return after
the customer has been questioned about the kinds of the road test, the customer needs to be
electronic equipment they may have been using in the informed that their aftermarket
vehicle when this issue was identified. A faulty TPM / equipment is causing unwanted RFI
VSM and a module affected by can behave in the same with the TPM / VSM and the system is
way. Care must be taken to make sure the root cause of functioning as designed under Federal
the issue is clearly identified. Communications guidelines.
Attempt to train the TPMS sensors with all aftermarket No

electronic equipment disconnected. Refer to Tire INSTALL a new TPM / VSM . REFER to
Pressure Monitoring System (TPMS) Sensor Training in Tire Pressure Monitoring System
this section. (TPMS) Module — 4-Door Sedan or
Did all the TPMS sensors transmit to the TPM / Tire Pressure Monitoring System
VSM ? (TPMS) Module — 5-Door Hatchback in
normal operation.
Pinpoint Test L: DTC U0155
information.
Normal Operation
DTC U0155 (Lost Communication With Instrument Panel Cluster) — this DTC sets in the Tire Pressure
Monitor (TPM)/Vehicle Security Module (VSM) if the vehicle speed or stoplamp switch messages that
should be received from the Instrument Panel Cluster (IPC) are missing for 10 seconds or longer. If a
communications failure is detected by the TPM / VSM , the DTC U0155 is present in the module.

Network communication concern
IPC
TPM / VSM
PINPOINT TEST L: DTC U0155

L1 VERIFY THE CUSTOMER
CONCERN
Ignition ON. Yes
Verify that there is an GO to L2 .
observable symptom present.
Is an observable symptom No
present? The system is operating normally at this time. The DTC may have
been set due to high network traffic or an intermittent fault
condition.
L2 CHECK THE
COMMUNICATION NETWORK
Enter the following diagnostic Yes
mode on the scan tool: IPC GO to L3 .
Network Test.
Carry out the network test. No
Does the IPC pass the REFER to Section 418-00 .
network test?
L3 RETRIEVE THE RECORDED
DTCs FROM THE TPM / VSM AND
IPC SELF-TESTS
Check for recorded TPM / Yes
VSM and IPC DTCs from the For the TPM / VSM , REFER to DTC Chart in this section.
self-test.
Is DTC U3003:16 (or B1318) For the IPC , REFER to Section 413-01 .
or DTC U3003:17 (or B1317)
recorded? No
GO to L4 .
L4 CHECK FOR DTC U0155 SET
IN OTHER MODULES
Clear the DTCs. Yes
Ignition OFF. INSTALL a new IPC . REFER to Section 413-01 . TEST the
Ignition ON. system for normal operation. REPEAT the ABS module self-test.
Wait 10 seconds.
Enter the following diagnostic No
mode on the scan tool: VSM INSTALL a new TPM / VSM . REFER to Tire Pressure Monitoring
Self-Test. System (TPMS) Module — 4-Door Sedan or Tire Pressure
Retrieve the continuous Monitoring System (TPMS) Module — 5-Door Hatchback in this
memory DTCs from all section. TEST the system for normal operation.
modules.
Is DTC U0155:00 or DTC
U0155 set in more than one
module?
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
Monitor
Tool, Tire Pressure Monitor
8CZT-1A203-AA

tool
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire
pressure information to the Tire Pressure Monitor (TPM)Vehicle Security Module (VSM). For additional
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation in this section.
NOTE: The TPMS Sensor Training procedure must be done on a single vehicle, in an area without
Radio Frequency Interference (RFI) and at least 1 m (3 ft) away from other vehicles equipped with
TPMS .
RFI is generated by certain electrical motors and appliance operation, cellular telephone chargers,
remote transmitters, power inverters and portable entertainment equipment.
NOTE: The TPM / VSM has a 2-minute time limit between sensor responses. If the TPM / VSM does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the
entire procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures the tire pressure sensors must be trained
following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate.
1. NOTE: An animated version of this procedure is available on-line.
Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
The horn will sound once and the TPMS indicator will flash if the training mode has been
entered successfully.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place at the valve stem.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the
vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor
again. If the sensor still does not respond, attempt to activate the same sensor again using the
customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor
with the vehicle doors open.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press
and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound
briefly to indicate that the tire pressure sensor has been recognized by the TPM / VSM . An
animated version of this procedure is available on-line.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall at the valve stem and press and release the test button to train the RF tire pressure
sensor.
8. NOTE: Do not wait more than 2 minutes between training each sensor or the TPM / VSM will time
out and the entire procedure must be repeated.
Repeat Step 7 for the RR and LR tires.

The procedure is completed after the last tire has been trained.
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 identifiers trained to the TPM / VSM and
document them on the applicable warranty claim.
10. NOTE: This step is required to clear DTC C2780, cause the TPM / VSM to exit the manufacturing
mode and to make sure there are no other concerns with a newly programmed TPM / VSM .
If the sensors are being trained due to the installation of a new TPM / VSM , clear any DTCs and
carry out the TPM / VSM On-Demand Self Test.
Tire Pressure Monitoring System (TPMS) Sensor Activation
Special Tool(s)
Monitor
Tool, Tire Pressure Monitor
NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve
battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake
them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position.
2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve
stem.
3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing
green light and a beep sound for each successful response from a tire pressure sensor. This
feedback may not always be present, do not rely on it as a confirmation that the module heard a
particular sensor.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the
vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor
again. If the sensor still does not respond, attempt to activate the same sensor again using the
customer activation tool (if available). If the sensor still fails to train, attempt to train the sensor
with the vehicle doors open.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate
the sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and
activating each sensor, refer to the Symptom Chart in Diagnosis and Testing in this section.
Tire Pressure Monitoring System (TPMS) Module — 4-Door Sedan
Special Tool(s)
scan tool
Part
1 — Tire Pressure Monitoring System (TPMS)/Vehicle
Security Module (VSM) electrical connector (part of
14401)
2 — External antenna coax connector
3 W711330 TPMS / VSM nut (2 required)
4 15K602 TPMS / VSM
Removal
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: The Tire Pressure Monitoring System (TPMS)/Vehicle Security Module (VSM) is also identified as the
VSM .
NOTE: Prior to the replacement of the TPMS / VSM , upload the module configuration information to a scan
tool. This information must be downloaded into the new TPMS / VSM after installation. For additional
NOTE: The steps included in this procedure are critical to restoring the TPMS to normal operation. A new
TPMS / VSM is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS . To clear the
DTCs, successful configuration of the TPMS / VSM must occur, followed by successful TPMS sensor training,
and a successful self-test. The DTCs are as follows:
B2477 — Module Configuration Failure

B2868 — Left Front Tire Pressure Sensor Fault
B2869 — Right Front Tire Pressure Sensor Fault
B2870 — Right Rear Tire Pressure Sensor Fault
B2871 — Left Rear Tire Pressure Sensor Fault
C2780 — ECU in Manufacturer Sub-State
1. NOTE: This step is necessary only if the TPMS / VSM is being replaced.
Upload the module configuration information from the TPMS / VSM . For additional information, refer to
Section 418-01 .
2. Position aside the LH cargo area trim panel.
3. Disconnect the 2 TPMS / VSM electrical connectors.
4. Remove the 2 nuts and the TPMS / VSM .
Installation
1. Position the TPMS / VSM and install the 2 nuts.

2. Connect the 2 TPMS / VSM electrical connectors.
3. Position the LH cargo area trim panel.
4. NOTE: When successful, this step provides the calibration necessary for the TPMS / VSM operation and
clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new TPMS / VSM .
Download the TPMS / VSM configuration information from the scan tool. For additional information, refer
to Section 418-01 .
5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these
DTCs indicates the TPMS / VSM has recognized the tire pressure sensors during the training procedure.
Train the tire pressure sensors. For additional information, refer to Tire Pressure Monitoring System
(TPMS) Sensor Training in this section.
6. NOTE: DTC C2780 will not clear if any other DTCs are present in the TPMS / VSM . When successful,
this step clears DTC C2780.
Carry out the TPMS / VSM self-test (including an on-demand self-test). Repeat the self-test to confirm all
DTCs have been cleared.
Tire Pressure Monitoring System (TPMS) Module — 5-Door Hatchback
Special Tool(s)
scan tool
Part
1 — Tire Pressure Monitoring System (TPMS)/Vehicle
Security Module (VSM) electrical connector (part of
14401)
2 — External antenna coax connector
3 W711330 TPMS / VSM nut (2 required)
4 15K602 TPMS / VSM
Removal
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: The Tire Pressure Monitoring System (TPMS)/Vehicle Security Module (VSM) is also identified as the
VSM .
NOTE: Prior to the replacement of the TPMS / VSM , upload the module configuration information to a scan
tool. This information must be downloaded into the new TPMS / VSM after installation. For additional
NOTE: The steps included in this procedure are critical to restoring the TPMS to normal operation. A new
TPMS / VSM is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS . To clear the
DTCs, successful configuration of the TPMS / VSM must occur, followed by successful TPMS sensor training,
and a successful self-test. The DTCs are as follows:
B2477 — Module Configuration Failure

B2868 — Left Front Tire Pressure Sensor Fault
B2869 — Right Front Tire Pressure Sensor Fault
B2870 — Right Rear Tire Pressure Sensor Fault
B2871 — Left Rear Tire Pressure Sensor Fault
C2780 — ECU in Manufacturer Sub-State
1. NOTE: This step is necessary only if the TPMS / VSM is being replaced.
Upload the module configuration information from the TPMS / VSM . For additional information, refer to
Section 418-01 .
2. Remove the LH quarter trim panel. For additional information, refer to Section 501-05
3. Disconnect the 2 TPMS / VSM electrical connectors.
4. Remove the 2 nuts and the TPMS / VSM .
Installation
1. Position the TPMS / VSM and install the 2 nuts.

2. Connect the 2 TPMS / VSM electrical connectors.
3. Install the LH quarter trim panel. For additional information, refer to Section 501-05
4. NOTE: When successful, this step provides the calibration necessary for the TPMS / VSM operation and
clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new TPMS / VSM .
Download the TPMS / VSM configuration information from the scan tool. For additional information, refer
to Section 418-01 .
5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these
DTCs indicates the TPMS / VSM has recognized the tire pressure sensors during the training procedure.
Train the tire pressure sensors. For additional information, refer to Tire Pressure Monitoring System
(TPMS) Sensor Training in this section.
6. NOTE: DTC C2780 will not clear if any other DTCs are present in the TPMS / VSM . When successful,
this step clears DTC C2780.
Carry out the TPMS / VSM self-test (including an on-demand self test). Repeat the self-test to confirm all
DTCs have been cleared.
Wheel and Tire
Material
Item Specification
High Temperature Nickel Anti-Seize —
Lubricant
XL-2

1 1130 Wheel cover
2 1012 Wheel nut (4 required)
3 — Wheel and tire assembly
Removal
All vehicles
Vehicles equipped with wheel cover
2. NOTICE: Do not use heat to loosen a seized wheel nut. Heat may damage the wheel and wheel
bearings.
NOTICE: Remove the wheel nuts prior to removing the wheel cover or damage to the wheel cover
may occur.
Remove the 4 wheel nuts.
3. Remove the wheel cover and the wheel and tire.
Vehicles equipped with aluminum wheels
4. Remove the 4 wheel nuts and the wheel and tire assembly.
Installation
All vehicles
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surface of the wheel and the mounting surface of the wheel hub, brake
drum or brake disc. Make sure that any fasteners that attach the rotor to the hub are secured so
they do not interfere with the mounting surfaces of the wheel. Failure to follow these instructions
when installing wheels may result in the wheel nuts loosening and the wheel coming off while the
vehicle is in motion, which could result in loss of control, leading to serious injury or death to
NOTICE: Apply a thin coat of anti-seize lubricant to the interface between the wheel pilot bore
and the hub pilot. Do not allow the anti-seize lubricant to contact the wheel-to-brake disc/drum
mounting surface, wheel studs, wheel nuts, brake pads or brake disc friction surfaces. Damage
to components may occur.
Clean the wheel mounting surfaces and apply a thin coat of anti-seize lubricant to the wheel hub pilot
surface (wheel only).
2. Install the wheel and tire assembly.
Vehicles with wheel cover
3. Align the wheel cover valve stem opening with the valve stem.
Install the 4 wheel nuts and tighten by hand while ensuring alignment of the wheel and wheel
cover assembly.
All vehicles
4. WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. Wheels
can loosen after initial tightening. Failure to follow this instruction may result in serious injury to
NOTICE: Failure to tighten the wheel nuts in a star/cross pattern can result in high brake disc
runout, which speeds up the development of brake roughness, shudder and vibration.
NOTE: The wheel nut torque specification is for clean, dry wheel studs and wheel nut threads.
Install the 4 wheel nuts and tighten by hand.
Tighten the wheel nuts in a star/cross pattern to 135 Nm (100 lb-ft).
Wheel and Tire
Special Tool(s)
Digital Tire Pressure Gauge
204-354
Part
1 1508 Tire
2 1007 Wheel
3 1700 Valve stem and screw (also part of 1A189)
4 1A189 Tire Pressure Monitoring System (TPMS) sensor (a new
sensor assembly includes W714266 screw and 1700
valve stem and cap)
5 — Valve stem-to- TPMS sensor screw (part of 1700)
6 1A163 Valve stem cap (also part of 1A189)
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the
battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the
correct procedures for hazardous material disposal. Failure to follow these instructions may result in
NOTICE: Failure to follow the instructions below may result in damage to the Tire Pressure Monitoring
System (TPMS) sensor.
NOTICE: The Tire Pressure Monitoring System (TPMS) sensor is mounted to the valve stem. Removal of
the valve stem requires dismounting the tire from the wheel and removal of the TPMS sensor.
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that accurate
values are obtained.
1. Remove the wheel and tire. For additional information, refer to Wheel and Tire in this section.
2. NOTICE: The valve stem is connected to the Tire Pressure Monitoring System (TPMS) sensor. Do
not pull the valve stem from the wheel, or damage to the sensor will occur.
Remove the valve stem core and fully deflate all air from the tire.
If a new Tire Pressure Monitoring System (TPMS) sensor is being installed, remove and discard
the valve stem-to-sensor screw and the sensor.
NOTICE: 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 Tire Pressure Monitoring System (TPMS) sensor
may occur.
3. NOTICE: Tire and valve stem position is critical to prevent damage to the Tire Pressure
Monitoring System (TPMS) sensor when using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position instead of the
paddle-type bead separator at the 3 o'clock position.
Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire from
the wheel.
For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position and
the paddle at the 3 o'clock position.
For a roller-type tire machine, align the valve stem with the roller at any position.
4. NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the outer bead from the wheel.
5. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the inner bead from the wheel.
6. NOTE: A new valve stem must be installed whenever a new tire or wheel is installed.
Remove the TPMS sensor in the following sequence.

1. Using a T10 Torx, remove the valve stem-to- TPMS sensor screw.
2. Carefully and firmly, pull the sensor straight down and separate it from the valve stem.
7. NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Using a suitable valve stem puller and a wood block, remove the valve stem from the wheel.
8. NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse the
TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor is
reused.
If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new sensor as
necessary.
Assembly
NOTICE: Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire mounting
is not carried out as instructed.
1. NOTICE: To prevent Tire Pressure Monitoring System (TPMS) sensor and valve stem damage, the
valve stem must be installed onto the TPMS sensor and then installed into the wheel as an
assembly.
Install a new valve stem onto the TPMS sensor.

Tighten the new valve stem-to- TPMS sensor screw to 1.5 Nm (13 lb-in).
2. NOTICE: It is important to pull the valve stem and Tire Pressure Monitoring System (TPMS)
sensor assembly through the wheel rim hole in a direction parallel to the valve stem hole axis. If
the assembly is pulled through at an angle, damage to the valve stem and sensor assembly may
occur.
NOTICE: Use care not to damage the wheel surface when installing the valve stem and Tire
Pressure Monitoring System (TPMS) sensor assembly.
Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor assembly into
the wheel using a block of wood and a suitable valve stem installer.
3. Make sure the valve stem rubber is fully seated against the wheel.
4. NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire bead lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of the
tire on the wheel.
5. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and mount the
bottom bead of the tire.
6. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and mount
the top bead of the tire.
7. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to make sure
that accurate values are obtained.
Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver door
or door pillar.
Proceed to Step 8 if the tire beads do not seat at the specified inflation pressure.
8. WARNING: If there is a need to exceed the maximum pressure indicated on the sidewall of
the tire, in order to seat the beads, follow ALL the steps listed below. Failure to follow these
steps may result in serious personal injury.
The following steps should only be carried out if the tire beads cannot be seated by inflating the
tire up to the maximum inflation pressure listed on the tire sidewall.
1. Relubricate the tire bead and wheel bead seat area.
2. Install a remote valve and pressure gauge.
3. Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel and
tire assembly.
4. Inflate the tire using the remote valve and tire gauge until the beads have seated or until the
pressure gauge is 138 kPa (20 psi) more than maximum inflation pressure on tire sidewall. If
beads have not seated, deflate the tire and proceed to the next step.
5. Place the wheel and tire assembly in an OSHA-approved tire safety cage.
6. Inflate the tire using the remote valve and pressure gauge until the beads have seated or until the
pressure gauge is 276 kPa (40 psi) more than maximum inflation pressure on the tire sidewall. Do
not exceed 276 kPa (40 psi) above the maximum pressure on tire sidewall. Install a new tire
if the beads do not seat at this pressure.
9. Install the wheel and tire. For additional information, refer to Wheel and Tire in this section.
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without
disassembly of the wheel and tire.
Disassemble the wheel and tire. For additional information, refer to Wheel and Tire in this section.
SECTION 205-00: Driveline System — General Information 2011 Fiesta Workshop Manual
Driveline System
The driveline system consists of the following:
Right halfshaft with inner and outer CV joint

Left halfshaft with inner and outer CV joint
Intermediate shaft connecting the transaxle to the right halfshaft
Intermediate shaft bearing that supports the inner right halfshaft CV joint
Circlips that retain the intermediate shaft and left halfshaft inner CV joint in the transaxle
differential side gears
Splined outer CV joints that mesh with the front drive hubs
Outboard CV joint wheel hub nuts that secure the CV joints to the wheel hubs
The transaxle contains the differential assembly. The differential receives torque directly from the
transmission. Inside the differential, side gears are splined to the right inboard CV joint and intermediate
shaft. The differential allows the halfshaft and intermediate shaft to be driven at different speeds as
required, such as when cornering. The rotational direction of the halfshafts determines the vehicle
movement. The articulation of the front wheels, both in steering and normal jounce and rebound, is
controlled by the CV joint. Both plunge and multi-ball style CV joints are used. The CV joints are
permanently lubricated with a special high temperature grease and require no periodic maintenance.
Halfshaft Handling
NOTICE: Excessive pulling force on the interconnecting shaft between the joints of the halfshaft
will result in internal joint damage and separation. Axial loads used in assisting removal should
be applied through the inboard joint housing only. Handle the halfshaft only by the
interconnecting shaft to avoid pull-apart and potential damage to the Constant Velocity (CV)
joints. Do not over-angle the CV joints. Damage will occur to an assembled inner CV joint if it is
over-plunged outward from the joint housing.
NOTE: Never use the halfshaft assembly as a lever to position other components. Always support the
free-end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust components.
Handle all halfshaft components carefully during removal and installation procedures.
SECTION 205-00: Driveline System — General Information 2011 Fiesta Workshop Manual
Driveline System
Principals of Operation
Driveline System — General Information
The driveline system enables the power generated by the engine and transferred through the transaxle
to place the vehicle in motion. Rotational torque received from the transaxle is delivered to the front
wheels by halfshafts. The CV joints at the ends of the shafts allow the shafts to rotate smoothly in an
allowable angle plane. The rotational torque is introduced into the differential ring gear which drives the
differential. The differential divides the torque between the left and right axle shafts, while permitting the
shafts to turn at different speeds when required, such as when cornering.

Mechanical
CV joints, housings, boots and clamps
Intermediate shaft support bearing
Intermediate shaft support bracket
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - NVH .
Intermediate Shaft Support Bearing
With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 . Rotate the intermediate
shaft by hand. If the support bearing shows any signs of roughness or wear, install a new intermediate
shaft bearing. Refer to Section 205-04 .
Driveline clunk — loud Damaged or INSPECT the CV joints for
clunk when shifting from worn CV joints wear or damage. INSTALL
reverse to drive Loose hub nut a new halfshaft as
necessary. REFER to
Section 205-04 . CHECK
the torque on the hub nut.
REPLACE the hub nut if
the torque is not at
Section 205-04 .
Driveline clunk (Front Damaged or INSPECT the inner CV joint
Wheel Drive (FWD) worn inner CV and boot. INSTALL a new
vehicles) — occurs joint halfshaft as necessary.
during acceleration or Loose hub nut REFER to Section 205-04 .
from cruise to CHECK the torque on the
coast/deceleration hub nut. REPLACE the hub
nut if the torque is not at
Section 205-04 .
Driveline clunk — occurs Loose hub nut CHECK the torque on the
as the vehicle starts to hub nut. REPLACE the hub
move forward following a nut if the torque is not at
stop specification. REFER to
Section 205-04 .
Clicking, popping or Inadequate or CHECK the CV boots and
grinding — occurs while contaminated joints for wear or damage.
the vehicle is turning lubrication in INSTALL new boot(s) or
the CV joints halfshaft as necessary.
Another CHECK the halfshafts and
component the area around the
contacting the halfshafts. REPAIR as
halfshaft necessary.
Grunting — normally Halfshaft CV CLEAN the CV joint and
associated with a joint binding INSTALL a new halfshaft
shudder experienced as necessary. REFER to
during acceleration from Section 205-04 .
a complete stop
SECTION 205-04: Front Drive Halfshafts 2011 Fiesta Workshop Manual
CV Joint Capacities
Description Liters
Grease, inner tripod joints Full sachet
Grease, outer joints Full sachet
Ball joint nut 62 46
Brake hose bracket bolt 25 18
Shield and bearing retainer strap nuts a — —
Stabilizer bar link upper nut 48 35
Wheel hub nut a — —
a Refer to Halfshaft—Exploded View in this section.
Front Drive Halfshafts
The front halfshafts consist of the following:
CV joints at both ends to make sure that the rotation is smooth

Tripod CV joints (with tripod, running rollers and tripod housing) are fitted on the transmission side
CV joints nearest the wheel are caged ball joints (with ball star, ball cage and ball shell)
LH tripod joint is secured in the differential with a circlip
Intermediate shaft (RH side) is secured in the differential by the intermediate shaft bearing
Tripod housing of the tripod CV joint for the RH front halfshaft and the intermediate shaft are
attached as a unique part
Outboard CV joints are attached to the splined wheel hubs with nuts that control wheel bearing
preload
The front halfshafts transmit torque generated by the engine from the transaxle to the wheels. In order to
allow vertical and horizontal movement of the wheels, the front drive halfshafts operate at varying
lengths and angles. The tripod CV joints allow for changes in halfshaft length during axial movements.
The caged balls of the outer CV joint permit the articulation of the front wheels and retain the stability of
the intermediate and interconnecting shafts.
Special care should be taken when removing and installing or assembling and disassembling front
halfshafts. The inner tripod joint must not be bent at more than 18 degrees. Do not allow the boots to
come into contact with sharp edges or the hot exhaust system. Do not drop the front halfshaft as this can
damage the inside of the boots without any signs of damage showing on the outside. Do not use front
halfshafts as levering tools for the installation of other components. The front halfshafts must always be
supported when disconnected from the wheel ends.
Halfshaft — Exploded View
Special Tool(s)
Installer, Halfshaft
204-161 (T97P-1175-A)
Remover, Front Wheel Hub

205-D070 (D93P-1175-B) or
equivalent
Remover, Halfshaft
205-241 (T86P-3514-A)
Remover, Halfshaft (Plate)

205-290 (T89P-3415-B)
Slide Hammer
100-001 (T50T-100-A)
Remover, Halfshaft
308-256
Wheel End Components
NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. Tighten the nut to
specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the
wheel bearing is loaded with the weight of the vehicle applied.
NOTICE: Install and tighten the new wheel hub nut to specification in a continuous rotation. Always
install a new wheel hub nut after loosening or when not tightened to specification in a continuous
rotation or damage to the components may occur.
NOTE: Apply the brake to keep the halfshaft from rotating while tightening the wheel hub nut.

1 W713760 Stabilizer bar link upper nut (install new)
2 W713640 Wheel hub nut (install new)
3 W709618 Ball joint bolt (install new)
4 W520203 Ball joint nut (install new)
5 W700936 Brake hose clip
6 W500222 Brake hose bracket bolt
Halfshafts
NOTICE: Install the bearing retainer strap (item 4) on the bracket studs before the shield (item 3) and
tighten the nuts evenly in stages (alternating from top to bottom) or incorrect bearing clampload may
occur causing component damage.
NOTICE: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more
than 45 degrees. Damage to the halfshaft will occur.
NOTICE: Install a new halfshaft seal any time the halfshaft is removed from the transmission/transaxle
or a leak may occur. For additional Information refer to Section 307-11 .
NOTE: Install the RH halfshaft shield so the clip is seated in the notch on the support bracket.
NOTE: For halfshaft CV boot service, refer to Halfshaft — RH or Halfshaft — LH In this section.
Part
1 3B437 LH halfshaft assembly
2 W520102 Shield and bearing retainer strap nuts (2 required,
install new)
3 3N278 Shield
4 3N324 Bearing retainer strap (install new)
5 3B436 RH halfshaft assembly
6 W500034 Support bracket upper bolt
7 W500024 Support bracket lower bolt (2 required)
8 3K305 Support bracket
Materials, Specifications and Special Tools. Items in the exploded views may not be listed in order of
removal.
3. Vehicles equipped with a manual transmission, use special tool 308-256 to detach the LH halfshaft.
Halfshaft — LH
Special Tool(s)
Installer, Constant Velocity Joint
Boot Clamp
205-343 (T95P-3514-A)
Part
1 — Outboard fixed ball CV joint (part of 3B437 halfshaft
assembly)
2 — Large CV boot clamps (part of 4A804 boot kit)
3 — CV boot (part of 4A804 boot kit)
4 — Small CV boot clamps (part of 4A804 boot kit)
5 — Tripod star with roller (part of 3B437 halfshaft assembly)
6 — Tripod snap-ring (part of 3B437 halfshaft assembly)
7 — Inboard tripod housing (part of 3B437 halfshaft
assembly)
8 — Halfshaft retaining circlip
Disassembly
1. Remove the LH halfshaft assembly. For additional information, refer to Halfshaft — Exploded View in this
section.
2. Clamp the intermediate shaft in a soft-jawed vise.

1. Remove and discard the 2 inner CV boot clamps.
2. Remove the inner CV joint housing.
3. Push the boot back along the shaft.
4. Separate the tripod joint from the housing and remove all of the grease.
5. Remove and discard the snap ring.
6. Using a suitable 3-jaw puller, remove the tripod joint.

7. Remove and discard the inner CV joint boot.
8. Remove and discard the outboard CV boot and boot insert.

1. Remove and discard the 2 boot clamps.
2. Pull the outboard boot down the length of the shaft and off the inboard end.
Remove the CV joint grease.
Assembly
NOTICE: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at
more than 45 degrees or damage to the component my occur.
NOTICE: Use care not to damage the boot or component damage may occur.
1. NOTE: Install the outboard CV boot from the inboard end.
Install the outboard CV boot and install half the grease in the sachet (supplied with boot kit) into the outer
joint and the remainder in the CV joint boot.
Slide a small flat-blade screwdriver under the boot seat to allow the air to escape.
Position the CV boot and remove the screwdriver.
2. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 new outboard boot clamps.
3. NOTICE: Do not damage the tripod joint roller bearings or component damage may occur.
Install the tripod joint on the inboard end of the shaft.

Using a suitable driver, push the tripod joint onto the front drive halfshaft as far as it will go.
4. Install a new snap ring.
5. Install half of the sachet of grease (supplied with boot kit) into the tripod joint housing. Inject the other
half of the grease into the boot.
6. NOTICE: Use care not to damage the boot or component damage may occur.
Install the tripod joint into the tripod joint housing.

1. Insert a small flat-blade screwdriver under the boot seat to allow the air to escape.
2. Slide the tripod joint in as far as it will go, then pull it out 20 mm (0.787 in).
Remove the screwdriver.
7. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 new CV boot clamps.
8. Install the LH halfshaft assembly. For additional information, refer to Halfshaft — Exploded View in this
section.
Halfshaft — RH
Special Tool(s)
Installer, Constant Velocity Joint
Boot Clamp
205-343 (T95P-3514-A)
Part
1 — Outboard fixed ball CV joint (part of 3B436 halfshaft
assembly)
2 — Large CV joint boot clamps (part of 4A804 boot kit)
3 — Outboard CV boots (part of 4A804 boot kit)
4 — Small CV joint boot clamps (part of 4A804 boot kit)
5 — Tripod joint (part of 3B436 halfshaft assembly)
6 — Snap ring (part of 3B436 halfshaft assembly)
7 — Intermediate shaft support bearing (part of 3B436
halfshaft assembly)
8 — Intermediate shaft (part of 3B436 halfshaft assembly)
Disassembly
more than 45 degrees or damage to the component may occur.
1. Remove the RH halfshaft assembly. For additional information, refer to Halfshaft — Exploded View in
this section.
2. Clamp the intermediate shaft in a soft-jawed vise.

Remove and discard the 2 inner boot clamps.
3. Push the boot back along the shaft.
4. Separate the tripod joint from the housing and remove all the grease.
5. Remove and discard the snap ring.
6. Using a suitable 3-jaw puller, remove the tripod joint.

7. Remove and discard the inner CV joint boot and boot insert.
8. Remove and discard the outboard CV boot.

1. Remove and discard the 2 CV boot clamps.
2. Remove and discard the boot.
Remove the CV joint grease.
Assembly
more than 45 degrees or damage to the component may occur.
1. Install the outboard CV boot and install half the grease in the sachet (supplied with boot kit) into the outer
joint and the remainder in the CV joint boot.
2. NOTICE: Use care not to damage the boot or component damage may occur.
Position the boot on the outer CV joint.

Slide a small flat-blade screwdriver under the boot seat to allow the air to escape.
Position the CV boot and remove the screwdriver.
3. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 new clamps in boot ring grooves.
4. NOTICE: Do not damage the tripod joint roller bearings or component damage may occur.
Install the tripod joint.

Using a suitable driver, push the tripod joint onto the front drive halfshaft as far as it will go.
5. Install a new snap ring.
6. Install half of the sachet of grease (supplied with boot kit) into the tripod joint housing. Inject the other
half of the grease into the boot.
7. Install the tripod joint into the tripod joint housing.

8. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 new inner CV boot clamps.
9. Install the RH halfshaft assembly. For additional information, refer to Halfshaft — Exploded View in this
section.
SECTION 206-00: Brake System — General Information 2011 Fiesta Workshop Manual
Material
High Performance WSS-M6C62-A or 648 ml -
DOT 3 Motor Vehicle WSS-M6C65-A1 Mannual
Brake Fluid transmission -
PM-1-C (US); CPM-1- 586 ml -
C (Canada) Automatic
transmission
Metal Brake Parts — —
Cleaner
PM-4-A or PM-4-B
(US); CPM-4
(Canada)
Silicone Brake Caliper ESE-M1C171-A —
Grease and Dielectric
Compound
XG-3-A
Item Specification
Brake Disc
Front brake disc minimum thickness 21 mm (0.826 in)
Brake Drum
Maximum brake drum diameter 202 mm (7.952 in)
Brake Pads and Shoes
Maximum brake shoe taper wear (in any direction) 3.0 mm (0.118 in)
Minimum brake pad thickness 3.0 mm (0.118 in)
Minimum brake shoe thickness 3.75 mm (0.147 in)
Brake caliper bleeder screws 10 89
Wheel cylinder bleeder screws 6 54
Master cylinder brake tube fittings 18 155
Brake System
The brake system consists of the following components:
Fixed brake pedal

Front disc brake system
Brake master cylinder and fluid reservoir
Mechanical parking brake system
ABS
Rear drum brake system
Red brake light indicator
Vacuum-assisted power brake booster
For information on:
the hydraulic brake actuation system, refer to Section 206-06 .

the front disc brakes, refer to Section 206-03 .
the parking brake actuation system, refer to Section 206-05 .
the ABS, refer to Section 206-09 .
the rear drum brake system, refer to Section 206-02 .
the vacuum assisted power brake booster, refer to Section 206-07 .
Brake System
Applying the brake pedal uses lever action to push a rod into the brake booster which, through the use of
vacuum, boosts the force of the rod and then transmits this force into the master cylinder. This produces
hydraulic pressure in the master cylinder. On vehicles not equipped with ABS, the hydraulic pressure is
transmitted by brake fluid through the brake tubes to the individual brake calipers. On vehicles equipped with
ABS, the hydraulic pressure is transmitted by brake fluid through the brake tubes to the ABS Hydraulic Control
Unit (HCU), which then distributes that pressure through brake tubes to the individual brake calipers. The brake
calipers use hydraulic pressure to apply the pads. The application of the brake pads will cause the rotation of the
wheels to slow or stop, depending on how much brake pressure is applied. The parking brakes carry out the
same function except that they are mechanically actuated by a cable that connects only to the rear brakes.
Brake Master Cylinder Compensator Ports
The purpose of the compensator ports in the brake master cylinder is to supply additional brake fluid from the
master cylinder reservoir when needed by the brake system due to brake lining wear and allow brake fluid to
return to the master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator ports
are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release.
Red Brake Warning Indicator
The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The
Instrument Cluster (IC) performs a bulb check when the ignition key is turned to the RUN position. The
conditions that cause the indicator to illuminate are low brake fluid level, the parking brake is applied or there is a
fault in the ABS (if the yellow ABS warning indicator is also illuminated). To diagnose red brake warning indicator
concerns, refer to Section 413-01 .
Inspection And Verification
Material
Item Specification
High Performance DOT 3 WSS-M6C62-A or
Motor Vehicle Brake Fluid WSS-M6C65-A1
PM-1-C (US); CPM-1-C
(Canada)

injury.
NOTICE: Blistering or swelling of rubber brake components can indicate contamination of the
brake fluid by a petroleum-based substance. The entire hydraulic brake system must be flushed
with clean, specified brake fluid and contaminated rubber components must be replaced to
prevent recontamination.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may
occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface
with water.
The first indication that something may be wrong in the brake system is a change in the feel through the
brake pedal. The brake warning indicator in the Instrument Cluster (IC) and the brake fluid level in the
brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out
enough fluid to relieve the pressure. Close the bleeder screw. If multiple wheels are locked, check the
brake pedal free play to verify brake pedal is not partially applied. These operations may release the
brakes, but will not correct the concern. If this does not relieve the locked wheel condition, repair the
locked components before proceeding.

For parking brake concerns, refer to Section 206-05 .
For ABS concerns, refer to Section 206-09 .
For all other concerns, continue with the next step.

Brake fluid level and condition Brake fluid level switch
Brake master cylinder Parking brake switch
Brake master cylinder reservoir Wiring, terminals or connectors
Brake booster
Brake booster check valve
Brake booster vacuum hose
Brake hoses and tubes
Brake caliper, guide pins and anchor plate
Brake discs/drums
Brake pads/shoes
Brake pedal, bracket and booster linkage
Aftermarket modifications
3. Visually inspect the suspension system and tires for obvious signs of wear or damage.
For suspension system concerns, refer to Section 204-00 .

For tire concerns, refer to Section 204-04 .
5. If the cause is not visually evident, GO to Symptom Chart - Brake System or GO to Symptom
Chart - NVH .
Symptom Chart
Symptom Chart — Brake System
Symptom Chart — Brake System

The red brake DTCs in the REFER to Section 206-09 to
warning indicator ABS module diagnose the ABS.
and the yellow ABS
warning indicator
are illuminated
The red brake Brake fluid level REFER to 413-01 to diagnose
warning indicator is switch the red brake warning indicator.
always/never on Parking brake
switch
Wiring, terminals
or connectors
Instrument
Cluster (IC)
Smart Junction
Box (SJB)
Electronic Brake
Distribution
(EBD)
Brakes drag Parking brake REFER to Section 206-05 to
component diagnose the parking brake
system.
Incorrect brake ADJUST the brake shoes and
shoe and/or parking brake cables. REFER
parking brake to Parking Brake Cable
cable Adjustment in Section 206-05 .
adjustment
Wheel cylinder INSPECT the brake system
(s) components. REFER to Brake
Brake flexible System Inspection in this
hose section.
Brake caliper
and/or guide
pins
Brake booster CARRY OUT the Brake Master
Brake master Cylinder — Compensator Port
cylinder Component Test in this section.
Hydraulic REFER to Section 206-09 to
Control Unit diagnose the HCU .
(HCU)
Stoplamp switch VERIFY correct installation of
the stoplamp switch. REFER to
Section 417-01 .
Cruise control VERIFY correct installation of
deactivator the cruise control deactivator
switch switch. REFER to Section 419-
03 .
Brakes lock up Stoplamp switch VERIFY correct installation of
under light brake the stoplamp switch. REFER to
pedal force Section 417-01 .
Cruise control VERIFY correct installation of
deactivator the cruise control deactivator
switch switch. REFER to Section 419-
03 .
Brake calipers INSPECT the brake system
and/or guide components. REFER to Brake
pins System Inspection in this
Wheel cylinders section.
and/or brake
hardware
Brake flexible
hose
Brake
pads/shoes
Brake
discs/drums
ABS REFER to Section 206-09 to
diagnose the ABS.
Vehicle pulls or Brake calipers INSPECT the brake system
drifts during braking and/or guide components. REFER to Brake
pins System Inspection in this
Wheel cylinders section.
and/or brake
shoe hardware
Brake flexible
hose
Brake
pads/shoes
Brake
discs/drums
Tires REFER to Section 204-04 to
diagnose tire concerns.
Suspension REFER to Section 204-00 to
component(s) diagnose suspension system.
and/or wheel
alignment
Brake pedal goes Brake fluid leaks INSPECT the system for leaks.
down fast or eases and/or air in the REPAIR as necessary. BLEED
down slowly system the system. REFER to Brake
System Bleeding in this section.
Brake master CARRY OUT the Brake Master
cylinder Cylinder — Bypass Condition
Component Test in this section.
HCU REFER to Section 206-09 to
diagnose the HCU .
Excessive brake Brake fluid leaks INSPECT the system for leaks.
pedal travel and/or air in the REPAIR as necessary. BLEED
(low/spongy pedal) system the system. REFER to Brake
System Bleeding in this section.
Incorrect brake REFER to Section 206-02 for
shoe adjustment the brake shoe adjustment
procedure.
cylinder Cylinder — Bypass Condition
Component Test in this section.
Brake calipers INSPECT the brake calipers
and/or guide and guide pins. REFER to
pins Brake System Inspection in this
section.
Brake flexible INSPECT the brake flexible
hose hoses during brake application.
REFER to Brake System
Inspection in this section.
Erratic brake pedal Brake pedal INSPECT the brake pedal for
travel binding, obstructions and
correct installation. REPAIR as
necessary. CHECK the brake
pedal fasteners for correct
torque. REFER to
Specifications in Section 206-
06 .
ABS REFER to Section 206-09 to
diagnose the ABS.
Excessive brake Insufficient CARRY OUT the Brake Booster
pedal effort vacuum for Component Test in this section.
brake booster
operation
Brake booster
manifold
vacuum hose
Brake booster
Brake booster
check valve
Brake INSPECT the brake
pads/shoes pads/shoes. REFER to Brake
System Inspection in this
section.
Vibration when the Brake disc GO to Pinpoint Test A .
brakes are applied (s)/drum(s)
Suspension
components
Brake Brake drag GO to Symptom Chart - Brake
vibration/shudder — System .
occurs when the brake
pedal is released
Rattling noise Caliper guide CHECK the caliper guide pins
pins or guide and guide pin bolts. REFER to
pin bolts Brake System Inspection in
this section.
Missing or CHECK the brake pads for
damaged anti- missing clips or broken
rattle clips or springs. INSTALL new
springs components as necessary.
Missing or CHECK the brake shoes for
damaged missing or broken hardware.
brake shoe INSTALL new components as
hardware necessary. REFER to Section
206-02 .
Loose or bent Realign the brake disc shield
brake disc to create a 5 mm (0.196 in)
shield minimum clearance between
the brake disc shield and the
brake disc rotor.
Squealing noise — Brake Acceptable condition. Caused
occurs on first pads/shoes by humidity and low brake pad
(morning) brake temperature.
application
Squealing noise — a Brake INSPECT the brake
continuous squeal pads/shoes pads/shoes. REFER to Brake
System Inspection in this
section.
Squealing noise — an Brake Acceptable condition. Caused
intermittent squeal pads/shoes by cold, heat, water, mud or
snow.
Groaning noise — Brake Acceptable condition.
occurs at low speeds pads/shoes
with brake lightly
applied (creeping)
Grinding/moaning Brake INSPECT the brake
noise — continuous pads/shoes pads/drums, brake
Brake discs/drums and attaching
disc/drums hardware for damage.
VERIFY brake components
are within specifications.
REFER to Brake System
Inspection in this section.
Pinpoint Tests
Pinpoint Test A: Vibration When the Brakes are Applied
Normal Operation
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. Pedal
pulsation or steering wheel nibble when the brakes are applied (frequency is proportioned to the vehicle
speed) indicates a concern with a brake or suspension component.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED
Result / Action to
Test Step
Take
A1 ROAD TEST THE VEHICLE — LIGHT BRAKING
Road test the vehicle. Warm the brakes by slowing the vehicle from Yes
80 to 32 km/h (50 to 20 mph) using light brake force. At highway GO to A4 .
speeds of 89-97 km/h (55-60 mph), apply the brake using light pedal
force. No
Is there a vibration/shudder felt in the steering wheel, seat or GO to A2 .
brake pedal?
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. GO to A3 .
Is there a vibration/shudder?
No
The concern is not
present at this time.
A3 CHECK ABS OPERATION
NOTE: During moderate to heavy braking, noise from the HCU and Yes
pulsation in the brake pedal can be observed. Pedal pulsation This is a normal
coupled with noise during heavy braking or on loose gravel, bumps, operating condition of
wet or snowy surfaces is acceptable and indicates correct operation the ABS.
of the ABS. Pedal pulsation or steering wheel nibble with the
frequency proportional to vehicle speed indicates a concern with a No
brake or suspension component. GO to A5 .
Road test the vehicle and apply the brakes on a dry, firm surface,
then apply the brakes on a wet, snowy or loose surface (such as
gravel).
Is the vibration/shudder only present on a wet, snowy or loose
surface?
A4 ISOLATE BRAKE VIBRATION
NOTE: This test is not applicable to vehicles with drum-in-hat type Yes
parking brakes. For vehicles with drum-in-hat parking brakes, GO to A7 .
proceed to the next test step. For all other vehicles, apply the
parking brake to identify if the problem is in the front or rear brake. No
GO to A5 .
Apply the parking brake to identify if the problem is in the front or
rear brake. At highway speeds of 89-97 km/h (55-60 mph), lightly
apply the parking brake until the vehicle slows down. Release the
parking brake immediately after the test.
Is there a vibration/shudder?
A5 CHECK THE FRONT SUSPENSION
Check the front suspension. Refer to Section 204-00 . Yes
Are all the suspension components in satisfactory condition? GO to A6 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
A6 CHECK THE FRONT BRAKE DISCS
Inspect the front brake discs. Refer to Brake System Inspection in Yes
this section. GO to A7 .
Road test the vehicle.
Is the vibration/shudder present? No
The concern has
been repaired.
A7 CHECK THE REAR SUSPENSION
Check the rear suspension. Refer to Section 204-00 . Yes
Are all the suspension components in satisfactory condition? INSPECT the rear
brake drums. REFER
to Brake System
Inspection in this
section.
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
Component Tests
Brake Booster
1. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure
tester to the booster side of the check valve.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
Allow the engine to reach normal operating temperature.
3. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m
(1,000 ft) of elevation above sea level.
Verify that vacuum is available at the check valve with engine running at normal idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
If specified vacuum is available, stop the engine, connect the check valve and continue
with Step 5.
If specified vacuum is not available, continue with Step 4.
4. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is
available at the hose with the engine at idle speed and the transmission in NEUTRAL.
If specified vacuum is available, stop the engine, install a new check valve and continue
with Step 5.
If specified vacuum is not available, stop the engine, connect the vacuum hose to the
check valve and refer to Section 303-00 to diagnose the no/low vacuum condition.
5. Apply the brake pedal several times to exhaust all vacuum from the system.
6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake
pedal moves downward after the engine starts.
If the brake pedal moves, the brake booster is operating correctly.
If the brake pedal does not move, install a new brake booster. Refer to Section 206-07 .
7. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for
10 minutes, then apply the brake pedal. The brake pedal feel should be the same as that noted
with the engine operating.
If the brake pedal feels hard (no power assist), install a new brake booster check valve and
retest.
If condition still exists, install a new brake booster. Refer to Section 206-07 .
If the brake pedal feels the same as noted with the engine operating, the check valve is
functioning properly.
Brake Master Cylinder — Bypass Condition
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.

4. NOTE: Make sure that the outlet port plugs do not show signs of leakage.
Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with
heavy force. If brake pedal height cannot be maintained, the brake master cylinder has an internal
leak and a new brake master cylinder must be installed.
If brake pedal height is maintained, reinstall brake tubes and tighten to specifications.
Refer to Specifications in this section. After installation, bleed the brake system. Refer to
Brake System Bleeding in this section.
Brake Master Cylinder — Compensator Port
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If an excessive amount of brake drag exists at multiple wheels, continue to Step 5.
If an excessive amount of brake drag exists at only one wheel, it indicates a possible
seized brake caliper, brake wheel cylinder or parking brake component. Repair or install
new components as necessary.
5. Check the brake pedal switches and the brake pedal free play to verify that the brake pedal is not
partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the
brake booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If the brake drag is no longer present, install a new brake booster. Refer to Section 206-
07 .
If the brake drag is still present, install a new master cylinder. Refer to Section 206-06 .
Brake System Inspection
Material
Item Specification
Metal Brake Parts Cleaner —
PM-4-A or PM-4-B (US); CPM-4
(Canada)
XG-3-A
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect and measure the thickness of the brake pad friction material. For additional information,
refer to Specifications in this section.
Minor surface cracks do not require pad replacement, however, if there are missing chunks
or cracks in the lining through to the backing plate, install new brake pads. For additional
information, refer to Section 206-03 for front brake pads.
If the thickness of the friction material is less than the specified thickness, install new brake
pads. For additional information, refer to Section 206-03 for front disc brakes.
If the friction material shows taper wear that is not within specifications, install new brake
pads and verify the caliper guide pins are functioning correctly. For additional information,
refer to Brake Caliper Guide Pins inspection.
Brake Shoes
1. Inspect and measure the thickness of the brake shoe friction material. For additional information,
refer to Specifications in this section.
Minor surface cracks do not require shoe replacement, however, if there are missing
chunks or cracks in the lining through to the backing plate, install new brake shoes.
If the thickness of the friction material is less than the specified thickness, install new brake
shoes.
Verify that the mounting hardware is installed correctly and operating correctly. Install new
hardware as necessary.
Verify that the backing plate contact points are free of corrosion that may cause binding.
Clean or install new as necessary.
Verify correct brake shoe adjustment.
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts.
This causes brake disc on-vehicle lateral runout and brake roughness.
NOTE: It is generally not required to install new brake discs to address noise issues.
1. Inspect the brake disc and measure the brake disc thickness. Record the measurement, refer to
If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Section 206-03 for front brakes.
If the measurement is below the minimum thickness specification, install a new brake disc.
For additional information, refer to Section 206-03 for front brakes.
If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking
that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar
to that caused by pads worn down to the backing plate, should also be machined. In order
to machine, discs must be above the minimum thickness specification. For additional
information, refer to Specifications and Brake Disc Machining in this section.
Brake Drums
NOTE: It is generally not required to install new brake drums to address noise issues.
1. Inspect the brake drums and measure the brake drum diameter. Record the measurements, refer
to Specifications in this section.
If the brake drum is cracked or otherwise damaged, install a new brake drum.
If the diameter measurement is more than the maximum specification, install a new brake
drum.
Heavily scored brake drums, similar to that caused by shoes worn down to the backing
plate, should be machined. In order to machine, drums must be below the maximum
diameter specification.
Wheel Cylinders
1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding.
If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder. For
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding.
If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For
additional information, refer to Section 206-03 for front brake calipers.
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper
wear or the guide pins are difficult to move, carry out the following steps.
Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores
for wear, damage and corrosion. If bore is worn or damaged, replace the damaged
component.
Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign
material from the caliper guide pin bores. Clean any remaining foreign material from the
bores with brake parts cleaner and compressed air.
Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an
ample amount of the specified grease to lubricate the bores and guide pins.
Inspect the brake pads. For additional information, refer to Brake System Inspection in this
section.
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may
result in brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings
must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the
underbody or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
If a section of the brake tube is damaged, the entire section must be installed with a new
tube of the same type, size, shape and length.
When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to
Brake System Bleeding in this section.
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any
other signs of damage.
Install a new brake flexible hose if the hose shows signs of softening, cracking or other
damage. For additional information, refer to Section 206-03 for the front brake flexible hose
or Section 206-02 for the rear brake flexible hose.
Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder
reservoir will fall during brake application and rise during release. The net fluid level (such as after brake
application and release) will remain unchanged. Fluid level will decrease with pad wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange.
This results from the normal lubricating action of the master cylinder bore and seal.
1. Inspect the brake master cylinder for fluid leaks.

Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are
present. For additional information, refer to Section 206-06 .
To check for correct brake master cylinder operation, refer to Component Tests in this
section.
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks
and kinks.
Install a new brake booster if signs of excessive corrosion or damage is found. For
Repair or replace vacuum hoses as necessary.
To check for correct brake booster operation, refer to Component Tests in this section.
Brake Disc Machining
NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read
the entire operating manual and/or view the video shipped with the lathe before installing, operating or
repairing the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if
the lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total
indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than
0.050 mm (0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to
machining, then the final brake disc runout will be within specification, and a runout measurement is not
necessary after machining.
NOTE: Do not machine new brake discs.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct
adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specifications.
2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
NOTE: It is not necessary to disconnect the brake tube from the brake caliper.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly
aside, as required.
Support the brake caliper using mechanic's wire.
3. Install the hub adapter using:

four wheel nuts on a 4-stud wheel hub.
five wheel nuts on a 5-stud wheel hub.
six wheel nuts on a 6-stud wheel hub.
four wheel nuts on a 7- or 8-stud wheel hub.
five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total
indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more
than 0.050 mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter
cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface
finish.
Machine the brake disc.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.

10. Remove the metal shavings.
11. Measure the brake disc thickness.

If the measurement is below the minimum specification, install a new brake disc. For
12. NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications in this section.
Position the brake caliper or brake caliper and anchor plate assembly.
Install the bolts.
For fastener torque specifications, refer to Section 206-03 .
Brake System Bleeding
Special Tool(s)
tool
Material
Item Specification
(Canada)
Pressure Bleeding

injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation.
Master cylinder may be damaged if operated without fluid, resulting in degraded braking
performance. Failure to follow this instruction may result in serious personal injury.
with water.
NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Clean all dirt from the brake master cylinder filler cap and remove the filler cap.
Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the
adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank
hose to the fitting on the adapter.
3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Open the valve on the bleeder tank.

Apply 207-345 kPa (30-50 psi) to the brake system.
4. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container
partially filled with clean, specified brake fluid.
5. Loosen the RR bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RR bleeder screw to specifications. Refer to Specifications in this section. Remove the rubber
hose.
6. Continue bleeding the rest of the system, going in order from the LR bleeder screw to the RF
bleeder screw, ending with the LF bleeder screw.
Tighten the brake caliper and wheel cylinder bleeder screws to specifications. Refer to
7. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter.
Fill the reservoir with clean, specified brake fluid and install the reservoir cap.
Manual Bleeding

injury.
with water.
1. Clean all the dirt from around the brake fluid reservoir cap and remove the filler cap.
Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container
3. Have an assistant pump and then hold firm pressure on the brake pedal.
4. Loosen the RR bleeder screw until a stream of brake fluid comes out. While an assistant
maintains pressure on the brake pedal, tighten the RR bleeder screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
5. Tighten the RR bleeder screw to specifications. Refer to Specifications in this section. Remove
the rubber hose and install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LR bleeder screw.
7. Remove the RF bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain hose to the RF bleeder screw and submerge the free end of the hose in a container partially
filled with clean, specified brake fluid.
8. Have an assistant pump and then hold firm pressure on the brake pedal.
9. Loosen the RF bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RF bleeder screw.
10. Tighten the RF bleeder screw to specifications. Refer to Specifications in this section. Remove
the rubber hose and install the bleeder screw cap.
11. Repeat Steps 7 through 10 for the LF bleeder screw.
Hydraulic Control Unit (HCU) Bleeding

injury.
with water.
1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
Component Bleeding
Material
Item Specification
(Canada)
Master Cylinder

injury.
with water.
NOTE: When the brake master cylinder has been installed new or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. Disconnect the brake outlet tubes from the master cylinder.
2. Install short brake tubes onto the primary and secondary ports with the ends submerged in a
container partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal until clear fluid flows from the brake tubes without air
bubbles.
4. Remove the short brake tubes, and install the master cylinder brake tubes.
Tighten the brake tube fittings to specifications. Refer to Specifications in this section.
5. Bleed the brake system. For additional information, refer to Brake System Bleeding in this
section.
Brake Caliper

injury.
with water.
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the bleeder screw and submerge the free end of the hose in a container
2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake
pedal.
3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder screw.
4. Tighten the bleeder screw to specifications. Refer to Specifications in this section. Remove the
rubber hose and install the bleeder screw cap.
Wheel Cylinder

injury.
with water.
NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was
disconnected or installed new.
1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the bleeder screw and submerge the free end of the hose in a container
2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake
pedal.
3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder screw.
4. Tighten the bleeder screw to specifications. Refer to Specifications in this section. Remove the
rubber hose and install the bleeder screw cap.
SECTION 206-02: Drum Brake 2011 Fiesta Workshop Manual
Material
Capacity
High Performance DOT 3 WSS-M6C62-A or 630 ml
Motor Vehicle Brake Fluid WSS-M6C65-A1 (1.33 pt)
(Canada)
Silicone Brake Caliper ESE-M1C171-A —
Compound
XG-3-A
Metal Brake Parts Cleaner — —
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Drum Brake Specification

Description mm Inch
Brake drum discard diameter 202 8.03
Brake lining discard thickness 1 0.039
Brake tube fittings 18 — 159
Wheel cylinder bolt 12 — 106
Brake drum retainers 13 — 115
Drum Brake
The drum brake system consists of the following components:
Brake backing plate

Brake drum
Brake flexible hose
Brake shoe hardware kit
Brake shoes
Self-adjuster
Wheel cylinder
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 wheel cylinders moving the brake
shoes against the friction surface of the brake drum. The friction of the brake shoes on the brake drum
causes the slowing or stopping of wheel rotation and the vehicle.
Brake Shoe Adjustment
Special Tool(s)
Brake Adjustment Gauge
206-D002 (D81L-1103-A) or
equivalent
1. Remove the brake drum. For additional information, refer to Drum Brake System — Exploded
View in this section.
2. Using the Brake Adjustment Gauge, measure the inside diameter of the brake drum.
3. Position the Brake Adjustment Gauge on the brake shoes and linings and adjust accordingly.
4. Install the brake drum. For additional information, refer to Drum Brake System — Exploded View
in this section.
Drum Brake System — Exploded View
Material
Item Specification
(Canada)
CPM-4 (Canada)
Silicone Brake Caliper ESE-M1C171-A
Compound
XG-3-A
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or
friction components. Remove dust using government-approved techniques. Friction component dust
may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if
dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure
may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or
may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure
to follow these instructions may result in serious personal injury.
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions will
help prevent system contamination, brake component damage and the risk of serious personal injury.
WARNING: Carefully read cautionary 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.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
1 — Brake tube fitting (part of 2L111 RH / 2268 LH)
4 2282 Brake flexible hose
5 — Brake tube fitting (2 required) (part of 2268)
6 2248 Wheel cylinder bolt
7 2261 Wheel cylinder
8 1126 Brake drum
9 W505741 Brake drum retainers (2 required)
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or
friction components. Remove dust using government-approved techniques. Friction component dust
may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if
dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure
may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or
may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure
to follow these instructions may result in serious personal injury.
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven
braking and serious personal injury.
NOTE: Make sure that all mating surfaces are free of foreign material and apply the specified silicone grease to
the brake shoe contact points on the brake backing plate.
1 — Brake shoe hold-down pin (2 required) (part of 2A225)
2 2211 Backing plate
3 — Brake shoe (part of 2200)
4 2K286 Self-adjuster assembly
5 — Upper return spring (part of 2A225)
6 — Self-adjuster lever (part of 2K286)
7 — Self-adjuster lever spring (part of 2K286)
8 — Lower return spring (part of 2A225)
9 — Brake shoe hold-down clip (2 required) (part of 2A225)
NOTE: For brake system and component bleeding procedures, refer to Section 206-00 .
NOTE: If removing the the drum brake backing plate, the wheel hub and bearing must be removed. For
additional information, refer to Section 204-02
removal.
SECTION 206-03: Front Disc Brake 2011 Fiesta Workshop Manual
Material
Capacity

(Canada)
Metal Brake Parts — —
Cleaner
CPM-4 (Canada)
Item Specification
Brake Disc
Brake disc minimum thickness 21 mm (0.905 in)
Brake Pads
Brake pad maximum taper wear (in any direction) 2.0 mm (0.118 in)
Brake pad minimum thickness 2.0 mm (0.118 in)
Brake caliper anchor plate bolts 68 50 —
Brake caliper flow bolt 35 26 —
Brake guide pin caliper bolts 28 21 —
Brake hose bracket bolt 27 20 —
Brake tube fitting 18 — 159
Front Disc Brake
The front brake disc system consists of the following components:
Brake caliper anchor plate

Brake caliper
Brake disc
Brake flexible hose
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 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.
Disc Brake System — Exploded View
Material
Item Specification
(Canada)
CPM-4 (Canada)

1 — Brake tube fitting (part of 2263)
2 W500222 Brake hose bracket bolt
3 2001 Brake caliper anchor plate bolt
4 2K204 Brake disc shield
5 1125 Brake disc
6 — Stainless steel shims (4 required) (part of 2001
kit)
7 — Brake pad (2 required) (part of 2001 kit)
8 — Brake caliper guide pin bolt (2 required) (part of
2L527 kit)
9 2B120RH/ Brake caliper
2B121LH
10 W711784 Washers (2 required)
11 2L122 Brake caliper flow bolt
12 2078 Brake flexible hose
14 — Brake pad slides (2 required) (part of 2001 kit)
15 2B292 Brake caliper anchor plate
16 — Dust boot (2 required) (part of 2L257 kit)
17 — Brake caliper guide pin (2 required) (part of 2L257
kit)
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven
braking and serious personal injury.
NOTICE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose can
occur.
NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and
boots.
NOTICE: Protect the caliper pistons and boots when pushing the caliper pistons into the caliper piston
bores or damage to components may occur.
NOTE: If installing new brake pads, install all of the new hardware and lubricant supplied with the brake pad kit.
NOTE: For brake system and component bleeding procedures, refer to Section 206-00 .
removal.
SECTION 206-05: Parking Brake and Actuation 2011 Fiesta Workshop Manual
Material
Capacity
Metal Brake Parts Cleaner — —
PM-4-A or PM-4-B (US); CPM-
4 (Canada)
Silicone Brake Caliper Grease ESE-M1C171- —
XG-3-A
Front parking brake cable nuts 10 — 89
Parking brake control nuts 24 18 —
Parking brake control bolt 24 18 —
Floor console bracket nuts 24 18 —
Crossmember nuts 24 18 —
Parking Brake
The parking brake system consists of the following components:
Parking brake control

Parking brake cable equalizer
Parking brake warning indicator switch
Rear parking brake cables and conduits
Rear brake shoes
Rear brake shoe actuators
The parking brake system is cable operated and controlled by an independent hand-operated parking
brake control. The parking brake control actuates the rear brake shoes directly through a cable system.
A red brake warning indicator, located in the instrument cluster, will illuminate to signal the driver that the
parking brake is applied. For information and diagnosis of the brake warning indicator, refer to Section
413-01 .
Parking Brake
Material
Item Specification
PM-4-A or PM-4-B (US); CPM-4
(Canada)
XG-3-A
The parking brake system is cable-actuated and controlled by an independent hand-operated parking
brake control that is not self adjusting, The parking brake system is actuated when the parking brake
control is pulled up. The parking brake cables are connected to the parking brake control by the parking
brake equalizer. When the parking brake control is pulled, the equalizer pulls on both rear parking brake
cables, which are attached to the parking brake actuators and apply the brake shoes. When the parking
brake release button is pressed and the brake control is released, the tension on the parking brake
cables return the system to the released position.
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
3. Visually inspect for obvious signs of mechanical or electrical damage. Refer to the following chart:

Mechanical
Brake shoe actuators
Brake shoe hardware
Brake shoe backing plate
Parking brake cable equalizer
Rear parking brake cables and conduits
5. If the concern is not visually evident, verify the symptom. GO to Symptom Chart .
Symptom Chart
Symptom Chart
The red brake Parking brake RELEASE the parking brake.
warning indicator is not fully TEST the system for normal
always illuminated released operation.
Low brake fluid REFER to Section 206-00 to
level diagnose the hydraulic brake
system.
Wiring, REFER to Section 206-00 to
terminals or diagnose the brake warning
connectors indicator circuit.
cylinder Cylinder Component Test.
inoperative REFER to Component Tests in
Section 206-00 .
The parking brake Rear brake VERIFY rear brake shoe
will not apply shoes out of adjustment, ADJUST as
adjustment necessary. REFER to Section
206-02 .
Parking brake VERIFY parking brake cable
cables out of adjustment, ADJUST as
adjustment necessary. REFER to Parking
Brake Cable Adjustment in this
section.
Parking brake GO to Pinpoint Test A .
control
Parking brake
cables
Parking brake
cable equalizer
Rear brake
shoes and/or
hardware
The parking brake Parking brake GO to Pinpoint Test B .
will not release control
and/or rear brakes Parking brake
drag cables
Parking brake
cable equalizer
Rear brake
shoes and/or
hardware
Pinpoint Tests
Pinpoint Test A: The Parking Brake Will Not Apply
Normal Operation
When the parking brake control is pulled, the parking brake equalizer pulls on both rear parking brake
cables, which are attached to the parking brake actuators and apply the brake shoes.

Parking brake cables and conduits
Parking brake equalizer
Rear brake hardware
Rear brake shoes
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY

A1 CHECK THE PARKING BRAKE
CONTROL FOR CORRECT
OPERATION
Pull the parking brake control Yes
handle. GO to A2 .
Does the parking brake control
move? No
GO to A4 .
A2 CHECK FOR BROKEN CABLES
AND HARDWARE
NOTE: Have an assistant pull and Yes
release the parking brake handle CONNECT the component(s) or INSTALL new parking
to help isolate disconnected brake component(s) as necessary. TEST the system for
cables or cables that do not normal operation.
move.
Inspect the following items for No
damage and correct connections: GO to A3 .
LH rear cable
RH rear cable
Is any damage found or are any
components disconnected?
A3 CHECK THE PARKING BRAKE
SHOES AND HARDWARE
Remove the rear brake drum. Yes
Refer to Section 206-02 . Inspect INSTALL new components as necessary. REFER to
the brake shoes and hardware for Section 206-02 . TEST the system for normal operation.
damage and/or missing
components.
Is any damage found or are any No
components missing? VERIFY that the rear brake shoes and linings are within
thickness specifications. REFER to Specifications in
Section 206-00 . INSTALL new brake shoes as
necessary. REFER to Section 206-02 . TEST the
A4 ISOLATE THE PARKING BRAKE
CONTROL AND FRONT PARKING
BRAKE CABLE
Disconnect the rear cables from Yes
the cable equalizer. GO to A5 .
Pull the parking brake control
handle. No
Does the parking brake control INSTALL a new parking brake control. REFER to
move? Parking Brake — Exploded View in this section. TEST
A5 ISOLATE THE REAR PARKING

BRAKE CABLES
Remove the rear brake drum. Yes
Refer to Section 206-02 . The system is operating normally at this time. The
Disconnect the parking brake concern may have been cause by a seized or binding
cables from the brake shoe component. CLEAN and LUBRICATE the brake backing
actuators. plate using the specified materials. CONNECT all
While holding the rear cable cables and INSTALL all components. TEST the system
conduit, attempt to slide the rear for normal operation.
cable inside the conduit.
Does the rear cable slide freely No
inside the conduit? INSTALL new rear brake cable(s). REFER to Parking
Brake — Exploded View in this section. TEST the
Pinpoint Test B: The Parking Brake Will Not Release and/or Rear Brakes Drag
Normal Operation
When the parking brake release button is pressed and the brake control is released, the tension on the
parking brake cables return the system to the released position.

Parking brake cables and conduits
Rear brake hardware
Rear brake shoes
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE AND/OR REAR BRAKES DRAG

B1 ISOLATE THE PARKING
BRAKE CONTROL
Disconnect the rear Yes
cables from the cable INSTALL a new parking brake control. REFER to Parking Brake
equalizer. — Exploded View in this section. TEST the system for normal
Does the parking brake operation.
release?
No
GO to B2 .
B2 CHECK THE REAR
BRAKE SHOES AND
HARDWARE
Remove the rear brake Yes
drum. Refer to Section GO to B3 .
206-02 .
Inspect the brake shoes, No
hardware and backing INSTALL new components as necessary. REFER to Section
plate. 206-02 . TEST the system for normal operation.
Are the shoes,
hardware and backing
plate in good
condition?
B3 ISOLATE THE REAR

PARKING BRAKE CABLES
Disconnect the parking Yes
brake cables from the The system is operating normally at this time. The concern may
brake shoe actuators. have been cause by a seized or binding component. CLEAN and
While holding the rear LUBRICATE the brake backing plate using the specified
cable conduit, attempt to materials. CONNECT all cables and INSTALL all components.
slide the rear cable TEST the system for normal operation.
inside the conduit.
Does the rear cable No
slide freely inside the INSTALL new rear brake cable(s). REFER to Parking Brake —
conduit? Exploded View in this section. TEST the system for normal
operation.
Parking Brake Cable Adjustment
1. Remove the floor console finish panel to access the parking brake cable adjuster nut. For additional
information, refer to the floor console procedure exploded view in Section 501-12 .
2. Make sure the parking brake control handle is in the fully released position.
3. Remove the brake drums For additional information, refer to . Section 206-02
Inspect drum brake assembly. Install new components as necessary.
4. Loosen the self-adjuster one full turn on both axle ends.
5. Using a cable tie, secure the parking brake actuation lever to the brake shoe as shown on the passenger side
rear.
6. Install a 4mm allen wrench against the parking brake actuation lever on driver side rear only.
7. Adjust the parking brake cable adjuster nut until the allen wrench falls out.
8. Remove the cable tie.

9. Adjust the brake shoes. For additional information, refer to Section 206-02
10. If new rear cables have been installed, carry out the following sub steps. If new rear cables have not been
installed, proceed to step 11.
1. Cycle parking brake control lever to the 10th notch 10 times to stretch the new cables.
2. Remove the rear drums and verify that the gap exists between the parking brake stop lever and the
brake shoe web.
3. If the gap is zero, repeat step 2 and steps 4 thru 9.
11. After assembling the wheel, verify the wheel turns freely to ensure there is no brake drag present.
12. Fully depress the brake pedal 10 times. Apply the parking brake to verify correct operation.
13. Install the floor console finish panel. For additional information, refer to the floor console exploded view in
Section 501-12
Parking Brake — Exploded View
Parking Brake Control
NOTE: The parking brake switch is not serviced separately . If a new parking brake switch is needed, a new
parking brake control must be installed.

1 — Parking brake cable adjuster nut (part of 2853)
2 W500223 Parking brake control bolt
3 2780 Parking brake control
4 W520102 Parking brake control nut (2 required)
5 7H406 Pin type retainer
6 W702751 Front parking brake cable nut (2 required)
7 2853 Front parking brake cable
8 W702751 Floor console bracket nut
9 58045B32 Floor console bracket
Parking Brake Cables
NOTICE: Use care when releasing the RH rear parking brake cable from the plastic brackets or damage
to the brackets may occur.
Part
1 — Parking brake cable retainers (3 required) (part of
2A603)
2 2A603 Rear parking brake cable
3 2A635 Parking brake actuation lever cable (2 required)
4 — Parking brake actuation lever (2 required) (part of
2200)
5 W708952 Plug
6 2853 Front parking brake cable
7 — Equalizer (part of 2A603)
8 W520413 Parking brake cable bracket nut
9 9A335 Parking brake cable bracket (2 required)
Heat Shields, Exhaust System and Crossmember

1 5411434 Exhaust heat shield
2 54114B06 Exhaust heat shield
3 W709729 Exhaust heat shield nut (9 required)
4 5230 Muffler assembly
5 5A262 Exhaust insulator (3 required)
6 W520102 Crossmember nut (8 required)
7 58108K38 Crossmember
Materials, Specifications and Special tools. Items in the exploded views may not be listed in order of
removal.
3. Remove the driver seat and the floor console to access the parking brake control.
For the driver seat, refer to Section 501-10 .
For the floor console, refer to Section 501-12 .
4. Loosen the front parking brake cable adjuster nut 5 turns to release the tension for parking brake
service. Remove the floor console finish panel to access the nut. For additional information, refer to the
floor console procedure exploded view in Section 501-12 .
5. Remove the crossmember and lower the exhaust and the exhaust heat shields in order to access the
parking brake equalizer.
6. Adjust the parking brake cables after parking brake component service. For additional information, refer
to Parking Brake Cable Adjustment in this section.
SECTION 206-06: Hydraulic Brake Actuation 2011 Fiesta Workshop Manual
Material
High Performance WSS-M6C62-A or 648 ml (1.37 pt)
DOT 3 Motor WSS-M6C65-A1 (manual
Vehicle Brake Fluid transmission)
PM-1-C (US); CPM- 586 ml (1.24 pt)
1-C (Canada) (automatic
transmission)
Brake booster nuts 25 18 —
Brake fluid reservoir nuts 7 — 62
Brake master cylinder nuts 20 — 177
Brake pedal bracket nuts 25 18 —
Knee air bag bracket nuts 8 — 71
Primary brake tube fitting 17 — 150
Secondary brake tube fitting 17 — 150
Steering shaft-to-steering gear bolt 32 24 —
Hydraulic Brake Actuation
The hydraulic brake actuation system consists of the following components:
Brake master cylinder and fluid reservoir

Brake pedal and bracket
Brake tubes and hoses
The brake pedal is connected to the power brake booster, which is connected to the brake master
cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tube
and flexible hoses to the front brake calipers and rear wheel cylinders. The brake fluid enters the
calipers and cylinders, forcing the pistons and brake pads/shoes outward against the friction surface,
slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning
the caliper pistons, wheel cylinders, brake pads and brake shoes to the unapplied position.
Brake Pedal and Bracket
NOTE: Automatic transmission shown, manual transmission similar.

1 W706840 Brake pedal bracket nut (2 required) - 25 Nm (18 lb-ft)
2 W706840 Brake booster nut (4 required) - 25 Nm (18 lb-ft)
3 2455 Brake pedal and bracket assembly
4 2L523 Brake booster push rod clevis locking pin
1. Remove the knee air bag module. For additional information, refer to Section 501-20B .
2. NOTICE: Do not service the brake pedal without first removing the stoplamp switch. Remove this
switch with the brake pedal in the at-rest position. Attempting to remove this switch when the
plunger is extended (during pedal apply) results in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
3. NOTICE: Do not service the brake pedal without first removing the cruise control deactivator
switch. Remove this switch with the brake pedal in the at-rest position. Attempting to remove this
switch when the plunger is extended (during pedal apply) results in damage to the switch.
Remove the cruise control deactivator switch. For additional information, refer to Section 419-03 .
steering column shaft detachment or loss of steering control. Failure to follow this instruction
may result in serious injury to vehicle occupant(s).
NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence the steering column
has rotated, remove and recenter the clockspring. For additional information, refer to Section
501-20B .
Remove and discard the steering shaft-to-steering gear bolt, then disconnect the steering shaft from the
steering gear.
6. Remove the 3 nuts and position the knee air bag bracket aside.
7. NOTE: The booster push rod clevis locking pin is a one-time use only part. Any time the booster push
rod clevis locking pin is removed, install a new booster push rod clevis locking pin.
NOTE: Use an 11 mm, 12-point socket or wrench to compress the 2 locking tabs on the clevis pin.
Remove and discard the brake booster push rod clevis locking pin, then position the booster push rod
aside.
8. Disconnect the accelerator pedal electrical connector.
9. Detach the wire harness from the brake pedal bracket.
10. Remove the 4 brake booster nuts and the 2 brake pedal bracket nuts.
11. NOTE: The accelerator pedal is removed with the brake pedal bracket, but is serviced separately from
the brake pedal bracket.
Remove the brake pedal and bracket assembly.
12. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch and cruise control deactivation switch. Install these switches with the booster push rod
attached to the brake pedal and with the brake pedal in the at-rest position. Installing these
switches with the brake pedal in any other position results in incorrect adjustment and damages
the switches.
13. Verify correct stoplamp switch and cruise control deactivator switch installation. For additional
information, refer to Brake Pedal Switch Adjustment in Section 206-09 .
Brake Master Cylinder
Material
Item Specification
(Canada)
NOTE: Manual transmission shown, automatic transmission similar.
Part
1 — Primary brake tube fitting (part of 2M020) - 17 Nm (150
lb-in)
2 — Secondary brake tube fitting (part of 2M019) - 17 Nm
(150 lb-in)
3 — Brake master cylinder nut (2 required) (part of 2140)
(also part of kit 2C144) - 20 Nm (177 lb-in)
4 2140 Brake master cylinder
5 2C251 Brake fluid level switch (also part of 2140)
6 — Brake fluid level switch electrical connector (part of
14K012)
7 — Brake booster-to-master cylinder O-ring (part of 2140)
(also part of kit 2C144)
8 2K478 Brake fluid reservoir
9 7T504 Brake master cylinder-to-clutch master cylinder tube
(manual transmission only)
10 W711330 Brake fluid reservoir nut (2 required) - 7 Nm (62 lb-in)
NOTICE: 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.
1. Disconnect the vacuum tube from the brake booster.
2. Detach the vacuum tube from the cowl and position aside.
3. Remove the battery tray. For additional information, refer to Section 414-01 .
4. Remove the 2 brake fluid reservoir nuts.

5. Disconnect the brake fluid reservoir tube from the master cylinder.
6. If equipped with a manual transmission, disconnect the brake master cylinder-to-clutch master cylinder
tube from the master cylinder.
7. Disconnect the brake fluid level switch electrical connector.
8. Disconnect the primary and secondary brake tubes from the master cylinder.
9. Remove and discard the 2 brake master cylinder nuts.

To install, tighten the new brake master cylinder nuts to 20 Nm (177 lb-in).
10. Remove the brake master cylinder and discard the brake booster-to-master cylinder O-ring.
11. NOTE: Before installing the master cylinder make sure a new brake booster-to-master cylinder O-ring is
in place and the mating faces are clean.
12. Bleed the master cylinder. For additional information, refer to Component Bleeding in Section 206-00 .
13. If equipped with a manual transmission, bleed the hydraulic clutch system. For additional information,
Brake Fluid Reservoir
Material
Item Specification
(Canada)

1 2162 Brake fluid reservoir cap (also part of 2K478)
2 W711330 Brake fluid reservoir nuts - 7 Nm (62 lb-in)
3 2K478 Brake fluid reservoir
NOTICE: 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.
1. Refer to exploded view and any Warnings, Notices, Materials and Specifications. Items in the exploded
views may not be listed in order of removal.
SECTION 206-07: Power Brake Actuation 2011 Fiesta Workshop Manual
Brake booster nuts 25 18
Brake Booster
The brake booster consists of:
brake booster assembly

brake booster vacuum hose
brake booster vacuum check valve
The brake booster is a single-diaphragm type which utilizes engine vacuum to reduce brake pedal effort
and travel. The brake booster is divided into separate vacuum and atmospheric chambers by the
diaphragms. Engine vacuum is supplied to the brake booster through the brake booster hose and a one-
way check valve. The check valve retains the engine vacuum in the brake booster and allows for several
power-assisted brake applications with the engine off.
When the brake pedal is applied, vacuum replaces the atmospheric pressure in the brake booster,
reducing the effort required at the brake pedal to slow the vehicle. When the brake pedal is released,
vacuum returns to the brake booster through the brake booster vacuum hose and check valve.
Brake Booster

1 9C490 Vacuum hose
2 — Spring clamp (part of 9C490)
3 2B195 Brake booster
4 2M078 Brake booster seal
5 W706840 Brake booster nut (4 required) - 25 Nm (18 lb-ft)
6 2L523 Brake booster push rod clevis locking pin
1. Remove the brake master cylinder. For additional information, refer to Brake Master Cylinder in Section
206-06 .
2. NOTICE: Do not service the brake pedal without first removing the stoplamp switch. Remove this
switch with the brake pedal in the at-rest position. Attempting to remove this switch when the
plunger is extended (during pedal apply) results in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
3. NOTICE: Do not service the brake pedal without first removing the cruise control deactivator
switch. Remove this switch with the brake pedal in the at-rest position. Attempting to remove this
switch when the plunger is extended (during pedal apply) results in damage to the switch.
Remove the cruise control deactivator switch. For additional information, refer to Section 419-03 .
4. NOTE: The brake booster push rod clevis locking pin is a one-time use only part. Any time the brake
booster push rod clevis locking pin is removed, install a new brake booster push rod clevis locking pin.
NOTE: Use an 11 mm, 12-point socket or wrench to compress the 2 locking tabs on the brake booster
push rod clevis locking pin.
Remove and discard the brake booster push rod clevis locking pin, then position the brake booster push
rod aside.
5. Remove the 4 brake booster nuts.

6. Remove the brake booster.
7. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch and cruise control deactivator switch. Install these switches with the booster push rod
attached to the brake pedal and with the brake pedal in the at-rest position. Installing these
switches with the brake pedal in any other position results in incorrect adjustment and damages
the switches.
8. Verify correct stoplamp switch and cruise control deactivator switch installation. For additional
information, refer to Brake Pedal Switch Adjustment in Section 206-09 .
SECTION 206-09: Anti-Lock Brake System (ABS) and Stability Control 2011 Fiesta Workshop Manual
Material
Capacity

(Canada)
ABS module-to-Hydraulic Control Unit (HCU) screws 2 — 18
Evaporator outlet tube bracket nut 8 — 71
HCU bracket bolts 24 18 —
HCU bracket-to-support plate bolts 9 — 80
HCU support plate bolts 9 — 80
Wheel speed sensor bolts 9 — 80
Anti-Lock Control
Anti-Lock Braking
The ABS consists of the following components:
ABS module — attached to the Hydraulic Control Unit (HCU) and cannot be serviced separately
from the HCU .
HCU — which contains several valves (inlet, outlet, isolation and dump) and the hydraulic pump
motor. The HCU is mounted on the RH side of the engine compartment and is serviced with the
ABS module.
Front wheel speed sensors — one sensor is located in each front wheel knuckle. The sensors are
serviced separately from the knuckle.
Rear wheel speed sensors — one sensor is located at each rear wheel end, is mounted to the
brake backing plate and can be serviced separately.
Wheel bearing magnetic strip — the wheel bearing magnetic strip is part of the wheel bearing and
is serviced with the bearing.
ABS aids in the prevention of wheel lock-up during braking events allowing the driver to maintain
steering control and stop in the shortest distance possible under most conditions. This is accomplished
by the ABS module and HCU modulating brake fluid pressure to the affected brake caliper(s) and wheel
cylinder(s).
When the ABS activates, the driver may notice the following operational symptoms:
A rumble or grinding sound may be heard ( HCU pump motor)

If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal ( HCU pump
motor and valves)
Electronic Brake Distribution (EBD)
The ABS module and HCU incorporate a strategy called Electronic Brake Distribution (EBD). The EBD
strategy uses the HCU as an electronic proportioning valve to create a balanced braking condition
between the front and rear wheels and minimize the chance of rear wheel lockup during hard braking. A
slight bump sensation may be felt in the brake pedal when EBD is active.
ABS with Advance Trac®
The ABS with Advance Trac® system consists of the same components as the conventional ABS above
with the following additional components:
Stability control sensors — located inside the Restraints Control Module (RCM) under the front
floor console, and contains several sensors (yaw rate, lateral and longitudinal accelerometers).
Steering wheel rotation sensor — is part of the Electronic Power Assist Steering (EPAS) column
assembly and is not available separately for service.
The Advance Trac® system is comprised of traction control and Electronic Stability Control (ESC). ABS
and the traction control portion of the Advance Trac® system will operate with the transmission in
reverse gear, but ESC will be disabled.
Traction Control System
The traction control system aids in the prevention of excessive wheel spin which allows the vehicle to
maintain traction during acceleration. This is accomplished in the same manner as anti-lock braking
(brake traction control) but also includes using the PCM for modulating engine torque (engine traction
control). The traction control system can be disabled by the driver through the message center. The
system will remain disabled until the driver enables it through the message center or until the ignition is
cycled to OFF and back to RUN.
Electronic Stability Control (ESC) System
The ESC system constantly monitors vehicle direction of travel relative to the intended course and aids
in keeping the vehicle traveling along that course. The ESC also aids in keeping the vehicle stable
during sudden or abrupt maneuvers. This is accomplished in the same manner as anti-lock braking and
traction control. ESC cannot be disabled by the driver.
When either of these 2 systems activate, the driver may notice the same operational symptoms as ABS
along with the following additional symptoms:
A small deceleration or a reduction in the acceleration of the vehicle (PCM modulating engine
torque)
The stability/traction control indicator (also known as the sliding-car icon) flashes (indicating a
traction or stability event is taking place)
Stability/Traction Indicator
The stability/traction indicator (also known as the sliding-car icon) is located in the Instrument Panel
Cluster (IPC). It alerts the driver to a stability/traction event taking place (flashes twice per second) and
to alert the driver of potential concerns in the AdvanceTrac® system (illuminates solidly).
Stability/Traction OFF Indicator
The stability/traction OFF indicator (also known as the sliding-car OFF icon) is located in the IPC .
Illumination of the indicator confirms to the driver that the brake traction control portion of the Advance
Trac® system has been disabled when the TRACTION CNTRL setting in the message center is set to
OFF.
Hill Start Assist (Automatic transmission only)
Hill start assist helps the driver when accelerating from a stop on an incline or side of a hill. Hill start
assist supports the driver during drive-off situations on upward gradients. When the driver releases the
vehicle brake, hill start assist prevents the vehicle from rolling back in the opposite direction.
Anti-Lock Control
Special Tool(s)
Flex Probe Kit

Rotunda Active Wheel Speed

Sensor Tester

tool
Principles of Operations
Anti-Lock Braking
The ABS module continuously monitors and compares the rotational speed of each wheel. This is
accomplished through the use of 4 active wheel speed sensors, 1 for each wheel. The wheel speed
sensors are connected to the ABS module by 2 circuits. One circuit provides voltage for sensor
operation and the other circuit provides sensor input to the ABS module. As the wheels spin, the wheel
bearing magnetic strip passes through the magnetic field generated by the active wheel speed sensor.
The active wheel speed sensor sends a square wave signal to the ABS module to indicate individual
wheel speed.
The ABS module uses a Hydraulic Control Unit (HCU) to isolate and modulate hydraulic pressure to the
caliper(s) and wheel cylinder(s). The HCU contains several solenoid-controlled valves, a pump motor, an
accumulator and several sensors. The fluid flows through 4 normally open inlet valves inside the HCU ,
and through the outlet ports of the HCU to the brake calipers and wheel cylinders. If the ABS module
senses that a wheel is nearing a lockup condition based on wheel speed sensor data and deceleration
algorithms, the module closes the normally open inlet valve for that wheel. This isolates the
corresponding caliper or wheel cylinder. The ABS module reads the wheel speed sensor signal from the
affected wheel again. If the wheel is still decelerating (locking up), the module opens the normally closed
outlet valve allowing a controlled amount of hydraulic pressure in the brake caliper to be relieved into the
HCU accumulator. The ABS pump motor runs during an ABS braking event so sufficient brake fluid
pressure is consistently available to the HCU valves. This procedure of closing and opening valves is
repeated several times per second until the speed of the affected wheel matches the speeds of the other
wheels. Once this has been accomplished, the ABS module returns the solenoid valves to their normal
position.
The ABS module is self-monitoring. When the ignition is turned to the RUN position, the ABS module
carries out a preliminary electrical check of the wheel speed sensor circuitry by sending voltage through
the sensor and checking for the voltage to return. At speeds above 20 km/h (12 mph), without the brake
pedal being pressed, the pump motor is commanded on for approximately one-half second to check
pump motor operation. Also, during all phases of operation while the vehicle is in motion, the ABS
module checks for correct operation of the wheel speed sensors. In the event the ABS module detects a
concern, the module sets a DTC and sends a message to the Instrument Panel Cluster (IPC) over the
High Speed Controller Area Network (HS-CAN) to illuminate the yellow ABS warning indicator and/or the
stability/traction control indicator (sliding-car icon). If the concern is severe enough, ABS may be
disabled. Normal power-assisted braking, however, remains.
Electronic Brake Distribution (EBD)
The ABS module incorporates a strategy called Electronic Brake Distribution (EBD). The EBD strategy
uses the HCU as an electronic proportioning valve. On initial application of the brake pedal, full pressure
is applied to the rear brakes. The ABS module uses wheel speed input to calculate an estimated rate of
deceleration. Once vehicle deceleration exceeds a certain threshold, the ABS module closes the
appropriate solenoid valves in the HCU to hold the rear brake pressure constant while allowing the front
brake pressure to build. This creates a balanced braking condition between the front and rear wheels
and minimizes the chance of rear wheel lockup during hard braking. As the vehicle decelerates, the
valves are opened to increase the rear brake pressure in proportion to the front brake pressure.
If there is a DTC in the ABS module specifically for the HCU or there are 2 or more wheel speed sensor
DTCs set, EBD is disabled. When EBD is disabled, the ABS warning indicator, the red brake warning
indicator and the stability/traction control indicator (sliding-car icon) illuminate.
AdvanceTrac® Stability Enhancement System
The AdvanceTrac® system provides the following stability enhancement features for certain driving
situations:
Traction Control System — helps to avoid excessive drive-wheel spin and loss of traction.
Electronic Stability Control (ESC) System — helps to avoid skids and lateral slides.
Traction Control System
The traction control system uses the ABS and the PCM to limit wheel spin. When the ABS module
detects a wheel spinning excessively, brake pressure to the appropriate brake caliper is modulated. This
is accomplished by opening and closing the appropriate solenoid valves inside the HCU while the
hydraulic pump motor is activated. At the same time, the ABS module sends a message over the HS-
CAN that a traction control event is taking place. When the IPC receives this message, it flashes the
stability/traction control indicator (sliding-car icon). If the event is severe enough, the ABS module sends
a message to the PCM over the HS-CAN to assist with traction control. When the PCM receives this
message, it adjusts engine timing and decreases fuel injector pulses. Once the affected wheel returns to
normal speed, the ABS module returns the solenoid valves in the HCU to their normal position,
deactivates the hydraulic pump motor and sends another message over the HS-CAN indicating the
traction event has ended. The PCM returns engine timing and fuel injectors to normal operation and the
IPC extinguishes the sliding-car icon.
Once vehicle speed reaches or exceeds 100 km/h (62 mph), traction control is accomplished only
through PCM intervention.
Certain DTCs in the ABS module disable the traction control system. Depending on the DTCs present,
the yellow ABS warning indicator and/or the sliding-car icon is illuminated.
The driver is able to enable and disable the traction control portion of the Advance Trac®. This is
independent of the ABS and ESC functions, which cannot be disabled by the driver. To disable or
enable the traction control system, the TRACTION CNTRL setting in the message center is changed
from ON to OFF. When the driver disables the traction control system, the IPC communicates traction
control system status to the ABS module over the HS-CAN bus. The ABS module will no longer
intervene when a traction event is detected. The ABS module sends a message to the IPC over the to
HS-CAN bus illuminate the stability/traction control OFF indicator (sliding-car OFF icon), which indicates
to the driver that the traction control system is disabled. The system automatically restores to full
functionality when the ignition is cycled to OFF and then back to RUN.
Electronic Stability Control (ESC) System
The ESC system is controlled by the ABS module and uses the same wheel speed sensors and wheel
bearing magnetic strips used for anti-lock braking. The ESC system also uses input from the stability
control sensors for the ESC system to help maintain vehicle stability. They include the yaw rate sensor,
lateral accelerometer and longitudinal accelerometer and are located in the Restraints Control Module
(RCM).
The ABS module uses the various sensors to continuously monitor vehicle direction of travel relative to
the intended course. If the ABS module determines from all these inputs that the vehicle is unable to
travel in the intended direction, it modulates brake pressure to the appropriate brake caliper(s) or wheel
cylinder(s) by opening and closing the appropriate solenoid valves inside the HCU while the hydraulic
pump motor is activated. At the same time, the ABS module sends a message over the HS-CAN that a
stability event is taking place. When the IPC receives this message, it flashes the sliding-car icon. Under
certain conditions during a stability event, the PCM may be requested to reduce engine torque as it does
for traction control. Once the stability condition has been corrected, the ABS module sends another
message over the HS-CAN indicating that the event has ended. The PCM returns engine timing and fuel
injectors to normal operation and the IPC extinguishes the sliding-car icon.
Certain DTCs being present in the ABS module may disable the ESC system. Depending on the DTCs
present, the yellow ABS warning indicator and/or the sliding-car icon is illuminated.
Hill Start Assist (Automatic transmission only)
Hill start assist helps the driver when accelerating from a stop on an incline or side of a hill. Hill start
assist supports the driver during drive-off situations on upward gradients when the driver releases the
vehicle brake by preventing the vehicle from rolling back in the opposite direction. The system engages
automatically when the following conditions are met:
Road inclination of approximately 4 degrees or more is detected.

The driver applies the vehicle brake and the vehicle is at a complete stop.
The vehicle transmission information must indicate that the driver intends to drive up the hill.
The parking brake is not engaged.
When the driver releases the brake pedal in drive gear, hill start assist holds the car stationary for up to
3 seconds giving the driver time to accelerate the vehicle. As the vehicle accelerates hill start assist
gradually reduces the brake pressure to ensure that the vehicle is neither rolling back nor driving off until
there is sufficient driving torque to accelerate the vehicle forward. Hill start assist functions if the vehicle
is facing downhill if the reverse gear is selected.
There is 1 message displayed by the multifunction display that informs the driver of the status of the hill
start assist. HILL START ASSIST NOT AVAILABLE is displayed and the hill start assist telltale in the
IPC is illuminated when it is not available.
Stability Control Sensors
The stability control sensors for the ESC system include the yaw rate sensor, lateral accelerometer and
longitudinal accelerometer. The sensors are housed in the RCM which sends sensor information to the
ABS module over a dedicated Controller Area Network (CAN). If any of the sensors are defective, install
a new RCM .
The yaw rate sensor measures the relative vehicle motion about the vertical axis through its
center of gravity.
The lateral accelerometer measures the acceleration that corresponds to the force involved when
the vehicle moves sideways.
The longitudinal accelerometer measures the acceleration corresponding to the force involved
when the vehicle moves forward and rearward in the horizontal plane, along the centerline of the
vehicle front and rear wheels.
Lateral acceleration has 2 forms. The first is the centrifugal acceleration that occurs when the vehicle
travels around in a circle. The second is the acceleration due to gravity. On level ground there is no
contribution from this acceleration. However, if the vehicle is parked sideways on a bank or incline, the
sensor measures some lateral acceleration due to gravity, even though the vehicle is not moving.
Steering Sensor
The Power Steering Control Module (PSCM) uses the steering sensor to determine speed and rotation
direction of the steering wheel. This information is transmitted to the ABS module along the HS-CAN .
The sensor is attached to the Electronic Power Assist Steering (EPAS) column assembly and cannot be
serviced separately.
ABS Module Configuration
ABS module configuration is a scan tool process which configures specific vehicle settings in a new ABS
module. If installing a new ABS module, it must be configured. Refer to Programmable Module
Installation (PMI) in Section 418-01 .
ABS Module Calibration
The calibration procedure is also required for the ABS module to learn the "zero-position" of the steering
and stability control sensors.
To calibrate the ABS module, connect the scan tool and carry out the IVD Initialization sequence,
following the scan tool directions. The vehicle must be on a level surface and not moving during
calibration. If a DTC is retrieved after calibration, refer to the ABS Module DTC Chart in this section.
2. Verify the stoplamps operate correctly by pressing and releasing the brake pedal. If the stoplamps
do not operate correctly, refer to Section 417-01 . If the stoplamps operate correctly, proceed to
the next step.

Base brake system ABS module
Hydraulic Control Unit (HCU) Battery Junction Box (BJB) fuse(s):
Incorrectly inflated tires 1 (40A)
Mismatched wheels or tires on vehicle 9 (20A)
Suspension components Central Junction Box (CJB) fuse(s):
Wheel bearing magnetic strip 22 (7.5A)
Stoplamp switch
PCM
Wheel speed sensors

tool.


418-00 .
9. Clear the continuous DTCs and carry out the self-test diagnostics for the ABS module.
10. If the DTCs retrieved are related to the concern, go to the ABS Module DTC Chart or the IPC
DTC Chart. For all other DTCs, refer to Section 419-10 .
DTC Charts
ABS Module DTC Chart
C0001:49 TCS Control Channel "A" This DTC indicates that part of the ABS module has failed
Valve 1: Internal Electronic internally. CLEAR the DTCs. REPEAT the self-test. If DTC
Failure C0001:49 returns, INSTALL a new ABS module. REFER to
Hydraulic Control Unit (HCU) in this section. TEST the
C0002:49 TCS Control Channel "A" This DTC indicates that part of the ABS module has failed
C0003:49 TCS Control Channel "B" This DTC indicates that part of the ABS module has failed
C0004:49 TCS Control Channel "B" This DTC indicates that part of the ABS module has failed
C0010:49 Left Front Inlet Control: This DTC indicates that part of the ABS module has failed
Internal Electronic Failure internally. CLEAR the DTCs. REPEAT the self-test. If DTC
C0010:49 returns, INSTALL a new ABS module. REFER to
C0011:49 Left Front Outlet Control: This DTC indicates that part of the ABS module has failed
C0014:49 Right Front Inlet Control: This DTC indicates that part of the ABS module has failed
C0015:49 Right Front Outlet Control: This DTC indicates that part of the ABS module has failed
C0018:49 Left Rear Inlet Control: This DTC indicates that part of the ABS module has failed
C0019:49 Left Rear Outlet Control: This DTC indicates that part of the ABS module has failed
C001C:49 Right Rear Inlet Control: This DTC indicates that part of the ABS module has failed
C001C:49 returns, INSTALL a new ABS module. REFER to
C001D:49 Right Rear Outlet Control: This DTC indicates that part of the ABS module has failed
C001D:49 returns, INSTALL a new ABS module. REFER to
C0020:11 ABS Pump Motor Control: This DTC indicates that part of the ABS module has failed
Circuit Short To Ground internally. CLEAR the DTCs. TEST drive the vehicle.
REPEAT the self-test. DTC C0020:11 returns, INSTALL a
new ABS module. REFER to Hydraulic Control Unit (HCU)
C0020:12 ABS Pump Motor Control: This DTC indicates that part of the ABS module has failed
Circuit Short To Battery internally. CLEAR the DTCs. TEST drive the vehicle.
REPEAT the self-test. DTC C0020:12 returns, INSTALL a
C0020:13 ABS Pump Motor Control: GO to Pinpoint Test A .
Circuit Open
C0020:71 ABS Pump Motor Control: GO to Pinpoint Test A .
Actuator Stuck
C0030:07 Left Front Tone Wheel: GO to Pinpoint Test B .
Mechanical Failure
C0031:01 Left Front Wheel Speed GO to Pinpoint Test D .
Sensor: General Electrical
Failure
C0031:19 Left Front Wheel Speed GO to Pinpoint Test D .
Sensor: Circuit Current
Above Threshold
C0031:29 Left Front Wheel Speed GO to Pinpoint Test B .
Sensor: Signal Invalid
C0031:2F Left Front Wheel Speed GO to Pinpoint Test B .
Sensor: Signal Erratic
C0031:64 Left Front Wheel Speed GO to Pinpoint Test B .
Sensor: Signal Plausibility
Failure
C0033:07 Right Front Tone Wheel: GO to Pinpoint Test B .
Mechanical Failure
C0034:01 Right Front Wheel Speed GO to Pinpoint Test D .
Failure
C0034:19 Right Front Wheel Speed GO to Pinpoint Test D .
Above Threshold
C0034:29 Right Front Wheel Speed GO to Pinpoint Test B .
C0034:2F Right Front Wheel Speed GO to Pinpoint Test B .
C0034:64 Right Front Wheel Speed GO to Pinpoint Test B .
Failure
C0036:07 Left Rear Tone Wheel: GO to Pinpoint Test B .
Mechanical Failure
C0037:01 Left Rear Wheel Speed GO to Pinpoint Test D .
Failure
C0037:19 Left Rear Wheel Speed GO to Pinpoint Test D .
Above Threshold
C0037:29 Left Rear Wheel Speed GO to Pinpoint Test B .
C0037:2F Left Rear Wheel Speed GO to Pinpoint Test B .
C0037:64 Left Rear Wheel Speed GO to Pinpoint Test B .
Failure
C0039:07 Right Rear Tone Wheel: GO to Pinpoint Test B .
Mechanical Failure
C003A:01 Right Rear Wheel Speed GO to Pinpoint Test D .
Failure
C003A:19 Right Rear Wheel Speed GO to Pinpoint Test D .
Above Threshold
C003A:29 Right Rear Wheel Speed GO to Pinpoint Test B .
C003A:2F Right Rear Wheel Speed GO to Pinpoint Test B .
C003A:64 Right Rear Wheel Speed GO to Pinpoint Test B .
Failure
C0044:28 Brake Pressure Sensor "A": GO to Pinpoint Test C .
Signal Bias Level Out of
Range/Zero Adjustment
Failure
Internal Electronic Failure
Signal Plausibility Failure
C0061:28 Lateral Acceleration Sensor: GO to Pinpoint Test I .
Signal Bias Level Out of
Failure
C0061:64 Lateral Acceleration Sensor: GO to Pinpoint Test I .
C0062:28 Longitudinal Acceleration GO to Pinpoint Test I .
Sensor: Signal Bias Level
Out of Range/Zero
Adjustment Failure
Failure
Sensor: Wrong Mounting
Position
C0063:28 Yaw Rate Sensor: Signal GO to Pinpoint Test I .
Bias Level Out of
Failure
C0063:64 Yaw Rate Sensor: Signal GO to Pinpoint Test I .
Plausibility Failure
C1B00:29 Steering Angle Sensor: DTC C1B00:29 sets when the ABS module receives invalid
Signal Invalid data from the Power Steering Control Module (PSCM)
regarding the steering wheel angle sensor input. RETRIEVE
and REPAIR all non-network DTCs in the PSCM . REFER
to Section 211-00 .
Signal Plausibility Failure data from the PSCM regarding the steering wheel angle
sensor input. RETRIEVE and REPAIR all non-network
DTCs in the PSCM . REFER to Section 211-00 .
Signal Invalid data from the PSCM regarding the steering wheel angle
sensor input. RETRIEVE and REPAIR all non-network
DTCs in the PSCM . REFER to Section 211-00
U0001:88 High Speed CAN REFER to Section 418-00 to diagnose the network
Communication: Bus Off communication concern.
U0100:00 Lost Communication With GO to Pinpoint Test E .
ECM/PCM "A": No Sub Type
Information
U0101:00 Lost Communication With GO to Pinpoint Test F .
TCM: No Sub Type
Information
U0131:00 Lost Communication With GO to Pinpoint Test G .
Power Steering Control
Module: No Sub Type
Information
U0140:00 Lost Communication With GO to Pinpoint Test H .
Body Control Module: No
Sub Type Information
U0151:00 Lost Communication With GO to Pinpoint Test I .
Restraints Control Module:
U0151:88 Lost Communication With GO to Pinpoint Test J .
Bus Off
U0300:51 Internal Control Module CONFIGURE the ABS module. CARRY OUT
Software Incompatibility: Not Programmable Module Installation (PMI). REFER to Section
Programmed 418-01 . REPEAT the self-test. If U0300:51 returns,
INSTALL a new ABS module. REFER to Hydraulic Control
Unit (HCU) in this section. TEST the system for normal
operation.
U0401:68 Invalid Data received From DTC U0401:68 sets when the ABS module receives invalid
ECM/PCM "A": Event network data from the PCM. RETRIEVE and REPAIR all
Information non-network DTCs in the PCM. REFER to Section 303-14 .
TCM: Event Information network data from the TCM . RETRIEVE and REPAIR all
non-network DTCs in the TCM . REFER to Section 307-11 .
Power Steering Control network data from the PSCM . RETRIEVE and REPAIR all
Module: Event Information non-network DTCs in the PSCM . REFER to Section 211-00
Body Control Module: Event network data from the BCM . This DTC refers to the IPC not
Information the Body Control Module (BCM), this vehicle is using the
IPC as a gateway module. RETRIEVE and REPAIR all non-
network DTCs in the IPC . REFER to Section 413-01 .
U0452:68 Invalid Data received From GO to Pinpoint Test I .
Event Information
U2007:46 Valve(s): This DTC indicates that part of the ABS module has failed
Calibration/Parameter internally. CONFIGURE the ABS module. CARRY OUT
Memory Failure PMI . REFER to Section 418-01 . CLEAR the DTCs.
REPEAT the self-test. If DTC U2007:46 returns, INSTALL a
U2100:00 Initial Configuration Not CONFIGURE the ABS module. CARRY OUT PMI . REFER
Complete: No Sub Type to Section 418-01 . TEST the system for normal operation.
Information
Complete: General to Section 418-01 . REPEAT the self-test. If U2100:41
Checksum Failure returns, INSTALL a new ABS module. REFER to Hydraulic
Control Unit (HCU) in this section. TEST the system for
normal operation.
Complete: Missing to Section 418-01 . TEST the system for normal operation.
Calibration
U2100:55 Initial Configuration Not CONFIGURE the ABS module. CARRY OUT the PMI .
Complete: Not Configured REFER to Section 418-01 . TEST the system for normal
operation.
U2101:00 Control Module Configuration CONFIGURE the ABS module. CARRY OUT the PMI .
Incompatible: No Sub Type REFER to Section 418-01 . TEST the system for normal
Information operation.
CONFIGURE the ABS module. CARRY OUT the PMI .

REFER to Section 418-01. TEST the system for normal
operation.
U3000:41 Control Module: General This DTC sets if the vehicle battery is disconnected within 1
Checksum Failure minute of the ignition being turned OFF. This doesn't allow
enough time for the stability sensor information to be
recorded to the ABS module memory. CARRY out the IVD
Initialization sequence, following the scan tool directions.
CLEAR the DTCs. TEST the system for normal operation.
U3000:43 Control Module: Special CLEAR the DTCs. CARRY OUT the ABS module self-test.
Memory Failure RETRIEVE and RECORD any DTCs. If DTC U3000:43 is
retrieved again, INSTALL a new ABS module. REFER to
U3000:47 Control Module: Watchdog This DTC can set if the ABS module electrical connector is
Safety Failure not fully seated and locked. DISCONNECT the ABS module
C135. INSPECT the connector for bent or loose pins. If OK,
RECONNECT C135. CLEAR the DTCs. REPEAT the self-
test. If DTC U3000:47 is retrieved again, INSTALL a new
ABS module. REFER to Hydraulic Control Unit (HCU) in this
U3000:49 Control Module: Internal CLEAR the DTCs. CARRY OUT the ABS module self-test.
Electronic Failure RETRIEVE and RECORD any DTCs. If DTC U3000:49 is
retrieved again, INSTALL a new ABS module. REFER to
U3002:62 Vehicle Identification NOTE: This DTC sets if the ABS module cannot
Number: Signal Compare communicate with the IPC . Correct any network
Failure communications DTCs prior to diagnosing DTC U3002:62.
GO to Pinpoint Test K .
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test L .
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test L .
Symptom Chart
Symptom Chart
No communication Fuse REFER to Section 418-00 ,
with the ABS module Wiring, terminals The ABS Module Does Not
or connectors Respond To The Scan Tool.
ABS module
No communication Fuse REFER to Section 418-00 ,
with the Instrument Wiring, terminals The IPC Does Not Respond
Panel Cluster (IPC) or connectors To The Scan Tool.
IPC
The red brake Wiring, terminals REFER to Diagnosis and
warning indicator is or connectors Testing in Section 413-01 .
always/never on Brake fluid level
switch
Parking brake
switch
IPC
The yellow ABS Wiring, terminals RETRIEVE and RECORD
warning indicator is or connectors any ABS module DTCs. If
always/never on IPC DTCs are present, GO to the
ABS module ABS Module DTC Chart in
this section. If no DTCs are
present, REFER to Diagnosis
and Testing in Section 413-
01 .
If scan tool is unable to
communicate with the ABS
module, REFER to Section
418-00 .
The stability/traction Wiring, terminals RETRIEVE and RECORD
control indicator or connectors any ABS module DTCs. If
(sliding-car icon) is IPC DTCs are present, GO to the
never/always on ABS module ABS Module DTC Chart. If no
DTCs are present, REFER to
Diagnosis and Testing in
Section 413-01 .
The stability/traction Wiring, terminals RETRIEVE and RECORD
control OFF indicator or connectors any ABS module DTCs. If
(sliding-car OFF IPC DTCs are present, GO to the
icon) is never/always ABS module ABS Module DTC Chart. If no
on DTCs are present, REFER to
Diagnosis and Testing in
Section 413-01 .
Spongy brake pedal Air in the brake REFER to Section 206-00 .
with no warning hydraulic system
indicator Base brake
system
Unintended ABS Incorrect or worn INSPECT the wheels and
activation with no tires tires, front and rear
DTCs present Underinflated tire suspension and the wheel
(s) bearing magnetic strips.
Worn or REPAIR or INSTALL new as
damaged necessary.
suspension
components
Missing,
damaged or
misaligned wheel
bearing magnetic
strips
Pinpoint Tests
Pinpoint Test A: DTCs C0020:13, C0020:71
Normal Operation
The ABS module uses an internal solid state switch to operate the ABS pump motor. The ABS module
tests the ABS pump motor by activating it for 30 milliseconds. While the pump motor is being activated,
the ABS module monitors the voltage drop across the ABS pump motor solid state switch and the
amount of current the ABS pump motor draws through the solid state switch. If the voltage drop is too
high or if the ABS pump motor is drawing too much current, the ABS module sets a DTC. After 30
milliseconds have passed, the ABS module stops applying voltage to the pump motor and observes the
voltage that the spinning ABS pump motor is generating. The voltage generated by the motor indicates
how fast the motor is spinning. Voltage that is too low indicates that the motor is not spinning freely and
a DTC sets.
The ABS module uses fused battery voltage from Battery Junction Box (BJB) to power the ABS pump
motor. The ABS module provides ground for the ABS pump motor. Insufficient power or ground along
the circuits causes multiple DTCs to set.
C0020:13 (ABS Pump Motor Control: Circuit Open) — this DTC sets if the voltage supplied to the
ABS module is less than 10 volts, if there is an open or high resistance on the ABS pump motor
circuit between the ABS module and the Hydraulic Control Unit (HCU), or if the ABS module is
faulted internally.
C0020:71 (ABS Pump Motor Control: Actuator Stuck) — this DTC sets if the ABS module detects
that the ABS pump motor is not rotating when it is commanded to run.

Fuse
Hydraulic pump motor
ABS module
PINPOINT TEST A: DTCs C0020:13 AND C0020:71

A1 CHECK THE PUMP MOTOR (PMP_MTR) ACTIVE
COMMAND
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: TOGGLE the PMP_MTR active
DataLogger — ABS Module. command OFF. CLEAR the
Toggle the PMP_MTR active command ON. DTCs. DRIVE the vehicle at
Listen for the ABS pump motor noise, does the ABS speeds greater than 20 km/h
pump motor run for approximately 2 seconds? (12 mph). RETRIEVE the
DTCs. If DTC C0020:13 or 71
is retrieved, GO to A5 . For all
other ABS module DTCs, GO
to the DTC Chart in this
section. If no ABS module
DTCs are retrieved, the system
is operating correctly at this
time.
No
TOGGLE the PMP_MTR active
command OFF. GO to A2 .
A2 CHECK THE ABS MODULE GROUND EYELET
Ignition OFF. Yes
Remove the bolt retaining G107/G108 at the inner RF GO to A3 .
fender.
Clean the chassis mating surface and ground No
eyelets. The concern was caused by a
Install the ground eyelet to the chassis with the loose or corroded connector.
retaining bolt. CLEAR the DTCs. REPEAT
Ignition ON. self-test.
Enter the following diagnostic mode on the scan tool: Self
Test — ABS Module.
A3 CHECK THE PUMP MOTOR VOLTAGE SUPPLY TO THE
ABS MODULE
Ignition OFF. Yes
Disconnect: ABS module C135. GO to A4 .
Measure the voltage between ABS module C135-1, circuit
SBB01 (RD), harness side and ground. No
VERIFY that BJB fuse 1 (40A)
is OK. If OK, REPAIR circuit
SBB01 (RD).
If the fuse is not OK, REFER to

the Wiring Diagrams manual to
identify the cause of the circuit
short.
CLEAR the DTCs and


A4 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN
OPEN
NOTE: Failure to disconnect the battery when instructed Yes

results in false resistance readings. Refer to Section 414- GO to A5 .
01 .
No
Ignition OFF. REPAIR circuit GD123
Disconnect: Battery Cable — Negative. (BK/GY) for an open circuit.
Measure the resistance between ABS module C135-47, CLEAR the DTCs. REPEAT
circuit GD123 (BK/GY), harness side and ground. the self-test.

A5 CHECK FOR CORRECT ABS MODULE OPERATION
Connect: Battery Cable — Negative. Yes
Check ABS module C135 for: INSTALL a new ABS module.
corrosion. REFER to Hydraulic Control
pushed-out pins. Unit (HCU) in this section.
spread terminals.
Connect: ABS Module C135. CLEAR the DTCs. DRIVE the
Make sure the connector is seated correctly, then operate vehicle at speeds greater than
the system and verify the concern is still present. 20 km/h (12 mph). TEST the
No
Pinpoint Test B: DTCs C0030:07; C0031:29, 2F, 64; C0033:07; C0034:29, 2F, 64; C0036:07:
C0037:29, 2F, 64; C0039:07; C003A:29, 2F or C003A:64
Normal Operation
The wheel speed sensor and wheel bearing magnetic strip generate a square wave signal to the ABS
module that is proportional to wheel speed. The ABS module compares wheel speed inputs from all
wheel speed sensors to determine an impending wheel lockup.

C0030:07 — Left Front These DTCs set if there is damage to the wheel bearing magnetic
Tone Wheel: Mechanical strip or damage to the wheel bearing, or contamination or
Failure deformation of the bearing seal.
C0033:07 — Right Front
Tone Wheel: Mechanical
Failure
C0036:07 — Left Rear
Failure
C0039:07 — Right Rear
Failure
C0031:29 — Left Front These DTCs set if any of the wheel bearing magnetic strips are
Wheel Speed Sensor: damaged or defective or not mounted properly. Also sets if the tire
Signal Invalid size is incorrect or incorrect wheel speed sensor or bearing is
C0031:64 — Left Front installed.
Wheel Speed Sensor:
Wheel Speed Sensor:
Signal Invalid
Wheel Speed Sensor:
Wheel Speed Sensor:
Signal Invalid
Wheel Speed Sensor:
C003A:29 — Right Rear
Wheel Speed Sensor:
Signal Invalid
Wheel Speed Sensor:
C0031:2F — Left Front These DTCs set if any of the wheel bearing magnetic strips are
Wheel Speed Sensor: damaged or defective or not mounted properly. Also sets if the tire
Signal Erratic size is incorrect, incorrect bearing is installed, or high frequency
C0034:2F — Right Front interference is present.
Wheel Speed Sensor:
Signal Erratic
C0037:2F — Left Rear
Wheel Speed Sensor:
Signal Erratic
C003A:2F — Right Rear
Wheel Speed Sensor:
Signal Erratic

Wheel speed sensor(s)
Wheel bearing magnetic strip(s)
ABS module
PINPOINT TEST B: DTC C0030:07; C0031:29, 2F, 64; C0033:07; C0034:29, 2F, 64; C0036:07:
C0037:29, 2F, 64; C0039:07; C003A:29, 2F or 64

B1 CHECK THE DTCs FROM THE SELF-TEST
Review the DTCs retrieved and recorded during Inspection Yes
and Verification. GO to Pinpoint Test D .
Are DTCs C0031:01; C0034:01; C0037:01 and/or
C003A:01 present? No
GO to B2 .
B2 CHECK THE TIRES SIZE AND PRESSURE
Verify that all tires and wheels are the same size and the tire Yes
size and inflation pressures are correct as indicated on the GO to B3 .
Vehicle Certification (VC) label.
Are the wheels and tires OK? No
INSTALL the correct size tire
or ADJUST tire pressure as
necessary.
B3 MONITOR THE WHEEL SPEED SENSOR PIDs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to B11 .
DataLogger — ABS Module.
Drive the vehicle at a speed greater than 20 km/h (12 mph) No
while monitoring the following PIDs: GO to B4 .
Left front wheel speed sensor (LF_WSPD)
Right front wheel speed sensor (RF_WSPD)
Left rear wheel speed sensor (LR_WSPD)
Right rear wheel speed sensor (RR_WSPD)
Are the wheel speed PIDs consistent with each other,
within 5 km/h (3 mph) and the vehicle speed as
indicated on the speedometer?
B4 CHECK THE WHEEL SPEED SENSOR FOR DAMAGE
NOTE: Examine the wheel speed sensor wire carefully with Yes
a good light source. Failure to verify damage in the wheel GO to B5 .
speed sensor wire can lead to unnecessary installation of a
new component. No
Inspect the wheel speed sensor and harness for abrasion, INSTALL a new wheel speed
broken connector tabs or water intrusion. sensor. REFER to Wheel
Is the wheel speed sensor and harness OK? Speed Sensor — Front , or
Wheel Speed Sensor —
Rear in this section. CLEAR
test.
B5 INSPECT THE WHEEL SPEED SENSOR MOUNTING
Ignition OFF. Yes
With the vehicle in NEUTRAL, position it on a hoist. Refer to GO to B6 .
Section 100-02 .
Inspect the wheel speed sensor and fastener for looseness. No
Are the wheel speed sensor and fastener tight? TIGHTEN the wheel speed
sensor to specification.
REFER to Specifications in
B6 CHECK WHEEL BEARING MAGNETIC STRIP FOR
DAMAGE
Inspect the wheel bearings for abnormal wear or roughness Yes
and for deformation or contamination of the seal and For wheel speed sensor
magnetic strip. testing with the Rotunda
Are the wheel bearing(s) OK? Active Wheel Speed Sensor
Tester, GO to B7 .
For wheel speed sensor

testing without the Rotunda
Active Wheel Speed Sensor
Tester, GO to B9 .
No
INSTALL a new wheel
bearing as necessary.
front wheel bearings or
Section 204-02 for rear wheel
bearings. CLEAR the DTCs.
B7 CHECK THE ABS MODULE OUTPUT USING THE
ROTUNDA ACTIVE WHEEL SPEED SENSOR TESTER
Ignition OFF. Yes
Disconnect: Suspect Wheel Speed Sensor. GO to B8 .
Connect the Rotunda Active Wheel Speed Sensor Tester to
the wheel speed sensor connectors. No
Select the correct system polarity on the Rotunda Active
Wheel Speed Sensor Tester and turn the power switch to
the ON position.
Is the module output LED illuminated?
B8 CHECK THE WHEEL SPEED SENSOR OUTPUT WITH THE
Raise the suspect wheel until it can spin freely. Refer to Yes
Section 100-02 . The system is operating
While monitoring the Rotunda Active Wheel Speed Sensor correctly at this time. The
Tester, slowly spin the suspect wheel. concern may have been
Do the sensor output LEDs illuminate and flash and is caused by a loose or
the current overload LED not illuminated? corroded connector. CLEAR
test.
No
If the current level LED is not
illuminated and the sensor
output LEDs do not illuminate
or if the current level LED is
illuminated red, INSTALL a
new wheel speed sensor.
REFER to Wheel Speed
Sensor — Front or Wheel
Speed Sensor — Rear in this
section. CLEAR the DTCs.
If the current level LED is not

illuminated and the sensor
output LEDs illuminate green,
but do not flash, INSPECT
the wheel bearing magnetic
strip(s) and INSTALL new if
necessary. If the wheel
bearing magnetic strip is OK,
INSTALL a new wheel speed
sensor. REFER to Wheel
Speed Sensor — Front or
Rear in this section. CLEAR
test.
B9 CHECK FOR CORRECT ABS MODULE OUTPUT
Ignition OFF. Yes
Disconnect: Suspect Wheel Speed Sensor. For vehicles built up to
Ignition ON. 1/14/2011, GO to B10 .
Vehicles Built Up To 1/14/2011 For vehicles built after

1/14/2011, GO to B11 .
No
GO to B12 .
For vehicles built up to 1/14/2011 , measure the voltage

between the suspect wheel speed sensor connector pins,
harness side as follows:
Vehicles Built Up To 1/14/2011

Connector-Pin/ Connector-Pin/
Location Circuit Circuit
LH front C150-1 C150-2
VCA03 (VT/WH) RCA17 (YE)

RH front C160-1 C160-2
VCA05 (GY/VT) RCA19 (VT)

LH rear C440-1 C440-2
VCA04 (BU/OG) RCA18 (BN/GN)

RH rear C426-1 C426-2
VCA06 (WH/OG) RCA20 (BN)
Vehicles Built After 1/14/2011

For vehicles built after 1/14/2011 , measure the voltage

Location Circuit Circuit
LH front C1315-1 C1315-2

RH front C1316-1 C1316-2

LH rear C4296-1 C4296-2

RH rear C4318-1 C4318-2

B10 CHECK THE WHEEL SPEED SENSOR OUTPUT
NOTE: Digital Multimeter must have the leads in the current Yes
sensing ports and the correct range selected. GO to B12 .
For LF wheel speed sensor DTCs : No
connect the meter between LF wheel speed sensor INSTALL a new wheel speed
C150-1, circuit VCA03 (VT/WH), harness side and LF sensor. REFER to Wheel
wheel speed sensor pin 1, component side. Speed Sensor — Front , or
connect a fused jumper wire between LF wheel speed Wheel Speed Sensor —
sensor C150-2, circuit RCA17 (YE), harness side and Rear in this section. CLEAR
LF wheel speed sensor pin 2, component side. the DTCs. REPEAT the self-
For RF wheel speed sensor DTCs : test.
connect the meter between RF wheel speed sensor
C160-1, circuit VCA05 (GY/VT), harness side and RF
wheel speed sensor pin 1, component side.
connect a fused jumper wire between RF wheel
speed sensor C160-2, circuit RCA19 (VT), harness
side and RF wheel speed sensor pin 2, component
side.
For LR wheel speed sensor DTCs :
connect the meter between LR wheel speed sensor
C440-1, circuit VCA04 (BU/OG), harness side and LR
wheel speed sensor pin 1, component side.
connect a fused jumper wire between LR wheel
speed sensor C440-2, circuit RCA18 (BN/GN),
harness side and LR wheel speed sensor pin 2,
component side.
For RR wheel speed sensor DTCs :
connect the meter between RR wheel speed sensor
C426-1, circuit VCA06 (WH/OG), harness side and
RR wheel speed sensor pin 1, component side.
connect a fused jumper wire between RR wheel
speed sensor C426-2, circuit RCA20 (BN), harness
side and RR wheel speed sensor pin 2, component
side.
Ignition ON.
Measure the current while slightly rotating the wheel, using
incremental turns.
Does the digital multimeter indicate the current switches
between the low state (5 to 8 mA) and the high state (12
to 16 mA)?
B11 CHECK THE OUTPUT OF THE WHEEL SPEED SENSOR
NOTE: Digital Multimeter must have the leads in the current Yes
sensing ports and the correct range selected. GO to B12 .
For LF wheel speed sensor DTCs : No
connect the meter between LF wheel speed sensor INSTALL a new wheel speed
C1316-1, circuit VCA03 (VT/WH), harness side and sensor. REFER to Wheel
LF wheel speed sensor pin 1, component side. Speed Sensor — Front , or
connect a fused jumper wire between LF wheel speed Wheel Speed Sensor —
sensor C1316-2, circuit RCA17 (YE), harness side Rear in this section. CLEAR
and LF wheel speed sensor pin 2, component side. the DTCs. REPEAT the self-
For RF wheel speed sensor DTCs : test.
connect the meter between RF wheel speed sensor
C1315-1, circuit VCA05 (GY/VT), harness side and
RF wheel speed sensor pin 1, component side.
connect a fused jumper wire between RF wheel
speed sensor C1315-2, circuit RCA19 (VT), harness
side and RF wheel speed sensor pin 2, component
side.
For LR wheel speed sensor DTCs :
connect the meter between LR wheel speed sensor
C4296-1, circuit VCA04 (BU/OG), harness side and
LR wheel speed sensor pin 1, component side.
connect a fused jumper wire between LR wheel
speed sensor C4296-2, circuit RCA18 (BN/GN),
harness side and LR wheel speed sensor pin 2,
component side.
For RR wheel speed sensor DTCs :
connect the meter between RR wheel speed sensor
C4318-1, circuit VCA06 (WH/OG), harness side and
RR wheel speed sensor pin 1, component side.
connect a fused jumper wire between RR wheel
speed sensor C4318-2, circuit RCA20 (BN), harness
side and RR wheel speed sensor pin 2, component
side.
Ignition ON.
Measure the current while slightly rotating the wheel, using
incremental turns.
Does the digital multimeter indicate the current switches
between the low state (5 to 8 mA) and the high state (12
to 16 mA)?
B12 CHECK FOR CORRECT ABS MODULE OPERATION
Ignition OFF. Yes
Disconnect: ABS Module C135. INSTALL a new ABS module.
Check for: REFER to Hydraulic Control
corrosion Unit (HCU) in this section.
pushed-out pins TEST the system for normal
spread terminals operation.
Connect: ABS Module C135.
Connect: Suspect Wheel Speed Sensor. No
Make sure the connector is seated correctly, then operate The system is operating
the system and verify the concern is still present. correctly at this time. The
Is the concern still present? concern may have been
test.
Pinpoint Test C: DTCs C0044:28, C0044:49 and C0044:64
Normal Operation
The ABS module uses internal pressure sensors to determine correct operation by monitoring internal
Hydraulic Control Unit (HCU) hydraulic pressures. These DTCs set if the brake pressure sensor signals
do not match. This fault could set by either an internal ABS module failure or a pressure sensor failure.
The pressure sensors are internal to the HCU and cannot be serviced separately.
DTC C0044:28 (Brake Pressure Sensor "A": Signal Bias Level Out of Range / Zero Adjustment
Failure) — this DTC sets if the brake pressure sensor signals do not match. This fault could set
by a misadjusted stoplamp switch or improperly installed brake pedal. An internal ABS module
failure or a pressure sensor failure can also cause this DTC to set. When the ABS module sets
DTC C0044:28, a message is also sent to the Transmission Control Module (TCM) along the
High Speed Controller Area Network (HS-CAN) bus. After received this message from the ABS
module, the TCM places the automatic transmission into NEUTRAL. There is no corresponding
DTC set in the Transmission Control Module (TCM).
DTC C0044:49 (Brake Pressure Sensor "A": Internal Electronic Failure) — this DTC sets if the
brake pressure sensor signals do not match. This fault could set by either an internal ABS module
failure or a pressure sensor failure.
DTC C0044:64 (Brake Pressure Sensor "A": Signal Plausibility Failure) — this DTC sets if the
brake pressure sensor signals do not match. This fault could set by either an internal ABS module
failure or a pressure sensor failure.

ABS module
HCU
PINPOINT TEST C: DTCs C0044:28, C0044:49 AND C0044:64

C1 CHECK THE STOPLAMP SWITCH, CRUISE
CONTROL DEACTIVATOR SWITCH AND BRAKE
PEDAL AND BRACKET
Inspect the stoplamp switch, cruise control Yes
deactivator switch and brake pedal assembly, If DTC C0044:28 is set, GO to C3 .
verify there is no brake pedal pressure
unintentionally applied due to incorrect Otherwise, GO to C2 .
stoplamp switch, cruise control deactivator
switch or brake pedal installation. No
Are the stoplamp switch, cruise control REPAIR or INSTALL new components as
deactivator switch and brake pedal OK? necessary. REFER to Section 206-06 .
C2 CHECK FOR DTC C0044:49 AND/OR
C0044:64 TO RETURN
Ignition ON. Yes
Using a scan tool, clear all ABS module GO to C3 .
CMDTCs .
Test drive the vehicle at speeds greater than No
32 km/h (20 mph). The system is operating correctly at this
Enter the following diagnostic mode on the time. The concern may have been caused
scan tool: Self Test — ABS Module. by air trapped in the hydraulic brake
Is DTC C0044:49 and/or C0044:64 present? system. REFER to Section 206-00 on
bleeding the base brake system. TEST the
C3 CARRY OUT THE BRAKE PEDAL SWITCH
ADJUSTMENT PROCEDURE
Refer to Brake Pedal Switch Adjustment in this Yes
section. GO to C4 .
Did the stoplamp switch and cruise control
deactivator switch pass the brake pedal No
switch adjustment test? INSTALL a new stoplamp switch or cruise
control deactivator switch as required.
REFER to Section 417-01 (stoplamp
switch) or Section 419-03 (cruise control
deactivator switch).
C4 CHECK FOR CORRECT ABS MODULE TO
HCU TORQUE VALUES
Verify all ABS module-to- HCU fasteners are Yes
tightened to their correct torque specifications. INSTALL a new ABS module. REFER to
Refer to Specifications in this section. Hydraulic Control Unit (HCU) in this
Are the ABS module-to- HCU fasteners section. TEST the system for normal
tightened correctly? operation.
No
TIGHTEN all ABS module-to- HCU
fasteners. CLEAR the DTCs. GO to C5 .
C5 CHECK FOR DTCs C0044:28, C0044:49
AND/OR C0044:64
Test drive the vehicle at speeds greater than Yes
32 km/h (20 mph). INSTALL a new HCU . REFER to
Enter the following diagnostic mode on the Hydraulic Control Unit (HCU) in this
scan tool: Self Test — ABS Module. section. TEST the system for normal
Record all ABS module DTCs. operation.
Is DTC C0044:28, C0044:49 and/or C0044:64
present? No
The system is operating correctly at this
time. The concern was likely cause by
incorrectly tightened fasteners.
Pinpoint Test D: DTCs C0031:01; C0034:01; C0037:01, C003A:01, C0031:19, C0034:19, C0037:19,
C003A:19
Normal Operation
Active wheel speed sensors generate a square wave signal that is sent to the 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 switch is turned to the RUN position, the ABS module carries out a self-
test by sending a reference voltage through the wheel speed sensors and their circuitry to determine if
they are functional.

C0031:01 — Left Front These DTCs set if any of the wheel speed sensor's signal
Wheel Speed Sensor: current is below 4.5 mA or above 20 mA for longer than 140
General Electrical Failure milliseconds, or if either sensor circuit is shorted to ground or
C0034:01 — Right Front battery voltage.
Wheel Speed Sensor:
General Electrical Failure
C0037:01 — Left Rear Wheel
Speed Sensor: General
Electrical Failure
Wheel Speed Sensor:
C0031:19 — LF Wheel
Speed Sensor Signal: Circuit
Current Above Threshold
C0034:19 — RF Wheel
C0037:19 — LR Wheel
C003A:19 — RR Wheel

Wheel speed sensors
ABS module
PINPOINT TEST D: DTCs C0031:01; C0034:01; C0037:01, C003A:01, C0031:19, C0034:19,

C0037:19, C003A:19

D1 CHECK FOR FAULT REPEATABILITY
Ignition ON. Yes
Using the scan tool, clear the ABS module DTCs. If the Rotunda Active Wheel
Drive the vehicle at least 20 km/h (12 mph). Speed Sensor Tester is
Enter the following diagnostic mode on the scan tool: Self available, GO to D2 . If the
Test — ABS Module. Rotunda Active Wheel
Is the concern still present? Speed Sensor Tester is not
available, GO to D4 .
No
INSPECT the wheel speed
sensors, wheel speed
sensor wiring and wheel
bearing magnetic strip.
REPAIR or INSTALL new
as necessary. If any other
DTCs are retrieved, GO to
the ABS Module DTC Chart
in this section.
D2 CHECK THE ABS MODULE OUTPUT USING THE ROTUNDA
ACTIVE WHEEL SPEED SENSOR TESTER
Ignition OFF. Yes
Disconnect: Suspect Wheel Speed Sensor. GO to D3 .
Connect the Rotunda Active Wheel Speed Sensor Tester to
the wheel speed sensor connectors. No
Ignition ON. GO to D6 .
Select the correct system polarity on the Rotunda Active
Wheel Speed Sensor Tester and turn the power switch to the
ON position.
Is the module output LED illuminated?
D3 CHECK THE WHEEL SPEED SENSOR OUTPUT WITH THE
Raise the suspect wheel until it can spin freely. Refer to Yes
Section 100-02 . The system is operating
While monitoring the Rotunda Active Wheel Speed Sensor correctly at this time. The
Tester, slowly spin the suspect wheel. concern may have been
Do the sensor output LEDs illuminate and flash and is the caused by a loose or
current overload LED not illuminated? corroded connector. CLEAR
self-test.
No
If the current level LED is
not illuminated and the
sensor output LEDs do not
illuminate or if the current
level LED is illuminated red,
INSTALL a new wheel
speed sensor. REFER to
Front or Wheel Speed
Sensor — Rear in this
If the current level LED is

not illuminated and the
sensor output LEDs
illuminate green, but do not
flash, INSPECT the wheel
bearing magnetic strip and
INSTALL new if necessary.
If the wheel bearing
magnetic strip is OK,
INSTALL a new wheel
Front or Wheel Speed
D4 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A
SHORT TO BATTERY VOLTAGE
Ignition OFF. Yes
Disconnect: ABS Module C135. REPAIR the affected circuit
Disconnect: Suspect Wheel Speed Sensor. (s) for a short to voltage.
Ignition ON. CLEAR the DTCs. REPEAT
For DTC C0031:01, 19 (LF) , measure the voltage between: the self-test.
ABS module C135-45, circuit VCA03 (VT/WH),
ABS module C135-46, circuit RCA17 (YE), harness GO to D5 .
side and ground.
For DTC C0034:01, 19 (RF) , measure the voltage between:

ABS module C135-33, circuit RCA19 (VT), harness
side and ground.
ABS module C135-34, circuit VCA05 (GY/VT), harness
side and ground.
For DTC C0037:01, 19 (LR) , measure the voltage between:

ABS module C135-36, circuit VCA04 (BU/OG),
ABS module C135-37, circuit RCA18 (BN/GN),
For DTC C003A:01, 19 (RR) , measure the voltage between:
ABS module C135-42, circuit RCA20 (BN), harness
side and ground.
ABS module C135-43, circuit VCA06 (WH/OG),

D5 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
For DTC C0031:01, 19 (LF) , measure the resistance GO to D6 .
between:
ABS module C135-45, circuit VCA03 (VT/WH), No
harness side and ground. REPAIR the affected circuit
ABS module C135-46, circuit RCA17 (YE), harness (s) for a short to ground.
side and ground. CLEAR the DTCs. REPEAT
the self-test.
For DTC C0034:01, 19 (RF) , measure the resistance

between:
ABS module C135-34, circuit VCA05 (GY/VT), harness
side and ground.
ABS module C135-33, circuit RCA19 (VT), harness
side and ground.
For DTC C0037:01, 19 (LR) , measure the resistance

between:
ABS module C135-36, circuit VCA04 (BU/OG),
ABS module C135-37, circuit RCA18 (BN/GN),
For DTC C003A:01, 19 (RR) , measure the resistance

between:
ABS module C135-43, circuit VCA06 (WH/OG),
ABS module C135-42, circuit RCA20 (BN), harness
side and ground.
D6 CHECK THE WHEEL SPEED CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: ABS Module C135 (if not previously GO to D7 .
disconnected).
Disconnect: Suspect Wheel Speed Sensor (if not previously No
disconnected). REPAIR the affected circuit
(s). CLEAR the DTCs.
Vehicles Built Up To 1/14/2011 REPEAT the self-test.
For vehicles built up to 1/14/2011 , measure the resistance

between ABS module connector C135, harness side and the
suspect wheel speed sensor connector, harness side as
indicated in the following chart:

ABS Wheel Speed
DTC Module Circuit Sensor
C0031:01, C135-45 VCA03 C150-1
19 (VT/WH)
C135-46 RCA17 (YE) C150-2
C0034:01, C135-34 VCA05 C160-1
19 (GY/VT)
C135-33 RCA19 (VT) C160-2
C0037:01, C135-36 VCA04 C440-1
19 (BU/OG)
C135-37 RCA18 C440-2
(BN/GN)
C003A:01, C135-43 VCA06 C426-1
19 (WH/OG)
C135-42 RCA20 (BN) C426-2
For vehicles built after 1/14/2011 , measure the resistance

between ABS module connector C135, harness side and the
suspect wheel speed sensor connector, harness side as
indicated in the following chart:

ABS Wheel Speed
DTC Module Circuit Sensor
C0031:01, C135-45 VCA03 C1315-1
19 (VT/WH)
C135-46 RCA17 (YE) C1315-2
C0034:01, C135-34 VCA05 C1316-1
19 (GY/VT)
C135-33 RCA19 (VT) C1316-2
C0037:01, C135-36 VCA04 C4296-1
19 (BU/OG)
C135-37 RCA18 C4296-2
(BN/GN)
C003A:01, C135-43 VCA06 C4318-1
19 (WH/OG)
C135-42 RCA20 (BN) C4318-2

D7 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS
Vehicles Built Up To 1/14/2011 Yes
GO to D8 .
No
REPAIR the affected circuit
For vehicles built up to 1/14/2011 , measure the resistance

DTC Circuit Circuit
C0031:01, C150-1 C150-2
19
C0034:01, C160-1 C160-2
19
C0037:01, C440-1 C440-2
19
C003A:01, C426-1 C426-2
19
For vehicles built after 1/14/2011 , measure the resistance


DTC Circuit Circuit
C0031:01, C1316-1 C1316-2
19
C0034:01, C1315-1 C1315-2
19
C0037:01, C4296-1 C4296-2
19
C003A:01, C4318-1 C4318-2
19
Is the resistance greater 10,000 ohms?

D8 CHECK FOR CORRECT ABS MODULE OUTPUT
Connect: ABS Module C135. Yes
Ignition ON. INSTALL a new wheel
Vehicles Built Up To 1/14/2011 Wheel Speed Sensor —
Front , or Wheel Speed
No
GO to D9 .
For vehicles built up to 1/14/2011 , measure the voltage


DTC Circuit Circuit
C0031:01, C150-1 C150-2
19
C0034:01, C160-1 C160-2
19
C0037:01, C440-1 C440-2
19
C003A:01, C426-1 C426-2
19

For vehicles built after 1/14/2011 , measure the voltage

DTC Circuit Circuit
C0031:01, C1316-1 C1316-2
19
C0034:01, C1315-1 C1315-2
19
C0037:01, C4296-1 C4296-2
19
C003A:01, C4318-1 C4318-2
19

D9 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect: ABS Module C135. Yes
Check for: INSTALL a new ABS
corrosion module. REFER to
pushed-out pins Hydraulic Control Unit
spread terminals (HCU) in this section. TEST
Connect: ABS Module C135. the system for normal
Make sure the connector is seated correctly, then operate the operation.
system and verify the concern is still present.
self-test.
Pinpoint Test E: DTC U0100:00
Normal Operation
DTC U0100:00 (Lost Communication With ECM/PCM "A": No Sub Type Information) — this DTC
sets if the brake pedal position switch, and traction control messages that should be received
from the ECM/PCM are missing for 5 seconds or longer.

PCM
ABS module
PINPOINT TEST E: DTC U0100

E1 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Using a scan tool, carry out the GO to E2 .
network test.
Does the PCM pass the network No
test? REFER to Section 418-00 .
E2 CHECK THE ABS MODULE
CMDTCs
on the scan tool: Self Test — ABS GO to E3 .
Module.
Using a scan tool, clear the ABS No
module DTCs. The system is operating correctly at this time. The
Ignition OFF. DTC may have been set due to high network traffic or
Ignition ON. an intermittent fault condition.
Enter the following diagnostic mode
on the scan tool: Self Test — ABS
Module.
Is DTC U0100:00 present?
E3 CHECK THE ABS MODULE FOR
BATTERY VOLTAGE DTCs
Review the ABS module DTCs Yes
retrieved in the previous step. GO to Pinpoint Test L .
U3003:17 present? No
GO to E4 .
E4 CHECK THE PCM CMDTCs
Using a scan tool, carry out the Yes
PCM Key ON Engine OFF (KOEO) DIAGNOSE the PCM DTCs. REFER to Section 414-
self-test. 00
Is DTC P1794:16 or P1794:17
present? No
GO to E5 .
E5 CHECK FOR DTC U0100 SET IN
OTHER MODULES
on the scan tool: Self Test — All INSTALL a new PCM. REFER to Section 303-14 .
CMDTCs . TEST the system for normal operation. REPEAT the
Is DTC U0100:00 or DTC U0100 ABS module self-test.
set in more than one module?
No
INSTALL a new ABS module. REFER to Hydraulic
Control Unit (HCU) in this section. TEST the system
Pinpoint Test F: DTC U0101:00
Normal Operation
DTC U0101:00 (Lost Communication With TCM: No Sub Type Information — this DTC sets in the
ABS module if the PRNDL message that should be received from the Transmission Control
Module (TCM) is missing for 5 seconds or longer.

TCM
ABS module
PINPOINT TEST F: DTC U0101

F1 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Using a scan tool, carry out the GO to F2 .
network test.
Does the TCM pass the network No
test? REFER to Section 418-00 .
F2 CHECK THE ABS MODULE
CMDTCs
on the scan tool: Self Test — ABS GO to F3 .
Module.
module DTCs. The system is operating correctly at this time. The
Ignition OFF. DTC may have been set due to high network traffic or
Ignition ON. an intermittent fault condition.
Enter the following diagnostic mode
on the scan tool: Self Test — ABS
Module.
F3 CHECK THE ABS MODULE FOR
GO to F4 .
F4 CHECK THE TCM CMDTCs
on the scan tool: Self Test — TCM . DIAGNOSE the TCM DTCs. REFER to Section 307-
Is DTC P0702, P0882 or P0883 11 .
present?
No
GO to F5 .
F5 CHECK FOR DTC U0101 SET IN
OTHER MODULES
on the scan tool: Self Test — All INSTALL a new TCM . REFER to Section 307-11 .
CMDTCs . TEST the system for normal operation. REPEAT the
Is DTC U0101:00 or DTC U0101 ABS module self-test.
No
Control Unit (HCU) in this section. TEST the system
Pinpoint Test G: DTC U0131:00
Normal Operation
DTC U0131:00 (Lost Communication With Power Steering Control Module: No Sub Type
Information) — this DTC sets if the steering sensor message that should be received from the
Power Steering Control Module (PSCM) is missing for 5 seconds or longer.

PSCM
ABS module
PINPOINT TEST G: DTC U0131:00

G1 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Using a scan tool, carry out the GO to G2 .
network test.
Does the PSCM pass the No
network test? REFER to Section 418-00 .
G2 CHECK THE ABS MODULE
CMDTCs
mode on the scan tool: Self Test GO to G3 .
— ABS Module.
module DTCs. The system is operating correctly at this time. The DTC
Ignition OFF. may have been set due to high network traffic or an
Ignition ON. intermittent fault condition.
Enter the following diagnostic
mode on the scan tool: Self Test
— ABS Module.
G3 CHECK THE ABS MODULE FOR
GO to G4 .
G4 CHECK THE PSCM CMDTCs
mode on the scan tool: Self Test DIAGNOSE the PSCM DTCs. REFER to Section 307-
— PSCM . 11 .
Is DTC P0702, P0882 or P0883
present? No
GO to G5 .
G5 CHECK FOR DTC U0131:00 SET
IN OTHER MODULES
mode on the scan tool: Self Test INSTALL a new PSCM . REFER to Section 211-00 .
— All CMDTCs . TEST the system for normal operation. CLEAR the
Is DTC U0131:00 or DTC U0131 DTCs. REPEAT the ABS module self-test.
No
normal operation.
Pinpoint Test H: DTCs U0140:00
Normal Operation
DTC U0140:00 (Lost Communication With Body Control Module: No Sub Type Information) —
this DTC sets in the ABS module if it cannot transmit or receive messages to the Body Control
Module (BCM) over the High Speed Controller Area Network (HS-CAN) for 5 seconds or longer.
This DTC is actually referring to the IPC as this vehicle is using the IPC as a gateway module and
never directly establishes communications with the BCM .

IPC
ABS module
PINPOINT TEST H: DTC U0140:00

H1 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Using a scan tool, carry out the GO to H2 .
network test.
Does the PSCM pass the No
network test? REFER to Section 418-00 .
H2 CHECK THE ABS MODULE
CMDTCs
mode on the scan tool: Self Test GO to H3 .
— ABS Module.
module DTCs. The system is operating correctly at this time. The DTC
Ignition OFF. may have been set due to high network traffic or an
Ignition ON. intermittent fault condition.
Enter the following diagnostic
mode on the scan tool: Self Test
— ABS Module.
H3 CHECK THE ABS MODULE FOR
GO to H4 .
H4 CHECK THE IPC CMDTCs
mode on the scan tool: Self Test DIAGNOSE the IPC DTCs. REFER to Section 413-01 .
— IPC .
Is DTC U3006:16 or U3006:17
present? No
GO to H5 .
H5 CHECK FOR DTC U0140:00 SET
IN OTHER MODULES
mode on the scan tool: Self Test INSTALL a new IPC . REFER to Section 413-01 .
— All CMDTCs . TEST the system for normal operation. CLEAR the
Is DTC U0140:00 or DTC U0140 DTCs. REPEAT the ABS module self-test.
No
normal operation.
Pinpoint Test I: DTC C0061:28, C0061:64, C0062:28, C0062:64, C0062:76, C0063:28, C0063:64,
U0151:00, U0452:68
Normal Operation
The ABS module uses information received from several sensors (wheel speed sensors, steering wheel
rotation sensor, stability/traction control system sensors, etc.) to determine if vehicle stability or traction
warrants ESC interaction. If an event is going to occur, the ABS module adjusts the brake torque at
specific wheels and the PCM reduces engine torque to make the vehicle more stable. Once the ABS
module has determined that the stability event has been corrected, it returns the brake and engine
torque to normal and continues to monitor the vehicle. DTCs set in the ignition cycle can only be cleared
by cycling the ignition off and on once the fault has been corrected. The Restraints Control Module
(RCM) measures the yaw rate and vehicle acceleration, then sends the signal through a secondary,
dedicated Controller Area Network (CAN) to the ABS module. This dedicated CAN is used only for
communication between the RCM and the ABS module. The ABS module uses this information for
AdvanceTrac® system operation. The ABS module also compares this information to information it
receives from other sensors (brake pedal input, steering wheel) to determine how valid the information is
and to determine if an instability event is about to occur. The yaw rate sensor, lateral and longitudinal
accelerometers are contained in the RCM .
DTC C0061:28 Lateral Acceleration Sensor: This DTC indicates that the lateral acceleration sensor
Signal Bias Level Out of Range/Zero signal is out of range.
Adjustment Failure
DTC C0061:64 Lateral Acceleration Sensor: This DTC sets if one of the sensor signals does not
Signal Plausibility Failure match the other sensor signals.
DTC C0062:28 Longitudinal Acceleration This DTC indicates that the longitudinal acceleration
Sensor: Signal Bias Level Out of sensor signal is out of range.
Range/Zero Adjustment Failure
DTC C0062:64 Longitudinal Acceleration This DTC sets if one of the sensor signals does not
Sensor: Signal Plausibility Failure match the other sensor signals.
DTC C0062:76 Longitudinal Acceleration This DTC sets if the RCM is loose or mounted
Sensor: Wrong Mounting Position incorrectly.
DTC C0063:28 Yaw Rate Sensor: Signal This DTC indicates that the yaw rate sensor signal is out
Bias Level Out of Range/Zero Adjustment of range.
Failure
DTC C0063:64 Yaw Rate Sensor: Signal This DTC sets if one of the sensor signals does not
Plausibility Failure match the other sensor signals.
DTC U0151:00 Lost Communication With This DTC sets in the ABS module if it does not receive
Restraints Control Module: No Sub Type Yaw, or other sensor messages from the Restraints
Information Control Module (RCM) for 5 seconds or longer.
DTC U0452:68 Invalid Data received From This DTC sets when the ABS module receives invalid
Restraints Control Module: Event network data from the RCM .
Information

RCM
ABS module
PINPOINT TEST I: DTC C0061:28, C0061:64, C0062:28, C0062:64, C0062:76, C0063:28, C0063:64,
U0151:00, U0452:68

NOTE: Supplemental Restraint System (SRS) components should only be disconnected or

reconnected when instructed to do so within a pinpoint test step. Failure to follow this
instruction may result in incorrect diagnosis of the SRS .
I1 CHECK FOR AN HS-CAN COMMUNICATION CONCERN
WITH THE RCM
NOTE: The network test does not test the dedicated CAN
communications between the ABS module and RCM . No
Using the scan tool, carry out the network test. REFER to Section 418-00 ,
Does the RCM pass the network test? The Restraints Control
Module (RCM) Does Not
Respond To The Scan Tool.
I2 VERIFY THE RCM PART NUMBER
Enter the following diagnostic mode on the scan tool: Log Yes
Viewer. GO to I3 .
Retrieve and record the RCM part number from the log
viewer. No
Check the part number recorded against the number listed in INSTALL the correct RCM .
the parts catalog. REFER to Section 501-20B .
Does the part number on the RCM match the part CLEAR the DTCs. REPEAT
number listed in the parts catalog? the self-test.
I3 CHECK FOR RCM AND ABS DTCs
Enter the following diagnostic mode on the scan tool: Self- Yes
Test — RCM . REFER to Section 501-20B
Enter the following diagnostic mode on the scan tool: Self to diagnose the RCM DTCs.
Test — ABS Module. TEST the system for normal
Are any RCM DTCs retrieved on-demand self-test? operation.
No
If only one of the following
ABS module DTCs
C0061:28, C0061:64,
C0062:28, C0062:64,
C0063:28, C0063:64,
U0452:68 was retrieved, GO
to I4 .
If more than one ABS module

DTC C0061:28, C0061:64,
C0062:28, C0062:64,
C0063:28,
C0063:64,U0452:68 was
retrieved, GO to I7 .
For DTC C0062:76 GO to

I12 .
For DTC U0151:00 GO to I7 .
For all other DTCs, REFER

to the ABS Module DTC
Chart.
I4 CHECK THE ABS MODULE YAW RATE (YAW_RATE) PID
Enter the following diagnostic mode on the scan tool: ABS Yes
Module DataLogger. GO to I5 .
NOTE: The vehicle must be on level ground and at a
complete standstill. Any vehicle movement results in false No
values for this test. GO to I13 .
Monitor the YAW_RATE PID.
Is the YAW_RATE PID value between -0.05 and 0.05?
I5 CHECK THE ABS MODULE LATERAL ACCELERATION
(LAT_ACCL) PID
NOTE: The vehicle must be on level ground and at a Yes
complete standstill. Any vehicle movement results in false GO to I6 .
values for this test.
Monitor the LAT_ACCL PID. No
Is the LAT_ACCL PID value between -0.4 and 0.4? GO to I13 .
I6 CHECK THE ABS MODULE LONGITUDINAL
ACCELERATION (LONG_ACCL) PID
NOTE: The vehicle must be on level ground and at a Yes
complete standstill. Any vehicle movement results in false GO to I7 .
values for this test.
Monitor the LONG_ACCL PID. No
Is the LONG_ACCL PID value between -0.4 and 0.4? GO to I13 .
I7 CHECK THE DEDICATED CAN CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to I8 .
(SRS) Depowering and Repowering in Section 501-20B .
Disconnect: ABS Module C135. No
Disconnect: RCM C310A and C310B. REPAIR the affected circuit
Measure the resistance between the ABS module C135, (s). CLEAR the DTCs.
harness side and the RCM C310B, harness side as CYCLE the ignition key.
indicated in the following chart: REPEAT the self-test.
ABS Module Circuit RCM

C135-18 VCA23 (BU/WH) C310B-20
C135-19 VCA24 (GN/OG) C310B-19

I8 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO
GROUND
Measure the resistance between ground and: Yes
ABS module C135-19, circuit VCA24 (GN/OG), GO to I9 .
harness side.
ABS module C135-18, circuit VCA23 (BU/WH), No
harness side. REPAIR the affected circuit
(s). TEST the system for
normal operation.
I9 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT
TOGETHER
Measure the resistance between ABS module C135-19, Yes
circuit VCA24 (GN/OG), harness side and ABS module GO to I10 .
C135-18, circuit VCA23 (BU/WH), harness side.
No

I10 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT
TO VOLTAGE
Repower the SRS . Do not prove out the SRS at this time. Yes
Refer to Supplemental Restraint System (SRS) Depowering REPAIR the affected circuit
and Repowering in Section 501-20B . (s) for a short to voltage.
Ignition ON. CLEAR the DTCs. REPEAT
Measure the voltage between ground and: the self-test.
ABS module C135-19, circuit VCA24 (GN/OG),
harness side. No
ABS module C135-18, circuit VCA23 (BU/WH), GO to I11 .
harness side.
I11 CHECK RCM TERMINATING RESISTOR
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System GO to I12 .
(SRS) Depowering and Repowering in Section 501-20B .
Prior to reconnecting any previously disconnected SRS No
component: INSTALL a new RCM .
inspect connector(s) (including any in-line connectors) REFER to Section 501-20B .
for pushed-out, loose or spread terminals and loose CLEAR all CMDTCs .
or frayed wire connections at terminals. PERFORM a road test.
inspect wire harness for any damage, pinched, cut or REPEAT the self test. If the
pierced wires. concern is still present, GO to
inspect RCM C310A and C310B Connector Position I14 . If other DTCs are
Assurance (CPA) lever/lock for correct operation. present, REFER to the
Refer to RCM in Section 501-20B . appropriate DTC chart.


Measure the resistance between ABS module C135-18,
circuit VCA23 (BU/WH), harness side and C135-19, circuit
VCA24 (GN/OG), harness side.

I12 CHECK THE RCM INSTALLATION AND MOUNTING
SURFACE
Ignition OFF. Yes
If not previously directed to do so, depower the GO to I13 .
Supplemental Restraint System (SRS). Refer to
Supplemental Restraint System (SRS) Depowering and No
REPAIR or INSTALL new as
Repowering in Section 501-20B . necessary. REPOWER the
Inspect the Restraints Control Module (RCM) installation and SRS . REFER to
make sure that the fasteners are fully seated and tightened Supplemental Restraint
correctly. Refer to RCM in Section 501-20B . System (SRS) Depowering
Inspect the mounting surface for damage, corrosion or and Repowering in Section
foreign material. 501-20B . CLEAR all
Is the RCM installed correctly and is the mounting CMDTCs . PERFORM a road
surface clean and free from damage? test. REPEAT the self test.
I13 CHECK FOR AN INTERMITTENT FAULT
Disconnect: RCM C310A and C310B. Yes
Disconnect: ABS module C135. INSTALL a new RCM .
inspect connector(s) (including any in-line connectors) REFER to Section 501-20B .
for corrosion, loose or spread terminals and loose or CLEAR all CMDTCs .
frayed wire connections at terminals. PERFORM a road test.
inspect wire harness for any damage, pinched, cut or REPEAT the self test. If the
pierced wires. concern is still present, GO to
repair any concerns found. I14 . If other DTCs are
present, REFER to the
Refer to Wiring Diagrams Cell 5 , Connector Repair appropriate DTC chart.
No
Connect: All Previously Disconnected Component cannot be recreated at this
(s)/Connector(s). time. Do not install any new
Repower the SRS . Do not prove out the SRS at this time. SRS components at this
Refer to Supplemental Restraint System (SRS) Depowering time. SRS components
and Repowering in Section 501-20B . should only be installed
Perform a road test. when directed to do so in
Ignition ON. the pinpoint test.
I14 CHECK THE ABS MODULE FOR CORRECT OPERATION
(SRS) Depowering and Repowering in Section 501-20B . INSTALL a new ABS module.
Prior to reconnecting any previously disconnected SRS REFER to Hydraulic Control
component: Unit (HCU) in this section.
for pushed-out, loose or spread terminals and loose No
or frayed wire connections at terminals. The system is operating
inspect wire harness for any damage, pinched, cut or correctly at this time. The
pierced wires. concern may have been
inspect RCM C310A and C310B CPA lever/lock for caused by a loose or
correct operation. Refer to RCM in Section 501-20B . corroded connector.
inspect ABS module C135 for dirt, corrosion, water
intrusion, pushed-out, loose or spread terminals and
loose or frayed wire connections at terminals.

Connect: All Previously Disconnected Component

(s)/Connector(s).
and Repowering in Section 501-20B .
Perform a road test.
Ignition ON.
Pinpoint Test J: DTC U0151:88
Normal Operation
The Restraints Control Module (RCM) measures vehicle yaw rate, lateral acceleration and longitudinal
acceleration and then sends the information to the ABS module along a dedicated pair of Controller Area
Network (CAN) circuits. This dedicated CAN is used only for communication between the RCM and the
ABS module. The yaw rate sensor, lateral accelerometer and longitudinal accelerometer are contained
in the RCM .
DTC U0151:88 (Lost Communication With Restraints Control Module: Bus Off) — This DTC can
set if either of the dedicated CAN circuits are open, shorted to ground or shorted to each other.
Other DTCs indicating missing messages or invalid signals from the RCM sensors can set as a
result of a dedicated CAN fault.

RCM
ABS module
PINPOINT TEST J: DTC U0151:88

NOTE: Supplemental Restraint System (SRS) components should only be disconnected or

reconnected when instructed to do so within a pinpoint test step. Failure to follow this
instruction may result in incorrect diagnosis of the SRS .

J1 CHECK FOR AN HS-CAN CONCERN WITH THE RCM
Ignition ON. Yes
NOTE: The Network Test does not test the dedicated CAN GO to J2 .
communications between the ABS module and RCM .
Using a scan tool, carry out the Network Test. No
Does the RCM pass the Network Test? REFER to Section 418-00
to diagnose the RCM does
not respond to scan tool.
J2 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO
VOLTAGE
Yes
WARNING: Turn the ignition OFF and wait one REPAIR the affected circuit
minute to deplete the backup power supply. Failure to (s) for a short to voltage.
follow this instruction may result in serious personal CLEAR the DTCs. REPEAT
injury or death in the event of an accidental deployment. the self-test. GO to J10 .
Depower the SRS . Refer to Refer to Supplemental Restraint
System (SRS) Depowering and Repowering Section 501- No
20B . GO to J3 .
Disconnect: ABS Module C135 .
Disconnect: RCM C310A .
Disconnect: RCM C310B .
Ignition ON.
Measure the voltage between ground and:
harness side.
ABS module C135-18, circuit VCA23 (BU/WH),
harness side.

J3 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF. Yes
Measure the resistance between ground and: GO to J4 .
harness side. No
ABS module C135-18, circuit VCA23 (BU/WH), REPAIR the affected circuit
harness side. (s). TEST the system for
normal operation. GO to
J10 .
J4 CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT
TOGETHER
Measure the resistance between ABS module C135-19, circuit Yes
VCA24 (GN/OG), harness side and ABS module C135-18, GO to J5 .
circuit VCA23 (BU/WH), harness side.
No
REPEAT the self-test. GO
to J10 .

J5 CHECK THE DEDICATED CAN CIRCUITS FOR AN OPEN
Measure the resistance between the ABS module C135, Yes
harness side and the RCM C310B, harness side as indicated GO to J6 .
in the following chart:
No
ABS Module Circuit RCM REPAIR the affected circuit
C135-18 VCA23 (BU/WH) C310B-20 CYCLE the ignition key.
REPEAT the self-test. GO
C135-19 VCA24 (GN/OG) C310B-19
to J10 .

J6 CHECK RCM TERMINATING RESISTOR
component: GO to J7 .
frayed wire connections at terminals. GO to J8 .
pierced wires.
inspect RCM C310A and C310B Connector Position
Assurance (CPA) lever/lock for correct operation. Refer
to RCM in Section 501-20B .

Connect: RCM C310A .

Connect: RCM C310B .
Measure the resistance between ABS module C135-19, circuit
VCA24 (GN/OG), harness side and ABS module C135-18,
circuit VCA23 (BU/WH), harness side.

J7 CHECK THE ABS MODULE FOR CORRECT OPERATION
component: INSTALL a new ABS
inspect connector(s) (including any in-line connectors) module. REFER to
for pushed-out, loose or spread terminals and loose or Hydraulic Control Unit
frayed wire connections at terminals. (HCU) in this section. GO to
inspect wire harness for any damage, pinched, cut or J10 .
pierced wires.
inspect RCM C310A and C310B CPA lever/lock for No
correct operation. Refer to RCM in Section 501-20B . The system is operating
inspect ABS module C135 for dirt, corrosion, water correctly at this time. The
intrusion, pushed-out, loose or spread terminals and concern may have been
loose or frayed wire connections at terminals. caused by a loose or
repair any concerns found. corroded connector. GO to
J10 .

(s)/Connector(s) .
— ABS Module .
Was DTC U0151 retrieved on-demand during the self-
test?
J8 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system components, sensor Yes

electrical connectors and the RCM electrical connectors are INSTALL a new RCM .
connected before carrying out the self-test. If not, DTCs will be REFER to Section 501-
recorded. 20B . GO to J10 .
If previously directed to repower the SRS , depower the SRS . No
Refer to Supplemental Restraint System (SRS) Depowering In the process of
and Repowering in Section 501-20B . diagnosing the fault, the
Prior to reconnecting any previously disconnected SRS fault condition has become
component: intermittent.
for pushed-out, loose or spread terminals and loose or CHECK for causes of the
frayed wire connections at terminals. intermittent fault. ATTEMPT
inspect wire harness for any damage, pinched, cut or to recreate the hard fault by
pierced wires. flexing the wire harness
inspect RCM C310A and C310B CPA lever/lock for and cycling the ignition
correct operation. Refer to RCM Removal and frequently. ACTIVATE other
Installation in Section 501-20B . systems in the same wire
inspect ABS module C135 for dirt, corrosion, water harness. Do not install
intrusion, pushed-out, loose or spread terminals and any new SRS
loose or frayed wire connections at terminals. components at this time.
repair any concerns found. SRS components should
only be installed when
Refer to Wiring Diagrams Cell 5 , Connector Repair directed to do so in the
Procedures for schematic and connector information. pinpoint test. GO to J9 .

(s)/Connector(s) .
— RCM .
Were DTCs U0028:08 and/or U0028:88 retrieved on-
demand during self-test?
J9 CHECK FOR AN INTERMITTENT FAULT
Ignition OFF. Yes
Depower the SRS . Refer to Supplemental Restraint System REFER to the Restraints
(SRS) Depowering and Repowering in Section 501-20B . Control Module (RCM) DTC
Disconnect RCM C310B and ABS module C135: Chart in Section 501-20B .
for corrosion, loose or spread terminals and loose or No
frayed wire connections at terminals. The fault is not present and
inspect wire harness for any damage, pinched, cut or cannot be recreated at this
pierced wires. time. Do not install any
repair any concerns found. new SRS components at
this time. SRS
Refer to Wiring Diagrams Cell 5 , Connector Repair components should only
Procedures for schematic and connector information. be installed when
pinpoint test. GO to J10 .
(s)/Connector(s) .
Ignition ON.
— RCM .
Are any RCM DTCs retrieved on-demand during the self-
test?
J10 CHECK FOR ADDITIONAL SRS DTCs
Ignition OFF. Yes
WARNING: Turn the ignition OFF and wait one all DTCs have been
minute to deplete the backup power supply. Failure to resolved. GO to the
follow this instruction may result in serious personal appropriate DTC Chart in
injury or death in the event of an accidental deployment. this section and/or Section
Reconnect all SRS components (if previously disconnected). 501-20B for pinpoint test
If previously directed to depower the SRS , repower the direction.
SRS . Do not prove out the SRS at this time. Refer to
Supplemental Restraint System (SRS) Depowering and No
Repowering in Section 501-20B . CLEAR all CMDTCs .
Ignition ON. PROVE OUT the SRS .
Using a scan tool, clear all RCM CMDTCs . REFER to Supplemental
Enter the following diagnostic mode on the scan tool: Self Test Restraint System (SRS)
— RCM . Depowering and
Were any DTCs retrieved on-demand from the RCM Repowering in Section 501-
during self-test? 20B .
Repair is complete.
RETURN the vehicle to the
customer.
Pinpoint Test K: DTC U3002:62
Normal Operation
When the ignition is turned to the RUN position, the ABS module and the IPC share Vehicle
Identification Number (VIN) information over the High Speed Controller Area Network (HS-CAN) bus.
Correct any network communications DTCs prior to diagnosing DTC U3002:62
DTC U3002:62 (Vehicle Identification Number: Signal Compare Failure) — this DTC sets when
the VIN message sent by the IPC over the HS-CAN does not match the VIN stored in the ABS
module.

Module configuration (ABS and IPC )
ABS module
PINPOINT TEST K: DTC U3002:62

K1 VERIFY IPC VIN
Ignition ON. Yes
Enter the following diagnostic mode on GO to K2 .
the scan tool: Log Viewer.
Compare the VIN in Log Viewer to the No
vehicle VIN plate. CARRY OUT Programmable Module Installation
Does VIN in Log Viewer match the (PMI) for the IPC . REFER to Section 418-01 .
vehicle VIN plate? TEST the system for normal operation.
K2 VERIFY ABS MODULE PART NUMBER
Retrieve and record the ABS module Yes
part number from Log Viewer and verify CARRY OUT PMI for the ABS module. Refer to
that the vehicle has the correct ABS Section 418-01 . TEST the system for normal
module installed. operation.
Is the correct ABS module installed in
the vehicle? No
INSTALL a new ABS module. REFER to
Hydraulic Control Unit (HCU) in this section.
CLEAR the DTC. CYCLE the ignition key.
Pinpoint Test L: DTCs U3003:16, U3003:17
Normal Operation
The operating voltage required to supply the ABS module, hydraulic pump and isolation valves is in a
range between 10 and 16 volts.
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — this DTC sets if the voltage
supplied to the ABS module falls below 10 volts during the ABS module self-test or normal
operation, with vehicle speed greater than 5 km/h (3 mph.
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — this DTC sets if the voltage
supplied to the ABS module is greater than 17 volts during the ABS module self-test or normal
operation, with vehicle speed greater than 5 km/h (3 mph.

Module configuration (ABS and PCM)
ABS module
PINPOINT TEST L: DTCs U3003:16 AND U3003:17
NOTE: DTCs U3003:16 and U3003:17 can set if the vehicle has been recently jump started, the 12-volt
battery has been recently charged or the 12-volt battery has been discharged. The 12-volt battery may
become discharged due to excessive load(s) on the charging system from aftermarket accessories or if
the battery has been left unattended with the accessories on.
inspection and verification in this section.

L1 RETRIEVE ALL CMDTCs IN ALL MODULES
Connect: ABS Module C135. Yes
Ignition ON. REFER to Section 414-00 for
Enter the following diagnostic mode on the scan tool: Self diagnosis of the battery and
Test — CMDTCs . charging system.
Are there battery, voltage or charging system DTCs
present in more than one module? No
For ABS DTC U3003:16 GO
to L2 . For ABS DTC
U3003:17 GO to L6
L2 CHECK BATTERY CONDITION
Ignition OFF. Yes
Refer to Section 414-01 and carry out the Battery — If the battery passed the
Condition Test. condition test but required a
Does the battery pass the condition test? recharge, REFER to Section
414-00 to diagnose the
charging system. CLEAR all
Continuous Memory
(CMDTCs). TEST the system

require a recharge, GO to L3 .
No
CLEAR all CMDTCs . TEST
operation.
L3 CHECK THE ABS MODULE GROUND EYELET
Ignition OFF. Yes
Remove the bolt retaining G107/G108 at the inner RF GO to L4 .
fender.
Clean the chassis mating surface and ground No
eyelets. The concern was caused by a
Install the ground eyelet to the chassis with the loose or corroded connector.
retaining bolt. CLEAR the DTCs. REPEAT
Ignition ON. self-test.
L4 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN
OPEN
NOTE: Failure to disconnect the battery when instructed Yes

results in false resistance readings. Refer to Section 414-01 GO to L5 .
Ignition OFF. No
Disconnect: Battery Cable — Negative. The concern was caused by a
Disconnect: ABS Module C135. loose or corroded connector.
Measure the resistance between ground and: CLEAR the DTCs. REPEAT
ABS module C135-47, circuit GD123 (BK/GY), self-test.
harness side.
Repeat this measurement while wiggling the harness.

L5 CHECK FOR VOLTAGE AT THE ABS MODULE
Connect: Battery Cable — Negative. Yes
Ignition ON. GO to L6 .
Measure the voltage between ground and:
ABS module C135-1, SBB01 (RD), harness side. No
ABS module C135-8, CBP22 (GN/OG), harness side. VERIFY that BJB fuses 1
ABS module C135-32, SBB28 (GN/RD), harness (40A), and 9 (20A) and CJB
side. 22 (7.5A) are OK. If OK,
(s).
If the fuses are not OK,

REFER to the Wiring
circuit short.
CLEAR the DTCs and


L6 CHECK CHARGING SYSTEM VOLTAGE
Measure the voltage of the battery with and without a load GO to L7 .
on the charging system as follows:
Turn off all accessories and measure battery voltage. No
Turn on headlights and HVAC fan on high and REFER to Section 414-00 to
measure battery voltage. diagnose the charging
system. CLEAR all CMDTCs .
operation.
Are the voltages between 13 and 15.2 volts?

L7 CHECK FOR CORRECT ABS MODULE OPERATION
Ignition OFF. Yes
Disconnect: ABS Module C135. INSTALL a new ABS module.
Check for: REFER to Hydraulic Control
corrosion Unit (HCU) in this section.
spread terminals operation.
Connect: ABS Module C135.
Make sure the connector seats correctly, then operate the No
system and verify the concern is still present. The system is operating
test.
Brake Pedal Switch Adjustment
NOTICE: Do not press the brake pedal when installing or removing the brake pedal position switch or
damage to the brake pedal-mounted switches can occur.
1. Inspect both brake pedal position switches and brake pedal assembly to verify there is no brake pedal
pressure unintentionally applied due to incorrect brake pedal position switch or brake pedal installation.
Correct any concerns before proceeding to the next step.
2. Confirm that all fasteners retaining the brake pedal assembly are correctly tightened. For additional
3. Using the Integrated Diagnostic System (IDS) scan tool, select DataLogger->Chassis->Braking->Brake
Switch Parameters.
4. NOTE: Using the scan tool record function makes it easier to observe the brake pressure sensor
readings.
Turn the ignition to the ON position.
5. Slowly apply the brake pedal to generate the pressure graph for the BPS PID.
The rate of brake pedal apply must not exceed 5 psi per second as indicated by the scan tool.
6. Record the initial value of the BPS PID when BRAKE_LAMP and CRUISE_CANCL change from OFF to
ON.
If BRAKE_LAMP and CRUISE_CANCL transition to ON before the BPS PID reads 44 psi or less,
the brake pedal position switch is correctly installed.
If BRAKE_LAMP and CRUISE_CANCL transition to ON after the BPS PID reads greater than 44
psi, replace the stoplamp switch and cruise control deactivation switch (if equipped). Clear all DTCs
and repeat Steps 3-6 to verify that the BRAKE_LAMP and CRUISE_CANCL transition to ON
before the BPS PID reads 44 psi or less.
Hydraulic Control Unit (HCU)
Special Tool(s)
scan tool
Material
Item Specification
(Canada)
Hydraulic Control Unit (HCU), Brake Tubes, Electrical Connector and Bracket
Part
1 W706859 Hydraulic Control Unit (HCU) bracket-to-frame bolt (2
required)
2 2C405 HCU /ABS module assembly
3 — HCU /ABS module electrical connector (part of 14A464)
4 — RH rear brake tube fitting (part of 2C294)
5 — LH rear brake tube fitting (part of 2C295)
6 — Master cylinder primary brake tube fitting (part of
2M020)
7 — LH front brake tube fitting (part of 2264)
8 — RH front brake tube fitting (part of 2263)
9 — Master cylinder secondary brake tube fitting (part of
2M019)
Hydraulic Control Unit (HCU) and Brackets

Part
10 W703244 Hydraulic Control Unit (HCU) support plate-to-bracket
bolt (3 required)
11 2C304 HCU bracket
12 W500011 HCU -to-support plate bolt (3 required)
13 2C325 HCU support plate
14 2C405 HCU /ABS module assembly
NOTE: The Hydraulic Control Unit (HCU) and ABS module are serviced as an assembly.
1. If installing a new HCU /ABS module, connect the scan tool and upload the module configuration
information from the ABS module. For additional information, refer to Section 418-01 .
3. Remove the 2 HCU bracket-to-frame bolts.

4. Remove the nut and evaporator outlet tube bracket.
5. Disconnect the exhaust camshaft Variable Camshaft Timing (VCT) oil control solenoid electrical
connector.
6. NOTE: Cap the brake tube connections to prevent fluid loss or dirt contamination.
Disconnect the 6 brake tubes from the HCU .

To install, tighten the brake tube fittings to 17 Nm (150 lb-in).
7. Disconnect the HCU /ABS module electrical connector.
8. Position the HCU to the center line of the vehicle and remove the HCU .

1. If a new HCU /ABS module was installed, download the module configuration information from the
scan tool. For additional information, refer to Section 418-01 .
2. Bleed the brake system. For additional information, refer to Section 206-00 .
Wheel Speed Sensor — Front

2 W500011 Wheel speed sensor bolt
2. Position the rear portion of the splash shield aside.

1. Remove the 3 pushpin retainers.
2. Position the splash shield aside.
3. Disconnect the wheel speed sensor electrical connector.
4. Detach the wheel speed sensor from the body and wheel knuckle.
5. Remove the wheel speed sensor bolt.

6. Remove the wheel speed sensor.
7. NOTICE: The white stripe on the wheel speed sensor harness is used for orientation purposes.
Correct routing of the wheel speed sensor and harness is essential to prevent contact damage to
the harness.

Wheel Speed Sensor — Rear
NOTE: RH shown, LH similar. Wheel and tire removed for clarity.

2 W500011 Wheel speed sensor bolt (also part of 2C204)
1. Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications and Special
SECTION 307-05: Automatic Transaxle/Transmission External Controls 2011 Fiesta Workshop Manual
Cross brace bolts 40 30 —
Exhaust flange nuts 47 35 —
Selector lever nuts 9 — 80
Selector lever cable bracket-to-battery tray bolt 10 — 89
Selector lever cable bracket-to-transaxle bolt 25 18 —
Selector lever cable grommet nuts 9 — 80
Selector lever knob screws 2 — 18
External Controls
Exploded View

1 7L010 Selector lever knob
2 — Transmission Control Switch (TCS) (part of 7L010)
3 — Selector lever knob screws (part of 7L010) (2
required)
4 — Selector lever knob bezel (part of 7L010)
5 7E034 Selector lever lower bezel
6 — Brake Shift Interlock Actuator (BSIA) (part of 7210)
7 7210 Selector lever
8 W711470- Selector lever nuts (4 required)
S441
9 7E395 Selector lever cable
10 57809 Selector lever cable grommet
11 W702751- Selector lever cable grommet nuts (2 required)
S437
12 7B229 Selector lever cable bracket
13 7H181 Selector lever cable clip
14 — Selector lever cable adjuster (part of 7E395)
15 7A256 Manual control lever
16 W714072- Selector lever cable bracket bolts (2 required)
S437
External Controls
The transaxle external controls system consists of the following components:
Selector lever assembly

Selector lever cable and bracket
Brake Shift Interlock Actuator (BSIA)
Transmission Control Switch (TCS)
The selector lever controls the transaxle gear selection through the selector lever cable. When the selector
lever is moved to the desired mode of operation it moves the selector lever cable which moves the manual
control lever on the transaxle. This results in the desired gear selection. The selector lever knob controls the
cable detent and selector lever locking position.
Range Selection
Range Positions
P Park In the PARK position,
there is no power flow through the transaxle.

the parking pawl locks the final drive.
the engine may be started.
the ignition key may be removed.
R Reverse In the REVERSE position,
the vehicle may be operated in a rearward direction, at a reduced rear

ratio.
engine braking occurs.
N Neutral In the NEUTRAL position,
the vehicle is able to roll.

the output shaft is not held and is free to turn.
D Drive position with Grade DRIVE is the normal position for most forward driving. The DRIVE position
Assist provides
automatic shifts —1st through 6th gears.

maximum fuel economy during normal operation.
L Manual Low Manual L position allows for 1st gear when the vehicle reaches slower speeds.
This position provides
maximum engine braking.
downshifts to the lowest available gear for the current vehicle speed.

1 — Actuator (part of 7210)
2 — Blocker (part of 7210)
3 — Manual release mechanism (part of 7210)
Location
The BSIA is part of the selector lever assembly.
The brake shift interlock system prevents the selector lever from being moved out of PARK unless the
requirements to do so are met. The ignition switch must be in the ON position and the brake pedal must be
pressed. The brake pedal position is detected by the Brake Pedal Position (BPP) switch. In the event the
vehicle will not come out of PARK, the manual release mechanism mechanically bypasses the electric portion
of the brake shift interlock system allowing the selector lever to be moved out of PARK. The manual release
mechanism is part of the selector lever assembly. If PARK is selected again, the selector lever will be locked
again.
Drive with Grade Assist
Drive with Overdrive (O/D) cancel and grade assist is activated when the Transmission Control Switch (TCS) is
pressed. The TCS is located on the selector lever knob. When the TCS is pressed, the 6th gear or O/D upshift
is prevented or the transaxle shifts down to 5th gear. The TCS is meant to be used when driving conditions
cause excessive shifting from 6th to other gears such as hilly terrain, mountainous areas or when engine
braking is required.
Grade Assist
O/D is cancelled.
The transaxle operates in gears 1 through 5.
The Grade Assist lamp illuminates on the Instrument Panel Cluster (IPC).
Improves vehicle handling in hilly terrain or mountainous areas by providing engine braking and
extending lower gear operation on uphill climbs.
Provides additional engine braking through the automatic transaxle shift strategy which reacts to vehicle
inputs (vehicle acceleration, accelerator pedal, brake pedal and vehicle speed).
The transaxle selects gears that provide the desired engine braking which is based on the vehicle inputs.
Engine braking increases engine rpm.
Returning to DRIVE mode on flat terrain provides the best fuel economy and transaxle performance. The
transaxle returns to O/D when the TCS is pressed again or the key is turned OFF.
Gear Availability
External Controls
Special Tool(s)

tool
3. If an obvious cause for an observed or reported concern is found, correct the cause before
4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart - External
Controls or GO to Symptom Chart - NVH .

Selector lever cable Central Junction Box (CJB) fuse 18 (10A)
Manual control lever CJB fuse 22 (7.5A)
Selector lever or selector lever knob Connections
Wiring harness
Brake Pedal Position (BPP) switch
Transmission Control Switch (TCS)
DTC Chart
DTC Component Description Condition Symptom Action
B2572 Brake Shift Brake Shift The associated circuitry Brake shift GO to
Interlock Interlock Output connected to the Central interlock is Pinpoint
Circuit Failure Junction Box (CJB) or fuse, or inoperative or Test A .
the CJB itself may have an does not operate
issue causing a brake shift correctly.
interlock concern.
PID Chart
PIDs PID Description
BOO TCM Brake Switch Input Status
TCS_DEPRES Transmission Control Switch Depressed
TCS_STATE Transmission Control Switch State
TR_A_DC Transmission Range Sensor Input A Duty Cycle
TR_A_POS_MEAS Transmission Range Sensor A Position - Measured
TR_A_UR Transmission Range Sensor Input A Unreliable
TR_B_DC Transmission Range Sensor Input B Duty Cycle
TR_POS_MEAS Transmission Range Sensor B Position - Measured
TR_B_UR Transmission Range Sensor Input B Unreliable
TR_CORRECTED Transmission Range Sensor Position - Corrected
TR_CRANK Transmission Range Input Allowing Engine Start
TR_CRANK_F Park Neutral Starter Enable Output Fault Detected
TR_SUPPLY_f Transmission Range Supply Voltage Output Fault
TRAN_RAT Transmission Gear Ratio
Symptom Chart — External Controls
Symptom Chart — External Controls

Brake shift interlock Circuitry GO to Pinpoint Test A .
system does not open/shorted
release/lock Central Junction
correctly Box (CJB) fuse
18 (10A)
Brake Pedal
Position (BPP)
switch
Brake Shift INSTALL a new selector lever
Interlock Actuator assembly. REFER to Selector
(BSIA) Lever in this section.
Transmission DIAGNOSE and REPAIR all
Range (TR) TR sensor DTCs. REFER to
sensor Section 307-11 .
Transmission Instrument Panel GO to Pinpoint Test B .
Control Switch Cluster (IPC)
(TCS) does not Circuitry
operate correctly open/shorted
CJB fuse 22
(7.5A)
Transmission
Control Module
(TCM)
Transmission
Control Switch
(TCS)
Selector lever Selector lever REFER to Selector Lever
linkage is out of linkage out of Cable Adjustment in this
correct gear adjustment section.
relationship
Loose selector CHECK the selector lever
lever cable cable bracket. TIGHTEN as
bracket necessary.
Unable to remove Circuitry shorted REFER to Diagnosis and
the key from the Ignition lock Testing in Section 211-05 .
ignition cylinder
Ignition switch
Selector lever
Selector lever Excessive CLEAN selector lever slide.
making creaking dirt/dust in the
noise selector lever
slide
Selector lever Selector lever CHECK the selector lever
binding bezel damaged bezel for damage. If
Selector lever necessary, INSTALL a new
damaged selector lever. REFER to
Selector lever Selector Lever .
cable damaged CHECK the selector lever for
Internal transaxle damage. If necessary,
components INSTALL a new selector lever
damaged assembly. REFER to Selector
Lever .
CHECK the selector lever
cable for damage. If
necessary, INSTALL a new
selector lever cable. REFER to
Selector Lever Cable in this
section.
CHECK manual control lever
and internal transaxle
components for damage.
Brake shift interlock Brake shift INSPECT the selector lever for
override does not interlock override damage. If necessary,
release the selector damaged INSTALL a new selector lever.
lever REFER to Selector Lever .
Vibration — a high frequency Selector lever cable CHECK the
(20-80 Hz) that is felt through incorrectly routed, selector lever
the seat or selector lever. grounded out or cable. REPAIR as
Changes with engine speed loose necessary.
Electrical Connectors
Selector Lever Harness C3245 (Vehicle Harness Side)
Pin
Number Circuit Circuit Function
1 CCA26 Brake Shift Interlock Actuator (BSIA) solenoid power circuit
(BU/GY)
2 CDC41 Park position signal to ignition switch
(WH/BN)
3 — Park position signal to Instrument Panel Cluster (IPC)
4 CLN04 Power to PRNDL LED Illumination
(BU/BN)
5 GD115 Ground
(BK/GY)
6 CBP22 Transmission Control Switch (TCS)/Grade Assist button power supply
(GN/OG) from Central Junction Box (CJB)
7 CE417 TCS /Grade Assist button signal return
(GY/BN)
8 Empty
9 Empty
10 Empty
11 Empty
12 CTE53 BSIA solenoid ground
(BU/OG)
Pinpoint Tests
Pinpoint Test A: The Brake Shift Interlock System Does Not Release/Lock Correctly
Refer to Wiring Diagrams Cell 29 , Transmission Controls for schematic and connector information.
PINPOINT TEST A: THE BRAKE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK
CORRECTLY
Result / Action to
Test Step
Take
A1 TEST THE BRAKE LIGHTS
Apply the brake pedal and view the brake lights. Yes
Do the brake lights illuminate? GO to A2 .
No
REFER to Section
417-01 .
A2 TEST THE BSIA POWER CIRCUIT
Disconnect: Selector Lever Harness C3245. Yes
Measure the voltage between selector lever harness C3245-1, circuit
CCA26 (BU/GY), vehicle harness side and ground, while applying the No
brake pedal. REPAIR circuit
CCA26 (BU/GY)
for an open.

A3 TEST THE TCM
Ignition OFF. Yes
Measure the resistance between selector lever harness C3245-5 INSTALL a new
circuit GD115 (BK/GY) and ground. selector lever.
REFER to Selector
Lever in this
section.
No
GO to A4 .
A4 TEST THE BSIA GROUND CIRCUIT
Disconnect: Transmission Control Module (TCM) C1ET02. Yes
Measure the resistance between selector lever harness C3245-12 and INSTALL a new
C1ET02-49. TCM .
No
REPAIR circuit
CET53 (BU/OG)
for an open.
Pinpoint Test B: Transmission Control Switch (TCS) Does Not Operate Correctly
PINPOINT TEST B: TCS DOES NOT OPERATE CORRECTLY

B1 TEST THE IPC
Using the scan tool, monitor the TCS_DEPRES PID while REFER to Section 413-01 .
cycling the Transmission Control Switch (TCS).
Does the TCS_DEPRES PID cycle from DEPRESSED to No
NOT DEPRESSED? GO to B2 .
B2 CHECK CJB FUSE 22 (7.5A)
Ignition OFF. Yes
Check fuse: Central Junction Box (CJB) 22 (7.5A). GO to B3 .
No
GO to B4 .
B3 CHECK FOR VOLTAGE AT THE SELECTOR LEVER
CONNECTOR
Disconnect: Selector Lever Harness C3245. Yes
Measure the voltage between selector lever harness
C3245-6, circuit CBP22 (GN/OG), vehicle harness side and No
ground. REPAIR circuit CBP22
(GN/OG). RECONNECT all
components. TEST the system
B4 TEST THE TCS
Measure the resistance between selector lever harness Yes
C3245 pins 6 and 7, component side, while cycling the GO to B5 .
TCS .
No
INSPECT the selector lever
wiring harness for damage.
REPAIR the wiring harness as
required. If the selector lever
wiring harness is not
damaged, INSTALL a new
selector lever knob. REFER to
Selector Lever Knob in this
normal operation.
Is the resistance less than 5 ohms when pressed and

greater than 10,000 ohms when released?
B5 TEST THE TCS SIGNAL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Transmission Control Module (TCM) C1ET02. GO to B6 .
Measure the resistance between selector lever harness
C3245-7, circuit CE417 (GY/BN) and ground. No
(GY/BN) for a short to ground.
operation.

B6 TEST THE TCS SIGNAL CIRCUIT FOR AN OPEN CIRCUIT
Measure the resistance between selector lever harness Yes
C3245-7, circuit CE417 (GY/BN) and TCM C1ET02-11. INSTALL a new TCM . REFER
to Section 307-11 .
No
(GY/BN) for an open.
RECONNECT all components.
operation.

Brake Shift Interlock Override
NOTE: If it is necessary to use the brake shift interlock override procedure to move the selector lever out
of the 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 selector lever from being
moved out of PARK when the ignition is in the ON or RUN position unless the brake pedal is depressed.
Perform the following if the selector 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.
2. Turn the ignition key to the ON position.
3. Remove the center console side panel.
4. Locate the brake shift interlock override mechanism on the Brake Shift Interlock Actuator (BSIA).
5. Using an suitable tool, depress the brake shift interlock override mechanism on the BSIA , apply
the brake, depress the button on the selector lever and move the selector lever into NEUTRAL.
6. Start the vehicle.
7. To install, reverse the procedure.

Selector Lever Cable Adjustment
Special Tool(s)
tool
1. Disconnect the selector lever cable end from the manual control lever.
2. Place the manual control lever in the D position as indicated on the transaxle case.
3. Place the manual control lever in the P position as indicated on the transaxle case.
4. Place the manual control lever in the D position as indicated on the transaxle case.
5. Place the selector lever in the D position.
6. Unlock the selector lever cable adjuster by sliding the locking tab over.
7. Slide the selector lever cable end forward or backward to align it with the manual control lever.
8. With the selector lever cable adjuster locking tab released, connect the selector lever cable end to
the manual control lever.
9. Slide the locking tab back to lock the selector lever cable adjuster.
10. Verify that the vehicle only starts in PARK and NEUTRAL and the reverse lamps illuminate in
REVERSE.
Selector Lever Cable
Removal
100-02 .
3. Disconnect the selector lever cable end from the selector lever ball stud.
4. Release the locking tab on the selector lever cable clip and remove the selector lever cable from
the selector lever housing.
5. Using a suitable tool, cut the carpet in the center under the heater core and evaporator core
housing to gain access to the selector lever cable grommet in the following sequence.
1. Begin cutting the carpet where the selector lever cable is exposed and cut the carpet back
until the tool no longer fits between the floor and the heater core and evaporator core
housing.
2. To cut the carpet further forward, access the carpet with the tool through the LH side of the
heater core and evaporator core housing.
6. Position the carpet aside to access the selector lever cable grommet.

9. Remove the 3 battery tray bolts and the battery tray.
10. Remove the selector lever cable bracket bolt.
11. Disconnect the selector lever cable end from the manual control lever.
12. Disconnect the selector lever cable from the selector lever cable bracket.
13. Remove and discard the 2 exhaust flange nuts and disconnect the exhaust flange.
Discard the exhaust flange gasket.
14. Disconnect the exhaust hangers and support the exhaust with wire.
15. Remove the 8 bolts and remove the cross brace.
16. Remove the 6 exhaust heat shield fasteners (5 shown) and the exhaust heat shield.
17. Remove the 2 selector lever cable grommet nuts.
18. NOTE: Remove the selector lever cable from outside of the vehicle.
Remove the selector lever cable.
Installation
1. Position the selector lever cable grommet in place.
2. Install the 2 selector lever cable grommet nuts.

3. Install the exhaust heat shield and the 6 exhaust heat shield fasteners (5 shown).
4. Install the cross brace and the 8 cross brace bolts.
5. Connect the exhaust hangers.

6. Using a new exhaust flange gasket and 2 new exhaust flange nuts, connect the exhaust flange.
7. Connect the selector lever cable to the selector lever cable bracket.
8. Connect the selector lever cable end to the manual control lever.
9. Install the selector lever cable bracket bolt.


13. Install the selector lever cable on the selector lever housing.
14. Connect the selector lever cable end to the selector lever ball stud.
15. Position the carpet back in place under the heater core and evaporator core housing.
17. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable
Selector Lever
Removal
2. Depower the Supplemental Restraint System (SRS). For additional information, refer to Section
501-20B .
3. Disconnect the selector lever cable end from the selector lever ball stud.
4. Release the locking tab on the selector lever cable clip and remove the selector lever cable from
the selector lever housing.
5. Disconnect the selector lever electrical connector.

6. Using a suitable tool, remove the wiring harness from the selector lever base.
7. Disconnect the Restraints Control Module (RCM) electrical connector.
8. Remove the 4 selector lever nuts and remove the selector lever.
Installation
1. Install the selector lever and the 4 selector lever nuts.

2. NOTE: When installing the selector lever cable, make sure the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the bracket and listen for the selector lever
cable to click in place. Pull back on the selector lever cable to make sure it is locked into the
selector lever cable bracket.
Install the selector lever cable in the selector lever housing.
3. NOTE: Make sure the selector lever cable end is correctly installed onto the ball stud. Pull back
on the selector lever cable end to make sure the selector lever cable end is correctly installed.
Connect the selector lever cable end to the selector lever ball stud.
4. Connect the selector lever electrical connector.
5. Connect the RCM electrical connector.
6. Connect the wiring harness to the selector lever base.

8. Repower the Supplemental Restraint System (SRS). For additional information, refer to Section
501-20B .
9. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable
Selector Lever Knob
Removal
1. Remove the selector lever trim ring.
2. Remove the upper console panel.
3. Slide the selector lever knob bezel downward.
4. Remove and discard the 2 selector lever knob screws.

5. Remove the center console LH panel.
6. Disconnect the Transmission Control Switch (TCS) electrical connector and remove the wiring
harness fastener from the selector lever housing.
7. Remove the selector lever knob.
Installation
1. NOTICE: Do not overtighten the selector lever knob screws or damage to the selector lever
or selector lever knob may occur.
Install the selector lever knob and the 2 new selector lever knob screws.
2. Slide the selector lever knob bezel up and into place.
3. Connect the TCS electrical connector and install the wiring harness fastener to the selector lever
housing.
4. Install the center console LH panel.

5. Install the upper console panel.
6. Install the selector lever trim ring.
7. Verify the selector lever knob functions correctly.

SECTION 307-11: Automatic Shifting Manual Transmission/Transaxle 2011 Fiesta Workshop Manual
Material
Capacity
Gasket Maker WSK-M2G348- —
TA-16 A5
Seize Lubricant
XL-2
Motorcraft® Dual Clutch WSS-M2C200- 1.7L (1.8
Transmission Fluid D2 qt)
XT-11-QDC
DPS6 Grease WSS-M1C270- —
9U7Z-19A506-BA A
Item Specification
Transaxle Weight 76 kg (168 lb)
Clutch
Clutch 1 26 mm (1.023 in) a
Clutch 2 15 mm (0.59 in) a
a Maximum after clutch reset
Synchronizer Ring Clearance

Clearance Between Synchronizer Ring and Flank Surface of Gear
Minimum 1.3 mm (0.051 in) minimum (1.6 mm (0.062 in) +/- 0.3 mm (0.011 in) )
Shift Fork and Hub Sleeve Clearance

Reverse/4th Gear Shift Fork and Hub Sleeve
Maximum 1.85 mm (0.072 in)
Standard 0.75-1.25 mm
(0.029-0.049 in)
Clearance Between 1st/5th Shift Fork and Hub Sleeve
(0.029-0.049 in)
Clearance Between 3rd Gear Shift Fork and Hub Sleeve
(0.024-0.044 in)
Clearance Between 2nd/6th Shift Fork and Hub Sleeve
(0.024-0.044 in)
Gear Clearance
1st Gear
Radial Clearance Maximum 0.055 mm (0.002 in)
Axial Clearance Maximum 0.645 mm (0.025 in)
2nd Gear
3rd Gear
4th Gear
5th Gear
6th Gear
Reverse Gear
Differential Shim Selection Chart

Tool Reading mm (in) Part Number Shim Thickness mm (in)
0.500-0.550 (0.0196-0.0216) AE8P-7F119-AA 0.500 (0.0197)
0.551-0.600 (0.0216-0.0236) AE8P-7F119-BA 0.550 (0.0217)
0.601-0.650 (0.0236-0.0255) AE8P-7F119-CA 0.600 (0.0236)
0.651-0.700 (0.0256-0.0275) AE8P-7F119-DA 0.650 (0.0256)
0.701-0.750 (0.0275-0.0295) AE8P-7F119-EA 0.700 (0.0276)
0.751-0.800 (0.0295-0.0314) AE8P-7F119-FA 0.750 (0.0295)
0.801-0.850 (0.0315-0.0334) AE8P-7F119-GA 0.800 (0.0315)
0.851-0.900 (0.0335-0.0354) AE8P-7F119-HA 0.850 (0.0335)
0.901-0.950 (0.0354-0.0374) AE8P-7F119-JA 0.900 (0.0354)
0.951-1.000 (0.0374-0.0393) AE8P-7F119-KA 0.950 (0.0374)
1.001-1.050 (0.0394-0.0413) AE8P-7F119-LA 1.000 (0.0394)
1.051-1.100 (0.0413-0.0433) AE8P-7F119-MA 1.050 (0.0413)
1.101-1.150 (0.0433-0.0452) AE8P-7F119-NA 1.100 (0.0433)
1.151-1.200 (0.0453-0.0472) AE8P-7F119-PA 1.150 (0.0452)
1.251-1.300 (0.0492-0.0511) AE8P-7F119-RA 1.200 (0.0472)
Gear Ratio
Gear Ratio Final Drive Overall Ratio
Reverse 3.508 4.35 15.270
1st 3.917 3.89 15.254
2nd 2.429 3.89 9.459
3rd 1.436 4.35 6.250
4th 1.021 4.35 4.446
5th 0.867 3.89 3.375
6th 0.702 3.89 2.735
Shift Speeds Chart

Throttle Position Shift km/h mph
Light 1-2 13-21 km/h 8-13 mph
2-3 23-31 km/h 14-19 mph
3-4 32-39 km/h 20-24 mph
4-5 40-63 km/h 25-39 mph
5-6 64-82 km/h 40-51 mph
Medium 1-2 29-42 km/h 18-26 mph
2-3 43-58 km/h 27-36 mph
3-4 59-76 km/h 37-47 mph
4-5 77-87 km/h 48-54 mph
5-6 88-121 km/h 55-75 mph
Wide Open 1-2 42-61 km/h 26-38 mph
2-3 63-90 km/h 39-56 mph
3-4 92-121 km/h 57-75 mph
4-5 122-208 km/h 76-129 mph
5-6 209-251 km/h 130-156 mph
Battery tray bracket nuts 10 — 89
Brake hose retainer bolts 25 18 —
Clutch actuator lever bolts 19 — 168
Clutch actuator lever spring retainer bolts a — — —
Clutch housing-to-case bolts 27 20 —
Clutch housing-to-engine bolts 48 35 —
Clutch motor bolts 5 — 44
Differential ring gear bolts a — — —
Drain plug 43 32 —
Fill plug 43 32 —
Flexplate-to-clutch nuts a — — —
Ground wire bolt 25 18 —
Guide tube bolts 8 — 71
Input shaft bearing retainer bolts 11 — 97
Input shaft speed sensor bolt 10 — 89
Manual control lever bolt 26 19 —
Output shaft bearing retainer bolts a — — —
Output Shaft Speed (OSS) sensor bolt 10 — 89
Park plunger plug 43 32 —
PCM cover bolt — 5.4 47.8
Roll restrictor-to-transaxle bracket bolt 48 35 —
Roll restrictor bolt 70 52 —
Selector lever battery tray bracket bolt 25 18 —
Selector lever cable bracket bolts 10 — 89
Shield and bearing retainer strap nuts a — — —
Shim selection tool bolts 18 — 159
Transaxle support insulator bracket bolts 90 66 —
Transaxle support insulator bracket nuts 125 92 —
Transmission Control Module (TCM) 27 20 —
Transmission Range (TR) sensor bolts 10 — 89
Upper strut mount nuts 48 35 —
Transaxle Description
This DPS6 is a fully automatic, dry dual clutch, automatic shifting manual, electronically controlled 6-
speed transaxle.
Its abbreviated designation DPS6 means:
D — Dry Dual Clutch

P — Powershift
S — Synchronized
6 — 6-speed transaxle
This transaxle features the following:
Computer Control with electro-mechanical actuation

Two piece aluminum housing design
Six (6) discrete stepped forward gears and one (1) reverse gear
Dual Output shafts with two separate final drive ratios
Full ball and roller bearing design for all gears and shafts
All gears are bevel cut for improved NVH characteristics and power transfer
All gears are in constant mesh for no loss of torque during the shifting process
All cast construction of shift fork/linkage mechanisms
This transaxle features two nested input shafts driven by a compact dry dual clutch system. These two
shafts are used in conjunction with each other to provide seamless shifting through the six (6) available
ratios with overdrive in the two top gears. As each gear is selected, the appropriate clutch is activated to
drive the vehicle. Each consecutive gear is then preselected for the next “shift” operation as power is
shifted from one clutch to the other and back again as moving up and down through the individual gears
This transaxle is designed to be operated in the same manner as a conventional torque converter
equipped automatic transaxle. It provides the smooth application of power, but with the bonus of
efficiencies found only in a manual transaxle. By delivering the power with a dual clutch system, fluid
volume is limited to less than 2 liters as compared against a conventional automatic transaxle, and that
is only within the gearbox case itself. The actuation of the clutch system is controlled by a dedicated
computer through two individual electrically driven clutch motors and actuator systems.
This transaxle provides six (6) discrete forward ratios with overdrive in the top two gears and a reverse
gear, giving a continuous flow of power for acceleration and deceleration
The selector lever gives the driver a choice of P, R, N, D and L.
With the selector lever in the D position, you can operate the Transmission Control Switch (TCS)/Grade
Assist switch on the selector lever to prevent the transaxle from shifting into 6th gear.
If a fault occurs continued motoring is guaranteed in the following limited conditions based on the failure:
1st, 3rd and 5th gear if a fault with clutch 2 and/or relational components occurs. 2nd, 4th, 6th and
reverse if a fault with clutch 1 and/or relational components occurs.
This transaxle can be tested using a scan tool through the Data Link Connector (DLC) in the passenger
compartment.
Internal components are based on manual transaxle technologies that include:

Dry friction clutches to transmit power between the engine and transaxle
Lay shaft gearing for high efficiency and uncoupled ratio selection
Rotating sequential shift drums for fast response
Synchronizers with dog clutches to pre-select and direct the power flow
Splash fluid lubrication without filter and external oil coolers
This transaxle is two transaxles within one housing that share a common:
Final drive which includes two output shaft pinions
Differential assembly
Output Shaft Speed (OSS) sensor
Transmission Range (TR) sensor
Park system
Transmission Control Module (TCM)
The first consists of three odd gear ratios (1st, 3rd & 5th):
Odd input clutch and actuator system including a clutch motor
Odd or inner input shaft with input shaft speed sensor 1 and related speed gears
Odd synchronizer system including a shift motor (part of TCM ), shift drum, shift forks and transfer
assemblies.
The second consists of three even gear ratios and reverse (2nd, 4th, 6th & Reverse):
Even input clutch and actuator system including a clutch motor
Outer or hollow input shaft with input shaft speed sensor 2 and related speed gears.
Even synchronizer system including a shift motor (part of TCM ), shift drum, shift forks and
transfer assemblies
1st Gear
The torque is introduced into the dual clutch via the flywheel. From there, the power is transmitted via
clutch 1 to the inner input shaft. The inner input shaft transmits the torque to the first gear of the output
shaft. The torque is transmitted to the differential via the output pinion.
2nd Gear
clutch 2 to the hollow input shaft. The inner input shaft transmits the torque to the second gear of the
output shaft. The torque is transmitted to the differential via the output pinion.
3rd Gear
clutch 1 to the inner input shaft. The inner input shaft transmits the torque to the third gear of the output
4th Gear
clutch 2 to the hollow input shaft. The hollow input shaft transmits the torque to the fourth gear of the
5th Gear
clutch 1 to the inner input shaft. The inner input shaft transmits the torque to the fifth gear of the output
6th Gear
clutch 2 to the hollow input shaft. The hollow input shaft transmits the torque to the sixth gear of the
Reverse
clutch 2 to the hollow input shaft. The hollow input shaft now transmits the torque to the reverse/2nd
double gear which acts as an idler gear to reverse the direction of rotation. This idler transmits torque to
the reverse gear of the output shaft. The torque is transmitted to the differential via the output pinion.
Identification Tags
When servicing the transaxle, refer to the identification tag located on the case.
Item Description
1 Part number
2 Build date
3 Serial number
Range Selection
The transaxle range selector has 5 positions: P, R, N, D, L.
Range Positions
P Park In the PARK position:
the parking pawl locks the final drive.
the ignition key may be removed.

R Reverse In the REVERSE position:
the vehicle may be operated in a rearward direction, at a reduced

rear ratio.
engine braking occurs.

N Neutral In the NEUTRAL position:
the vehicle is able to roll.
the output shaft is not held and is free to turn.

D Drive position with DRIVE is the normal position for most forward driving. The DRIVE position
Grade Assist provides:
automatic shifts —1st through 6th gears.
maximum fuel economy during normal operation.

with Transmission Control Switch (TCS)/Grade assist switch
pressed, only gears 1-5 are available.
L Manual Low Manual L position allows for 1st gear when the vehicle reaches slower
speeds. This position provides:
maximum engine braking.
downshifts to the lowest available gear for the current vehicle

speed.
Main Components and Functions
This transmission system has been divided into 6 sub-systems that relate to specific functional areas. These
sub-systems are:
a clutch/actuator system which transfers engine crankshaft speed and torque.

an active input system which includes applied clutch disc, bearings, speed gears and output shaft.
a passive input system which includes disengaged clutch disc, bearings, speed gears and an output
shaft system.
a synchronizer/engagement system which includes a torque carrying interface between speed gear and
output shaft.
a differential system that is the final drive output system which includes drive pinions, ring gear, support
bearings and side gears.
an electrical control system which includes control system logic, Transmission Control Module (TCM),
speed sensors, electric motors and a wire harness.
Sub-System Overview
Clutch/Actuator System

1 7B546 Clutch assembly
2 7A508 Clutch engagement system bearing assembly
3 7515 Clutch engagement system actuator lever 1
4 7515 Clutch engagement system actuator lever 2
5 7A564 Clutch engagement system guide tube
The clutch and actuator sub – system consists of engine crankshaft mounted rotating components. These
include, a center flywheel, odd and even clutch pressure plates, clutch actuating mechanisms and engagement
components. The clutch actuators are independent systems within the clutch housing that apply an axial force
to the clutch diaphragm springs causing their respective clutch to apply. This apply force is reacted back into
the transaxle through the input shaft unlike a manual transaxle dry clutch system, no thrust is applied to the
engine crankshaft. Normally the clutch capacity commands are mutually exclusive (to prevent tie-up) with minor
overlaps to allow synchronous shifting. A clutch “touch point” position must be established by a learning
algorithm within the system software. Establishing the touch point is the system’s method for ensuring that the
displacement-based clutch actuation system is properly calibrated. This is necessary so that the clutch capacity
can be controlled correctly by the TCM and be engaged and released to the required torque capacity and within
the required time.
Active Input System
ACTIVE INPUT GEAR PASSIVE INPUT GEAR OUTPUT

1 2 K1
3 4 K2
5 6 K1
R
2 1 K1
4 3 K2
6 5 K1
R K2
The active input system of the transaxle can be viewed as two transaxles within a common housing (one for
1st, 3rd & 5th and another for Reverse, 2nd, 4th & 6th). For any driving gear there is one transaxle actively
engaged in the power flow between the engine and the wheels and one that is disconnected or passive. This
section will discuss considerations for the driving input shaft system whether it be the ODD or EVEN transaxle.
The driving or active input shaft system consists of the input shaft and clutch disc, support bearings and the
meshed speed gears with their needle roller bearings.
Passive Input System
ACTIVE INPUT GEAR PASSIVE INPUT GEAR OUTPUT

1 2 K1
3 4 K2
5 6 K1
R
2 1 K1
4 3 K2
6 5 K1
R K2
The passive input system can be viewed as two transaxles within a common housing (one for 1st, 3rd & 5th
and another for Reverse, 2nd, 4th & 6th). For any driving gear there is one transaxle actively engaged in the
power flow between the engine and the wheels and one that is disconnected or passive. The non-driving, or
passive input shaft system consists of the input shaft and clutch disc, support bearings and the meshed speed
gears with their needle roller bearings.
Synchronizer Systems
Part
1 — 3rd gear single cone synchronizer system (part of 7060)
2 — 4th gear and reverse gear single cone synchronizer
systems (part of 7060)
3 — 1st, 5th and 6th gears single cone synchronizer systems
(part of 7060)
4 — 2nd gear dual cone synchronizer system (part of 7060)
The synchronizer systems are comprised of single and dual cone synchronizer systems. The synchronizers are
designed to act as the torque carrying interfaces between each speed gear and corresponding output shaft.
The synchronizer design and function are similar to manual transaxle operations.
Basic Synchronizer Hardware Operation
As in manual transaxle operation, gear pre-selection is made by sliding the synchronizer sleeve towards a
speed gear. This causes the internal splines of the synchronizer sleeve to bridge a gap between the output hub
and the external spline feature of the speed gear, thus transmitting speed and torque between the gear and
output shaft. Synchronizers are small cone wet friction clutches mounted to the transaxle output shaft. They are
used to bring the rotation speed of the engaging speed gear in sync with the output shaft speed. After
synchronous speed has been attained the final power flow connection is made possible and the synchronizer
sleeve is permitted to pass by and engage the external spline teeth on the speed gear.
Shift Fork Mechanical System Overview

1 7230 3rd gear shift fork
2 7P081 3rd gear linkage
3 7230 1st/5th gear shift fork
4 7J047 Shift drum 1
5 7J048 Small clock gear
6 7J049 Large clock gear
7 7J047 Shift drum 2
8 7230 Reverse/4th gear shift fork
9 7P081 2nd/6th linkage
10 7230 2nd/6th gear shift fork
The shift system consists of two independent sub-systems for controlling the transaxle synchronizer pre –
selections and engagements. Using this arrangement provides an independent control of the two transaxles
and a mechanical interlock that prevents two gears within the same transaxle from being engaged
simultaneously. The TCM houses two electric motors that mesh with and drive the first double gear wheel,
which drives the second double gear which finally drives the shift drum. Gearing between the shift motors and
the drums reduce speed and multiply torque. Position sensors in the TCM detect feedback of the motor angular
position. Shift drum position is learned by the TCM during a teach-in process that involves rotating each drum
against hard stops located on the shift drum and the transaxle housing.
Differential System

1 7D392 Differential ring gear
2 7H150 Differential impulse ring
3 — Differential carrier (part of 4026)
4 — Differential pinion gear (part of 4026)
5 — Differential pinion shaft (part of 4026)
The output shaft system consists of the output shaft gears, differential ring (final drive) gear and the differential
assembly. Typically when a vehicle is traveling down the road both wheels are rotating at the same speed;
however, when a vehicle is turning, the outside wheel must travel a greater distance than the inside wheel. To
do this, in the same time, the outside wheel must rotate faster than the inside wheel. The differential is
designed to provide speed compensation for the wheels to allow the vehicle to negotiate turns smoothly.
Electrical Control System

1 7M101 Input shaft speed sensor 1
2 7M101 Input shaft speed sensor 2
3 7G276 Wiring harness
4 7F293 Transmission Range (TR) sensor
5 7H103 Output Shaft Speed (OSS) sensor
6 7C604 Clutch motor 2
7 7C604 Clutch motor 1
8 7Z369 TCM
Electrical components function:
Input shaft speed sensor 1 measures the speed and the rotating direction of the input shaft 1. The input
shaft can be stationary.
Input shaft speed sensor 2 measures the speed of the input shaft 2. The rotation direction is not
measured.
OSS sensor measures the speed of the output shaft. The rotation direction is not measured.
Two electrical clutch motors are used to actuate the dual clutch in the transmission – one motor for each
clutch. The motors work independently of each other. When the clutch is fully closed, the clutch motor
provides the holding torque in addition with spring force. The clutch motors work against a clutch spring
and self disengage with no electrical power.
TR sensor detects the angular position of the shift lever shaft.
TCM is an assembly of an electronic module, sensors, and electrical motors.
The TCM 's electrical motors (2) control the mechanical shift fork system. The shift drums are the link
from electrical to mechanical operation. The TCM collects incoming vehicle, transmission and driver
demand signals and uses these signals to select the next required gear ratio. The TCM receives
transmission sensor signals and transmits clutch motor current through externally mounted wire harness.
The TCM uses these signals to control shift feel.
Transaxle Electronic Control System
Overview Electronic Transaxle Control
The electronic transaxle control system includes:
a Transmission Control Module (TCM)

a Transmission Range (TR) sensor
an Output Shaft Speed (OSS) sensor
2 input shaft speed sensors each with pre-measured shims.
2 shift motors
2 clutch motors
a Brake Pedal Position (BPP) switch
a Brake Shift Interlock Actuator (BSIA)
a starter inhibitor relay
an Transmission Control Switch (TCS)/Grade Assist button
an TCS /Grade Assist Indicator
Electrical System Components
The TCM is an assembly of an electronic module, sensors, and electrical actuators. It combines a
control module and two electric motors for gear shifting. The primary function of TCM is to collect
incoming data signals to control the transaxle, perform the interpretation of incoming data signals,
communicate with the periphery and connect the electrical and mechanical contact to the signal
transmitter and actuating elements. Vehicle and transaxle interface is achieved via two connectors;
vehicle and transaxle connector. The transaxle connector plug is located at the TCM and is the electrical
connection between the TCM and the clutch actuators and the sensors. The vehicle connector is located
at the TCM and is the electrical connection between TCM and the vehicle. The TCM is a programmable
module.
Transmission Range (TR) Sensor
The TR sensor detects the position of the manual control lever shaft. The TR sensor is mounted on the
transaxle. The TR sensor allows the vehicle to start in PARK and NEUTRAL positions. The TR sensor
output signal is linear over the measurement range and the TCM receives the selector lever position.
The signals of the TR sensor are used for the following functions:
to recognize the selector lever position.

to actuate the starter inhibitor relay.
to actuate the reversing lamps.
No substitute signal is available for the TR sensor.
If the connection is cut, the vehicle cannot be started.
The TR sensor requires to be calibrated through the adaptive learning procedures.

Output Shaft Speed (OSS) Sensor
The OSS sensor measures the speed of the output shaft. The rotation direction is not measured.
The OSS sensor is located in the clutch housing above the differential.
The OSS sensor is an inductive sensor which detects the vehicle speed by means of an impulse ring on
the differential.
The signal is used for the following functions among other things:
to determine the shift timing.

to supply the vehicle speed input signal for the TCM .
Input Shaft Speed Sensors
Input shaft speed sensor 1 measures the input speed and the rotating direction of the input shaft 1. The
input shaft can be stationary. Therefore it is necessary, that the sensor system can detect the stationary
state of the input shaft accurate. By being stationary the sensor must not indicate speed unequal to 0
(also not, if the motor runs by high speeds). The slow rolling of the car has to be detected safely.
Input shaft speed sensor 2 measures the input speed of the input shaft 2. The rotation direction is not
measured.
Shift Motors
Two electric motors are used to shift the gears in the transaxle, one motor for gears 1-3-5 and one motor
for gears R-2-4-6. The gear shifting is made by two shift drums connected to shift motor pinion via two
ideal gears. The max shifting force is 1500 N (337 lb). The motors are integrated in the TCM and work
independently of each other.
Clutch Motors
Two electrically commuted motors are used to actuate the double clutch in the transaxle – one motor per
clutch. The motors work independently of each other. When the clutch is fully closed, the motor provides
the holding torque in addition with spring force. The clutch motors work against a clutch spring and are
disengaged when they reach the zero position (rest position) with the spring force.
Brake Pedal Position (BPP) Switch
The BPP switch is mounted on the brake pedal bracket.
The signal of the BPP switch is used by the PCM for the following functions:
to activate the Brake Shift Interlock Actuator (BSIA) when the brake pedal is pressed in PARK.
No substitute signal is available for the BPP switch.
If the connection to the BPP switch is cut, the selector lever cannot be moved out of PARK.
When the ignition is switched to the ON or RUN position, the BSIA is actuated by pressing the brake
(signal from the BPP switch). This retracts the blocker so that the selector lever can be moved out of
PARK.
Brake Shift Interlock Override
NOTE: If PARK is selected again, the selector lever is locked again.
If the brake signal should fail due to a malfunction, manual unlocking of the selector lever is possible.
For this, the release of the mechanism must be done by removing the side console panel and using a
suitable tool press the BSIA lever until the selector lever can be moved out of PARK.
Starter Inhibitor Relay
The relay prevents the engine starting in selector lever positions R, D and L.
The relay obtains the information about the position of the selector lever directly from the TR sensor.
Transmission Control Switch (TCS) Button
The TCS button is located on the selector lever.
Grade Assist improves vehicle handling in hilly terrain or mountainous areas by providing additional
engine braking and extends lower gear operation on uphill climbs. Additional engine braking is provided
through the automatic transaxle shift strategy which reacts to vehicle inputs including vehicle
acceleration, accelerator pedal, brake pedal and vehicle speed. The transaxle will select gears that will
provide the desired engine braking, based on the vehicle inputs, the engine rpm during engine braking
will increase. It is recommended to return to DRIVE mode on flat terrain to provide the best fuel
economy and transaxle function. The transaxle returns to Overdrive (O/D) and grade assist is cancelled
when the TCS is pressed again.
TCS /Grade Assist Indicator
The TCS /Grade Assist indicator is located in the Instrument Cluster (IC).
It tells the driver that shifting into 6th gear is prevented by the transaxle control.
The O/D /Grade Assist light flashes to tell the driver that the transaxle control has switched to the
emergency operating mode.
Emergency Operating Program
If correct gear shifting can no longer be guaranteed due to failure of certain signals, the TCM changes to
an emergency operating program.
The driver is informed of the operation of the emergency operating program by the illumination of the
powertrain warning indicator in the IC .
Continued motoring is guaranteed in the following limited conditions based on the failure:
1st, 3rd and 5th gear if a fault with clutch 2 and/or relational components occurs.
2nd, 4th, 6th and reverse if a fault with clutch 1 and/or relational components occurs.
Diagnostic Strategy
Special Tool(s)
tool
Troubleshooting an electronically-controlled automatic transaxle is simplified by using the proven

method of diagnosis. One of the most important things to remember is that there is a definite procedure
to follow.
Preliminary Inspection
Verify the concern by operating the vehicle.

Check the transmission fluid levels and condition.
Check selector lever linkages for correct adjustment.
Diagnostics
Carry out On-Board Diagnostic (OBD) procedures Key ON Engine OFF (KOEO) and Key ON
Engine Running (KOER).
Record all DTCs.
Repair all non-transaxle DTCs first.
Repair all transaxle DTCs second.
Erase all continuous DTCs and attempt to repeat them.
Repair all continuous DTCs.
If only pass DTCs are obtained, proceed to the Diagnosis by Symptom Index. Refer to Diagnosis
By Symptom in this section for further information and diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time.
Preliminary Inspection
Determine Customer Concern
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention
to the following items:
Hot or cold vehicle operating temperature

Hot or cold ambient temperatures
Type of terrain
Vehicle loaded/unloaded
City/highway driving
Upshift
Downshift
Coasting
Engagement
Noise/vibration — check for dependencies, either rpm dependent, vehicle speed dependent, shift
dependent, gear dependent, range dependent or temperature dependent.
Transmission Fluid Level and Condition Check
NOTICE: If transaxle noise is reported, first check the transmission fluid level. The vehicle
should not be driven if the transmission fluid level is low or damage can occur.
NOTE: The vehicle should not be driven if the transmission fluid level is low.
An incorrect transmission fluid level may affect the transaxle operation and can result in transaxle
damage. To correctly check and add transmission fluid to the transaxle, refer to Transmission Draining
and Filling in this section.
A low transmission fluid level can result in poor transaxle shifting, engagement or damage. It can also
indicate a leak in the transaxle seals.
1. Check the transmission fluid condition.

Observe the color of the transmission fluid. Allow the transmission fluid to drip onto a white
cloth and examine the stain. Check the transmission fluid for contamination or metal
particles.
Transmission fluid should appear nearly clear.
Visual Inspection
Special Tool(s)
tool
Visually inspect the vehicle for obvious causes of the customer concern. Check for:
Electronic add-on items

Vehicle modification
Leaks; refer to Leakage Inspection in this section.
Inspect the Selector Lever and Components
Check selector lever linkage adjustment by matching the detents in the selector lever with those in the
transaxle. If they do not match, adjust the selector lever cable. Refer to Section 307-05 .
Inspect the selector lever and components for:
binding
signs of damage.
broken clips
binding
cable not fully seated or in brackets
hold-down bracket bolts are loose
correct routing
correct adjustment
Evaluation of the Transaxle
1. During the road test, use the following driving methods to diagnose the problem.
Start the engine.
Evaluate the noise in NEUTRAL while the vehicle is parked.
Check whether the noise is present.
With the parking brake engaged, move the selector lever to DRIVE. Apply very
slight pressure to the throttle and note if the noise level is reduced.
With the vehicle in PARK, check whether the noise is present as the engine speed
is increased. If the noise reduces, note the engine speed at which this occurs.
Listen for any change in noise while changing engine rpm.
Drive the vehicle and allow it to shift through all of the gear ranges, including reverse.
Listen for any change in noise in a particular gear.
Drive the vehicle in the gear in which the noise is most noticeable. Listen for any change in
noise.
Drive the vehicle in the gear in which the noise is most noticeable and shift the transaxle
into NEUTRAL. Allow the vehicle to coast. Note any change in noise.
2. Compare the road test results with the symptom charts. It is a list of conditions that are typical
faults into which the transaxle will fall:
GO to Diagnosis By Symptom .
Diagnostic Parameters Identification (PID) Chart
Accessing PIDs
The following general PID list may be of use to the technician when exercising output state control:
PIDs PID Description

1stBLCK_GR_JMP 1st Gear Is Blocked Due To Gear Jump Occurred
1stBLOCK_TMP 1st Gear Is Blocked Temporarily Protect Mode
2ndBLCK_GR_JMP 2nd Gear Is Blocked Due To Gear Jump Occurred
2ndBLOCK_TMP 2nd Gear Is Blocked Temporarily Protect Mode
3rdBLCK_GR_JMP 3rd Gear Is Blocked Due To Gear Jump Occurred
3rdBLOCK_TMP 3rd Gear Is Blocked Temporarily Protect Mode
4thBLCK_GR_JMP 4th Gear Is Blocked Due To Gear Jump Occurred
4thBLOCK_TMP 4th Gear Is Blocked Temporarily Protect Mode
CLTC_A_BLCK Clutch A Actuator Blocked a
CLTC_A_CLOS_F Clutch A Reference Position Closed Failed a
CLTC_A_CUR_MES Clutch A Actuator Current - Measured a
CLTC_A_F_MANAG Clutch A Failure Management Status a
CLTC_A_LOWCONF Clutch A Low Confidence In Sensed Position a
CLTC_A_MTR_DSD Clutch A Actuator Motor - Desired a
CLTC_A_OPEN_F Clutch A Reference Position Open Direction Failed a
CLTC_A_POS_F Clutch Motor A - Position Sensor Fault
CLTC_A_SEQ_F Clutch Motor A - Phase Sequence Fault
CLTC_A_SLFDIAG Clutch A Self Diagnostic Procedure Status a
CLTC_A_SLIPMES Clutch A Measured Slip a
CLTC_A_SPRNG Clutch A Spring Cannot Fully Open Clutch a
CLTC_B_BLCK Clutch B Actuator Blocked b
CLTC_B_CLOSE_F Clutch B Reference Position Closed Failed b
CLTC_B_CUR_MES Clutch B Actuator Current - Measured b
CLTC_B_F_MANAG Clutch B Failure Management Status b
CLTC_B_LOWCONF Clutch B Low Confidence In Sensed Position
CLTC_B_MTR_DSD Clutch B Actuator Motor - Desired b
CLTC_B_OPEN_F Clutch B Reference Position Open Direction Failed b
CLTC_B_POS_F Clutch Motor B - Position Sensor Fault
CLTC_B_SEQ_F Clutch Motor B - Phase Sequence Fault
CLTC_B_SLFDIAG Clutch B Self Diagnostic Procedure Status b
CLTC_B_SLIPMES Clutch B Measured Slip b
CLTC_B_SPRNG Clutch B Spring Cannot Fully Open Clutch b
CLTC_MTR_A_F Clutch Motor A - Phase Circuit Fault
CLTC_MTR_B_F Clutch Motor B - Phase Circuit Fault
CLUTCH_A_OPEN Clutch A Is Completely Open - Measured
CLUTCH_B_OPEN Clutch B Is Completely Open - Measured
FOOT_BRAKE Foot Brake - Foot brake state used by strategy
GEAR_CMD Gear Commanded
GEAR_ENGAGED Transmission Gear Engaged
GEAR_OSC Gear Command by Output State Control
GEARBX_SF_A_F Gearbox Error Status for Shift Fork A
GEARBX_SF_B_F Gearbox Error Status for Shift Fork B
ISS_A_PC_F Input Shaft Speed Sensor A - Power/Circuit Fault
ISS_A_RAW Input Shaft Speed A - Raw
ISS_B_PC_F Input Shaft Speed Sensor B - Power/Circuit Fault
ISS_B_RAW Input Shaft Speed B - Raw
ISS_EFFECT_RPM Effective Input Shaft Speed
OSS_PC_F Output Shaft Speed Sensor - Power or Circuit Fault
OSS_SRC Unfiltered Output Shaft Speed A
REVBLCK_GR_JMP Reverse Gear Is Blocked Due To Gear Jump Occurred
REVBLOCK_TMP Reverse Is Blocked Temporarily Protect Mode
RLC Reverse Lamp Control
RLC_F Reverse Control Lamp Status
SF_A_CURR_MES Shift Fork A Actuator Current - Measured
SF_A_ENGAG_STA Shift Fork A Engagement Control Status
SF_A_GRRAT_MES Shift Fork A Gear Ratio - Measured
SF_A_POS_MES Shift Fork A Actuator Position - Measured
SF_A_POS_STAT Position Signal Status for Shift Fork A Actuator
SF_A_POS_TARG Shift Fork A Actuator Position - Target
SF_A_ROTAT_MES Shift Fork A Rotational Position - Measured
SF_B_CURR_MES Shift Fork B Actuator Current - Measured
SF_B_ENGAG_STA Shift Fork B Engagement Control Status
SF_B_GRRAT_MES Shift Fork B Gear Ratio - Measured
SF_B_POS_MES Shift Fork B Actuator Position - Measured
SF_B_POS_STAT Position Signal Status for Shift Fork B Actuator
SF_B_POS_TARG Shift Fork B Actuator Position - Target
SF_B_ROTAT_MES Shift Fork B Rotational Position - Measured
SHFRK_A_CAL_E1 Self Calibration Error - Shift Fork A Movement
SHFRK_A_CAL_E2 Self Calibration Error - Shift Fork A Reference
SHFRK_B_CAL_E1 Self Calibration Error - Shift Fork B Movement
SHFRK_B_CAL_E2 Self Calibration Error - Shift Fork B Reference
SHFRK_NO_CAL_0 Self Calibration Prevented - Brake Input Status
SHFRK_NO_CAL_1 Self Calibration Prevented - Clutch A is Not Open
SHFRK_NO_CAL_2 Self Calibration Prevented - Clutch B is Not Open
SHFRK_NO_CAL_3 Self Calibration Prevented - Output Shaft Speed
SHFRK_NO_CAL_4 Self Calibration Prevented - Actuator Supply Voltage
SHFTLCK_ALLW Transmission Range Shift Lock Output Allow
SHFTLCK_ALLW_F Transmission Range Shift Lock Output Allow Status
SHIFT_A Shifting In Progress on Shift Fork A
SHIFT_B Shifting In Progress on Shift Fork B
TCIL Transmission Control Indicator Light
TCS_DEPRES Transmission Control Switch Pressed
TCS_STATE Transmission Control Switch Requested State
TR_A_DC Transmission Range Sensor Input A Duty Cycle
TR_A_POS_MEAS Transmission Range Sensor A Position - Measured
TR_A_UR Transmission Range Sensor Input A Unreliable
TR_B_DC Transmission Range Sensor Input B Duty Cycle
TR_B_POS_MEAS Transmission Range Sensor B Position - Measured
TR_B_UR Transmission Range Sensor Input B Unreliable
TR_CORRECTED Transmission Range Sensor Position - Corrected
TR_CRANK Transmission Range Input Allowing Engine Start
TR_CRANK_F Park Neutral Starter Enable Output Fault Detected
TR_SUPPLY_F Transmission Range Supply Voltage Output Fault
TRAN_RAT Transmission Gear Ratio
a Clutch A = Clutch 1
b Clutch B = Clutch 2
Diagnostic Trouble Code (DTC) Charts
Special Tool(s)
tool
DTC Chart
Five
Digit
DTC Description Condition Symptom Action
C0044:28 Brake pressure Brake pressure Transaxle defaults For additional
sensor A: signal bias sensor signals do not to NEUTRAL information, refer to
level out of range / match Section 206-09 .
zero adjustment
failure
P06A6 Sensor reference Input shaft speed Disabled 3rd and GO to Pinpoint Test
voltage A circuit sensor 1 power 5th gears. Only C.
range/performance supply circuit failure engage in 1st gear
at a stop. Neutral
shift drum 1 after
launch.
P06A7 Sensor reference Input shaft speed Disabled 2nd, 4th GO to Pinpoint Test
voltage B circuit sensor power supply and 6th gears. C.
range/performance circuit failure Neutral shift drum 2
in forward range.
P06A8 Sensor reference Output Shaft Speed Substitute Anti-Lock GO to Pinpoint Test
voltage C circuit (OSS) power supply Brake System (ABS) C .
range/performance circuit failure. wheel speed, input
shaft speed sensor
1 or input shaft
speed sensor 2 for
OSS .
P0700 Transmission control TCM has sent a DTC Malfunction Code set in PCM to
system DTC present error code to PCM Indicator Lamp indicate that there is a
indicating that (MIL) may be transmission code(s)
additional TCM DTCs illuminated. Other present and technician
may be present. transmission should check the TCM
concerns present. for codes. RERUN
OBD test and retrieve
transmission DTCs
from TCM .
P0701 Wrong engine control Transmission control Will turn on See more specific
fault - monitors the system Malfunction DTC. If no other DTCs
torque up and engine range/performance Indicator Lamp are set, clear code and
speed requests from (MIL). re-test.
the Transmission
Control Module
(TCM), if it finds a
fault it turns off these
requests
P0702 Transmission control Sets with P0882 See more specific Verify TR
system electrical (voltage out of range DTC. sensor adaptive
low) or P0883 learning. For
(voltage out of range additional
high) information,
refer to
Transmission
Adaptive
Learning in this
section.
Adjust selector
lever cable.
Refer to Section
307-05 . If
concern still
present, replace
TR sensor.
P0706 TR sensor A circuit TR sensor A Default to GO to Pinpoint Test
range/performance frequency out of NEUTRAL at D .
range (200-300 Hz). low speed.
Code does not set for Crank
open, short to ground disabled if
or short to power fault present
(duty cycle less than at start-up
2.0 or greater than Will turn on
98.0 disables this Malfunction
code) Indicator
Lamp (MIL).
P0707 TR sensor A circuit TR sensor A duty Default to Verify TR
low cycle out of range low NEUTRAL at sensor adaptive
(below Park Min duty low speed. learning. For
cycle) Crank additional
disabled if information,
fault present refer to
at start-up Transmission
Will turn on Adaptive
MIL . Learning in this
section.
Adjust selector
lever cable.
Refer to Section
307-05 . If
concern still
present, replace
TR sensor.
P0708 TR sensor A circuit TR sensor A duty Default to GO to Pinpoint Test
high cycle out of range NEUTRAL at D .
high (below Low Max low speed.
duty cycle). Crank
disabled if
fault present
at start-up
Will turn on
MIL .
P0709 TR sensor A circuit TR intermittent PARK Sets with GO to Pinpoint Test
intermittent or NEUTRAL signal P0706, D.
during pre-crank test P0707 or
P0708.
Will turn on
MIL .
P0715 Insufficient input from Input shaft speed Disabled 3rd and GO to Pinpoint Test
input shaft speed sensor 1 circuit failure 5th gears. Only C.
sensor detected engages in 1st at a
stop, Neutral Shift
Drum 1 after launch.
P0716 Input shaft speed Erratic input shaft Disabled 3rd and GO to Pinpoint Test
sensor A circuit speed sensor 1 signal 5th gears. Only C.
- noisy signal, out of engages in 1st at a
range high, or not stop, neutral shift
plausible. Detection drum 1 after launch.
of this fault is
disabled if a power
supply (P06A6) or
circuit fault (P0715) is
present.
P0717 Input shaft speed Input shaft speed Disabled 3rd and GO to Pinpoint Test
sensor A circuit no sensor 1 failed to 0 5th gears. Only C.
signal speed. Detection of engages in 1st at a
this fault is disabled if stop, neutral shift
a power supply drum 1 after launch.
(P06A6) or circuit
fault (P0715) is
present
P0718 Input shaft speed PCM has detected an Disabled 3rd GO to Pinpoint Test
sensor A signal erratic input shaft and 5th C.
intermittent speed sensor signal. gears. Only
engages in
1st at a stop,
neutral shift
drum 1 after
launch.
Sets with
P06A6,
P0715,
P0716 or
P0717
Will turn on
Malfunction
Indicator
Lamp (MIL).
P0720 Insufficient input from OSS circuit failure Substitute ABS GO to Pinpoint Test
OSS sensor circuit detected. wheel speed, input C.
shaft speed sensor
1 or input shaft
speed sensor 2 for
OSS
P0721 OSS sensor signal Erratic OSS signal - Substitute ABS GO to Pinpoint Test
error noisy signal, out of wheel speed, input C.
range high, or not shaft speed sensor
plausible. Detection 1 or input shaft
of this fault is speed sensor 2 for
disabled if a power OSS
supply (P06A8) or
circuit fault (P0720) is
present.
P0722 OSS sensor no OSS failed to 0 speed Substitute ABS GO to Pinpoint Test
signal when vehicle wheel speed, input C.
conditions indicate shaft speed sensor
OSS should be non- 1 or input shaft
zero. Detection of this speed sensor 2 for
fault is disabled if a OSS
power supply
(P06A8) or circuit
fault (P0720) is
present.
P0723 OSS sensor circuit Sets with P0720, Substitute GO to Pinpoint Test
intermittent P0721 or P0722 ABS wheel C.
speed, input
shaft speed
sensor 1 or
input shaft
speed sensor
2 for OSS
Will turn on
Malfunction
Indicator
Lamp (MIL).
P072B Stuck in reverse Shift drum 2 is unable Shift drum 2 REPAIR all
to disengage mechanical speed sensor,
REVERSE gear fault. clutch motor 2,
Shift drum 2 and clutch 2
motor fault. performance
Electrical DTCs first.
faults that GO to Pinpoint
prevent shift Test B .
drum 2 from INSPECT shift
rotating (open drum, shift fork,
circuits synchronizer
cannot be and TCM Shift
detected Motors for wear
during or damage.
operation). REPLACE as
Clutch 2 needed.
stuck on (if REFER to
undetected Transaxle in
may prevent this section.
shift drum 2
movement).
2nd, 4th and
6th gears
disabled.
P072C Stuck in gear 1 Shift drum 1 is unable Shift drum 1 REPAIR all
to disengage 1st gear mechanical speed sensor,
fault. clutch motor 1,
cannot be and TCM shift
detected motors for wear
during or damage.
Clutch 1 needed.
shift drum 1
movement).
3rd and 5th
gears
disabled.
P072D Stuck in gear 2 Shift drum 2 is unable Shift drum 2 REPAIR all
to disengage 2nd mechanical speed sensor,
gear fault. clutch motor 2,
during or damage.
Clutch 2 needed.
shift drum 2
movement).
REVERSE,
4th and 6th
gears
disabled.
P072E Stuck in gear 3 Shift drum 1 is unable Shift drum 1 REPAIR all
to disengage 3rd gear mechanical speed sensor,
during or damage.
Clutch 1 needed.
shift drum 1
movement).
1st and 5th
gears
disabled.
P072F Stuck in gear 4 Shift drum 2 unable Shift drum 2 REPAIR all
to disengage 4th gear mechanical speed sensor,
during or damage.
Clutch 2 needed.
shift drum 2
movement).
REVERSE,
2nd and 6th
gears
disabled.
P073A Stuck in gear 5 Shift drum 1 unable Shift drum 1 REPAIR all
during or damage.
Clutch 1 needed.
shift drum 1
movement).
1st and 3rd
gears
disabled.
P073B Stuck in gear 6 Shift drum 2 unable Shift drum 2 REPAIR all
during or damage.
Clutch 2 needed.
shift drum 2
movement).
REVERSE,
2nd and 4th
gears
disabled.
P073E Unable to engage Shift drum 2 is unable Motor turns, INSPECT shift fork
reverse to engage REVERSE but cannot and synchronizer for
synchronize wear or damage.
and engage REPLACE as needed.
REVERSE REFER to Transaxle in
gear. this section.
Reverse gear
is disabled.
P073F Unable to engage Shift drum 1 is unable Motor turns, INSPECT shift fork
gear 1 to engage 1st gear but cannot and synchronizer for
1st gear. REFER to Transaxle in
1st gear this section.
disabled.
P074A Unable to engage Shift drum 2 is unable Motor turns, INSPECT shift fork
gear 2 to engage 2nd gear but cannot and synchronizer for
2nd gear. REFER to Transaxle in
2nd gear this section.
disabled.
For certain
faults shift
drum controls
will not pass
through a
failed gear;
reverse, 4th
and 6th gears
may also be
disabled.
P074B Unable to engage Shift drum 1 is unable Motor turns, INSPECT shift fork
gear 3 to engage 3rd gear but cannot and synchronizer for
3rd gear. REFER to Transaxle in
3rd gear this section.
disabled.
For certain
faults shift
drum controls
will not pass
through a
failed gear;
1st and 5th
gears may
also be
disabled.
P074C Unable to engage Shift drum 2 is unable Motor turns, INSPECT shift fork
gear 4 to engage 4th gear but cannot and synchronizer for
4th gear. REFER to Transaxle in
4th gear this section.
disabled.
For certain
faults shift
drum controls
will not pass
through a
failed gear;
reverse, 2nd
and 6th gears
may also be
disabled.
P074D Unable to engage Shift drum 1 is unable Motor turns, INSPECT shift fork
disabled.
P074E Unable to engage Shift drum 2 is unable Motor turns, INSPECT shift fork
disabled.
P07A2 Transmission friction Clutch A (1st, 3rd and 1st, 3rd and 5th Check the clutch for
element A 5th gears) stuck off a gears disabled. wear or damage. For
performance/stuck additional information,
off refer to Clutch in this
section.
P07A3 Transmission friction Clutch A (1st, 3rd and Spring. Check the clutch for
element A stuck on 5th gears) spring fault Blockage. wear or damage. For
or clutch motor 1 is 3rd and 5th additional information,
blocked, preventing it gears refer to Clutch in this
traveling its full range. disabled. section.
a
P07A4 Transmission friction Clutch B (R, 2nd, 4th Reverse, 2nd, 4th Check the clutch for
element B and 6th) stuck off. b and 6th gears wear or damage. For
performance/stuck disabled additional information,
off refer to Clutch in this
section.
P07A5 Transmission friction Clutch B (reverse, Spring. Check the clutch for
element B stuck on 2nd, 4th and 6th Blockage. wear or damage. For
gears) spring fault or Reverse, additional information,
clutch motor 2 is 2nd, 4th and refer to Clutch in this
blocked, preventing it 6th gears section.
traveling its full range. disabled.
b
P0805 Clutch position Clutch motor 1 (ATIC) 1st, 3rd and 5th GO to Pinpoint Test
sensor A circuit fault gears disabled. A.
P0806 Clutch position Clutch motor 1 hall 1st, 3rd and 5th GO to Pinpoint Test
sensor A circuit sensor fault detected gears disabled A.
range/performance
P0809 Clutch position Clutch motor 1 1st, 3rd and 5th GO to Pinpoint Test
sensor A circuit sequence fault gears disabled. A.
intermittent detected
P087A Clutch position Clutch motor 2 (ATIC) Reverse, 2nd, 4th GO to Pinpoint Test
sensor B circuit fault detected and 6th gears A.
disabled.
P087B Clutch position Clutch motor 2 hall Reverse, 2nd, 4th GO to Pinpoint Test
sensor B circuit sensor fault detected and 6th gears A.
range/performance disabled.
P087E Clutch position Clutch motor 2 Reverse, 2nd, 4th GO to Pinpoint Test
sensor B circuit sequence fault and 6th gears A.
intermittent detected disabled.
P0882 TCM power input TCM voltage out of Shift drums will not GO to Pinpoint Test
signal low range - low engage new gears. A.
P0883 TCM power input TCM voltage out of No noticeable Section 414-00 .
signal high range - high problems.
P0900 Clutch A actuator Clutch motor 1 open 1st. 3rd and 5th GO to Pinpoint Test
control circuit / open circuit fault detected gears disabled. A.
P0901 Clutch A actuator Sets with P0900, Will turn on MIL . GO to Pinpoint Test
control circuit P0902 or P0903 A.
range/performance
P0902 Clutch A actuator Clutch motor 1 short 1st, 3rd and 5th GO to Pinpoint Test
control circuit low to ground fault gears disabled. A.
detected
P0903 Clutch A actuator Clutch motor 1 short 1st, 3rd and 5th GO to Pinpoint Test
control circuit high to power fault gears disabled. A.
detected
P090A Clutch B actuator Clutch motor 2 open Reverse, 2nd, 4th GO to Pinpoint Test
control circuit / open circuit fault detected and 6th gears A.
disabled.
P090B Clutch B actuator Sets with P090A, Will turn on MIL . GO to Pinpoint Test
control circuit P090C or P090D A.
performance
P090C Clutch B actuator Clutch motor 2 short Reverse, 2nd, 4th GO to Pinpoint Test
control circuit low to ground fault and 6th gears A.
detected disabled.
P090D Clutch B Actuator Clutch motor 2 short Reverse, 2nd, 4th GO to Pinpoint Test
Control Circuit High to power fault and 6th gears A.
detected disabled.
P163E TCM programming Gear ratio calibration Gear ratios Verify TCM calibration.
error error used within For additional
Ford software information, refer to
and shift Transmission Adaptive
drum controls Learning in this
do not match. section.
The
calibration
does not
match the
hardware.
P2700 Transmission friction — — Check the clutch for
element A apply time wear or damage. For
range/performance additional information,
refer to Clutch in this
section.
P2701 Transmission friction — — Check the clutch for
element B apply time wear or damage. For
range/performance additional information,
refer to Clutch in this
section.
P2765 Input speed sensor 2 Input shaft speed 2 2nd, 4th and 6th GO to Pinpoint Test
circuit circuit failure detected gears disabled. C.
P2766 Input speed sensor 2 Erratic input shaft 2nd, 4th and 6th GO to Pinpoint Test
circuit range / speed sensor 1 signal gears disabled. C.
performance - noisy signal, out of
range high, or not
plausible
P2767 Input speed sensor 2 Input shaft speed 2nd, 4th and 6th GO to Pinpoint Test
circuit no signal sensor failed to 0 gears disabled. C.
speed when vehicle
conditions indicate
that input shaft speed
sensor should be
non-zero
P2768 Input speed sensor 2 Sets with P06A7, 2nd, 4th and GO to Pinpoint Test
circuit intermittent P2765, P2766 or 6th gears C.
P2767 disabled.
Will turn on
MIL .
P2801 TR sensor B circuit TR B frequency out of Default to GO to Pinpoint Test
range/performance range (200-300 Hz). neutral at low D .
Code does not set for speed.
open, short to ground Crank
or short to power disabled if
(duty cycle less than fault present
2.0 or greater than at start-up
98.0 disables this
code.
P2802 TR sensor B circuit TR sensor B duty Default to GO to Pinpoint Test
low cycle out of range low neutral at low D .
speed.
Crank
disabled if
fault present
at start-up
P2803 TR sensor B circuit TR sensor B duty Default to GO to Pinpoint Test
high cycle out of range neutral at low D .
high speed.
Crank
disabled if
fault present
at start-up
P2804 TR sensor B circuit Sets with P2801, See P0706, P0707 GO to Pinpoint Test
intermittent P2802 or P2803 and P0708. D.
P2805 TR sensor A / B TR sensor A and B Defaults to GO to Pinpoint Test
correlation sum must be 100 +/- neutral at low D .
2x sensor tolerance. speed.
If both are "in- Crank
range" (no other disabled if
DTC's set) but the fault present
sum fails to add up to at start up.
100% this DTC will
set
P2831 Shift fork A position Shift drum motor 1 Shift drum 1 will no GO to Pinpoint Test
circuit intermittent fault detected longer move, so B.
only the current gear
is available on shift
drum 1
P2832 Shift fork A position Shift drum - shift 1st, 3rd, and GO to Pinpoint Test
circuit drum controls found 5th gears B.
range/performance an error with shift disabled.
drum 1 that indicated If shift drum 1
it has lost position indicates
confidence. state of shift
drum 1
unknown the
transaxle will
default to
neutral.
P2835 Shift fork A position Shift drum motor 1 Disables all the GO to Pinpoint Test
circuit intermittent sequence fault gears but the B.
detected current engaged
gear.
P2836 Shift fork B position Shift drum motor 2 Shift drum will no GO to Pinpoint Test
circuit fault detected longer move. B.
Current gear is the
only gear available.
P2837 Shift fork B position Shift drum 2 - shift Reverse, GO to Pinpoint Test
circuit drum controls found 2nd, 4th and B.
range/performance an error with shift 6th gears
drum 2 that indicated disabled.
it has lost position If shift drum
confidence control
indicates
state of shift
drum 2 as
unknown the
transaxle will
default to
neutral.
P283A Shift fork B position Shift drum motor 2 Disables all gears GO to Pinpoint Test
circuit intermittent sequence fault but the current gear. B .
detected
P285B Shift fork A actuator Shift drum motor 2 Disables all gears GO to Pinpoint Test
circuit / open open circuit fault but the current gear. B .
detected
P285C Shift fork A actuator Sets with P285F, Disables all GO to Pinpoint Test
circuit performance P2861 or P2862 gears but the B .
current gear.
Will turn on
MIL .
P285D Shift fork A actuator Shift drum motor 1 Disables all gears GO to Pinpoint Test
circuit low short to ground fault but the current gear. B .
detected
P285E Shift fork A actuator Shift drum motor 1 Disables all gears GO to Pinpoint Test
circuit high short to power fault but the current gear. B .
detected
P285F Shift fork B actuator Shift drum motor 1 Disables all gears GO to Pinpoint Test
circuit / open open circuit fault but the current gear. B .
detected
P2860 Shift fork B actuator Sets with P285F, Disables all GO to Pinpoint Test
circuit performance P2861 or P2862 gears but the B .
current gear.
Will turn on
MIL .
P2861 Shift fork B actuator Shift drum motor 2 Disables all gears GO to Pinpoint Test
circuit low short to ground fault but the current gear. B .
detected
P2862 Shift fork B actuator Shift drum motor 2 Disables all gears GO to Pinpoint Test
circuit high short to power fault but the current gear. B .
detected
P286F Clutch A TIP unintended Disables clutch 1. Check the clutch for
disengagement time launch protection or wear or damage. For
performance/too slow wrong driving additional information,
direction tripped. refer to Clutch in this
section.
P2872 Clutch A stuck Clutch confidence Neutral shift drum 1 GO to Pinpoint
engaged error and disables all Test B .
gears with clutch 1 Check the
on. clutch for wear
or damage. For
additional
information,
refer to Clutch
in this section.
P2877 Clutch B TIP unintended Disables clutch 2. Check the clutch for
disengagement time launch protection or wear or damage. For
performance/too slow wrong driving additional information,
direction tripped. refer to Clutch in this
section.
P287A Clutch B stuck Clutch confidence Neutral shift drum 2 GO to Pinpoint
engaged error and disables all Test B .
gears with clutch 2 Check the
on. clutch for wear
or damage. For
additional
information,
refer to Clutch
in this section.
P287B Shift fork calibration Transmission control Defaults to neutral Verify TCM calibration.
not learned module adaptive until a transmission For additional
learning failure control module information, refer to
adaptive learning Transmission Adaptive
completes Learning in this
successfully section.
U0028 Vehicle non- MIL sister code Holds current Refer to Section 418-
communication bus A to U0073 gear until the 00 .
vehicle speed
is too low,
then defaults
to neutral.
U0073 Control module Complete Controller Holds current Refer to Section 418-
communication bus A Area Network (CAN) gear until the 00 .
off failure vehicle speed
is too low,
then defaults
to NEUTRAL.
Will turn on
MIL .
U0100 Lost communication Lost communication Holds current Refer to Section 418-
with Engine Control with the PCM . gear until the 00 .
Module (ECM)/ PCM vehicle speed
A is too low,
then defaults
to neutral.
Will turn on
MIL .
U0115 Lost Communication Lost communication FMEM mode. Refer to Section 418-
With ECM / PCM B with the PCM . 00 .
U0121 Lost communication Lost communication Provide failure mode Refer to Section 418-
with ABS control with ABS substitutions for 00 .
module missing brake
pressure and wheel
speeds
U0129 Lost communication Lost communication Provide failure mode Refer to Section 418-
with ABS control with ABS control substitutions for 00 .
module module missing brake
pressure and wheel
speeds
U0140 Lost communication — — Refer to Section 418-
with Body Control 00 .
Module (BCM)
U0141 Lost communication — — Refer to Section 418-
with BCM A 00 .
U0155 Lost communication Lost communication — Refer to Section 418-
with Instrument with the IPC control 00 .
Panel Cluster (IPC) module
control module
U0294 Lost communication Lost communication Holds current gear Refer to the
with PCM with PCM until speed is too Powertrain
low then defaults to Control/Emissions
neutral. Diagnosis (PC/ED)
manual.
U0401 Invalid data received Receiving CAN Holds current gear Refer to the
from ECM / PCM A messages from until speed is too Powertrain
PCM , but PCM is low then defaults to Control/Emissions
indicating failures of neutral. Diagnosis (PC/ED)
certain key signals manual.
U0415 Invalid data received Receiving CAN — Refer to Section 206-
from ABS control messages from ABS , 09 .
module but ABS is indicating
failures of certain key
signals
a Clutch A = Clutch 1
b Clutch B = Clutch 2
Transaxle Connector Layouts
Transmission Control Module (TCM) Connector C1750B
Item Description
1 Clutch 2 Phase W
2 Clutch 2 Phase U
3 Clutch 2 Phase V
4 Clutch 1 Phase W
5 Clutch 1 Phase V
6 Clutch 1 Phase U
8 Input Shaft Speed Sensor 2
9 Output Shaft Speed (OSS)
10 Input Shaft Speed Sensor 1
12 Input Shaft Speed Sensor 2 Supply
19 Clutch Motor 1
21 Input Shaft Speed Sensor 1 Supply
24 Transmission Range (TR) Sensor 1 Input
25 TR Sensor 2 Input
32 Clutch Motor 1
34 TR Sensor Supply 5 Volt
35 TR Sensor Ground
37 OSS Supply
42 Clutch Motor 2
43 Clutch Motor 2
44 Clutch Motor 2
45 Clutch Motor 1
55 Clutch Motor 2
56 Clutch Motor 2
57 Clutch Motor 1
58 Clutch Motor 1
Transmission Control Module (TCM) Connector C1750A
Item Description
1 Power
2 Power
3 Ground
4 Ground
5 Ground
6 Ground
11 Overdrive (O/D) Cancel
18 Power
31 Ignition Run Start
34 Can Bus High Speed High
35 Can Bus High Speed Low
39 P/N Switch/Clutch 2
40 REVERSE Lamp
49 Brake Shift Interlock Actuator (BSIA)
Transmission Range (TR) Sensor Vehicle Harness C167
Pin Number Circuit Function

1 Transmission Range (TR) sensor 2 input
2 Ground
3 Power
4 TR sensor 1 input
Output Shaft Speed (OSS) Vehicle Harness C193

1 Power
2 Output Shaft Speed (OSS)
Input Shaft Speed Sensor 1 Vehicle Harness C143

1 Input Shaft Speed Sensor
2 Power
Input Shaft Speed Sensor 2 Vehicle Harness C164

1 Power
2 Input Shaft Speed Sensor
Clutch Motor 1 C1633 and Clutch Motor 2 C1634

1 Power
2 Hall Effect
3 Hall Effect
4 Hall Effect
5 Ground
6 Phase U
7 Phase W
8 Phase V
Pinpoint Tests
Special Tool(s)

tool
Any time an electrical connector is disconnected, inspect the connector for terminal condition, corrosion
and contamination. Also inspect the connector seal for damage. Clean, repair or install new as
necessary.
Pinpoint Tests
Refer to Wiring Diagrams Cell 29 for schematic and connector information.
PINPOINT TEST A: CLUTCH MOTORS
NOTE: Refer to the transaxle connector illustrations Transaxle Connector Layouts in this section.

A1 TEST BJB FUSE 2 (50A)
Check fuse: Battery Junction Box (BJB) fuse 2 (50A). Yes
Is the resistance less than 5 ohms? GO to A2 .
No
(YE/RD) for a short to
ground. INSTALL a new
fuse. TEST the system
Refer to clutch test in
Transmission Adaptive
Learning .
A2 TEST BJB FUSE 27 (7.5A)
Check fuse: BJB fuse 27 (7.5A). Yes
No
(BU/RD) for a short to
A3 TEST CJB FUSE 23 (10A)
Check fuse: Central Junction Box (CJB) fuse 23 (10A). Yes
No
(BN/YE) for a short to
A4 CHECK FOR VOLTAGE AT THE TCM CONNECTOR
Ignition OFF. Yes
Disconnect: Transmission Control Module (TCM) C1750A. GO to A5 .
Inspect both ends of the connector for damage or pushed-out
pins, corrosion, loose wires and missing or damaged seals. No
Measure the voltage between TCM C1750A-1, circuit SBB02 REPAIR circuit SBB02
(YE/RD) harness side and ground. (YE/RD) for an open.
RECONNECT all
components. TEST the
system for normal
operation.
Measure the voltage between TCM C1750A-2, circuit SBB02

(YE/RD) harness side and ground.

A5 CHECK FOR KAM VOLTAGE AT THE TCM CONNECTOR
Measure the voltage between TCM C1750A-18, circuit SBB27 Yes
(BU/RD) harness side and ground. GO to A6 .
No
(BU/RD) for an open.
RECONNECT all
system for normal
operation.

A6 CHECK FOR IGNITION POWER AT THE TCM CONNECTOR
Ignition ON. Yes
Measure the voltage between TCM C1750A-31, circuit CBP23 GO to A7 .
(BN/YE) harness side and ground.
No
(BN/YE) for an open.
RECONNECT all
system for normal
operation.

A7 CHECK THE TRANSAXLE WIRING HARNESS FOR AN OPEN
CIRCUIT
Ignition OFF. Yes
Disconnect: TCM C1750B. GO to A8 .
Disconnect: Clutch Motor 1 C1633. REPAIR the circuit(s) for
Inspect both ends of the connector for damage or pushed-out an open. RECONNECT
pins, corrosion, loose wires and missing or damaged seals. all components. TEST
Disconnect: Clutch Motor 2 C1634. the system for normal
Inspect both ends of the connector for damage or pushed-out operation.
pins, corrosion, loose wires and missing or damaged seals.
If diagnosing a clutch motor 1 concern, measure the resistance
between TCM C1750B, harness side and clutch motor 1 C1633,
TCM Clutch Motor 1

C1750B-58 C1633-1
C1750B-19 C1633-2
C1750B-45 C1633-3
C1750B-32 C1633-4
C1750B-57 C1633-5
C1750B-6 C1633-6
C1750B-4 C1633-7
C1750B-5 C1633-8

between TCM C1750B, harness side and clutch motor 2 C1634,
TCM Clutch Motor 2

C1750B-55 C1634-1
C1750B-42 C1634-2
C1750B-44 C1634-3
C1750B-43 C1634-4
C1750B-56 C1634-5
C1750B-2 C1634-6
C1750B-1 C1634-7
C1750B-3 C1634-8

A8 CHECK THE TRANSAXLE WIRING HARNESS FOR A SHORT
TO GROUND
If diagnosing a clutch motor 1 concern, measure the resistance Yes
between TCM C1750B, harness side and ground using the Inspect the transaxle
following chart. wiring harness for signs
of physical damage and
TCM Ground repair or install a new
transaxle wiring harness
C1750B-58 Ground as necessary. TEST the
system for normal
C1750B-19 Ground
operation. If the transaxle
C1750B-45 Ground wiring harness is not
damaged, GO to A9 .
C1750B-32 Ground
C1750B-57 Ground No
REPAIR the circuit(s) for
C1750B-6 Ground a short to ground.
C1750B-4 Ground RECONNECT all
C1750B-5 Ground system for normal
operation.
between TCM C1750B, harness side and ground using the
following chart.
TCM Ground
C1750B-55 Ground
C1750B-42 Ground
C1750B-44 Ground
C1750B-43 Ground
C1750B-56 Ground
C1750B-2 Ground
C1750B-1 Ground
C1750B-3 Ground

A9 CHECK THE CLUTCH MOTOR
Remove both clutch motors. Install clutch motor 1 in the original Yes
clutch motor 2 location and install clutch motor 2 in the original INSTALL a new TCM .
clutch motor 1 location. RECONNECT all components. Clear the
DTC's and TEST the system for normal operation. No
Does the TCM set the same DTC? INSTALL a new clutch
motor. TEST the system
PINPOINT TEST B: SHIFT MOTORS

B1 TEST BJB FUSE 2 (50A)
Check fuse: Battery Junction Box (BJB) fuse 2 (50A). Yes
Is the resistance less than 5 ohms? GO to B2 .
No
(YE/RD) for a short to
fuse. TEST the system for
normal operation.
B2 TEST BJB FUSE 27 (7.5A)
Check fuse: BJB fuse 27 (7.5A). Yes
No
(BU/RD) for a short to
normal operation. Refer to
Shift Drum Test in
Learning .
B3 TEST CJB FUSE 23 (7.5A)
Check fuse: CJB fuse 23 (7.5A). Yes
No
normal operation.
B4 CHECK FOR VOLTAGE AT THE TCM CONNECTOR
Ignition OFF. Yes
Disconnect: Transmission Control Module (TCM) C1750A. GO to B5 .
Inspect both ends of the connector for damage or pushed-
out pins, corrosion, loose wires and missing or damaged No
seals. REPAIR circuit SBB02
Measure the voltage between TCM C1750A-1, circuit SBB02 (YE/RD) for an open.
(YE/RD) harness side and ground. RECONNECT all
Measure the voltage between TCM C1750A-2, circuit SBB02

(YE/RD) harness side and ground.

B5 CHECK FOR KAM VOLTAGE AT THE TCM CONNECTOR
Measure the voltage between TCM C1750A-18, circuit Yes
SBB27 (BU/RD) harness side and ground. GO to B6 .
No
(BU/RD) for an open.
RECONNECT all

B6 CHECK FOR IGNITION POWER AT THE TCM CONNECTOR
Ignition ON. Yes
Measure the voltage between TCM C1750A-31, circuit INSTALL a new TCM .
CBP23 (BN/YE) harness side and ground.
No
RECONNECT all
PINPOINT TEST C: SPEED SENSORS
NOTE: Perform speed sensor test prior to beginning speed sensor pinpoint tests. For additional
information, refer to Transmission Adaptive Learning in this section.

C1 CHECK THE TRANSAXLE WIRING HARNESS FOR AN
OPEN CIRCUIT
Ignition OFF. Yes
Disconnect: Transmission Control Module (TCM) C1750B. GO to C2 .
Disconnect: Input Shaft Speed Sensor 1 C143. REPAIR the circuit(s) for an
Inspect both ends of the connector for damage or pushed-out open. RECONNECT all
pins, corrosion, loose wires and missing or damaged seals. components. TEST the
Disconnect: Input Shaft Speed Sensor 2 C164. system for normal operation.
Disconnect: Output Shaft Speed (OSS) sensor C193.
If diagnosing an input shaft speed sensor 1 concern, measure
the resistance between TCM C1750B-21, harness side and
input shaft speed sensor 1 C143-2.



If diagnosing an OSS sensor concern, measure the

resistance between TCM C1750B-9, harness side and OSS
sensor C193-2.
resistance between TCM C1750B-37, harness side and OSS
sensor C193-1.

C2 CHECK THE TRANSAXLE WIRING HARNESS FOR A
SHORT TO GROUND
If diagnosing an input shaft speed sensor 1 concern, measure Yes
the resistance between TCM C1750B, harness side and Inspect the transaxle wiring
ground using the following chart. harness for signs of physical
damage and repair or install
TCM Ground a new transaxle wiring
harness as necessary.
C1750B-21 Ground TEST the system for normal
operation. If the transaxle
C1750B-10 Ground
wiring harness is not
damaged, GO to C3 .
the resistance between TCM C1750B, harness side and No
ground using the following chart. REPAIR the circuit(s) for a
short to ground.
TCM Ground RECONNECT all
C1750B-12 Ground system for normal operation.
C1750B-8 Ground

resistance between TCM C1750B, harness side and ground
TCM Ground
C1750B-37 Ground
C1750B-9 Ground

C3 CHECK THE TCM
Connect: TCM C1750B. Yes
Ignition ON. INSTALL a new speed
If diagnosing an input shaft speed sensor 1 concern, measure sensor. RECONNECT all
the voltage between input shaft speed sensor 1 C143-2, components. TEST the
harness side and ground. system for normal operation.
Refer to ISS or OSS Test in
Learning .
No
INSTALL a new TCM .
RECONNECT all

the voltage between input shaft speed sensor 2 C164-2,
If diagnosing an OSS sensor concern, measure the voltage

between OSS sensor C193-1, harness side and ground.

PINPOINT TEST D: TR SENSOR
NOTE: Prior to beginning TR sensor pinpoint test, verify TR sensor adaptive learning. For additional

D1 VERIFY SELECTOR LEVER CABLE/LINKAGE
ADJUSTMENT
Verify that the selector lever cable/linkage is correctly Yes
adjusted. Refer to Section 307-05 . GO to D2 .
Is the selector lever cable/linkage correctly adjusted?
No
ADJUST the selector lever
cable/linkage. REFER to
Section 307-05 .
D2 CHECK THE TRANSAXLE WIRING HARNESS FOR AN
OPEN CIRCUIT
Ignition OFF. Yes
Disconnect: Transmission Control Module (TCM) C1750B. GO to D3 .
Inspect both ends of the connector for damage or pushed-
out pins, corrosion, loose wires and missing or damaged No
seals. REPAIR the circuit(s) for an
Disconnect: Transmission Range (TR) sensor C167. open. RECONNECT all
Inspect both ends of the connector for damage or pushed- components. TEST the
out pins, corrosion, loose wires and missing or damaged system for normal operation.
seals. Refer to TR Sensor Adaptive
Measure the resistance between TCM C1750B, harness Learning in Transmission
side and TR sensor C167, using the following chart. Adaptive Learning .
TCM Transmission Range Sensor

C1750B-24 C167-4
C1750B-25 C167-1
C1750B-34 C167-3
C1750B-35 C167-2

D3 CHECK THE TRANSAXLE WIRING HARNESS FOR A
SHORT TO GROUND
Measure the resistance between TCM C1750B, harness Yes
side and ground using the following chart. Inspect the transaxle wiring
harness for signs of physical
TCM Ground damage and repair or install a
new transaxle wiring harness
C1750B-24 Ground as necessary. TEST the
system for normal operation. If
C1750B-25 Ground
the transaxle wiring harness is
C1750B-34 Ground not damaged, GO to D4 .
C1750B-35 Ground No
REPAIR the circuit(s) for a
Is the resistance greater than 10,000 ohms? short to ground.
RECONNECT all
D4 CHECK THE TCM
Connect: Transmission Control Module (TCM) C1750B. Yes
Inspect both ends of the connector for damage or pushed- INSTALL a new TR sensor.
out pins, corrosion, loose wires and missing or damaged RECONNECT all
seals. components. TEST the
Ignition ON. system for normal operation.
Measure the voltage between TR sensor C167-3, harness
side and TR sensor C167-2, harness side. No
INSTALL a new TCM .
RECONNECT all
Refer to TR Sensor Adaptive
Learning in Transmission
Adaptive Learning .
Is the voltage between 4.5 and 5.5 volts?

Leakage Inspection
Material
Item Specification
Motorcraft® Dual Clutch WSS-M2C200-
Transmission Fluid D2
XT-11-QDC
NOTICE: Do not try to stop the transmission fluid leak by increasing the torque beyond specification.
This may cause damage to the case threads.
If leakage is found at the Transmission Range (TR) manual control lever, install a new seal. Refer to Manual
Control Lever Shaft Seal in this section.
If leakage is found at the TCM , install a new O-rings. Refer to Transmission Control Module (TCM) in this
section.
Check the fill plug and drain plug. If leakage is present refer to Transmission Draining and Filling in this
section.
Check all the speed sensors for leakage. Refer to Input Shaft Speed Sensor — No. 1 , Input Shaft Speed
Sensor — No. 2 or Output Shaft Speed (OSS) Sensor in this section.
Check the RH and LH halfshaft seals. Refer to Halfshaft Seal — RH and Halfshaft Seal — LH in this section.
The transaxle has the following parts to prevent external transmission fluid leakage:
Sealer
O-ring seals
Diagnosis By Symptom
Special Tool(s)
tool
Symptom Chart — Transaxle Operation
Symptom Chart — Transaxle Operation

No forward or Brake pressure Go to Section 206-09 .
reverse, stuck in sensor
neutral.
Harsh or Clutch Adaptive Go to Transmission Adaptive
Soft/delayed Learn Learning in this section and
engagement or Clutch verify the clutch adaptive
shifts learning.
Go to Clutch .
NVH in 1st, 3rd, Clutch 1 Go to Clutch .
and/or 5th Input Shaft 1 Go to Transaxle .
NVH in Park, Clutch 2 Go to Clutch .
Neutral, R, 2nd, Input Shaft 2 Go to Transaxle .
4th, and/or 6th
NVH in 1st, 2nd, Output shaft 1 Go to Transaxle .
5th and/or 6th
NVH in 3rd and/or Output shaft 2 Go to Transaxle .
4th and/or Reverse
NVH in all gears Differential Go to Transaxle .
No PARK / Stuck Selector lever Go to Section 307-05 .
in PARK cable adjustment Go to Transaxle .
Park components Go to Clutch Adaptive
TCM software Learning in Transmission
wrong level Adaptive Learning .
TCM B+ too high
Wiring harness
TCM can
command PRNDL
to stay in PARK
Differential Shim Selection
Special Tool(s)
Differential Bearing Preload
Tool DPS6
307-681 (includes 307-681/1
and 307-681/2)
Shim Selection Set

308-164
NOTE: If the differential, differential bearings, clutch housing or transaxle case have been replaced this
procedure must be performed.
1. Install the differential.
2. NOTE: Install the alignment standoffs at the transaxle dowel locations.
NOTE: Place the special tools around the differential area as shown.
Install the special tools.

3. Position the differential bearing race on the differential. For removal of the differential bearing
race from the clutch housing refer to Differential Shim in this section.
4. Install the special tool on the differential.
5. Position the clutch housing on the special tools and install the 6 special tool bolts, 4 shown.
6. Turn the differential several times clockwise and counter-clockwise to make sure the differential
turns freely and that the bearing is seated.
7. Turn the differential pre-load tool as shown.
8. Loosen the differential pre-load tool bolt.
9. NOTE: The shim size should be the average of the 3 measurements.
Using a feeler gauge measure the clearance at points 1, 2 and 3 and record. Using the average
of the recorded measurements, select the appropriate shim from the shim selection chart in the
specifications section.
10. Remove the special tools.
11. Install the selected shim into the clutch housing and install the differential bearing race. For
additional information, refer to Differential Shim in this section.
Transmission Adaptive Learning
Special Tool(s)
tool
1. The adaptive learning procedures and self-tests should be done with the Vehicle Communication
Module (VCM) and Integrated Diagnostic System (IDS).
2. NOTE: The VCM LED prove-out confirms power and ground from the Data Link Connector (DLC)
to the VCM .

refer to, Section 418-00 to diagnose no power to the scan tool.

verify the ignition is in the RUN position.
verify scan tool operation with a known good vehicle.
refer to, Section 418-00 to diagnose no response from the scan tool.

Section 418-00
If the network test passes, continue with the transmission adaptive learning procedures.
5. Verify that the calibration file is present on the scan tool. If the file is present, go to Step 10. If the
file is not present, continue with this procedure.
6. Update the PCM/Transmission Control Module (TCM) calibration. Calibration files maybe
obtained at Professional Technician Society (PTS) website. Independent Technicians refer to
www.motorcraft.com.
The scan tool checks to see if the file is present on the scan tool. If the calibration file is present,
the technician may proceed with downloading the file to the PCM/ TCM . If the file is not present,
the scan tool will need to be connected to the server to download the file onto the scan tool.
7. Connect the scan tool to the PTS server.
8. Follow the instructions on the network to download the strategy file to the scan tool.
9. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically
be downloaded.
10. Reconnect the scan tool to the vehicle.

TCM Reprogramming
1. Using the scan tool, navigate to the Module Reprogramming sub menu.
1. Module Programming
2. Module Reprogramming
3. TCM
2. Follow the instructions displayed on the scan tool.
TCM Programming
1. Using the scan tool, navigate to the Module Reprogramming sub menu.
1. Module Programming
2. Programmable Module Installation
3. TCM
Transmission Range (TR) Sensor Adaptive Learning
1. Using the scan tool, navigate to the TCM Adaptive Learning sub menu.
1. PCM
2. TCM
3. TCM Adaptive Learning
2. Select TR sensor.
3. Select Perform Adaptive Learning.
Shift Drum Adaptive Learning
1. PCM
2. Transmission
2. Select Shift Drum.
Clutch Adaptive Learning
1. PCM
2. Transmission
Clutch System Test
1. PCM
2. Transmission
3. Clutch System Test
Speed Sensor Test
1. PCM
2. Transmission
3. Speed Sensor Test
2. Select the desired speed sensor.
Drive Cycle
NOTICE: If a drive cycle is not completed, the customer may feel erratic shifts and driveability
concerns.
NOTE: To perform drive cycle, drive the vehicle on a level road surface.
1. Depress vehicle brake pedal (do not use parking brake).
2. Shift to Drive.
3. Wait 15 seconds.
4. Shift to Reverse.
5. Wait 2 seconds.
6. Repeat (1-5) ten (10) times.
7. Accelerate from a stop with light throttle to 15 mph (24 km/h).
8. Brake gently to a complete stop (allow at least 6 seconds).
9. Repeat steps (7-8) five (5) times in dealership parking lot or similar setting.
10. Accelerate from a stop with light throttle performing 1-2, 2-3, 3-4 shifts maintaining 1700-2000
rpm.
11. Accelerate to a speed between 50 mph (80 km/h) and 65 mph (104 km/h), achieve 6th gear, keep
throttle steady with engine below 3000 rpm for a minimum of two (2) minutes.
12. Repeat step 11 two (2) times.
13. Test drive the vehicle.

Transmission Draining and Filling
Material
Item Specification
XT-11-QDC
100-02 .
2. NOTE: Prior to removal, clean the area surrounding the fill plug.
Remove the fill plug.
3. Remove the drain plug and drain the fluid.
4. Install the drain plug.

5. NOTE: Do not overfill the transaxle. This will cause transaxle fluid to be forced out of the case.
Using a suitable oil suction gun, fill the transaxle to the correct level with the specified fluid. Add
transmission fluid until the oil runs out of the fill port in a continuous stream. The transaxle is full
when the oil flow from the fill port has slowed to a broken stream or dripping.
6. NOTE: Use a ball head hex socket to torque to specifications.
Install the fill plug.

Transmission Fluid Level Check
Material
Item Specification
XT-11-QDC
100-02 .
2. NOTE: Prior to removal, clean the area around the fill plug.
3. NOTE: Do not overfill the transaxle. This causes transmission fluid to be forced out of the case.
Using a suitable oil suction gun, fill the transaxle to the correct level with the specified fluid. Add
transmission fluid until the oil runs out of the fill port in a continuous stream. The transaxle is full
when the oil flow from the fill port has slowed to a broken stream or dripping.
4. NOTE: Use a ball head hex socket to tighten the transaxle fill plug.
Install the fill plug.
Clutch
Special Tool(s)
Actuator Reset, Spline Socket
307-677
Clutch Reset
307-676 (includes 307-676/1,
307-676/2, 307-676/3, 307-
676/4, 307-676/5 and 307-
676/6)
Fixture, Clutch
Remover/Installer
307-675 (includes 307-675/1,
307-675/2, 307-675/3 and 307-
675/4)
Holding Fixture
307-580
Material
Item Specification
DPS6 Grease WSS-M1C270-
9U7Z-19A506-BA A
High Temperature Nickel Anti- —
Seize Lubricant
XL-2
XT-11-QDC
Removal
NOTICE: After installation of the transaxle be sure to perform the Clutch Adaptive Learning
procedure or transaxle damage can occur. For additional information, refer to Transmission
Adaptive Learning in this section.
1. Remove the transaxle from the vehicle. For additional information, refer to Transaxle in this
section.
2. Install the special tools.
3. Stand the transaxle on its back.
4. Remove the 4 clutch motor 1 bolts and remove clutch motor 1.

6. Remove and discard the clutch hub snap ring.
7. NOTE: Index mark the clutch hub and clutch for installation.
Remove the clutch hub.
9. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in)
of torque to push the clutch down to release the pressure from the hollow input shaft snap ring.
10. Remove and discard the hollow input shaft snap ring.
11. NOTE: Make sure the lifting legs are installed on the 3 clutch studs marked with the
manufacturing mark as shown.
NOTE: Make sure the lifting leg with the angle is in the location shown.

13. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch
is free of the input shaft.
14. Using the special tools, remove the clutch as an assembly from the transaxle.
Installation
1. If installing a new clutch go to step 19.
2. NOTE: Make sure the special tool washer is also installed.
Install the special tool in a vise.

3. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special
tool.
4. Install the special tool loosely on the clutch.

5. Install the special tool on the clutch making sure the legs are inserted in the slots.
6. Turn the special tool clockwise to the stops and hold.

7. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch,
causes damage to the clutch.
Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.

9. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.
10. NOTICE: Make sure the clutch self-adjuster is held to the stops before compressing the
clutch or damage will occur to the clutch.
NOTE: An audible click can be heard when the clutch locks lock.
While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to
the stops on the clutch. The locks on clutch 2 lock at this time.
12. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers
align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.
Visually check the locks to make sure they have locked. 4 locks shown, 12 total.
13. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to
check for clutch wear.
14. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and
lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.
15. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover.
Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.
16. Apply a small amount of transmission fluid on the input shaft bearing surface.
17. Apply a small amount of DPS6 Grease on both input shaft splines.
18. Verify the Z-washers are installed correctly.

19. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not
operate correctly and damage can occur. If the clutch locks are not locked go to step 2
within this procedure.
NOTE: Make sure the angled lifting leg is installed in the location shown.
Using the special tools, install the clutch in the transaxle.
20. Remove all the special tools.
21. Install the special tools onto the transaxle case.

22. NOTICE: Do not overtighten the special tool or damage can occur.
Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until
seated on the input shaft bearing and the snap ring groove is visible.
23. NOTE: Make sure the hollow input shaft snap ring is fully seated.
Install the new hollow input shaft snap ring.
24. NOTE: Align the index marks on the clutch hub and clutch.
Install the clutch hub.

25. Install the new clutch hub snap ring in the position shown.
26. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator
engagement lever can occur.
Using the special tool, release the clutch 1 locks and then the clutch 2 locks by slowly turning the
special tool counterclockwise. An audible click will be heard when the clutch locks are released.
27. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where
indicated.
28. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.
29. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
31. NOTICE: After installation of the transaxle be sure to perform the Clutch Adaptive Learning
procedure or transaxle damage can occur. For additional information, refer to
Transmission Adaptive Learning in this section.
Install the transaxle in the vehicle. For additional information, refer to Transaxle in this section.
Clutch Engagement System
Removal
1. Remove the clutch. For additional information, refer to Clutch in this section.
2. Remove the Z-washers from the engagement system bearing unit.
3. NOTE: The engagement system bearing unit should be removed easily.
Remove the engagement system bearing unit. Inspect for wear or damage. Replace as
neccessary. Refer to Transaxle in this section.
4. NOTICE: Remove the spring retainer bolts by loosening them slightly in an alternating
pattern or damage can occur to the clutch actuator levers.
NOTE: The spring retainers and actuator levers are matched sets with corresponding serial
numbers. If the spring retainers and actuator levers are being reused, mark on each spring
retainer and actuator lever for assembly.
Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.
5. Install clutch actuator lever locks as shown if available.
6. Remove the 2 bolts from the clutch actuator lever 1.

8. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
Remove the clutch actuator lever 1.
Installation
1. Inspect the guide tube for wear or damage. For additional information, refer to Transaxle in this
section.
2. NOTE: One clutch actuator lever bushing shown, one per clutch actuator lever.
Install the clutch actuator lever bushings.
Install the clutch actuator lever 2.
4. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
5. Install the 2 clutch actuator lever 2 bolts.


9. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating
pattern or damage can occur to the clutch actuator levers.
NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown.
NOTE: Make sure the serial number on the spring retainer matches the serial number on the
actuator lever. If reusing the spring retainers and actuator levers use the marks made during
removal for assembly.
Install the spring retainers and spring retainer bolts.

10. Remove the clutch actuator lever locks if installed.
11. NOTE: The engagement system bearing unit should be installed easily.
Install the engagement system bearing unit.

12. NOTICE: Do not tilt transaxle after the Z-washers are installed, they may come off center
and damage can occur.
Install the Z-washers onto the engagement system bearing unit and center them correctly.
13. Install the clutch. For additional information, refer to Clutch in this section.
Clutch Motor — No. 1
Material
Item Specification
Seize Lubricant
XL-2
Removal
1. Clean the area around the clutch motor to ensure no debris gets into the clutch motor pocket.
2. Disconnect the clutch motor electrical connector.
3. Remove the 4 clutch motor bolts and the clutch motor.
Installation
1. Inspect the clutch motor pocket for damage or debris. Clean or repair as needed.
2. Apply anti-seize to the clutch motor surfaces where indicated.
3. Apply anti-seize to the clutch actuator lever splines as shown.

4. NOTE: Clutch motor splines may need to be turned to ease installation.
Install the clutch motor and the 4 clutch motor bolts.

5. Connect the clutch motor electrical connector.

Clutch Motor — No. 2
Material
Item Specification
Seize Lubricant
XL-2
Removal
1. Clean the area around the clutch motor to ensure no debris gets into the clutch motor pocket.
2. Disconnect the clutch motor electrical connector.
3. Remove the 4 clutch motor bolts and the clutch motor.
Installation
1. Inspect the clutch motor pocket for damage or debris. Clean or repair as needed.
2. Apply anti-seize to the clutch motor surfaces as shown.
3. Apply anti-seize to the clutch actuator lever splines as shown.

4. NOTE: Clutch motor splines may need to be turned to ease installation.
Install the clutch motor and the 4 clutch motor bolts.

5. Connect the clutch motor electrical connector.

Transaxle
Special Tool(s)
Adapter for 303-290A
303-290-01
Adapter for 303-290A (Support

Leg)
303-290-03A
Handle
205-153
Installer, Axle Seal

307-671
Remover, Halfshaft
205-241 (T86P-3514-A)

205-290 (T89P-3415-B)
Slide Hammer
100-001 (T50T-100-A)
Support Bar, Engine

303-290A
tool
Removal
100-02 .
2. NOTE: Transmission Control Module (TCM) Programming does not need to be performed if the
transmission is being removed for flexplate or rear main seal service.
Using the scan tool, recover all module information before removing the transaxle. For additional
4. Remove the cowl assembly. For additional information, refer to Section 501-02 .
5. Remove the Air Cleaner (ACL) assembly and outlet pipe. For additional information, refer to
Section 303-12 .

9. Using a suitable tool, detach the wiring harness from the battery tray bracket.
10. Remove the selector lever cable bracket bolt, the battery tray bracket nuts and remove the battery
tray bracket.
11. Disconnect the selector lever cable from the manual control lever.
12. Remove the wiring harness from the selector lever cable bracket.
13. Remove the 2 selector lever cable bracket bolts from the transaxle and position the selector lever
cable and bracket aside.
14. Remove the 2 upper clutch housing-to-engine bolts.
15. Remove the transaxle vent hose from the cooling fan housing and position aside.
16. Remove the ground wire bolt and the ground wire from the transaxle.
17. Disconnect the engine harness electrical connector from the Transmission Control Module (TCM).
18. If equipped, remove the engine splash shield.
19. Remove the starter motor. For additional information, refer to Section 303-06 .
20. Remove the flexplate-to-clutch nut access cover.

NOTICE: To prevent the flexplate-to-clutch nuts from falling into the clutch housing and
causing damage, use a magnetic socket to remove the 6 flexplate-to-clutch nuts.
NOTE: Index mark one clutch stud and the flexplate for installation reference.
Rotate the crankshaft in a clockwise direction to gain access to the flexplate-to-clutch nuts.
Remove and discard the 6 flexplate-to-clutch nuts.
22. Remove and discard the exhaust flange nuts and exhaust flange gasket. Disconnect the exhaust
flange.
23. Detach the Heated Oxygen Sensor (HO2S) electrical connector from the HO2S bracket.
24. Remove the transaxle roll restrictor bolts and the transaxle roll restrictor.
25. Remove the drain plug and drain the transmission fluid.

27. Remove the front wheels. For additional information, refer to Section 204-04 .
28. Remove the brake hose retainer bolt and the brake hose retainer from the RH strut.
29. Remove and discard the RH ball joint nut and bolt.
30. Separate the RH ball joint from the knuckle.
31. Remove and discard the bearing retainer strap nuts, shield and the bearing retainer strap.
32. Remove the RH intermediate shaft assembly from the transaxle and position aside. Support the
intermediate shaft assembly.
33. Remove the brake hose retainer bolt and the brake hose retainer from the LH strut.
34. Remove and discard the LH ball joint nut and bolt.
35. Separate the LH ball joint from the knuckle.
36. Using the special tools, remove the LH halfshaft assembly from the transaxle and position aside.
Support the LH halfshaft assembly.
37. Install the special tools and support the engine.
38. Remove the 2 transaxle support insulator bolts and nuts and remove the transaxle support
insulator.
39. Using the special tools, lower the transaxle.

40. NOTICE: Use caution not to damage the transaxle wiring harness or sensors.
Position a suitable high-lift transmission jack under the transaxle and secure the transaxle to the
high-lift transmission jack.
41. Remove the 6 lower clutch housing-to-engine bolts.

42. Remove the transaxle.
43. Remove and discard the engine-to-transaxle separator plate.

Installation
1. NOTICE: Use caution not to damage the engine-to-transaxle separator plate or damage can
occur.
Install the new engine-to-transaxle separator plate.
2. NOTICE: If installing the existing transaxle, the halfshaft seals must be replaced or
damage to the transaxle can occur.
Using a suitable tool, remove and discard the LH halfshaft seal.
3. Install the new LH halfshaft seal onto the special tool.

4. Using the special tools, install the new LH halfshaft seal.
5. Using a suitable tool, remove and discard the RH halfshaft seal.
6. Install the new RH halfshaft seal onto the special tool.

7. Using the special tools, install the new RH halfshaft seal.
8. If using a new clutch assembly, make sure the clutch-to-flexplate alignment marks are aligned.
9. NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch
stud made during removal.
Install the transaxle.
10. Install 2 lower clutch housing-to-engine bolts.

NOTICE: Tighten the flexplate-to-clutch nuts in a star pattern or transaxle damage can
occur.
NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If
the flexplate-to-clutch nuts fall into the clutch housing, the transaxle will have to be removed to
retrieve them.
Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.
Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).
Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).
12. Install the flexplate-to-clutch nut access cover.

13. Install the starter motor. For additional information, refer to Section 303-06 .
14. If equipped, install the engine splash shield.
15. Install the 4 lower clutch housing-to-engine bolts.

16. Using the special tools, raise the transaxle.
17. Install the transaxle support insulator and install the 2 transaxle support insulator bolts and the 2
nuts.
18. Install the ground wire and bolt onto the transaxle.
19. Install the transaxle roll restrictor and the 2 roll restrictor bolts. Tighten the bolts in the sequence
shown.
1. Tighten to 70 Nm (52 lb-ft).
20. Attach the HO2S electrical connector to the HO2S bracket.

21. Using a new exhaust flange gasket and nuts, connect the exhaust flange to the exhaust.
22. Using the LH halfshaft seal protector provided with the new LH halfshaft seal, install the LH
halfshaft partially into the transaxle.
23. Remove the LH halfshaft seal protector and install the LH halfshaft into the transaxle.
24. Install the LH ball joint into the knuckle.
25. Install the new LH ball joint bolt and nut.

26. Install the brake hose retainer and bolt on the LH strut.
27. Using the RH halfshaft seal protector provided with the new RH halfshaft seal, install the RH
intermediate shaft assembly partially into the transaxle.
28. Remove the RH halfshaft seal protector and install the RH intermediate shaft assembly into the
transaxle.
29. Install the new bearing retainer strap, shield and bearing retainer strap nuts. Tighten the nuts in 2
stages.
30. Install the RH ball joint into the knuckle.
31. Install the new RH ball joint bolt and nut.

32. Install the brake hose retainer and bolt on the RH strut.
33. Install the front wheels. For additional information, refer to Section 204-04 .
34. Install the 2 upper clutch housing-to-engine bolts.

35. Connect the engine harness electrical connector to the TCM .
36. Install the selector lever cable bracket and the 2 selector lever cable bracket bolts on the
transaxle.
37. Attach the wiring harness to the selector lever cable bracket.
38. Connect the selector lever cable to the manual control lever.
39. Attach the transaxle vent hose to the cooling fan housing.
40. Install the battery tray bracket, battery tray bracket nuts and the selector lever cable bracket bolt.
41. Attach the wiring harness to the battery tray bracket.
42. Install the battery tray and the 3 battery tray bolts.
44. Install the PCM cover and bolt.

45. Install the ACL assembly and outlet pipe. For additional information, refer to Section 303-12 .
47. Install the cowl assembly. For additional information, refer to Section 501-02 .
48. Fill the transaxle with transmission fluid. For additional information, refer to Transmission Draining
and Filling .
50. Using the scan tool, install all recovered module information after installing the transaxle. For
additional information, refer to Transmission Adaptive Learning in this section.
Halfshaft Seal — LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Output Shaft Seal

307-671
Remover, Halfshaft
205-241 (T86P-3514-A)

205-290 (T89P-3415-B)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-11-QDC
Removal
1. Remove the front wheel and tire. For additional information, refer to Section 204-04 .
2. Remove the drain plug and drain the transmission fluid.

5. Remove and discard the LH ball joint bolt and nut.

8. Using a suitable tool, remove and discard the LH halfshaft seal.
Installation
1. Install the LH halfshaft seal onto the special tool.

2. Using the special tools, install the LH halfshaft seal.
3. Using the LH halfshaft seal protector provided with the new LH halfshaft seal, install the LH
halfshaft partially into the transaxle.
4. Remove the LH halfshaft seal protector and install the LH halfshaft into the transaxle.


8. Install the front wheel and tire. For additional information, refer to Section 204-04 .
9. Fill the transaxle with transmission fluid. For additional information, refer to Transmission Draining
Halfshaft Seal — RH
Special Tool(s)
Handle
205-153

307-671
Material
Item Specification
XT-11-QDC
Removal
1. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 .
3. Remove and discard the RH ball joint bolt and nut.

5. Remove and discard the bearing retainer strap nuts, shield and the bearing retainer strap.
6. Detach the RH intermediate shaft assembly from the transaxle and position aside. Support the
RH intermediate shaft assembly.
7. Using a suitable tool. remove and discard the RH halfshaft seal.
Installation
1. Install the RH halfshaft seal onto the special tool.

2. Using the special tools, install the RH halfshaft seal.
3. Using the RH halfshaft seal protector provided with the new RH halfshaft seal, install the RH
intermediate shaft assembly partially into the transaxle.
4. Remove the RH halfshaft seal protector and install the RH intermediate shaft assembly into the
transaxle.
stages.
7. Install the new RH ball join bolt and nut.


9. Install the RH front wheel and tire. For additional information, refer to Section 204-04 .
10. Fill the transmission fluid. For additional information, refer to Transmission Draining and Filling in
this section.
Inner Input Shaft Seal
Special Tool(s)
Remover, Outer Input Shaft
Seal
307-673
Installer, Outer Input Seal

307-674 (includes 307-674/1
and 307-674/2)
Removal
1. Remove the transaxle. For additional information, refer to Transaxle .
2. Remove the clutch. For additional information, refer to Clutch .
3. Using the special tools, remove and discard the inner input shaft seal.
Installation
1. Using the special tools, install the new inner input shaft seal.
2. Install the clutch. For additional information, refer to Clutch .
3. Install the transaxle into the vehicle. For additional information, refer to Transaxle .
Outer Input Shaft Case Seal
Special Tool(s)
Installer, Input Guide and Seal
307-672 (includes 307-672/1
and 307-672/2)

308-375
Slide Hammer
100-001
Removal
1. Remove the clutch engagement system. For additional information, refer to Clutch Engagement
2. Remove the guide tube bolts.
3. Remove the guide tube.

4. Using the special tools, remove and discard the outer input shaft case seal.
Installation
1. Using the special tools, install the new outer input shaft case seal.
2. Using the locating tab on the guide tube, install the guide tube.
3. NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch
engagement levers.
Install the guide tube bolts.

4. Install the clutch engagement system. For additional information, refer to Clutch Engagement
5. Install the clutch. For additional information, refer to Clutch in this section.
6. Install the transaxle into the vehicle. For additional information, refer to Transaxle in this section.
Input Shaft Speed Sensor — No. 1
Material
Item Specification
XT-11-QDC
Removal
1. Disconnect the input shaft speed sensor 1 electrical connector.
2. Remove the input shaft speed sensor 1.

1. Remove the input shaft speed sensor 1 bolt.
3. Remove the input shaft speed sensor 1 shim.
Installation
1. Inspect the input shaft speed sensor 1 and transaxle bore for debris or damage. Clean, repair
and/or replace as needed.
2. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input
shaft speed sensor 1 or damage can occur to the transaxle.
NOTE: Install a new O-ring if installing the existing input shaft speed sensor 1.
NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for
installation.
Install the input shaft speed sensor 1.

1. Install the input shaft speed sensor 1 shim.
2. Install the input shaft speed sensor 1.
3. Install the input shaft speed sensor 1 bolt.
3. Connect the input shaft speed sensor 1 electrical connector.

Input Shaft Speed Sensor — No. 2
Material
Item Specification
XT-11-QDC
Removal
1. Disconnect the input shaft speed sensor 2 electrical connector.

Installation
1. Inspect the input shaft speed sensor 2 and transaxle bore for debris or damage. Clean, repair
and/or replace as needed.
2. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage
can occur to the transaxle.
NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for
installation.

3. Connect the input shaft speed sensor 2 electrical connector.

Manual Control Lever Shaft Seal
Special Tool(s)
Remover/Installer, Manual
Lever Seal
307-670 (includes 307-670/1
and 307-670/2)
Removal
1. Remove the transaxle. For additional information, refer to Transaxle in this section.
2. Remove and discard the manual control lever bolt and remove the manual control lever.
3. Install the special tool.
4. NOTE: Use care to prevent clutch housing cup plug from being dislodged.
Using the special tool and a suitable tool, apply slight pressure to the special tool, remove and
discard the manual control lever seal.
5. Inspect the transaxle case bore for debris or damage. Clean and/or repair as needed.
Installation
1. Using the special tools, install the new manual control lever shaft seal.
2. Install the manual control lever and the new manual control lever bolt.
3. Install the transaxle. For additional information, refer to Transaxle in this section.
Output Shaft Speed (OSS) Sensor
Material
Item Specification
XT-11-QDC
Removal
100-02 .
2. Remove and discard the heat tape from the Output Shaft Speed (OSS) sensor and electrical
connector.
3. Disconnect the OSS sensor electrical connector.
4. Remove the OSS sensor bolt and OSS sensor.

Installation
1. Inspect the transaxle case bore. Clean and/or repair as needed.
2. Inspect the OSS sensor for debris or damage. Clean or replace the OSS as needed.
3. NOTE: If installing the old OSS sensor, install a new O-ring.
Apply a small amount of transmission fluid to the O-ring and install the OSS sensor and the OSS
sensor bolt.
4. Connect the OSS sensor electrical connector.
5. Thoroughly clean the OSS sensor, electrical connector and wire.

6. Install new heat tape on the OSS sensor as shown in the preceding steps.
7. Remove the heat tape backing only from this location first.
8. Wrap the heat tape around the OSS sensor wiring harness.
9. Remove the heat tape backing from the rest of the heat tape and wrap it around the OSS sensor
and sticking the ends together.
10. Fold the remaining portion of the heat tape and crimp around the edge starting from the sensor
portion moving around.
Roll Restrictor
Removal
100-02 .
2. Remove the roll restrictor bolts and the roll restrictor.
Installation
1. NOTE: The bolts are different lengths, make sure the bolts are in the correct location using the
marks made during removal.
Install the roll restrictor and the roll restrictor bolts.

Transaxle Support Insulator
Special Tool(s)
Adapter for 303-290
303-290-01

Leg)
303-290A-03A
Support Bar, Engine

303-290A
Removal
100-02 .
Section 303-12 .

8. Remove the selector lever cable bracket bolt, the battery tray bracket nuts and remove the battery
tray bracket.

insulator.
Installation
nuts.
2. Install the battery tray bracket, battery tray bracket nuts and the selector lever cable bracket bolt.
4. Install the battery tray and 3 battery tray bolts.


6. Install the ACL and the outlet pipe. For additional information, refer to Section 303-12 .

Transaxle Vent

1 — Vent cap housing
2 — Vent base
3 — Transaxle
Removal
1. Remove the battery and battery tray. For additional Information, refer to Section 414-01 .
2. Remove the Air Cleaner (ACL) assembly and the outlet pipe. For additional Information, refer to Section
303-12 .
3. Remove the vent assembly end from the cooling fan housing and position it aside.
4. Remove the vent assembly from the transaxle.
Installation
1. Inspect the vent transaxle bore for damage or debris. Clean or repair as needed.
2. Install the vent assembly in the transaxle bore.
3. NOTICE: Make sure the transaxle vent hose is properly routed or damage can occur.
Install the vent assembly end onto the cooling fan housing.
4. Install the ACL assembly and outlet pipe. For additional Information, refer to Section 303-12 .
5. Install the battery tray and battery. For additional Information, refer to Section 414-01 .
Special Tool(s)
tool
Material
Item Specification
XT-11-QDC
Removal
1. Using the scan tool, recover all module information before removing the Transmission Control
Module (TCM). For additional information, refer to Transmission Adaptive Learning in this section.
2. Remove the battery and battery tray. For additional information, refer to Section 414-01 .
3. Remove the Air Cleaner (ACL) assembly and the outlet pipe. For additional information, refer to
Section 303-12 .
5. Remove the selector lever cable bracket bolt, the battery tray bracket nuts and the battery tray
bracket.
6. Remove the wiring harness from the transaxle housing.
7. Detach the wiring harness clips from the Transmission Control Module (TCM) housing.
8. Disconnect the 2 TCM electrical connectors.

9. Remove the 4 TCM bolts.
10. Using a suitable flat blade screwdriver, carefully pry the TCM from the transaxle, at the location
shown, and remove the TCM , discard the O-rings.
Installation
1. Carefully inspect the TCM and the transaxle bore for debris or damage. Clean and/or repair as
needed.
2. NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.
Install new O-rings if the TCM is being reused.
3. NOTICE: Do not force the TCM onto the transaxle or damage may occur.
NOTICE: Make sure the TCM sits flush on the transaxle or damage can occur.
Install the TCM on the transaxle. Apply light pressure to seat the O-rings. If the TCM does not
push in place with light pressure, remove the TCM and slightly turn the TCM gears and retry
installing the TCM on the transaxle.
4. Install the 4 TCM bolts.
5. Connect the 2 TCM electrical connectors.
6. Install the wiring harness clips on the TCM housing.

7. Install the wiring harness on the transaxle housing.
8. Install the battery tray bracket, battery tray bracket nuts and selector lever cable bracket bolt.
9. Install the wiring harness onto the battery tray bracket.

10. Install the ACL assembly and outlet pipe. For additional information, refer to Section 303-12 .
11. Install the battery tray and battery. For additional information, refer to Section 414-01 .
12. If a new TCM was installed, it will need to be reprogrammed to the latest calibration level
available. For additional Information, refer to Transmission Adaptive Learning in this section.
Transmission Range (TR) Sensor
Special Tool(s)
tool
Removal
1. Disconnect the Transmission Range (TR) sensor electrical connector.
2. Remove the 2 TR sensor bolts and the TR sensor.
Installation
1. Install the TR sensor and the 2 TR sensor bolts.

2. Connect the TR sensor electrical connector.
4. Re-calibrate the TR sensor. For additional information, refer to Transmission Adaptive Learning in
this section.
5. Verify the vehicle starts in PARK and NEUTRAL only.

Transaxle
Special Tool(s)
Slide Hammer
100-001
Holding Fixture
307-580
Installer, Input Guide and Seal

307-672 (includes 307-672/1 and
307-672/2)
Fixture, Clutch Remover/Installer

307-675 (includes 307-675/1, 307-
675/2, 307-675/3 and 307-675/4)
Table, Assembly (DPS6)

307-680 (includes 307-680/1, 307-
680/2, 307-680/3, 307-680/4 and
307-680/5)

308-375
Material
Item Specification
DPS6 Grease WSS-M1C270-A
9U7Z-19A506-BA
Gasket Maker WSK-M2G348-
TA-16 A5
Seize Lubricant
XL-2
XT-11-QDC
Transaxle Exploded View

1 7B546 Clutch assembly (part of 7C601 kit)
2 W790187 Actuator lever bolts (4 required)
3 7515 Actuator lever 1 (part of 7C601 kit)
4 7N080 Actuator lever dowels (2 required)
5 7515 Actuator lever 2 (part of 7C601 kit)
6 7A508 Engagement bearing (part of 7C603 kit)
7 7A564 Guide tube
8 W790185 Guide tube bolts (3 required)
9 7L013 Drain plug
10 7048 Input shaft case seal
11 1177 Halfshaft seals (2 required)
12 7505 Clutch housing
13 4067 Differential shim (part of kit)
14 4220 Differential bearings (2 required)
15 7M037 Output shaft bearings (2 required)
16 7060 Output shaft assembly
17 W790208 Output shaft bearing retainer bolts (6 required)
18 7060 Output shaft assembly
20 W790237 Differential ring gear bolts (10 required)
21 7D392 Differential ring gear
22 4026 Differential case
23 7L027 Magnet
24 7005 Transaxle case
25 7C013 Fill plug
26 W790189 Transmission Control Module (TCM) bolt
27 W790209 Clutch housing-to-case bolts (21 required)
28 W790188 TCM bolt
29 7Z369 TCM
30 7B498 TCM O-ring seal
31 7118 Input shaft bearing
32 7D000 Oil spout
33 7017 Inner input shaft
34 7M037 Needle bearing
36 7118 Bearing
37 7017 Hollow input shaft
38 7064 Snap ring
39 7917 Snap ring
40 7052 Hollow input shaft seal
41 W790236 Bolts (3 required)
42 7049 Bearing retainer
43 7D000 Lube feed tubes (2 required)
44 7118 Input shaft bearing
45 7052 Manual control lever shaft seal
46 — Shift drum pin (2 required) (part of 7J047)
47
7J047 Shift drum (2 required)
48 7J048 Small clock gear (2 required)
49 7J048 Large clock gear (2 required)
50 6397 Clock gear pin (2 required)
51 6397 Clock gear pin (2 required)
52 7L013 Park plunger plug
53 7233 Park plunger
54 6397 Park pawl rod
55 7A248 Park pawl
56 7H296 Park pawl actuation shaft assembly
57 7A256 Manual control lever
58 W790198 Manual control lever bolt
59 7240 Shift fork rod
60 7230 2nd/6th gear shift fork
61 7B081 3rd gear shift fork linkage
62 7B081 2nd/6th gear shift fork linkage
63 7230 4th/reverse gear shift fork
65 7230 3rd gear shift fork
67 7230 1st/5th gear shift fork
69 W790186 Bolt
70 7M101 Input shaft speed sensor
71 7Z101 Input shaft speed sensor shim
72 7Z101 Input shaft speed sensor shim
73 7F293 Transmission Range (TR) sensor
76 7C604 Clutch motor (2 required)
77 7G276 Transmission wiring harness
78 7H103 Output Shaft Speed (OSS) sensor
Disassembly
1. NOTE: Take note of the transaxle wiring harness clip locations for installation.
Remove the transaxle wiring harness.

2. Remove the 4 Transmission Control Module (TCM) bolts.
3. Using a flat blade screwdriver, carefully pry the TCM from the transaxle, at the location shown, and
remove the TCM , discard the O-rings.
4. Remove the 2 Transmission Range (TR) sensor bolts and the TR sensor.
5. Remove the Output Shaft Speed (OSS) sensor bolt and OSS sensor.


9. Stand the transaxle on its back.
12. Remove and discard the clutch hub snap ring.

13. NOTE: Index mark the clutch hub and clutch for installation.
Remove the clutch hub.
15. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of
torque to push the clutch down to release the pressure from the hollow input shaft snap ring.
16. Remove and discard the hollow input shaft snap ring.
17. NOTE: Make sure the lifting legs are installed on the 3 clutch studs marked with the manufacturing mark
as shown.
NOTE: Make sure the lifting leg with the angle is in the location shown.

19. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch is free
of the input shaft.
20. Using the special tools, remove the clutch as an assembly from the transaxle.
21. Remove the Z-washers from the engagement system bearing unit.
22. NOTE: The engagement system bearing unit should be removed easily.
Remove the engagement system bearing unit. Inspect for wear or damage. Replace as necessary. Refer
to Transaxle in this section.
23. NOTICE: Remove the spring retainer bolts by loosening them slightly in an alternating pattern or
damage can occur to the clutch actuator levers.
NOTE: The spring retainers and actuator levers are matched sets with corresponding serial numbers. If
the spring retainers and actuator levers are being reused, mark on each spring retainer and actuator
lever for assembly.
Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.
24. Install clutch actuator lever locks as shown if available.

29. Remove the guide tube bolts.
30. Remove the guide tube.

31. Using the special tools, remove and discard the input shaft case seal.
32. Remove and discard the input shaft snap ring.
33. Remove discard the manual control lever bolt and remove the manual control lever.
34. Remove the top 3 clutch housing-to-case bolts.
35. Remove the bottom 18 clutch housing-to-case bolts (13 shown).
37. NOTE: Install the special tools in the position shown.

Install the special tools and special tools bolts.
38. Turn the special tool bolt approximately 20 turns to separate the clutch housing from the transaxle case.
39. Lift the clutch housing off the transaxle case.
40. Remove the differential.

41. Remove the park pawl actuation shaft assembly.
42. Remove the park pawl rod and park pawl.
43. Remove the large clock gears and clock gear pins.
44. Remove the small clock gears and clock gear pins.
45. Remove the magnet.
46. Install the special tool on the transaxle case and gear set assembly.
47. Turn the transaxle case and gear set assembly over on the special tool.
48. Remove the special tool from the transaxle case.
49. Remove and discard the 6 output shaft bearing retainer bolts.
50. Lift the transaxle case off the gearset assemblies.

51. Remove the park plunger plug.
52. Remove the park plunger.
53. Remove the oil spout.

54. Remove the 4 shift fork rods.
55. Remove the 2 shift drums.
56. Remove the shift forks and linkages.

58. Turn the gearset assembly over on its side.

59. Remove the special tool.
60. Remove output shaft 1 assembly by removing the special tool.
61. Remove the input shaft assembly by removing the special tool.
62. Remove the special tool from output shaft 2 assembly.
63. Remove the hollow input shaft from the solid input shaft.
Assembly
1. NOTICE: Do not to damage the inner input shaft seal or bearing when installing the hollow input
shaft onto the inner input shaft.
Install the hollow input shaft onto the inner input shaft.
2. NOTE: Apply pressure on the synchronizer ring while taking the measurements.
NOTE: If the clearance is less than the minimum measurement stated in the specifications section,
install a new output shaft assembly.
Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various
places around the circumference.
3. NOTE: Apply pressure on the synchronizer ring while taking the measurements.
NOTE: If the clearance is less than the minimum measurement stated in the specifications section,
install a new output shaft assembly.
Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various
places around the circumference.
4. NOTE: Make sure the synchronizers are in the neutral position.
Install output shaft 2 assembly on the special tool.
5. Install the input shaft assembly on the special tool.

6. NOTE: Make sure the synchronizers are in the neutral position.
Install output shaft 1 assembly on the special tool.
8. Turn the gearset assembly over onto the special tool.

10. Install the 4th/reverse gear shift fork.
11. Install the 2nd/6th gear shift fork and linkage.

12. NOTE: Make sure shift drum 1 is in the neutral position as shown.
Install shift drum 1.
13. NOTE: Make sure shift drum 2 is in the neutral position as shown.
Install the 3rd gear linkage and shift drum 2.
14. Install the 1st/5th gear shift fork.

15. Install the 3rd gear shift fork.
16. Install the 4 shift fork rods.

1. Install the small shift fork rods.
2. Install the large shift fork rods.
17. Install the oil spout.

18. NOTE: Make sure the output shaft bearing retainer brackets are positioned as shown.
Install the special tools on the output shafts assemblies.
19. Install the transaxle case onto the gearset assemblies.
20. Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
Stage 1: tighten to 10 Nm (89 lb-in).
Stage 2: tighten to 32 Nm (24 lb-ft).
21. Install the special tool on the transaxle case.
22. Turn the transaxle case and gearset assembly over onto the special tool.
24. Install the magnet.

25. Install the small clock gears and clock gear pins.
26. Install the large clock gears and clock gear pins.
27. Install the park pawl and park pawl rod.

28. NOTE: Make sure the pin is installed as shown.
Install the park pawl actuation shaft assembly.
29. NOTE: If the differential bearings, differential, clutch housing and/or transaxle case are replaced refer to
Differential Shim Selection in this section.
Install the differential.
30. NOTICE: Make sure the transaxle case and the clutch housing are clean and no old sealant is
present or transmission fluid leaks can occur and cause transaxle damage.
Apply a 1 mm (0.039 in) bead of Gasket Maker around the inside of the bolt holes on the case side and
completely around each dowel.
31. NOTICE: Do not overheat the bearing or damage to the bearing may occur.
Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for
approximately 5 minutes.
32. Install the clutch housing onto the transaxle case.

33. Using the special tool and a hammer, tap the clutch housing down onto the transaxle case.
34. Install the 18 bottom clutch housing-to-case bolts (13 shown).

35. Install the 3 top clutch housing-to-case bolts.

36. Install the park plunger.
37. Install the park plunger plug.

38. Install the manual control lever and the new manual control lever bolt.
39. Install a new input shaft snap ring.
40. Using the special tools, install a new input shaft case seal.
41. Using the locating flange on the guide tube, install the guide tube.
42. NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch engagement
levers.
Install the 3 guide tube bolts.

43. Inspect the guide tube for wear or damage. Replace as necessary.
44. NOTE: One clutch actuator lever bushing shown, one per clutch actuator lever.
Install the clutch actuator lever bushings.




51. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or
damage can occur to the clutch actuator levers.
NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown.
NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator
lever. If reusing the spring retainers and actuator levers use the marks made during removal for
assembly.
Install the spring retainers and spring retainer bolts.

52. Remove the clutch actuator lever locks if installed.
53. NOTE: The engagement system bearing unit should be installed easily.
Install the engagement system bearing unit.

54. NOTICE: Do not tilt transaxle after the Z-washers are installed, they may come off center and
damage can occur.
Install the Z-washers onto the engagement system bearing unit and center them correctly.
55. If installing a new clutch go to step 19.
56. NOTE: Make sure the special tool washer is also installed.
Install the special tool in a vise.
57. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.
59. Install the special tool on the clutch making sure the legs are inserted in the slots.
60. Turn the special tool clockwise to the stops and hold.
61. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes
damage to the clutch.
Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.

63. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.
64. NOTICE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or
damage will occur to the clutch.
NOTE: An audible click can be heard when the clutch locks lock.
While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the
stops on the clutch. The locks on clutch 2 lock at this time.
66. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align
with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.
Visually check the locks to make sure they have locked. 4 locks shown, 12 total.
67. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for
clutch wear.
68. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1
spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.
69. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the
clutch assembly if the measurement is 15 mm (0.59 in) or less.
70. Apply a small amount of transmission fluid on the input shaft bearing surface.
71. Apply a small amount of DPS6 Grease on both input shaft splines.
72. Verify the Z-washers are installed correctly.

73. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not operate
correctly and damage can occur. If the clutch locks are not locked go to step 2 within this
procedure.
NOTE: Make sure the angled lifting leg is installed in the location shown.
Using the special tools, install the clutch in the transaxle.
74. Remove all the special tools.
75. Install the special tools onto the transaxle case.

76. NOTICE: Do not overtighten the special tool or damage can occur.
Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated
on the input shaft bearing and the snap ring groove is visible.
77. NOTE: Make sure the hollow input shaft snap ring is fully seated.
Install the new hollow input shaft snap ring.
78. NOTE: Align the index marks on the clutch hub and clutch.
Install the clutch hub.
79. Install the new clutch hub snap ring in the position shown.
80. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator
engagement lever can occur.
Using the special tool, release the clutch 1 locks and then the clutch 2 locks by slowly turning the special
tool counterclockwise. An audible click will be heard when the clutch locks are released.
81. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.
82. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.
85. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can
occur to the transaxle.
NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.

86. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft
speed sensor 1 or damage can occur to the transaxle.
NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.

87. NOTE: If installing the old OSS sensor, install a new O-ring.
Install the OSS sensor and the OSS sensor bolt.

88. Install the TR sensor and the 2 TR sensor bolts.

89. Carefully inspect the TCM and the transaxle bore for debris or damage. Clean and/or repair as needed.
90. NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.
Install new O-rings if the TCM is being reused.

91. NOTICE: Do not force the TCM onto the transaxle or damage may occur.
NOTICE: Make sure the TCM sits flush on the transaxle or damage can occur.
Install the TCM on the transaxle. Apply light pressure to seat the O-rings. If the TCM does not push in
place with light pressure, remove the TCM and slightly turn the TCM gears and retry installing the TCM
on the transaxle.
92. Install the 4 TCM bolts.

93. Install the transaxle wiring harness.
Clutch Housing
Special Tool(s)
Collet, 1 1/4" to 1 1/2"
303-D022
Forcing Screw
204-594
Handle
205-153
Installer, Countershaft Needle

Bearing
307-679
Installer, Differential Bearing

Cup
205-118

307-671
Remover, Differential Bearing

Cup
307-678
Slide Hammer
100-001
Disassembly
1. Remove and discard the clutch housing input shaft bearing retainer bolts and remove clutch
housing input shaft bearing retainer.
2. By lightly tapping, remove and discard the clutch housing input shaft bearing.
3. Break the lube feed tubes off the clutch housing output shaft bearings and discard.
4. NOTE: If the clutch housing output shaft bearing is broken, use the next size larger special tool.
NOTE: The clutch housing output shaft bearing 1 is shown, the clutch housing output shaft
bearing 2 is similar.
Using the special tool, remove the 2 clutch housing output shaft bearings.
5. Using the special tools, remove the clutch housing differential bearing race and shim.
Assembly
1. NOTE: If new differential bearings, differential, clutch housing or transaxle case are installed refer
to the Differential Shim Selection in this section.
Install the clutch housing differential bearing shim.

2. Using the special tools, install the clutch housing differential bearing race.
3. NOTE: The clutch housing output shaft bearing 1 is shown, the clutch housing output shaft
Install the new lube feed tubes and position the clutch housing output shaft bearings into the
clutch housing.
4. NOTE: The clutch housing output shaft bearing 1 is shown, the clutch housing output shaft
Using the special tool, install the 2 clutch housing output shaft bearings.
5. Using the special tools, install the new clutch housing input shaft bearing.
6. Install the clutch housing input shaft bearing retainer and the new clutch housing input shaft
bearing retainer bolts.
Differential
Special Tool(s)
Handle
205-153

205-206
Puller, Bearing
205-D064
Remover/Installer, Front Wheel

Hub
204-069
Step Plate
205-D014
1 4220 Differential bearings
3 W790237 Differential ring gear bolts
4 — Differential ring gear (part of 4026)
5 — Differential case (part of 4026)
Disassembly
1. NOTICE: Take care not to damage the differential impulse ring.
Using the special tools, remove and discard the differential bearings.
2. Using a 1500W heat gun, slightly heat the impulse ring. Remove the impulse ring.
3. Remove and discard the differential ring gear bolts. Lightly tap the ring gear to separate it from the
differential case.
4. Clean all parts in clean solvent and dry with compressed air.
Assembly
1. Inspect differential parts for damage or wear. Repair or replace as needed.
2. Install the differential ring gear onto the differential case.
3. Install the new differential ring gear bolts.

Using the illustration, tighten to 85 Nm (63 lb-ft) in a star pattern.
4. NOTE: Make sure the differential impulse ring is fully seated and flush on the differential.
Using a 1500W heat gun, slightly heat the differential impulse ring. Install it onto the differential
assembly.
5. NOTICE: Take care not to damage the differential impulse ring.
Using the special tools, install the new differential bearings.

Differential Shim
Special Tool(s)
Forcing Screw
204-594

Cup
205-118
Handle
205-153
Installer, Axle Seal

307-671

Cup
307-678
Disassembly
1. Using the special tools, remove the clutch housing differential bearing race and shim.
Assembly
1. Install the selected differential bearing shim. If the differential bearings, differential, clutch housing
or transaxle case were replaced, refer to Differential Shim Selection in this section.
2. Using the special tools, install the differential bearing race.

Input Shaft — Inner
Special Tool(s)
Puller, Bearing
205-D064

1 7717 Inner input shaft
2 7B412 Radial bearing
3 7B412 Roller bearing
Disassembly
1. Remove the inner input shaft needle bearing.
2. Remove the inner input shaft needle bearing.
3. Remove the inner input shaft roller bearing.
4. Using the special tools and a press, remove the inner input shaft radial bearing.
Assembly
1. Inspect the inner input shaft for wear or damage, replace as needed.
2. Using the special tools and a press, install the inner input shaft radial bearing.
3. Install the inner input shaft roller bearing.
4. Install the inner input shaft needle bearing.
5. Install the inner input shaft needle bearing.

Transaxle Case
Special Tool(s)
Forcing Screw
204-594
Handle
205-153

307-671

Cup
307-678
Disassembly
1. Remove and discard the halfshaft seal.
2. Using the special tools, remove the differential case bearing cup.
Assembly
1. NOTE: If a new differential gear bearing, transmission case, differential or clutch housing are
installed, measure the differential shim for the correct size. For additional information, refer to
Differential Shim Selection .
Using the special tools, install the differential gear bearing cup.
2. Install the new halfshaft seal on the special tools.
3. Using the special tools, install the new halfshaft seal.

SECTION 308-00: Manual Transaxle/Transmission and Clutch — General 2011 Fiesta Workshop
Information Manual
Procedure revision date:
SPECIFICATIONS 05/13/2010
Material
Capacity
Motorcraft® Full Synthetic WSD-M2C200-C 2.1L (2.2
Manual Transmission qt)
Fluid
XT-M5-QS
High Performance DOT 3 WSS-M6C62-A or —
(Canada)
Gear Ratios
Gear Ratio
1st 3.85
2nd 2.04
3rd 1.28
4th 0.95
5th 0.76
Reverse 3.62
Final Drive 4.07
Information Manual
DESCRIPTION AND OPERATION 05/13/2010
Manual Transaxle and Clutch
The IB5 manual transaxle and clutch system consists of the following:
Five-speed manual transaxle

Clutch disc
Clutch pressure plate
Clutch release hub and bearing
Clutch hydraulic system
Clutch pedal
Flywheel
The function of the transaxle is to move the vehicle from a rest position to motion. The transaxle uses
gears to adapt the torque to the demands of load and road conditions. It matches engine power to
vehicle needs. This power is delivered from the engine flywheel to the transaxle. The power is
transmitted through a driver-operated clutch, which allows for engagement and disengagement of the
engine to the transaxle.
The transaxle input shaft receives the power when the clutch is engaged. The transaxle then uses a
system of gears to change the speed and torque relationship between the engine crankshaft and the
transaxle differential.
The purpose of the clutch is to connect and disconnect a manually operated transaxle and the halfshafts
from the engine. This allows starting and stopping the vehicle, shifting and changing speeds that
correspond to the engine speed through gear changes.
Information Manual
DIAGNOSIS AND TESTING 05/13/2010
Manual Transaxle and Clutch
Special Tool(s)
Holding Tool, Flywheel
303-103 (T74P-6375-A)
Dial Indicator Gauge With

Holding Fixture
100-002 (TOOL-4201-C)
Material
Item Specification
Motorcraft® Full Synthetic WSD-M2C200-C
Manual Transmission Fluid
XT-M5-QS
(Canada)
NOTICE: If transaxle noise is reported, check the fluid level first. Do not drive the vehicle if the
fluid level is low or damage can occur.
NOTE: If any evaluation or inspection reveals an obvious concern, repair the vehicle.
NOTE: Before attempting to repair any concerns, road test the vehicle to determine in which system the
concern falls.
The technician should have a thorough knowledge of transaxle/clutch operation and accepted general
transaxle/clutch guidelines to detect any problems.
A gear driven unit produces a certain amount of noise. Some noise is acceptable and audible at certain
speeds or under various driving conditions. Certain conditions, such as road and weather, amplify
normal vehicle noise.
Use the following to diagnose and repair a transaxle/clutch concern:
Verify the Customer Concern

NOTICE: If transaxle noise is reported, first check the fluid level. The vehicle should not be
driven if the fluid level is low or damage can occur.
1. Verify and document the customer concern.

1. When was it first noticed?
2. Did it appear suddenly or gradually?
3. Did anything unusual occur that would coincide with it or precede it?
4. Identify when the condition occurs.
Hot or cold vehicle operating conditions
Type of terrain
City or highway driving
Driving at a particular speed
coasting
hard acceleration
Shifting
upshifts
downshifts
in a particular gear
in all gears
Hot or cold ambient temperatures
5. Check TSBs and On-Line Automotive Service Information System (OASIS) messages.
Check Fluid Level and Condition
NOTICE: Do not drive the vehicle if the fluid level is low or damage can occur.
An incorrect fluid level may affect transaxle operation and can result in transaxle damage. To correctly
check and add fluid to the transaxle, refer to transaxle draining and filling in Section 308-03 .
Low fluid level can result in poor transaxle shifting, engagement or damage. It can also indicate a leak in
one of the transaxle seals or gaskets.
1. Check the fluid condition.

Observe the color and the odor of the fluid. Allow the fluid to drip onto a white cloth and
examine the stain. Check the fluid for contamination or metal particles.
Fluid should appear nearly clear, similar to clean engine oil.
Evaluation of Clutch Hydraulic System
1. Verify the clutch hydraulic fluid reservoir is filled to the correct level.
If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks
and repair as necessary. Refer to Section 308-02 .
Evaluation Of The Clutch
1. Slowly press and release the clutch pedal to see if the pedal is binding. Make sure the clutch
pedal can be fully pressed and is not restricted by the floor mat. Verify the pedal return spring is
present and is functioning correctly.
2. Measure the clutch reserve. GO to Pinpoint Test A .
3. With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift
lever into a forward or reverse gear, until gear clash can be heard. Slowly press the clutch pedal.
If the gears cease to clash (full disengage at 25-38 mm [1-1.5 in] from the floor), hold the
pedal at the point of disengagement and increase engine to 4,000 rpm. If the clutch
remains disengaged, it is functioning correctly.
Any concerns indicate a worn or damaged clutch. Repair as necessary. Refer to Section
308-01 .
4. With the engine idling, move the gearshift lever into 4th gear. Increase the engine to 2,000 rpm
and slowly release the clutch pedal.
If the engine stalls, the clutch is OK.
If the engine does not stall, the clutch is slipping. Repair as necessary.
5. Compare the road test results with the symptom chart. The chart is a list of conditions that are
typical faults. GO to Symptom Chart - Clutch .
Inspect The Gearshift Components
1. Inspect the gearshift cables for:

signs of damage
broken locks
binding
cables not fully seated or in hold-down brackets
correct routing
correct adjustment
If the concern is a gear(s) cannot be selected, jumps out of gear or gear clashes,
adjust the gearshift cables. Refer to Section 303-06 .
2. Inspect the gearshift lever for free play.

If the gearshift lever free play is more than 15 mm (0.59 in), check the gearshift cables and
repair as necessary.
If the gearshift lever free play is 15 mm (0.59 in), adjust the gearshift cables. Refer to
Section 308-06 .
Road Test the Vehicle
1. During the road test, use the following driving methods to diagnose the problem.
Start the engine.
Evaluate the noise in NEUTRAL while the vehicle is parked.
Check whether the noise is present with the clutch fully disengaged (pedal fully
pressed). Check to see if the pedal pulsates abnormally (for clutch diaphragm finger
run out).
Check whether the noise is present with the gearshift in the NEUTRAL position and
the clutch fully engaged (foot off pedal). With the parking brake engaged, move the
gearshift towards the 1st gear position. Apply very slight pressure and note if the
gear noise level is reduced (for gear rollover noise).
With the clutch fully engaged (foot off pedal) check whether the noise is present as
the engine rpm increases. If the noise reduces, note the engine rpm at which this
occurs.
Listen for any change in noise while pressing and releasing the clutch pedal.
Listen for any change in noise while changing the engine rpm.
Drive the vehicle and shift through all of the gear ranges, including reverse. Listen for any
change in noise in a particular gear.
Drive the vehicle in the gear in which the noise is most noticeable. Press the clutch pedal
and leave the gear engaged. Listen for any change in noise.
Drive the vehicle in the gear in which the noise is most noticeable. Press the clutch pedal
and shift the transaxle into NEUTRAL. Release the clutch pedal and allow the vehicle to
coast.
2. Compare the road test results with the symptom charts. The charts are a list of conditions that are
typical faults.GO to Symptom Chart - Clutch , GO to Symptom Chart - Transaxle or GO to
Symptom Chart - NVH in this section.
Symptom Chart — Clutch

Clutch slippage Clutch pedal reserve GO to Pinpoint
Worn or damaged pressure plate Test A .
Clutch disc facing
Hardened or oiled clutch disc
facing surface
Flywheel
Clutch chatter, rattle Loose or damaged engine or GO to Pinpoint
or shudder transaxle mounts Test B .
Oil on clutch disc facing
Worn pressure plate
Clutch disc facing
Loose or damaged flywheel
Worn clutch disc
Clutch drag Insufficient clutch hydraulic fluid GO to Pinpoint
Air in hydraulic system Test C .
Clutch pedal reserve
Diaphragm springs
Clutch disc
Clutch disc splines
Oil on clutch disc facing
Clutch pedal Clutch and brake pedal pivot GO to Pinpoint
pulsation shaft not correctly lubricated Test D .
Flywheel
Worn pressure plate springs
Clutch related Engine component grounding GO to Pinpoint
vibrations against frame Test E .
Accessory drive belt
Flywheel bolts loose
Flywheel
Imbalanced clutch pressure plate
Hard shifting Insufficient clutch hydraulic fluid GO to Pinpoint
Clutch pedal reserve Test F .
Transaxle concern
Excessive noise Clutch pedal reserve GO to Pinpoint
Clutch slave cylinder Test G .
Excessive crankshaft endplay
Clutch system Clutch master cylinder GO to Pinpoint
leakage Clutch slave cylinder Test H .
Clutch hydraulic tubes
Symptom Chart — Transaxle
Symptom Chart — Transaxle

Gears clash Gear INSPECT and REPAIR as
when shifting teeth/synchronizer necessary. REFER to Section
from one damaged 308-03 .
forward gear
to another
Transaxle Bolts retaining TIGHTEN the bolts to
jumps out of transaxle to engine specification. REFER to Section
gear loose 308-03 .
Preload incorrect CHECK preload. INSPECT the
Internal components synchronizer for free movement
damaged on their hubs. INSPECT the
synchronizer blocking rings for
widened index slots, rounded
clutch teeth and smooth internal
surface. CHECK the countershaft
cluster gear for excessive end
play. INSPECT the shift forks for
wear. CHECK for loose shift forks
on the shift rails. INSPECT the
synchronizer sliding sleeve and
the gear clutch teeth for wear and
damage. REPAIR as necessary.
Gear teeth INSPECT and REPAIR as
worn/damaged necessary. REFER to Section
308-03 .
Transaxle will Internal components For the gear in question,
not shift into INSPECT the shift rail and fork,
one gear — all the synchronizer, and the gear
others OK clutch teeth for restricted travel.
REPAIR as necessary. REFER to
Section 308-03 .
Transaxle is Internal components INSPECT the gears, the shift
locked in one rails, the forks and the
gear and will synchronizer for wear or damage.
not shift out of REPAIR as necessary. REFER to
that gear Section 308-03 .
Fluid leaks Transmission fluid CHECK the transmission fluid
level and type.
REMOVE all traces of fluid on the
exposed transaxle surfaces.
CHECK the vent for free
breathing. OPERATE the
transaxle. INSPECT for new
leakage. REFER to Section 308-
03 .
Other components REMOVE all traces of fluid on
leaking exposed transaxle surfaces.
CHECK the vent for free
breathing. OPERATE the
transaxle and INSPECT for new
leakage. IDENTIFY the leaking
fluid as engine, power steering or
transmission fluid. REPAIR as
necessary.
Halfshaft seals INSPECT and INSTALL new
seals as necessary. REFER to
Section 308-03 .
Input shaft seal INSPECT, and REPAIR as
308-03 .
Fill and drain plugs INSPECT the plug, O-ring, and
the threads in the case. REPAIR
as necessary. TIGHTEN the plug
to specification. REFER to
Section 308-03 .
Significant Gear INSPECT the transaxle. INSTALL
effort required synchronization is a new synchronizer assembly
when inadequate. Gear with synchronizer rings. INSTALL
downshifting teeth/synchronizer two new gears belonging to the
damaged synchronizer assembly. REFER
to Section 308-03 .
Stiff gearshift Transmission fluid CHECK that the transaxle is filled
Damaged with the specified transmission
synchronizer rings fluid and, if necessary, FILL and
or inner selector ADD transmission fluid as
mechanism necessary.
CHECK the internal components
for wear or damage, REPAIR as
308-03 .
One of the Fault between the INSPECT the gearshift lever.
gears cannot gearshift lever and REFER to Section 308-06 .
be selected gearshift lever
housing
Reverse gear Gearshift lever CHECK the gearshift lever for
cannot be Internal components damage. REPAIR as necessary,
selected remove the gearshift lever to see
whether reverse gear can be
selected.
CHECK the reverse idler gear
and the appropriate selector fork,
shift rail and synchronizer unit.
REPAIR as necessary. REFER to
Section 308-03 .
Grinding or Deflected lubrication INSTALL a new 3rd gear, 3rd/4th
clashing condition causing gear shift fork, outer synchronizer
noises when early 3rd gear wear ring, inner synchronizer ring, 3rd
shifting into gear synchronizer cone, 3rd/4th
3rd gear gear synchronizer assembly.
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of
these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 .
Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to
use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not
the causal system for the symptom, refer back to Section 100-04 for the next likely system and continue
diagnosis.
Noisy in forward gears Transmission fluid ADD or REFILL with the
— noise described as level low/incorrect specified transmission
rattle or a knock type fluid. REFER to
Specifications in this
section.
Components CHECK for screws and
grounding out on bolts of chassis
transaxle components grounding
out. REPAIR as
necessary.
Bearings/gears INSPECT the bearings,
worn/damaged the gears, and the gear
teeth for wear and
damage. REPAIR as
necessary. REFER to
Section 308-03 .
Bolts retaining VERIFY the bolts are
transaxle to tightened to specification.
engine loose REFER to Section 308-
03 .
Noise in NEUTRAL Neutral rollover A slight rollover gear noise
occurs after hot soak noise is an acceptable condition.
or under load INSTALL a new clutch
disc. REFER to Section
308-01 .
Transaxle INSPECT and REPAIR as
necessary. REFER to
Section 308-03 .
Slight buzzing, rattling Rotational These noises do not affect
or metallic scraping vibration from the the operation and
noise from the engine not durability of the transaxle.
transaxle at 2,500 to sufficiently
3,500 rpm when damped by the
coasting or driving clutch
without load
(particularly in 2nd and
3rd gear)
Brief scratching noise Inadequate gear INSPECT the transaxle for
during gear shifting synchronization wear or damage. REPAIR
as necessary. INSTALL a
complete synchronizer
assembly with
synchronizer rings.
INSTALL two new gears
belonging to the
synchronizer assembly.
03 .
Gear growl — to occur, Reduced preload Acceptable noise under
lug the engine in 1st or on the input shaft these conditions.
2nd gears, press the
throttle to floor and the
noise will be heard
Gear whistle — occurs Driven gears on Acceptable noise under
in 2nd, 3rd and 4th the output shaft these conditions.
gear by pressing the
throttle to the floor and
letting the vehicle
accelerate, hard
acceleration to Wide
Open Throttle (WOT),
a very light whistle
noise can be heard
Clicking noises in Reverse gear INSPECT the gears for
reverse gear wear or damage. INSTALL
new gears as necessary.
03 .
Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
Result /
Test Step Action to
Take
A1 TEST CLUTCH SLIPPAGE
Apply the parking brake. Yes
Start engine and engage 4th gear. Clutch is OK.
Run the engine at approximately 2,000 rpm.
Slowly release clutch pedal. No
Does the engine stall when the clutch pedal is fully released? GO to A2 .
A2 MEASURE THE CLUTCH RESERVE
NOTE: Remove the floor mat, if equipped, to allow the clutch pedal to travel Yes
to the downstop. Clutch pedal
reserve is OK.
Install a cable tie to the lower clutch pedal, than attach a tape measure to VERIFY
the cable tie. customer
concern. GO
to Symptom
Chart -
Clutch .
No
INSTALL a
new pressure
plate and
clutch disc.
REFER to
Section 308-
01 .
Pull the tape measure up to the steering wheel. Position it through the
steering wheel opening. Put a piece of masking tape on the wheel, index
mark the tape.
Press the clutch fully and start the vehicle.
Shift the transaxle into reverse gear, then move the gearshift lever forward
to the position in between reverse gear and neutral. Slowly release the
clutch pedal (if the vehicle creeps rearward, move the gearshift lever
forward a little more). The transaxle will work as if in neutral, but the
reverse gear synchronizer will be bypassed.
With the clutch pedal released, gently pull the gearshift lever toward the
reverse gear position. Gear clash can now be heard.
Slowly press the clutch pedal. Using the mark on the tape as a reference,
note the measurement when the gear clash stops or the gearshift lever
slides into reverse gear. Press the clutch pedal to the downstop. The
difference between the measurement taken when the gear clash stopped
and the measurement taken at the downstop is the clutch reserve.
Item Pedal Position

1 Gear clash begins
2 Gear clash ends
3 Clutch pedal downstop
Is the clutch reserve between 25-38 mm (1 to 1.5 in)?
PINPOINT TEST B: CLUTCH CHATTER, RATTLE OR SHUDDER

B1 CHECK THE ENGINE OR TRANSAXLE
MOUNTS
Inspect all the engine and transaxle Yes
mounts for looseness or damage. TIGHTEN or INSTALL new engine or transaxle
Are any of the engine or transaxle mounts. TEST the system for normal operation.
mounts loose or damaged?
No
GO to B2 .
B2 INSPECT THE PRESSURE PLATE
BOLTS
Inspect the pressure plate-to-flywheel Yes
bolts. TIGHTEN or INSTALL new bolts. REFER to
Are any of the pressure plate-to- Section 308-01 .
flywheel bolts loose?
No
GO to B3 .
B3 INSPECT THE PRESSURE PLATE
Remove the clutch pressure plate. Yes
Inspect the clutch pressure plate for INSTALL a new clutch pressure plate. REFER to
wear or damage. Section 308-01 . TEST the system for normal
Are any signs of damage present on operation.
the clutch pressure plate?
No
GO to B4 .
B4 CHECK THE CLUTCH DISC
NOTE: If the internal damper of the Yes

clutch disc is damaged or GO to B5 .
contaminated with grease or oil, it will
sound similar to a "transaxle rattle". No
INSTALL a new clutch disc. REFER to Section
Check the clutch disc for wear or 308-01 . TEST the system for normal operation.
damage.
Is the clutch disc OK?
B5 INSPECT THE FLYWHEEL
Inspect the flywheel for wear or Yes
damage. GO to B6 .
Is the flywheel OK?
No
REPAIR or INSTALL a new flywheel as necessary.
REFER to Section 308-01 . TEST the system for
normal operation.
B6 INSPECT THE INPUT SHAFT
Inspect the input shaft for signs of Yes
wear, damage or corrosion. If wear or damage is found, INSTALL a new input
Are any signs of wear damage, or shaft. REFER to Section 308-03 . If corrosion is
corrosion present on the input found on the splines of the input shaft, apply a
shaft? small amount of grease to the splines of the input
shaft.
No
VERIFY the customer concern. GO to Symptom
Chart - Clutch , GO to Symptom Chart -
Transaxle , GO to Symptom Chart - NVH if
necessary.
PINPOINT TEST C: CLUTCH DRAG

C1 CHECK CLUTCH FLUID LEVEL
Yes
Check clutch fluid level. GO to C2 .
Is the clutch fluid level between the MAX
and MIN marks on the brake fluid No
reservoir? FILL reservoir to specification, CHECK the
brake and clutch systems for leaks. TEST
clutch system for normal operation.
C2 TEST CLUTCH PEDAL FREE TRAVEL
Manually operate the clutch pedal to the point Yes
of resistance and release. GO to C3 .
Measure pedal travel.
Is the measured dimension within 10 mm No
(0.393 in)? GO to Pinpoint Test B .
C3 CHECK THE BELLEVILLE SPRING WASHER
OF THE CLUTCH PRESSURE PLATE
Remove transaxle. Yes
Does the clutch pressure plate or the INSTALL a new clutch pressure plate. TEST
Belleville spring washer of the clutch the system for normal operation.
pressure plate show signs of wear or
damage? No
VERIFY the customer concern. GO to
Symptom Chart - Clutch .
PINPOINT TEST D: CLUTCH PEDAL PULSATION

D1 CHECK THE CLUTCH PEDAL
PULSATION
Start engine. Yes
With the transaxle in neutral, GO to D2 .
slowly press the clutch pedal.
Does the clutch pedal pulsate No
while being pressed? VERIFY the customer concern. GO to Symptom Chart -
Clutch if necessary.
D2 INSPECT THE PRESSURE
PLATE BOLTS
Inspect the pressure plate-to- Yes
flywheel bolts. TIGHTEN or INSTALL new bolts. REFER to Section 308-
Are any of the pressure plate- 01 . TEST the system for normal operation.
to-flywheel bolts loose?
No
GO to D3 .
D3 INSPECT THE CLUTCH
PRESSURE PLATE
Remove the clutch pressure Yes
plate. REFER to Section 308- INSTALL a new clutch pressure plate. REFER to Section
01 . 308-01 . TEST the system for normal operation.
Inspect the clutch pressure
plate for wear or damage. No
Are there any signs of GO to D4 .
damage present on the clutch
pressure plate?
D4 INSPECT THE CLUTCH DISC
Check the clutch disc for wear Yes
or damage. GO to D5 .
Is the clutch disc OK?
No
INSTALL a new clutch disc. REFER to Section 308-01 .
D5 INSPECT THE FLYWHEEL
Inspect the flywheel for wear or Yes
damage. VERIFY the customer concern. GO to Symptom Chart -
Is flywheel OK? Clutch , GO to Symptom Chart - Transaxle , GO to
Symptom Chart - NVH if necessary.
No
TIGHTEN, RESURFACE or INSTALL a new flywheel as
necessary. REFER to Section 308-01 . TEST the system
PINPOINT TEST E: CLUTCH RELATED VIBRATIONS

E1 CHECK FOR ENGINE COMPONENT
GROUNDING
Raise and support the vehicle. Yes
Check the engine mount interlocks for REPAIR any components as necessary. TEST
grounding on the body or frame. the system for normal operation.
Check the exhaust manifold or other
engine component grounding on the No
body or frame. GO to E2 .
Is there evidence of grounding on
body or frame?
E2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS
Feel accessory vibration at clutch Yes
engage/disengage when engine torque REPAIR or INSTALL new accessory drive belt
changes. components. REFER to Section 303-05 .
Disconnect the accessory drive belt and
check for vibration. No
Does the vibration stop when the GO to E3 .
drive belt is removed from the
engine?
E3 CHECK FOR RELEASE BEARING NOISE
Start engine. Yes
Press and hold clutch pedal. INSTALL a new clutch slave cylinder. REFER to
Is a whirring, grating or grinding noise Section 308-02 . TEST the system for normal
present? operation.
No
GO to E4 .
E4 INSPECT THE FLYWHEEL
Remove the transaxle. REFER to Yes
Section 308-03 . DIAGNOSE engine vibration concern. REFER to
Inspect for loose flywheel bolts. Section 308-00 .
Carry out flywheel runout check. REFER
to Section 303-00 . No
Is the flywheel OK? TIGHTEN the flywheel bolts or INSTALL a new
flywheel. REFER to Section 303-01 . TEST the
PINPOINT TEST F: HARD SHIFTING

F1 CHECK THE FLUID LEVEL
NOTE: The hydraulic clutch Yes

fluid is supplied from the brake GO to F2 .
master cylinder.
No
Ignition OFF. ADD brake fluid and CHECK for leaks in the clutch and
Inspect the fluid level in the brake system. TEST the system for normal operation.
brake master cylinder reservoir.
Is the fluid within the MAX
and MIN level marks?
F2 CHECK THE CLUTCH PEDAL
FREE PLAY
Press the clutch pedal lightly by Yes
hand. DIAGNOSE hard shifting concern. REFER to Section 308-
Measure the distance the clutch 03 .
pedal travels.
Is the clutch pedal free play No
within 1-3 mm (0.04-0.12 in)? INSPECT the clutch pressure plate for wear or damage.
REPAIR as necessary. REFER to Section 308-01 . TEST
PINPOINT TEST G: EXCESSIVE NOISE

G1 CHECK THE TRANSAXLE
NEUTRAL POSITION
Start engine and run it in Yes
neutral. GO to G2 .
Press clutch pedal fully.
Are there noises when the No
clutch is operated? There is a problem with the transaxle. GO to Symptom
Chart - Transaxle if necessary.
G2 TEST THE CLUTCH PEDAL
FREE TRAVEL
Manually press the clutch pedal Yes
down until resistance is felt, GO to G3 .
then release.
Measure pedal travel. No
Is the travel within 10 mm REFER to Section 308-02 .
(0.393 in)?
G3 TEST THE CLUTCH SLAVE
CYLINDER WITH RELEASE
BEARING
Remove the transaxle. Yes
Check the clutch slave cylinder TIGHTEN the bolts or INSTALL a new clutch slave
bolts. cylinder with the release bearing. REFER to Section 308-
Check the release bearing for 02 . TEST the system for normal operation.
wear and rust.
Are the bolts loose or are No
there signs of wear or rust? GO to G4 .
G4 TEST THE CLUTCH FRICTION
DISC TORSION SPRINGS
Check torsion springs for wear Yes
or damage. INSTALL a new clutch disc. REFER to Section 308-01 .
Do the torsion springs have TEST the system for normal operation.
signs of wear or damage?
No
CHECK the crankshaft end play. REFER to Section 303-
00 .
PINPOINT TEST H: CLUTCH SYSTEM LEAKAGE

H1 INSPECT THE CLUTCH MASTER
CYLINDER
Inspect clutch master cylinder for Yes
leakage. GO to H2 .
Is the clutch master cylinder
OK? No
REPAIR or INSTALL a new clutch master cylinder as
H2 INSPECT THE CLUTCH SLAVE
CYLINDER
Inspect clutch slave cylinder for Yes
leaks. GO to H3 .
Is the clutch slave cylinder OK?
No
REPAIR or INSTALL a new clutch slave cylinder as
H3 INSPECT THE SYSTEM
HYDRAULIC TUBES
Inspect clutch hydraulic tubes for Yes
loose or damaged fittings causing CARRY OUT a road test to VERIFY customer
leakage. complaint.
Are the clutch hydraulic tubes
OK? No
REPAIR or INSTALL new components as necessary.
REFER to Section 308-02 . TEST the clutch system for
normal operation.
Information Manual
GENERAL PROCEDURES 05/13/2010
Clutch Slave Cylinder Check
1. Check the clutch slave cylinder with release bearing for:

leaks.
transmission fluid.
brake fluid.
damage or rust.
Information Manual
Clutch System Bleeding
Special Tool(s)
Vacuum Pump Kit
416-D002 (D95L-7559-A)
Material
Item Specification
(Canada)

injury.
NOTICE: If brake fluid is spilled on the paint, immediately wash the affected area with cold water
or damage can occur.
NOTE: Do not reuse brake fluid.
Section 303-12 .
2. Remove the brake fluid reservoir cap.
3. Drain the brake fluid reservoir to the MIN mark.

4. Remove the clutch slave cylinder bleed fitting dust cap.
5. Install the special tool and loosen the clutch slave cylinder bleed fitting.
6. Using the special tool, bleed the clutch system.

1. Fill the reservoir of the special tool with approximately 120 ml (4.06 oz) of brake fluid.
2. Loosen the clutch slave cylinder bleed fitting.
3. Pump approximately 100 ml (3.38 oz) of brake fluid into the clutch system.
7. Tighten the clutch slave cylinder bleed fitting.
8. Install the clutch slave cylinder bleed fitting dust cap.
9. Install the brake fluid reservoir cap.

10. Check the fluid level in the brake fluid reservoir and add as necessary.
11. NOTE: Carefully move the gearshift lever into REVERSE.
Test the operation of the clutch control system.

Start the engine, after 2 seconds press the clutch pedal and carefully move the gearshift
lever into REVERSE. If there are abnormal noises, automatically bleed the clutch control
system by pressing the clutch pedal 4 or 5 times. During bleeding, full travel of the clutch
pedal must be reached.
Test the operation of the clutch control system again after 30 seconds. If there are still
abnormal noises perform steps 2 to 10 again.
12. Install the ACL assembly and outlet pipe assembly. For additional information, refer to Section
303-12 .
Information Manual
Flywheel Runout Check
NOTICE: Do not clean the dual mass flywheel with any kind of fluid. Use a dry cloth only or
damage to the dual mass flywheel may occur.
NOTICE: Do not clean the gap between the primary and secondary mass. Only clean the bolt
connection surface and the clutch surface or damage to the flywheel may occur.
1. Check the transmission fluid level and fill to the correct level as necessary.
2. With the engine operating at idle and the transaxle in NEUTRAL, listen and check for
unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is
pressed. For additional information, refer to the Flywheel Inspection procedure in Section 303-00 .
Information Manual
Gearshift Cable Adjustment
100-02 .
2. Remove the gearshift cables cover.
3. Adjust the selector cable.

1. Unlock the selector cable (press colored insert).
2. Move the selector lever to its center position.
4. Adjust the selector cable.

1. Select 3rd or 4th gear (move the gearshift lever to its RH or LH stop position).
2. Lock the selector cable.
5. Install the gearshift cables cover.
6. Check system for normal operation.

SECTION 308-01: Clutch 2011 Fiesta Workshop Manual
Item Specification
Clutch
Type Single-plate dry clutch
Operation Hydraulic
External diameter of clutch disc 220 mm (8.661 in)
Pedal travel (not adjustable) 132-138 mm (5.197-5.433 in)
Clutch pressure plate-to-flywheel a — —
Clutch
Clutch Components

1 7563 Clutch pressure plate (part of 7B546)
2 7550 Clutch friction disc (part of 7B546)
3 6375 Flywheel
The clutch transmits the engine torque to the transaxle.
The clutch is a single-plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The
clutch disc has a hub which is splined to the transmission input shaft. The clutch disc has friction
material where it contacts the flywheel and the clutch pressure plate. The clutch pressure plate applies
pressure to the clutch disc, holding it tightly against the surface of the flywheel. In the engaged position,
the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is
transmitted to the input shaft.
When the clutch pedal is applied, the release bearing pushes the diaphragm spring center of the clutch
pressure plate toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the
clutch pressure plate. The clutch slave cylinder assists in the effort it takes to relieve the load on the
clutch pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch
pressure plate from the clutch disc, disengaging the engine torque from the transaxle.
Clutch

Clutch Disc and Pressure Plate

1 W702426 Clutch pressure plate-to-flywheel bolt (6 required)
2 7563 Clutch pressure plate (part of 7B546)
3 7550 Clutch disc (part of 7B546)
Removal
1. Remove the transaxle. For additional information, refer to Section 308-03 .
2. NOTICE: Loosen the clutch pressure plate retaining bolts evenly, by two turns at a time.
Remove and discard the 6 clutch pressure plate retaining bolts, remove the clutch disc and
pressure plate.
Installation
1. NOTICE: Be sure the clutch is installed correctly in the pressure plate. The side of the
clutch marked gearbox side faces the pressure plate fingers. Failure to install the clutch
plate will damage the clutch assembly during installation on the flywheel.
NOTICE: Do not use cleaners with a petroleum base and do not immerse the clutch
pressure plate in solvent or damage may occur.
Position the clutch disc on the clutch pressure plate with the side of the clutch marked gearbox
side facing the pressure plate fingers. Using a suitable clutch aligner, centralize the clutch disc to
the clutch pressure plate.
2. NOTE: Tighten the clutch pressure plate-to-flywheel bolts finger tight and then evenly by two
turns at a time to the specified torque.
Using a suitable clutch aligner, position the clutch disc and clutch pressure plate on the flywheel.
Install the 6 new clutch pressure plate-to-flywheel bolts.
Tighten the bolts evenly two turns at a time in the pattern shown.
3. Install the transaxle. For additional information, refer to Section 308-03 .

SECTION 308-02: Clutch Controls 2011 Fiesta Workshop Manual
Material
Capacity

(Canada)
Item Specification
Clutch adjustment Automatic
Clutch operation Hydraulic
Total pedal travel (not adjustable) 132-138 mm (5.197-5.433 in)
Clutch pedal assembly nuts 25 18 —
Clutch slave cylinder bolts 10 — 89
Clutch Controls
Components — Clutch Control

1 — Brake fluid reservoir
2 — Brake fluid filling reservoir
3 — Clutch master cylinder
4 — Clutch pedal
5 — Clutch slave cylinder
The clutch control system is a hydraulic/mechanical clutch system. The clutch control system disengages the
clutch when the clutch pedal is pressed and engages the clutch when the clutch pedal is released. When the
clutch pedal is pressed, pressure builds up in the clutch master cylinder and the release bearing in the clutch
slave cylinder is actuated.
The advantages of a hydraulic clutch system are:
Automatic adjustment
Low operating effort
Minimal wear
A self-adjusting clutch system eliminates the need for maintenance adjustments. It provides for consistent pedal
height throughout the service life of the clutch.
Brake Fluid Reservoir
The brake fluid reservoir supplies brake fluid to the hydraulic clutch system and the brake system. The
hydraulic clutch system and brake system are arranged separately inside the brake fluid reservoir. If a leak
occurs in the hydraulic clutch system, the brake system continues to operate unrestricted.
Brake Fluid Filling Reservoir
The brake fluid filling reservoir is remotely attached to the brake fluid reservoir. Due to the brake fluid reservoirs
location the brake fluid filling reservoir allows the technician to easily fill the brake fluid reservoir.
Clutch Master Cylinder
The clutch master cylinder generates the system pressure required to actuate the clutch. When the clutch pedal
is depressed, the piston rod moves the clutch master cylinder piston. The hydraulic fluid in the clutch master
cylinder is forced through the high-pressure tube to the clutch slave cylinder.
Clutch Pedal
When the clutch pedal is pressed, the clutch master cylinder transmits hydraulic fluid pressure to the clutch
slave cylinder. The clutch slave cylinder and the clutch release fork transfer the clutch pedal motion to the
clutch release bearing. The release bearing presses against the pressure plate diaphragm spring, releasing the
clutch disc. Once the clutch pedal is released, the diaphragm spring pushes the piston in the clutch slave
cylinder back to its initial position. The non-positive connection between the clutch disc and the flywheel is re-
established.
Clutch Slave Cylinder
The central clutch slave cylinder is equipped with a release bearing and is attached to the clutch bell housing
with three bolts. The release bearing is an interference installed in the clutch slave cylinder and is not serviced
separately.
The hydraulic fluid forced from the piston in the clutch master cylinder moves the piston in the clutch slave
cylinder which, moves the release bearing in an axial direction. The release bearing inner ring presses onto the
diaphragm spring. The non-positive connection between the clutch disc and the flywheel is interrupted.
Clutch Master Cylinder
Material
Item Specification
(Canada)

1 — Clutch master cylinder (part of 7519)
2 W706840 Clutch pedal nut (3 required)
3 7519 Clutch pedal assembly
4 7K502 Brake master cylinder to clutch master cylinder tube
5 7K592 Clutch master cylinder to slave cylinder tube
6 2140 Brake master cylinder assembly
Removal
Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may get
into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it
has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
1. Remove the brake fluid reservoir cap.
2. Drain the brake fluid into a suitable container until the brake fluid level reaches the MIN mark.
3. Disconnect the clutch master cylinder tubes.

4. Disconnect the clutch pedal position switch, starter inhibitor switch electrical connectors and remove the
3 clutch pedal assembly nuts.
5. Remove the clutch pedal/master cylinder assembly.
Installation
1. Install the clutch pedal/ master cylinder assembly
2. Install the 3 clutch pedal assembly nuts, connect the starter inhibitor switch and clutch pedal position
switch electrical connectors.
3. Connect the clutch master cylinder tubes.
Clutch Slave Cylinder
Removal
1. Remove the transaxle. For additional information, refer to Section 308-03 .
2. NOTICE: If brake fluid is spilled on the paint work, the affected area must be immediately
washed down with cold water.
NOTE: Any oily or greasy deposits witnessed on the slave cylinder release bearing surface
should be wiped off with a suitable de-greasing agent or cleaner. Do not use detergent or other
corrosive agents.
Remove the 3 clutch slave cylinder bolts and remove the clutch slave cylinder.
Installation
1. NOTICE: If brake fluid is spilled on the paint work, the affected area must be immediately
washed down with cold water.
Install the clutch slave cylinder and the 3 clutch slave cylinder bolts.
Tighten to 11 Nm (97 lb-in.).
2. Install the transaxle. For additional information, refer to Section 308-03 .
3. Fill and bleed the clutch system. For additional information, refer to Section 308-00 .
SECTION 308-03: Manual Transaxle/Transmission 2011 Fiesta Workshop Manual
Material
Capacity
Gasket Maker WSK-M2G348-A5 —
TA-16
(Canada)
Motorcraft® Full Synthetic WSD-M2C200-C 2.3L (2.4
Manual Transmission qt)
Fluid
XT-M5-QS
Silicone Gasket and WSE-M4G323-A4 —
Sealant
TA-30
Threadlock and Sealer WSK-M2G351-A5 —
TA-25
Item Specification
Transaxle Weight 36.8 kg (81 lbs)
Transaxle Ratios
Description 1.6L
1st gear 3.85
2nd gear 2.04
3rd gear 1.41
4th gear 1.11
5th gear 0.88
Reverse gear 3.62
Final drive 3.82
Battery tray bracket nuts 25 18 —
Brake hose retainer bolts 25 18 —
Clutch housing-to-engine bolts 48 35 —
Clutch slave cylinder 11 — 97
Differential ring gear bolts 90 66 —
Fifth gear cover 12 — 106
Fifth gear housing-to-transaxle 17 — 150
Fill plug 35 26 —
Gearshift cables shroud 5 — 44
Gearshift cables bracket nuts 20 — 177
Ground wire bolt 25 18 —
Heated Oxygen Sensor (HO2S) bracket nut 25 18 —
PCM cover bolt 6 — 53
Reversing lamp switch 14 — 124
Roll restrictor bolt 70 52 —
Roll restrictor bracket bolts 48 35 —
Roll restrictor-to-transaxle bracket bolt 48 35 —
Selector shaft interlock mechanism 25 18 —
Shield and bearing retainer strap nuts a — — —
Transaxle housing 33 24 —
Transaxle housing special tool bolts 28 21 —
Transaxle support insulator bolts 90 66 —
Transaxle support insulator nuts 125 92 —
Upper strut mount nuts 48 35 —
Wiring harness bracket bolt 25 18 —
Manual Transaxle
General View

1 7A564 Clutch slave cylinder
2 7D494 Transaxle vent
3 7L226 Input shaft
4 7061 Output shaft
5 4026 Differential
The IB5 transaxle has an aluminum transaxle housing which comprises of two sections. Its rigidity has been
improved with the inclusion of reinforcement ribbing in the design. The transaxle housing sections come in pairs
and cannot be obtained separately. The clutch is hydraulically actuated.
All the gears are constant mesh gears (except reverse gear). In each gear, the required transaxle ratio is
achieved by means of a pair of gears.
When reverse gear is selected, the direction of rotation of the output shaft is changed by an idler gear.
The gears are all helical gears (except reverse gear). They all have synchronizers (except reverse gear) and
run on plain bearings.
First and second gears have dual synchronizers.
IB5 Manual Transaxle Components
General View
Part
1 — Quick-release coupling
2 7052 Oil seal (accessible from outside)
3 7A564 Clutch slave cylinder with release bearing (cannot be
serviced separately)
4 3B436 RH intermediate shaft
5 7F343 Differential ring gear
6 3B437 LH halfshaft
7 7124 Gear synchronizer — 1st/2nd gear
8 7124 Gear synchronizer — 3rd/4th gear
9 7107 Gear synchronizer — 5th gear
10 7D494 Transaxle vent
In neutral, no gear is connected to the output shaft via the gear synchronizers. No input torque is transmitted to
the differential.
Selector Mechanism

1 7K024 Selector rod guide sleeve, 5th/reverse gear
2 7M038 Selector gate
3 7K201 Select interlock plate
4 7M131 Selector shaft interlock mechanism
5 7C031 Selector shift shaft
6 7K205 Return spring for selector lever, reverse gear
7 7K001 Selector lever, reverse gear
8 W527007 Snap-ring
9 7302 Selector fork, 5th/reverse gear
Input Shaft
1 7025 Bearing
2 7L226 Input shaft
3 7141 Reverse idler gear
4 — 1st gear (part of 7L226)
5 — Reverse gear (part of 7L226)
6 — 2nd gear (part of 7L226)
7 — 3rd gear (part of 7L226)
8 — 4th gear (part of 7L226)
9 7026 Retaining ring
11 E860332 Snap-ring
Output Shaft
1 7A043 Bearing
2 7061 Output shaft
3 7100 1st gear
4 7107 Inner synchronizer ring
5 7M000 Synchronizer cone
6 7107 Outer synchronizer ring
7 7124 1st/2nd gear synchronizer with reverse gear
8 E860141 Snap-ring
9 — Outer synchronizer ring (part of 7124)
12 7102 2nd gear
13 7A385 Half moon washer (2 required)
14 7A046 Snap-ring
15 7B340 3rd gear
16 7107 Synchronizer ring, 3rd gear
17 7124 Gear synchronizer, 3rd/4th gear
18 7107 Synchronizer ring, 4th gear
19 7110 4th gear
20 7065 Bearing
21 E860303 Circlip
23 7K136 5th gear
25 7L053 Gear synchronizer, 5th gear
26 7L049 Retaining plate
27 W702295 Circlip
Dual Synchronizer

1 7100 Gear
5 7124 Synchronizer assembly
Dual Synchronizer
First and second gear have dual synchronizers. The use of a second synchronizer ring means that the effective
synchronization area is increased approximate. 100% in relation to single synchronizers. Dual synchronization
gives considerable improvement in gearshift quality.
The dual synchronizers consist of inner synchronizer ring, cone ring, outer synchronizer ring and synchronizer
assembly.
The conical surface on the gear wheel is discontinued. Synchronization occurs through both synchronizer rings
and the cone ring which is positively fitted to the gear wheel.
Differential
Major components of the differential include:
Differential ring gear

Differential housing with two taper roller bearings
Differential pinion gears
Input shaft pinion gears
The transaxle and differential are housed in a two-section aluminum housing and flange-mounted to the engine.
The input torque is transmitted to the differential via a ring gear which is bolted to the differential case.
The differential case contains the differential pinions mounted on one pin as well as the front halfshaft pinions
connected to the front drive shafts through the splines.
If the front wheels are travelling at different speeds (when cornering), the front halfshaft pinions can move on
the differential pinions.
Power Flow
Neutral
1 Input shaft
2 Output shaft
3 Output pinion
First Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 1st gear
5 Gear synchronizer, 1st/2nd gear
6 Gearing, 1st gear
Second Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 Gear synchronizer, 1st/2nd gear
5 2nd gear
6 Gearing, 2nd gear
Third Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 Gearing, 3rd gear
5 Gear synchronizer, 3rd/4th gear
6 3rd gear
Fourth Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 Gear synchronizer, 3rd/4th gear
5 Gearing, 4th gear
6 4th gear
Fifth Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 Gearing, 5th gear
5 Gear synchronizer, 5th gear
6 5th gear
Reverse Gear
1 Input shaft
2 Output shaft
3 Output pinion
4 Reverse gear wheel
5 Gearing, reverse gear
6 Reverse idler gear
The reverse idler gear is driven off the input shaft. Its purpose is to change the direction of rotation of the output
shaft when reverse gear is selected.
The reverse idler gear runs in a plain bearing on the idler gear shaft and a bearing block.
The selector interlock mechanism and the selector finger are mounted on a sleeve in the transaxle housing.
They hold the selected gear by means of a spring-loaded ball until a different gear is selected.
The selector interlock mechanism has three different positions.

Transaxle Draining and Filling
Material
Item Specification
Motorcraft® Full Synthetic WSD-M2C200-
Manual Transmission Fluid C
XT-M5-QS
100-02 .
2. Release the 7 retainers (2 shown) and remove the shift cable cover.
3. NOTE: Before removing, clean the area around the filler plug.

4. Using a suitable oil suction gun, fill the transaxle to the correct level with the specified fluid.
Transaxle fluid level: 5-10 mm (0.196-0.393 in.) below the lower edge of the filler plug
bore.
5. Install the fill plug.

6. Install the shift cables cover.

Halfshaft Seal — LH
Special Tool(s)
Installer, Halfshaft Oil Seal
308-039
Remover, Halfshaft Oil Seal

307-163 (T86P-70043-A)
Remover, Pilot Bearing

308-001 (T58L-101-B)
Material
Item Specification
Motorcraft® Full Synthetic Manual WSD-M2C200-
Transmission Fluid C
XT-M5-QS
1 3K169 Halfshaft seal
2 7003 Transaxle
Removal
1. Remove the LH halfshaft. For additional information, refer to Section 205-04 .
2. Using the Pilot Bearing Remover with the Halfshaft Oil Seal Remover, remove and discard the halfshaft
oil seal.
Installation
1. Using the Halfshaft Oil Seal Installer, install the new halfshaft oil seal.
2. Install the halfshaft. For additional information, refer to Section 205-04 .
3. NOTE: The fill height is 0.0-0.5 mm (0.0-0.2 in) below the lower edge of the filler hole.
Remove the transaxle fluid filler plug. Check the transaxle fluid level and fill with manual transmission
fluid as necessary.
Halfshaft Seal — RH
Special Tool(s)
308-039
Remover, Halfshaft Oil Seal

307-163 (T86P-70043-A)
Remover, Pilot Bearing

308-001 (T58L-101-B)
Material
Item Specification
XT-M5-QS
Removal
100-02 .
2. Remove the RH halfshaft and intermediate shaft assembly. For additional information, refer to
Section 205-04 .
3. Using the Pilot Bearing Remover with the Halfshaft Oil Seal Remover, remove and discard the
halfshaft oil seal.
Installation
1. Using the Halfshaft Oil Seal Installer, install the new halfshaft oil seal.
2. Install the RH halfshaft and intermediate shaft assembly. For additional information, refer to
Section 205-04 .
3. NOTE: The fill height is 0.0-5.0 mm (0.0-0.2 in) below the lower edge of the filler hole.
Remove the transaxle fluid filler plug. Check the transaxle fluid level and fill with manual
transmission fluid as necessary.
Transaxle Support Insulator
Special Tool(s)
303-290-01

Leg)
303-290-03A
Support Bar, Engine

303-290A
Removal
100-02 .
Section 303-12 .
5. Remove the PCM cover bolt and the PCM cover.

9. Remove the 3 battery tray bracket nuts and remove the battery tray bracket.
insulator.
Installation
nuts.
2. Install the battery tray bracket and the 3 battery tray bracket nuts.

6. Install the PCM cover and the PCM cover bolt.

7. Install the ACL and the outlet pipe. For additional information, refer to Section 303-12 .

Roll Restrictor
Removal
100-02 .
2. Remove the Heated Oxygen Sensor (HO2S) electrical connector bracket nut and the HO2S
electrical connector bracket from the roll restrictor bracket.
3. NOTE: The roll restrictor bolts are different types, make note of their location prior to removal.
Remove the roll restrictor bolts, roll restrictor bracket bolts and the roll restrictor with roll restrictor
bracket.
Installation
1. NOTE: The bolts are different types, make sure the bolts are in the correct location.
Install the roll restrictor with roll restrictor bracket, roll restrictor bolts and the roll restrictor bracket
bolts.
2. Install the HO2S electrical connector bracket to the roll restrictor bracket and install the HO2S
electrical connector bracket nut.
Transaxle
Special Tool(s)
303-290-01

Leg)
303-290-03A
Support Bar, Engine

303-290A
Remover, Halfshaft
308-256
Removal
100-02 .
Section 303-12 .
5. Remove the PCM cover bolt and the PCM cover.

9. Remove the 3 battery tray bracket nuts and remove the battery tray bracket.
10. Remove the wiring harness bracket bolt from the transaxle and position the wiring harness
bracket aside.
11. Disconnect the reverse light switch electrical connector.

12. Remove the transaxle vent hose from the hose retainer.
13. Remove the transaxle vent hose from the cooling fan housing and position aside.
14. Remove the 4 clutch housing-to-engine bolts (3 shown).

15. Remove the 2 top clutch housing-to-engine bolts.
16. Remove the front wheels. For additional information, refer to Section 204-04 .
17. Release the 7 shift cables cover retainers (2 shown) and remove the shift cables cover.
18. Remove the gearshift cables from the transaxle.
1. Using a suitable tool, gently pry the shift and selector cables off the transaxle shift control
levers.
2. Remove the shift and selector cables by pulling the lower part of abutment down and
removing from the brackets.
19. Remove and discard the exhaust flange nuts and exhaust flange gasket. Disconnect the exhaust
flange.
20. Remove the Heated Oxygen Sensor (HO2S) bracket nut and position the HO2S bracket aside.
21. NOTE: The roll restrictor bolts are different lengths, mark the roll restrictor bolts for installation.
Remove the roll restrictor bolts, bracket and the roll restrictor.
22. Remove the 2 LH clutch housing-to-engine bolts.
24. Remove and discard the RH ball joint nut and bolt.
26. Remove and discard the bearing retainer strap nuts, shield and bearing retainer strap.
27. Remove the RH intermediate shaft assembly from the transaxle and position aside. Support the
intermediate shaft assembly.
29. Remove and discard the LH ball joint nut and bolt.

surface with water.
Remove the clip and disconnect the clutch hydraulic hose.
34. Remove the clutch hydraulic hose from the transaxle retainer.
35. Remove the ground wire bolt and position the ground wire aside.
36. Remove the 2 bolts, 2 nuts and the transaxle support insulator.
37. Position a suitable high-lift transmission jack under the transaxle and secure the transaxle to the
high-lift transmission jack.
38. Remove the 4 lower clutch housing-to-engine bolts (3 shown).

39. Remove the transaxle.
DISASSEMBLY Procedure revision date: 11/04/2010
Transaxle
Special Tool(s)
Remover, Drive Pinion Oil Seal
205-078
Remover, Bearing Cup,

Differential
205-176
Remover, Stator Case Bearing

307-163 (T86P-70043-A)
Holding Fixture, Transmission

307-003 (T57L-500-B)
Remover, Input Shaft Fifth Gear
308-082
Material
Item Specification
ZC-31-A
Disassembly
1. Using the special tool, install the transaxle.

2. Remove the clutch slave cylinder.
1. Remove the 3 clutch slave cylinder bolts.
2. Remove the clutch slave cylinder.
3. Remove the Vehicle Speed Sensor (VSS).

1. Remove the retaining pin.
2. Remove the VSS .
4. Remove the reversing lamp switch.

5. Remove the gearshift cables shroud retainers and the gearshift cables shroud.
6. Remove the selector lever.

1. Remove the protective cap.
2. Remove and discard the snap-ring and remove the selector lever.
7. Remove the 2 gearshift cables bracket nuts and remove the gearshift cables bracket.
8. Remove the shift lever snap ring and remove the shift lever.
9. Remove the selector shaft interlock mechanism.
10. Remove the 5th gear cover bolts and remove the 5th gear cover.
11. Remove the 5th gear synchronizer unit and the selector fork.
1. Remove and discard the 5th gear synchronizer unit circlip.
2. Remove and discard the selector fork roll pin.
12. NOTE: Mark the installation position of the gear synchronizer before disassembling.
Disassemble the 5th gear synchronizer unit.

1. Remove the retaining plate
2. Remove the 5th gear synchronizer
3. Remove the synchronizer ring
4. Remove the 5th gear
13. Remove and discard the 5th gear retaining ring.
14. Using the special tool, remove the 5th gear.

15. NOTICE: Do not strike directly on the gear housing mating surfaces or damage can occur.
Remove the 5th gear housing.

1. Remove and discard the 9 bolts and carefully separate the 5th gear housing sections by
tapping lightly.
2. Using Motorcraft® Metal Surface Prep, clean the 5th gear housing mating surfaces.
16. Remove the input shaft and output shaft retaining rings.
1. Remove and discard the input shaft retaining ring.
2. Remove and discard the output shaft retaining ring.
17. Remove the LH and RH halfshaft seals.
18. NOTICE: Do not use metal scrapers to clean the transaxle gear housing surfaces or
damage can occur.
NOTE: Slightly turn the transaxle housing to raise it.
Separate the transaxle housing from the clutch housing.

Using Motorcraft® Metal Surface Prep, clean the transaxle housing and clutch housing
mating surfaces.
19. Remove the upper snap-ring from the selector rod guide sleeve.
1. Remove and discard the upper snap-ring.
2. Push the selector rod guide sleeve downwards.
20. Remove the selector rod guide sleeve.

1. Remove and discard the lower snap-ring from the guide sleeve.
2. Pull off the selector rod guide sleeve.
21. NOTE: Install a rubber belt to the auxiliary selector shaft to aid disassembly.
Remove the input and output shaft with the shift forks.
22. Remove the differential and the magnet.
23. Remove the reverse idle gear.
24. Remove the selector rod and locking plate.

1. Remove the selector interlock plate.
2. Remove the 5th/reverse gear selector rod.
25. Remove and discard the input shaft oil seal.
26. Remove output shaft roller bearing.

Press out the track rollers from the bearing cage.
Remove the bearing cage.
27. NOTICE: Only use the special tool in the position indicated, otherwise the blanking plug
will be forced out of the housing.
Using the special tool, remove the output shaft bearing cone.
Remove the oil thrower.
28. Remove the bearing cone.
29. Using the special tool, remove the differential bearing cone.
Selector Plate
Selector Mechanism

1 — Selector rod guide sleeve, 5th/reverse gear
2 7M038 Selector plate
3 7K201 Selector gate
4 7M131 Selector shaft interlock mechanism
5 7C031 Selector shift shaft
6 7K205 Return spring for selector lever, reverse gear
7 7K001 Selector lever, reverse gear
8 W527007 Snap-ring
9 — Fifth and reverse gear selector rod
Disassembly
1. Remove the 2 selector plate bolts.

2. Remove the selector mechanism.
1. Fifth and reverse gear selector rod.
2. Selector shift shaft.
3. Reverse gear selector lever.
4. Fifth and reverse gear selector rod guide sleeve.
5. Selector plate.
Assembly
1. Install the selector mechanism.

1. Selector plate.
2. Fifth and reverse gear selector rod guide sleeve.
3. Reverse gear selector lever.
4. Selector shift shaft.
5. Fifth and reverse gear selector rod.
2. Install the 2 selector plate bolts.

Input Shaft
Special Tool(s)
Remover, Bearing
205-055
Input Shaft

1 7025 Bearing
2 7L226 Input shaft
3 7141 Reverse idler gear
4 — 1st gear (part of 7L226)
5 — Reverse gear (part of 7L226)
6 — 2nd gear (part of 7L226)
7 — 3rd gear (part of 7L226)
11 E860332 Snap-ring
Disassembly
1. Using the special tools, remove and discard the bearing.
2. Using a suitable tool, remove and discard the bearing.

Assembly
1. Using a suitable tube, install the new bearing.
2. Using a suitable tube, install the new bearing.

Output Shaft
Special Tool(s)
Remover, Bearing
205-055
Material
Item Specification
Motorcraft® Full Synthetic Manual WSD-M2C200-
Transmission Fluid C
XT-M5-QS
Output Shaft
1 7065 Bearing
2 7061 Output shaft
3 7100 1st gear
7 7124 1st/2nd gear synchronizer with reverse gear
8 E860141 Snap-ring
9 — Outer synchronizer ring (part of 7124)
12 7102 2nd gear
13 7A385 Half moon washer (2 required)
14 7A046 Snap-ring
15 7B340 3rd gear
16 7107 Synchronizer ring, 3rd gear
17 7124 Gear synchronizer, 3rd/4th gear
19 7110 4th gear
20 7065 Bearing
21 E860303 Circlip
23 7K136 5th gear
25 7L053 Gear synchronizer, 5th gear
26 7L049 Retaining plate
27 W702295 Circlip
Disassembly
1. Remove the bearing.

Remove and discard the circlip.
Using the special tools, remove and discard the bearing.
2. Remove 4th gear, remove and discard the snap-ring and remove the 3rd/4th gear synchronizer.
3. Remove the 3rd gear synchronizer ring and 3rd gear.
4. Remove the 2 half moon washers and 2nd gear.

5. Remove the inner and outer synchronizer rings and the synchronizer cone.
6. Remove and discard the snap-ring and remove the 1st/2nd gear synchronizer with reverse gear.
7. Remove the outer synchronizer ring.
8. Remove the synchronizer cone, inner synchronizer ring and the 1st gear.
9. Remove the bearing cone.

Remove and discard the snap-ring.
Using the special tools, remove and discard the bearing cone.
Assembly
1. Install the new bearing cone and new snap-ring.

1. Evenly heat the new bearing cone to approximately 176°F (80°C) and slide it onto the output
shaft.
2. Install the new snap-ring.
2. Install the 1st gear, inner synchronizer ring and the synchronizer cone.
3. Install the outer synchronizer ring.

4. Install the new snap-ring.
5. Install the synchronizer cone and the outer and inner synchronizer rings.
6. Install the 2nd gear and the 2 half moon washers.

7. Install the 3rd gear and 3rd gear synchronizer ring.
8. Install the 3rd/4th gear synchronizer and new snap-ring.

9. Install 4th gear and using a suitable tube, install the new bearing and new circlip.
Differential
Special Tool(s)
Remover, Wheel Knuckle
205-253 (T87C-1104-A)
Puller, Drive Pinion/Differential

Carrier
205-D036 (D81L-4220-A)
Handle
205-153 (T80T-4000-W)
Installer, Differential Bearing Cup

308-162 (T88C-77000-C)

1 1177 Differential seal
2 4221 Differential bearing
3 17285 Speed sensor trigger wheel
4 E860187 Retainer
5 4211 Differential pinion shaft
6 W700427 Differential bolt
7 4205 Differential case
8 4K322 Differential case lining
9 — Differential pinion gears (part of 4026)
10 7F343 Differential ring gear
11 4220 Differential bearing
12 4228 Differential cup
Disassembly
1. NOTE: Clutch side shown, transaxle side similar.
2. NOTE: Transaxle side shown, clutch side similar.
Using the special tools, remove the differential bearings from the differential assembly.
3. Remove the differential pinions.
1. Remove the differential pinion shaft snap ring.
2. Remove the differential pinion shaft.
3. Rotate and remove the differential pinion gears.
4. Rotate and remove the differential pinion gears.
5. Remove the differential pinion gear case lining.
4. Remove the differential ring gear bolts as follows:
1. Loosen the 3 differential bolts four turns.
2. Remove and discard the 2 differential bolts.
3. Remove and save the 3 differential bolts.
5. Using a hammer, hit the 3 remaining differential bolts, remove and discard the differential bolts and
remove the differential ring gear.
Assembly
1. Install the differential ring gear and the 3 bolts saved during disassembly.
2. Remove and discard the 3 bolts.
3. Install 8 new differential ring gear bolts.

4. Install the differential pinion gears.

1. Install the differential pinion gear case lining.
4. Install the differential pinion shaft.
5. Install the differential pinion shaft snap ring.
5. NOTE: Transaxle side shown, clutch side similar.
Using the special tools, install the differential bearings.

ASSEMBLY Procedure revision date: 11/04/2010
Transaxle
Special Tool(s)
Installer, Rear Hub Bearing/Oil
Seal
205-296 (15-085)
Installer, Input Shaft Snap Ring

308-076
Installer, Bearing Cones

308-041
Holding Fixture, Transmission

307-003 (T57L-500-B)

308-039 (16-018)
Installer, Extension Housing

Bushing/Oil Seal
308-045 (16-0159)
Blanking Plugs, Transaxle

Housing
308-152 (T88C-7025-AH)
Material
Item Specification
Gasket Maker WSK-M2G348-
TA-16 A5
XT-M5-QS
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4
Threadlock and Sealer WSK-M2G351-
TA-25 A5
Assembly
1. NOTE: Apply transmission fluid to all rotating surfaces.
Clean and check all parts carefully before reassembly.
2. Using the special tool, install the output shaft roller bearing and bearing cone.
1. Install the oil thrower.
2. Install the bearing as far as stop.
3. Using the special tool, install the differential bearing cone.
4. Install the shift selector interlock plate and the selector rod.
1. Install the shift selector interlock plate.
2. Install the 5th/reverse gear selector rod.
5. Install the reverse gear idler (as shown), the differential and the magnet.
1. Reverse gear idler.
2. Differential.
3. Magnet.
6. Prepare the input and the output shaft for installation.

1. Position the input shaft and the output shaft together.
2. Position the 1st and 2nd gear selector fork on the shaft assemblies.
3. Position the 3rd and 4th gear selector fork on the shaft assemblies.
7. Install the input shaft, output shaft and selector fork assemblies into the transaxle case.
Install a rubber band to the selector shaft to aid assembly.
Insert the input shaft to a depth of approximately 50 mm (1.968 in) and swivel it slightly to
the side.
Insert the output shaft to the level of the input shaft and engage the gears.
Install the input shaft and the output shaft.
8. Install the selector shaft guide sleeve and new lower snap ring.
1. Push in the selector shaft guide sleeve.
2. Install the new lower snap ring.
9. Install the selector shaft guide sleeve new upper snap ring.
1. Pull up the selector shaft guide sleeve.
2. Install the new upper snap ring.
10. Move the inner gearshift linkage to 5th gear.

Turn the selector shaft clockwise until the reverse and 5th gear passage is reached, then
press downwards.
11. NOTE: The inner diameters of the Belleville washers are touching.
Install the shim and secure it by staking the edge of the housing.
1. Belleville washers.
2. Shim.
3. Install the bearing cone and secure it by staking the edge of the housing.
12. Apply Gasket Maker to the transaxle housing.
13. Install the transaxle housing bolts and evenly tighten.

14. NOTE: Use a wooden block.
Install the new input shaft and output shaft retaining rings.
15. NOTE: Turn the retaining rings so that they are located in the cut-outs in the gasket.
16. Install the new 5th gear housing gasket, 5th gear housing and the 9 new 5th gear housing bolts.
17. NOTE: Remove the transaxle from the special tool and carry out the following step on a press.
NOTE: Install an anti twist stop for the selector rod.
NOTE: The transaxle housing must not rest on the press table. Support the input shaft clutch
splines on the press.
Using the special tool and a press, install the 5th gear wheel onto the input shaft.
18. Install the special tool onto the transaxle.
19. Using the special tool, install the new 5th gear snap ring.
1. Install the new snap ring onto the special tool.
2. Install the special tool and push on the new snap ring.
20. Assemble the 5th gear synchronizer unit.
1. 5th gear.
2. Synchronizer ring.
3. Synchronizer (as shown).
4. Retaining plate.
21. Install the 5th gear synchronizer unit with selector fork on the transaxle.
Install the new roll pin.
Install the new circlip.
22. Apply Silicone Gasket and Sealant evenly to the end cap.
23. Install the 5th gear cover and the 5th gear cover bolts.
24. NOTE: Install the selector shaft interlock in the neutral position.
Install the selector shaft interlock as shown.
25. NOTE: Make sure the selector shaft interlock in the neutral position.
Apply Threadlock and Sealer to the selector interlock mechanism and install.
26. Install the shift lever.
27. Using the special tool, install the halfshaft seal until it engages audibly.
28. Engage 5th gear.

Turn the selector shaft clockwise as far as possible and press it in.
29. Install the gearshift cables bracket and the gearshift cables bracket nuts.
30. Install the selector lever.

1. Install the new snap ring.
2. Install the protective cap.
31. Install the gearshift cables shroud and gearshift cables shroud fasteners.
32. Install the reversing lamp switch.
33. Install the Vehicle Speed Sensor (VSS).

1. Connect the VSS .
2. Install the retaining pin.
34. NOTICE: Apply adhesive tape to cover the input shaft splines to prevent damage to the
input shaft seal.
Using the special tools, install the new input shaft seal.
1. Apply a small amount of adhesive tape to the input shaft.
2. Put the input shaft seal on the input shaft.
3. Using the special tool, install the new input shaft seal.
35. Install the clutch slave cylinder and the clutch slave cylinder bolts.
1. Apply a small amount of grease to the input shaft.
2. Install the clutch slave cylinder.
3. Install the 3 clutch slave cylinder bolts.
Tighten evenly to 11 Nm (97 lb-in).
Transaxle
Special Tool(s)
303-290-01

Leg)
303-290-03A
Support Bar, Engine

303-290A
Material
Item Specification
XT-M5-QS
Installation
1. Install the transaxle.
2. Install the 4 lower clutch housing-to-engine bolts (3 shown).

3. Using the special tools, lower the transaxle.
4. Install the transaxle support insulator, the 2 transaxle support insulator bolts and the 2 nuts.
5. Install the ground wire and bolt onto the transaxle.

6. Attach the clutch hydraulic hose to the transaxle retainer.

surface with water.
Install the clutch hydraulic hose onto the transaxle and install the clip.
8. Install the 2 LH clutch housing-to-engine bolts.

9. NOTE: The roll restrictor bolts are different lengths, make sure the roll restrictor bolts are in the
correct location using the marks made during removal.
Install the roll restrictor bracket, roll restrictor and the roll restrictor bolts.
Loosely install the 2 roll restrictor bolts and the 2 roll restrictor bracket bolts at this time.
Only tighten the top 2 roll restrictor bracket bolts.
Tighten the to 48 Nm (35 lb-ft).
10. Tighten the roll restrictor bolts.

1. Tighten the roll restrictor bolt to 70 Nm (52 lb-ft).
2. Tighten the roll restrictor-to-transaxle bracket bolt to 70 Nm (52 lb-ft).
11. Attach the Heated Oxygen Sensor (HO2S) bracket to the transaxle and install the HO2S bracket
nut.
12. Using a new exhaust flange gasket and nuts, connect the exhaust flange to the exhaust.
13. Install the LH halfshaft into the transaxle.

17. Install the RH intermediate shaft assembly into the transaxle.

stages.
20. Install the new RH ball joint bolt and nut.

22. Install the front wheels. For additional information, refer to Section 204-04 .
23. Install the 2 top clutch housing-to-engine bolts.
24. Install the 4 clutch housing-to-engine bolts (3 shown).

25. Install the transaxle vent hose on the cooling fan housing.
26. Attach the transaxle vent hose to the hose retainer.
27. Connect the reverse light switch electrical connector.
28. Install the wiring harness bracket and wiring harness bracket bolt to the transaxle.
29. Install the battery tray bracket and the 3 battery tray bracket nuts.

33. Install the PCM cover and the PCM cover bolt.
36. Fill the transaxle with transmission fluid. For additional information, refer to Transaxle Draining
38. Adjust the gearshift cables. For additional information, refer to Section 308-00 .
SECTION 308-06: Manual Transaxle/Transmission External Controls 2011 Fiesta Workshop Manual
Exhaust flange bolts 47 35 —
Gearshift lever nuts 9 — 80
Shift and selector cable grommet nuts. 9 — 80
External Controls

1 — Gearshift knob (part of 7213)
2 — Gearshift boot (part of 7213)
3 — Gearshift lever base (part of 7210)
4 W706131 Gearshift nuts
5 — Shift cable (part of 7E395)
6 — Selector cable (part of 7E395)
7 — Gearshift cables grommet (part of 7E395)
8 W706131 Gearshift cables grommet nuts (2 required)
9 W709047 Gearshift cable clip
10 7474 Gearshift cables bracket
11 W703125 Gearshift cables bracket studs
12 7222 Gearshift cables cover
13 7220 Gearshift cables shroud
14 7210 Transaxle selector lever
15 7F116 Transaxle shift lever
The IB5 manual transaxle external controls consists of the following:
Gearshift cables
shift cable
selector cable
Gearshift lever
Gearshift lever knob and boot
Transaxle shift lever
Transaxle selector lever
The manual transaxle is controlled by a floor-mounted gearshift lever located in the floor console. Connection
between the floor-mounted gearshift lever and the transaxle shift lever and selector lever is made through 2
gearshift cables. When the operator moves the floor mounted gearshift lever, that movement is transmitted
through 2 gearshift cables routed through the floor to the transaxle. The 2 gearshift cables are attached to the
transaxle at the shift lever and selector lever. The shift and selector levers transfer the movement of the
gearshift cables to the shift rods and shift forks located inside the transaxle. Removal and installation of the
gearshift cables require specific adjustments for correct shifting of the transaxle. For information regarding
gearshift cable adjustments, refer to Section 308-00 .
The shift cable has white ends and the selector cable has black ends. The selector cable (black) does not have
an adjustment.
External Controls
4. If the concern is not evident, verify the symptom. GO to Symptom Chart .
Symptom Chart
Symptom Chart
Gearshift Cables Do Gearshift cables ADJUST gearshift cables.
Not Operate Freely incorrectly adjusted REFER to Section 308-
00 .
Gearshift Cables Do Gearshift lever GO to Pinpoint Test A .
Not Operate Freely Gearshift cables
Pinpoint Test
PINPOINT TEST A: GEARSHIFT CABLES DO NOT OPERATE FREELY

A1 CHECK GEARSHIFT LEVER
Disconnect the gearshift cables from Yes
the gearshift lever. INSTALL a new gearshift lever. REFER to Gearshift
Is the gearshift lever difficult to Lever in this section.
operate?
No
GO to A2 .
A2 CHECK THE GEARSHIFT CABLES.
Attach the gearshift cables to the Yes
gearshift lever. INSTALL a new gearshift cable assembly. REFER to
Disconnect the gearshift cables from Gearshift Cables in this section.
the transaxle.
Is the gearshift lever difficult to No
operate? There is a problem with the transaxle. REFER to
Section 308-03 .
Gearshift Lever

1 7213 Gearshift lever
3 W706131 Gearshift lever nuts (4 required)
Removal
2. Depower the Supplemental Restraint System (SRS). For additional information, refer to Section 501-
20B .

4. Using a suitable tool, remove the wiring harness from the gearshift lever base.
5. Disconnect the RCM electrical connector.
6. Remove the 4 gearshift lever nuts and remove the gearshift lever.
Installation
1. Install the gearshift lever and the 4 gearshift lever nuts.

2. Connect the RCM electrical connector.
3. Install the wiring harness to the gearshift lever base.

6. Repower the Supplemental Restraint System (SRS). For additional information, refer to Section 501-
20B .
7. Adjust the gearshift mechanism. For additional information, refer to Section 308-00 .
Gearshift Cables

1 — Gearshift knob (part of 7213)
2 — Gearshift boot (part of 7213)
4 W706131 Gearshift nuts
7 — Gearshift cables grommet (part of 7E395)
8 W706131 Gearshift cables grommet nuts (2 required)
9 W709047 Gearshift cable clip
10 7474 Gearshift cables bracket
11 W703125 Gearshift cables bracket studs
12 7222 Gearshift cables cover
13 7220 Gearshift cables shroud
14 7210 Transaxle selector lever
15 7F116 Transaxle shift lever
Removal
2. Remove the battery tray. For additional information, refer to Section 414-01 .
3. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12 .
4. Remove the gearshift cables from the gearshift cables bracket.
5. Remove the gearshift cable from the gearshift cable clip.
6. Release the 7 retainers and remove the gearshift cables cover.

Using a suitable tool, gently pry the gearshift cables off the transaxle shift control levers.
Remove the gearshift cables by pulling the lower part of the abutment down and removing from
the gearshift cables bracket.
8. Remove and discard the 2 exhaust flange nuts and the exhaust flange gasket. Disconnect the exhaust
flange.
9. Remove the 4 cross brace nuts and remove the cross brace.
10. Remove the 6 exhaust heat shield fasteners (5 shown).
11. Disconnect the exhaust hangers and support the exhaust with wire.
12. Remove the exhaust heat shield.
13. Remove the 2 gearshift cables grommet nuts.
15. Detach the gearshift cables from the gearshift lever.

16. NOTE: Heater core and evaporator core housing not shown.
Remove the gearshift cables.

1. Release the clips.
2. Push the studs through the floor pan.
3. Push the gearshift cables grommet through the floor pan and remove the gearshift cables through
to the vehicle interior.
Installation
1. NOTE: Heater core and evaporator core housing not shown.
Position the gearshift cables and gearshift cables grommet in place.

2. Install the 2 gearshift cables grommet nuts.
3. Install the exhaust heat shield.
4. Connect the exhaust hangers.

5. Install the 6 exhaust heat shield fasteners (5 shown).
6. Install the cross brace and the 4 cross brace nuts.
7. Using a new exhaust flange gasket and 2 new exhaust flange nuts, connect the exhaust flange.

Install the gearshift cables by pulling the lower part of the abutment down and installing the
gearshift cables onto the gearshift cables bracket.
Push the gearshift cables onto the transaxle shift control levers.
9. Install the gearshift cable on the gearshift cable clip.
10. Install the gearshift cables on the gearshift cables bracket.
11. Attach the gearshift cables to the gearshift lever.

13. Install the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12
14. Install the battery tray. For additional information, refer to Section 414-01
15. Adjust the shift and selector cables. For additional information, refer to Section 308-00 .
SECTION 309-00: Exhaust System 2011 Fiesta Workshop Manual
Catalytic converter bracket-to-engine bolts 50 37 —
Catalytic converter manifold studs 17 — 150
Catalytic converter manifold-to-cylinder head bolt and nuts a — — —
Catalytic converter-to-catalytic converter bracket bolts 25 18 —
Catalytic converter-to-muffler and tailpipe assembly nuts 48 35 —
Heat shield bolts 10 — 89
RH halfshaft support bracket upper bolt 48 35 —
RH halfshaft support bracket lower bolts 24 18 —
Worm gear clamp 7 — 62
a See the procedure for specification.
Exhaust System
The exhaust system consists of:
a one-piece catalytic converter manifold with exhaust flexible pipe.

a resonator.
a muffler and tailpipe assembly with isolators.
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust
gases through the catalytic converter, a muffler and tailpipe assembly and resonator. Rubber exhaust
hanger isolators attach the exhaust system to the mounting hooks on the body.
Catalytic Converter
The catalytic converter plays a major role in the emission control system by functioning as a gas reactor.
The catalytic converter speeds up the heat producing chemical reaction between the components of the
exhaust gases to reduce air pollutants. Due to the high temperatures at which the catalytic converter
operates, the vehicle body areas around the catalytic converter are protected by heat shields. The
catalytic converter controls Hydrocarbon (HC), Carbon Monoxide (CO) and Nitrogen Oxides (NOx)
emissions.
Exhaust System
2. Visually inspect the components of the exhaust system and related controls that may affect
exhaust gas quality or loss of power.

Mechanical
Exhaust pipe pinched or crushed
Damaged muffler
Broken or damaged exhaust hanger brackets
Damaged catalytic converter
Cracked exhaust manifold
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 - Exhaust
System or GO to Symptom Chart - NVH .
Symptom Chart — Exhaust System
Symptom Chart — Exhaust System

Vehicle has low Exhaust pipe INSPECT the exhaust
or no power — pinched or crushed components for damage.
vehicle Damaged catalytic REPAIR or INSTALL new
performance converter components as necessary.
complaint Loose obstruction in TEST the system for normal
exhaust operation. If the concern is still
present, REFER to the
Powertrain Control/Emissions
Restricted exhaust CHECK drain holes for foreign
(possible frozen material. PARK the vehicle
condensate in inside to thaw. TEST the vehicle
muffler) for normal operation. If the
concern is still present, REFER
to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
Burning smell Foreign material Visually INSPECT the exhaust
— usually caught in exhaust system for foreign material or
occurs at idle, system missing heat shields. REPAIR
with possible Missing heat shields or INSTALL new components as
traces of smoke necessary. TEST the system for
repair.
Odor — Catalytic converter At times, a slight sulfur smell is
described as a Excessive sulfur normal for catalytic converters.
sulfur or rotten content in fuel The cause is the sulfur content
egg smell in the gasoline being used.
ADVISE the customer no repair
is required.
Rich fuel conditions REFER to the Powertrain
Misfire conditions Control/Emissions Diagnosis
(PC/ED) manual.
Visible rust on Catalytic Surface rust is a characteristic
surface of converter/exhaust of materials used on exhaust
exhaust pipes system systems. Exposure to heat or
road salt may result in surface
rust. INSPECT for perforations.
If there are no perforations, the
condition is normal.
Rattle, squeaks Loose or damaged INSPECT the exhaust system
or buzz type heat shield for loose or missing heat shields
noise — from the or foreign material trapped
bottom of the between the heat shields and
vehicle 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. TEST
after the repair.
Loose or damaged VERIFY that the exhaust
exhaust isolators isolators are correctly installed.
INSPECT the exhaust isolators
for wear or damage. INSTALL
new isolators as necessary.
Damaged exhaust INSPECT the exhaust system
isolator hanger components for damaged or
bracket broken hangers. INSTALL new
CHECK for loose or damaged
exhaust hanger brackets or
fasteners. TIGHTEN the bolts to
specification or INSTALL new
Loose or damaged MOVE the exhaust system to
catalytic converter simulate the bouncing action of
or muffler 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 INSTALL new components
as necessary. TEST the system
repair.
Exhaust grounded INSPECT for signs of exhaust
to chassis components-to-body contact. If
necessary, CARRY OUT the
Exhaust System Alignment in
this section.
Drone or clunk Loose or damaged INSPECT the exhaust isolators
type noise — exhaust isolators for wear or damage. INSTALL
from the bottom new isolators as necessary.
of the vehicle TEST the system for normal
Exhaust grounded INSPECT for signs of exhaust
to chassis components-to-body contact. If
necessary, CARRY OUT the
Exhaust System Alignment in
this section.
Whistles, boom, Exhaust system INSPECT the entire exhaust
hum or ticking leak system for leaks. CHECK for
type noise — punctures, loose or damaged
noise tends to clamps/fasteners, gaskets,
change as the sensors or broken welds.
engine warms. EXAMINE the chassis for
The noises are grayish-white or black exhaust
often soot, which indicates exhaust
accompanied by leakage at that point. To
exhaust fumes 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 and
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 components
repair.
Exhaust CONFIRM the drain holes are
muffler/resonator the noise source. INSTALL new
drain hole enlarged components as necessary.
due to corrosion TEST the system for normal
Hissing or Exhaust system. CHECK the exhaust system for
rushing noise — Exhaust flow leaks. Using a rubber mallet,
high frequency through pipes TAP on the exhaust
sound. Vehicle components to duplicate the
performance is noise concern. Lightly TAP on
unaffected the muffler and 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
Pinging noise — Catalytic Cool down pinging is a result of
occurs when converter/exhaust the exhaust system expanding
exhaust system system and contracting during heating
is hot, engine and cooling. This is a normal
turned off condition.
Vibration — Loose or damaged INSPECT the exhaust isolators
occurs at idle exhaust isolator for wear or damage. INSTALL
and at low new isolators as necessary.
speeds. Also TEST the system for normal
accompanied by operation after the repair.
a clunk or buzz
type noise
Loose or damaged INSPECT the exhaust isolator
exhaust isolator hanger brackets for wear or
hanger brackets damage. INSTALL or REPAIR
repair.
Damper broken or CHECK for the correct damper
out of position orientation in this section.
RELOCATE to the correct
position and tighten the nuts to
specification. INSPECT for
missing or damaged damper.
INSTALL new components as
necessary. TEST the system for
repair.
Exhaust system CARRY OUT the Exhaust
grounded to System Alignment in this
chassis section.
Engine Damaged or INSPECT the exhaust system
drumming noise misaligned exhaust for loose or damaged fasteners,
— normally system Torca® clamps, or isolators.
accompanied by CARRY OUT the Exhaust
vibration System Alignment in this
section.
Sputter type Damaged or worn INSPECT the exhaust system
noise — noise exhaust system for leaks or damage. REPAIR
worse when as necessary. TEST the system
cold, lessens or for normal operation after the
disappears when repair.
the vehicle is at
operating
temperature
Thumping noise Misaligned exhaust CHECK the exhaust system to
— from the system chassis clearance. CHECK the
bottom of the exhaust system isolators for
vehicle, worse damage. REPAIR as necessary.
during TEST the system for normal
acceleration operation after the repair.
Engine vibration Strain on exhaust CARRY OUT the Exhaust
— is felt with system isolators System Alignment in this
increases and section. REPAIR as necessary.
decreases in TEST the system for normal
engine rpm. operation after the repair.
Drumming noise Exhaust system GO to Pinpoint Test A .
— occurs inside vibration excites
the vehicle the body
during idle or resonances
high idle, hot or inducing interior
cold. Very low- noise
frequency
drumming is very
rpm dependent
Pinpoint Test
PINPOINT TEST A: DRUMMING NOISE
Result / Action to
Test Step
Take
A1 CHECK THE EXHAUST SYSTEM
Key in RUN position. Yes
Increase the engine rpm until the noise is the loudest. Note the REFER to Exhaust
engine rpm. System Alignment in
Ignition OFF. this section. TEST the
Add approximately 9 kg (20 lb) of weight to the exhaust system. system for normal
First place the weight at the tailpipe and test, then at the front pipe. operation.
No
CONDUCT a diagnosis
on other suspect
systems. REFER to
Section 100-04 .
Key in RUN position.

Increase the engine rpm and listen for the drumming noise. Note
the engine rpm if the noise occurs.
Ignition OFF.
Remove the weight from the exhaust system.
Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm?
Exhaust System Alignment
100-02 .
2. Loosen all fasteners joining the exhaust system components.
3. Beginning at the front of the vehicle, align the exhaust system to establish the maximum
clearance. Make sure all fit pipes are pushed all the way into the preceding pipe and the notches
are correctly lined up with the tabs.
4. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For
additional information, refer to Specifications in this section.
5. Start the engine and check the exhaust system for leaks.
Exhaust System — Exploded View
Part
1 5230 Muffler and tailpipe assembly
2 — Muffler and tailpipe assembly isolator (4 required)
3 W703540 Catalytic converter manifold stud (4 required)
4 9N454 Heat shield
5 W703715 Heat shield bolt (4 required)
6 9448 Catalytic converter manifold gasket
7 W500634 Catalytic converter manifold-to-cylinder head bolt
8 W703662 Catalytic converter manifold-to-cylinder head nut (4
required)
9 W500433 Catalytic converter bracket-to-engine bolts (2 required)
10 5G232 Catalytic converter assembly
11 9450 Gasket
12 W703662 Catalytic converter-to-muffler and tailpipe assembly nut
(2 required)
13 5K291 Catalytic converter bracket
14 W703404 Catalytic converter-to-catalytic converter bracket bolts
(2 required)
15 5230 Muffler and tailpipe assembly
removal.
Catalytic Converter
General Equipment
Cable Ties
NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part
number as the original. Torque values must be used as specified during reassembly to make sure of
correct retention of exhaust components.
100-02 .
3. Remove the 4 bolts and position aside the heat shield.
4. Remove and discard the 4 nuts and 1 bolt.
5. Remove the RH halfshaft. For additional information, refer to Front Drive Halfshafts, Halfshaft —
Exploded View in Section 205-04 .
7. Remove the 3 bolts and the halfshaft support bracket.
8. Remove the 4 bolts and the catalytic converter bracket.
9. NOTICE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these
Using cable ties, support the exhaust flexible pipe with a support wrap or suitable splint.
Detach the muffler and tailpipe assembly isolator and remove the 2 catalytic converter-to-muffler
and tailpipe assembly nuts.
Remove the catalytic converter assembly.
Discard the 2 nuts and gaskets.
Installation

Install a new gasket, catalytic converter assembly and new fasteners. Tighten the bolt and 4 nuts
in the sequence shown, in 3 stages.
Install a new gasket and 2 new catalytic converter-to-muffler and tailpipe assembly nuts.
Attach the muffler and tailpipe assembly isolator.
3. Remove the cable ties, support wrap or suitable splint from the exhaust flexible pipe.
4. Install the catalytic converter bracket and the 4 bolts.

1. Tighten the 2 catalytic converter bracket-to-engine block bolts to 50 Nm (37 lb-ft).
2. Tighten the 2 catalytic converter bracket-to-catalytic converter bolts to 25 Nm (18 lb-ft).
5. Install the halfshaft support bracket and the 3 bolts.

1. Tighten the upper bolt to 48 Nm (35 lb-ft).
2. Tighten the 2 lower bolts to 24 Nm (18 lb-ft).
6. Install the RH halfshaft. For additional information, refer to Front Drive Halfshafts, Halfshaft —
Exploded View in Section 205-04 .
8. Install the 4 bolts and the heat shield.

9. Install the Heated Oxygen Sensor (HO2S). For additional information, refer to Section 303-14 .
10. Fill the transmission/transaxle to the correct fluid level. For Automatic Transmission/Transaxle,
refer to Transmission Fluid Level Check in Section 307-11 . For Manual Transmission/Transaxle,
refer to Transaxle Draining and Refilling in Section 308-03 .
Muffler and Tailpipe
General Equipment
Air Body Saw
Cable Ties
NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the
original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust
components.
NOTE: Check the exhaust hanger isolators for damage and fatigue. Install new exhaust hanger isolators as required.
2. Remove the 4 nuts and the brace.
3. Cut the pipe where shown.

4. NOTICE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these instructions may
cause damage to the flexible pipe.
Detach the front muffler and tailpipe assembly isolators and remove the 2 catalytic converter-to-muffler and
tailpipe assembly nuts.
Remove the front muffler and tailpipe section.
Discard the 2 nuts and gasket.
5. Detach the 2 isolators and remove the rear muffler and tailpipe section.
Installation
1. Install the rear muffler and tailpipe section and attach the 2 isolators.
2. NOTE: If the rear muffler and tailpipe section is being serviced, the rear muffler service part is sized to overlap
the front muffler and tailpipe section (shown). If the front muffler and tailpipe section is being serviced, install
the service sleeve and clamp.
Install the front muffler and tailpipe section.

1. Attach the front muffler and tailpipe assembly isolator.
2. Install a new gasket and 2 new catalytic converter-to-muffler and tailpipe assembly nuts.
Attach the front muffler and tailpipe assembly isolator.
3. Install the service clamp.
3. Install the 4 nuts and the brace.

SECTION 310-00: Fuel System — General Information 2011 Fiesta Workshop Manual
Material
Capacity
(Canada)
5W20-LSP12 (Canada); or
equivalent
Item Specification
Fuel Pressure
Key ON Engine Running (KOER) 379 kPa (55 psi)
Fuel Tank Capacity
Fuel tank capacity 47 L (12.5 gal)
Fuel System
The fuel system consists of:
a Multi-Port Fuel Injection (MFI) system.

a 2-speed Mechanical Returnless Fuel System (MRFS).
Easy Fuel TM (capless) fuel tank filler pipe assembly.
a fuel tank filler pipe containing:
a recirculation tube.
a fresh air hose.
a restrictor plate to permit only unleaded fuel to be pumped into the tank.
a fuel tank.
a Fuel Pump (FP) module containing:
an electric FP , which provides pressurized fuel to the fuel rail.
a lifetime fuel filter serviced as part of the FP module.
a serviceable fuel level sender.
a check valve, which maintains system pressure after the FP is shut off.
a pressure relief valve for overpressure protection in the event of restricted fuel flow.
fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the
vehicle by retaining clips.
a fuel rail.
fuel injectors.
fuel pump control module.
The fuel tank filler pipe cannot be modified in any way.
The vehicle is equipped with electronic Multi-Port Fuel Injection (MFI) that is supplied by a 2-speed
Mechanical Returnless Fuel System (MRFS) . The PCM is able to maintain constant fuel pressure by
varying the FP output. This is accomplished by increasing or decreasing voltage supplied by the fuel
pump control module to the FP based on the duty cycle request from the PCM. The returnless fuel
system offers improved economy, lower fuel temperatures and decreased fuel vapor in the fuel tank.
Fuel Pump (FP) Shut-off Feature
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump (FP) shut-off
feature that is initiated by the event notification signal.
The event notification signal is a signal provided by the Restraints Control Module (RCM) to the FP
control module. Signal communication between the RCM and the FP control module allows the PCM to
shut-off the FP .
Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first
turning the ignition switch to the OFF position and then turn the ignition switch to the ON position. In
some instances the vehicle may not start the first time and may take one additional key cycle.
Fuel System
Special Tool(s)

tool
NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents
spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel
Pump (FP) module. The FP module consists of a fuel level sender and a FP . The fuel level sender
sends a signal to the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP
provides fuel to the fuel tubes, which supply the fuel rail.
During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles
without On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR , the
fuel tank and filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel
tank travel to the Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the
pressure from the fuel tank during refueling.
personal injury.
1. Verify the customer's concern by refueling the vehicle and observe the fuel fill rate.
2. Inspect to determine if any of the following mechanical concerns apply.

Mechanical
Bent, kinked or damaged fuel tank filler pipe
Bent, kinked or damaged fuel tank filler pipe fresh air hose or recirculation tube (if equipped)
Incorrect routing of the fuel tank filler pipe
Incorrect routing of the fuel tank filler pipe fresh air hose or recirculation tube (if equipped)
Incorrect position of fuel tank filler pipe clamps
Incorrect position of fuel tank filler pipe fresh air hose or recirculation tube clamps (if equipped)
Fuel tank mounted vapor tubes bent or damaged
Evaporative Emission (EVAP) system tubes or hoses bent or damaged
Accident damage to the fuel tank
Accident damage to the vehicle effecting the fuel tank filler pipe-to-body connection
Unauthorized modifications and/or alterations to the vehicle
EVAP fresh air hose or recirculation tube plugged (dirt, spider webbing)

tool.


418-00 .
8. Clear the continuous memory DTCs and carry out the self-test diagnostics for the EVAP system.
9. If the DTCs retrieved are related to the concern, go to Evaporative Emission (EVAP) System DTC
Chart. For PCM related DTCs, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual. For all other DTCs, refer to Section 419-10 .

DTC Chart
Evaporative Emission (EVAP) System DTC Chart

P0446 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test
A.
P0451 Evaporative Emission System Pressure Sensor/Switch GO to Pinpoint Test
Range/Performance A.
P0452 Evaporative Emission System Pressure Sensor/Switch Low GO to Pinpoint Test
A.
P0453 Evaporative Emission System Pressure Sensor/Switch High GO to Pinpoint Test
A.
P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent GO to Pinpoint Test
A.
P1450 Unable to Bleed up Fuel Tank Vacuum GO to Pinpoint Test
A.
P1451 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test
A.
P260F Emission System Monitoring Processor Performance GO to Pinpoint Test
A.
Symptom Chart
Symptom Chart
Slow to fill Fuel tank filler pipe GO to Pinpoint Test A .
Fuel tank filler pipe fresh
air hose or recirculation
tube, if equipped
Evaporative Emission
(EVAP) system
Fuel tank inlet check
valve (part of the fuel
tank)
Fuel level vent valve
(part of the fuel tank)
All other fuel Fuel system REFER to the Powertrain
system components Control/Emissions Diagnosis
concerns (PC/ED) manual.
Pinpoint Test
Pinpoint Test A: Slow to Fill
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel
tank. As fuel enters the fuel tank, air is vented through the filler pipe or the On-Board Refueling Vapor
Recovery (ORVR) system.

Fuel tank filler pipe fresh air hose or recirculation tube, if equipped
Fuel tank filler pipe
Evaporative Emission (EVAP) system
Fuel tank inlet check valve (part of the fuel tank)
Fuel level vent valve (part of the fuel tank)
PINPOINT TEST A: SLOW TO FILL

A1 CARRY OUT INSPECTION AND
VERIFICATION
Carry out inspection and verification. Yes
Was the cause of the concern REPAIR or INSTALL new components to correct
found? the concern.
No
GO to A2 .
A2 CHECK THE SYSTEM FOR ANY EVAP
DTCs
Check the system for any of the REFER to Powertrain Control/Emissions
following EVAP DTCs: P0446, P0451, Diagnosis (PC/ED) manual to diagnosis the EVAP
P0452, P0453, P0454, P1450, P1451 system.
and P260F.
Are any of these DTCs present? No
GO to A3 .
A3 CHECK THE FUEL TANK FILLER PIPE
ASSEMBLY FOR BLOCKAGE OR
RESTRICTION
Remove the fuel tank filler pipe Yes
assembly. Refer to Section 310-01 . If possible, REPAIR the blockage or restriction. If
Inspect the fuel tank filler pipe and fuel the blockage or restriction cannot be repaired,
tank filler pipe fresh air hose or INSTALL a new fuel tank filler pipe. REFER to
recirculation tube (if equipped) for a Section 310-01 .
blockage or restriction.
Is the fuel tank filler pipe or fuel tank No
filler pipe fresh air hose or GO to A4 .
recirculation tube (if equipped)
blocked or restricted?
A4 CHECK THE FUEL TANK INLET
CHECK VALVE
Inspect the fuel tank inlet check valve Yes
for restriction or sticking. If possible, REPAIR the restriction. If the
Is the fuel tank inlet check valve restriction cannot be repaired, INSTALL a new
restricted or sticking? fuel tank. REFER to Section 310-01 .
No
INSTALL a new fuel tank. REFER to Section 310-
01 .
Fuel System Pressure Release
1. NOTE: The Fuel Pump (FP) module fuse is located in the Battery Junction Box (BJB), location
F8.
Remove the FP module fuse.
2. NOTE: The engine will crank and not start.
Crank the engine for approximately 20 seconds.
3. Crank the engine an additional 20 seconds to make sure the fuel system pressure has been
released.
5. When fuel system service is complete, install the FP module fuse.
6. 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 prior to starting the engine.
7. Start the vehicle and check the fuel system for leaks.
Fuel System Pressure Test
Special Tool(s)
Fuel Pressure Test Kit
310-D009 or equivalent
Fuel Pressure T-Adapter 5/16"

310-D251 or equivalent
personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release in this section.
3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to
Spring Lock Couplings in this section.
4. Install the Fuel Pressure T-Adapter 5/16" and Fuel Pressure Test Kit in line between the fuel
supply line and fuel rail.
5. NOTE: The Fuel Pump (FP) module fuse was removed previously in the Fuel System Pressure
Release.
Install the FP module fuse.
7. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to
completing the Fuel System Pressure Test.
NOTE: After completion of the fuel system pressure test, open the drain valve on the Fuel
Pressure Test Kit and release any residual fuel into a suitable container prior to removing the Fuel
Pressure Test Kit.
Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications in this section.
Fuel Tank Draining
Special Tool(s)
Fuel Storage Tanker
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy
Fuel TM (capless) fuel tank filler pipe.
3. Attach the Fuel Storage Tanker to the fuel drain tube and drain as much fuel as possible from the
Easy Fuel TM (capless) fuel tank filler pipe, lowering the fuel level below the fuel tank inlet spout.
4. NOTE: Some residual fuel may remain in the fuel tank filler pipe. Carefully drain into a suitable
container.
Release the clamp and position the fuel tank filler pipe hose aside.
5. Secure the fuel tank filler pipe hose above the fuel level.
6. Insert the fuel drain tube into the fuel tank filler pipe hose, attach the Fuel Storage Tanker and
drain as much fuel as possible from the fuel tank.
Spring Lock Couplings
Special Tool(s)
Disconnect Tool, Spring Lock
Coupling
Disconnect
personal injury.
NOTICE: 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 or damage to the tube or connector retaining clip can occur.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is essential that absolute cleanliness is observed when working with these
components or component damage can occur. Always install plugs to any open orifices or
tubes.
1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release in this section.
3. Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock
coupling to release.
4. Separate the spring lock coupling from the tube.
Connect
1. Align and push the spring lock coupling onto the tube until a click is heard.
2. Pull on the coupling to make sure it is fully engaged.
Quick Connect Coupling
Disconnect — Type I
personal injury.
tubes.
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For
additional information, refer to Fuel System Pressure Release in this section.
3. Squeeze the quick connect coupling retainer clip tabs to release the locking mechanism.
4. Push the locking mechanism outward to release the tube.
5. Remove the quick connect coupling from the tube.
Connect — Type I
1. Install the quick connect coupling onto the tube.

2. Depress the quick connect coupling locking mechanism into the locked position.
3. NOTE: Make sure the coupling is completely seated and locked onto the tube by pulling on the
quick connect coupling.
Visually inspect and verify that the locking mechanism is flush with the quick connect coupling
housing and that the tabs are locked in place.
Disconnect — Type II
personal injury.
tubes.
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For
additional information, refer to Fuel System Pressure Release in this section.
3. Position the secondary latch outward.
4. Squeeze both of the release tabs.

5. Remove the quick connect coupling from the tube.
Connect — Type II
1. Install the quick connect coupling onto the tube until completely seated.
2. NOTE: Make sure the coupling is completely seated and locked onto the tube by pulling on the
Apply the secondary latch into the locked position.

SECTION 310-01: Fuel Tank and Lines 2011 Fiesta Workshop Manual
Material
Capacity
(Canada)
5W20-LSP12 (Canada)
Item Specification
Fuel tank capacity 47 L (12.5 gal)
Fuel tank filler pipe bracket bolt 11 — 97
Fuel tank filler pipe hose clamp 4 — 35
Fuel tank strap bolt 25 18 —
Fuel Tank and Lines
The fuel system consists of:
a Multi-Port Fuel Injection (MFI) system.

a 2-speed Mechanical Returnless Fuel System (MRFS).
Easy Fuel TM (capless) fuel tank filler pipe assembly.
a fuel tank filler pipe containing:
a recirculation tube.
a fresh air hose.
a restrictor plate to permit only unleaded fuel to be pumped into the tank.
a fuel tank.
a Fuel Pump (FP) module containing:
an electric FP , which provides pressurized fuel to the fuel rail.
a lifetime fuel filter serviced as part of the FP module.
a serviceable fuel level sender.
a check valve, which maintains system pressure after the FP is shut off.
a pressure relief valve for overpressure protection in the event of restricted fuel flow.
fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the
vehicle by retaining clips.
a fuel rail.
fuel injectors.
fuel pump control module.
The fuel tank filler pipe cannot be modified in any way.
The vehicle is equipped with electronic Multi-Port Fuel Injection (MFI) that is supplied by a 2-speed
Mechanical Returnless Fuel System (MRFS) . The PCM is able to maintain constant fuel pressure by
varying the FP output. This is accomplished by increasing or decreasing voltage supplied by the fuel
pump control module to the FP based on the duty cycle request from the PCM. The returnless fuel
system offers improved economy, lower fuel temperatures and decreased fuel vapor in the fuel tank.
Fuel Pump (FP) Shut-off Feature
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump (FP) shut-off
feature that is initiated by the event notification signal.
The event notification signal is a signal provided by the Restraints Control Module (RCM) to the FP
control module. Signal communication between the RCM and the FP control module allows the PCM to
shut-off the FP .
Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first
turning the ignition switch to the OFF position and then turn the ignition switch to the ON position. In
some instances the vehicle may not start the first time and may take one additional key cycle.
Fuel Tank and Lines

Fuel Tank and Filler Pipe — Exploded View
Fuel Tank Filler Pipe Assembly

1 W700228 Fuel tank filler pipe bracket bolt (2 required)
2 9K072 Fuel tank filler pipe information bezel
3 — Fresh air hose (part of 9J279)
5 9J279 Natural vacuum leak detection valve
6 9B033 Fuel vapor tube assembly
7 9002 Fuel tank
Fuel Fuel Pump (FP) Module and Lock Ring

Part
1 — Fuel Pump (FP) module electrical connector (part of
14A005)
2 9L291 Fuel supply tube
3 9C385 FP module lock ring
4 9H307 FP module
5 9276 FP module O-ring seal
6 9002 Fuel tank
Fuel Tank and Fuel Tank Supports

Part
1 9B337 Evaporative Emission (EVAP) vapor tube quick connect
coupling-to-fuel vapor tube assembly
2 9L291 Fuel supply tube quick connect coupling
3 9B337 EVAP vapor tube quick connect coupling-to- EVAP
canister
4 9B033 Fuel vapor tube quick connect coupling-to- EVAP
canister
5 — Natural vacuum leak detection valve hose (part of 9J279)
7 9B033 Fuel vapor tube assembly
8 9054 Fuel tank strap
9 9054 Fuel tank strap
10 9002 Fuel tank
11 W700222 Fuel tank strap bolt (3 required)

Fuel Tank
Special Tool(s)
Powertrain Lift
300-OTC1585AE or equivalent
personal injury.
100-02 .
4. Drain the fuel tank. For additional information, refer to Section 310-00 .
5. Disconnect the muffler and tailpipe assembly from the insulators.

6. Remove the 5 nuts and fuel tank heat shield.
7. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. For additional
8. Loosen the hose clamp and disconnect the fuel tank filler pipe from the fuel tank.
9. Position the Powertrain Lift under the fuel tank.
10. NOTE: Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank.
Carefully drain any residual fuel into a suitable container.
Release the clamp and disconnect the fuel tank filler pipe from the fuel tank.
To install, tighten clamp to 4Nm (35 lb-in).
11. Position the Powertrain Lift under the fuel tank.
12. Remove the 3 fuel tank strap bolts.

13. Partially lower the fuel tank for access.
14. Disconnect the fuel supply tube-to-Fuel Pump (FP) module quick connect coupling. For additional
15. Disconnect the FP module electrical connector.
16. Lower the fuel tank.

Fuel Tank Filler Pipe
Special Tool(s)
Fuel Storage Tanker
personal injury.
100-02 .
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy
Fuel TM (capless) fuel tank filler pipe.
4. NOTE: If the fuel tank is completely full, this step will lower the fuel level to the fuel tank Inlet.
Attach the Fuel Storage Tanker to the fuel drain tube and drain the fuel from the fuel tank filler
pipe.
5. Remove the information bezel.
6. Remove the LR wheel and tire. For additional information, refer to Section 204-04 .
7. Remove the 3 retainers, 2 pin-type retainers and position LR splash shield aside.
8. Release the fresh air hose from the fuel tank filler pipe bracket and disconnect the fresh air hose
retainer from the fuel tank filler pipe.
9. Disconnect the fuel vapor tube-to-Evaporative Emission (EVAP) canister quick connect coupling.
10. Release the clamp and disconnect the fuel tank filler pipe recirculation tube.
11. NOTE: The fuel tank filler pipe may have some residual fuel remaining in it after draining. Upon
disconnecting the fuel tank filler pipe, carefully drain the residual fuel into a suitable container.
Release the clamp and disconnect the fuel tank filler pipe from the fuel tank.
12. Remove the 2 fuel tank filler pipe bracket bolts.

13. Remove the fuel tank filler pipe from the vehicle.

Fuel Pump Module
Special Tool(s)
Lock Ring Wrench
310-123
Material
Item Specification
LSP12 (Canada)
personal injury.
NOTE: The Fuel Pump (FP) module has a serviceable fuel level sender. For additional information, refer
to Fuel Level Sender in this section.
1. NOTE: To avoid introducing contamination into the fuel tank use water to clean the FP module
connections, couplings, flange surface and the immediate surrounding area of any dirt or foreign
material. Blow dry thoroughly with shop air after cleaning.
Remove the fuel tank. For additional information, refer to Section 310-01 .
2. NOTICE: Carefully install the lock ring wrench to avoid damaging the Fuel Pump (FP)
module when removing the lock ring
Using the lock ring wrench, rotate the lock ring counterclockwise and remove the FP module lock
ring.
3. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the
float arm.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Remove the FP module from the fuel tank.
4. NOTE: Inspect the mating surfaces of the FP module flange and the 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.
NOTE: To install, apply clean engine oil to the new O-ring seal.
Remove and discard the FP module O-ring seal.

Install a new FP module O-ring seal.
Fuel Level Sender

1 — Fuel level sender electrical connector (part of 9A299)
2 9A299 Fuel level sender
3 9H307 Fuel Pump (FP) module
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
equipment of any type when working on or near any fuel-related component. Highly flammable mixtures
are always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the
event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module in this
section.
2. Disconnect the fuel level sender electrical connector.
3. Depress the lock tabs and slide the fuel level sender upwards.
Remove the sender from the FP module.

Fuel Lines — Exploded View

1 — Fuel tube spring lock coupling (part of 9L291)
2 — Fuel tube bundle retainer (part of 9L291)
3 9L291 Fuel tube bundle
Fuel Lines
personal injury.
100-02 .
4. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
5. Disconnect the fuel tube-to-fuel rail spring lock coupling.
6. Disconnect the Evaporative Emission (EVAP) canister purge valve-to-fuel vapor tube assembly
7. NOTE: Cap the brake tube connections to prevent fluid loss or dirt contamination.
Disconnect the 2 Hydraulic Control Unit (HCU) brake tube inline fittings-to-fuel bundle assembly
and postion aside.
To install, tighten to 17 Nm (150 b-in).
8. Disconnect the 2 rear brake tube fittings-to-fuel bundle assembly.

To install, tighten to 17 Nm (150 b-in).
9. Disconnect the 5 fuel tube bundle retainers and remove fuel tube bundle assembly.

Bleed the brake system. For additional information, refer to Section 206-00 .
SECTION 310-02: Acceleration Control 2011 Fiesta Workshop Manual
Accelerator pedal and sensor assembly nuts 22 16
Acceleration Control
The acceleration controls consist of the accelerator pedal and sensor assembly.
The engine management system electronically operates the throttle of the engine in response to
accelerator pedal movements initiated by the driver. In 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.
Acceleration Control

Accelerator Pedal
Part
1 — Accelerator pedal sensor electrical connector (part of
14K733)
2 W706840 Accelerator pedal and sensor assembly nut (2 required)
3 9F836 Accelerator pedal and sensor assembly
1. NOTE: To prevent setting DTCs, make sure the ignition switch is in the OFF position prior to
disconnecting the accelerator pedal electrical connectors.
Disconnect the accelerator pedal sensor electrical connector.
2. Remove the 2 nuts and the accelerator pedal and sensor assembly.

SECTION 211-00: Steering System 2011 Fiesta Workshop Manual
Steering System
Electronic Power Assist Steering (EPAS) System
NOTICE: The steering sensor contains a clockspring that will be damaged if the steering column
is not handled correctly. To prevent damage to the steering sensor, use the service bolt (HB1) to
lock the steering column in the straight ahead position before disconnecting the steering column
from the steering gear. Damage caused to the steering sensor by failing to lock the steering
when disconnecting the column from the steering gear leads to a complete failure of the
Electronic Power Assist Steering (EPAS) system and requires a new EPAS column to be
installed.
The Electronic Power Assist Steering (EPAS) system consists of the following components:
Power Steering Control Module (PSCM) — the PSCM controls the functions of the EPAS system
and communicates with other modules on the High Speed Controller Area Network (HS-CAN).
The PSCM is attached to the EPAS column assembly and cannot be serviced separately.
Motor — the EPAS column uses a 12-volt brushless, reversible motor, a worm gear and a
reduction gear to control the steering effort. The motor is attached to the EPAS column assembly
and cannot be serviced separately.
Steering sensor — the PSCM uses the steering sensor to determine force applied to, speed and
direction of the steering wheel. This information is transmitted to other modules along the HS-
CAN . The sensor is attached to the EPAS column assembly and cannot be serviced separately.
Steering column shaft — the steering column shaft connects the EPAS column assembly to the
steering gear and can be serviced separately. For additional information, refer to Section 211-04 .
Steering gear — the steering gear is a rack and pinion type gear, which is serviced as an
assembly and contained within a one-piece aluminum housing. The steering gear uses tie-rod
ends to connect the gear to the wheel knuckles. The steering gear can be serviced separately
from the EPAS column assembly. For additional information, refer to Section 211-02 .
Tie-rod ends — one inner and outer tie rod is located at each end of the steering gear and can be
serviced separately. For additional information, refer to Section 211-02 .
The EPAS system provides power steering assist to the driver by replacing the conventional hydraulic
valve system with an electric motor coupled to the steering shaft. The motor is controlled by the PSCM
which senses the steering effort using sensors mounted between the steering column shaft and the
steering gear. Steering assist is provided in proportion to the steering input effort and vehicle speed.
SECTION 211-00: Steering System 2011 Fiesta Workshop Manual
Steering System
Special Tool(s)
Flex Probe Kit
NUD150-
R025D or
equivalent
Fluke 77-IV
Digital
Multimeter
FLU77-4 or
equivalent
Tie-Rod End
Remover
211-001
(TOOL-3290-
D)
Vehicle
Communication
Module (VCM)
and Integrated
Diagnostic
System (IDS)
software with
appropriate
hardware, or
equivalent
scan tool
Electronic Power Assist Steering (EPAS)
The Electronic Power Assist Steering (EPAS) system provides power steering assist to the driver by
replacing the conventional hydraulic valve system with an electric motor coupled to the steering shaft.
The motor is controlled by the Power Steering Control Module (PSCM) that senses the steering effort
using a torque sensor mounted internally to the steering column assembly. Steering assist is provided in
proportion to the steering input effort and vehicle speed.
The EPAS system requires a 12-volt, hot at all times feed for system operation. The PSCM is activated
when power is applied to the hardwired ignition/run input. After activation, the PSCM monitors the High
Speed Controller Area Network (HS-CAN) to determine if the vehicle is operating in a manner capable of
supporting the EPAS system.
The PSCM recieves vehicle speed from the PCM over the HS-CAN and steering shaft speed, direction
and position from the steering shaft sensor to determine the amount or level of power steering assist
provided by the EPAS system.
The level of steering assist is primarily based on vehicle speed. As vehicle speed increases, the amount
of assist decreases to improve and enhance road feel at the steering wheel. As vehicle speed decreases
the amount of assist increases to ease vehicle maneuvering. If the vehicle speed is missing or out of
range, the PSCM defaults to a safe level of assist for all driving conditions. If the vehicle speed returns to
the correct in-range values, the PSCM adjusts the level of assist accordingly. Steering wheel/shaft
speed, torque and direction information allows the PSCM to determine how much assist is needed to
turn the wheels right and left.
The PSCM continually monitors and adjusts steering efforts based on the sensor inputs to enhance the
feel of the steering. Compensation is made to reduce the effect of pull or drift that may be experienced
when driving on roads with a high degree of camber. Active nibble control is also employed by the
PSCM to reduce the vibrating movement felt at the steering wheel that can be caused by driving on
rough surfaces or out of balance wheels.
The PSCM is self-monitoring and is capable of setting and storing DTCs. Depending on the DTC set, the
control module enters into a safe mode of manual steering. In addition, the PSCM may send a request to
the Instrument Panel Cluster (IPC) module over the HS-CAN to display a message in the message
center, part of the Front Controls Interface Module (FCIM) alerting the driver of a potential EPAS
concern.
Low battery and/or charging system voltage or a charging system DTC being present may cause the
PSCM to enter into a limited operation mode resulting in uneven steering assist or a lack of steering
assist. This limited operation mode feature is built into the PSCM to allow the safe, continued operation
of the vehicle in the event of an EPAS concern. A DTC may or may not be present when the PSCM is
operating in limited operation mode. Additionally, overheating the steering system may cause the PSCM
to go into the limited operation mode, to protect the electronic components from overheating.
The PSCM is an integral part of the EPAS column assembly and cannot be serviced separately.
Power Steering Control Module (PSCM) Power Down
The internal circuitry of the PSCM enables the PSCM to remain powered for 90 seconds after the igniton
state has been switched to OFF. When carrying out diagnostic procedures that require DTCs to be
cleared and a new ignition cycle to be started, make sure the ignition state remains OFF for a minimum
of 90 seconds before switching to ON. This allows the PSCM to shut down completely and a new
ignition cycle to be entered.
Power Steering Motor
The EPAS system uses a 12-volt brushless reversible motor to control the steering effort. The motor is
connected to the steering shaft through a worm gear and a reduction gear on the steering column. The
motor is part of the steering column assembly and is not serviced separately.
Steering Sensor
NOTICE: The steering sensor contains a clockspring that will be damaged if the steering column
is not handled correctly. To prevent damage to the steering sensor, use the service bolt (HB1) to
lock the steering column in the straight ahead position before disconnecting the steering column
from the steering gear. Damage caused to the steering sensor by failing to lock the steering
when disconnecting the column from the steering gear leads to a complete failure of the EPAS
system and requires a new EPAS column to be installed.
The steering sensor provides the PSCM with information on the direction, speed and amount of force
being applied to the steering wheel. The steering sensor is a split sensor that monitors the steering
inputs from the driver and the output side of the EPAS assembly. The PSCM uses the inputs from the
sensor to determine the amount of steering assist required and adjusts steering efforts based on the
sensor inputs. The sensor is a 5-volt dual analog sensor with an output voltage range of 0.25 volt to 4.75
volts. When the steering wheel is turned to the left, the left signal increases while the right signal
decreases, likewise when the steering wheel is turned to the right, the right signal increases while the
left signal decreases.
Interactive Diagnostics
For diagnosing and testing please refer to the on-line Workshop Manual. If you do not have an on-line
subscription, go to www.motorcraftservice.com.
SECTION 211-02: Power Steering 2011 Fiesta Workshop Manual
Engine roll restrictor bolt 50 37
Forward subframe bolts 60 44
Outer tie-rod end nuts 53 39
Rearward subframe bolts a — —
Stabilizer bar link-to-strut nuts 48 35
Steering column shaft-to-steering gear bolt 32 24
Steering gear bolts 90 66
Subfame brace-to-body bolts 50 37
Tie-rod end jam nuts 63 46
Power Steering
The rack and pinion steering gear that is used with the Electronic Power Assist Steering (EPAS) system
is a manual (non-hydraulic) steering gear that is contained within a 1-piece die cast aluminum housing.
The power assist is provided by a 12-volt, 65 amp brush-less motor, mounted to the steering column.
The steering column and motor/module are serviced as an assembly. For information on steering
column service, refer to Section 211-04 . A new steering gear includes inner tie rods, however, the inner
and outer tie rods can also be serviced separately. For information on tie-rod service, refer to Section
211-03 .
Steering Gear
Special Tool(s)
211-001 (Tool-3290-D)
General Equipment
Transmission Jack
Removal
damage to the clockspring may result. If there is evidence that the steering column shaft has rotated,
remove and recenter the clockspring. For additional information, refer to Section 501-20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering column shaft
4. Remove and discard the 2 outer tie rod nuts.
5. Using the Tie Rod End Remover, separate the outer tie rods from the wheel knuckles.
6. Remove and discard the 2 stabilizer bar link-to-strut nuts and disconnect the stabilizer bar links from the struts.
7. Remove the 2 subframe brace-to-body bolts.
8. Disconnect the exhaust isolator.
9. Remove the engine roll restrictor bolt.
10. Support the front subframe using a suitable transmission jack.

11. Mark the position of the subframe-to-frame mounting location at each mounting point on the vehicle frame rails
to aide in installation.
12. Remove the 4 subframe bolts and discard the 2 rearward bolts.
13. Lower the front subframe approximately 155 mm (6.102 in).
14. Remove the 3 steering gear bolts and the steering gear.
Installation
1. Position the steering gear and install the 3 bolts.

2. Raise the subframe and loosely install the 4 subframe bolts.
3. Align the subframe to the locating marks made during removal.
Measure for correct positioning of the subframe to vehicle underbody.

1. Location 1 — 260 mm (10.236 in)
2. Location 2 — 666 mm (26.22 in)
Tighten the rearward bolts an additional 240°.
6. Position the engine roll restrictor and install the engine roll restrictor bolt.
7. Connect the exhaust isolator.

8. Install the 2 subframe brace-to-body bolts.
9. Position the stabilizer bar links and install the 2 new stabilizer bar link-to-strut nuts.
10. Position the outer tie rods and install the new 2 outer tie rod nuts.
Connect the steering column shaft and install a new steering column shaft-to-steering gear bolt.
12. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .
SECTION 211-03: Steering Linkage 2011 Fiesta Workshop Manual
Material
Capacity
Premium Long-Life Grease ESA-M1C75- —
XG-1-C or XG-1-K (US); CXG- B
1-C (Canada)
Inner tie-rod end 83 61
Outer tie-rod end nut 53 39
Tie-rod end jam nut 63 46
Steering Linkage
The steering linkage consists of the following components:
Inner tie-rod end

Steering gear
Outer tie-rod end
Steering gear boot
The inner and outer tie rods connect the steering gear to the wheel knuckles. The tie rods are lubricated
for life and do not contain grease fittings. The steering linkage is adjustable at the 2 tie-rod ends.
Tie Rod — Inner
Special Tool(s)
211-001
Material
Item Specification
Premium Long-Life Grease ESA-M1C75-
XG-1-C or XG-1-K (US); CXG-1-C B
(Canada)
Removal
Part
1 3A130 Outer tie-rod end
2 W520204 Outer tie-rod nut
3 W303694 Tie-rod end jam nut
4 3280 Inner tie-rod end
5 — Steering gear bellows boot kit (part of 3332A boot kit)
6 — Steering gear bellows boot clamp, inner (part of 3332A
boot kit)
7 3504 Steering gear
NOTICE: The steering gear bellows boots and clamps are designed to produce an airtight seal and
protect the internal components of the steering gear. If the seal is not airtight, the vacuum generated
during turning will draw water and contamination into the gear, causing damage. Zip ties do not provide
an airtight seal and must not be used.
NOTICE: The inner tie-rod ball joint grease is not compatible with water. Water trapped in the grease
will damage the joint.
NOTE: If the RH inner tie rod is being serviced, remove the LH outer tie-rod end and bellows boot to access
and hold the steering gear rack when loosening and tightening the inner tie rod. An assistant will be needed to
hold the steering gear rack on the LH side when servicing the RH inner tie rod.
2. Loosen the tie-rod jam nut.
3. Remove and discard the outer tie rod nut.
4. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or
damage to the wheel knuckle can result.
Use the Tie-Rod End Remover to separate the outer tie-rod end from the wheel knuckle.
5. NOTE: Count and record the number of turns required to remove the outer tie-rod end for reference
during installation.
Remove the outer tie-rod end.
6. Remove the tie-rod jam nut.
7. Remove and discard the inner bellows boot clamp.
8. Remove and discard the steering gear bellows boot.
9. NOTICE: Use an appropriate-sized wrench on the flat of the rack gear to resist rotation and to
prevent damage during the removal of the inner tie rod.
NOTE: An assistant will be needed to hold the steering gear rack on the LH side when servicing the RH
inner tie rod.
NOTE: Set screw style inner tie rod tool shown.
While holding the steering gear rack, use a set screw style inner tie rod tool (such as Matco® stock #
TRT48) to remove the inner tie rod.
Installation
1. NOTICE: Thoroughly remove any abrasive material. This material is extremely harmful to the
steering gear.
Thoroughly clean the bellows boot-to-steering gear housing mating surface and install the O-ring
supplied with the new bellows boot.
2. NOTICE: Use an appropriate-sized wrench on the flat of the rack gear to resist rotation and to
prevent damage during the installation of the inner tie rod.
While holding the steering gear rack, use a set screw style inner tie rod tool (such as Matco® stock #
TRT48) to install the inner tie rod.
3. Apply the specified grease to the bellows boot-to-steering gear mating surfaces and bellows boot
grooves in the inner tie-rod casting.
4. NOTE: Make sure the bellows boot is positioned correctly over the steering gear housing bead and the
groove in the inner tie rod.
Install the steering gear bellows boot.
5. Using bellows boot clamp pliers, install a new inner bellows boot clamp.
6. Install the tie-rod jam nut onto the inner tie rod.
7. NOTE: Install the outer tie rod end(s) the same number of turns recorded during removal.
Install the outer tie-rod end.
8. Connect the outer tie-rod end to the wheel knuckle and install the outer tie-rod end nut.
9. Tighten the tie-rod jam nut to 63 Nm (46 lb-ft).
11. Check and if necessary, adjust the front toe. For additional information, refer to Section 204-00 .
SECTION 211-04: Steering Column 2011 Fiesta Workshop Manual
Material
Instant Gel Adhesive WSK-M2G402-A4 —
TA-19
Ignition switch/lock cylinder housing shear bolt 15 — 133
Knee air bag brace nuts 8 — 71
Steering column nuts 24 18 —
Steering column shaft-to-steering column bolt 33 24 —
Steering column shaft-to-steering gear bolt 32 24 —
Steering column shroud screws 1 — 9
Steering column switch carrier bolt 7 — 62
Steering wheel bolt 40 30 —
Steering Column
The steering column is the mechanical linkage between the steering wheel and the steering gear.
However, the steering column housing also contains the Power Steering Control Module (PSCM), motor
and steering sensor, which are used to provide the power assist. The programmable module uses inputs
from the sensor to determine when and how much assist is needed. The 12-volt brushless, reversible
motor uses a worm gear and a reduction gear to apply the power assist to the steering column shaft.
The steering column, module, motor and sensor are serviced as an assembly. For information on
Electronic Power Assist Steering (EPAS) diagnosis, refer to Section 211-00 .
The steering wheel is mounted to a shaft which passes through the center of the steering column. The
shaft is centered by roller ball bearings within the steering column. The steering column shaft then
connects the steering column to the steering gear. The upper and lower steering column shaft
connections utilize U-joint type couplings. The tilt function of the 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 lever is unlocked, the steering column can then be adjusted to various
positions through a pin-type pivot. 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.
For information on steering column switches, refer to Section 211-05 .
Steering Wheel Wrap Bonding
Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
1. NOTE: If re-adhering leather to the front side of the steering wheel only, it will not be necessary to
remove the steering wheel. Steering wheel removal is necessary only when repairing loose
leather on the backside of the steering wheel.
If necessary remove the steering wheel. For additional information, refer to Steering Wheel in this
section.
2. Position the loose leather out of the way.
3. Apply the specificed adhesive evenly over the wheel spoke.
4. Position the loose leather back into the original position.
5. NOTE: The adhesive should be completely set after 5 minutes. Do not pull on the repair area.
Smooth the leather and tuck in for neat appearance.

Apply pressure (for at least 30 seconds) until the leather is bonded to the wheel spoke.
6. If removed, Install the steering wheel. For additional information, refer to Steering Wheel in this
section.
Steering Column — Exploded View
Part
1 W750985 Steering wheel bolt
3 3530A Upper steering column shroud
5 W714630 Lower steering column shroud screw (3 required)
6 3530B Lower steering column shroud
7 13341 Steering column multifunction switch
8 3F791 Steering column switch carrier
9 17A553 Wiper/washer switch
10 3C529 Steering column
11 — Steering column anti-rotation bolt (M6 x 1 x 30)
12 11582 Ignition lock cylinder
13 15607 Passive Anti-Theft System (PATS) transceiver electrical
connector (part of 14401)
14 3F527 Ignition switch/lock cylinder housing (push button start
and key start)
15 W709942 Ignition switch/lock cylinder housing shear bolt (or part of
3F790)
16 W520102 Steering column nut (4 required)
17 — Steering column module (part of 3C529)
18 3R827A Steering column shaft-to-steering column bolt
19 3A525 Steering column shaft (or part of 3C529)
20 3R827B Steering column shaft-to-steering gear bolt
21 3D677 Dash seal
1. Refer to the procedures in this section.

Steering Column
Special Tool(s)
Vehicle Communication Module (VCM)
and Integrated Diagnostic System
(IDS) software with appropriate
hardware, or equivalent scan tool
1. Remove the steering wheel. For additional information, refer to Steering Wheel in this section.
2. Remove the knee airbag module. For additional information, refer to Section 501-20B .
3. Remove the 3 screws and the upper and lower steering column shroud.
damage to the steering column internal sensor may result.
To prevent steering column rotation, install a M6 x 1 x 30 bolt into the steering column and tighten hand tight.
5. Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering column shaft
6. Disconnect the electrical connectors, detach the wiring harness retainers and position the wiring harness aside.
7. Remove the 3 nuts and the knee airbag brace.

8. Disconnect the 3 steering column electrical connectors.
9. Unclip the wiring harness shield from the steering column in the order shown.
10. Remove and discard the 4 steering column nuts in the order shown.
To install, tighten the new nuts to 24 Nm (18 lb-ft).
11. Remove the steering column and steering column shaft as an assembly.
12. NOTICE: Leave the anti-rotation cap on the new column until the steering column shaft has been
connected and the steering column shaft-to-steering gear bolt has been installed or damage to the
steering column may occur. Once the anti-rotation cap has been removed from the new column it must
be installed on the old steering column and the anti-rotation bolt can be removed.
NOTE: If a new column is being installed, a new ignition switch/lock cylinder housing shear bolt (W709942) will
be required to transfer the ignition switch/lock cylinder housing to the new column. For additional information,
refer to Ignition Lock Cylinder Housing in Section 501-14 .
13. Calibrate the steering wheel position sensor if a new steering column has been installed.
Using the scan tool, select programable parameters/steering wheel position sensor calibration and follow
the scan tool instructions.
Steering Column Shaft
1. Turn the steering wheel 45 degrees to the right and using a suitable holding device, secure the
steering wheel.
2. NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence that the
steering column has rotated, remove and recenter the clockspring. For additional
information, refer to Section 501-20B .
NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the steering column internal sensor may result.
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering
column shaft from the steering gear.
To install, tighten a new bolt to 32 Nm (24 lb-ft).
3. Remove and discard the steering column shaft-to-steering column bolt and remove the steering
column shaft.
To install, tighten a new bolt to 33 Nm (24 lb-ft).
Steering Column Shroud
1. Pulling upward, detach the upper steering column shroud from the lower steering column shroud.
Slide the upper steering column shroud out of the Instrument Cluster (IC) trim panel and
remove the shroud.
2. Remove the 3 screws and the lower steering column shroud.


Steering Wheel
1. Remove the driver air bag module. For additional information, refer to Section 501-20B .
2. Turn the steering wheel to the straight-ahead position.
3. Remove the steering wheel as shown.

2. Remove the bolt and the steering wheel.
To install, tighten the steering wheel bolt to 40 Nm (30 lb-ft).
4. Tape the clockspring center rotor to the outer housing to keep it from rotating.
SECTION 211-05: Steering Column Switches 2011 Fiesta Workshop Manual
Steering Column Switches
The steering column switches consist of the following components:
LH multifunction switch – controls the turn signals, headlamp low/high beam, headlamp flash-to-
pass and the trip computer display (if equipped). The LH multifunction switch can be serviced
separately. For additional information on exterior lighting, refer to Section 417-01 . For additional
information on the trip computer, refer to Section 413-01 .
RH multifunction switch – controls the front windshield wipers and the rear window wiper (if
equipped). The RH multifunction switch can be serviced separately. For additional information on
the wiper/washer system, refer to Section 501-16 .
Ignition switch – used in conjunction with the ignition lock cylinder and ignition key to achieve the
various ignition modes.
Start/stop switch – available only on vehicles equipped with a push button start system. Located
in the instrument panel just to the right of the steering column, the start/stop switch is used
instead of a conventional ignition switch to achieve the various ignition modes.
Push Button Start System Ignition Modes
The push button start system has 3 ignition modes:
OFF
ON (engine off)
START
The start/stop button is used in conjunction Intelligent Access (IA) key and the brake pedal (automatic
transaxle) or clutch pedal (manual transaxle) to achieve the different ignition modes as indicated in the
table below. For additional information on the IA key, refer to Section 419-01B .
Push Button Start Ignition Modes

Ignition Entry Desired Ignition
Condition Modes Action
Ignition off ON (engine off) Press the start/stop switch without pressing the brake or
clutch pedal.
Any ignition mode START Press and hold the brake or clutch pedal and then push
the start/stop switch.
On (engine off) OFF Push the start/stop switch.
On (engine running) OFF Press and hold the start/stop switch.
OFF Mode
If the vehicle is in motion, a momentary press of the start/stop switch will not shut the engine off. If the
vehicle is moving, the start/stop switch must be pressed and held for longer than one second to achieve
OFF mode.
ON Mode
When the vehicle enters ON mode, multiple indicators in the IPC will prove out (just like a vehicle
equipped with an ignition key cylinder), the indicator in the start/stop switch will illuminate and the IPC
will display the vehicle mileage and current transmission gear selection.
Steering Column Switches
Special Tool(s)
Flex Probe Kit


tool
Ignition Switch
The ignition switch is controlled by the ignition lock cylinder with a key. When the ignition lock cylinder is
turned, a mechanical connection positions the ignition switch to the selected position. The available
ignition switch positions are:
OFF
ACC
ON
START
The ignition switch supplies battery voltage to the Central Junction Box (CJB) which then distributes this
voltage to multiple circuits and modules throughout the vehicle, based on ignition switch position.
Push Button Start System
The Remote Function Actuator (RFA) module applies battery voltage to the same circuits that a
conventional ignition switch uses to achieve 3 of the 4 standard ignition states (OFF, ON and START).
Unlike a conventional ignition switch system, this push button start system does not have a driver
accessible ACC mode. The RFA module automatically cycles through the ACC mode when the driver
cycles the vehicle to the ON mode. The RFA module receives input from the following:
Clutch Pedal Position (CPP) switch (manual transaxle)
Cruise control deactivator switch (automatic transaxle)
Intelligent Access (IA) key (wireless input)
Park detect switch (automatic transaxle)
Start/stop switch
The RFA module uses input from the IA key to authorize use of the vehicle. The RFA module uses input
from the start/stop switch, the park detect switch (automatic transaxle), the cruise control deactivator
switch (automatic transaxle) and/or the CPP switch (manual transaxle) to transition between ignition
modes.
Intelligent Access (IA) Key
To achieve any ignition state other than OFF, the IA key must be present inside the vehicle. The driver
need not perform any actions with the IA key to operate the push button start system. It is sufficient that
the IA key is located inside the vehicle when the start/stop switch is pressed. Pressing the start/stop
switch triggers radio frequency communication between the IA key and the RFA module.
Backup Antenna
If the battery inside the IA key is weak, if the IA key is damaged or if excessive ambient Radio
Frequency Interference (RFI) prevents communication between the RFA module and the IA key, the
backup antenna located on the RH side of the steering column (where a conventional ignition lock
cylinder would be located) provides a secondary means for the RFA module to validate the IA key and
authorize use of the vehicle. The backup antenna uses passive radio frequency identification to
exchange signals with the IA key, similar to the way a typical encoded Passive Anti-Theft System
(PATS) key and transceiver operate. For additional information on the IA key and backup antenna, refer
Push Button Start System Front Control/Display Interface Module (FCDIM) Messages
The FCDIM provides instruction for operating the push button start system. The FCDIM can also display
warnings that could indicate a potential issue with the push button start system. The following FCDIM
messages pertain to the push button start system:
TO START PRESS BRAKE — Momentarily displays when the start/stop switch is pressed
without the brake pedal being applied (vehicles equipped with an automatic transaxle).
TO START PRESS CLUTCH — Momentarily displays when the start/stop switch is pressed
without the clutch pedal being applied (vehicles equipped with a manual transaxle).
TO START SELECT N OR P — Displays when attempting to start the vehicle and the transaxle is
not in NEUTRAL or PARK (vehicles equipped with an automatic transaxle).
VEHICLE NOT IN PARK SELECT P — Displays when the start/stop switch is pressed to shut off
the engine with the transaxle selector lever in any position other than PARK (vehicles equipped
with an automatic transaxle).
KEY OUTSIDE CAR — Whenever a door is opened and then closed while the engine is running,
the RFA module searches for the IA key. This message displays if the key is not detected by the
module.
KEY NOT DETECTED — Displays if the IA key is not detected by the RFA module when
attempting to enter ON mode or attempting to start the vehicle. If this message is observed with
the IA key located inside the vehicle, go to Section 419-01B to diagnose the IA key.
Remote Function Actuator (RFA) Module Programming
If it is necessary to replace the RFA module, the replacement module must be programmed. Carry out
the following scan tool functions if an RFA module is installed new:
NOTE: All of the following scan tool functions must be completed before the vehicle will start.
Programmable Module Installation (PMI) — This process configures the new module with specific
vehicle information. Refer to Programmable Module Installation (PMI) in Section 418-01 .
PATS Parameter Reset — This process initiates an exchange of information between the RFA
module and the PCM specific to the anti-theft/engine immobilizer feature. Carry out a PATS
parameter reset when either the RFA module or the PCM is installed new. For additional
information, refer to Passive Anti-Theft System (PATS) Parameter Reset-Intelligent Access (IA) in
Section 419-01B .
IA Key Programming — This process programs the IA keys to the RFA module. If the RFA
module is installed new, 2 IA keys will have to be programmed before the vehicle will start. For
additional information, refer to Key Programming Using Diagnostic Equipment-Intelligent Access
(IA) in Section 419-01B .
Multifunction Switches
The multifunction switches control the various components (high beam headlamps, flash-to-pass, turn
signal, trip computer display and windshield wiper/washer) by grounding certain Body Control Module
(BCM) or Instrument Panel Cluster (IPC) circuits. When the BCM or IPC detects the ground signal,
voltage is sent to activate the appropriate component. The BCM controls the high beam headlamps,
flash-to-pass, turn signals and windshield wipers/washers. The IPC controls the trip computer display.
For multifunction switch concerns, refer to one of the following sections:
For high beam headlamps, flash-to-pass and turn signal concerns, refer to Section 417-01 .
For wiper and washer concerns, refer to Section 501-16 .
For trip computer concerns, refer to Section 413-01 .
NOTE: Make sure the vehicle battery is fully charged and in good condition before diagnosing any
ignition switch concerns.

CPP switch (if equipped with a manual Battery Junction Box (BJB) fuse(s):
transaxle) 5 (60A)
Cruise control deactivator switch (if 7 (60A)
equipped with an automatic transaxle) Wiring, terminals or connectors
Ignition lock cylinder (if equipped with an Central Junction Box (CJB) fuse(s):
ignition key) 1 (15A)
Ignition key (if equipped with an ignition 19 (7.5A)
switch) 20 (10A)
Ignition switch (if equipped) 21 (10A)
Intelligent Access (IA) key (if equipped 22 (7.5A)
with a push button start system) 23 (10A)
Multifunction switches 26 (7.5A)
Start/stop switch (if equipped with a push 34 (30A)
button start system) Ignition switch (if equipped)
Steering column shrouds Start/stop switch (if equipped with a push
button start system)
Remote Function Actuator (RFA) module (if
equipped with a push button start system)

Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the VCM .

The air bag warning indicator prove-out confirms ignition ON (other indicators may
NOT prove ignition is ON). If ignition does not turn ON, GO to Symptom Chart .
refer to Section 418-00 Inspection and Verification to establish a scan tool session.

418-00 .
Codes (CMDTCs).
8. If equipped with a start/stop switch, carry out the self-test diagnostics for the RFA module.
9. If the DTCs retrieved are related to the concern, refer to the Remote Function Actuator (RFA)
Module DTC Chart. If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure-type code. The failure-
CMDTCs have an additional 2-character DTC status code suffix to assist in determining DTC history.

B108B:23 Start Button Circuit "A": Signal Stuck GO to Pinpoint Test E .
Low
B108B:29 Start Button Circuit "A": Signal Invalid GO to Pinpoint Test E .
B108C:23 Start Button Circuit "B": Signal Stuck GO to Pinpoint Test E .
Low
B10E7:11 Ignition On Relay: Circuit Short to GO to Pinpoint Test F .
Ground
B10E7:12 Ignition On Relay: Circuit Short to GO to Pinpoint Test F .
Battery
B10E7:16 Ignition On Relay: Circuit Voltage Below GO to Pinpoint Test F .
Threshold
B10E7:17 Ignition On Relay: Circuit Voltage Above GO to Pinpoint Test F .
Threshold
U3004:11 Accessory Power Relay: Circuit Short to GO to Pinpoint Test G .
Ground
U3004:12 Accessory Power Relay: Circuit Short to GO to Pinpoint Test G .
Battery
U300E:62 Ignition Input On: Signal Compare GO to Pinpoint Test I .
Failure
U300F:62 Ignition Input Accessory: Signal GO to Pinpoint Test I .
Compare Failure
U3010:62 Ignition Input Start: Signal Compare GO to Pinpoint Test I .
Failure
U3011:62 Ignition Input Off: Signal Compare GO to Pinpoint Test I .
Failure
— All Other Remote Function Actuator REFER to the Diagnostic Trouble Code (DTC)
(RFA) Module DTCs Chart in Section 419-10 .
Symptom Chart
Symptom Chart
No communication with Wiring, terminals REFER to Section 418-
the Remote Function or connectors 00 to diagnose the no
Actuator (RFA) module RFA module communication
concern.
No power in all ignition Battery Junction GO to Pinpoint Test A .
switch positions — Box (BJB) fuse
vehicles with an ignition Central Junction
switch Box (CJB) fuse
Wiring, terminals
or connectors
Ignition switch
No power in ACC — Wiring, terminals GO to Pinpoint Test B .
vehicles with an ignition or connectors
switch Ignition switch
CJB fuse(s)
No power in ON — Wiring, terminals GO to Pinpoint Test C .
switch Ignition switch
CJB fuse(s)
No power in ON — Wiring, terminals GO to Pinpoint Test H .
vehicles with a push or connectors
button start system CJB fuse(s)
Start/stop switch
Smart keyless
entry accessory
relay
Smart keyless
entry ignition relay
Ignition relay
Cruise control
deactivation switch
Clutch Pedal
Position (CPP)
switch
RFA module
No power in START — Wiring, terminals GO to Pinpoint Test D .
switch Starting system
Ignition switch
No power in START — Wiring, terminals GO to Pinpoint Test H .
vehicles with a push or connectors
button start system Start/stop switch
CJB fuse(s)
Smart keyless
entry accessory
relay
Smart keyless
entry ignition relay
Cruise control
deactivation switch
Clutch Pedal
Position (CPP)
switch
Starting system
Passive Anti-Theft
System (PATS)
RFA module
KEY NOT DETECTED is Wiring, terminals REFER to Section 419-
displayed in the Front or connectors 01B to diagnose the IA
Control/Display Interface Intelligent Access key concern.
Module (FCDIM) (IA) key
RFA module
antennas
RFA module
The ignition key cannot be Wiring, terminals GO to Pinpoint Test J .
returned to the OFF or connectors
position Ignition lock
cylinder
Key removal inhibit
solenoid (part of
the ignition switch)
Park detect switch
(part of the
selector lever)
Instrument Panel
Cluster (IPC)
The ignition key can be Wiring, terminals GO to Pinpoint Test K .
turned to the OFF position or connectors
when the selector lever is Key release
not in PARK interlock actuator
(part of the ignition
switch)
Park detect switch
(part of the
selector lever)
The ignition key is hard to Ignition lock GO to the Ignition
turn cylinder Switch — Mechanical
Ignition key Component Test in this
Ignition switch section.
The multifunction switch Multifunction REFER to Section 417-
does not operate correctly switch 01 to diagnose an
exterior lighting
concern.
16 to diagnose a wiper
or washer concern.
01 to diagnose a trip
computer concern.
Pinpoint Tests
Pinpoint Test A: No Power in All Ignition Switch Positions — Vehicles With an Ignition Switch
Refer to Wiring Diagrams Cell 13 , Power Distribution for schematic and connector information.
Normal Operation
The ignition switch receives fused battery voltage from Central Junction Box (CJB) fuse 1 (15A). The
ignition switch distributes this voltage to the PCM and/or the CJB depending on the ignition switch
position.

CJB fuse
Battery Junction Box (BJB) fuse
Ignition switch
PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS — VEHICLES WITH AN

IGNITION SWITCH
NOTICE: 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 FOR POWER TO CJB FUSE 1 (15A)
Disconnect: CJB Fuse 1 (15A). Yes
Measure the voltage between CJB fuse 1 (15A), circuit GO to A2 .
SBP01 (RD), input side and ground.
No
VERIFY BJB fuse 5 (60A) is
OK. If OK, REPAIR circuit
SBB05 (GY/RD). If not OK,
REFER to the Wiring
the possible cause of the
circuit short. TEST the system
A2 CHECK CJB FUSE 1 (15A)
Check fuse: CJB fuse 1 (15A). Yes
No
REFER to the Wiring
the possible cause of the
circuit short. TEST the system
A3 CHECK FOR POWER TO THE IGNITION SWITCH
Connect: CJB Fuse 1 (15A). Yes
Disconnect: Ignition Switch C250. INSTALL a new ignition
Measure the voltage between ignition switch C250-4, circuit switch. REFER to Ignition
SBP01 (RD), harness side and ground. Switch in this section. TEST
operation.
No
VERIFY in-line connector
C212 is OK. If not OK,
If OK, REPAIR circuit SBP01

(RD). TEST the system for
normal operation.

Pinpoint Test B: No Power in ACC — Vehicles With an Ignition Switch
Normal Operation
When the ignition switch is in the ACC position, voltage is provided to Central Junction Box (CJB) fuses
19 (7.5A) and 26 (7.5A).

CJB fuse(s)
Ignition switch
PINPOINT TEST B: NO POWER IN ACC — VEHICLES WITH AN IGNITION SWITCH
Result / Action to
Test Step
Take
B1 CHECK THE IGNITION ACC CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Ignition Switch C250. VERIFY CJB fuses 19
Disconnect: CJB Fuse 26 (7.5A). (7.5A) and 26 (7.5A)
Measure the resistance between CJB fuse 26 (7.5A), circuit are OK.
CDC33 (VT/GN), input cavity and ignition switch C250-6, circuit
CDC33 (VT/GN), harness side. If OK, INSTALL a new
ignition switch. REFER
to Ignition Switch in this
section. TEST the
system for normal
operation.

Wiring Diagrams
possible cause of the
system for normal
operation.
No
(VT/GN). TEST the
system for normal
operation.
Pinpoint Test C: No Power in ON — Vehicles With an Ignition Switch
Normal Operation
The switch side of the ignition relay receives fused battery voltage from Battery Junction Box (BJB) fuse
7 (60A). When the ignition switch is in the ON position, voltage is provided to Central Junction Box (CJB)
fuses 19 (7.5A), 20 (10A), 21 (10A), 22 (7.5A), 23 (10A), 26 (7.5A) and the coil side of the ignition relay.

CJB fuse(s)
Ignition switch
PINPOINT TEST C: NO POWER IN ON — VEHICLES WITH AN IGNITION SWITCH

C1 CHECK FOR POWER TO CJB FUSE 19 (7.5A)
Disconnect: CJB Fuse 19 (7.5A). Yes
Ignition ON. GO to C2 .
Measure the voltage between CJB fuse 19 (7.5A), circuit CDC33
(VT/GN), input cavity and ground. No
GO to Pinpoint Test B .

C2 CHECK FOR POWER TO THE SWITCH SIDE OF THE IGNITION
RELAY
Disconnect: Ignition Relay. Yes
Measure the voltage between ignition relay cavity 3, circuit GO to C3 .
SBB07 (WH/RD), and ground.
No
VERIFY BJB fuse 7
(60A) is OK.
If OK, REPAIR circuit

SBB07 (WH/RD).

Wiring Diagrams
circuit short. REPAIR as
necessary.
TEST the system for

normal operation.
C3 CHECK FOR POWER AT THE COIL SIDE OF THE IGNITION
RELAY
Measure the voltage between ignition relay cavity 1, circuit Yes
CDC32 (BN/YE), and ground. GO to C4 .
No
GO to C5 .
C4 CHECK THE IGNITION RELAY COIL GROUND CIRCUIT FOR AN
OPEN
Measure the resistance between ignition relay cavity 2, circuit Yes
GD145 (BK/BU), and ground. INSTALL a new ignition
relay. TEST the system
No
(BK/BU). TEST the
system for normal
operation.
C5 CHECK THE IGNITION ON CIRCUIT FOR AN OPEN
Measure the resistance between ignition switch C250-1, circuit Yes
CDC32 (BN/YE), harness side and ignition relay cavity 1, circuit INSTALL a new ignition
CDC32 (BN/YE). switch. REFER to
Ignition Switch in this
section. TEST the
system for normal
operation.
No
(BN/YE). TEST the
system for normal
operation.
Pinpoint Test D: No Power in START — Vehicles With an Ignition Switch
Normal Operation
When the ignition switch is in the START position, voltage is sent to the PCM.

Ignition switch
PINPOINT TEST D: NO POWER IN START — VEHICLES WITH AN IGNITION SWITCH
Result / Action to
Test Step
Take
D1 CHECK THE IGNITION START CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Ignition Switch C250. GO to D2 .
Measure the resistance between ignition switch C250-7, circuit No
CDC35 (BU/WH), harness side and PCM C175B-9, circuit CDC35 REPAIR circuit CDC35
(BU/WH), harness side. (BU/WH). TEST the
system for normal
operation.

D2 ISOLATE THE IGNITION SWITCH
Carry out the ignition switch component test. Yes
INSTALL a new
Refer to Wiring Diagrams Cell 149 for component testing. ignition switch. REFER
to Ignition Switch in
Is the ignition switch OK? system for normal
operation.
No
REFER to Section
303-06 to continue
diagnosing the starting
system.
Pinpoint Test E: DTCs B108B:23, 29 and B108C:23
Normal Operation
The start stop/switch is a momentary, dual-contact, normally-open switch. This means that the 2 internal
contacts will only remain closed for as long as the switch is pressed. As soon as the switch is released,
the contacts will open. The start/stop switch is connected to the Remote Function Actuator (RFA)
module by 2 circuits. When the switch is pressed, both contacts close and connect to a ground circuit.
The RFA module detects this ground signal and enters into 1 of the 3 ignition modes, depending on
other RFA module inputs. The start/stop switch uses 2 sets of contacts and 2 circuits for redundancy; if
there is a concern in one of the 2 circuits/contacts, the other can still provide a ground signal to the RFA
module. Also, if there is a concern in one of the 2 circuits/contacts, the RFA module sets one or more
DTCs.
DTC B108B:23 (Start Button Circuit "A": Signal Stuck Low) — Pressing the start/stop switch starts
a 120 second timer in the RFA module. This DTC sets if the signal from circuit "A" is still present
when the timer expires. Pressing and holding the start/stop switch for more than 120 seconds
also causes this DTC to set. This DTC only sets during normal operation and not during a module
self-test.
DTC B108B:29 (Start Button Circuit "A": Signal Invalid) — Pressing and releasing the start/stop
switch causes both internal contacts to change state (open to closed and then closed to open) at
the same time. The RFA module detects this change in state and increases an internal counter by
1 if the change does not happen at the same time or if only one of the contacts changes state.
When the internal counter reaches 5, the RFA module sets this DTC. This DTC only sets during
normal operation and not during a module self-test.
DTC B108C:23 (Start Button Circuit "B": Signal Stuck Low) — Pressing the start/stop switch starts
a 120 second timer in the RFA module. This DTC sets if the signal from circuit "B" is still present
when the timer expires. Pressing and holding the start/stop switch for more than 120 seconds
also causes this DTC to set. This DTC only sets during normal operation and not during a module
self-test.

Start/stop switch
RFA module
PINPOINT TEST E: B108B:23, 29 AND B108C:23

E1 CHECK THE START/STOP SWITCH
Ignition OFF. Yes
Disconnect: Start/Stop Switch C2195. GO to E2 .
Carry out the start/stop switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new start/stop
switch.
Does the start/stop switch pass the test? CLEAR the DTCs. TEST the
E2 ISOLATE THE DTC
Review the RFA module DTCs recorded during Inspection Yes
and Verification. GO to E3 .
Is DTC B108B:29 the only DTC present?
No
If DTC B108B:23 is also
present, GO to E5 . If DTC
B108C:23 is also present,
GO to E6 .
E3 CHECK THE RFA MODULE START/STOP SWITCH INPUT
Measure resistance between RFA module C3503B, harness GO to E4 .
side and start/stop switch C2195, harness side using the
following chart: No
RFA Module Circuit Start/Stop Switch (s). CLEAR the DTC. TEST
C3503B-23 CPK35 (YE/OG) C2195-4 operation.
C3503B-22 CPK34 (BN/VT) C2195-3

E4 CHECK THE RFA MODULE START/STOP SWITCH INPUT
Connect: RFA Module C3503B. Yes
Connect: Start/Stop Switch C2195. REPAIR the affected circuit
Ignition ON. (s). CLEAR the DTC. TEST
Disconnect: Start/Stop Switch C2195. the system for normal
Measure the voltage between ground and: operation.
start/stop switch C2195-3, circuit CPK34 (BN/VT),
harness side. No
start/stop switch C2195-4, circuit CPK35 (YE/OG), GO to E7 .
harness side.

E5 CHECK START/STOP SWITCH CIRCUIT A FOR A SHORT
TO GROUND
Measure the resistance between start/stop switch C2195-3, GO to E7 .
circuit CPK34 (BN/VT), harness side and ground.
No
REPAIR circuit CPK34
(BN/VT). CLEAR the DTCs.
operation.

E6 CHECK START/STOP SWITCH CIRCUIT B FOR A SHORT
TO GROUND
Measure the resistance between start/stop switch C2195-4, GO to E7 .
circuit CPK35 (YE/OG), harness side and ground.
No
REPAIR circuit CPK35
(YE/OG). CLEAR the DTCs.
operation.

E7 CHECK FOR CORRECT RFA MODULE OPERATION
Disconnect all RFA module electrical connectors. Yes
Check connectors for: INSTALL a new RFA
corrosion module. REFER to Section
pushed-out pins 419-10 .
bent pins
spread terminals CONFIGURE the new RFA
Connect all RFA module electrical connectors and make sure module. REFER to
they are seated correctly. Programmable Module
Connect: Start/Stop Switch C2195. Installation (PMI) in Section
Operate the system and verify the concern is still present. 418-01 .
CARRY OUT a Passive
Anti-Theft System (PATS)
Parameter Reset. REFER to
Passive Anti-Theft System
(PATS) Parameter Reset-
Intelligent Access (IA) in
Section 419-01B .
PROGRAM 2 Intelligent
Access (IA) keys. REFER to
Key Programming Using
Diagnostic Equipment-
Section 419-01B .

operation.
No
operation.
Pinpoint Test F: DTCs B10E7:11, 12, 16 and 17
Normal Operation
The Remote Function Actuator (RFA) module controls and monitors the coil side of the smart keyless
entry ignition relay. When the RFA module enters ON mode, it activates the relay. When energized, the
relay sends power to the Central Junction Box (CJB), the main ignition relay and back to the RFA
module. The RFA module uses this voltage input for diagnostic purposes.
DTC B10E7:11 (Ignition On Relay: Circuit Short To Ground) — The RFA module monitors the
output to the coil side of the smart keyless entry ignition relay. This DTC sets if the module
detects a short to ground on this circuit during normal operation or during an RFA module on-
demand self test.
DTC B10E7:12 (Ignition On Relay: Circuit Short To Battery) — The RFA module monitors the
output to the coil side of the smart keyless entry ignition relay. This DTC sets if the module
detects a short to battery voltage on this circuit during normal operation or during an RFA module
on-demand self test.
DTC B10E7:16 (Ignition On Relay: Circuit Voltage Below Threshold) — The RFA module
monitors the smart keyless entry ignition relay coil input circuit and the relay switch output. This
DTC sets if the RFA module activates the relay but does not receive input voltage from the relay
due to a short to ground or an open on the relay switch output circuit, an open in the relay coil
input circuit or a relay fault. This DTC sets only if DTC B10E7:11 is not set and sets during normal
operation or during an RFA module on-demand self test.
DTC B10E7:17 (Ignition On Relay: Circuit Voltage Above Threshold) — The RFA module
monitors the input from the smart keyless entry ignition relay. This DTC sets if the RFA module
receives an input voltage from the relay but has not activated the relay. This DTC sets only if DTC
B10E7:12 is not set and sets during normal operation or during an RFA module on-demand self
test.

Smart keyless entry ignition relay
RFA module
PINPOINT TEST F: DTCs B10E7:11, 12, 16 and 17

F1 REVIEW THE RFA MODULE DTCs
Review the DTCs retrieved and recorded during Inspection and Yes
Verification. For B10E7:11, GO to F2 .
Is DTC B10E7:11, 12, 16 or 17 present?
For B10E7:12, GO to F4 .
No
DTCs, REFER to the
(RFA) Module DTC Chart
in this section.
F2 CHECK THE SMART KEYLESS ENTRY IGNITION RELAY
CONTROL CIRCUIT AND RFA MODULE FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Smart Keyless Entry Ignition Relay. INSTALL a new smart
Measure the resistance between smart keyless entry ignition keyless entry ignition
relay cavity 1, circuit ZA102 (OG/YE), and ground. relay. CLEAR the DTC.
No
GO to F3 .

F3 ISOLATE THE SMART KEYLESS ENTRY IGNITION RELAY
CONTROL CIRCUIT AND CHECK FOR A SHORT TO GROUND
Measure the resistance between smart keyless entry ignition GO to F14 .
relay cavity 1, circuit ZA102 (OG/YE), and ground.
No
REPAIR circuit ZA102
(OG/YE). CLEAR the
test.

CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Smart Keyless Entry Ignition Relay. REPAIR circuit ZA102
Disconnect: RFA Module C3503B. (OG/YE). CLEAR the
Connect a fused jumper wire between smart keyless entry DTCs. REPEAT the self-
ignition relay cavity 3, circuit SBP01 (RD) and smart keyless test.
entry ignition relay cavity 5, circuit CDC32 (BN/YE).
No
GO to F14 .
Measure the voltage between smart keyless entry ignition relay
cavity 1, circuit ZA102 (OG/YE), and ground.

CONTROL CIRCUIT FOR AN OPEN
Ignition OFF. Yes

Disconnect: Smart Keyless Entry Ignition Relay. GO to F6 .
Disconnect: RFA Module C3503B.
Measure the resistance between smart keyless entry ignition No
relay cavity 1, circuit ZA102 (OG/YE), and RFA module REPAIR circuit ZA102
C3503B-18, circuit ZA102 (OG/YE), harness side. (OG/YE). CLEAR the
DTC. REPEAT the self-
test.

F6 CHECK THE RELAY CONTROL GROUND CIRCUIT FOR AN
OPEN
Measure the resistance between smart keyless entry ignition Yes
relay cavity 2, circuit GD145 (BK/BU), and ground. GO to F7 .
No
(BK/BU). CLEAR the DTC.
F7 CHECK THE RELAY OUTPUT CIRCUIT FOR AN OPEN
Measure the resistance between smart keyless entry ignition Yes
relay cavity 5, circuit CDC32 (BN/YE), and RFA module GO to F8 .
C3503B-13, circuit CDC32 (BN/YE), harness side.
No
(BN/YE). CLEAR the DTC.
OPERATION
Carry out the micro ISO relay component test. Yes
GO to F14 .
Refer to Wiring Diagrams Cell 149 for component testing.
No
INSTALL a new smart
Does the relay pass the test? keyless entry ignition
relay. CLEAR the DTC.
OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: RFA Module C3503B. GO to F10 .
Disconnect: Ignition Relay.
NOTE: This step may cause one or more DTCs to set in the No
RFA module. INSTALL a new smart
Connect a fused jumper wire between ignition relay cavity 3, keyless entry ignition
circuit SBB07 (WH/RD) and ignition relay cavity 5, circuit relay. CLEAR the DTC.
CDC21 (GY/BN). REPEAT the self-test.
Measure the voltage between RFA module C3503B-13, circuit
CDC32 (BN/YE), harness side and ground.

F10 ISOLATE CJB FUSE 20 (10A) OUTPUT CIRCUIT AND
RECHECK THE RELAY OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Measure the voltage between RFA module C3503B-13, circuit GO to F11 .
No
REFER to the Wiring
Diagrams manual to
identify possible causes of
the short on circuit CBP20
(YE/VT). REPAIR as
necessary.
CLEAR the DTC.

VOLTAGE
No
REFER to the Wiring
Diagrams manual to
identify the cause of the
short on circuit CBP21
(BU/GY). REPAIR as
necessary.
CLEAR the DTC.


F12 ISOLATE CJB FUSE 22 (7.5A) OUTPUT CIRCUIT AND
VOLTAGE
Disconnect: CJB Fuse 22 (7.5A). Yes
No
REFER to the Wiring
Diagrams manual to
(GN/OG). REPAIR as
necessary.
CLEAR the DTC.


VOLTAGE
No
REFER to the Wiring
Diagrams manual to
(BN/YE). REPAIR as
necessary.
CLEAR the DTC.


F14 CHECK FOR CORRECT RFA MODULE OPERATION
pushed-out pins Section 419-10 .
bent pins
spread terminals CONFIGURE the new
Connect all RFA module electrical connectors and make sure RFA module. REFER to
Connect: Smart Keyless Entry Ignition Relay. Installation (PMI) in
Connect: Ignition Relay (if previously disconnected). Section 418-01 .
Connect: CJB Fuse 20 (10A) (if previously disconnected).
Connect: CJB Fuse 21 (10A) (if previously disconnected). CARRY OUT a Passive
Connect: CJB Fuse 22 (7.5A) (if previously disconnected). Anti-Theft System (PATS)
Connect: CJB Fuse 23 (10A) (if previously disconnected). Parameter Reset. REFER
Operate the system and verify the concern is still present. to Passive Anti-Theft
Is the concern still present? System (PATS) Parameter
Reset-Intelligent Access
Access (IA) keys. REFER
to Key Programming
Using Diagnostic
Equipment-Intelligent
Access (IA) in Section
419-01B .
TEST the system for

normal operation.
No
operation.
Pinpoint Test G: DTCs U3004:11 and 12
Normal Operation
The Remote Function Actuator (RFA) module controls and monitors the coil side of the smart keyless
entry accessory relay. When the RFA module enters ACC mode, it activates the relay. When energized,
the relay sends power to the Audio Control Module (ACM) and the Instrument Panel Cluster (IPC)
through Central Junction Box (CJB) fuse 19 (7.5A); and to the Tire Pressure Monitoring System
(TPMS)/Vehicle Security Module (VSM) through CJB fuse 26 (7.5A).
DTC U3004:11 (Accessory Power Relay: Circuit Short To Ground) — The RFA module monitors
the output to the coil side of the smart keyless entry accessory relay. This DTC sets if the module
detects a short to ground on this circuit. This DTC only sets during normal operation.
DTC U3004:12 (Accessory Power Relay: Circuit Short To Battery) — The RFA module monitors
the output to the coil side of the smart keyless entry accessory relay. This DTC sets if the module
detects a short to battery voltage on this circuit. This DTC only sets during normal operation.

Smart keyless entry accessory relay
RFA module
PINPOINT TEST G: DTCs U3004:11 AND 12

G1 REVIEW THE RFA MODULE DTCs
Review the DTCs retrieved and recorded during Inspection and Yes
Verification. For U3004:11, GO to G2 .
Is DTC U3004:11 or U3004:12 present?
For U3004:12, GO to G4 .
No
DTCs, REFER to the
(RFA) Module DTC Chart
in this section.
G2 CHECK THE SMART KEYLESS ENTRY ACCESSORY RELAY
CONTROL FOR A SHORT TO GROUND
Ignition OFF. Yes
Disconnect: Smart Keyless Entry Accessory Relay. INSTALL a new smart
Measure the resistance between smart keyless entry accessory keyless entry accessory
relay cavity 1, circuit ZA101 (OG), and ground. relay. CLEAR the DTC.
TEST the system for
normal operation.
No
GO to G3 .
G3 ISOLATE THE SMART KEYLESS ENTRY ACCESSORY
RELAY CONTROL CIRCUIT AND RECHECK FOR A SHORT TO
GROUND
Disconnect: RFA Module C3503C. Yes
Measure the resistance between smart keyless entry accessory GO to G5 .
relay cavity 1, circuit ZA101 (OG), and ground.
No
REPAIR circuit ZA101
(OG). CLEAR the DTC.
TEST the system for
normal operation.
G4 CHECK THE SMART KEYLESS ENTRY ACCESSORY RELAY
CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: RFA Module C3503C. REPAIR circuit ZA101
Disconnect: Ignition Relay. (OG). CLEAR the DTC.
Disconnect: Smart Keyless Entry Ignition Relay. TEST the system for
Disconnect: Smart Keyless Entry Accessory Relay. normal operation.
NOTE: This step may cause one or more DTCs to set in the
RFA module. No
Connect a fused jumper wire between ignition relay cavity 3, GO to G5 .
circuit SBB07 (WH/RD) and ignition relay cavity 5, circuit
CDC21 (GY/BN).
NOTE: This step may cause one or more DTCs to set in the
RFA module.
Connect a fused jumper wire between smart keyless entry
ignition relay cavity 3, circuit SBP01 (RD) and smart keyless
entry ignition relay cavity 5, circuit CDC32 (BN/YE).
Measure the voltage between RFA module C3503C-8, circuit
ZA101 (OG), and ground.

pushed-out pins Section 419-10 .
bent pins
spread terminals CONFIGURE the new
Connect all RFA module electrical connectors and make sure RFA module. REFER to
Connect: Ignition Relay. Installation (PMI) in
Connect: Smart Keyless Entry Accessory Relay. Section 418-01 .
Connect: Smart Keyless Entry Ignition Relay.
Operate the system and verify the concern is still present. CARRY OUT a Passive
Is the concern still present? Anti-Theft System (PATS)
Parameter Reset. REFER
to Passive Anti-Theft
System (PATS) Parameter
Reset-Intelligent Access
Access (IA) keys. REFER
to Key Programming
Using Diagnostic
Equipment-Intelligent
Access (IA) in Section
419-01B .
TEST the system for

normal operation.
No
operation.
Pinpoint Test H: No Power in ON/No Power in START — Vehicles With a Push Button Start
System
Normal Operation
To place the vehicle in ON mode, place the Intelligent Access (IA) key inside the vehicle and press the
start/stop switch for at least one second without applying the brake pedal (or clutch pedal if equipped
with a manual transmission). When in ON mode, the Remote Function Actuator (RFA) module applies
battery voltage to the coil side of the smart keyless entry ignition relay and the smart keyless entry
accessory relay. When activated, the smart keyless entry ignition relay provides battery voltage to the
main ignition relay and several fuses in the Central Junction Box (CJB). The main ignition relay provides
power to various vehicle systems. When activated, the smart keyless entry accessory relay provides
battery voltage to CJB fuses 19 (7.5A) and 26 (7.5A).
To start the engine; place the IA key inside the vehicle, shift the transaxle into PARK (automatic
transaxle) or NEUTRAL (automatic or manual transaxle), place the vehicle in either OFF mode or ON
mode, press and hold the brake pedal (automatic transaxle) or clutch pedal (manual transaxle), then
press the start/stop switch.
At that time, the RFA module sends a voltage signal to the input side of the starter inhibit relay coil. If the
Passive Anti-Theft System (PATS) authorizes the system to start the engine, the PCM supplies a ground
to the coil of the starter inhibit relay, closing the relay and engaging the starter motor.
In the event the vehicle will not enter ON or START mode, the Front Control/Display Interface Module
(FCDIM) displays messages that may indicate possible causes.

Fuses
Start/stop switch
Smart keyless entry ignition relay
Ignition relay
Cruise control deactivation switch
Clutch Pedal Position (CPP) switch
Starting system
PATS
RFA module
PINPOINT TEST H: NO POWER IN ON/NO POWER IN START — VEHICLES WITH A PUSH

BUTTON START SYSTEM

H1 CONFIRM THE IA KEY ALLOWS VEHICLE ENTRY
NOTE: Do not place the IA key inside the vehicle during this Yes
test step. GO to H3 .
With the driver door unlocked and the IA key within 1 meter
(3 feet) of the driver door, press the button on the driver door No
handle; the driver door should lock. GO to H2 .
Did the driver door lock?
H2 CHECK VEHICLE BATTERY
Carry out the Battery Condition Test. Refer to Section 414- Yes
01 . REFER to Section 501-14 to
Is the battery OK? diagnose the Remote
Keyless Entry (RKE) system.
No
CORRECT the battery
condition. TEST the system
H3 ATTEMPT VEHICLE START WHILE MONITORING THE
FCDIM
With the vehicle in PARK (automatic transaxle) or NEUTRAL Yes
(automatic or manual transaxle) and the IA key in the CARRY OUT Key ON
vehicle, press the brake pedal (automatic transaxle) or clutch Engine OFF (KOEO) self-
pedal (manual transaxle) and then press the start/stop switch test. REFER to the
while monitoring FCDIM messages. Powertrain
Did the engine crank? Control/Emissions Diagnosis
(PC/ED) manual to diagnose
the no start concern.
No
If NO KEY DETECTED is
displayed in the FCDIM ,
REFER to Section 419-01B
to diagnose the RFA module
and interior antenna
concern.
If TO START PRESS
BRAKE is displayed in the
FCDIM , GO to H19 .
If TO START SELECT N OR
P is displayed in the FCDIM ,
GO to H24 .
If TO START PRESS
CLUTCH is displayed in the
FCDIM , GO to H29 .
If there is no message
displayed in the FCDIM , GO
to H4 .
H4 CHECK FOR IGNITION ON MODE
NOTE: The air bag warning indicator in the Instrument Panel Yes
Cluster (IPC) only illuminates and proves out when the GO to H11 .
vehicle successfully enters ON mode.
Monitor the air bag warning indicator while attempting to No
enter ON mode. GO to H5 .
Did the air bag warning indicator illuminate for
approximately 6 seconds and then go out?
H5 CARRY OUT A NETWORK TEST
NOTE: Entering the vehicle with the IA key will cause the Yes
RFA module to "wake up". While the RFA module is awake, GO to H6 .
it is able to report DTCs from a Network Test. Other modules
may not be able to pass the Network Test with the ignition in No
the OFF mode. REFER to Section 418-00 to
diagnose no communication
Enter the following diagnostic mode on the scan tool: with the RFA module.
Network Test.
Did the RFA module pass the Network Test?
H6 CHECK THE START/STOP SWITCH PIDs
NOTE: The RFA module is able to provide DataLogger Yes

information with the ignition in the OFF mode. When the GO to H12 .
scan tool indicates "Turn the Ignition ON", ignore this
command and press or click the "continue" button. No
GO to H7 .
DataLogger — RFA Module.
Monitor the following RFA module PIDs while pressing and
releasing the start/stop switch:
Start Button Circuit A (START_SW_1)
Start Button Circuit B (START_SW_2)
Do both PIDs display ON when the switch is pressed and
OFF when the switch is released?
H7 CHECK THE START/STOP SWITCH
Ignition OFF. Yes
Disconnect: Start/Stop Switch C2195. GO to H8 .
Carry out the start/stop switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new start/stop
switch.
Does the start/stop switch pass the test? CLEAR the DTCs. TEST the
H8 CHECK THE START/STOP SWITCH GROUND CIRCUIT
FOR AN OPEN
Measure the resistance between start/stop switch C2195-1, Yes
circuit GD115 (BK/GY), and ground. GO to H9 .
No
(BK/GY).

operation.

H9 CHECK THE RFA MODULE START/STOP SWITCH INPUT
Measure resistance between RFA module C3503B, harness GO to H10 .
side and start/stop switch C2195, harness side using the
following chart: No
RFA Module Circuit Start/Stop Switch (s). CLEAR the DTC. TEST
C3503B-23 CPK35 (YE/OG) C2195-4 operation.
C3503B-22 CPK34 (BN/VT) C2195-3

H10 CHECK THE RFA MODULE START/STOP SWITCH INPUT
Measure the resistance between ground and: Yes
start/stop switch C2195-3, circuit CPK34 (BN/VT), GO to H34 .
harness side.
start/stop switch C2195-4, circuit CPK35 (YE/OG), No
harness side. REPAIR the affected circuit
(s). CLEAR the DTC. TEST
operation.
H11 CARRY OUT AN RFA MODULE SELF-TEST
Enter the following diagnostic mode on the scan tool: Self Yes
Test — RFA Module. For DTCs B108B:23,
Review the results of the self-test. B108B:29 and B108C:23,
Are any RFA module DTCs present? GO to Pinpoint Test E . For
DTCs B10E7:11, B10E7:12,
B10E7:16 and B10E7:17,
GO to Pinpoint Test F . For
DTCs U3004:11 and
U3004:12, GO to Pinpoint
Test G . For DTCs
U300E:62, U300F:62,
U3010:62 and U3011:62,
GO to Pinpoint Test I . For all
other RFA module DTCs,
REFER to the Remote
Function Actuator (RFA)
Module DTC Chart in this
section.
No
diagnose the starting
system.
H12 ISOLATE THE IGNITION RELAY
Ignition OFF. Yes
Disconnect: Ignition Relay. GO to H13 .
Carry out the appropriate relay component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new ignition
relay. CLEAR the DTCs.
Is the relay OK? operation.
H13 CHECK FOR POWER TO THE IGNITION RELAY
Disconnect: Ignition Relay. Yes
Measure the voltage between ignition relay cavity 3, circuit GO to H14 .
SBB07 (WH/RD), and ground.
No
VERIFY Battery Junction
Box (BJB) fuse 7 (60A) is
OK.
If OK, REPAIR circuit SBB07

(WH/RD).
the circuit short. REPAIR as
necessary.

operation.

H14 CHECK THE IGNITION RELAY GROUND CIRCUIT FOR AN
OPEN
Measure the resistance between ignition relay cavity 2, Yes
circuit GD145 (BK/BU), and ground. GO to H15 .
No
(BK/BU). TEST the system
H15 CHECK THE IGNITION RELAY OUTPUT CIRCUIT FOR AN
OPEN
Measure the resistance between ignition relay pin 5, circuit GO to H16 .
CDC21 (GY/BN), and CJB fuse 34 (30A), circuit CDC21
(GY/BN), input side. No
(GY/BN). TEST the system
H16 CHECK FOR POWER TO THE SMART KEYLESS ENTRY
ACCESSORY RELAY
Ignition OFF. Yes
Disconnect: Smart Keyless Entry Accessory Relay. GO to H17 .
Measure the voltage between smart keyless entry accessory
relay cavity 3, circuit SBP01 (RD), and ground. No
VERIFY CJB fuse 1 (15A) is
OK.
If OK, REPAIR circuit SBP01

(RD).

the circuit short. REPAIR as
necessary.

operation.
H17 CHECK THE SMART KEYLESS ENTRY ACCESSORY
RELAY GROUND CIRCUIT FOR AN OPEN
Measure the resistance between smart keyless entry Yes
accessory relay cavity 2, circuit GD145 (BK/BU), and ground. GO to H18 .
No
(BK/BU). TEST the system
H18 CHECK THE SMART KEYLESS ENTRY ACCESSORY
RELAY OUTPUT CIRCUIT FOR AN OPEN
accessory relay cavity 5, circuit CDC33 (VT/GN), and CJB INSTALL a new smart
fuse 19 (7.5A), circuit CDC33 (VT/GN), input side. keyless entry accessory
relay. TEST the system for
normal operation.
No
(VT/GN). TEST the system
H19 CHECK THE RFA MODULE BRAKE SWITCH
(BRAKE_SW) PID

GO to H20 .
Monitor the BRAKE_SW PID while applying the brake pedal.
Does the PID change from NO to YES when the brake
pedal is applied?
H20 CHECK THE RFA MODULE CRUISE CONTROL
DEACTIVATOR SWITCH INPUT
While pressing and releasing the brake pedal, measure the GO to H34 .
resistance between RFA module C3503B-21, circuit CCA29
(GN/BU), harness side and ground. No
GO to H21 .
Is the resistance less than 5 ohms with the brake pedal
released and greater than 10,000 ohms with the brake
pedal applied?
DEACTIVATOR SWITCH INPUT CIRCUIT FOR AN OPEN
Disconnect: Cruise Control Deactivator Switch C278. Yes
Measure the resistance between RFA module C3503B-21, GO to H22 .
circuit CCA29 (GN/BU), harness side and cruise control
deactivator switch C278-2, circuit CCA29 (GN/BU), harness No
side. REPAIR circuit CCA29
(GN/BU). TEST the system

DEACTIVATOR SWITCH INPUT CIRCUIT FOR A SHORT TO
GROUND
Measure the resistance between RFA module C3503B-21, Yes
circuit CCA29 (GN/BU), harness side and ground. GO to H23 .
No
REPAIR circuit CCA29
(GN/BU). TEST the system

DEACTIVATOR SWITCH GROUND CIRCUIT FOR AN OPEN
Measure the resistance between cruise control deactivator Yes
switch C278-1, circuit GD187 (BK/GN), harness side. INSTALL a new cruise
control deactivator switch.
operation.
No
(BK/GN). TEST the system

H24 CHECK THE RFA MODULE CRANK FACTOR PARK
(CRK_FACT_PK) PID

GO to H25 .
Monitor the Crk_Fact_Pk PID while shifting the transaxle into
and out of PARK and NEUTRAL.
Does the PID display YES with the transaxle in
PARK/NEUTRAL and NO with the transaxle out of
PARK/NEUTRAL?
H25 CHECK THE RFA MODULE PARK POSITION SWITCH
INPUT
Select PARK. Yes
Disconnect: RFA Module C3503C. GO to H34 .
Measure the resistance between RFA module C3503C-14,
circuit CDC41 (WH/BN), harness side and ground. No
GO to H26 .
Is the resistance less than 5 ohms with the transaxle in

PARK?
INPUT CIRCUIT FOR AN OPEN
Disconnect: Floor Shifter C3245. Yes
Measure the resistance between RFA module C3503C-14, GO to H27 .
circuit CDC41 (WH/BN), harness side and floor shifter
C3245-2, circuit CDC41 (WH/BN), harness side. No
(WH/BN). TEST the system

INPUT CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between RFA module C3503C-14, Yes
circuit CDC41 (WH/BN), harness side and ground. GO to H28 .
No

Measure the resistance between floor shifter C3245-5, circuit Yes
GD115 (BK/GY), harness side and ground. INSTALL a new transaxle
selector lever (floor shifter).
operation.
No

H29 CHECK THE RFA CLUTCH SWITCH (CLUTCH_SW) PID
GO to H30 .
Monitor the CLUTCH_SW PID while pressing and releasing
the clutch pedal.
Does the PID display YES with the clutch pedal fully
applied and NO with the clutch pedal released?
H30 CHECK THE RFA MODULE CPP SWITCH INPUT
While pressing and releasing the clutch pedal, measure the GO to H34 .
resistance between RFA module C3503B-17, circuit CE903
(BU/OG), harness side and ground. No
GO to H31 .
Is the resistance less than 5 ohms with the clutch pedal

fully applied and greater than 10,000 ohms with the
clutch pedal released?
H31 CHECK THE RFA MODULE CPP SWITCH INPUT CIRCUIT
FOR AN OPEN
Disconnect: CPP Switch C257. Yes
Measure the resistance between RFA module C3503B-17, GO to H32 .
circuit CE903 (BU/OG), harness side and CPP switch C257-
1, circuit CE903 (BU/OG), harness side. No
(BU/OG). TEST the system

H32 CHECK THE RFA MODULE CPP SWITCH INPUT CIRCUIT
Measure the resistance between RFA module C3503B-17, Yes
circuit CE903 (BU/OG), harness side and ground. GO to H33 .
No
(BU/OG). TEST the system

H33 CHECK THE RFA MODULE CPP SWITCH GROUND
CIRCUIT FOR AN OPEN
GD187 (BK/GN), harness side. INSTALL a new CPP switch.
operation.
No
(BK/GN). TEST the system

H34 CHECK FOR CORRECT RFA MODULE OPERATION
corrosion module. REFER to Section
pushed-out pins 419-10 .
bent pins
spread terminals CONFIGURE the new RFA
Connect all RFA module electrical connectors and make module. REFER to
sure they are seated correctly. Programmable Module
Operate the system and verify the concern is still present. Installation (PMI) in Section
Is the concern still present? 418-01 .
CARRY OUT a Passive Anti-

Theft System (PATS)
Section 419-01B .
Section 419-01B .

operation.
No
operation.
Pinpoint Test I: DTCs U300E:62, U300F:62, U3010:62 and U3011:62
Normal Operation
The Remote Function Actuator (RFA) module receives a direct input from the start/stop switch. After
receiving this input, the RFA module activates the smart keyless entry ignition relay, the smart keyless
entry accessory relay and the main ignition relay. The Instrument Panel Cluster (IPC) receives power
from the 2 smart keyless entry relays and sends an ignition status message to the RFA module over the
Controller Area Network (CAN), the RFA module uses this status message as a way to self-test.

U300E:62 — One or more of these DTCs are set if the IPC ignition status message
Ignition Input received by the RFA module does not match the start/stop switch input to the
On: Signal RFA module. This can be caused by a communication issue between the IPC
Compare Failure and the RFA module, a wiring concern in the CAN , a wiring concern in the
U300F:62 — ignition input to the RFA module, a wiring concern in the relay inputs to the
Ignition Input IPC , a failure of the start/stop switch or a failure in either module. The input
Accessory: from the start/stop switch to the RFA module supersedes the input message
Signal Compare from the IPC .
Failure
U3010:62 —
Ignition Input
Start: Signal
Compare Failure
U3011:62 —
Ignition Input
Off: Signal
Compare Failure

Fuses
Start/stop switch
IPC
RFA module
PINPOINT TEST I: DTCs U300E:62, U300F:62, U3010:62 AND U3011:62

I1 CARRY OUT THE IPC SELF-TEST
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self GO to I9 .
Test — IPC .
Did the IPC communicate with the scan tool? No
GO to I2 .
I2 CHECK THE IGNITION AND ACCESSORY INPUTS TO THE
IPC
NOTE: Record the results for this pinpoint test step, they Yes
will be referred to later in this pinpoint test. REFER to Section 418-00 to
diagnose no communication
Ignition OFF. with the IPC .
Disconnect: IPC C220.
Ignition ON. No
Measure the voltage between ground and: If the voltage on both CBP21
IPC C220-4, circuit CBP21 (BU/GY), harness side. (BU/GY) and CBP19 (BN/WH)
IPC C220-15, circuit CBP19 (BN/WH), harness side. are less than 10 volts, GO to
I3 . If only the voltage on
CBP19 (BN/WH) is less than
10 volts, GO to I5 . If only the
voltage on CBP21 (BU/GY) is
less than 10 volts, GO to I7 .

I3 CHECK THE IPC SMART KEYLESS ENTRY IGNITION
RELAY INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: CJB Fuse 21 (10A). VERIFY CJB fuse 21 (10A) is
Measure the resistance between IPC C220-4, circuit OK.
CBP21 (BU/GY), harness side and CJB fuse 21 (10A),
circuit CBP21 (BU/GY), output side. If OK, GO to I4 .

circuit short.
No
(BU/GY). CLEAR the DTCs.
I4 CHECK THE SMART KEYLESS ENTRY IGNITION RELAY
OUTPUT TO CJB FUSE 21 (10A)
Disconnect: Smart Keyless Entry Ignition Relay. Yes
Measure the resistance between smart keyless entry If the voltage measured on
ignition relay cavity 5, circuit CDC32 (BN/YE), and CJB CBP19 (BN/WH) in Step I2
fuse 21 (10A), circuit CDC32 (BN/YE), input side. was also less than 10 volts,
GO to I5 . If the voltage
measured on CBP19 (BN/WH)
in Step I2 was greater than 10
volts, GO to I10 .
No
(BN/YE). CLEAR the DTCs.
I5 CHECK THE IPC SMART KEYLESS ENTRY ACCESSORY
RELAY INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: CJB Fuse 19 (7.5A). VERIFY CJB fuse 19 (7.5A) is
Measure the resistance between IPC C220-15, circuit OK.
CBP19 (BN/WH), harness side and CJB fuse 19 (7.5A),
circuit CBP19 (BN/WH), output side. If OK, GO to I6 .

circuit short.
No
(BN/WH). CLEAR the DTCs.
I6 CHECK THE SMART KEYLESS ENTRY ACCESSORY
RELAY OUTPUT TO CJB FUSE 19 (7.5A)
Disconnect: Smart Keyless Entry Accessory Relay. Yes
Measure the resistance between smart keyless entry GO to I7 .
accessory relay cavity 5, circuit CDC33 (VT/GN), and CJB
fuse 19 (7.5A), circuit CDC33 (VT/GN), input side. No
(VT/GN). CLEAR the DTCs.
I7 CHECK THE SMART KEYLESS ENTRY ACCESSORY
RELAY GROUND CIRCUIT FOR AN OPEN
accessory relay cavity 2, circuit GD145 (BK/BU), and GO to I8 .
ground.
No
(BK/BU). CLEAR the DTCs.
I8 ISOLATE THE SMART KEYLESS ENTRY ACCESSORY
RELAY
Carry out the appropriate relay component test. Yes
GO to I10 .
No
INSTALL a new smart keyless
Is the relay OK? entry accessory relay. CLEAR
the DTCs. TEST the system
I9 ACT ON IPC DTCs
Refer to the results of the IPC self-test. Yes
Were any IPC DTCs present? REFER to the Instrument
Panel Cluster (IPC) DTC Chart
in Section 413-01 .
No
GO to I10 .
I10 REVIEW THE RFA MODULE DTCs
Review the RFA module DTCs retrieved during Inspection Yes
and Verification. DIAGNOSE all other RFA
Are any DTCs other than U300E:62, U300F:62, module DTCs before
U3010:62 and/or U3011:62 present? diagnosing U300E:62,
U300F:62, U3010:62 and
U3011:62. For DTCs
B108B:23, B108B:29 and
B108C:23, GO to Pinpoint Test
E . For DTCs B10E7:11,
B10E7:12, B10E7:16 and
B10E7:17, GO to Pinpoint Test
F . For DTCs U3004:11 and
U3004:12, GO to Pinpoint Test
G . For all other RFA module
DTCs, REFER to the Remote
Function Actuator (RFA)
Module DTC Chart in this
section.
No
For DTCs U300E:62,
U300F:62 and/or U3011:62,
GO to I11 . For DTC
U3010:62, GO to I12 .
I11 CHECK THE STARTER MOTOR CONTROL SENSE
Ignition OFF. Yes
Disconnect: RFA Module C3503C. REPAIR circuit CDC54
Disconnect: IPC C220. (WH/GN). CLEAR the DTCs.
Disconnect: Starter Inhibit Relay. REPEAT the self-test.
Disconnect: ACM C240A (Vehicles Built After 1/14/2011).
Ignition ON. No
Measure the voltage between starter inhibit relay, cavity 1, GO to I12 .
circuit CDC54 (WH/GN), harness side and ground.

I12 CHECK THE IPC ACCESSORY INPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220 (if not previously disconnected). GO to I13 .
Connect: CJB Fuse 19 (7.5A) (if previously disconnected).
Connect: Smart Keyless Entry Accessory Relay (if No
previously disconnected). GO to I14 .
Ignition ON.
Measure the voltage between IPC C220-15, circuit CBP19
(BN/WH), harness side and ground.

I13 ISOLATE THE SMART KEYLESS ENTRY ACCESSORY
RELAY AND CHECK THE IPC ACCESSORY INPUT CIRCUIT
Disconnect: Smart Keyless Entry Accessory Relay. Yes
Measure the voltage between IPC C220-15, circuit CBP19 REPAIR circuit CBP19
(BN/WH), harness side and ground. (BN/WH). CLEAR the DTCs.
No
INSTALL a new smart keyless
entry accessory relay. CLEAR
test.

CIRCUIT FOR AN OPEN CIRCUIT
Ignition OFF. Yes
Measure the resistance between starter inhibit relay cavity GO to I15 .
1, circuit CDC54 (WH/GN), and RFA module C3503C-6,
circuit CDC54 (WH/GN), harness side. No
(WH/GN). CLEAR the DTCs.
Measure the resistance between starter inhibit relay cavity Yes
1, circuit CDC54 (WH/GN), and ground. GO to I16 .
No
(WH/GN). CLEAR the DTCs.
I16 CHECK FOR CORRECT RFA MODULE OPERATION
Check connectors for: INSTALL a new RFA module.
pushed-out pins
bent pins CONFIGURE the new RFA
spread terminals module. REFER to
Connect all RFA module electrical connectors and make Programmable Module
sure they are seated correctly. Installation (PMI) in Section
Connect all other disconnected module connectors, relays 418-01 .
and/or fuses.
Operate the system and verify the concern is still present. CARRY OUT a Passive Anti-
Is the concern still present? Theft System (PATS)
Section 419-01B .
Section 419-01B .

operation.
No
connector. TEST the system
Pinpoint Test J: The Ignition Key Cannot Be Returned to the OFF Position
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from Central
Junction Box (CJB) fuse 1 (15A). Moving the selector lever out of the PARK position closes the park
detect switch (part of the selector lever) and provides a ground path for the key removal inhibit solenoid.
The ground path activates the solenoid and prevents the ignition lock cylinder from being turned to the
OFF position, which prevents the ignition key from being removed. The Instrument Panel Cluster (IPC)
also receives input from the park detect switch along the same circuit as the key removal inhibit
solenoid.

Key removal inhibit solenoid (part of the ignition switch)
Park detect switch (part of the selector lever)
IPC
PINPOINT TEST J: THE IGNITION KEY CANNOT BE RETURNED TO THE OFF POSITION

J1 CHECK FOR AN ENERGIZED KEY REMOVAL INHIBIT
SOLENOID
Remove CJB fuse 1 (15A). Yes
Attempt to turn the ignition lock cylinder to the RUN position GO to J3 .
and then back to the OFF position and remove the key.
Does the ignition lock cylinder turn to the OFF position No
and can the key be removed? GO to J2 .
J2 CHECK THE IGNITION SWITCH FOR MECHANICAL
DAMAGE
Remove the ignition switch. Refer to Ignition Switch in this Yes
section. INSTALL a new ignition
Attempt to turn the ignition lock cylinder to the OFF position switch. REFER to Ignition
and remove the ignition key. Switch in this section. TEST
Does the ignition lock cylinder turn to the OFF position the system for normal
and can the key be removed? operation.
No
REFER to Section 501-14
to continue diagnosis of the
ignition lock cylinder.
J3 CHECK THE KEY REMOVAL INHIBIT SOLENOID CIRCUIT

Disconnect: Ignition Switch C250. Yes
Measure the resistance between ignition switch C250-3, INSTALL a new ignition
circuit CDC41 (WH/BN), harness side and ground. switch. REFER to Ignition
Switch in this section. TEST
operation.
No
GO to J4 .

J4 ISOLATE THE IPC
Measure the resistance between ignition switch C250-3, GO to J6 .
circuit CDC41 (WH/BN), harness side and ground.
No
GO to J5 .

J5 ISOLATE THE SHORT TO GROUND IN THE KEY REMOVAL
INHIBIT SOLENOID CIRCUIT
Measure the resistance between ignition switch C250-3, INSTALL a new selector
circuit CDC41 (WH/BN), harness side and ground. lever. REFER to Section
307-05 . TEST the system
No
J6 CHECK FOR CORRECT IPC OPERATION
Check IPC C220 for: Yes
corrosion INSTALL a new IPC .
pushed-out pins REFER to Section 413-01 .
bent pins
spread terminals TEST the system for normal
Connect: IPC C220. operation.
Connect: Ignition Switch C250.
Make sure the connectors are seated correctly, then operate No
the system and verify the concern is still present. The system is operating
operation.
Pinpoint Test K: The Ignition Key Can Be Turned to the OFF Position When the Selector Lever is
Not In PARK
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from Central
Junction Box (CJB) fuse 1 (15A). Moving the selector lever out of the PARK position closes the park
detect switch (part of the selector lever) and provides a ground path for the key removal inhibit solenoid.
The ground path activates the solenoid and prevents the ignition lock cylinder from being turned to the
OFF position, which prevents the ignition key from being removed. The Instrument Panel Cluster (IPC)
also receives input from the park detect switch along the same circuit as the key removal inhibit
solenoid.

Key removal inhibit solenoid (part of the ignition switch)
Park detect switch (part of the selector lever)
PINPOINT TEST K: THE IGNITION KEY CAN BE TURNED TO THE OFF POSITION WHEN THE
SELECTOR LEVER IS NOT IN PARK
Result / Action to
Test Step
Take
K1 CHECK THE KEY INHIBIT SOLENOID CIRCUIT FOR GROUND
Select NEUTRAL. Yes
Disconnect: Ignition Switch C250. INSTALL a new
Measure the resistance between ignition switch C250-3, circuit ignition switch.
CDC41 (WH/BN), harness side and ground. REFER to Ignition
TEST the system for
normal operation.
No
GO to K2 .

K2 CHECK THE KEY INHIBIT SOLENOID CIRCUIT FOR AN OPEN
Measure the resistance between ignition switch C250-3, circuit GO to K3 .
CDC41 (WH/BN), harness side and floor shifter C3245-2, circuit
CDC41 (WH/BN), harness side. No
REPAIR circuit
CDC41 (WH/BN).
TEST the system for
normal operation.

K3 CHECK THE FLOOR SHIFTER GROUND CIRCUIT FOR AN OPEN
Measure the resistance between floor shifter C3245-5, circuit Yes
GD115 (BK/GY), harness side and ground. INSTALL a new
selector lever (floor
shifter). REFER to
Section 307-05 .
TEST the system for
normal operation.
No
REPAIR circuit
GD115 (BK/GY).
TEST the system for
normal operation.
Component Tests
Ignition Switch — Mechanical
The following conditions can cause difficulty in operating the ignition switch and lock cylinder:
burrs on the lock cylinder key

insufficient lube on the lock cylinder
binding lock cylinder
burrs or foreign material around the rack-and-pinion actuator in the lock cylinder housing
insufficient lube on the actuator (do not apply lubricant to the inside of the ignition switch.)
binding ignition switch
Carry out the following test to determine if the ignition switch and lock cylinder are operating correctly.
1. Inspect the ignition key for any burrs, damage or incorrect cut. Have a new ignition key made as
necessary.
2. Turn the key to the ACC position and then the ON position.
If the ignition key turns to the ACC and ON position, continue with Step 3.
If the ignition key will not turn to the ACC and ON position, continue with Step 4.
3. NOTE: The ignition switch and lock cylinder should return from the START position back to the
ON position without assistance.
Turn the ignition key to the START position and release the key.
If the ignition switch and lock cylinder return from the START position back to the ON
position without assistance, the ignition switch is operating correctly at this time.
If the ignition switch and lock cylinder do not return from the START position back to the
ON position without assistance, continue with Step 4.
4. Remove the ignition lock cylinder. Refer to Section 501-14 .
5. Rotate the ignition lock cylinder through all of the switch positions.
If the lock cylinder operates correctly, install a new ignition switch. Refer to Ignition Switch
in this section.
If the lock cylinder does not operate correctly, install a new ignition lock cylinder. Refer to
Section 501-14 .
Ignition Switch — Electrical
Multifunction Switch — Electrical

Ignition Switch
remove the shroud.
3. Disconnect the ignition switch electrical connector.

4. Remove the ignition switch in the sequence shown.
1. Press the 2 retaining tabs.
2. Remove the ignition switch.

Steering Column Multifunction Switch
remove the shroud.
3. Remove the multifunction switch in the sequence shown.

2. Push inward to release the locking clip.
3. Slide the multifunction switch upward on the carrier and remove the multifunction switch.
Start/Stop Switch

1 11572 Start/stop switch
2 — Start/stop switch electrical connector (part 14K024)
1. Remove the upper instrument panel finish panel. For additional information, refer to Section 501-12 .
2. Position aside the Front Controls Interface Module (FCIM) finish panel in the following order.
1. Remove the 4 upper screws.
2. Pull outward to detach the 2 lower clips.
3. Disconnect the FCIM electrical connector and position the FCIM finish panel aside.
3. Release the 2 start/stop switch tabs (upper and lower) and detach the start/stop switch from the instrument
panel.
4. Disconnect the start/stop switch electrical connector and remove the start/stop switch.

SECTION 412-00: Climate Control System — General Information and 2011 Fiesta Workshop
Diagnostics Manual
SPECIFICATIONS 05/13/2010
Item Specification
A/C Compressor Magnetic Clutch
Air gap between pulley and hub 0.3-0.6 mm
(0.012-0.024 in)
A/C Pressure Relief Valve
Open 3,682 kPa (534 psi) minimum
A/C Evaporator Discharge Air Temperature Sensor
Cut-in/cut-out 2.2°C (36°F)/0.6°C (33°F)
Material
Capacity
Motorcraft® A/C Cooling Coil — —
Coating
YN-29
Motorcraft® A/C System — —
Flushing Solvent
YN-23
Motorcraft® PAG Refrigerant WSH-M1C231- 100 ml
Compressor Oil B (3.4 fl oz)
YN-12-D
Motorcraft® R-134a WSH-M17B19- 0.54 kg
Refrigerant A (19 oz)
YN-19 (US); CYN-16-R (1.19 lb)
(Canada)
Stay-Brite® R-134a Leak — —
Detection Dye
164-R6060 (Rotunda)
Diagnostics Manual
DESCRIPTION AND OPERATION 05/13/2010
Climate Control System
Climate Control System Operation
WARNING: Take the following precautions when repairing an air conditioning system
containing R-134a:
Always wear safety goggles.

Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°
F) under atmospheric pressure and will freeze skin tissue.
Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will
displace the oxygen needed to support life.
Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all
normal conditions, but it decomposes when exposed to high temperatures such as a torch
flame. During decomposition it releases irritating and toxic gasses (as described in the
MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid,
carbon dioxide and water.
NOTICE: To avoid damaging the vehicle or Air Conditioning (A/C) components, observe the
following precautions.
Identify and analyze the A/C refrigerant of all vehicles prior to refrigerant charging. Failure
to do so can contaminate the shop bulk refrigerant and other vehicles.
Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant.
These 2 types of refrigerant must never be mixed. Doing so can damage the A/C system.
Charge the A/C system with R-134a refrigerant gas while the engine is running only at the
low-pressure side to prevent refrigerant slugging from damaging the A/C compressor.
Use only R-134a refrigerant. Due to environmental concerns, when the A/C system is
drained, collect the refrigerant using refrigerant recovery/recycling equipment. Federal,
State/Provincial and/or local laws REQUIRE that R-134a be recovered into appropriate
recovery equipment and the process be conducted by qualified technicians who have
been certified by an approved organization, such as ASE or Mobile Air Conditioning
Society (MACS). Use of a recovery machine dedicated to R-134a is necessary to reduce the
possibility of oil and refrigerant incompatibility concerns. Refer to the instructions
provided by the equipment manufacturer when removing refrigerant from or charging the
A/C system.
R-134a Refrigerant must not be mixed with air for leak testing or used with air for any other
purpose above atmospheric pressure. R-134a is combustible when mixed with high
concentrations of air and higher pressures.
A number of manufacturers are producing refrigerant products described as direct
substitutes for R-134a. The use of any unauthorized substitute refrigerant can severely
damage the A/C components. If repair is required, use only new or recycled R-134a
refrigerant.
NOTICE: To avoid contamination of the Air Conditioning (A/C) system, observe the following
precautions.
Never open or loosen a connection before recovering the refrigerant.

When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
Evacuate a system that has been opened to install a new component or one that has
discharged through leakage before charging.
Seal open fittings with a cap or plug immediately after disconnecting a component from
the system.
Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
Do not remove the sealing caps from a new component until ready to install.
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an
oil container until ready to use and install the cap immediately after using. Store the oil in
a clean, moisture-free container.
Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal
with PAG oil before connecting.
When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
Tighten threaded fittings only to specifications. The steel and aluminum fittings used in
the refrigerant system will not tolerate overtightening.
When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting
of the refrigerant lines or tubes.
Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The climate control system, not equipped with A/C , consists of the following components:
Heater core and evaporator core housing

HVAC module
Temperature blend door actuator
Floor/defrost/panel mode door actuator
Air inlet mode door actuator
Blower motor resistor
Blower motor
The climate control system, equipped with A/C , consists of the following components:
A/C compressor
A/C compressor clutch assembly
A/C condenser core
A/C evaporator core
Receiver/drier
Connecting refrigerant lines
Thermostatic Expansion Valve (TXV)
HVAC module
Floor/defrost/panel mode door actuator
Blower motor
Evaporator discharge air temperature sensor
HVAC System Operation
The Electronic Manual Temperature Control (EMTC) system heats or cools the vehicle depending on the
HVAC control panel selection.
The control panel selection determines heating or cooling, air distribution and enables blower
motor operation.
The temperature control setting determines the air outlet temperature.
The blower motor switch varies the blower motor speed.
During A/C operation (if equipped), the system reduces the relative humidity of the air inside the
vehicle.
HVAC System Airflow and Mode Description
Max A/C (if equipped)
When MAX A/C is selected:
the air inlet door closes off outside air and admits only recirculated air.
the RECIRC button is disabled and the indicator is illuminated. (RECIRC forced on)
the defrost/panel/floor door directs airflow to the instrument panel registers.
blended air temperature is available.
the A/C request button disabled and the indicator is illuminated.
the A/C compressor operates if the outside temperature is above approximately 0°C (32°F).
the blower motor is on.
PANEL
When PANEL is selected:
the RECIRC request button is enabled. If the RECIRC request button is selected (indicator on),
the air inlet door closes off outside air from entering the passenger compartment. If the RECIRC
request button is not selected (indicator off), the air inlet door admits only outside air into the
passenger compartment.
the defrost/panel/floor door directs airflow to the instrument panel registers.
blended air temperature is available. Only when A/C compressor operation (if equipped) has been
selected by pressing the A/C request button (indicator on), can the airflow temperature be cooled
below the outside air temperature.
the A/C request button (if equipped) is enabled. The A/C compressor operates and the indicator
illuminates if the A/C request button is selected and the outside temperature is above
approximately 0°C (32°F).
PANEL/FLOOR
When PANEL/FLOOR is selected:
passenger compartment.
the defrost/panel/floor door directs airflow to the floor duct and the instrument panel A/C registers.
A small amount of airflow from the side window demisters and defrost duct is present.
the A/C request button (if equipped) is enabled. The A/C compressor operates and the indicator
illuminates if the A/C request button is selected and the outside temperature is above
approximately 0°C (32°F).
OFF
When OFF is selected:
the RECIRC request button is disabled.

the air inlet door closes off outside air and admits only recirculated air.
the A/C request button (if equipped) is disabled.
the blower motor is off.
FLOOR
When FLOOR is selected:
passenger compartment. When RECIRC is selected, the air inlet mode door remains in
recirculated air mode for 5 minutes. After 5 minutes, the RECIRC indicator turns off and the air
inlet mode door changes to fresh air mode.
the defrost/panel/floor door directs airflow to the floor duct. A small amount of airflow from the
defroster duct and side window demisters is present.
the A/C request button is enabled. The A/C compressor operates and the indicator illuminates if
the A/C request button is selected and the outside temperature is above approximately 0°C (32°
F).
FLOOR/DEFROST
When the FLOOR/DEFROST is selected:
passenger compartment. When RECIRC is selected, the air inlet mode door remains in
recirculated air mode for 5 minutes. After 5 minutes, the RECIRC indicator turns off and the air
inlet mode door changes to fresh air mode.
the defrost/panel/floor door actuator directs airflow to the floor duct, the defroster duct and the
side window demisters.
the A/C request button (if equipped) indicates the last status and the indicator can be toggled. To
reduce fogging, the A/C compressor operates automatically, regardless of indicator status, if the
outside temperature is above approximately 0°C (32°F).
DEFROST
When DEFROST is selected:
the RECIRC request button is disabled. The air inlet door opens, admitting only outside air into
the passenger compartment.
the defrost/panel/floor door directs airflow to the defroster duct and side window demisters. A
small amount of airflow from the floor duct is present.
the A/C request button (if equipped) will indicate the last status and the indicator can be toggled.
To reduce fogging, the A/C compressor will operate automatically, regardless of indicator status,
if the outside temperature is above approximately 0°C (32°F).
SECTION 412-00: Climate Control System — General Information and Diagnostics 2011 Fiesta Workshop Manual
Climate Control System
Special Tool(s)
A/C Flush Adapter Kit
Adapters/O-rings for Filter

Flex Probe Kit


Pressure Test Kit

R-134a Manifold Gauge Set

176-R032A or equivalent
Refrigerant Leak Detector

Test Light
SGT27000 or equivalent 250-300
mA incandescent bulb test lamp

scan tool
The Refrigerant Cycle
During stabilized conditions (A/C system shutdown), the refrigerant pressures are equal throughout the system.
When the A/C compressor is in operation, it increases pressure on the refrigerant vapor, raising its
temperature. The high-pressure and high-temperature vapor is then released into the top of the A/C condenser
core.
The A/C condenser, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid
when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The now liquid
refrigerant, still at high pressure, exits from the bottom of the A/C condenser and enters the inlet side of the A/C
receiver/drier. The receiver/drier is designed to remove moisture from the refrigerant.
The outlet of the receiver/drier is connected to the Thermostatic Expansion Valve (TXV). The TXV provides the
orifice which is the restriction in the refrigerant system and separates the high and low pressure sides of the
A/C system. As the liquid refrigerant passes across 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 A/C evaporator, it
absorbs heat from the airflow passing over the plate/fin sections of the A/C evaporator. This addition of heat
causes the refrigerant to boil (convert to gas). The now cooler 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.
The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature
of the refrigerant.
The evaporator discharge air temperature sensor monitors the temperature of the evaporator core controls A/C
clutch cycling. If the temperature of the evaporator core is low enough to cause the condensed water vapor to
freeze, the A/C clutch is disengaged by the PCM.
The high-side line pressure is monitored by the A/C pressure transducer so that A/C compressor operation is
interrupted if the system pressure becomes too high or is determined to be too low (low charge condition).
The A/C compressor relief valve opens and vents refrigerant to relieve unusually high system pressure.
Thermostatic Expansion Valve (TXV) Type Refrigerant System

Item Description
1 A/C evaporator core
2 A/C evaporator core temperature sensor
3 Thermostatic Expansion Valve (TXV)
4 Manifold and tube assembly — TXV
5 A/C charge valve port (low side)
6 Manifold and tube assembly — A/C compressor
7 A/C compressor
8 A/C pressure relief valve
9 A/C pressure transducer
10 Low-pressure vapor
11 High-pressure vapor
12 Low-pressure liquid
13 High-pressure liquid
14 A/C condenser core
15 A/C receiver/drier
16 Manifold and tube assembly — receiver/drier
17 A/C charge valve port (high side)
1. Verify the customer concern by operating the climate control system to duplicate the condition.

Loose, missing or damaged A/C compressor drive Battery Junction Box (BJB) fuse
belt (s):
Loose or disconnected A/C clutch 4 (40A)
Broken or leaking refrigerant lines 29 (10A)
Central Junction Box (CJB) fuse
(s):
2 (10A)
7 (7.5A)
21 (10A)
Blower motor inoperative
A/C compressor inoperative
Circuitry open/shorted
Disconnected electrical
connectors
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms voltage and ground from the

refer to Section 418-00 , No Power To The Scan Tool, to diagnose no voltage to the scan tool.

If the scan tool responds with no communication from one or more modules, refer to Section 418-
00 .
If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics from the Instrument Panel Cluster (IPC) and
PCM.
9. NOTE: Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those
first. Refer to the PCM DTC Chart.
If the PCM DTCs retrieved are related to the concern, go to the PCM DTC Chart. If the IPC DTCs
retrieved are related to the concern, go to the Instrument Panel Cluster (IPC) DTC Chart. For all other
DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Climate Control Systems or GO
to Symptom Chart - NVH .
Self-Test — Retrieving And Clearing HVAC Module DTCs
To retrieve HVAC module DTCs, Carry out the following steps:
1. With the ignition on, select any mode except OFF on the HVAC controls.
2. While pressing the RECIRC mode button, select OFF on the HVAC controls.
3. Continue holding the RECIRC mode button for 5 seconds after OFF is selected.
The recirc mode indicator flashes at the rate of 1 flash per second for the first digit of the DTC, pause for 2
seconds, then resumes flashing at 1 flash per second for the second digit of the DTC. There is a 5 second
pause between DTCs. DTC 1-1 indicates no faults present.
To exit without clearing DTCs , select any mode except FLOOR or PANEL/FLOOR or turning the ignition off
after retrieving HVAC module DTCs.
To exit and clear HVAC DTCs , select FLOOR after retrieving HVAC module DTCs. The recirc mode indicator
flashes 5 times a second for 2 seconds, then resumes flashing to indicate any DTCs. DTC 1-1 indicates no
faults present.
Calibrating the HVAC Actuators
NOTE: The HVAC module will initialize and calibrate the actuators. The purpose of the HVAC module actuator
position calibration is to allow the HVAC module to reinitialize and calibrate the actuator stop points.
To calibrate HVAC actuators, Carry out the following steps:
1. With the ignition on, select any mode except OFF on the HVAC controls.
2. While pressing the RECIRC mode button, select OFF on the HVAC controls.
3. Continue holding the RECIRC mode button for 5 seconds after OFF is selected.
4. Select PANEL/FLOOR mode on the HVAC controls.
The recirc mode indicator flashes at the rate of 1 flash per second for the duration of the actuator calibration.
After the calibration is complete, the recirc mode indicator resumes flashing to indicate any DTCs. DTC 1-1
indicates no faults present.
DTC Charts
PCM DTC Chart

P0531:2F A/C Refrigerant Pressure INSPECT the refrigerant system for leaks. REFER to Electronic
Sensor A Circuit Leak Detection or Fluorescent Dye Leak Detection . If refrigerant
Range/Performance: Signal system leaks or is low, RECHARGE the refrigerant system. REFER
Erratic to Specifications in this section. If the refrigerant system does not
leak and is properly charged, INSTALL a new A/C pressure
transducer. CLEAR the DTCs and REPEAT the self-test. TEST the
P0532:16 A/C Refrigerant Pressure GO to Pinpoint Test a .
Sensor A Circuit Low:
Circuit Voltage Below
Threshold
P0533:17 A/C Refrigerant Pressure GO to Pinpoint Test a .
Sensor A Circuit High:
Circuit Voltage Above
Threshold
P0645:13 A/C Clutch Relay Control GO to Pinpoint Test b .
Circuit: Circuit Open
P0646:11 A/C Clutch Relay Control GO to Pinpoint Test B .
Circuit Low: Circuit Short To
Ground
P0647:12 A/C Clutch Relay Control GO to Pinpoint Test B .
Circuit High: Circuit Short
To Battery
All Other — REFER to Powertrain Control/Emissions Diagnosis (PC/ED)
DTCs manual.
Instrument Panel Cluster (IPC) DTC Chart

B101E:01 Air Conditioning Mode PLACE the HVAC selector in the OFF position, CLEAR the DTCs
Switch: General Electrical and REPEAT the self-test. If the DTC does not return, ignore the
Failure DTC and continue diagnosing other DTCs or symptoms.
If the DTC returns and HVAC DTC 5-2 is also set, GO to Pinpoint
Test l and diagnose HVAC DTC 5-2.
If the DTC returns and HVAC DTC 5-2 is not also set, INSTALL a
new Instrument Panel Cluster (IPC). REFER to Section 413-01 .
B1B71:11 Evaporator Temperature GO to Pinpoint Test C .
Ground
B1B71:13 Evaporator Temperature GO to Pinpoint Test C .
Sensor: Circuit Open
All Other — REFER to Section 413-01 .
DTCs
HVAC Module DTC Chart
NOTE: Some PCM and Instrument Panel Cluster (IPC) DTCs may inhibit A/C operation. If any PCM or IPC
DTCs are retrieved, diagnose those first. Refer to the PCM DTC Chart or the Instrument Panel Cluster (IPC)
DTC Chart.

1-0 Recirculation Button If the RECIRC button is held for more than 2 minutes, this DTC sets.
Performance ATTEMPT to clean buttons. CLEAR the DTCs. REPEAT the self-test. If
DTC returns, INSTALL a new HVAC module. REFER to Section 412-01 .
1-1 Diagnostics Mode Entered This DTC indicates that no HVAC faults are present at this time.
— No DTC Set
1-2 A/C Button Performance If the A/C button is held for more than 2 minutes, this DTC sets. ATTEMPT
to clean buttons. CLEAR the DTCs. REPEAT the self-test. If code returns,
INSTALL a new HVAC module. REFER to Section 412-01 . TEST the
2-1 Blend Feedback GO to Pinpoint Test m .
Circuit/Performance
2-2 Blend Motor Driver GO to Pinpoint Test m .
Circuit/Performance
2-3 Blend Actuator Calibration GO to Pinpoint Test m .
Performance
3-1 Mode Feedback GO to Pinpoint Test h .
Circuit/Performance
3-2 Mode Motor Driver GO to Pinpoint Test h .
Circuit/Performance
3-3 Mode Actuator Calibration GO to Pinpoint Test h .
Performance
4-2 Recirculation Motor Driver GO to Pinpoint Test g .
Circuit/Performance
4-4 Feedback Reference GO to Pinpoint Test d .
Circuit/Performance
5-1 Blower Relay Driver If the blower motor is inoperative, GO to Pinpoint Test n .
Circuit/Performance
If the blower motor is always on, GO to Pinpoint Test o .
5-2 A/C Select Drive If the A/C is inoperative, GO to Pinpoint Test j .
Circuit/Performance
If the A/C is always commanded on, GO to Pinpoint Test l .
5-3 Battery Voltage Low GO to Pinpoint Test e .
5-4 Battery Voltage High GO to Pinpoint Test e .
Symptom Chart — Climate Control System
Symptom Chart — Climate Control System
NOTE: Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose
those first. Refer to the PCM DTC Chart.
All HVAC functions Fuse GO to Pinpoint Test P .
inoperative Wiring, terminals or
connectors
HVAC module
Unable to duplicate Incorrect functioning GO to Pinpoint Test F .
the customer of the HVAC system
concern and no and/or related
DTCs present components
Reduced outlet Wiring, terminals or If the vehicle is not equipped
airflow connectors with A/C, GO to Pinpoint Test O
A/C compressor If the A/C compressor is
clutch air gap engaged and does not cycle,
A/C pressure GO to Pinpoint Test K .
transducer If the A/C compressor cycles
Evaporator discharge normally, GO to Pinpoint Test
air temperature O.
sensor
A/C clutch relay
Blower motor
HVAC module
PCM
The air inlet door is Wiring, terminals or GO to Pinpoint Test G .
inoperative connectors
Air inlet mode door
actuator
Air inlet mode door
binding or stuck
HVAC module
Incorrect/erratic Wiring, terminals or GO to Pinpoint Test H .
direction of airflow connectors
from outlets Defrost/panel/floor
mode door actuator
Defrost/panel/floor
mode door binding or
stuck
HVAC module
Insufficient, erratic or Low engine coolant GO to Pinpoint Test I .
no heat level
Plugged or partially
plugged heater core
Temperature blend
door binding or stuck
Temperature blend
door actuator
The air conditioning Fuse(s) GO to Pinpoint Test J .
(A/C) is inoperative Wiring, terminals or
connectors
A/C system
discharged/low
charge
PCM
HVAC module
A/C clutch relay
A/C compressor
clutch air gap
A/C pressure
transducer
Evaporator discharge
air temperature
sensor
A/C compressor
clutch field coil
The air conditioning Wiring, terminals or GO to Pinpoint Test K .
(A/C) is always on — connectors
A/C compressor PCM
does not cycle A/C clutch relay
A/C compressor
clutch air gap
Evaporator discharge
air temperature
sensor
The A/C is always Wiring, terminals or GO to Pinpoint Test L .
on — A/C mode connectors
always commanded HVAC module
ON PCM
Temperature control Wiring, terminals or GO to Pinpoint Test M .
is inoperative/does connectors
not operate correctly HVAC module
Temperature blend
door is binding or
stuck
Temperature blend
door actuator
The blower motor is Fuse(s) GO to Pinpoint Test N .
inoperative Wiring, terminals or
connectors
HVAC module
Blower motor relay
Blower motor
The blower motor Wiring, terminals or GO to Pinpoint Test O .
does not operate connectors
correctly A/C blower motor
resistor
HVAC module
A/C pressure relief High system pressure CHECK the high side system
valve discharging A/C pressure relief pressure. If the pressure is
valve below the A/C pressure relief
valve open pressure,
REPLACE the A/C pressure
relief valve. If the system
pressure is above the A/C
pressure relief valve open
pressure, REPAIR the system
for a restriction.
NOTE: NVH symptoms will be identified using the diagnostic tools that are available. For a
list of these tools, an explanation of their uses and a glossary of common terms, refer to
Section 100-04 . Since it is possible any one of multiple systems may be the cause of a
symptom, it may be necessary to use a process of elimination type of diagnostic approach
to pinpoint the responsible system. If this is not the causal system for the symptom, refer
back to Section 100-04 for the next likely system and continue diagnosis.
Noisy A/C A/C compressor CHECK and ADJUST the A/C compressor
compressor clutch air gap out clutch gap if necessary. REFER to Air
of specification Conditioning (A/C) Clutch Air Gap
Adjustment in this section. TEST the
If the A/C compressor clutch gap is OK,
INSTALL an A/C compressor clutch.
REFER to Section 412-01 . TEST the
A/C compressor INSPECT the A/C compressor pulley
pulley bearing bearing for roughness. If bearing
worn roughness is found, INSTALL an A/C
compressor pulley. REFER to Section 412-
01 . TEST the system for normal operation.
Pinpoint Tests
Pinpoint Test A: DTC P0532:16 or P0533:17
Refer to Wiring Diagrams Cell 23 , Electronic Engine Controls for schematic and connector information.
Refer to Wiring Diagrams Cell 54 , Manual Climate Control System for schematic and connector information.
Normal Operation
Under normal operation, the A/C pressure transducer receives a ground from the PCM. A 5-volt reference
voltage is supplied to the A/C pressure transducer from the PCM. The A/C pressure transducer then sends a
voltage to the PCM to indicate the A/C pressure.
DTC P0532:16 (A/C Refrigerant Pressure Sensor A Circuit Low: Circuit Voltage Below Threshold) —
The A/C pressure transducer inputs a feedback voltage to the PCM. This DTC sets if the feedback
voltage is less than 0.26 volts for at least 2 seconds and the ambient air temperature is greater than 0°C
(32°F).
DTC P0533:17 (A/C Refrigerant Pressure Sensor A Circuit High: Circuit Voltage Above Threshold) —
The A/C pressure transducer inputs a feedback voltage to the PCM. This DTC sets if the feedback
voltage is greater than 4.95 volts for at least 2 seconds and the ambient air temperature is greater than
0°C (32°F).

A/C pressure transducer
PCM
PINPOINT TEST A: DTC P0532:16 OR P0533:17

A1 CHECK THE PCM OUTPUT VOLTAGE
Ignition OFF. Yes
Disconnect: A/C Pressure Transducer C1260. GO to A4 .
Ignition ON.
Measure the voltage between ground and A/C pressure transducer No
C1260-2, circuit LH108 (GY/BN), harness side. If the voltage is less than
4.7 volts, GO to A2 .
If the voltage is greater

than 5.1 volts REPAIR
circuit LH108 (GY/BN) for
a short to voltage. CLEAR

A2 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Measure the resistance between ground and A/C pressure transducer
C1260-2, circuit LH108 (GY/BN), harness side. No
REPAIR circuit LH108
(GY/BN) for a short to
TEST the system for
normal operation.

A3 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR AN OPEN
Measure the resistance between A/C pressure transducer C1260-2, Yes
circuit LH108 (GY/BN), harness side and PCM C175B-16, circuit GO to A15 .
LH108 (GY/BN), harness side.
No
REPAIR circuit LH108
CLEAR the DTCs.
TEST the system for
normal operation.

A4 CHECK THE PCM SENSOR GROUND
Measure the voltage between A/C pressure transducer C1260-1, Yes
circuit RH108 (BN), harness side and A/C pressure transducer If diagnosing DTC P0532 ,
C1260-2, circuit LH108 (GY/BN), harness side. GO to A8 .
If diagnosing DTC P0533 ,

GO to A11 .
No
GO to A5 .

A5 CHECK THE SIGNAL RETURN CIRCUIT FOR VOLTAGE
Ignition OFF. Yes
Disconnect: PCM C175B. REPAIR circuit RH108
Ignition ON. (BN) for a short to voltage.
Measure the voltage between ground and A/C pressure transducer CLEAR the DTCs.
C1260-1, circuit RH108 (BN), harness side. REPEAT the self-test.
TEST the system for
normal operation.
No
GO to A6 .

A6 CHECK THE SIGNAL RETURN CIRCUIT FOR A SHORT TO THE
REFERENCE VOLTAGE CIRCUIT
circuit RH108 (BN), harness side and A/C pressure transducer GO to A7 .
C1260-2, circuit LH108 (GY/BN), harness side.
No
REPAIR circuit RH108
(BN) for a short to circuit
LH108 (GY/BN). CLEAR

A7 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between A/C pressure transducer C1260-1, GO to A15 .
circuit RH108 (BN), harness side and PCM C175B-40, circuit RH108
(BN), harness side. No
(BN) for an open. CLEAR

A8 CHECK THE A/C PRESSURE TRANSDUCER
Enter the following diagnostic mode on the scan tool: PCM Yes
DataLogger. INSTALL a new A/C
Observe the A/C Pressure Sensor (ACP_V) PCM PID voltage. pressure transducer.
Does the ACP_V PCM PID voltage read greater than 4.7 volts? CLEAR the DTCs.
TEST the system for
normal operation.
No
GO to A9 .
A9 CHECK THE A/C PRESSURE TRANSDUCER FEEDBACK CIRCUIT
FOR A SHORT TO THE SIGNAL RETURN CIRCUIT
Ignition OFF. Yes
Measure the resistance between A/C pressure transducer C1260-3,
circuit VH442 (GN/BN), harness side and A/C pressure transducer No
C1260-1, circuit RH108 (BN), harness side. REPAIR circuit VH442
(GN/BN) for a short to
circuit RH108 (BN).
CLEAR the DTCs.
TEST the system for
normal operation.

Measure the resistance between ground and A/C pressure transducer Yes
C1260-3, circuit VH442 (GN/BN), harness side. GO to A15 .
No
REPAIR circuit VH442
TEST the system for
normal operation.

Ignition OFF. Yes
Disconnect: PCM C175B. REPAIR circuit VH442
Ignition ON. (GN/BN) for a short to
Measure the voltage between ground and A/C pressure transducer voltage. CLEAR the DTCs.
C1260-3, circuit VH442 (GN/BN), harness side. REPEAT the self-test.
TEST the system for
normal operation.
No
GO to A12 .

FOR A SHORT THE REFERENCE VOLTAGE CIRCUIT
circuit VH442 (GN/BN), harness side and A/C pressure transducer GO to A13 .
C1260-2, circuit LH108 (GY/BN), harness side.
No
circuit LH108 (GY/BN).
CLEAR the DTCs.
TEST the system for
normal operation.

FOR AN OPEN
circuit VH442 (GN/BN), harness side and PCM C175B-28, circuit GO to A14 .
VH442 (GN/BN), harness side.
No
(GN/BN) for an open.
CLEAR the DTCs.
TEST the system for
normal operation.

A14 CHECK THE A/C PRESSURE SENSOR (ACP_V) PCM PID WITH
THE A/C PRESSURE TRANSDUCER SHORTED
NOTE: If the jumper fuse opens while carrying out this test step, Yes
repair circuit VH442 (GN/BN) for a short to ground. INSTALL a new A/C
pressure transducer.
Ignition OFF. CLEAR the DTCs.
Connect: PCM C175B. REPEAT the self-test.
Ignition ON. TEST the system for
Enter the following diagnostic mode on the scan tool: PCM normal operation.
DataLogger.
While observing the ACP_V PCM PID, connect a fused jumper No
between A/C pressure transducer C1260-1, circuit RH108 (BN), GO to A15 .
harness side and A/C pressure transducer C1260-3, circuit VH442
(GN/BN), harness side.
Does the ACP_V PCM PID voltage read 0 volts?

A15 CHECK THE PCM CONNECTION
Disconnect all the PCM connectors. Yes
Inspect the PCM connectors for: INSTALL a new PCM.
pushed-out terminals. 14 . TEST the system for
damaged terminals. normal operation.
Connect and correctly seat all the PCM connectors.
corroded connector.
Pinpoint Test B: DTC P0645:13, P0646:11 or P0647:12
Normal Operation
Voltage is provided to the A/C clutch relay coil. When A/C is requested and A/C line pressures allow, a ground
is provided to the A/C clutch relay coil from the PCM, energizing the A/C clutch relay.
DTC P0645:13 (A/C Clutch Relay Control Circuit: Circuit Open) — This DTC sets when the relay circuit
is OFF and no voltage is detected on the relay circuit. The PCM expects to detect voltage coming
through the relay coil to the relay circuit when it is not grounding it.
DTC P0646:11 (A/C Clutch Relay Control Circuit Low: Circuit Short To Ground) — This DTC sets when
the relay circuit is OFF and ground is detected on the relay circuit. The PCM expects to detect voltage
coming through the relay coil to the relay circuit when it is not grounding it.
DTC P0647:12 (A/C Clutch Relay Control Circuit High: Circuit Short To Battery) — This DTC sets when
the PCM grounds the relay circuit and excessive current draw (short to voltage) is detected on the relay
circuit.

A/C clutch relay
PCM
PINPOINT TEST B: DTC P0645:13, P0646:11 OR P0647:12

B1 CHECK PCM DTCS
Ignition ON. Yes
Check the PCM DTCs retrieved during the self-test. GO to B2 .
Is DTC P0645:13 present?
No
For DTC P0646:11 , GO
to B5 .
For DTC P0647:12 , GO

to B6 .
B2 CHECK THE VOLTAGE TO THE A/C CLUTCH RELAY COIL
Ignition OFF. Yes
Disconnect: A/C Clutch Relay. GO to B3 .
Ignition ON.
Measure the voltage between ground and the A/C clutch relay socket No
pin 1, circuit CBP02 (GN). VERIFY Central Junction
Box (CJB) fuse 2 (10A)
is OK. If OK, REPAIR
circuit CBP02 (GN) for
an open. CLEAR the
test. TEST the system
for normal operation. If
short.

B3 CHECK THE A/C CLUTCH RELAY
NOTICE: The following step uses a test light to simulate normal Yes
circuit loads. Use only the test light recommended in the Special INSTALL a new A/C
Tools table at the beginning of this section or equivalent. To avoid clutch relay. CLEAR the
connector terminal damage, use the Flex Probe Kit for the test DTCs. REPEAT the self-
light probe connection to the vehicle. Do not use the test light test. TEST the system
probe directly on any connector. for normal operation.
Start the engine. No

Select PANEL and press the A/C button (indicator on) on the HVAC GO to B4 .
controls.
With the engine running, connect a 12-volt test light between A/C clutch
relay socket pin 1, circuit CBP02 (GN) and A/C clutch relay socket pin
2, circuit CH302 (WH/BN).
B4 CHECK THE A/C CLUTCH RELAY COIL SWITCHED GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: PCM C175B. GO to B7 .
Measure the resistance between A/C clutch relay socket pin 2, circuit
CH302 (WH/BN) and PCM C175B-25, circuit CH302 (WH/BN), harness No
side. REPAIR circuit CH302
(WH/BN) for an open.
CLEAR the DTCs.
TEST the system for
normal operation.
Ignition OFF. Yes
Disconnect: A/C Clutch Relay. GO to B7 .
Measure the resistance between ground and PCM C175B-25, circuit No
CH302 (WH/BN), harness side. REPAIR circuit CH302
(WH/BN) for a short to
ground. CLEAR the
test. TEST the system

Ignition OFF. Yes
Disconnect: A/C Clutch Relay. REPAIR circuit CH302
Disconnect: PCM C175B. (WH/BN) for a short to
Ignition ON. voltage. CLEAR the
Measure the voltage between ground and PCM C175B-25, circuit DTCs. REPEAT the self-
CH302 (WH/BN), harness side. test. TEST the system
No
CARRY OUT the A/C
clutch relay component
test. Refer to

Cell 149 for component
testing.
If the relay tests OK, GO

to B7 .

B7 CHECK THE PCM CONNECTION
corroded connector.
Pinpoint Test C: DTC B1B71:11 or B1B71:13
Normal Operation
The evaporator discharge air temperature sensor receives a ground from the Instrument Panel Cluster (IPC).
The sensor varies its resistance with the temperature. As the temperature rises, the resistance falls. As the
temperature falls, the resistance rises. The IPC measures this resistance on the feedback circuit to determine
the temperature at the sensor. The sensor value is sent from the IPC to the PCM through the High Speed
Controller Area Network (HS-CAN).
The evaporator discharge air temperature sensor is used for A/C compressor cycling. An accurate evaporator
discharge air temperature is critical to prevent evaporator icing. The PCM uses the temperature measurement
to turn off the A/C compressor before the evaporator temperature is cold enough to freeze the condensation.
This prevents ice blockage of airflow over the evaporator core.
DTC B1B71:11 (Evaporator Discharge Air Temperature Sensor: Circuit Short to Ground) — The module
senses lower than expected voltage on the sensor feedback circuit, indicating a short to ground.
DTC B1B71:13 (Evaporator Discharge Air Temperature Sensor: Circuit Open) — The module senses
greater than expected voltage on the sensor feedback circuit, indicating an open circuit or sensor.

IPC
PINPOINT TEST C: DTC B1B71:11 OR B1B71:13

C1 CHECK THE SENSOR RESISTANCE
Ignition OFF. Yes
Disconnect: Evaporator Discharge Air Temperature Sensor C296. GO to C2 .
Allow enough time for the evaporator to stabilize to the ambient
temperature. No
Measure the resistance between evaporator discharge air INSTALL a new evaporator
temperature sensor C296 terminals and compare to the table discharge air temperature
below. sensor. REFER to Section
412-01 . CLEAR the DTCs.
Ambient Temperature Resistance REPEAT the self-test. TEST
0-10°C (32-50°F) 5,892-9,893 ohms operation.
10-20°C (50-68°F) 3,689-6,048 ohms
20-25°C (68-77°F) 2,950-3,805 ohms
25-30°C (77-86°F) 2,374-3,050 ohms
30-35°C (86-95°F) 1,923-2,460 ohms
35-40°C (95-104°F) 1,566-1,996 ohms
40-50°C (104-122°F) 1,057-1,630 ohms
Is the resistance within the specified values for the

temperatures?
C2 CHECK THE IPC SENSOR OUTPUT VOLTAGE
Ignition ON. Yes
Select PANEL and press the A/C button (indicator on) on the INSTALL a new evaporator
HVAC controls. discharge air temperature
Measure the voltage between evaporator discharge air sensor. REFER to Section
temperature sensor C296-1, circuit VH406 (VT/BN), harness side 412-01 . CLEAR the DTCs.
and C296-3, circuit RH119 (YE/VT), harness side. REPEAT the self-test. TEST
operation. If the DTC returns,
GO to C7 .
No
If diagnosing DTC
B1B71:13 , GO to C3 .
If diagnosing DTC
B1B71:11 , GO to C5 .

C3 CHECK THE EVAPORATOR TEMPERATURE SENSOR
FEEDBACK CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Instrument Panel Cluster (IPC) C220. GO to C4 .
Measure the resistance between IPC C220-26, circuit VH406
(VT/BN), harness side and evaporator discharge air temperature No
sensor C296-1, circuit VH406 (VT/BN), harness side. REPAIR circuit VH406
(VT/BN) for an open. CLEAR
normal operation.
C4 CHECK THE SIGNAL RETURN CIRCUIT FOR AN OPEN
Measure the resistance between IPC C220-24, circuit RH119 Yes
(YE/VT), harness side and evaporator discharge air temperature GO to C7 .
sensor C296-3, circuit RH119 (YE/VT), harness side.
No
(YE/VT) for an open. CLEAR
normal operation.

FEEDBACK CIRCUIT FOR A SHORT TO THE SIGNAL RETURN
CIRCUIT
Ignition OFF. Yes
Disconnect: IPC C220. GO to C6 .
Measure the resistance between evaporator discharge air
temperature sensor C296-1, circuit VH406 (VT/BN), harness side No
and C296-3, circuit RH119 (YE/VT), harness side. REPAIR circuits VH406
(VT/BN) and RH119 (YE/VT)
for a short together. CLEAR
normal operation.

FEEDBACK CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between IPC C220-26, circuit VH406 Yes
(VT/BN), harness side and ground. GO to C7 .
No
(VT/BN) for a short to ground.
the self-test. TEST the system

C7 CHECK THE IPC CONNECTION
Disconnect all the IPC connectors. Yes
Inspect the IPC connectors for: INSTALL a new IPC . REFER
corrosion. to Section 413-01 . TEST the
pushed-out terminals. system for normal operation.
damaged terminals.
Connect and correctly seat all the IPC connectors. No
corroded connector. TEST the
Pinpoint Test D: DTC 4-4
Normal Operation
A 5-volt reference voltage is supplied to the sensors and actuators from the HVAC module.
DTC 4-4 (Feedback Reference Circuit/Performance) — The module senses less than expected voltage
on the reference voltage circuit, indicating a short directly to ground or the module senses greater than
expected voltage on the sensor reference voltage circuit, indicating an open or a short directly to voltage.

HVAC module
PINPOINT TEST D: DTC 4-4

D1 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to D2 .
Measure the resistance between ground and HVAC module
C228A-12, circuit CH232 (WH/BN), harness side. No
REPAIR circuit CH232 (WH/BN)
for a short to ground. CLEAR the
operation.
D2 CHECK THE REFERENCE VOLTAGE CIRCUIT AND THE
SIGNAL RETURN CIRCUIT FOR A SHORT TOGETHER
Measure the resistance between HVAC module C228A-12, Yes
circuit CH232 (WH/BN), harness side and HVAC module GO to D4 .
C228A-2, circuit CH233 (VT/BN), harness side.
No
GO to D3 .
Is the resistance greater than 100 ohms?

D3 CHECK THE ACTUATORS
circuit CH233 (VT/BN), harness side and HVAC module INSTALL a new actuator (the last
C228A-12, circuit CH232 (WH/BN), harness side. one to be disconnected). REFER
to Section 412-01 . CONNECT
the actuator electrical connector
before the HVAC module
connector(s). This allows the
actuator to be calibrated when
the HVAC module is
reconnected. TEST the system
No
REPAIR circuits CH233 (VT/BN)
and CH232 (WH/BN) for a short
together. CLEAR the DTCs.
REPEAT the self-test. TEST the
While measuring the resistance, disconnect the following
components one at a time, in order. Stop disconnecting
components if the measured resistance rises above 100 ohms.
Defrost/panel/floor door actuator C236
Temperature blend door actuator C2092
Did the resistance rise above 100 ohms?
D4 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition ON. Yes
Measure the voltage between ground and HVAC module REPAIR circuit CH232 (WH/BN)
C228A-12, circuit CH232 (WH/BN), harness side for a short to voltage. CLEAR the
operation.
No
GO to D5 .

D5 CHECK THE RETURN CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON. Yes
Measure the voltage between ground and HVAC module REPAIR circuit CH233 (VT/BN)
C228A-2, circuit CH233 (VT/BN), harness side for a short to voltage. CLEAR the
operation.
No
GO to D6 .

D6 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Temperature Blend Door Actuator C2092. GO to D7 .
Measure the resistance between ground and HVAC module
C228A-12, circuit CH232 (WH/BN), harness side and No
temperature blend door actuator C2092-2, circuit CH232 REPAIR circuit CH232 (WH/BN)
(WH/BN). for an open. CLEAR the DTCs.

D7 CHECK THE HVAC MODULE CONNECTION
Disconnect all the HVAC module connectors. Yes
Inspect the HVAC module connectors for: INSTALL a new HVAC module.
pushed-out terminals. TEST the system for normal
damaged terminals. operation.
Connect and correctly seat all the HVAC module connectors.
Is the concern still present? The system is operating correctly
at this time. The concern may
have been caused by a loose or
Pinpoint Test E: DTCs 5-3 and 5-4
NOTE: DTCs 5-3 and 5-4 can be set if the vehicle has been recently jump started, the battery has been
recently charged or the battery has been discharged. The battery may become discharged due to excessive
load(s) on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
Inspection and Verification in this section.
Normal Operation
The HVAC module receives a ground. The HVAC module is supplied constant battery voltage and ignition
voltage.
DTC 53 (Battery Voltage Low) — The module senses when battery voltage is less than 8 volts for more
than 2 seconds.
DTC 54 (Battery Voltage High) — The module senses when battery voltage is greater than 16 volts for
more than 2 seconds.

HVAC module
Battery
PINPOINT TEST E: DTCs 5-3 AND 5-4

E1 RETRIEVE ALL CMDTCs IN ALL MODULES
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self Test — All REFER to Section 414-00
CMDTCs . for diagnosis of the battery
Are any charging system DTCs present in the PCM?? and charging system.
No
GO to E2 .
E2 CHECK BATTERY CONDITION
Ignition OFF. Yes
Refer to Section 414-01 and carry out the Battery — Condition Test. If the battery passed the
Does the battery pass the condition test? condition test but required
Section 414-00 to
diagnose the charging
system. CLEAR all
Continuous Memory
(CMDTCs). TEST the
system for normal
operation.

require a recharge, GO to
E3 .
No
CLEAR all CMDTCs .
TEST the system for
normal operation.
E3 CHECK THE CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine rpm to exceed above 2,000 rpm while Yes
performing this step or the generator may self-excite and result in If diagnosing DTC 5-3 ,
default charging system output voltage. If engine rpm has exceeded GO to E4 .
2,000 rpm, shut the vehicle off and restart the engine before
performing this step. If diagnosing DTC 5-4 ,
INSTALL a new HVAC
Start the engine. module. REFER to
Measure the voltage of the battery: Section 412-01 . CLEAR
For DTC 54 , turn on headlights and HVAC fan on high and run all CMDTCs . REPEAT
engine at 1,500 rpm for a minimum of 2 minutes. the self-test.
For DTC 53 , turn off all accessories and run the engine at
1,500 rpm for a minimum of 2 minutes. No
REFER to Section 414-00
to diagnose the charging
system. CLEAR all
CMDTCs . TEST the
system for normal
operation.
Is the battery voltage between 13 and 15.2 volts?

E4 CHECK THE HVAC MODULE VOLTAGE SUPPLY CIRCUITS
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to E5 .
Ignition ON.
With the engine running, measure the voltage between ground and: No
HVAC module C228A-10, circuit SBP07 (WH/RD), harness REPAIR circuit SBP07
side. (WH/RD) or CBP21
HVAC module C228A-14, circuit CBP21 (BU/GY), harness (BU/GY) for high
side. resistance. CLEAR all
CMDTCs . REPEAT the
self-test.
E5 CHECK THE HVAC MODULE GROUND CIRCUIT
Ignition OFF. Yes
Measure the resistance between ground and HVAC module C228A- GO to E6 .
13, circuit GD115 (BK/GY), harness side.
No
(BK/GY) for high
resistance. CLEAR all
CMDTCs . REPEAT the

E6 CHECK THE HVAC MODULE CONNECTION
Inspect the HVAC module connectors for: INSTALL a new HVAC
corrosion. module. REFER to
pushed-out terminals. Section 412-01 . TEST the
damaged terminals. system for normal
Connect and correctly seat all the HVAC module connectors. operation.
operation.
Pinpoint Test F: Unable to Duplicate the Customer Concern and No DTCs Present
Normal Operation
This pinpoint test tests the functions of the HVAC system and identifies the correct HVAC symptom pinpoint
test.

Incorrect functioning of the HVAC system and/or related components
PINPOINT TEST F: UNABLE TO DUPLICATE THE CUSTOMER CONCERN AND NO DTCS PRESENT

F1 CHECK THE BLOWER MOTOR OPERATION
Ignition ON. Yes
Select PANEL mode. GO to F2 .
Observe blower motor operation and select
each blower motor speed. No
Does the blower motor operate in all If the blower motor does not operate in any
selections and change speed in each? setting, GO to Pinpoint Test N .
If the blower motor does not properly change

speeds or shut off, GO to Pinpoint Test O .
F2 CHECK AIRFLOW OPERATION
Select the highest blower motor setting. Yes
NOTE: Refer to Description and Operation in GO to F3 .
this section for proper airflow descriptions.
While observing the airflow, select each of the No
airflow positions (PANEL, PANEL/FLOOR, GO to Pinpoint Test H .
FLOOR, FLOOR/DEFROST, DEFROST).
Is the airflow directed to the proper outlets?
F3 VERIFY TEMPERATURE CONTROL
OPERATION
Start the vehicle and allow it to reach normal Yes
operating temperature. If the vehicle is equipped with A/C, GO to F4 .
Select PANEL and press the A/C button
(indicator on) (if equipped) on the HVAC If the vehicle is not equipped with A/C, GO to
controls. F6 .
Change the temperature setting from the
coldest to the warmest and back to the coldest. No
Does the temperature change between very If the temperature does not get very warm, GO to
warm to cool? Pinpoint Test I .
If the temperature does not change at all, GO to

Pinpoint Test M .
F4 VERIFY THE A/C CLUTCH DOES NOT
ENGAGE WITH A/C OFF
Select PANEL and press the A/C button GO to F5 .
(indicator off) on the HVAC controls.
Select the coldest temperature setting. No
Is the outlet temperature close to ambient If the temperature is warmer than ambient
temperature? temperature, GO to Pinpoint Test M and
diagnose for inoperative blend door.
If the outlet temperature is significantly colder

than ambient temperature and the A/C
compressor clutch cycles normally, GO to
Pinpoint Test L .
If the outlet temperature is significantly colder

than ambient temperature and the A/C
compressor clutch is engaged and does not
cycle, GO to Pinpoint Test K .
F5 VERIFY A/C CLUTCH ENGAGEMENT IN THE
A/C MODE
Make sure the ambient air temperature is Yes
above 0°C (32°F). GO to F6 .
Select PANEL mode on the HVAC controls.
Press the A/C button (indicator on). No
Does the A/C clutch engage when the GO to Pinpoint Test J .
PANEL and A/C button (indicator on) is
pressed?
F6 CHECK THE RECIRC OPERATION
With the engine running, press the RECIRC Yes
button (indicator off). The system is operating normally.
Select PANEL mode.
Select the highest blower motor setting. No
Observe airflow noise. GO to Pinpoint Test G .
Press the RECIRC button (indicator on).
Does the airflow noise increase when the
RECIRC mode is selected (indicator on)?
Pinpoint Test G: The Air Inlet Door is Inoperative
Normal Operation
The HVAC module supplies voltage and ground to the air inlet mode door actuator through the actuator motor
circuits to rotate the air inlet mode door actuator. To reverse the air inlet mode door actuator rotation, the HVAC
module reverses voltage and ground on the circuits.
When the HVAC is in FLOOR/DEFROST or FLOOR mode, RECIRC is a timed function. When RECIRC is
selected, the air inlet mode door remains in recirculated air mode for 5 minutes. After 5 minutes, the RECIRC
indicator turns off and the air inlet mode door changes to fresh air mode.
DTC 4-2 (Recirculation Motor Driver Circuit/Performance) — This DTC sets when either of the following
occurs:
The module senses lower than expected voltage on an actuator motor circuit when voltage is
applied to drive the motor, indicating a short to ground.
The module senses greater than expected voltage on the actuator motor circuit when ground is
applied to drive the motor, indicating a short to voltage.

HVAC module
Air inlet mode door binding or stuck
PINPOINT TEST G: THE AIR INLET DOOR IS INOPERATIVE

G1 CHECK THE HVAC MODULE FOR DTCs
Ignition ON. Yes
CARRY OUT the HVAC module self-test. GO to G2 .
Check for HVAC DTCs retrieved during the self-test.
Is DTC 4-2 present? No
GO to G6 .
G2 CHECK THE AIR INLET MODE DOOR ACTUATOR MOTOR
Ignition OFF. Yes
Disconnect: HVAC Module C228A. REPAIR circuit CH206
Ignition ON. (YE/VT) or CH208 (GN/OG)
Measure the voltage between ground and: for a short to voltage. CLEAR
HVAC module C228A-9, circuit CH206 (YE/VT), harness the DTCs. REPEAT the self-
side. test. TEST the system for
HVAC module C228A-18, circuit CH208 (GN/OG), harness normal operation.
side.
No
GO to G3 .
Are any voltages present?

Ignition OFF. Yes
Measure the resistance between ground and: GO to G4 .
HVAC module C228A-9, circuit CH206 (YE/VT), harness
side. No
HVAC module C228A-18, circuit CH208 (GN/OG), harness REPAIR circuit CH206
side. (YE/VT) or CH208 (GN/OG)
for a short to ground. CLEAR
normal operation.

RESISTANCE
Measure the resistance between HVAC module C228A-9, circuit Yes
CH206 (YE/VT), harness side and HVAC module C228A-18, circuit GO to G8 .
CH208 (GN/OG), harness side.
No
GO to G5 .

CIRCUITS FOR A SHORT TOGETHER
Disconnect: Air Inlet Mode Door Actuator C289. Yes
Measure the resistance between HVAC module C228A-9, circuit INSTALL a new air inlet
CH206 (YE/VT), harness side and HVAC module C228A-18, circuit actuator. REFER to Section
CH208 (GN/OG), harness side. 412-01 . CLEAR the DTCs.
REPEAT the self-test. TEST
operation.
No
REPAIR circuits CH208
(GN/OG) and CH206
(YE/VT) for a short together.

Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to G7 .
Disconnect: Air Inlet Mode Door Actuator C289.
Measure the resistance between HVAC module C228A-18, circuit No
CH208 (GN/OG), harness side and air inlet mode door actuator REPAIR circuit CH206
C289-1, circuit CH208 (GN/OG), harness side. (YE/VT) or CH208 (GN/OG)
for an open. TEST the
Measure the resistance between HVAC module C228A-9, circuit

CH206 (YE/VT), harness side and air inlet mode door actuator
C289-6, circuit CH206 (YE/VT), harness side.

G7 CHECK THE AIR INLET MODE DOOR AND LINKAGE
Yes
Disconnect: Air Inlet Mode Door Actuator C289. REPAIR the air inlet mode
REMOVE the air inlet mode mode door actuator. REFER to Section mode door or linkage TEST
412-01 . the system for normal
INSPECT the air inlet mode mode door and linkage for a broken, operation.
loose or binding condition.
Is any binding condition found during inspection? No
GO to G8 .
G8 CHECK THE AIR INLET MODE DOOR ACTUATOR CONNECTION
Disconnect the air inlet mode door actuator connector. Yes
Inspect the air inlet door actuator connector for: CARRY OUT the Air Inlet
corrosion. Mode Door Actuator
pushed-out terminals. component test in this
damaged terminals. section. INSTALL a new air
Connect and correctly seat the actuator connector. inlet mode door if necessary.
Operate the system and verify the concern is still present. REFER to Section 412-01 . If
Is the concern still present? the actuator tests OK, GO to
G9 .
No
operation.
G9 CHECK THE HVAC MODULE CONNECTION
corrosion. module. REFER to Section
pushed-out terminals. 412-01 . TEST the system for
Connect and correctly seat all the HVAC module connectors.
operation.
Pinpoint Test H: Incorrect/Erratic Direction of Airflow From Outlets
Normal Operation
The HVAC module supplies voltage and ground to the defrost/panel/floor mode door actuator motor through the
actuator motor circuits to rotate the defrost/panel/floor mode door actuator. To reverse the defrost/panel/floor
mode door actuator rotation, the HVAC module reverses voltage and ground on the circuits.
The defrost/panel/floor mode door actuator feedback resistor is supplied a 5-volt reference voltage and ground
from the HVAC module. The HVAC module measures the resistance on the defrost/panel/floor mode door
actuator feedback circuit to determine the defrost/panel/floor mode door actuator position by the position of the
actuator feedback resistor wiper arm.
During an actuator calibration cycle, the HVAC module drives the defrost/panel/floor mode door until the door
reaches both internal stops in the HVAC case. If the defrost/panel/floor mode door is temporarily obstructed or
binding during a calibration cycle, the HVAC module may interpret this as the actual end of travel for the door.
When this condition occurs and the HVAC module commands the actuator to its end of travel, the airflow may
not be from the expected outlets.
DTC 3-1 (Mode Feedback Circuit/Performance) — The module senses no changes in the feedback
circuit when motor movement is commanded and no motor electrical DTCs are present. This indicates
an open actuator motor, an open or shorted feedback circuit, an open feedback resistor reference
voltage circuit, or an internal electrical or mechanical failure.
DTC 3-2 (Mode Motor Driver Circuit/Performance) — The module senses lower than expected voltage
on an actuator motor circuit when voltage is applied to drive the motor. This indicates a short to ground
or the module senses greater than expected voltage on the actuator motor circuit when ground is applied
to drive the motor, indicating a short to voltage.
DTC 3-3 (Mode Actuator Calibration Performance) — The module senses the actuator has moved
outside its travel limits during calibration. This indicates broken/disconnected linkage or door or an
internal mechanical failure.

Defrost/panel/floor mode door actuator
HVAC module
Defrost/panel/floor mode door binding or stuck
PINPOINT TEST H: INCORRECT/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS

H1 CHECK THE HVAC MODULE FOR DTCs
NOTE: If HVAC DTC 4-4 is present, GO to Pinpoint Test D Yes

and diagnose that DTC first. For DTC 3-1 , GO to H2 .
Ignition ON. For DTC 3-2 , GO to H9 .
CARRY OUT the HVAC module self-test.
Check for HVAC DTCs retrieved during the self-test. For DTC 3-3 , GO to H8 .
Are HVAC DTCs present?
No
GO to H7 .
H2 CHECK THE ACTUATOR MOTOR AND CIRCUITS
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to H4 .
circuit CH202 (BU/GN), harness side and HVAC module No
C228A-8, circuit CH203 (GN/BN), harness side. GO to H3 .

H3 CHECK THE DEFROST/PANEL/FLOOR MODE DOOR
ACTUATOR
Ignition OFF. Yes
Disconnect: Defrost/Panel/Floor Mode Door Actuator C236. REPAIR circuit CH202 (BU/GN) or
CARRY OUT the Defrost/Panel/Floor Mode Door Actuator CH203 (GN/BN) for an open or
component test in this section. high resistance. REPEAT the self-
Did the defrost/panel/floor mode door actuator test OK? test. TEST the system for normal
operation.
No
GO to H13 .
H4 CHECK THE POTENTIOMETER LOW- AND HIGH-SIDE
RESISTANCE
Measure the high-side resistance between HVAC module Yes
C228A-12, circuit CH232 (WH/BN), harness side and HVAC GO to H5 .
module C228A-1, circuit CH204 (GY/OG), harness side.
No
CARRY OUT the
Defrost/Panel/Floor Mode Door
Actuator component test in this
defrost/panel/floor mode door
actuator if necessary. REFER to
Section 412-01 .
If the actuator tests OK and:
If the high-side resistance only is

greater than 4,375 ohms, REPAIR
circuit CH232 (WH/BN) for an
open.
Measure the low-side resistance between HVAC module
C228A-2, circuit CH233 (VT/BN), harness side and HVAC If the high-side resistance only is
module C228A-1, circuit CH204 (GY/OG), harness side. less than 215 ohms, REPAIR
circuits CH204 (GY/OG) and
CH232 (WH/BN) for a short
together.
If the low-side resistance only is

circuit CH233 (VT/BN) for an open.

less than 215 ohms, REPAIR
circuits CH204 (GY/OG) and
CH233 (VT/BN) for a short
together.
If both the high-side and low-side

Are the resistances between 215 and 4,375 ohms? resistance is greater than 4,375
ohms, REPAIR circuit CH204
Once the repair is complete,

CALIBRATE the actuators. REFER
to Calibrating the HVAC Actuators
in this section. TEST the system for
normal operation.
H5 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition ON. Yes
Measure the voltage between ground and HVAC module REPAIR circuit CH204 (GY/OG) for
C228A-1, circuit CH204 (GY/OG), harness side. a short to voltage. CLEAR the
DTCs. REPEAT the self-test. TEST
No
GO to H6 .
H6 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between ground and HVAC module GO to H7 .
C228A-1, circuit CH204 (GY/OG), harness side.
No
REPAIR circuit CH204 (GY/OG) for

ACTUATOR OPERATION
Ignition OFF. Yes
Disconnect: HVAC Module C228A (If not previously GO to H14 .
disconnected).
Measure the resistance between HVAC module C228A-2, No
circuit CH233 (VT/BN), harness side and HVAC module GO to H8 .
C228A-1, circuit CH204 (GY/OG), harness side.
Connect a fused jumper wire between:

HVAC module C228A-10, circuit SBP07 (WH/RD),
harness side and HVAC module C228A-7, circuit
CH202 (BU/GN), harness side.
HVAC module C228A-13, circuit GD115 (BK/GY),
CH203 (GN/BN), harness side.
Remove the fused jumpers.

CH202 (BU/GN), harness side.
CH203 (GN/BN), harness side.
Does the resistance smoothly increase to approximately

3,500 ohms and/or decrease to approximately 290 ohms
when the jumpers are connected?
H8 CHECK THE DEFROST/PANEL/FLOOR MODE DOOR AND
LINKAGE
Disconnect: Defrost/Panel/Floor Mode Door Actuator C236. Yes
REMOVE the defrost/panel/floor mode door actuator. REFER REPAIR the defrost/panel/floor
to Section 412-01 . mode door or linkage REINSTALL
INSPECT the defrost/panel/floor mode door and linkage for a the defrost/panel/floor mode door
broken, loose or binding condition. actuator. CALIBRATE the
Is any condition found during inspection? actuators. REFER to Calibrating
the HVAC Actuators in this section.
operation.
No
GO to H13 .
H9 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: HVAC Module C228A. REPAIR circuit CH202 (BU/GN) or
Ignition ON. CH203 (GN/BN) for a short to
Measure the voltage between ground and: voltage. TEST the system for
HVAC module C228A-7, circuit CH202 (BU/GN), normal operation.
harness side.
HVAC module C228A-8, circuit CH203 (GN/BN), No
harness side. GO to H10 .

H10 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between ground and: GO to H11 .
HVAC module C228A-7, circuit CH202 (BU/GN),
harness side. No
HVAC module C228A-8, circuit CH203 (GN/BN), REPAIR circuit CH202 (BU/GN) or
harness side. CH203 (GN/BN) for a short to

H11 CHECK THE ACTUATOR MOTOR AND CIRCUIT
RESISTANCE
circuit CH202 (BU/GN), harness side and HVAC module GO to H14 .
C228A-8, circuit CH203 (GN/BN), harness side.
No
GO to H12 .
H12 CHECK THE ACTUATOR MOTOR CIRCUITS FOR A
SHORT TOGETHER
Disconnect: Defrost/Panel/Floor Mode Door Actuator C236. Yes
Measure the resistance between HVAC module C228A-7, GO to H13 .
circuit CH202 (BU/GN), harness side and HVAC module
C228A-8, circuit CH203 (GN/BN), harness side. No
REPAIR circuits CH202 (BU/GN)
and CH203 (GN/BN) for a short

ACTUATOR CONNECTION
Disconnect the defrost/panel/floor mode door actuator Yes
connector. INSTALL a new defrost/panel/floor
Inspect the defrost/panel/floor mode door actuator connector mode door actuator. REFER to
for: Section 412-01 . CALIBRATE the
corrosion. actuators. REFER to Calibrating
pushed-out terminals. the HVAC Actuators in this section.
damaged terminals. TEST the system for normal
REINSTALL the defrost/panel/floor mode door actuator, If operation.
removed.
Connect and correctly seat the defrost/panel/floor mode door No
actuator connector. The system is operating correctly at
CALIBRATE the actuators. REFER to Calibrating the HVAC this time. The concern may have
Actuators in this section. been caused by a loose or
Operate the system and verify the concern is still present. corroded connector. TEST the
H14 CHECK THE HVAC MODULE CONNECTION
corrosion. REFER to Section 412-01 . TEST
pushed-out terminals. the system for normal operation.
damaged terminals.
Connect and correctly seat all the HVAC module connectors. No
Operate the system and verify the concern is still present. The system is now operating
Is the concern still present? correctly at this time. The concern
may have been caused by a foreign
object in the HVAC case or
temporary binding that restricted
actuator door travel. CHECK any
actuator external linkage. If
condition recurs, INSPECT actuator
linkage and door for binding and
CHECK HVAC case for foreign
objects.
Pinpoint Test I: Insufficient, Erratic or No Heat
Normal Operation
Coolant flows from the engine through the heater core and back to the engine. Proper coolant temperatures are
critical for good heater performance.

Plugged or partially plugged heater core
Low engine coolant level
Temperature blend door binding or stuck
PINPOINT TEST I: INSUFFICIENT, ERRATIC OR NO HEAT

I1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
Ignition OFF. Yes
Check the engine coolant level. GO to I3 .
Is the engine coolant at the correct level as indicated
on the engine coolant recovery reservoir? No
GO to I2 .
I2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS
Pressure test the cooling system for leaks. Refer to Yes
Section 303-03 . REPAIR the engine coolant leak.
Does the engine cooling system leak? TEST the system for normal operation.
No
FILL and BLEED the cooling system.
REFER to Section 303-03 . After filling
and bleeding the cooling system, GO
to I3 .
I3 CHECK FOR COOLANT FLOW TO THE HEATER CORE
Run the engine until it reaches normal operation Yes
temperature. Select the FLOOR position on the control GO to I4 .
assembly. Set the temperature control to full warm and
the blower to the lowest setting. No
Using a suitable temperature measuring device, check the REFER to Section 303-03 to diagnose
heater core inlet hose to see if it is hot. the engine not reaching normal
Is the heater core inlet hose temperature above 65.5°C operating temperature.
(150°F)?
I4 CHECK FOR A PLUGGED OR RESTRICTED HEATER
CORE
Using a suitable temperature measuring device, measure Yes
the heater core outlet hose temperature. GO to Pinpoint Test M .
Is the heater core outlet hose temperature similar to
the inlet hose temperature (within approximately 6-17° No
C [10-30°F])? INSTALL a new heater core. REFER
to Section 412-01 . TEST the system
Pinpoint Test J: The Air Conditioning (A/C) is Inoperative
Normal Operation
When A/C is requested the HVAC module grounds a circuit to the Instrument Panel Cluster (IPC). The IPC then
sends an A/C request through the High Speed Controller Area Network (HS-CAN) to the PCM.
Voltage is provided to the A/C clutch relay coil and switch contacts. When A/C is requested and A/C line
pressures allow, a ground is provided to the A/C clutch relay coil from the PCM, energizing the A/C clutch relay.
When the PCM energizes the relay, voltage is supplied to the A/C clutch from the relay. Ground is supplied for
the A/C clutch.
temperature is critical for compressor engagement. The PCM uses the temperature measurement to turn the
A/C compressor off before the evaporator temperature is cold enough to freeze the condensation on the
evaporator core.
When an A/C request is received by the PCM, the A/C compressor clutch only engages the A/C clutch relay if
all of the following conditions are met:
The A/C pressure transducer does not indicate excessively low or high refrigerant pressure. Refer to
The PCM does not detect excessively high engine coolant temperature.
The PCM does not detect an ambient air temperature below 0°C (32°F).
The PCM has not detected a Wide Open Throttle (WOT) condition.
The HVAC module does not detect an evaporator discharge air temperature below 0.6°C (33°F).
DTC 52 (A/C Select Drive Circuit/Performance) — This DTC sets when any of the following occur during
a self-test:
The module senses ground on the A/C request circuit when the circuit is not grounded by the
HVAC module, indicating a short directly to ground.
The module senses voltage on the A/C request circuit when the circuit is grounded by the HVAC
module, indicating a short directly to voltage.
The module senses no voltage on the A/C request circuit when the relay is not grounded by the
HVAC module, indicating an open.

Fuse(s)
A/C system discharged/low charge
PCM
HVAC module
IPC
A/C pressure transducer
A/C compressor clutch field coil
A/C clutch relay
A/C compressor clutch air gap
PINPOINT TEST J: THE AIR CONDITIONING (A/C) IS INOPERATIVE
DTC Chart.

J1 CHECK THE HVAC MODULE FOR DTCs
Ignition ON. Yes
CARRY OUT the HVAC module self-test. GO to J19 .
IS DTC 52 present? No
GO to J2 .
J2 CHECK THE A/C SYSTEM PRESSURE
Ignition OFF. Yes
With the R-134a manifold gauge set connected, check the A/C system GO to J3 .
pressure.
Is the A/C system pressure above 290 kPa (42 psi) ? No
CHECK the A/C system
for leaks. REFER to
Fluorescent Dye Leak
Detection or Electronic
Leak Detection in this
section. RECHARGE the
A/C system. REFER to
Air Conditioning (A/C)
System Recovery,
Evacuation and
Charging . TEST the
system for normal
operation.
J3 CHECK THE A/C PRESSURE SENSOR (ACP_PRESS) PCM PID
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: PCM GO to J4 .
DataLogger.
With the R-134a manifold gauge set connected, compare the pressure No
readings of the manifold gauge set and the ACP_PRESS PCM PID. INSTALL a new A/C
Are the pressure values of the manifold gauge set and the pressure transducer.
ACP_PRESS PCM PID similar? TEST the system for
normal operation.
J4 CHECK THE A/C EVAPORATOR TEMPERATURE (EVAP_TEMP)
INSTRUMENT PANEL CLUSTER (IPC) PID
Allow the vehicle exterior and interior to stabilize to the ambient Yes
temperature. GO to J5 .
Enter the following diagnostic mode on the scan tool: IPC DataLogger.
Monitor the EVAP_TEMP IPC PID No
Does the EVAP_TEMP IPC PID read similar to the ambient GO to J21
temperature?
J5 CHECK THE AIR CONDITIONING SWITCH (A/C_SWITCH) IPC PID
WITH THE A/C ON
Enter the following diagnostic mode on the scan tool: IPC DataLogger. Yes
Monitor the A/C_SWITCH IPC PID GO to J7 .
Select PANEL and press the A/C button (indicator on) on the HVAC
controls. No
Does the A/C_SWITCH IPC PID read ACTIVE? GO to J6 .
J6 CHECK THE A/C REQUEST TO THE IPC
circuit loads. Use only the test light recommended in the Special GO to J24 .
Tools table at the beginning of this section. To avoid connector
terminal damage, use the Flex Probe Kit for the test light probe No
connection to the vehicle. Do not use the test light probe directly GO to J22 .
on any connector.
Ignition OFF.
Disconnect: Instrument Panel Cluster (IPC) C220.
Ignition ON.
Connect a 12-volt test light between IPC C220-4, circuit CBP21
(BU/GY), harness side and IPC C220-12, circuit CH434 (GY/YE),
harness side.
controls.
J7 CHECK THE AIR CONDITIONING REQUEST SIGNAL (AC_REQ) PCM
PID WITH THE A/C ON
controls. No
Monitor the AC_REQ PCM PID GO to J24 .
Does the AC_REQ PCM PID read YES?
J8 CHECK THE AIR CONDITIONING COMPRESSOR COMMANDED
STATE (ACC_CMD) PCM PID WITH THE A/C ON
controls. No
Monitor the ACC_CMD PCM PID GO to J23 .
Does the ACC_CMD PCM PID read ON?
J9 CHECK THE VOLTAGE AT THE A/C COMPRESSOR CLUTCH FIELD
COIL
Ignition OFF. Yes
Disconnect: A/C Compressor Clutch Field Coil C100. GO to J10 .
Start the engine.
Select MAX A/C on the HVAC module. No
Measure the voltage between ground and A/C compressor clutch field GO to J13 .
coil C100-1, circuit CH401 (VT/WH), harness side.

J10 CHECK THE GROUND AT THE A/C COMPRESSOR CLUTCH FIELD
COIL
Ignition OFF. Yes
Measure the resistance between ground and A/C compressor clutch GO to J11 .
field coil C100-2, circuit GD120 (BK/GN), harness side.
No
TEST the system for
normal operation.

J11 CHECK THE A/C COMPRESSOR CLUTCH FIELD COIL
Measure the resistance between the A/C compressor clutch field coil Yes
C100 terminals, component side. GO to J12 .
No
INSTALL a new A/C
compressor clutch field
coil. REFER to Section
412-01 . TEST the
system for normal
operation.
J12 CHECK THE A/C COMPRESSOR CLUTCH FIELD COIL FOR A
SHORT TO GROUND
Measure the resistance between the A/C compressor clutch field coil Yes
C100 terminals, component side and ground. ADJUST the A/C
Is the resistance greater than 10,000 ohms? compressor clutch gap.
REFER to Air
Conditioning (A/C) Clutch
Air Gap Adjustment in
system for normal
operation.
No
INSTALL a new A/C
compressor clutch field
coil. REFER to Section
412-01 . TEST the
system for normal
operation.
J13 CHECK THE VOLTAGE TO THE A/C CLUTCH RELAY COIL
Ignition OFF. Yes
Disconnect: A/C Clutch Relay. GO to J14 .
Start the engine.
Measure the voltage between A/C clutch relay socket pin 1, circuit No
CBP02 (GN) and ground. VERIFY Central Junction
Box (CJB) fuse 2 (10A) is
OK. If OK, REPAIR
circuit CBP02 (GN) for an
open. TEST the system
short.
J14 CHECK THE A/C CLUTCH RELAY
circuit loads. Use only the test light recommended in the Special GO to J17 .
Tools table at the beginning of this section or equivalent. To avoid
connector terminal damage, use the Flex Probe Kit for the test No
light probe connection to the vehicle. Do not use the test light GO to J15 .
probe directly on any connector.
Start the engine.
controls.
With the engine running, connect a 12-volt test light between A/C clutch
relay socket pin 1, circuit CBP02 (GN) and A/C clutch relay socket pin
2, circuit CH302 (WH/BN).
J15 CHECK THE A/C CLUTCH RELAY COIL SWITCHED GROUND
Ignition OFF. Yes
Disconnect: PCM C175B. REPAIR circuit CH302
Ignition ON. (WH/BN) for a short to
Measure the voltage between ground and PCM C175B-25, circuit voltage. TEST the
CH302 (WH/BN), harness side. system for normal
operation.
No
GO to J16 .

J16 CHECK THE A/C CLUTCH RELAY COIL SWITCHED GROUND
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between A/C clutch relay socket pin 2, circuit GO to J23 .
CH302 (WH/BN) and PCM C175B-25, circuit CH302 (WH/BN), harness
side. No
REPAIR circuit CH302
TEST the system for
normal operation.
J17 CHECK THE VOLTAGE TO THE A/C CLUTCH RELAY SWITCH
CONTACTS
Measure the voltage between ground and the A/C clutch relay socket Yes
pin 3, circuit SBB29 (GY/RD). GO to J18 .
No
VERIFY Battery Junction
Box (BJB) fuse 29 (10A)
is OK. If OK, REPAIR
circuit SBB29 (GY/RD)
system for normal
operation. If not OK,
REFER to the Wiring
Diagrams manual to
short.

J18 CHECK THE A/C COMPRESSOR CLUTCH FIELD COIL VOLTAGE
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between A/C clutch relay socket pin 5, circuit INSTALL a new A/C
CH401 (VT/WH) and A/C compressor clutch field coil C100-1, circuit clutch relay. TEST the
CH401 (VT/WH), harness side. system for normal
operation.
No
(VT/WH) for an open.
TEST the system for
normal operation.

J19 CHECK THE A/C REQUEST CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Instrument Panel Cluster (IPC) C220. (GY/YE) for a short to
Ignition ON. voltage. CLEAR the
Measure the voltage between ground and HVAC module C228A-4, DTCs. REPEAT the self-
circuit CH434 (GY/YE), harness side. test. TEST the system for
normal operation.
No
GO to J20 .

J20 CHECK THE A/C REQUEST CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between HVAC module C228A-4, circuit GO to J22 .
CH434 (GY/YE), harness side and IPC C220-12, circuit CH434
(GY/YE), harness side. No
(GY/YE) for an open.
CLEAR the DTCs.
TEST the system for
normal operation.

J21 CHECK THE EVAPORATOR TEMPERATURE AIR TEMPERATURE
SENSOR
Ignition OFF. Yes
Disconnect: Evaporator Discharge Air Temperature Sensor C296. GO to J24 .
CARRY OUT the Evaporator Discharge Air Temperature Sensor
component test in this section. No
Did the evaporator discharge air temperature sensor test OK? INSTALL a new
evaporator discharge air
temperature sensor.
01 . TEST the system for
normal operation.
J22 CHECK THE HVAC MODULE CONNECTION
pushed-out terminals. Section 412-01 . TEST
damaged terminals. the system for normal
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
J23 CHECK THE PCM CONNECTION
corroded connector.
J24 CHECK THE IPC CONNECTION
Inspect the IPC connectors for: INSTALL a new IPC .
Connect and correctly seat all the IPC connectors.
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
Pinpoint Test K: The Air Conditioning (A/C) is Always On — A/C Compressor Does Not Cycle
Normal Operation
When A/C is requested the HVAC module grounds a circuit to the Instrument Panel Cluster (IPC). The IPC then
sends an A/C request through the High Speed Controller Area Network (HS-CAN) to the PCM.
Voltage is provided to the A/C clutch relay coil and switch contacts. When A/C is requested and A/C line
pressures allow, a ground is provided to the A/C clutch relay coil from the PCM, energizing the A/C clutch relay.
When the PCM energizes the relay, voltage is supplied to the A/C clutch from the relay. Ground is supplied for
the A/C clutch.
temperature is critical for compressor engagement. The PCM uses the temperature measurement to turn the
A/C compressor off before the evaporator temperature is cold enough to freeze the condensation on the
evaporator core.

PCM
IPC
A/C clutch relay
A/C compressor clutch air gap
PINPOINT TEST K: THE AIR CONDITIONING (A/C) IS ALWAYS ON — A/C COMPRESSOR DOES NOT
CYCLE
Result / Action to
Test Step
Take
K1 CHECK THE A/C EVAPORATOR TEMPERATURE (EVAP_TEMP)
INSTRUMENT PANEL CLUSTER (IPC) PID
Ignition ON. Yes
Allow the vehicle exterior and interior to stabilize to the ambient GO to K2 .
temperature.
Enter the following diagnostic mode on the scan tool: IPC DataLogger. No
Monitor the EVAP_TEMP IPC PID GO to K8 .
Does the EVAP_TEMP IPC PID read similar to the ambient
temperature?
K2 CHECK AIR CONDITIONING COMPRESSOR COMMANDED STATE
(ACC_CMD) PCM PID WITH THE A/C OFF
Enter the following diagnostic mode on the scan tool: PCM DataLogger. Yes
Select PANEL and press the A/C button (indicator off) on the HVAC GO to K3 .
controls.
Monitor the ACC_CMD PCM PID No
Does the ACC_CMD PCM PID read OFF? GO to K10 .
K3 CHECK THE A/C RELAY
Ignition OFF. Yes
Disconnect: A/C Clutch Relay. GO to K4 .
Start the engine.
OBSERVE A/C compressor clutch operation. No
Does the A/C compressor clutch disengage? GO to K6 .
K4 CHECK THE A/C CLUTCH RELAY
circuit loads. Use only the test light recommended in the Special GO to K5 .
Tools table at the beginning of this section or equivalent. To avoid
connector terminal damage, use the Flex Probe Kit for the test light No
probe connection to the vehicle. Do not use the test light probe INSTALL a new A/C
directly on any connector. clutch relay. TEST the
system for normal
Connect a 12-volt test light between A/C clutch relay socket pin 1, circuit operation.
CBP02 (GN) and A/C clutch relay socket pin 2, circuit CH302 (WH/BN).

K5 CHECK THE A/C CLUTCH RELAY COIL SWITCHED GROUND CIRCUIT
Ignition OFF. Yes
Disconnect: PCM C175B. GO to K10 .
Measure the resistance between ground and PCM C175B-25, circuit
CH302 (WH/BN), harness side. No
ground. TEST the
system for normal
operation.
K6 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR CLUTCH FIELD
COIL
Ignition OFF. Yes
Disconnect: A/C Compressor Clutch Field Coil C100. REPAIR circuit CH401
Ignition ON. (VT/WH) for a short to
Measure the voltage between A/C compressor clutch field coil C100-1, voltage. TEST the
circuit CH401 (VT/WH), harness side and ground. system for normal
operation.
No
GO to K7 .

K7 CHECK THE A/C COMPRESSOR CLUTCH AIR GAP
Measure the A/C compressor clutch air gap at 3 equally spaced locations Yes
between the clutch hub and the A/C compressor clutch pulley. ADJUST the A/C
compressor clutch
gap. REFER to Air
Conditioning (A/C)
Clutch Air Gap
Adjustment in this
section. TEST the
system for normal
operation.
No
INSTALL a new A/C
compressor clutch.
REFER to Section
412-01 . TEST the
system for normal
Is the A/C compressor clutch air gap average less than 0.3 mm operation.
(0.012 in)?
K8 CHECK THE EVAPORATOR TEMPERATURE AIR TEMPERATURE
SENSOR
Ignition OFF. Yes
Disconnect: Evaporator Discharge Air Temperature Sensor C296. GO to K9 .
CARRY OUT the Evaporator Discharge Air Temperature Sensor
component test in this section. No
Did the evaporator discharge air temperature sensor test OK? INSTALL a new
evaporator discharge
air temperature
sensor. REFER to
operation.
K9 CHECK THE IPC CONNECTION
Inspect the IPC connectors for: INSTALL a new IPC .
corrosion. REFER to Section
pushed-out terminals. 413-01 . TEST the
Connect and correctly seat all the IPC connectors. operation.
The system is
this time. The concern
may have been
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
K10 CHECK THE PCM CONNECTION
corrosion. REFER to Section
pushed-out terminals. 303-14 . TEST the
Connect and correctly seat all the PCM connectors. operation.
The system is
may have been
corroded connector.
Pinpoint Test L: The Air Conditioning (A/C) is Always On — A/C Mode Always Commanded ON
Normal Operation
Under normal operation, when A/C is requested the HVAC module grounds a circuit to the Instrument Panel
Cluster (IPC). The IPC then sends an A/C request through the High Speed Controller Area Network (HS-CAN)
to the PCM.
DTC 52 (A/C Select Drive Circuit/Performance) — This DTC sets when any of the following occur during
a self-test:
The module senses ground on the A/C request circuit when the circuit is not grounded by the
The module senses voltage on the A/C request circuit when the circuit is grounded by the HVAC
module, indicating a short directly to voltage.
The module senses no voltage on the A/C request circuit when the relay is not grounded by the
HVAC module, indicating an open.

PCM
HVAC module
PINPOINT TEST L: THE AIR CONDITIONING (A/C) IS ALWAYS ON — A/C MODE ALWAYS COMMANDED
ON
DTC Chart.

L1 CHECK THE HVAC MODULE FOR DTCs
Ignition ON. Yes
Select OFF on the HVAC controls. GO to L2 .
Check for HVAC DTCs retrieved during the self-test. No
Is DTC 52 present? GO to L3 .
L2 CHECK THE A/C REQUEST CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to L8 .
Disconnect: Instrument Panel Cluster (IPC) C220.
Ignition ON. No
Measure the resistance between ground and HVAC module REPAIR circuit CH434 (GY/YE)
C228A-4, circuit CH434 (GY/YE), harness side. for a short to ground. CLEAR the
operation.

L3 CHECK THE AIR CONDITIONING SWITCH (A/C_SWITCH)
IPC PID WITH THE A/C OFF
Enter the following diagnostic mode on the scan tool: IPC Yes
DataLogger. GO to L4 .
Monitor the A/C_SWITCH IPC PID
Select PANEL and press the A/C button (indicator off) on the No
HVAC controls. GO to L6 .
Does the A/C_SWITCH IPC PID read INACTIVE?
L4 CHECK THE AIR CONDITIONING REQUEST SIGNAL
(AC_REQ) PCM PID WITH THE A/C OFF
Select PANEL and press the A/C button (indicator off) on the
HVAC controls. No
Monitor the AC_REQ PCM PID GO to L7 .
Does the AC_REQ PCM PID read NO?
L5 CHECK AIR CONDITIONING COMPRESSOR COMMANDED

STATE (ACC_CMD) PCM PID WITH THE A/C OFF
Select PANEL and press the A/C button (indicator off) on the
HVAC controls. No
Monitor the ACC_CMD PCM PID GO to L7 .
Does the ACC_CMD PCM PID read OFF?
L6 CHECK THE HVAC MODULE CONNECTION
damaged terminals.
Operate the system and verify the concern is still present. The system is operating correctly
Is the concern still present? at this time. The concern may
corroded connector. CLEAR the
operation.
L7 CHECK THE PCM CONNECTION
Inspect the PCM connectors for: INSTALL a new PCM. REFER to
corrosion. Section 303-14 . TEST the system
pushed-out terminals. for normal operation.
damaged terminals.
Connect and correctly seat all the PCM connectors. No
corroded connector.
L8 CHECK THE IPC CONNECTION
Inspect the IPC connectors for: INSTALL a new IPC . REFER to
corrosion. Section 413-01 . TEST the system
pushed-out terminals. for normal operation.
damaged terminals.
Connect and correctly seat all the IPC connectors. No
operation.
Pinpoint Test M: Temperature Control is Inoperative/Does Not Operate Correctly
Normal Operation
The HVAC module supplies voltage and ground to the temperature blend door actuator motor through the
actuator motor circuits to rotate the temperature blend door actuator. To reverse the temperature blend door
actuator rotation, the HVAC module reverses the voltage and ground on the circuits.
The temperature blend door actuator feedback resistor is supplied a 5-volt reference voltage and ground from
the HVAC module. The HVAC module measures the resistance on the temperature blend door actuator
feedback circuit to determine the temperature blend door actuator position by the position of the actuator
feedback resistor wiper arm.
During an actuator calibration cycle, the HVAC module drives the temperature blend door until the door reaches
both internal stops in the HVAC case. If the temperature blend door is temporarily obstructed or binding during
a calibration cycle, the HVAC module may interpret this as the actual end of travel for the door. When this
condition occurs and the HVAC module commands the actuator to its end of travel, the airflow may not be the
expected temperature.
DTC 2-1 (Blend Feedback Circuit/Performance) — The module senses no changes in the feedback
circuit when motor movement is commanded and no motor electrical DTCs are present. This indicates
an open actuator motor, an open or shorted feedback circuit, an open feedback resistor reference
voltage circuit, or an internal electrical or mechanical failure.
DTC 2-2 (Blend Motor Driver Circuit/Performance) — The module senses lower than expected voltage
on an actuator motor circuit when voltage is applied to drive the motor. This indicates a short to ground
or the module senses greater than expected voltage on the actuator motor circuit when ground is applied
to drive the motor, indicating a short to voltage.
DTC 2-3 (Blend Actuator Calibration Performance) — The module senses the actuator has moved
outside its travel limits during calibration. This indicates broken/disconnected linkage or door or an
internal mechanical failure.

HVAC module
Temperature blend door is binding or stuck
PINPOINT TEST M: TEMPERATURE CONTROL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

M1 CHECK THE HVAC MODULE FOR DTCs
NOTE: If HVAC DTC 4-4 is present, GO to Pinpoint Test D Yes

and diagnose that DTC first. For DTC 2-1 , GO to M2 .
Ignition ON. For DTC 2-2 , GO to M9 .
Check for HVAC DTCs retrieved during the self-test. For DTC 2-3 , GO to M8 .
Are HVAC DTCs present?
No
GO to M7 .
M2 CHECK THE ACTUATOR MOTOR AND CIRCUITS
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to M4 .
circuit CH235 (BU), harness side and HVAC module C228A- No
19, circuit CH236 (WH), harness side. GO to M3 .

M3 CHECK THE TEMPERATURE BLEND DOOR ACTUATOR
Ignition OFF. Yes
Disconnect: Temperature Blend Door Actuator C2092. REPAIR circuit CH235 (BU) or
CARRY OUT the Temperature Blend Door Actuator CH236 (WH) for an open or high
component test in this section. resistance. REPEAT the self-test.
Did the temperature blend door actuator test OK? TEST the system for normal
operation.
No
GO to M13 .
M4 CHECK THE POTENTIOMETER LOW- AND HIGH-SIDE
RESISTANCE
Measure the high-side resistance between HVAC module Yes
C228A-12, circuit CH232 (WH/BN), harness side and HVAC GO to M5 .
module C228A-11, circuit CH206 (YE/VT), harness side.
No
CARRY OUT the Temperature
Blend Door Actuator component
test in this section. INSTALL a new
defrost/panel/floor mode door
actuator if necessary. REFER to
Section 412-01 .
If the actuator tests OK and:
If the high-side resistance only is

circuit CH232 (WH/BN) for an
open.
Measure the low-side resistance between HVAC module If the high-side resistance only is
C228A-2, circuit CH233 (VT/BN), harness side and HVAC less than 215 ohms, REPAIR
module C228A-11, circuit CH206 (YE/VT), harness side. circuits CH206 (YE/VT) and CH232
(WH/BN) for a short together.

circuit CH233 (VT/BN) for an open.

less than 215 ohms, REPAIR
circuits CH206 (YE/VT) and CH233
(VT/BN) for a short together.
If both the high-side and low-side

resistance is greater than 4,375
ohms, REPAIR circuit CH206
Are the resistances between 215 and 4,375 ohms? (YE/VT) for an open.
Once the repair is complete,

CALIBRATE the actuators. REFER
to Calibrating the HVAC Actuators
in this section. TEST the system
M5 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition ON. Yes
Measure the voltage between ground and HVAC module REPAIR circuit CH206 (YE/VT) for
C228A-11, circuit CH206 (YE/VT), harness side. a short to voltage. CLEAR the
No
GO to M6 .
M6 CHECK THE ACTUATOR FEEDBACK CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between ground and HVAC module GO to M7 .
C228A-11, circuit CH206 (YE/VT), harness side.
No
REPAIR circuit CH206 (YE/VT) or
CH233 (VT/BN) for a short to

M7 CHECK THE TEMPERATURE BLEND DOOR ACTUATOR
OPERATION
Ignition OFF. Yes
Disconnect: HVAC Module C228A (If not previously GO to M14 .
disconnected).
Measure the resistance between HVAC module C228A-2, No
circuit CH233 (VT/BN), harness side and HVAC module GO to M8 .
C228A-11, circuit CH206 (YE/VT), harness side.

CH235 (BU), harness side.
CH236 (WH), harness side.
Remove the fused jumpers.

CH235 (BU), harness side.
CH236 (WH), harness side.
Does the resistance smoothly increase to approximately

3,500 ohms and/or decrease to approximately 290 ohms
when the jumpers are connected?
M8 CHECK THE TEMPERATURE BLEND DOOR AND LINKAGE
Disconnect: Temperature Blend Door Actuator C2092. Yes
REMOVE the temperature blend door actuator. REFER to REPAIR the temperature blend
Section 412-01 . door or linkage REINSTALL the
INSPECT the temperature blend door and linkage for a temperature blend door actuator.
broken, loose or binding condition. CALIBRATE the actuators. REFER
Is any condition found during inspection? to Calibrating the HVAC Actuators
in this section. TEST the system
No
GO to M13 .
M9 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: HVAC Module C228A. REPAIR circuit CH235 (BU) or
Ignition ON. CH236 (WH) for a short to voltage.
Measure the voltage between ground and: TEST the system for normal
HVAC module C228A-17, circuit CH235 (BU), harness operation.
side.
HVAC module C228A-19, circuit CH236 (WH), No
harness side. GO to M10 .

M10 CHECK THE ACTUATOR MOTOR DRIVE CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between ground and: GO to M11 .
HVAC module C228A-17, circuit CH235 (BU), harness
side. No
HVAC module C228A-19, circuit CH236 (WH), REPAIR circuit CH235 (BU) or
harness side. CH236 (WH) for a short to ground.
CLEAR the DTCs. REPEAT the
self-test. TEST the system for
normal operation.

M11 CHECK THE ACTUATOR MOTOR AND CIRCUIT
RESISTANCE
circuit CH235 (BU), harness side and HVAC module C228A- GO to M14 .
19, circuit CH236 (WH), harness side.
No
GO to M12 .

M12 CHECK THE ACTUATOR MOTOR CIRCUITS FOR A
SHORT TOGETHER
Disconnect: Temperature Blend Door Actuator C2092. Yes
Measure the resistance between HVAC module C228A-17, GO to M13 .
circuit CH235 (BU), harness side and HVAC module C228A-
19, circuit CH236 (WH), harness side. No
REPAIR circuits CH235 (BU) and
CH236 (WH) for a short together.
self-test. TEST the system for
normal operation.

M13 CHECK THE ACTUATOR CONNECTION
Disconnect the temperature blend door actuator connector. Yes
Inspect the temperature blend door actuator connector for: INSTALL a new temperature blend
corrosion. door actuator. REFER to Section
pushed-out terminals. 412-01 . CALIBRATE the
damaged terminals. actuators. REFER to Calibrating
REINSTALL the temperature blend door actuator, If removed. the HVAC Actuators in this section.
Connect and correctly seat the temperature blend door TEST the system for normal
actuator connector. operation.
CALIBRATE the actuators. REFER to Calibrating the HVAC
Actuators in this section. No
Is the concern still present? at this time. The concern may have
been caused by a loose or
M14 CHECK THE HVAC MODULE CONNECTION
damaged terminals.
Operate the system and verify the concern is still present. The system is now operating
Is the concern still present? correctly at this time. The concern
may have been caused by a
foreign object in the HVAC case or
temporary binding that restricted
actuator door travel. CHECK any
actuator external linkage. If
condition recurs, INSPECT
actuator linkage and door for
binding and CHECK HVAC case
for foreign objects.
Pinpoint Test N: The Blower Motor is Inoperative
Normal Operation
The blower motor relay coil and relay switch contacts receive voltage. The blower motor relay is energized
when the coil receives ground from the HVAC module, if the HVAC power is on. When the relay coil is
energized, voltage is delivered to the blower motor. Ground for the blower motor is provided from the blower
resistor or the blower switch (HI). The blower resistor is grounded through the blower motor switch. The blower
motor switch is grounded. The blower motor switch is part of the HVAC module and can not be replaced
separately.
DTC 51 (Blower Relay Driver Circuit/Performance) — This DTC sets when any of the following occur:
The module senses ground on the relay coil ground circuit when the relay is not grounded by the
The module senses voltage on the relay coil ground circuit when the relay is grounded by the
HVAC module, indicating a short directly to voltage.
The module senses no voltage on the relay coil ground circuit when the relay is not grounded by
the HVAC module, indicating an open.

Fuse
Blower motor
Blower motor relay
HVAC module
PINPOINT TEST N: THE BLOWER MOTOR IS INOPERATIVE
Result / Action to
Test Step
Take
N1 CHECK THE HVAC MODULE FOR DTCs
Ignition ON. Yes
CARRY OUT the HVAC module self-test. GO to N2 .
Is DTC 51 present? No
GO to N6 .
N2 CHECK THE BLOWER MOTOR RELAY COIL SUPPLY VOLTAGE
Ignition OFF. Yes
Disconnect: Blower Motor Relay. GO to N3 .
Ignition ON.
Measure the voltage between blower motor relay socket pin 1, circuit No
CBP21 (BU/GY) and ground. REPAIR circuit CBP21
(BU/GY) for an open.
CLEAR the DTCs.
TEST the system for
normal operation.
N3 CHECK THE BLOWER MOTOR RELAY COIL
circuit loads. Use only the test light recommended in the Special INSTALL a new blower
Tools table at the beginning of this section or equivalent. To avoid motor relay. CLEAR the
connector terminal damage, use the Flex Probe Kit for the test light DTCs. REPEAT the
probe connection to the vehicle. Do not use the test light probe self-test. TEST the
directly on any connector. system for normal
operation.
Select PANEL on the HVAC controls.
Connect a 12-volt test light between blower motor relay socket pin 1, No
circuit CBP21 (BU/GY) and blower motor relay socket pin 2, circuit GO to N4 .
CH123 (VT/GN).
N4 CHECK THE BLOWER MOTOR RELAY COIL GROUND CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Ignition ON. (VT/GN) for a short to
Measure the voltage between blower motor relay socket pin 2, circuit voltage. CLEAR the
CH123 (VT/GN) and ground. DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
No
GO to N5 .
N5 CHECK THE BLOWER MOTOR RELAY COIL GROUND CIRCUIT FOR
AN OPEN
Ignition OFF. Yes
Measure the resistance between blower motor relay socket pin 2, circuit GO to N12 .
CH123 (VT/GN) and HVAC module C228A-3, circuit CH123 (VT/GN),
harness side. No
(VT/GN) for an open.
CLEAR the DTCs.
TEST the system for
normal operation.
N6 CHECK THE BLOWER MOTOR RELAY SWITCH CONTACTS SUPPLY
VOLTAGE
Ignition OFF. Yes
Disconnect: Blower Motor Relay. GO to N7 .
Ignition ON.
Measure the voltage between blower motor relay socket pin 3, circuit No
SBB04 (GN/RD) and ground. VERIFY Battery
Junction Box (BJB)
OK, REPAIR circuit
SBB04 (GN/RD) for an
Wiring Diagrams
circuit short.
N7 CHECK THE BLOWER MOTOR RELAY
Select the highest blower motor speed on HVAC controls. Yes
Connect a fused jumper lead between blower motor relay socket pin 3, INSTALL a new blower
circuit SBB04 (GN/RD) and blower motor relay socket pin 5, circuit motor relay. TEST the
CH402 (YE/GN). system for normal
operation.
No
GO to N8 .
Does the blower motor operate?
N8 CHECK THE BLOWER MOTOR GROUND CIRCUIT
Ignition OFF. Yes
Disconnect: Blower Motor C2004. GO to N9 .
Turn the blower motor switch to the HI position.
Measure the resistance between blower motor connector C2004-2, circuit No
CH430 (VT/OG), harness side and ground. GO to N10 .

N9 CHECK THE BLOWER MOTOR VOLTAGE CIRCUIT FOR AN OPEN
Measure the resistance between blower motor relay socket pin 5, circuit Yes
CH402 (YE/GN) and blower motor C2004-1, circuit CH402 (YE/GN), INSTALL a new blower
harness side. motor. TEST the
system for normal
operation.
No
(YE/GN) for an open.
TEST the system for
normal operation.

N10 CHECK THE BLOWER MOTOR GROUND CIRCUIT FOR AN OPEN
Disconnect: HVAC Module C228B. Yes
Measure the resistance between HVAC module C228B-6, circuit CH430 GO to N11 .
(VT/OG), harness side and blower motor C2004-2, circuit CH430
(VT/OG), harness side. No
(VT/OG) for an open.
TEST the system for
normal operation.

N11 CHECK THE BLOWER MOTOR SWITCH GROUND CIRCUIT FOR AN
OPEN
Measure the resistance between HVAC module C228B-3, circuit GD115 Yes
(BK/GY), harness side and ground. GO to N12 .
No
(BK/GY) for an open.
TEST the system for
normal operation.

N12 CHECK THE HVAC MODULE CONNECTION
pushed-out terminals. Section 412-01 . TEST
damaged terminals. the system for normal
The system is
may have been caused
by a loose or corroded
connector. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
Pinpoint Test O: The Blower Motor Does Not Operate Correctly
Normal Operation
Under normal operation, the blower motor is provided a ground through part of the blower resistor in LO, MED-
LO and MED-HI blower setting. The blower motor resistor is grounded through the blower motor switch in any
setting except HI. In HI, the blower motor is grounded directly through the blower motor switch. The blower
switch is provided a ground. The blower motor switch is part of the HVAC module and can not be replaced
separately.
DTC 51 (Blower Relay Driver Circuit/Performance) — This DTC sets when any of the following occur:
The module senses ground on the relay coil ground circuit when the relay is not grounded by the
The module senses voltage on the relay coil ground circuit when the relay is grounded by the
HVAC module, indicating a short directly to voltage.
The module senses no voltage on the relay coil ground circuit when the relay is not grounded by
the HVAC module, indicating an open.

HVAC module
PINPOINT TEST O: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY
Result / Action to
Test Step
Take
O1 CHECK THE HVAC MODULE FOR DTCs
Ignition ON. Yes
CARRY OUT the HVAC module self-test. REPAIR circuit CH123
Check for HVAC DTCs retrieved during the self-test. (VT/GN) for a short to
Is DTC 51 present? ground. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
No
GO to O2 .
O2 CHECK THE BLOWER MOTOR OPERATION
Turn the function selector switch to the FLOOR position. Yes
Select all blower speed positions. If the blower motor will
Does the blower motor operate in any position? not turn off, REPAIR
circuit CH402
(YE/GN) for a short to
voltage. TEST the
system for normal
operation.
If the blower motor

does not operate in HI
setting only, GO to
O3 .
If the blower motor

does not operate in
LO, MED-LO or MED-
HI setting only, GO to
O4 .
If the blower motor

operates in HI setting
only, GO to O6 .
For all other

symptoms, GO to O7 .
No
GO to Pinpoint Test
N.
O3 CHECK THE BLOWER MOTOR GROUND CIRCUIT TO THE BLOWER
MOTOR SWITCH FOR AN OPEN
Ignition OFF. Yes
Disconnect: HVAC Module C228B. GO to O9 .
Disconnect: Blower Motor C2004.
Measure the resistance between HVAC module C228B-6, circuit CH430 No
(VT/OG), harness side and blower motor C2004-2, circuit CH430 (VT/OG), REPAIR circuit CH430
harness side. (VT/OG) for an open.
TEST the system for
normal operation.

O4 CHECK THE BLOWER MOTOR RESISTOR
circuit loads. Use only the test light recommended in the Special INSTALL a new
Tools table at the beginning of this section. To avoid connector blower motor resistor.
terminal damage, use the Flex Probe Kit for the test light probe REFER to Section
connection to the vehicle. Do not use the test light probe directly on 412-01 . TEST the
any connector. system for normal
operation.
Ignition OFF.
Disconnect: Blower Motor Resistor C293. No
Ignition ON. GO to O5 .
Turn the function selector switch to the FLOOR position.
For LO inoperative
For LO inoperative : With the blower motor switch in the LO speed

position, connect a 12-volt test light between blower motor resistor C293-
2, circuit CH430 (VT/OG), harness side and blower motor resistor C293-4,
circuit CH427 (BN), harness side.
For MED-LO inoperative

For MED-LO inoperative : With the blower motor switch in the MED-LO
speed position, connect a 12-volt test light between blower motor resistor
C293-2, circuit CH430 (VT/OG), harness side and blower motor resistor
C293-1, circuit CH428 (GN/WH), harness side.
For MED-HI inoperative
For MED-HI inoperative : With the blower motor switch in the MED-HI
speed position, connect a 12-volt test light between blower motor resistor
C293-2, circuit CH430 (VT/OG), harness side and blower motor resistor
C293-3, circuit CH429 (GY/BN), harness side.
O5 CHECK THE BLOWER MOTOR RESISTOR TO BLOWER MOTOR
SWITCH CIRCUITS
Disconnect: HVAC Module C228B. Yes
GO to O9 .
For LO inoperative
No
(BN), CH428
(GN/WH) or CH429
TEST the system for
normal operation.
For LO inoperative , measure the resistance between HVAC module

C228B-1, circuit CH427 (BN), harness side and blower motor resistor
C293-4, circuit CH427 (BN), harness side.
For MED-LO inoperative

For MED-LO inoperative , measure the resistance between HVAC
module C228B-4, circuit CH428 (GN/WH), harness side and blower motor
resistor C293-1, circuit CH428 (GN/WH), harness side.
For MED-HI inoperative
For MED-HI inoperative , measure the resistance between HVAC module

C228B-5, circuit CH429 (GY/BN), harness side and blower motor resistor
C293-3, circuit CH429 (GY/BN), harness side.
O6 CHECK THE BLOWER MOTOR GROUND CIRCUIT TO THE BLOWER

MOTOR RESISTOR FOR AN OPEN
Ignition OFF. Yes
Disconnect: Blower Motor C2004. INSTALL a new
Disconnect: Blower Motor Resistor C293. blower motor resistor.
Measure the resistance between blower motor resistor C293-2, circuit REFER to Section
CH430 (VT/OG), harness side and blower motor C2004-2, circuit CH430 412-01 . TEST the
(VT/OG), harness side. system for normal
operation.
No
(VT/OG) for an open.
TEST the system for
normal operation.

O7 CHECK THE BLOWER MOTOR RESISTOR CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Blower Motor C2004. GO to O8 .
Disconnect: Blower Motor Resistor C293.
Disconnect: HVAC Module C228B. No
Measure the resistance between ground and blower motor resistor: REPAIR the affected
C293-1, circuit CH428 (GN/WH), harness side. circuit for a short to
C293-3, circuit CH429 (GY/BN), harness side. ground. TEST the
C293-2, circuit CH430 (VT/OG), harness side. system for normal
operation.

O8 CHECK THE BLOWER MOTOR RESISTOR CIRCUITS FOR SHORTS
TOGETHER
Measure the resistance between blower motor resistor C293, harness side Yes
using the following chart: GO to O9 .
Blower Motor Blower Motor No

Resistor Circuit Resistor Circuit REPAIR the affected
circuits. TEST the
C293-1 CH428 C293-2 CH430 system for normal
(GN/WH) (VT/OG) operation.
C293-1 CH428 C293-3 CH429
(GN/WH) (GY/BN)
C293-1 CH428 C293-4 CH427 (BN)
(GN/WH)
C293-2 CH430 C293-3 CH429
(VT/OG) (GY/BN)
C293-2 CH430 C293-4 CH427 (BN)
(VT/OG)
C293-3 CH429 C293-4 CH427 (BN)
(GY/BN)

O9 CHECK THE HVAC MODULE CONNECTION
Inspect the HVAC module connectors for: INSTALL a new
corrosion. HVAC module.
pushed-out terminals. REFER to Section
damaged terminals. 412-01 . TEST the
Connect and correctly seat all the HVAC module connectors. system for normal
No
The system is
may have been
corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
Pinpoint Test P: All HVAC Functions Inoperative
Normal Operation
The HVAC module receives a ground. The HVAC module is supplied constant battery voltage and ignition
voltage.

HVAC module
Battery
PINPOINT TEST P: ALL HVAC FUNCTIONS INOPERATIVE

P1 CHECK THE HVAC MODULE VOLTAGE SUPPLY CIRCUITS
FOR AN OPEN
Ignition OFF. Yes
Disconnect: HVAC Module C228A. GO to P2 .
Ignition ON.
With the engine running, measure the voltage between ground No
and: REPAIR circuit SBP07 (WH/RD)
HVAC module C228A-10, circuit SBP07 (WH/RD), or CBP21 (BU/GY) for high
harness side. resistance. CLEAR all CMDTCs .
HVAC module C228A-14, circuit CBP21 (BU/GY), REPEAT the self-test.
harness side.
P2 CHECK THE HVAC MODULE GROUND CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Measure the resistance between ground and HVAC module GO to P3 .
C228A-13, circuit GD115 (BK/GY), harness side.
No
REPAIR circuit GD115 (BK/GY)
for high resistance. CLEAR all
CMDTCs . REPEAT the self-test.
operation.

P3 CHECK THE HVAC MODULE CONNECTION
damaged terminals.
Component Tests
Evaporator Discharge Air Temperature Sensor
Ambient Temperature Resistance

0-10°C (32-50°F) 5,892-9,893 ohms
10-20°C (50-68°F) 3,689-6,048 ohms
20-25°C (68-77°F) 2,950-3,805 ohms
25-30°C (77-86°F) 2,374-3,050 ohms
30-35°C (86-95°F) 1,923-2,460 ohms
35-40°C (95-104°F) 1,566-1,996 ohms
40-50°C (104-122°F) 1,057-1,630 ohms
Blower Motor Resistor
Blower Motor Resistor Pins Resistance

4 and 2 2.0-2.6 ohms
2 and 3 0.2-0.4 ohms
2 and 1 0.8-1.1 ohms
Defrost/Panel/Floor Mode Door Actuator
Actuator Pins Approx. Resistance

1 and 6 30-40 ohms
2 and 4 215-4,375 ohms
3 and 4 215-4,375 ohms
2 and 3 2,800-4,200 ohms
Temperature Blend Door Actuator

1 and 6 30-40 ohms
2 and 4 215-4,375 ohms
3 and 4 215-4,375 ohms
2 and 3 2,800-4,200 ohms
Air Inlet Mode Door Actuator

1 and 6 30-40 ohms
Heater Core
1. NOTE: If a heater core leak is suspected, test he heater core by following the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking the
heater system thoroughly.
Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in
the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater
core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-
specified clamps can cause leakage at the heater hose connection and damage the heater core.
Check the integrity of the heater hose clamps.

Heater Core — Plugged
1. Verify that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, check the heater core inlet and outlet hoses to
see if they are hot.
4. If the outlet only is not hot the heater core may have an air pocket or may be plugged.
5. If the inlet only is not hot the thermostat may not be working correctly.
Heater Core — Pressure Test
Use the Pressure Test Kit to carry out the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system.
2. Disconnect the heater hoses from the heater core.
3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube.
4. Fill the heater core and heater hoses with water and install the plug BT-7422-B and the adapter BT-
7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater
core.
7. Observe the pressure gauge for a minimum of 3 minutes.
8. If the pressure drops, check the heater hose connections to the heater core tubes for leaks. If the heater
hoses do not leak, remove the heater core from the vehicle and carry out the bench test.
Heater Core — Bench Test
1. Remove the heater core from the vehicle.
2. Drain all of the coolant from the heater core.

3. Connect the 101 mm (4 in) test heater hoses with plug and adapter to the heater core tubes. Then
connect the Pressure Test Kit to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Evaporator/Condenser Core — On-Vehicle Leak Test
1. Discharge and recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and
Charging in this section.
2. Disconnect the suspect evaporator core or condenser core from the A/C system.
3. Clean the manifold fittings.
4. Connect the appropriate test fittings from the A/C Flush Adapter Kit to the condenser or evaporator core
tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test
fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure
the valve opens when attached to the test fittings or install an adapter that will activate the valve. The
test is not valid if the shut-off valve does not open.
Attach the correct adapters from the Adapters/O-rings for Filter kit to the test fittings and connect the red
and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or
condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a
minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45
minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core or
condenser core. If the refrigerant is not completely removed from the oil, outgassing degrades the
vacuum and appears as a refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and
manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the
low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting
connections and gauge set connections before installing a new evaporator core or condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low
pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark.
If the low pressure gauge reading rises 34 kPa (10 in-Hg) or more of vacuum from the 101 kPa
(30 in-Hg) position in 10 minutes, a leak is indicated.
If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or
condenser core. Then recheck for loss of vacuum.
If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check
for vacuum loss.
9. If the evaporator core or condenser core leaks, as verified by the above procedure, install a new
evaporator core or condenser core.
A/C Compressor — External Leak Test
1. Install the adapter from the A/C Flush Adapter Kit on the port of the A/C compressor, using the existing
manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling
station to the corresponding fittings on the adapter.
3. Attach the center hose of a manifold gauge set to a refrigerant container standing in an upright position.
4. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant
container to allow the refrigerant vapor to flow into the A/C compressor.
5. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft.
6. If an external leak is found, install a new A/C compressor.
7. When the leak test is complete, recover the refrigerant from the compressor.
SECTION 412-00: Climate Control System — General Information and Diagnostics 2011 Fiesta Workshop Manual
Refrigerant System Tests
Special Tool(s)
R-134a Refrigerant Management

Machine (SAE J-2788 Compliant)


Procedure 1 — Ambient Temperature at or Below 38°C (100°F)
NOTE: The system performance can be evaluated and diagnosed by analysis of the compressor suction and
discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.
NOTE: The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°
F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow Procedure 2.
NOTE: If the A/C compressor cycles at any time during this test, refer to the diagnostic table.
1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect an R-134a Manifold Gauge Set or R-134a Refrigerant Management Machine with high-pressure and
low-pressure gauges to the refrigerant system.
3. Set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, HI blower. If the vehicle
has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to
A/C ON.
4. Open all vehicle windows and leave the hood open for the test. Open the rear doors.
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the
vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range
that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant
Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction
Pressures chart.
11. Proceed to the Diagnostic Table.

Procedure 2 — Ambient Temperature Above 38°C (100°F)
NOTE: The system performance can be evaluated and diagnosed by analysis of the compressor suction and
discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.
NOTE: The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38°C (100°
F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow Procedure 2.
1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect an R-134a Manifold Gauge Set or R-134a Refrigerant Management Machine with high-pressure and
low-pressure gauges to the refrigerant system.
3. Set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, MED LO blower. If the
vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch,
set it to A/C ON.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if
equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the
vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range
that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant
Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction
Pressures chart.
11. Proceed to the Diagnostic Table.
Diagnostic Table
1. NOTE: The following table is used to guide diagnosis of the refrigerant system if operating pressures are
outside normal limits.
Refer to the chart below.
High
(Discharge) Low (Suction)
Pressure Pressure Component — Causes
High or Clutch High Condenser — inadequate airflow.
Cycling
High Normal to High Engine — overheating.
Normal to High Normal Refrigerant overcharge — air in refrigerant.
Normal to Low Normal to High A/C suction line — partially restricted or plugged. a
Normal to Low Low or Clutch Low refrigerant charge, A/C suction line — partially restricted or plugged.
Cycling b
Erratic Operation or Compressor Evaporator discharge air temperature sensor or A/C pressure transducer
Not Running — poor connection at A/C clutch connector. A/C electrical circuit erratic —
see A/C Electrical Circuit Wiring Diagram.
Normal to Low High Compressor — low performance.
Additional Possible Cause Components Associated With Inadequate Compressor Operation
Compressor Drive Belt — loose
Compressor Clutch — slipping
Clutch Coil Open — shorted, or loose mounting
HVAC Module
Clutch Wiring Circuit — high resistance, open or blown fuse
Compressor Operation Interrupted by PCM
Additional Possible Cause Components Associated With a Damaged Compressor
Incorrect Clutch Air-gap
Refrigerant Leaks
a Low pressure reading will be normal to high if restriction is downstream of service access valve.
b Low pressure reading will be low restriction is upstream of service access valve.
Diagnostics Manual
Air Conditioning (A/C) Odor Treatment
Special Tool(s)
Flexible Applicator Tool
258-00005
Material
Item Specification
Motorcraft® A/C Cooling Coil —
Coating
YN-29
WARNING: Carry out this procedure in a well-ventilated area with all vehicle windows and
doors opened. Carefully read cautionary information on product label. For EMERGENCY
MEDICAL INFORMATION, seek medical advice. On Ford/Motorcraft products in the USA or
Canada call: 1-800-959-3673. For additional information, consult the product Material Safety Data
Sheet (MSDS), if available. Failure to follow these instructions may result in serious personal
injury.
NOTE: There are typically 4 types of objectionable odors found in a vehicle:
Chemical odors
Environmental odors
Human and other interior-generated odors
Microbiological odors
Before determining that A/C odor treatment is 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. Most chemical odors are caused by fluid leaks or 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 only detected when the vehicle windows are open, or when
the climate control system is operating in a mode that allows for fresh air. Environmental odors cannot
be eliminated because they are external in source, but they may be minimized by switching to a climate
control setting that uses recirculated air.
NOTE: Human and other interior-generated odors occur while the source is present and may linger for a
short time after. These odors may be more noticeable during A/C operation. Human odors may be
eliminated by removing the source and cleaning the affected area.
NOTE: Microbiological odors, if in the A/C system, usually last for about 30 seconds after the system is
turned on. They will be detected while the A/C is turned on and using either outside or recirculated air.
Microbiological odors that occur in areas other than the A/C system (for example, water in doors or wet
carpeting) may last indefinitely and will be more intense when recirculated air is used. Microbiological
odors will not be present at temperatures at or below 10°C (50°F).
Microbiological odors can be eliminated by removing the source and treating the affected area. Standing
water must be allowed to drain and dry out. A/C systems may be treated by using A/C cooling coil
coating as described in the service procedure below.
Microbiological odors result from microbial growth supported by warm temperatures and moisture.
Microbiological odors are described as musty/mildew type smells and may occur on/in:
foam seals.
rubber seals.
adhesives.
standing water.
water soaked carpet/trim.
1. Identify the type of odor present in the vehicle. Do not proceed with A/C odor treatment if the odor
source is found to be outside of the A/C system. Refer to the following chart for examples.
Odor Source Odor Description

Chemical Odors
Coolant Sweet smell
Fuel Gasoline or diesel fuel smell
Oil Oil type or burning smell
Power Steering Fluid Oil type or burning smell
Transmission Fluid Oil type or burning smell
Washer Fluid Alcohol type smell
Gear Lube Garlic/sulfur smell
Refrigerant Oil Ether type smell
Carpet/trim Adhesives Fishy, urine or sweet smell
Evaporator Core Coating Wet cement type smell
Environmental Odors
Exhaust Exhaust, fuel or burning type smell
Industrial Pollutants Various smells
Dust Musty, mildew or wet cement type smell
Pollen Sweet smell
Tobacco Burning, tar smell
Human and Other Interior Generated Odors
Body Secretions Body odor
Perfuming Agents Sweet or fragrance smell
Clothing Musty, mildew or body odors
Food/Beverage Sweet, musty, mildew or fishy smell
Microbiological Odors
Microbiological Odors Occurring Musty, mildew smell lasting about 30 seconds after A/C is
Inside of A/C System turned on
Microbiological Odors Occurring Musty, mildew smell lasting indefinitely and possibly more
Outside of A/C System pronounced when using recirculated air
2. Identify the source of the odor.

Check the evaporator core drain tube for restriction.
Check the passenger and driver side carpet for moisture. If moisture is found, A/C odor
treatment is not necessary. Diagnose for a water leak as needed.
Check the blower motor and blower motor cover (if equipped) for moisture resulting from
water bypassing the cowl baffling system. If moisture is found, A/C odor treatment is not
necessary. Diagnose for a water leak as needed.
Check the cowl top panel and air inlet screen for standing water or foreign material. If
possible, remove any standing water and clean the air inlet screen using a wet/dry
vacuum.
3. Open all vehicle windows and doors.
4. Make sure that the A/C is off.
5. Set the following.

Select PANEL mode (A/C off).
Adjust the temperature setting to full warm.
Adjust the blower motor speed to HI.
6. Run the engine for 25 minutes to dry out the A/C system.
8. Remove the blower motor.
9. NOTE: Blower motor speed controls that are mounted outside of the evaporator core housing and
not exposed to the blower motor airflow do not need to be removed.
Remove the blower motor resistor (if equipped) or blower motor speed control (if equipped and
exposed to the inside of the evaporator core housing).
10. NOTICE: To avoid damage to the vehicle interior, do not spill or spray this product on any
interior surface.
Add one full bottle of A/C cooling coil coating to the Flexible Applicator Tool.
11. Insert the nozzle into the evaporator housing and direct the spray toward the evaporator core
face. Spray the entire evaporator core face until empty.
12. Install the blower motor and blower motor resistor (if equipped) or blower motor speed control (if
equipped).
13. Repeat Steps 4 through 6 to cure the evaporator core coating.

Diagnostics Manual
Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C
clutch pulley.
2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between
the clutch plate hub and the compressor shaft until the clearance is within specification.
Diagnostics Manual
Electronic Leak Detection
Special Tool(s)
Heated Pentode Halogen Leak
Detector
NOTE: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If
the surrounding air is contaminated with refrigerant gas, the Heated Pentode Halogen Leak Detector will
indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel 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.
NOTE: R-134a is heavier than air, and will tend to move downward from the source of the leak if
present. It is possible that a leak may not be detected if the leak detector tip is held above the leaking
fitting, line or component. Always be sure to thoroughly leak test below the fitting, line or component for
the presence of R-134a as well as leak testing above and around.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off and cool. The pressure reading may be higher if the engine is hot.
Leak test the refrigerant system using the Heated Pentode Halogen Leak Detector. Follow the
instructions included with the Heated Pentode Halogen Leak Detector for handling and operation
techniques.
Diagnostics Manual
Fluorescent Dye Leak Detection
Special Tool(s)
Cordless/Rechargeable True
UV LED Light ES
R-134a Loop/Add On Injector

Kit-Set

300-R0B40134AE or equivalent
R-134a Refrigerant
Management Machine (SAE J-
2788 Compliant)
300-R0B34788-PROE or
equivalent
R-134a Refrigerant
2788 Compliant)
R-134a Refrigerant
2788 Compliant)
Material
Item Specification
Stay-Brite® R-134a Leak —
Detection Dye
164-R6060 (Rotunda)
Fluorescent Dye Injection Using a R-134a Refrigerant Management Machine and Dye Injector —
Vehicles Requiring R-134a Addition
NOTE: This method of fluorescent dye injection requires the addition of R-134a from a R-134a
Refrigerant Management Machine or R-134a Manifold Gauge Set hooked to an external tank to charge
the dye into the refrigerant system. If adding fluorescent dye to a refrigerant system that is already fully
charged, the R-134a Loop/Add On Injector Kit-Set method should be used.
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not 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. 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 fitting separation, hose rupture or
other damage.
NOTE: Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the
manufacturer's instructions on evacuation of any non-condensable gases from the hoses.
NOTE: Only connect the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set when
fluorescent dye is to be injected. The dye/lubricant injector has a one-way check valve that will prevent
refrigerant system recovery and evacuation.
1. NOTE: If no R-134a pressure is present in the refrigerant system, the system should be
evacuated before carrying out the injection procedure. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
Connect a R-134a Refrigerant Management Machine or a R-134a Manifold Gauge Set to the
refrigerant system service port valves.
2. Verify that the valves on the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set
are closed.
3. Fill the R-134a fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye.
4. Install the dye/lubricant injector between the low-pressure service gauge port valve and the R-
134a Refrigerant Management Machine or R-134a Manifold Gauge Set.
5. NOTE: Following fluorescent dye injection, the refrigerant system should be fully charged to make
sure of correct movement of the dye.
Open all valves and inject the fluorescent dye into the refrigerant system by charging the
refrigerant system with the required amount of R-134a.
6. When fluorescent dye injection is complete, close all valves.
7. Recover the refrigerant from the dye/lubricant injector.
8. Remove the dye/lubricant injector from the low-pressure service gauge port valve and the R-134a
Refrigerant Management Machine or R-134a Manifold Gauge Set.
Fluorescent Dye Injection Using a R-134a Loop/Add On Injector Kit-Set — Vehicles Not Requiring
R-134a Addition
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not 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. 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 fitting separation, hose rupture or
other damage.
NOTE: Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the equipment
manufacturer's instructions on evacuation of non-condensable gases from the hoses.
NOTE: Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off and cool.
1. Verify that the valves on the R-134a Loop/Add On Injector Kit-Set are closed.
2. Fill the R-134a Loop/Add On Injector Kit-Set reservoir with 7 ml (0.25 oz) of fluorescent dye.
3. Install the R-134a Loop/Add On Injector Kit-Set between the high-pressure and low-pressure
service gauge port valves.
4. NOTICE: Make sure all tools and hoses are clear of the engine cooling fan and drive belt
before starting the engine. Failure to keep tools and hoses clear from the engine cooling
fan and drive belt will result in damage to the tools and/or vehicle.
With the A/C off, start the engine. Allow engine speed to stabilize below 1,000 rpm.
5. Set the A/C to the ON position.
6. Open the high-pressure service valve.
7. NOTE: To prevent pressure spike/liquid slug, crack the R-134a Loop/Add On Injector Kit-Set
valves and slowly open to inject the fluorescent dye into the refrigerant system.
Open the R-134a Loop/Add On Injector Kit-Set valves and inject the fluorescent dye into the
refrigerant system.
8. Close the high-pressure service valve to allow the pressure inside the R-134a Loop/Add On
Injector Kit-Set to equalize with the suction side of the refrigerant system.
9. NOTE: Close the valves on the R-134a Loop/Add On Injector Kit-Set while the A/C compressor is
operating.
Close the valves on the R-134a Loop/Add On Injector Kit-Set.
10. NOTE: Leave all valves on the R-134a Loop/Add On Injector Kit-Set closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the R-134a Loop/Add
On Injector Kit-Set from the vehicle.
Fluorescent Dye Detection
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.
NOTE: Use of dye-enhancing glasses or goggles greatly improves the detection of the dye under the UV
lamp.
NOTE: Not all UV lamps will fluoresce the dye used in Ford vehicles. All Rotunda UV lamps are
optimized to fluoresce the dye.
1. Check for leaks using a Rotunda-approved UV lamp and dye enhancing glasses.
Inspect all components, lines and fittings of the refrigerant system.
2. After the leak(s) is repaired, remove any traces of fluorescent dye with a general purpose oil
solvent.
3. Verify the repair by running the vehicle for a short period of time and rechecking the area of the
leak with a Rotunda-approved UV lamp.
Diagnostics Manual
Air Conditioning (A/C) System Flushing
Special Tool(s)
A/C Flush and Purge Machine

219-00022 (part of 219-00023)
or equivalent
Connector, Refrigerant Flushing

Equipment
412-145
Material
Item Specification
Motorcraft® A/C System —
Flushing Solvent
YN-23
Motorcraft® PAG Refrigerant WSH-M1C231-
Compressor Oil B
YN-12-D
WARNING: Use extreme care and observe all safety and service precautions related to the
use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment.

injury.
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle A/C refrigerant. Failure to do so puts the shop bulk refrigerant at risk of contamination. If
the vehicle A/C refrigerant is contaminated, refer the customer to the repair facility that carried
out the last A/C repair. All contaminated A/C refrigerant must be disposed of as hazardous
waste. For all equipment, follow the equipment manufacturer procedures and instructions.
NOTICE: The Thermostatic Expansion Valve (TXV) and hoses with mufflers, should be removed
when flushing the Air Conditioning (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.
NOTE: Prior to using the A/C Flush and Purge Machine 219-00022 for the first time, review the
operating instructions.
NOTE: Only the A/C Flush and Purge Machine kit, which includes A/C Flush and Purge Machine, A/C
Flush and Purge Fitting Kit and the A/C Systems Flushing Solvent, is approved for use. 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.
NOTE: Ford Motor Company has approved a procedure to provide technicians with a non-
Chlorofluorocarbons (CFC) method of flushing contaminated A/C system heat exchangers. The
procedure allows the specific components to be cleaned and flushed while installed in their normal in-
vehicle location. The types of contamination flushed include particle matter that results from A/C
compressor or desiccant failure and gummy residue that can form when refrigerant oil is overheated
during A/C compressor seizure. The flushing process is a 2-step procedure that involves the use of an
A/C Flush and Purge Machine to:
circulate the flushing solvent through the heat exchanger in the reverse direction of normal
refrigerant flow (back-flushing). Particulate matter picked up during flushing is filtered from the
returning solvent before the solvent is returned to the reservoir for continued circulation.
remove the flushing solvent from the heat exchanger. In this step of the procedure, pressurized
air 621-862 kPa (90-125 psi) is used to push and evaporate any remaining flush solvent from the
heat exchanger.
1. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging in this section.
2. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
3. Connect the A/C Flush and Purge Machine to the heat exchanger to be flushed using the
Refrigerant Flushing Equipment Connector or the correct adapters from the A/C Flush Adapter
Kit. Do not flush through the evaporator core orifice or hoses. The internal plumbing and material
make-up of these components make it impossible to correctly remove foreign material or residual
flushing solvent.
4. NOTE: Flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for
one or both heat exchangers in the A/C system. However, the flush solvent and the flushing unit
filter is intended for one vehicle only.
Flush the heat exchanger for a minimum of 15 minutes.
5. Apply 621-862 kPa (90-125 psi) of pressurized air to the component for a minimum of 30 minutes.
The 30-minute purge time is required to force and evaporate all residual solvent from the A/C
system component. Failure to successfully remove all residual solvent within the component can
result in system damage when reconnected and operated. Dispose of the used flush solvent and
filter in accordance with local, state and federal regulations.
6. NOTE: A/C system filtering as described in this section is optional if system flushing is carried
out. However, the filter kit use is recommended after flushing if the A/C system contamination is
extensive.
Install a new Thermostatic Expansion Valve (TXV) in any vehicle being repaired for an internal
A/C compressor or desiccant failure.
7. Install new refrigerant hoses if clogged with foreign material.

8. Install a new receiver/drier in any vehicle being repaired for an internal A/C compressor or
desiccant failure.
9. Reconnect the heat exchanger being repaired.
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.
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.
Diagnostics Manual
Air Conditioning (A/C) System Recovery, Evacuation and Charging
Special Tool(s)
6.0 CFM Vacuum Pump
300-R0B15600E or equivalent
Automatic Refrigerant Charging

Meter

300-R0B40134AE or equivalent
R-134a Refrigerant
2788 Compliant)
300-R0B34788-PROE or
equivalent
R-134a Refrigerant
2788 Compliant)
R-134a Refrigerant
2788 Compliant)
Material
Item Specification
Compressor Oil B
YN-12-D
Refrigerant System Recovery
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of
contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service
facility that carried out the last A/C service. If the customer wishes 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 equipment manufacturer procedures and instructions.
NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that
meets the requirements of the SAE J2788 standard.
1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer
to Refrigerant Identification Testing in this section.
2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge
port valves following the operating instructions provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any).
Add that same amount back into the system once repairs are complete.
4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF
the power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the
vacuum is not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable
for 2 minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine
1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum
and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a
minimum of 45 minutes.
3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that
the system vacuum is held.
Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum
that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test
all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are
present.
1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the
Vacuum Pump.
3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves.
4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least
99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to
operate the Vacuum Pump for a minimum of 45 minutes.
5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service
gauge port valves) and turn OFF the Vacuum Pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If
vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system
again.
Refrigerant System Charging Using a R-134a Refrigerant Management Machine
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding in this section.
2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant
Charging Meter
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry
out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available,
refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging
Meter and R-134a Manifold Gauge Set.
2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a
supply tank following the Automatic Refrigerant Charging Meter operating instructions.
3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating
instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX
A/C operation and allow the refrigerant charge to complete.
Diagnostics Manual
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor

Installation
Special Tool(s)
A/C Flush and Purge Fitting Kit

Material
Item Specification
Compressor Oil B
YN-12-D
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of
contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service
facility that carried out the last A/C service. If the customer wishes 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 equipment manufacturer's procedures and instructions.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new
suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core
orifice and any hoses containing mufflers must be installed prior to filtering the Air Conditioning
(A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any
foreign material. 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 filter is intended for use on one vehicle only.
1. NOTE: The filter inlet is marked with a label on one side of the filter body.
Orient the filter inlet toward the A/C condenser core.

2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are
designed for low-pressure flushing and are not designed for use with a charged refrigerant
system. Do not make the condenser fitting connections using the flexible extension
adapters or damage to the adapters and loss of refrigerant will occur.
NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at
the end of this procedure.
Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2
halves of the fitting.
Use flexible R-134a service hoses of 17,238 kPa (2,500 psi) burst rating.
Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or
A/C Flush and Purge Fitting Kit.
4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and Charging in this section.
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure
they do not interfere with other engine compartment components. If necessary, use tie straps to
make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation
and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the
A/C system is operating correctly.
7. Using a scan tool, command the idle to gradually bring the engine up to 1,200 rpm by running it at
lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and
run it for one hour with the A/C system operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the
condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air
Diagnostics Manual
Refrigerant Oil Adding
Special Tool(s)
R-134a Loop/Add On Injector
Kit-Set
Material
Item Specification
Compressor Oil B
YN-12-D
Refrigerant Oil Adding
NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small
amount is retained in each component. If certain components of the system are removed, some of the
PAG 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.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
Component PAG Oil Amount Method of Adding

A/C Compressor Refer to Adding Refrigerant Oil Add or remove directly through
After A/C Compressor A/C compressor low-side port
Replacement before installation.
Suction Accumulator or Refer to Adding Refrigerant Oil Add directly to suction
Receiver/Drier After New Suction Accumulator accumulator inlet port or inject to
or Receiver/Drier Replacement low-side service port during
system charging.
Evaporator Core 45 ml (1.5 fl oz) added to the Add directly to evaporator core
amount collected during inlet tube or inject to low-side
refrigerant recovery service port during system
charging.
Condenser Core 60 ml (2 fl oz) added to the Add directly to condenser core
amount collected during inlet or inject to low-side service
refrigerant recovery port during system charging.
Evaporator Core Orifice The amount collected during Inject to low-side service port
or Thermostatic refrigerant recovery during system charging.
Expansion Valve (TXV)
A/C Pressure Relief Valve 60 ml (2 fl oz) added to the Inject to low-side service port
amount collected during during system charging.
refrigerant recovery
Refrigerant Hose/Line 60 ml (2 fl oz) added to the Inject to low-side service port
refrigerant recovery a
O-ring Leak Repair 60 ml (2 fl oz) added to the Inject to low-side service port
refrigerant recovery b
Service Port Leak Repair 60 ml (2 fl oz) added to the Inject to low-side service port
refrigerant recovery
a Ifan excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the
total system PAG oil capacity must be added.
b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the
PAG oil amount by the number of O-ring leaks being repaired.
Adding Refrigerant Oil After A/C Compressor Replacement
Service A/C compressors shipped without clutch and pulley
1. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz),
pour the same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a
Systems) (YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor.
If the amount of oil that was removed from the old A/C compressor is greater than 142 ml
(5 oz), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent into the new A/C compressor.
If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3
oz), pour 85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or
equivalent into the new A/C compressor.
Service A/C compressors shipped with clutch and pulley
2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove
118 ml (4 oz) from the new A/C compressor.
If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3
oz) from the new A/C compressor.
If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz),
remove 0 ml (0 oz) from the new A/C compressor.
Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement
NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or receiver
drier only has been installed. If a new A/C compressor and evaporator core orifice or Thermostatic
Expansion Valve (TXV) have also been installed due to system contamination, refer to the appropriate
heading.
1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain
the oil into a clean measuring cup.
2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and
60 ml (2 fl oz).
Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination
NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction
accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system
contamination and the A/C system has been flushed.
1. If the new A/C compressor is shipped with a new clutch and pulley already installed, remove the
shipping caps and rotate the new A/C compressor shaft 6 to 8 revolutions while collecting the oil
in a clean measuring cup.
2. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port.
3. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during
system charging. For the total PAG oil capacity specification, refer to the Specifications table in
this section.
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, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On
Injector Kit-Set to match the amount of refrigerant compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant
service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air
Diagnostics Manual
Refrigerant Identification Testing
Special Tool(s)
Refrigerant Blend Identifier with
Printer
Refrigerant Identification
1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken
directly from the refrigeration system or storage containers prior to recovering or charging the
refrigerant system.
Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the
sample for testing.
2. The Refrigerant Blend Identifier with Printer will display one of the following:
If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light.
The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed
on the digital display.
If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an
alarm will sound alerting the user of potential hazards. The weight concentrations of R-
134a, R-12, R-22 and hydrocarbons will be displayed on the digital display.
If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will 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.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The Refrigerant Blend Identifier with Printer eliminates the effect of air when determining
the refrigerant sample content because air is not considered a contaminant, although air can
affect A/C system performance. When the Refrigerant Blend Identifier with Printer 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, it will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Contaminated Refrigerant Handling
NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the
recovered refrigerant supply and may damage the recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system
flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
If this equipment is not available, contact an A/C service facility in the area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations.
SECTION 412-01: Climate Control 2011 Fiesta Workshop Manual
Material
Capacity
Motorcraft® PAG Refrigerant WSH-M1C231- 100 ml
Compressor Oil B (3.4 fl oz)
YN-12-D
Motorcraft® R-134a WSH-M17B19- 0.54 kg
Refrigerant A (19 oz)
YN-19 (US); CYN-16-R (1.19 lb)
(Canada)
A/C clutch disc and hub bolt 13 — 115
A/C compressor bolts 24 18 —
A/C compressor fitting nuts (suction and discharge) 15 — 133
A/C compressor pressure relief valve 10 — 89
A/C compressor stud-bolt 24 18 —
Compressor-to-condenser discharge line bracket nut 7 — 62
Condenser fitting nuts (outlet and inlet) 8 — 71
Evaporator outlet line bracket nut 8 — 71
Evaporator outlet line fitting nut 8 — 71
Heater core and evaporator core housing bolt 6 — 53
Heater core and evaporator core housing nuts 6 — 53
Radiator support reinforcement bolts 8 — 71
Receiver/drier fitting nuts 8 — 71
Thermostatic Expansion Valve (TXV) bolts 8 — 71
TXV fitting nuts (high-pressure and low-pressure) 10 — 89
Air Conditioning
The refrigerant system components include the following:
A/C compressor and clutch assembly

A/C condenser core
A/C evaporator core
Receiver/drier
Connecting refrigerant lines
The A/C compressor contains a pressure relief valve to protect the refrigerant system against
excessively high refrigerant pressures.
A/C Compressor and Clutch Assembly
NOTE: Internal A/C compressor components are not serviced separately. The A/C compressor is
serviced as an assembly. A new A/C pressure relief valve is included with replacement A/C
compressors, but the valve is also available as a separate component and can be independently
replaced if needed. The A/C compressor clutch, A/C compressor pulley and A/C clutch field coil can be
serviced separately.
The A/C compressor has the following characteristics:
A non-serviceable shaft seal.

Uses PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D. This oil contains special
additives required for the A/C compressor.
The A/C compressor oil may darken over time while maintaining normal oil viscosity. This is
normal because of break-in wear.
Use the refrigerant oil adding procedure specified for this vehicle when installing a new A/C
compressor or any other A/C component. Refer to the Refrigerant Oil Adding procedure in
Section 412-00 .
When battery voltage is applied to the A/C compressor clutch field coil, the clutch disc and hub assembly
is drawn toward the A/C compressor pulley. The magnetic force locks the clutch disc and hub assembly
and the A/C compressor pulley together as one unit, causing the compressor shaft to rotate with the
engine. When battery voltage is removed from the A/C compressor clutch field coil, springs in the clutch
disc and hub assembly move the clutch disc away from the A/C compressor pulley.
A/C Pressure Relief Valve
NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting or
leaking around the threads, install a new A/C pressure relief valve and O-ring. If the new A/C pressure
relief valve still vents after it is installed, diagnose the refrigerant system for a restriction.
An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C
compressor and other system components by relieving unusually high system discharge pressure
buildups. For specifications regarding operating pressure(s), refer to Section 412-00 .
The A/C pressure relief valve can be serviced separately from the A/C compressor. It is necessary to
recover the refrigerant before removing the A/C pressure relief valve.
A/C Condenser Core
The condenser core is an aluminum fin-and-tube design heat exchanger located in front of the vehicle
radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat,
and condenses gas to liquid refrigerant as it is cooled.
A/C Evaporator Core
The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core
housing. A mixture of liquid refrigerant and oil enters the bottom of the evaporator core through the
evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet
tube as a vapor. During A/C compressor operation, air flow from the blower motor is cooled and
dehumidified as it flows through the evaporator core fins.
The Thermostatic Expansion Valve (TXV) is located at the evaporator core inlet and outlet tubes at the
center rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant from the
high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of
the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV
through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the
refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the
refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant
entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the
evaporator core at higher temperatures.
Receiver/Drier
NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, unless there is
physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.
Damage to the receiver/drier includes leaks, physical damage to the receiver/drier shell or desiccant, or
moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and
equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one
hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before
repairs are carried out, a new receiver/drier should not be installed.
The receiver/drier is mounted to the RH side of the condenser core above the condenser outlet fitting. It
stores high-pressure liquid after it leaves the condenser core. A desiccant cartridge mounted inside the
receiver/drier removes moisture from the refrigerant.
Evaporator Discharge Air Temperature Sensor
The evaporator discharge air temperature sensor contains a thermistor. The resistance of this thermistor
varies by a specific amount based on the evaporator discharge air temperature. The PCM measures a
voltage ratio between the reference voltage it supplies to the sensor and the sensor voltage to determine
this resistance and the associated evaporator discharge air temperature.
As the evaporator core removes heat and moisture from the air flow moving through the evaporator core
fins, the removed moisture condensates on the exterior of the evaporator core. The PCM uses input
from the evaporator discharge air temperature sensor to prevent this moisture from freezing on the
exterior of the evaporator core, and inhibiting air flow through the evaporator core fins. When the
evaporator core temperature drops to a temperature near the freezing point of water, the PCM switches
off the A/C compressor. The A/C compressor is switched back on when the evaporator core temperature
rises to an acceptable level.
The evaporator discharge air temperature sensor is located below the glove compartment outside of the
heater core and evaporator core housing.
A/C Pressure Transducer
The A/C pressure transducer monitors the compressor discharge pressure and communicates with the
PCM. The PCM interrupts A/C compressor operation in the event the A/C pressure transducer indicates
high system discharge pressures. It also to senses low charge conditions. If the pressure is below a
predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage.
The A/C pressure transducer is located at the lower RH corner of the condenser core near the
condenser outlet fitting. It is not necessary to recover the refrigerant before removing the A/C pressure
transducer.
Service Gauge Port Valves
The high-pressure service gauge port valve is located on the compressor-to-condenser discharge line
near the condenser inlet fitting.
The low-pressure service gauge port valve is located on the A/C compressor suction line near the RH
shock tower.
1 19D702 A/C charging valve cap
2 — Low-pressure service gauge port valve
3 19D701 Low-pressure Schrader-type valve core
4 19D701 High-pressure Schrader-type valve core
5 — High-pressure service gauge port valve
6 19D702 A/C charging valve cap
The service gauge port valve 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 is always detectable around the Schrader-type valve with the
service gauge port valve cap removed, and is considered normal. If the seal leaks excessively,
install a new Schrader-type valve core.
The service gauge port valve caps each include an O-ring seal used as a primary seal in the
refrigerant system to prevent any leakage through the Schrader-type valves from reaching the
atmosphere. Check the service gauge port valve cap O-ring seals when checking the refrigerant
system for leaks and install a new cap if necessary. Always install and tighten the A/C service
gauge port valve caps to the correct torque after they are removed.
Refrigerant System Dye
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis when using a Rotunda-approved ultraviolet black light. It is not
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. Replacement receiver/driers are shipped with
a fluorescent dye "wafer" included in the desiccant bag, which dissolves 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 receiver/drier is installed as part of the flushing or filtering procedure. Only add additional
refrigerant system dye if more than 50% of the refrigerant system lubricant capacity has been lost due to
a fitting separation or hose rupture. Refer to Section 412-00 .
Air Distribution and Filtering
Air Distribution and Filtering
NOTE: The air distribution system is equipped with a factory installed cabin air filter.
There are 2 sources of air available to the air distribution system:
Fresh (outside) air

Recirculated air
Recirculated air is always used when the HVAC module is set to the MAX A/C mode and can be
selected in any mode except DEFROST or FLOOR/DEFROST.
Air distribution within the vehicle is determined by the air flow mode selected. Electric mode door
actuator-positioned airflow mode control doors direct airflow within the heater core and evaporator core
housing.
Air enters the passenger compartment from the following outlets:
Instrument panel registers

Floor duct outlets
Windshield defroster
Side window demisters
Rear footwell duct
Passenger compartment air is exhausted from the vehicle through open windows or body air vents.
Cabin Air Filter
The cabin air filter is located in the heater core and evaporator core housing. For cabin air filter
maintenance intervals, refer to Section 100-03 .
Control Components
Electronic Manual Temperature Control (EMTC)
The HVAC module allows the vehicle occupants to select the following:
Air inlet source (outside or recirculated)

Blower motor speed
Discharge air temperature (temperature blend)
Discharge air location (defrost, panel, floor, panel/floor, defrost/floor)
A/C compressor operation
Rear window defroster operation
Control System Inputs
The blower motor speed switch is mounted in the HVAC module and controls blower motor speed by
adding or bypassing resistors in the blower motor resistor in all modes except OFF. The blower motor
speed switch is serviced only as an assembly with the HVAC module.
The temperature control switch adjusts the discharge air temperature. Movement of the temperature
knob from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend
door. The position of the temperature blend door determines the discharge air temperature that the air
distribution system will maintain. The temperature control selector is an integral part of the HVAC
module and cannot be serviced separately.
The airflow mode setting adjusts the discharge air outlet location. Movement of the airflow mode selector
causes a corresponding movement of the airflow mode doors and determines the discharge air outlet
location. The airflow mode selector is an integral part of the HVAC module and cannot be serviced
separately.
The A/C request button determines A/C compressor operation, except when the airflow mode selector is
in the OFF, MAX A/C, DEFROST or FLOOR/DEFROST mode. The A/C request button is an integral
part of the HVAC module and cannot be serviced separately.
The recirculated air request button can select recirculated air in any mode except DEFROST, and fresh
air in any mode except MAX A/C or OFF. The recirculated air request button is an integral part of the
HVAC module and cannot be serviced separately.
The rear defog button signals activation of the heated backlight. Under certain conditions, the heated
backlight may be activated automatically by the PCM and Body Control Module (BCM). The rear defog
button indicator may remain off during this time. The rear defog button is an integral part of the HVAC
module and cannot be serviced separately.
Control System Outputs
The Electronic Manual Temperature Control (EMTC) system has 4 system outputs.
Blower Motor Speed

The HVAC module blower motor speed selector varies the blower motor ground circuit resistance by
adding or bypassing series resistance in the blower motor resistor. Increased resistance lowers the
blower motor speed, and lowered resistance increases blower motor speed. When the blower motor is in
the HI (4) position, the blower motor resistor is bypassed.
The blower motor resistor is located on the heater core and evaporator core housing below the glove
compartment.
Temperature Blend Door Position
The temperature blend door actuator moves the temperature blend door on command from the HVAC
module.
The temperature blend door actuator contains a reversible electric motor and a potentiometer. The
potentiometer circuit reports the position of the temperature blend door to the HVAC module. The HVAC
module drives the temperature blend door actuator motor in whichever direction is necessary to move
the temperature blend door to the position set by the vehicle occupants.
The temperature blend door actuator is mounted to the RH side of the heater core and evaporator core
housing and can be serviced separately.
Airflow Mode Door Position
The airflow mode door actuator controls the airflow mode door actuating assembly to position the airflow
mode doors on command from the HVAC module.
The airflow mode door actuator contains a reversible electric motor and potentiometer. The
potentiometer circuit reports the position of the airflow mode doors to the HVAC module. The HVAC
module drives the actuator motor in whichever direction is necessary to move the airflow mode doors to
the position set by the vehicle occupants. The airflow mode door actuating assembly contains a cam and
gear arrangement which transfers the rotation of the airflow mode door actuator to the individual airflow
mode doors.
The airflow mode door actuating assembly is mounted to the LH side of the heater core and evaporator
core housing and can be serviced separately. The airflow mode door actuator is mounted to the airflow
mode door actuating assembly and can be serviced separately.
Air Inlet Mode Door Position
The air inlet mode door actuator moves the air inlet door between the fresh and RECIRC positions on
command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically
stop at, the full RECIRC or full fresh air inlet position and does not require a potentiometer circuit to
monitor its position. The airflow mode door does not stop at any point between the RECIRC or fresh air
inlet position. When the air inlet mode is switched, the airflow mode door actuator is driven by the HVAC
module for 9 seconds, and will stall at the end of travel until the 9 second timer has expired.
The air inlet mode door actuator is mounted to the air inlet duct and can be accessed through the glove
compartment. The air inlet mode door actuator can be serviced separately.
Heating and Ventilation
The heating and ventilation system has the following features:
Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside
the vehicle
Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level
Cooling or heating can be adjusted to maintain the desired temperature
The heating and ventilation system includes the following components:
Blower motor
Heater core
Blower Motor
The blower motor draws air from the air inlet and forces it into the heater core and evaporator core
housing where it is mixed and distributed. The blower motor receives battery voltage at all times when
the ignition is in the RUN position, and is grounded by the HVAC module blower motor switch.
The blower motor is mounted to the LH side of the heater core and evaporator core housing to the right
of the pedal assembly.
Heater Core and Evaporator Core Housing
The heater core and evaporator core housing directs air flow from the blower motor through the
evaporator core (if equipped) and heater core. All air flow from the blower motor passes through the
evaporator core. The air flow is then directed through or around the heater core by an electric motor
actuated temperature blend door. After passing through or around the heater core, the air flow is
distributed to the selected outlet. The air flow mode doors are actuated by a single electric motor using a
cam and gear setup.
Heater Core
The heater core receives a flow of coolant from the engine cooling system through the heater core inlet.
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer
it to air passing through the heater core. The engine coolant is then returned to the engine cooling
system through the heater core outlet.
The heater core is located in the heater core and evaporator core housing.
Air Conditioning — Exploded View
A/C Compressor

1 386802-S Rubber cap
2 W520111 Compressor-to-condenser discharge line bracket nut
3 W520413 A/C compressor fitting nut (2 required)
4 — A/C compressor electrical connector (part of 12A522)
5 W714403 A/C compressor stud-bolt
6 W701331 A/C compressor bolt (2 required)
7 19703 A/C compressor
8 19B596 O-ring seal and gasket seal kit
A/C High-Pressure Lines
Part
1 W520412 Thermostatic Expansion Valve (TXV) high-pressure
fitting nut
2 19E889 O-ring seal (2 required)
3 W520413 Condenser outlet fitting nut
4 19835 Condenser-to-evaporator line
5 W520413 Condenser inlet fitting nut
7 W520413 A/C compressor discharge fitting nut
8 19972 Compressor-to-condenser discharge line
10 19E889 O-ring seal
A/C Condenser Core
Part
2 W500213 Radiator support reinforcement bolt (3 required)
3 — A/C pressure transducer electrical connector (part of
12A522)
5 19712 Condenser core
Receiver/Drier
1 W705460 Receiver/drier fitting nut (2 required)
2 19959 Receiver/drier

Part
1 W520412 Thermostatic Expansion Valve (TXV) fitting nut (2
required)
4 — TXV bolt (2 required) (part of 19849)
5 19849 TXV
Evaporator Core

1 19B588 Dash panel seal
2 W506945 Evaporator tube bracket screw (2 required)
3 — Evaporator tube bracket (part of 19850)
4 W506945 Cabin air filter access cover screw (5 required)
5 19D672 Cabin air filter access cover
6 W506945 Evaporator core cover screw (9 required)
7 — Evaporator core cover (part of 19850)
8 19860 Evaporator core
A/C Low-Pressure Lines
Part
1 W520412 Thermostatic Expansion Valve (TXV) low-pressure
fitting nut
2 W520413 Evaporator outlet line fitting nut
3 W520412 Evaporator outlet line bracket nut
6 19867 Evaporator outlet line
7 386802 Rubber cap
8 W520413 A/C compressor suction fitting
9 19D734 Evaporator-to-compressor suction line
10 19D596 O-ring seal and gasket seal kit
removal.
Air Distribution and Filtering — Exploded View
Center Registers
NOTE: LH center register shown, RH similar

1 W506962 Center register screw
2 19893 Center register
Outer Registers
NOTE: RH outer register shown, LH similar

1 19893 Outer register
Rear Footwell Ducts

1 W701374 LH rear footwell duct pin-type retainer (2 required)
2 18C297 LH rear footwell duct
3 W701374 RH rear footwell duct pin-type retainer (2 required)
4 18C297 RH rear footwell duct
5 18C297 LH rear footwell duct adapter
6 18C297 RH rear footwell duct adapter
Cabin Air Filter

1 W506945 Cabin air filter access cover screw (5 required)
2 19D672 Cabin air filter access cover
3 19N619 Cabin air filter
removal.
Control Components — Exploded View
HVAC Housing
Part
1 W707628 HVAC module screw (4 required)
2 — HVAC module electrical connector (part of 14401)
3 — HVAC module blower motor switch electrical connector
(part of 14401)
4 18549 HVAC module (vehicles not equipped with A/C)
4 19980 HVAC module (vehicles equipped with A/C)
HVAC Control Components

Part
1 W506945 Airflow mode door actuator screw (2 required)
2 19E616 Airflow mode door actuator
3 W506945 Airflow mode door actuating assembly screw (5
required)
4 19788 Airflow mode door actuating assembly
5 19C734 Evaporator discharge air temperature sensor
6 W506945 Temperature blend door actuator screw (2 required)
7 — Temperature blend door actuator (part of 19788)
8 — Temperature blend door actuator cam (part of 19788)
9 W506945 Air inlet mode door actuator screw (2 required)
10 19E616 Air inlet mode door actuator
11 W506945 Blower motor resistor screw (2 required)
12 18591 Blower motor resistor
removal.
Heating and Ventilation — Exploded View
Heater Core and Evaporator Core Housing
Part
1 19D888 Radio vent tube
2 W505422 Heater core and evaporator core housing bolt
3 W700430 Heater core and evaporator core housing nut (4
required)
4 19850 Heater core and evaporator core housing
Blower Motor and Heater Core

1 19B588 Dash panel seal
2 W506495 Heater core tube bracket screw (2 required)
3 W506495 Heater tube cover screw (3 required)
4 — Heater core tube cover
5 W506495 Heater core retainer screw
6 18476 Heater core
7 W506495 Blower motor screw (3 required)
8 19805 Blower motor
removal.
Air Conditioning (A/C) Compressor
Material
Item Specification
Compressor Oil B
YN-12-D

1 386802-S Rubber cap
3 W520413 A/C compressor fitting nut (2 required)
4 — A/C compressor electrical connector (part of 12A522)
5 W714403 A/C compressor stud-bolt
6 W701331 A/C compressor bolt (2 required)
7 — A/C compressor wire harness bracket (part of 12A522)
8 19703 A/C compressor
NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit,
the following procedures must be carried out to remove contamination from the A/C system. Failure to
remove contamination from the A/C system, if present, will result in poor A/C performance and/or
damage to the new A/C compressor and other components.
If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a
new A/C compressor. For additional information, refer to Section 412-00 .
If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C
compressor has been installed. For additional information, refer to Section 412-00 .
Install a new Thermostatic Expansion Valve (TXV), as directed by the A/C flushing or filtering
procedure.
Install a new receiver/drier as directed by the A/C flushing or filtering procedure.
NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is
physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. Damage to
the receiver/drier includes leaks in the receiver/drier, physical damage to the receiver/drier shell or desiccant, or
moisture contamination. Moisture contamination results only from a complete loss of refrigerant and
equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If
even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the
receiver/drier should not be replaced.
NOTE: A new A/C compressor may come equipped with an A/C clutch disc and hub, A/C compressor pulley
and A/C clutch field coil already installed. If these components are not pre-installed, it will be necessary to
transfer these parts from the old A/C compressor to the new compressor prior to installation of the A/C
compressor if suitable for reuse.
1. If flushing of the refrigerant system has not been carried out, recover the refrigerant. For additional
2. Remove the compressor-to-condenser discharge line bracket nut.

3. Remove the 2 A/C compressor fitting nuts and disconnect the fitting.
Discard the O-ring seals and gasket seals.
5. Disconnect the A/C clutch field coil electrical connector.
6. Detach the wire harness from the A/C compressor wire harness bracket.
7. Remove the 2 A/C compressor bolts, the A/C compressor stud bolt and the A/C compressor wire
harness bracket.
8. Remove the A/C compressor.

Install new O-ring seals and gasket seals.
If filtering of the refrigerant system is not to be carried out, add the correct amount of clean PAG
oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding
procedure in Section 412-00 .
10. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant
system. For additional information, refer to Section 412-00 .
Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor
1. Remove the RH floor console trim panel.

1. Remove the pin-type retainer.
2. Detach the 3 clips and remove the trim panel.
2. Disconnect the evaporator discharge air temperature sensor electrical connector and rotate the
sensor clockwise to remove.

Air Conditioning (A/C) Pressure Relief Valve
Material
Item Specification
Compressor Oil B
YN-12-D
2. Remove the A/C compressor pressure relief valve and O-ring seal.
3. NOTE: A new O-ring seal will already be installed on the new A/C compressor pressure relief
valve service part.

Add the correct amount of clean PAG oil to the refrigerant system. For additional
information, refer to the Refrigerant Oil Adding procedure in Section 412-00 .
4. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section
412-00 .
Air Inlet Duct

1 W506945 Air inlet duct screw (4 required)
2 19A618 Air inlet duct
1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core
And Evaporator Core Housing in this section.
2. Remove the 4 air inlet duct screws.
3. Remove the air inlet duct.

Blower Motor
1. With the ignition in the ON position , select the PANEL climate control mode. Switch the ignition to
the OFF position.
2. Remove the brake pedal and bracket assembly. For additional information, refer to Section 206-
06 .
3. Disconnect the blower motor electrical connector.
4. Remove the 3 blower motor screws.
5. Remove the blower motor.

Blower Motor Resistor
1. Remove the RH floor console side panel.

1. Remove the side panel pin-type retainer.
2. Detach the clips and remove the RH floor console side panel.
2. Remove the blower motor resistor.

Disconnect the blower motor resistor electrical connector.
Remove the 2 blower motor resistor screws and the blower motor resistor.

Clutch and Clutch Field Coil
Special Tool(s)
Holding Tool, Compressor Clutch
412-134
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)
Remover, Compressor Pulley

412-001 (T71P-19703-B)
1 W711877 A/C clutch disc and hub bolt
2 19D786 A/C clutch disc and hub
3 19D648 A/C clutch disc and hub spacer
4 N805338 A/C compressor pulley snap ring
5 19D784 A/C compressor pulley
6 19D798 A/C clutch field coil
Removal
1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor in
this section.
2. Remove the A/C clutch disc and hub bolt.

1. Using the Compressor Clutch Holding Tool, hold the A/C clutch disc and hub.
2. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub.

4. Remove the A/C clutch disc and hub spacer(s).
5. Remove the A/C compressor pulley snap ring.
6. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) compressor pulley or A/C
compressor may result.
Remove the A/C compressor pulley.

1. Install the Compressor Pulley Remover.
2. Remove the A/C compressor pulley.
7. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) clutch field coil or A/C
Remove the A/C clutch field coil.

1. Install the A/C Compressor Field Coil Remover.
2. Install the Compressor Pulley Remover.
3. Remove the A/C clutch field coil.
Installation
1. Clean the A/C clutch field coil and pulley mounting surfaces.
2. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) clutch field coil or A/C
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 A/C Compressor Field Coil Installer on the A/C clutch field coil.
3. Place the A/C Compressor Coil Installer on the A/C Compressor Field Coil Installer.
4. Use the Compressor Pulley Remover to install the A/C clutch field coil.
3. Install the A/C compressor pulley.
4. Install the A/C compressor pulley snap ring.
5. Install the A/C clutch disc and hub spacer(s) and the A/C clutch disc and hub.
6. Install the A/C clutch disc and hub bolt.

1. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool.
2. Tighten to 13 Nm (115 lb-in).
7. Measure and adjust the clutch air gap by adding or removing A/C clutch disc and hub spacers. For
additional information, refer to the A/C clutch air gap procedure in Section 412-00 .
8. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor in this
section.
Compressor to Condenser Discharge Line
Material
Item Specification
Compressor Oil B
YN-12-D
100-02 .
3. Remove the condenser inlet fitting nut and disconnect the fitting.
4. Remove the compressor-to-condenser discharge line bracket nut.

5. Remove the compressor discharge fitting nut and disconnect the fitting.
Discard the O-ring seal and gasket seal.

Install new O-ring seals and a new gasket seal.
412-00 .
Condenser Core
Material
Item Specification
Compressor Oil B
YN-12-D
Part
2 W500213 Radiator support reinforcement bolt (3 required)
3 — A/C pressure transducer electrical connector (part of
12A522)
5 19712 Condenser core
4. Remove the condenser inlet fitting nut and disconnect the fitting.
5. Remove the LH radiator grille pin-type retainer.
6. Release the LH and RH upper radiator bracket tabs and remove the LH and RH upper radiator insulators.
7. Remove the 3 radiator support reinforcement bolts and the radiator support reinforcement.
9. Remove the condenser outlet fitting nut and disconnect the fitting.
10. Lift the radiator out of the lower insulator bushings and position it rearward.
11. Release the tabs and detach the condenser core from the radiator.
12. Remove the condenser core.

Install new O-ring seals and a new gasket seal.
Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the
Refrigerant Oil Adding procedure in Section 412-00 .
14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412-00 .
Condenser to Evaporator Line
Material
Item Specification
Compressor Oil B
YN-12-D
100-02 .
3. Release the clips and position the coolant bottle aside.
4. Remove the Thermostatic Expansion Valve (TXV) inlet fitting nut and disconnect the fitting.
Discard the O-ring seals.
5. Disconnect the evaporator outlet line fitting.
1. Remove the evaporator outlet line bracket nut.
2. Remove the evaporator outlet line fitting nut and disconnect the fitting.
To install, tighten the evaporator outlet line fitting nut to 8 Nm (71 lb-in).
To install, tighten the evaporator outlet line bracket nut to 8 Nm (71 lb-in).
6. Remove the condenser outlet fitting nut and disconnect the fitting.
7. Detach the condenser-to-evaporator line from the clips.

8. Remove the condenser-to-evaporator line.

Install new O-ring seals.
412-00 .
Evaporator Outlet Line
Material
Item Specification
Compressor Oil B
YN-12-D
2. Remove the Thermostatic Expansion Valve (TXV) outlet fitting nut and disconnect the fitting.
3. Remove the evaporator outlet line bracket nut.

4. Remove the A/C compressor suction fitting nut and disconnect the fitting.
Discard the O-ring seal and gasket seal.
5. Remove the evaporator outlet line.

Install new O-ring seals, and a new gasket seal.
412-00 .
Evaporator to Compressor Suction Line
Material
Item Specification
Compressor Oil B
YN-12-D
2. Remove the evaporator outlet line fitting nut.

3. Remove the rubber cap from the A/C compressor suction fitting stud.
4. Remove the A/C compressor suction fitting nut.

Discard the gasket seal.

Install a new gasket seal and new O-ring seals.
412-00 .
Footwell Duct — Rear
1. Remove the front seats. For additional information, refer to Section 501-10 .
2. Remove the LH and RH front scuff plates, and the RH and LH cowl side trim panels. For
3. Remove the 2 LH rear footwell duct pin-type retainers and the LH rear footwell duct.
4. Remove the 2 RH rear footwell duct pin-type retainers and the RH rear footwell duct.

Heater Core
1. Remove the heater core and evaporator core housing. For additional information, refer to Heater
Core And Evaporator Core Housing in this section.
2. Remove the dash panel seal.
3. Remove the 2 heater core tube bracket screws and remove the bracket.
4. Remove the 3 heater tube cover screws and remove the heater tube cover
5. Remove the heater core retainer screw and position the retainer aside.
6. Remove the heater core.

Heater Core And Evaporator Core Housing
Part
1 19D888 Audio unit vent tube
2 W505422 Heater core and evaporator core housing bolt
3 W700430 Heater core and evaporator core housing nuts (4
required)
4 19850 Heater core and evaporator core housing
1. Remove the instrument panel. For additional information, refer to Section 501-12 .
2. Remove the 2 floor ducts.

3. Disconnect the electrical connectors and detach the wire harness clips from the RH side of the heater
core and evaporator core housing.
4. Disconnect the electrical connectors and detach the wire harness retainer from the LH side of the heater
core and evaporator core housing.
5. Release the clamp and detach the audio unit vent tube from the heater core and evaporator core
housing.
6. Remove the 4 heater core and evaporator core housing nuts, and the heater core and evaporator core
housing bolt.

Heating Ventilation Air Conditioning (HVAC) Module
Part
1 W707628 HVAC module screw (4 required)
2 — HVAC module electrical connector (part of 14401)
3 — HVAC module blower motor switch electrical connector
(part of 14401)
4 18549 HVAC module (vehicles not equipped with A/C)
4 19980 HVAC module (vehicles equipped with A/C)
2. Remove the 4 HVAC module screws.
3. Disconnect the 2 HVAC module electrical connectors.
4. Remove the HVAC module.

Mode Door Actuator — Air Inlet Door
1. Lower and remove the glove compartment.
2. Disconnect the air inlet mode door actuator electrical connector.
3. Remove the 2 air inlet mode door actuator screws.
4. Remove the air inlet mode door actuator.

Mode Door Actuator — Defrost/Panel/Floor Door
1. If replacing the defrost/panel/floor mode door actuator motor only, remove the knee air bag module and the
lower steering column shroud. For additional information, refer to Section 501-20B and Section 211-04 .
2. If replacing the airflow mode door actuating assembly, remove the heater core and evaporator core housing.
For additional information, refer to Heater Core And Evaporator Core Housing in this section.
3. Disconnect the defrost/panel/floor mode door actuator electrical connector.
4. Remove the 2 defrost/panel/floor mode door actuator screws and the defrost/panel/floor door mode door
actuator.
5. Remove the defrost/panel/floor mode door actuator.
6. If removing the airflow mode door actuating assembly, remove the 5 airflow mode door actuating assembly
screws and the actuating assembly.
7. NOTE: When installing the airflow mode door actuating assembly, make sure that each airflow mode door gear
or lever is correctly aligned with the actuating assembly.

Receiver Drier
Material
Item Specification
Compressor Oil B
YN-12-D

1 W705460 Receiver/drier fitting nut (2 required)
2 19959 Receiver/drier
NOTE: Installation of a new receiver/drier is not required when repairing the A/C system, except when there is
physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. Damage to
the receiver/drier includes leaks in the receiver/drier, physical damage to the receiver/drier shell or desiccant, or
moisture contamination. Moisture contamination results only from a complete loss of refrigerant and
equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If
even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the
receiver/drier should not be replaced.
3. Remove the 2 receiver/drier fitting nuts.

4. Remove the receiver/drier.


Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer
to Section 412-00 .
6. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412-
00 .
Register
Outer registers
1. With a non-metallic trim-type tool, gently pry out on the outer rim of the register to release and
remove the register.
Center registers
2. Remove the FCIM finish panel. For additional information, refer to Section 501-12 .
3. Remove the center register screws.
4. Release the center register clips and remove the center registers.
All registers

Temperature Blend Door Actuator
1. Remove the instrument panel. For additional information, refer to Section 501-12 .
2. Disconnect the temperature blend door actuator electrical connector.
3. Remove the 2 temperature blend door actuator screws.
4. Remove the temperature blend door actuator.
5. NOTE: When installing the temperature blend door actuator, be sure that the actuator gear, and
the blend door gear are aligned so that the center (keyed) portion of each gear mates with the
center (keyed) portion of the opposite gear as the gears are rotated.

Thermostatic Expansion Valve
Material
Item Specification
Compressor Oil B
YN-12-D
Part
1 W520412 Thermostatic Expansion Valve (TXV) fitting nut (2
required)
4 — TXV bolt (2 required) (part of 19849 kit)
5 19849 TXV
2. Remove the 2 Thermostatic Expansion Valve (TXV) fitting nuts and disconnect the fittings.
3. Remove the 2 TXV bolts.
4. Remove the TXV .


Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer
to Section 412-00 .
6. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412-
00 .
SECTION 413-00: Instrument Cluster and Panel Illumination 2011 Fiesta Workshop Manual
Instrument Cluster and Panel Illumination
Overview
The backlighting system consist of dimmable components and non-dimmable components.
Dimmable Components
The functional dimmable components are:
Driver heated seat switch

Floor shifter
Instrument panel dimmer switch
Front Controls Interface Module (FCIM)
Headlamp switch
HVAC module
Passenger heated seat/ambient lighting switch
Start/stop switch
Steering wheel switches
Instrument Panel Cluster (IPC) (via network message)
Front Control/Display Interface Module (FCDIM) (via network message)
The dimmable backlighting is controlled by the BCM . The dimmable switches and components are
illuminated when the parking lamps are on. The instrument panel dimmer switch is a single detent rocker
switch used to control all dimmable interior illuminated components. The up detent increases dimmable
backlighting intensity and the down detent decreases dimmable backlighting intensity. When the parking
lamps are off, the Instrument Panel Cluster (IPC) is illuminated to full brightness.
Non-Dimmable Components
The functional non-dimmable components are:
Window control switches
The non-dimmable illumination provides backlighting to the window switches when the ignition relay is
energized.
Instrument Cluster and Panel Illumination
Special Tool(s)
tool

Flex Probe Kit

Dimmable Backlighting
When the parking lamps are on, the Body Control Module (BCM) monitors the input from the instrument
panel dimmer switch. The BCM sends voltage to the dimmable components based on input received
from the instrument panel dimmer switch.
If a fault is detected by the BCM on the dimmable illumination output circuit, the BCM sets a DTC and
disables the circuit function until the fault is cleared and an ignition cycle takes place.
The BCM also sends a message over the network to the Front Control/Display Interface Module
(FCDIM) and the Instrument Panel Cluster (IPC) to control the backlighting intensity level.
If the receiving module does not receive the backlighting status message from the BCM , or if the data
received is deemed invalid for more than 5 seconds, the receiving module sets a missing message
related DTC in continuous memory and defaults the backlighting to full nighttime intensity.
Non-Dimmable Backlighting
When the ignition relay (located in the Central Junction Box (CJB)) is energized, switched voltage is
supplied to the window control switches.
Field-Effect Transistor (FET) Protection
Field-Effect Transistor (FET) is a type of transistor that when used with module software, monitors and
controls current flow on module outputs. The FET protection strategy prevents module damage in the
event of excessive current flow.
The BCM utilizes an FET protective circuit strategy for many of its outputs, for example a backlighting
illumination output circuit. Output loads (current level) are monitored for excessive current (typically short
circuits) and are shut down when a fault event is detected. A short circuit DTC sets when the fault
occurs.
The FET protection continues to shut off the circuit so long as the fault exists. When the fault is
corrected and the ignition state is cycled off and then back on, the module resets the FET protection and
allows the circuit to function.
The FET protected circuit for the dimmable backlighting system is the dimmable backlighting illumination
circuit.

Headlamp switch Illuminated components
4. NOTE: Make sure to use the latest scan tool release software.
5. NOTE: The Vehicle Communication Module (VCM) prove-out confirms power and ground from
the DLC are provided to the VCM .

Check the VCM connection to the vehicle.
Check the scan tool connection to the VCM .
Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan
tool.

Verify the ignition key is in the ON position.
Verify the scan tool operation with a known good vehicle.
Refer to Section 418-00 to diagnose no response from the PCM.

If the scan tool responds with no communication with one or more modules, refer to
Section 418-00 .
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to
the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts

B134E:23 Switch Illumination Adjustment Control: GO to Pinpoint Test A .
Signal Stuck low
U2010:11 Switch Illumination: Circuit Short To GO to Pinpoint Test B .
Ground
Symptom Chart
Symptom Chart
All dimmable Wiring, GO to Pinpoint Test A .
illumination does not terminals or
increase/decrease connectors
brightness Instrument
panel dimmer
switch
Body Control
Module (BCM)
All dimmable non- Wiring, GO to Pinpoint Test B .
networked illumination terminals or
is inoperative connectors
BCM
All dimmable non- Wiring, GO to Pinpoint Test C .
networked illumination terminals or
is always on connectors
BCM
The steering wheel Wiring, GO to Pinpoint Test D .
switch illumination is terminals or
Steering
wheel switch
(es)
Steering
wheel
harness
Clockspring
One or more switch Wiring, GO to Pinpoint Test E .
illumination is terminals or
Illuminated
switch
The window control Window CHECK the operation of the
switch illumination is control switch power windows.
inoperative If the power windows
operate correctly,
INSTALL a new window
control switch. REFER
to Section 501-11 .
TEST the system for
normal operation.
If the power windows do
not operate correctly,
11 .
All network controlled Medium CARRY OUT the network test.
illumination does not Speed If the scan tool responds
dim Controller with no communication
Area Network to any module on the
(MS-CAN) MS-CAN , REFER to
BCM Section 418-00 .
If the scan tool
communicates with the
modules on the MS-
CAN , INSTALL a new
BCM . REFER to
operation.
The Instrument Panel MS-CAN CARRY OUT the network test.
Cluster (IPC) IPC If the scan tool responds
illumination is with no communication
inoperative with the IPC , REFER to
Section 418-00 .
If the scan tool
communicates with the
IPC , INSTALL a new
IPC . REFER to Section
413-01 . TEST the
system for normal
operation.
The Front MS-CAN REFER to Section 415-00 .
Control/Display FCDIM
Interface Module
(FCDIM) illumination
operate correctly
Pinpoint Tests
Pinpoint Test A: All Dimmable Illumination Does Not Increase/Decrease Brightness
Refer to Wiring Diagrams Cell 71 , Cluster and Panel Illumination for schematic and connector
information.
Normal Operation
The instrument panel dimmer switch is a rocker style switch with 2 inputs to the Body Control Module
(BCM) to increase or decrease the backlighting illumination. When the instrument panel dimmer switch
is pressed up or down, a ground signal is routed to the BCM .
Based on the ground signal input from the instrument panel dimmer switch, the BCM sends a message
over the network to the modules with backlighting output indicating the backlighting intensity level, and
provides voltage to the hard-wired dimmable illumination sources.
DTC B134E:23 (Switch Illumination Adjustment Control: Signal Stuck low) — a continuous and
on-demand DTC that sets when the BCM detects the instrument panel dimmer switch is stuck or
held low for more than 2 minutes or the increase or decrease control circuits are shorted to
ground. If the instrument panel dimmer switch is stuck low the BCM defaults the backlighting
illumination to full backlighting intensity.

BCM
PINPOINT TEST A: ALL DIMMABLE ILLUMINATION DOES NOT INCREASE/DECREASE

BRIGHTNESS
Result / Action to
Test Step
Take
A1 CHECK THE RECORDED RESULTS FROM THE BCM ON-DEMAND
SELF-TEST
Ignition OFF. Yes
Review the recorded results from the BCM on-demand self-test. GO to A2 .
Is DTC B134E:23 present?
No
GO to A4 .
A2 CHECK THE INSTRUMENT PANEL DIMMER SWITCH FOR A SHORT
TO GROUND
Disconnect: Instrument Panel Dimmer Switch C2298. Yes
Enter the following diagnostic mode on the scan tool: BCM Self-Test.
Clear the DTCs and repeat the BCM self-test. No
Is on-demand DTC B134E:23 still present? INSTALL a new
instrument panel
dimmer switch.
REFER to
Instrument Panel
Dimmer Switch in
this section. TEST
the system for
normal operation.
A3 CHECK THE INSTRUMENT PANEL DIMMER SWITCH INPUT
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to A7 .
Measure the resistance between the instrument panel dimmer switch
C2298-3, circuit CLN56 (BN/VT), harness side and ground; and No
between the instrument panel dimmer switch C2298-7, circuit CLN55 REPAIR the circuit
(YE/VT), harness side and ground. in question for a
short to ground.
CLEAR the DTCs.
REPEAT the self-
test.

A4 CHECK THE INSTRUMENT PANEL DIMMER SWITCH
Disconnect: Instrument Panel Dimmer Switch C2298. Yes
NOTE: For this step, the PID should indicate "DIMMER" each time the INSTALL a new
fused jumper wire is connected. instrument panel
For the illumination decrease function, while monitoring the BCM PID dimmer switch.
IP_DIMMER_SW, connect and disconnect a fused jumper wire REFER to
between the instrument panel dimmer switch C2298-3, circuit CLN56 Instrument Panel
(BN/VT), harness side and the instrument panel dimmer switch C2298- Dimmer Switch in
4, circuit GD115 (BK/GY), harness side. this section. TEST
the system for
normal operation.
No
GO to A5 .
NOTE: For this step, the PID should indicate "BRIGHTER" each time
the fused jumper wire is connected.
For the illumination increase function, while monitoring the BCM PID
IP_DIMMER_SW, connect and disconnect a fused jumper wire
between the instrument panel dimmer switch C2298-7, circuit CLN55
(YE/VT), harness side and the instrument panel dimmer switch C2298-
4, circuit GD115 (BK/GY), harness side.
Does the PID indication agree with the fused jumper wire
position?
A5 CHECK THE INSTRUMENT PANEL DIMMER SWITCH GROUND
CIRCUIT
NOTE: For this step, the PID should indicate "DIMMER" each time the Yes
fused jumper wire is connected to C2298-3, and "BRIGHTER" each REPAIR circuit
time the fused jumper wire is connected to C2298-7. GD115 (BK/GY)
While monitoring the BCM PID IP_DIMMER_SW, connect and for an open. TEST
disconnect a fused jumper wire between the instrument panel dimmer the system for
switch C2298-3, circuit CLN56 (BN/VT), harness side and ground; and normal operation.
between the instrument panel dimmer switch C2298-7, circuit CLN55
(YE/VT), harness side and ground. No
GO to A6 .
Does the PID indication agree with the fused jumper wire
position?
A6 CHECK THE INSTRUMENT PANEL DIMMER SWITCH DIM UP AND
DIM DOWN CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to A7 .
C2298-3, circuit CLN56 (BN/VT), harness side and the BCM C2280E- No
11, circuit CLN56 (BN/VT), harness side. REPAIR the circuit
in question for an
open. TEST the
system for normal
operation.

C2298-7, circuit CLN55 (YE/VT), harness side and the BCM C2280E-
12, circuit CLN55 (YE/VT), harness side.
Connect all disconnected connectors. Yes
Disconnect all the BCM connectors. INSTALL a new
Check for: BCM . REFER to
corrosion Section 419-10 .
damaged pins TEST the system
pushed-out pins for normal
Connect all the BCM connectors and make sure they seat correctly. operation.
The system is
operating correctly
at this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test B: All Dimmable Non-Networked Illumination Is Inoperative
information.
Normal Operation
When the parking lamps are on, the Body Control Module (BCM) provides voltage to the hard-wired
dimmable illumination sources based on the hard-wired inputs from the instrument panel dimmer switch
to the BCM .
DTC U2010:11 (Switch Illumination: Circuit Short To Ground) — A continuous and on-demand
DTC that sets when the BCM has temporarily shut down the output driver. The module has
temporarily disabled the backlighting output because an excessive current draw exists (such as a
short to ground). The BCM cannot enable the backlighting output until the cause of the short is
corrected, the DTCs have been cleared and an ignition cycle takes place.

BCM
PINPOINT TEST B: ALL DIMMABLE NON-NETWORKED ILLUMINATION IS INOPERATIVE


B1 CHECK THE INSTRUMENT PANEL DIMMER SWITCH
While observing the Instrument Panel Cluster (IPC), press the Yes
instrument panel dimmer switch up and down. GO to B2 .
Does the backlighting in the IPC increase and decrease
intensity? No
B2 BYPASS THE BCM
Ignition OFF. Yes
Disconnect: BCM C2280E . REMOVE the jumper
NOTE: If the jumper wire fails, refer to the Wiring Diagrams wire. GO to B3 .
manual to identify the possible causes of the circuit short. After
the repair: No
REMOVE the jumper
If no DTCs are present, test the system for normal operation. wire. REPAIR circuit
CLN04 (BU/BN) for an
If DTCs are present, clear the DTCs and repeat the self-test. Test for normal operation.
Connect a fused jumper wire between the BCM C2280E-20,

circuit CLN04 (BU/BN) and battery positive.
Do the backlighting components illuminate?

correctly. No
Is the concern still present? correctly at this time.
Pinpoint Test C: All Dimmable Non-Networked Illumination Is Always On
information.
Normal Operation
When the parking lamps are on, the Body Control Module (BCM) provides voltage to the hard-wired
dimmable illumination sources based on the hard-wired inputs from the instrument panel dimmer switch
to the BCM .

BCM
PINPOINT TEST C: ALL DIMMABLE NON-NETWORKED ILLUMINATION IS ALWAYS ON

C1 CHECK THE EXTERIOR LIGHTING
Place the headlamp switch in the OFF Yes
position. REFER to Section 417-01 .
Observe the parking lights.
Are the parking lights illuminated? No
GO to C2 .
C2 CHECK THE BCM BACKLIGHTING
OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280E. REPAIR circuit CLN04 (BU/BN) for a short to
Ignition ON. voltage. TEST the system for normal operation.
Do the dimmable backlighted
components continue to illuminate? No
GO to C3 .
C3 CHECK FOR CORRECT BCM
OPERATION
Ignition OFF. Yes
Disconnect all the BCM connectors. INSTALL a new BCM . REFER to Section 419-
Check for: 10 . TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time.
Connect all the BCM connectors and The concern may have been caused by a loose
make sure they seat correctly. or corroded connector.
Operate the system and verify the
Pinpoint Test D: The Steering Wheel Switch Illumination Is Inoperative
information.
Normal Operation
The Body Control Module (BCM) sends voltage to the steering wheel switches. The voltage passes
through the clockspring to the steering wheel harness and on to the steering wheel switches.

Steering wheel switch(es)
Steering wheel harness
Clockspring
PINPOINT TEST D: THE STEERING WHEEL SWITCH ILLUMINATION IS INOPERATIVE
Result / Action to
Test Step
Take
D1 CHECK THE OTHER DIMMABLE LIGHTING SWITCHES
Ignition OFF. Yes
Place the headlamp switch in the PARKING LAMPS ON position. GO to Pinpoint Test
Press and hold the instrument panel dimmer switch up to the full B.
illumination position and observe other dimmable switches.
Are all the dimmable switches inoperative? No
GO to D2 .
D2 CHECK THE HORN OPERATION
Press the driver air bag module against the steering wheel. Yes
Does the horn sound? GO to D3 .
No
REFER to Section
413-06 to diagnose
the horn is
inoperative.
D3 CHECK FOR VOLTAGE TO THE CLOCKSPRING
Place the headlamp switch in the OFF position. Yes
Disconnect: Clockspring C218B. GO to D4 .
Place the headlamp switch in the PARKING LAMPS ON position.
Press and hold the instrument panel dimmer switch up to the full No
illumination position. REPAIR circuit
Measure the voltage between the clockspring C218B-13, circuit CLN04 (BU/BN) for
CLN04 (BU/BN), harness side and ground. an open. TEST the
system for normal
operation.

D4 CHECK THE GROUND CIRCUIT TO THE CLOCKSPRING FOR
CONTINUITY
Measure the voltage between the clockspring C218B-13, circuit Yes
CLN04 (BU/BN), harness side and the clockspring C218B-15, circuit GO to D5 .
GD115 (BK/GY), harness side.
No
REPAIR circuit
GD115 (BK/GY) for
an open. TEST the
system for normal
operation.

D5 CHECK FOR VOLTAGE TO THE STEERING WHEEL SWITCH
Connect: Clockspring C218B. Yes
Place the headlamp switch in the OFF position. REPLACE the
Remove the driver air bag module. Refer to Section 501-20B . inoperative steering
Disconnect: Inoperative Steering Wheel Switch. wheel switch.
Place the headlamp switch in the PARKING LAMPS ON position.
For the cruise control switch, measure the voltage between the For the cruise
cruise control switch C2999-3, harness side and the cruise control control switch,
switch C2999-1, harness side. REFER to Section
For the steering wheel controls switch, measure the voltage between 419-03 .
the steering wheel controls switch C2998-3, harness side and the
steering wheel controls switch C2998-1, harness side. For the steering
wheel controls
switch, REFER to
Section 415-00
TEST the system for

normal operation.
No
GO to D6 .

D6 CHECK FOR VOLTAGE TO THE UPPER CLOCKSPRING
Disconnect: Clockspring C218C . Yes
Measure the voltage between the clockspring C218C-6, component INSTALL a new
side and the clockspring C218C-8, component side. steering wheel.
REFER to Section
211-04 . TEST the
system for normal
operation.
No
INSTALL a new
clockspring. REFER
TEST the system for
normal operation.
Pinpoint Test E: One Or More Switch Illumination is Inoperative
information.
Normal Operation
The Body Control Module (BCM) sends voltage to the dimmable components.

Illuminated switch
PINPOINT TEST E: ONE OR MORE SWITCH ILLUMINATION IS INOPERATIVE
Result / Action to
Test Step
Take
E1 CHECK THE VOLTAGE TO THE SINGLE ILLUMINATION
NOTE: If the instrument panel dimmer switch illumination is the Yes

inoperative source, increase the backlighting brightness to the GO to E2 .
highest setting before disconnect the instrument panel dimmer
switch connector. No
REPAIR circuit CLN04
Ignition OFF. (BU/BN) for an open.
Disconnect: Inoperative Illumination Source. TEST the system for
Ignition ON. normal operation.
NOTE: If the headlamp switch illumination is the inoperative
source, unplugging the headlamp switch connector causes the
BCM to turn the exterior lights on by default, so there is no need to
turn the parking lamps on.
Place the headlamp switch to the PARKING LAMPS ON position.
Increase the backlighting brightness to the highest setting.
Measure the voltage between the inoperative illumination source,
harness side and ground as follows:
Connector-
Component Pin Circuit
Instrument panel dimmer switch C2298-2 CLN04
(BU/BN)
Headlamp switch C205-1 CLN04
(BU/BN)
Front Controls Interface Module C2402-3 CLN04
(FCIM) (BU/BN)
HVAC module C228A-6 CLN04
(BU/BN)
Floor shifter C3245-4 CLN04
(BU/BN)
Driver heated seat switch C2400-5 CLN04
(BU/BN)
Passenger heated seat/ambient C2401-5 CLN04
lighting switch (BU/BN)
Start/stop switch C2195-6 CLN04
(BU/BN)

E2 CHECK THE GROUND CIRCUIT TO THE ILLUMINATION SOURCE
FOR CONTINUITY
Measure the voltage between the inoperative illumination source Yes
pins, harness side as follows: INSTALL a new
component in
Connector-Pin/ Connector-Pin/ question. TEST the
Component Circuit Circuit system for normal
operation.
Instrument panel dimmer C2298-2 C2298-1
switch No
CLN04 (BU/BN) GD115 (BK/GY) REPAIR the ground
circuit in question for
Headlamp switch C205-1 C205-8
an open. TEST the
system for normal
CLN04 (BU/BN) GD115 (BK/GY)
operation.
Front Controls Interface C2402-3 C2402-5
Module (FCIM)
HVAC module C228A-6 C228A-13

Floor shifter C3245-4 C3245-5

Driver heated seat switch C2400-5 C2400-4

Passenger heated C2401-5 C2401-4
seat/ambient lighting switch
Start/stop switch C2195-6 C2195-1

Instrument Panel Dimmer Switch
Part
1 11691 Instrument panel dimmer switch
2 — Instrument panel dimmer switch electrical connector
(part of 14K024)
1. Using a suitable non-marring tool, pry the dimmer switch from the instrument panel.

SECTION 413-01: Instrumentation, Message Center, and Warning Chimes 2011 Fiesta Workshop Manual
Part
1 — LH turn indicator
2 — Low engine oil pressure warning indicator
3 — ABS warning indicator
4 — Engine over-temperature warning indicator
5 — High beam indicator
6 — Powertrain malfunction (wrench) warning indicator
7 — Tire Pressure Monitoring System (TPMS) warning indicator
(Note that the TPMS warning indicator is the only
indication on this vehicle. There are no additional warnings
for low tire pressure.)
8 — Odometer display area
9 — Hill start assist indicator
10 — Air bag warning indicator
11 — Low fuel warning indicator
12 — Upshift indicator
13 — Traction control indicator
14 — Cruise control indicator
15 — RH turn indicator
16 — Speedometer
17 — Safety belt warning indicator
18 — Malfunction Indicator Lamp (MIL)
19 — Charging system warning indicator
20 — Anti-theft indicator
21 — Fuel gauge
22 — Brake warning indicator
23 — Door ajar warning indicator
24 — Oil change minder
25 — Overdrive off
26 — Tachometer
The Instrument Panel Cluster (IPC) contains gauges, informational indicators, warning indicators and an
integrated circuit display designed to provide the driver with system status and to alert the driver when certain
conditions exist in the vehicle.
The integrated circuit display, located in the top center of the IPC , uses a 3-line Liquid Crystal Display (LCD) of
basic informational items such as the odometer, trip odometer, gear position display, Distance To Empty (DTE),
average fuel economy and outside air temperature.
Gauges
Gauges inform the driver of the status of systems. The systems that use gauges are as follows:
Engine rpm
Fuel level
Vehicle speed
Transport Mode
The vehicle is placed in a transport mode at the completion of production to reduce the drain on the battery.
Various systems may be altered in how they operate or are disabled when in the transport mode. The vehicle
automatically reverts to normal operation after 80 km (50 miles). To disable or turn off the transport mode, carry
out the following within 10 seconds:
Verify the battery is fully charged.

With ignition in RUN, press brake pedal 5 times.
Press hazard switch 4 times (on, off, on, off).
Informational Indicators/Warning Indicators
Informational indicators inform the driver of vehicle conditions. Warning indicators inform the driver of conditions
that could potentially cause personal injury or alter vehicle performance.
Hardwired Inputs
The hardwired inputs are provided from the following systems or components:
Accelerator Pedal Position (APP) sensor

A/C request switch
Ambient temperature sensor
Brake fluid level switch
Evaporator temperature sensor
Clutch pedal switch
Cruise control switch
Fuel pump module
Message center switch (located in the multifunction switch)
Network communications High Speed Controller Area Network (HS-CAN) and Medium Speed Controller
Area Network (MS-CAN)
Park detect switch
Parking brake switch
Passive Anti-Theft System (PATS) transceiver
Network Messaged Inputs
Module messaging has increased over time and has become the standard for sending and receiving
information required to operate the IPC . For a complete list of module messages with the message origination
sources, refer to Section 418-00 .
The following is a partial list of status and information messages the IPC requires from other vehicle inputs:
ABS
ABS braking
Stability/traction control
Chassis
Electronic Power Assist Steering (EPAS)
Lighting system
LH/RH turn
High beam
Powertrain
Charging system
Cruise control system
Engine emission system
Engine oil pressure
Engine rpm
Engine temperature
Overdrive status
Hill start assist status
Oil life
Tow haul status
Transaxle range
Transaxle upshift (manual transaxle)
Transaxle fault
Vehicle speed
Security/safety
Door ajar
Supplemental Restraint System (SRS)
Air bag
Safety belt/Belt-Minder®
Information And Message Center
The message center consists of the following:

Front Control/Display Interface Module (FCDIM)
The message center is integrated into the FCDIM , which displays message center warning messages,
message center warning indicators and audio information. The message center displays are controlled
by the IPC through messages sent to the FCDIM over the High Speed Controller Area Network (HS-
CAN) communication bus. The message center constantly monitors different vehicle systems and
displays all warnings and message center functions in the FCDIM . The message center notifies the
driver of potential vehicle concerns by displaying a warning message pertaining to the system in which a
fault has been detected.
Oil Change Minder
The message center provides an oil change minder to inform the driver that an oil change is required.
The calculated interval between oil changes is based on mileage and time. The interval for the oil
change minder is 16,093 km (10,000 miles) or 1 year. The oil change minder can be reset by the driver.
Refer to Message Center Configuration in this section.
Message Center Indicators
The FCDIM displays message center indicators along with warning messages. Many of the message
center indicators use the same or similar iconic representations that are used in the IPC as informational
or warning indicators. For example: the door ajar message center warning indicator is represented by
the same door ajar symbol used in the IPC . The message center indicators are displayed along with
warning messages and may also be accompanied by a warning chime.
System Warning Messages
The system warning messages alert the operator to possible concerns or malfunctions in the vehicle
operating systems. The warning messages that are displayed in the message center are as follows:
Body
AIR BAG MALFUNCTION SERVICE NOW

ALARM SYSTEM MALFUNCTION NEXT SERVICE
ALARM TRIGGERED CHECK VEHICLE
DRIVER DOOR OPEN
DRIVER'S REAR DOOR OPEN
HOOD OPEN
PASSENGER DOOR OPEN
PASSENGER REAR DOOR OPEN
TRUNK OPEN
Chassis
ABS MALFUNCTION SERVICE NOW

BRAKE FLUID LEVEL LOW SERVICE NOW
BRAKE SYSTEM MALFUNCTION STOP SAFELY
STEERING ASSIST FAULT SERVICE NOW
TCS OFF
Intelligent Access (IA)
KEY BATTERY LOW REPLACE BATTERY

KEY NOT DETECTED
TURN IGNITION OFF USE POWER BUTTON
KEY OUTSIDE CAR
TO START PRESS BRAKE
CLOSE TRUNK OR USE SPARE KEY
TO START PRESS CLUTCH
IMMOBILIZER MALFUNCTION SERVICE NOW
TO START PRESS BRAKE
VEHICLE NOT IN PARK SELECT P
TO START SELECT N
TO START SELECT N OR P
Powertrain
DOOR OPEN APPLY BRAKE

ENGINE OIL CHANGE NEXT SERVICE
ENGINE OIL PRESSURE LOW STOP SAFELY
ENGINE MALFUNCTION SERVICE NOW
TRANSMISSION HOT STOP OR SPEED UP
TRANSMISSION HOT STOP SAFELY
TRANSMISSION MALFUNCTION SERVICE NOW
TRANSMISSION HOT WAIT 1 MINUTE
TRANSMISSION HOT WAIT XX MINUTES
TRANSMISSION HOT WAIT...
TRANSMISSION READY
USE BRAKE TO STOP SAFELY
Warning Chimes
The warning chimes provide the driver with an audible warning that acts as a supplemental alert to the
Instrument Panel Cluster (IPC) indication and message center warnings. The IPC controls all warning
chimes based on messages received from external modules.
The warning chime system consists of the following:
IPC
Safety belt warning indicator switch(es)
Door ajar switch(es)
Headlamp switch
Key-in-ignition warning switch (without Intelligent Access (IA))
The following chimes are controlled by the IPC :
Belt-Minder®
Door ajar
Headlamps on
Key-in-ignition
Parking brake applied
Safety belt warning
Turn signal/hazard
Instrumentation, Message Center and Warning Chimes
Special Tool(s)
Instrument Gauge System

Tester
Vehicle Security Module (VSM)

and Integrated Diagnostic
appropriate hardware, or
equivalent scan tool
Flex Probe Kit

NOTE: Whenever a network message is suspected as missing or confirmed by a missing message DTC
(U-code), it is important to look for other conditions that may also be present in the Instrument Panel
Cluster (IPC) and throughout the vehicle. Once a DTC sets in the IPC , it may be helpful to review the
complete message list available in Section 418-00 to see what other modules also rely on the same
message and run the self-test for those modules. If the message is missing from other modules, the
same DTC may also be set in those modules. Confirmation of missing messages common to multiple
modules may indicate that the originating module is the source of the concern or the communication
network may be experiencing some problems.
The IPC uses input messages from other modules to control the gauges, informational indicators,
warning indicators, message center and warning chimes over the communication networks. If a required
message is missing or invalid for less than 5 seconds, the gauge or indicator that requires the message
remains at the last commanded state based upon the last known good message. For example, if the
brake status message is missing for less than 5 seconds and the brake warning indicator was
illuminated, the indicator remains in the on state until the next good message is received. If the message
remains missing or invalid for more than 5 seconds, the IPC sets a U-code DTC and the output becomes
a default action for the indicator or gauge. Each indicator or gauge utilizes a different default strategy
depending on the nature of the indication. Refer to the normal operation descriptions located before
each individual pinpoint test for further description of the default action specific to each indicator or
gauge. If the messaged input to the IPC returns at any time, the normal function of the gauge or
indicator resumes.
It is very important to understand:
where the input originates.

all the information necessary in order for a feature to operate.
which module(s) receive(s) the input or command message.
whether the module which received the input controls the output of the feature, or whether it
outputs a message over the communication network to another module.
which module controls the output of the feature.
The IPC utilizes a microprocessor to control the gauge and indicator functions. Data is sent to the IPC
over the Medium Speed Controller Area Network (MS-CAN) and the High Speed Controller Area
Network (HS-CAN) bus lines and through hardwired circuitry from individual components. The IPC uses
each input to output an action to the gauges or indicators.
IPC Gateway Function
The IPC acts as a gateway module by receiving information in one format and transmitting it to other
modules using another format. For example, the IPC receives the vehicle speed data from the PCM over
the HS-CAN , converts the data into an MS-CAN message and sends (gateways) the message to other
network modules such as the Body Control Module (BCM). This enables network communication
between modules that do not communicate using the same network ( HS-CAN or MS-CAN ).
IPC Configuration
The IPC contains items that are configurable. Configurable items include customer preference items,
which can be set with a scan tool. The remaining items can be set only through the Programmable
Module Installation (PMI) procedure using As-Built data. Refer to Section 418-01 .
NOTE: When installing a new IPC , it is necessary to upload the module configuration to the scan tool.
Following installation of the IPC download the module configuration from the scan tool into the new IPC .
It is also necessary to carry out key programming and parameter reset whenever a new IPC or PCM is
installed. Refer to Section 419-01B .
IPC Configuration Parameters

Customer Preference As-Built Parameter
— Air bag driver side
— Alarm
— Alternator
— Climate control unit
— Cruise control
— Emission standard
— Engine type
— Front center mounted display
— Fuel
— Gearbox
— Gearbox type
— Hill start assist
— Integrated vehicle dynamic control
— KVM (Intelligent Access (IA))
— Power steering type
— Shift indication
— Speedometer display
— Speed warning device
— Steering wheel position
— Transmission driveline
— Tire pressure mode system
— Trip computer
— Vehicle type
IPC Prove-Out
The IPC and other vehicle modules carry out a display prove-out to verify that all module controlled
informational and warning indicators and monitored systems are functioning correctly within the IPC .
When the ignition is transitioned to the ON state with the engine off, the indicators illuminate to prove-out
according to the following table:
Indicator
Indicator Type Prove-Out Duration
ABS Warning 3 seconds
Air bag Warning 6 seconds
Anti-theft indicator Informational 3 seconds
Brake Warning 3 seconds
Charge Informational Engine start up
Cruise control Informational 3 seconds
Door ajar Informational No prove-out
Engine over- Warning 3 seconds
temperature
High beam Informational No prove-out
Low engine oil pressure Warning Engine start up
Low fuel Informational 3 seconds
Malfunction Indicator Warning Engine start up
Lamp (MIL)
Overdrive off Informational No prove-out
RH/LH turn signals Informational No prove-out
Safety belt Warning 60 seconds if the safety belt is unbuckled, turns off when the
safety belt is buckled (controlled by the Restraints Control
Module (RCM))
Tire Pressure Warning 3 seconds
Monitoring System
(TPMS)
Traction control Informational 3 seconds (controlled by the ABS module)
Upshift Informational 3 seconds
Information and Message Center
The message center is integrated into the Front Control/Display Interface Module (FCDIM). The
message center is controlled by the IPC and acts upon much of the same information that is input and
used to operate the IPC gauges, informational indicators, and warning indicators. The FCDIM receives
the message center display information from the IPC over the MS-CAN communication bus.
Whenever conditions are present that require a warning message, the message center replaces the last
selected display with the new warning message. Once the message is reset or cleared, the message
center returns to the last selected display. If multiple warnings are present, the message center displays
each warning for approximately 4 seconds. Warning messages are also generally associated with other
observable IPC indications. For example, when the LH front door is opened, the message center
displays the message DRIVER DOOR AJAR along with the door ajar warning indicator. This allows the
message center to be a more informative supplement to the IPC gauges and indicators.
Warning Chimes
The IPC uses inputs that are both hardwired to individual components and messages that are sent from
other modules over the HS-CAN or MS-CAN to control the warning chime functions.
Warning Chime Characteristics
Each warning chime has unique characteristics that help identify and differentiate one warning chime
from another. The warning chimes use volume, chime frequency, length of time the chime sounds and
the number of chime tones to identify which chime is sounding. The IPC prioritizes the chimes according
to a preset hierarchy programmed into the IPC software. Generally, when more than one chime request
is received by the IPC , the most important chime sounds. If a lower priority chime is currently sounding,
the higher priority request takes over and replaces the lower priority chime.
There are 3 different chimes as listed below:
Repetitive
Single tone
Tick-tock
The following table provides a summary of the chime characteristics including the chime priority:
IPC Chime Characteristics

Chime
Chime Name Type Condition Description
Belt-Minder® A Repetitive Belt-Minder® A is a repetitive on/off chime tone sequence that sounds for
and B as long as the IPC receives the Belt-Minder® chime request.
Belt-Minder® B is a repetitive on/off chime tone sequence that increases

the tone frequency and duration of the tone. On for as long as the IPC
receives the Belt-Minder® chime request.
Door ajar Single A single on/off chime tone that sounds whenever the IPC receives a door
tone ajar message.
Headlamps on Repetitive A repetitive on/off chime tone sequence that sounds for as long as the
headlamps are on and the IPC receives the chime on command.
Key-in-ignition Repetitive A repetitive on/off chime tone sequence that sounds for as long as the
key is in the ignition (without Intelligent Access (IA)) or with the ignition in
the off state and the transaxle range selector out of park (with IA ) with the
door ajar and IPC receives the chime on command.
Parking brake Repetitive A repetitive on/off chime tone sequence that sounds for as long as the
on parking brake is applied and the IPC receives the chime on command.
Safety belt Repetitive A series of 4 on/off chime tone sequences that sound when the safety belt
is unbuckled and the IPC receives the chime on command.
Turn Tick-tock Repetitive tick-tock sound for as long as the RH or LH turn signal, or
signal/hazard hazard lamps are on and the IPC receives the chime on command.
Belt-Minder®
The Belt-Minder® is configurable. To configure the Belt-Minder®, refer to Belt-Minder®

Deactivating/Activating in this section.
The Belt-Minder® feature supplements the current safety belt warning function and is enabled after the
current safety belt warning is complete. The Belt-Minder® informs the driver that the driver or front
passenger safety belt is unbuckled by intermittently and simultaneously sounding a chime and
illuminating the safety belt warning indicator in the IPC once the vehicle speed has exceeded 9.7 km/h
(6 mph). The Belt-Minder® remains active for 5 minutes from the time it is started. While activated, the
Belt-Minder® chime provides a series of 6 chimes/safety belt warning indicator flash sequences, which
consist of a 1-second chime tone and safety belt warning indicator on/off state. The Belt-Minder® chime
and the safety belt warning indicator sound and flash for 6 seconds, then the chime stops and the safety
belt warning indicator remains on for 30 seconds. The IPC repeats the chime cycle for 5 minutes.
If the vehicle speed drops below 4.8 km/h (3 mph) once the Belt-Minder® chime has activated, the
chime turns off and the safety belt warning indicator remains on. When the vehicle speed exceeds 9.7
km/h (6 mph) again, the Belt-Minder® chime resumes.
The Belt-Minder® warning chime inputs are the:
Ignition state.
Safety belt warning request communicated by the RCM to the IPC through the HS-CAN .
Belt-Minder® chime request communicated by the RCM to the IPC through the HS-CAN .
Safety Belt Warning Chime
The safety belt warning chime warns that the driver safety belt is not fastened and sounds when the
driver safety belt is not fastened, the ignition is transitioned from the OFF/LOCK or ACC state to the
RUN or START state.
The safety belt warning chime stops sounding when the safety belt is fastened, the ignition is
transitioned from the RUN or START state to the OFF/LOCK or ACC state, or the chime has sounded
for approximately 6 seconds.
The safety belt warning chime inputs are the:
Ignition state.
Driver safety belt warning request communicated by the RCM to the IPC through the HS-CAN .
Driver safety belt warning chime request communicated by the RCM to the IPC through the HS-
CAN .
Door Ajar Warning Chime
The door ajar warning chime warns that a door is open or not fully closed. The chime sounds when any
door, or the luggage compartment lid becomes ajar while the ignition is in the RUN state.
The door ajar warning chime stops sounding and resets when all of the doors and the luggage
compartment lid are closed, or the ignition is placed in the OFF/LOCK or ACC state.
The door ajar warning chime inputs are the:
Ignition state.
Door ajar data communicated by the BCM to the IPC through the MS-CAN .
Headlamps On Warning Chime
The headlamps on warning chime sounds if the driver door is ajar, the headlamp switch is in the PARK
or HEADLAMP position, and the ignition is in the OFF/LOCK state with the key removed ( IA only).
The headlamps on warning chime stops sounding when any one of the above conditions are removed or
the battery saver has expired.
The headlamps on warning chime inputs are the:
Ignition state.
Door ajar input from the driver door ajar switch to the BCM .
Headlamp switch input to the BCM .
Headlamps on chime request communicated by the BCM to the IPC through the MS-CAN .
Key-In-Ignition Warning Chime
On vehicles without IA , the key-in-ignition warning chime warns that the key is still in the ignition when
the driver door is ajar. On vehicles with IA , the key-in-ignition warning chime sounds when the ignition is
in the ON state with the door ajar.
On vehicles with IA and a automatic transaxle, the key-in-ignition warning chime is also used when the
ignition is in the OFF mode with the transaxle range selector out of park. The message center displays a
warning message and the chime sounds.
The key-in-ignition warning chime inputs are:
Ignition state.
Key-in-ignition chime request to the IPC from the BCM over the MS-CAN (without IA ).
Key-in-ignition chime request to the IPC from the Remote Function Actuator (RFA) module over
the MS-CAN (with IA ).
Door ajar input to the BCM .
Parking Brake Warning Chime
The parking brake warning chime warns that the parking brake is engaged when the vehicle is in motion.
The parking brake warning chime sounds if the ignition is in the ON state, the parking brake is engaged,
and the vehicle speed is greater than 4.8 km/h (3 mph).
The parking brake warning chime stops sounding and resets if the parking brake is released, the ignition
is not in the ON state, if the vehicle speed is less than 4.8 km/h (3 mph), or after 90 seconds from the
time the chime is activated.
The parking brake warning chime inputs are:
Ignition state.
Parking brake switch status to the IPC .
Vehicle speed data communicated by the PCM to the IPC through the HS-CAN .
Turn/Hazard On Tone
The IPC provides a tick-tock tone along with the visual turn signal indicators to indicate that the RH/LH
TURN or HAZARD indicators are on.
The turn/hazard on tone inputs are:
Left turn indicator signal from the BCM to the IPC through the HS-CAN .
Right turn indicator signal from the BCM to the IPC through the HS-CAN .

Accessory drive belt Central Junction Box (CJB) fuse(s):
Brake fluid level 3 (7.5A)
Door adjustment 19 (7.5A)
Engine oil level 21 (10A)
Engine coolant level Wiring, terminals or connectors
Fuel evaporative system Message center switch
Fuel tank Instrument Panel Cluster (IPC)
Tire pressure
Tire size

tool.

verify the ignition is in the ON state.
The air bag indicator (other indicators may not prove ignition on) confirms ignition
ON. If the ignition does not turn on, refer to Section 211-05 to diagnose no power in
RUN.

418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the IPC , Body Control
Module (BCM), PCM, ABS module and Restraints Control Module (RCM).
Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Instrument Panel Cluster
(IPC) , GO to Symptom Chart - Information And Message Center or GO to Symptom Chart -
Warning Chimes .
DTC Charts
Instrument Panel Cluster (IPC) DTC Chart

B101E:01 Air Conditioning Mode Switch: REFER to Section 412-00 .
B1029:11 Accelerator Pedal Sensor: FOLLOW the PCM diagnostics in section 3, Powertrain
Circuit Short To Ground Control Module (PCM) Quick Test, of the Powertrain
B1029:13 Accelerator Pedal Sensor: FOLLOW the PCM diagnostics in section 3, Powertrain
Circuit Open Control Module (PCM) Quick Test, of the Powertrain
B1048:01 Brake Fluid Level Switch: GO to Pinpoint Test M .
B1053:11 Fuel Tank Level Sensor: GO to Pinpoint Test B .
Circuit Short To Ground
B1053:13 Fuel Tank Level Sensor: GO to Pinpoint Test B .
Circuit Open
B10BD:01 Multifunctional Switch: GO to Pinpoint Test AE .
B10D5:94 PATS Antenna: Unexpected REFER to Section 419-01B .
Operation
B10D7:05 PATS Key: System REFER to Section 419-01B .
Programming Failure
B10D7:51 PATS Key: Not Programmed REFER to Section 419-01B .
B10D7:81 PATS Key: Invalid Data Signal REFER to Section 419-01B .
Received
B10D7:87 PATS Key: Missing Message REFER to Section 419-01B .
B10D7:94 PATS Key: Unexpected REFER to Section 419-01B .
Operation
B10D8:00 PATS Key Less Than REFER to Section 419-01B .
Minimum Programmed: No
B10DA:51 PATS PCM Identifier: Not REFER to Section 419-01B .
Programmed
B10DA:62 PATS PCM Identifier: Signal REFER to Section 419-01B .
Compare Failure
B1A14:11 RCM Warning Lamp: Circuit CLEAR the DTC. REPEAT the self-test. If DTC
Short To Ground B1A14:11 returns, INSTALL a new Instrument Panel
Cluster (IPC). REFER to Instrument Panel Cluster
(IPC) . TEST the system for normal operation.
B1A14:13 RCM Warning Lamp: Circuit CLEAR the DTC. REPEAT the self-test. If DTC
Open B1A14:13 returns, INSTALL a new IPC . REFER to
Instrument Panel Cluster (IPC) . TEST the system for
normal operation.
B1A68:11 Ambient Temperature Sensor: GO to Pinpoint Test AD .
Circuit Short To Ground
B1A68:13 Ambient Temperature Sensor: GO to Pinpoint Test AD .
Circuit Open
B1A84:41 Car Configuration Data: CARRY OUT Programmable Module Installation (PMI)
General Checksum Failure (when the original module is not available). REFER to
Section 418-01 . TEST the system for normal
operation.
B1A84:51 Car Configuration Data: Not CARRY OUT PMI (when the original module is not
Programmed available). REFER to Section 418-01 . TEST the
B1B71:11 Evaporator Temperature REFER to Section 412-00 .
Sensor: Circuit Short To
Ground
B1B71:13 Evaporator Temperature REFER to Section 412-00 .
Sensor: Circuit Open
P0565:01 Cruise Control ON Signal: REFER to Section 419-03 .
P0566:01 Cruise Control OFF Signal: REFER to Section 419-03 .
P0567:01 Cruise Control RESUME REFER to Section 419-03 .
Signal: General Electrical
Failure
P0568:01 Cruise Control SET Signal: REFER to Section 419-03 .
P0569:01 Cruise Control COAST Signal: REFER to Section 419-03 .
P0579:01 Cruise Control Multi-Function REFER to Section 419-03 .
Input A Circuit
Range/Performance: General
Electrical Failure
P0581:13 Cruise Control Multi-Function REFER to Section 419-03 .
Input A Circuit High: Circuit
Open
P0704:01 Clutch Switch Input Circuit: REFER to Section 419-03 .
P081C:01 Park Input Circuit: General GO to Pinpoint Test AG .
Electrical Failure
P1536:01 Parking Brake Switch Circuit: GO to Pinpoint Test M .
P1572:01 Brake Pedal Switch Circuit: REFER to Section 419-03 .
P1607:81 MIL Output Circuit: Invalid DTC P1607:81 sets when the IPC receives invalid
Serial Data Received network data from the PCM. RETRIEVE and REPAIR
all non-network DTCs in the PCM and other modules
on the network. REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual and
Section 419-10 for navigation of all DTCs. TEST the
P1607:87 MIL Output Circuit: Missing GO to Pinpoint Test AM .
Message
U0100:00 Lost Communication With GO to Pinpoint Test AM .
ECM/PCM "A": No Sub Type
Information
U0101:00 Lost Communication With GO to Pinpoint Test AN .
TCM : No Sub Type
Information
U0121:00 Lost Communication With GO to Pinpoint Test AO .
Anti-Lock Brake System (ABS)
Control Module: No Sub Type
Information
U0131:00 Lost Communication With GO to Pinpoint Test AP .
Power Steering Control
Module: No Sub Type
Information
U0140:00 Lost Communication With GO to Pinpoint Test AQ .
Body Control Module: No Sub
Type Information
U0151:00 Lost Communication With GO to Pinpoint Test AR .
Restraints Control Module: No
U0214:00 Lost Communication With GO to Pinpoint Test AS .
Remote Function Actuation:
U0257:00 Lost Communication With GO to Pinpoint Test AT .
Front Controls / Display
Interface Module: No Sub
Type Information
U0401:68 Invalid Data Received From DTC U0401:68 sets when the IPC receives invalid
ECM/PCM "A": Event network data from the PCM for the vehicle speed,
Information engine rpm, engine temperature or odometer count
input. RETRIEVE and REPAIR all non-network DTCs
in the PCM and other modules on the network. REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual and Section 419-10 for navigation of all DTCs.
U2023 (this Fault Received From External DTC U2023 (U0427:68) sets when the IPC receives
may display Node (this may display Invalid invalid network data from the Tire Pressure Monitor
as DTC Data Received From Vehicle (TPM)/Vehicle Security Module (VSM) for the Tire
U0427:68) Security Module: Event Pressure Monitoring System (TPMS) input. RETRIEVE
Information) and REPAIR all non-network DTCs in the TPM / VSM
and other modules on the network. REFER to Section
204-04 for navigation of all DTCs. TEST the system for
normal operation.
U2101:00 Control Module Configuration DTC U2101:00 sets when the IPC configuration does
Incompatible: No Sub Type not match the configuration of the other vehicle
Information modules.
DETERMINE which module was recently installed and

CARRY OUT Programmable Module Installation (PMI)
(when the original module is not available) for that
specific module. REFER to Section 418-01 . TEST the
U2104:01 Trip Meter Reset Button: CLEAR the DTC. REPEAT the self-test. If DTC
General Electrical Failure U2104:01 is still present, INSTALL a new IPC . REFER
to Instrument Panel Cluster (IPC) . TEST the system
U3000:00 Control Module: No Sub Type CLEAR the DTC. REPEAT the self-test. If DTC
Information U3000:00 returns, INSTALL a new IPC . REFER to
Instrument Panel Cluster (IPC) . TEST the system for
normal operation.
U3006:16 Control Module Input Power GO to Pinpoint Test AU .
"A": Circuit Voltage Below
Threshold
U3006:17 Control Module Input Power GO to Pinpoint Test AV .
"A": Circuit Voltage Above
Threshold
U3010:01 Ignition Input Start: General GO to Pinpoint Test AW .
Electrical Failure
PCM DTC Chart

P0460 Fuel Level Sensor A Circuit REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual first.
If sent here from the PC/ED manual, GO to Pinpoint

Test B .
P0461 Fuel Level Sensor A Circuit REFER to the Powertrain Control/Emissions
Range/Performance Diagnosis (PC/ED) manual first.

Test B .
P0462 Fuel Level Sensor A Circuit Low REFER to the Powertrain Control/Emissions

Test B .
P0463 Fuel Level Sensor A Circuit High REFER to the Powertrain Control/Emissions

Test B .
All other — REFER to the Powertrain Control/Emissions
DTCs Diagnosis (PC/ED) manual.

B10F1:23 Key In Switch: Signal Stuck Low GO to Pinpoint Test AI .
All other DTCs — REFER to Section 419-10 .
Instrument Panel Cluster (IPC) Dealer Test Mode
To enter the IPC dealer test mode, begin with the ignition in the OFF mode. Press and hold the IPC
TRIP/RESET button. Place the ignition in the RUN mode and hold the TRIP/RESET button until the
display indicates tESt, usually within 3 to 5 seconds. Press the TRIP/RESET button once to advance
through each stage of the self-test. To exit the IPC dealer test mode, turn the ignition to the OFF
position.
NOTE: The displays listed in the table below use xxx's to represent a numeric or alpha-numeric value.
The value may display the same amount of characters represented by the xxx's or there may be
more/less depending on the type of display. For example, DTC xxxx xxxx xxxx may display DTC C0100.
Note that there were 12 x's in the display description but only 4 digits in the actual display.
IPC Display Description

Test Initial entry display into the dealer test mode.
Gauge Carries out the gauge sweep of all gauges, then displays the
present gauge values.
LED Illuminates all the microprocessor controlled lamps and LEDs.
Read-Only Memory (ROM) level Displays the hexadecimal ROM level. For a ROM checksum fault,
FAIL displays on the bottom line
Non-Volatile Memory (NVM) target Displays the hexadecimal ROM level and type as stored in NVM .
ROM For an NVM checksum fault is detected, FAIL displays on the
bottom line
NVM Electrically Erasable Displays the hexadecimal value for the EEPROM level. For an
Programmable Read-Only NVM checksum fault, FAIL displays on the bottom line
Memory (EEPROM) level
Manufacturing date Displays the hexadecimal coding of the final manufacturing test
date.
DTC Displays DTCs detected in continuous operation not during self-
test.
Speed mph Displays the English speed value being inputs in tenths of mph to
the IPC , the speedometer indicates the present filtered speed.
Speed km/h Displays the metric speed value being inputs in tenths of km/h to
the IPC , the speedometer indicates the present filtered speed.
Speedometer Displays corresponding speedometer gauge driver counts output
for present filtered speed.
Engine rpm Displays the tachometer value being input in rpm to the IPC ,
tachometer indicates the present filtered rpm.
Tachometer Displays corresponding tachometer driver counts output for
present filtered engine rpm.
Odometer Displays the odometer rolling count input to the IPC .
Fuel analog/digital input Displays the present fuel level analog/digital input in decimal. The
IPC indicates the present fuel level.
Fuel gauge Displays corresponding fuel gauge driver counts output for present
filtered fuel level.
Fuel flow Displays the present filtered fuel flow status in decimal (used for
Distance To Empty (DTE) calculation).
Fuel percent Displays the present fuel level percent status in decimal.
Engine temperature Displays the last temperature gauge input value from the High
Speed Controller Area Network (HS-CAN) in degrees C,
temperature gauge indicates the present filtered temperature.
Temperature gauge Displays corresponding temperature gauge driver counts output
for present filtered temperature value.
Battery voltage Displays the present battery monitor reading in volts.
Analog/digital input Displays hexadecimal value of the analog/digital port input reads.
Personality input Displays the vehicle configuration for the personality settings.
Port input Displays hexadecimal value of the digital port reads.
DTE Displays the calculated DTE .
Average fuel economy Displays the running average fuel economy in decimal.
Passive Anti-Theft System (PATS) Displays the current PATS settings.
Manufacturing start date Displays the hexadecimal manufacturing start date.
Symptom Charts
Symptom Chart — Instrument Panel Cluster (IPC)

No communication Fuse(s) REFER to Section 418-00 to
with the Instrument Wiring, terminals diagnose The IPC Does Not
Panel Cluster (IPC) or connectors Respond to The Scan Tool.
IPC
The Instrument Fuse(s) GO to Pinpoint Test A .
Panel Cluster (IPC) Wiring, terminals
is inoperative or connectors
IPC
Incorrect fuel gauge Wiring, terminals GO to Pinpoint Test B .
indication or connectors
Fuel pump
module
Fuel level sender
(float and card)
Fuel tank
IPC
The tachometer is PCM GO to Pinpoint Test C .
inoperative IPC
Incorrect tachometer PCM concern GO to Pinpoint Test D .
indication IPC
The speedometer is PCM GO to Pinpoint Test E .
inoperative IPC
Incorrect Tire size GO to Pinpoint Test F .
speedometer configuration
indication PCM concern
IPC
The odometer is PCM concern GO to Pinpoint Test G .
inoperative IPC
The low oil pressure Wiring, terminals GO to Pinpoint Test H .
warning indicator is or connectors
never/always on Engine oil
pressure switch
Base engine oil
pressure concern
PCM
IPC
The engine over- PCM GO to Pinpoint Test I .
temperature warning IPC
indicator is
never/always on
The low fuel warning IPC GO to Pinpoint Test J .
indicator is never on
The low fuel warning IPC VERIFY that the fuel gauge
indicator is always is operating correctly and
on that the Distance To Empty
(DTE) is less than 80 km (50
miles).
If the DTE is less than
80 km (50 miles), the
system is operating
If the DTE is not less
than 80 km (50 miles),
INSTALL a new IPC .
REFER to Instrument
Panel Cluster (IPC) .
TEST the system for
normal operation.
The charging system Charging system GO to Pinpoint Test K .
warning indicator is concern
never/always on PCM
IPC
The brake warning Wiring, terminals GO to Pinpoint Test L .
indicator is never on or connectors
Parking brake
warning indicator
switch
Brake fluid level
switch
IPC
The brake warning Wiring, terminals GO to Pinpoint Test M .
indicator is always or connectors
on Parking brake
warning indicator
switch
Brake fluid level
switch
ABS concern
IPC
The ABS warning ABS module GO to Pinpoint Test N .
indicator is IPC
never/always on
The stability/traction Traction control GO to Pinpoint Test O .
control indicator is concern
never/always on ABS module
IPC
The Malfunction PCM GO to Pinpoint Test P .
Indicator Lamp (MIL) IPC
is never/always on
The powertrain Electronic Throttle GO to Pinpoint Test Q .
malfunction (wrench) Control (ETC)
never/always on Transmission
concern
IPC
The hill start assist Hill start assist GO to Pinpoint Test R .
indicator is function concern
never/always on ABS module
IPC
The overdrive off Overdrive function GO to Pinpoint Test S .
indicator is concern
never/always on Transmission
Control Module
(TCM)
IPC
The upshift indicator PCM GO to Pinpoint Test T .
is never/always on IPC
The cruise control PCM GO to Pinpoint Test U .
indicator is IPC
never/always on
The oil change PCM GO to Pinpoint Test V .
minder indicator is IPC
never/always on
The door ajar Interior lamps GO to Pinpoint Test W .
never/always on Hood ajar
concern
Decklid ajar
concern
Wiring, terminals
or connectors
Body Control
Module (BCM)
IPC
The LH/RH turn or Turn signal GO to Pinpoint Test X .
high beam indicator concern
is never/always on High beam
concern
BCM
IPC
The Tire Pressure Tire pressure GO to Pinpoint Test Y .
Monitoring System TPMS concern
(TPMS) warning Tire Pressure
indicator is Monitor
never/always on (TPM)/Vehicle
Security Module
(VSM)
IPC
The safety belt Restraints Control GO to Pinpoint Test Z .
warning indicator is Module (RCM)
never/always on IPC
The air bag warning RCM GO to Pinpoint Test AA .
indicator is IPC
never/always on
The anti-theft Passive Anti-Theft GO to Pinpoint Test AB .
indicator is System (PATS)
never/always on concern
IPC
The transaxle range TCM concern GO to Pinpoint Test AC .
display is never on IPC
The outside air Wiring, terminals GO to Pinpoint Test AD
temperature display or connectors
does not operate Ambient Air
correctly Temperature
(AAT) sensor
IPC
The integrated circuit Fuse(s) GO to Pinpoint Test A .
display is inoperative Wiring, terminals
or connectors
IPC
The trip computer Wiring, terminals GO to Pinpoint Test AE .
switch is inoperative or connectors
Message center
switch
IPC
Not all integrated IPC INSTALL a new IPC .
circuit display REFER to Instrument Panel
segments illuminate Cluster (IPC) in this section.
operation.
Symptom Chart — Information And Message Center

The Front Control/Display Communication GO to Pinpoint Test
Interface Module (FCDIM) concern AF .
does not display warning FCDIM
messages or message center
warning indicators
The FCDIM display is blank Fuse REFER to Section
Wiring, terminals 415-00 .
or connectors
FCDIM
An Intelligent Access (IA) IA system REFER to Section
warning is never/always on concern 419-01B .
The VEHICLE NOT IN PARK Wiring, terminals GO to Pinpoint Test
SELECT P warning is or connectors AG .
inoperative/always on Park detect switch
IPC
The DRIVER, PASSENGER, Door ajar warning GO to Pinpoint Test
REAR LEFT, REAR RIGHT indication concern W.
DOOR or TRUNK AJAR
warning is never/always on
The BRAKE SYSTEM Brake warning GO to Pinpoint Test
MALFUNCTION STOP indication concern L (never on) or GO
SAFELY or BRAKE FLUID to Pinpoint Test M
LEVEL LOW SERVICE NOW (always on).
warning is never/always on
The ABS MALFUNCTION ABS warning GO to Pinpoint Test
SERVICE NOW warning is indication concern N.
never/always on
The TCS MALFUNCTION Traction control GO to Pinpoint Test
NEXT SERVICE (base warning indication O.
message center) or ESP concern
MALFUNCTION NEXT
SERVICE (optional message
center) warning is
never/always on
The AIR BAG Air bag warning GO to Pinpoint Test
MALFUNCTION SERVICE indication concern AA .
NOW warning is
never/always on
The POWER STEERING Electronic Power Section 211-00 .
MALFUNCTION SERVICE Assist Steering
NOW warning is always on (EPAS) concern
The ENGINE OIL Base engine oil GO to Pinpoint Test
PRESSURE LOW STOP pressure concern H.
SAFELY warning is Low oil pressure
never/always on warning indication
concern
The TRANSPORT MODE Vehicle still in REFER to Transport
CONTACT DEALER transport mode Mode in Instrument
message is always on Panel Cluster (IPC)
and CARRY OUT
the procedure to
place the vehicle in
normal operation
mode.
A transmission warning is Transaxle Section 307-11 .
never/always on concern
Symptom Chart — Warning Chimes

All the chimes are Instrument Panel INSTALL a new IPC . REFER
inoperative Cluster (IPC) to Instrument Panel Cluster
(IPC) in this section. TEST the
The chime sounds Wiring, terminals GO to Pinpoint Test AH .
when the driver or connectors
door is ajar (no key Key-in-ignition
in ignition and warning switch
headlamps off) (without
Intelligent Access
(IA))
Body Control
Module (BCM)
The key-in-ignition Wiring, terminals GO to Pinpoint Test AI .
warning chime is or connectors
inoperative Key-in-ignition
warning switch
(without IA )
BCM
IPC
The headlamps on Door ajar GO to Pinpoint Test AJ .
warning chime is indication
inoperative BCM
IPC
The door ajar Wiring, terminals OPEN the driver door and
warning chime is or connectors OBSERVE the door ajar
inoperative BCM warning indicator.
IPC If the door ajar warning
indicator does not
operate correctly, GO to
Pinpoint Test W .
If the door ajar warning
indicator operates
correctly, INSTALL a
new IPC . REFER to
Instrument Panel Cluster
(IPC) in this section.
TEST the system for
normal operation.
The safety belt Safety belt GO to Pinpoint Test AK .
warning chime is warning
inoperative indication
concern
Speedometer
concern
IPC
The Belt-Minder® Belt-Minder® GO to Pinpoint Test AK .
feature does not deactivated
operate Safety belt
warning
indication
concern
Speedometer
concern
IPC
The parking brake Brake warning GO to Pinpoint Test AL .
warning chime is indication
inoperative concern
IPC
The turn Turn signal VERIFY that the turn signal
signal/hazard on indication indicator operates correctly.
tone is inoperative concern If the turn signal
IPC indicator does not
operate correctly, GO to
Pinpoint Test X .
If the turn signal
indicator operates
correctly, INSTALL a
new IPC . REFER to
(IPC) . TEST the system
Pinpoint Tests
Pinpoint Test A: The Instrument Panel Cluster (IPC) Is Inoperative
Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.
Normal Operation
The Instrument Panel Cluster (IPC) receives the ignition RUN state input from Central Junction Box
(CJB) fuse 21 (10A). The IPC receives the ignition ACC state input from CJB fuse 19 (7.5A). The IPC
receives hot at all times B+ voltage from CJB fuse 22 (7.5A). The IPC is grounded through a single
hardwired ground circuit.
Fuse(s)
IPC
PINPOINT TEST A: THE IPC IS INOPERATIVE

A1 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-
TEST
Check for recorded IPC DTCs from the self-test. Yes
Is DTC U3010:01 recorded? GO to Pinpoint Test AW .
No
GO to A2 .
A2 CHECK THE IPC B+ VOLTAGE SUPPLY
Ignition OFF. Yes
Disconnect: IPC C220. GO to A3 .
Measure the voltage between the IPC C220-32, circuit SBP03
(BU/RD), harness side and ground. No
VERIFY the CJB fuse 3
(7.5A) is OK. If OK,
REPAIR circuit SBP03
(BU/RD) for an open. If not
system for normal
operation.

A3 CHECK THE IPC RUN VOLTAGE SUPPLY
Ignition ON. Yes
Measure the voltage between the IPC C220-4, circuit CBP21 GO to A4 .
(BU/GY), harness side and ground.
No
(10A) is OK. If OK, REPAIR
circuit CBP21 (BU/GY) for
an open. If not OK, REFER
system for normal
operation.

A4 CHECK THE IPC ACC VOLTAGE SUPPLY
Ignition In ACC. Yes
Measure the voltage between the IPC C220-15, circuit CBP19 GO to A5 .
(BN/WH), harness side and ground.
No
(7.5A) is OK. If OK,
(BN/WH) for an open. If not
system for normal
operation.

A5 CHECK THE IPC START VOLTAGE SUPPLY
Place the ignition in the START position. Yes
Measure the voltage between the IPC C220-9, circuit CDC54 GO to A6 .
(WH/GN), harness side and ground.
No
(WH/GN) for an open.
operation.

A6 CHECK THE IPC GROUND CIRCUIT FOR AN OPEN
Ignition ON. Yes
Measure the voltage between the IPC C220-32, circuit SBP03 GO to A7 .
(BU/RD), harness side and the IPC C220-6, circuit GD115
(BK/GY) for an open. TEST
operation.

A7 CHECK FOR CORRECT IPC OPERATION
Disconnect the IPC connector. Yes
Check for: INSTALL a new IPC .
corrosion REFER to Instrument Panel
damaged pins Cluster (IPC) in this section.
Connect the IPC connector and make sure it seats correctly. operation.
Operate the system and determine if the concern is still
present. No
corroded connector.
Pinpoint Test B: Incorrect Fuel Gauge Indication
Normal Operation
The fuel pump module is hardwired to the Instrument Panel Cluster (IPC) between the fuel level signal
circuit and the fuel level signal return circuit. The fuel level sender (float and card) is a variable resistor
attached to the fuel pump module that ranges from 180 ohms ± 4 ohms at empty (E) and 10 ohms ± 2
ohms at full (F). The IPC provides a reference voltage to the fuel pump module on the fuel level input
circuit. As the fuel level changes, a float actuates a variable resistor on the fuel level sensor card and
raises or lowers the fuel level signal voltage depending on the resistance of the fuel level sensor. The
IPC monitors the changes in voltage and commands the fuel gauge with a corresponding movement of
the pointer. If the IPC detects a fault on the fuel level input circuit, fuel level return circuit or the fuel
pump module, the IPC defaults the fuel gauge to the empty (E) position and illuminates the low fuel
warning indicator.
IPC DTCs
B1053:11 — Fuel A continuous and on-demand DTC that sets after 33 seconds if the IPC
Tank Level Sensor: detects that the fuel sender is out of range on the fuel level input circuit
Circuit Short to with a short to ground. The IPC defaults the fuel gauge to empty (E)
Ground once the IPC detects a fault and sets DTC B1053:11.
B1053:13 — Fuel A continuous and on-demand DTC that sets after 33 seconds if the IPC
Tank Level Sensor: detects that the fuel sender is out of range on the fuel level input circuit
Circuit Open with an open or short to voltage. The IPC defaults the fuel gauge to
empty (E) once the IPC detects a fault and sets DTC B1053:13.
PCM DTCs
P0460 — Fuel Level Sensor Sets when the PCM determines the value of the fuel level input
A Circuit signal is stuck, that the fuel level input signal does not change or
does not correspond with the calculated fuel usage.
P0461 — Fuel Level Sensor Sets when the PCM determines the fuel level input signal
A Circuit Range/Performance 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.
P0462 — Fuel Level Sensor Sets when the PCM detects a short to ground on the fuel pump
A Circuit Low module signal circuit based on the messaged input received
from the IPC .
P0463 — Fuel Level Sensor Sets when the PCM detects an open or a short to voltage on the
A Circuit High fuel pump module signal circuit based on the messaged input
received from the IPC .

Fuel pump module
Fuel level sender (float and card)
Fuel tank
IPC
PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION
Result / Action to
Test Step
Take
B1 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Are any DTCs recorded? For DTC B1053:11,
GO to B2 .
For DTC B1053:13,

GO to B5 .
For all other DTCs,

REFER to DTC Charts
in this section.
No
GO to B9 .
B2 CHECK THE FUEL PUMP MODULE FOR A SHORT TO GROUND
Disconnect: Fuel Pump Module C463. Yes
Wait one minute.
Enter the following diagnostic mode on the scan tool: IPC Self- No
Test. GO to B3 .
NOTE: DTC B1053:13 may also be present when carrying out this
step and should be ignored at this time.
Repeat the IPC self-test.
Retrieve the IPC continuous DTCs.
Is DTC B1053:13 retrieved?
B3 CHECK THE FUEL LEVEL SIGNAL AND RETURN CIRCUITS FOR
A SHORT TOGETHER
Measure the resistance between the IPC C220-8, circuit VE724
(GY), harness side and the IPC C220-7, circuit VE721 (WH/OG), No
harness side. REPAIR the circuits for
a short together.
CLEAR the DTCs.

B4 CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR A SHORT TO
GROUND
Measure the resistance between the IPC C220-8, circuit VE724 Yes
(GY), harness side and ground. GO to B15 .
No
REPAIR circuit VE724
(GY) for a short to
ground. CLEAR the
DTCs. REPEAT the
self-test.

B5 CHECK THE FUEL PUMP MODULE FOR AN OPEN
Ignition OFF. Yes
Disconnect: Fuel Pump Module C463. REMOVE the jumper
Connect a fused jumper wire between the fuel pump module C463- wire. GO to B13 .
1, circuit VE721 (WH/OG), harness side and the fuel pump module
C463-2, circuit VE724 (GY), harness side. No
REMOVE the jumper
wire. GO to B6 .
Ignition ON.
Wait one minute.
Enter the following diagnostic mode on the scan tool: IPC Self-
Test.
NOTE: DTC B1053:13 may also be present when carrying out this
step and should be ignored at this time.
Retrieve the IPC continuous DTCs.
Is DTC B1053:11 retrieved?
B6 CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220. REPAIR circuit VE724
Ignition ON. (GY) for a short to
Measure the voltage between the IPC C220-8, circuit VE724 (GY), voltage. CLEAR the
harness side and ground. DTCs. REPEAT the
self-test.
No
GO to B7 .

B7 CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between the IPC C220-8, circuit VE724 GO to B8 .
(GY), harness side and the fuel pump module assembly C463-2,
circuit VE724 (GY), harness side. No
(GY) for an open.
CLEAR the DTCs.
B8 CHECK THE FUEL LEVEL RETURN CIRCUIT FOR AN OPEN
Measure the resistance between the IPC C220-7, circuit VE721 Yes
(WH/OG), harness side and the fuel pump module assembly C463- GO to B15 .
1, circuit VE721 (WH/OG), harness side.
No
(WH/OG) for an open.
CLEAR the DTCs.

B9 CARRY OUT THE IPC FUEL GAUGE ACTIVE COMMAND USING
THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to B10 .
DataLogger.
Select the IPC fuel gauge (FUELLEVEL) active command. No
Command the fuel gauge from 0% to 20%, 50%, 70% and 100% GO to B15 .
while observing the fuel gauge.
Does the fuel gauge begin at (E) empty, move to
approximately 1/4, 1/2, 3/4 and F (full)?
B10 CHECK THE FUEL LEVEL INPUT TO THE IPC
NOTE: Since the IPC may be in anti-slosh fuel indication mode, Yes
the self-test and tester values may not match the fuel gauge DISCONNECT the
readings. Disregard the actual gauge indication during this test instrument gauge
step. system tester. GO to
B12 .
Ignition OFF.
Disconnect: Fuel Pump Module C463. No
Connect one lead of the instrument gauge system tester to the fuel DISCONNECT the
pump module C463-2, circuit VE724 (GY), harness side and the instrument gauge
other lead to the fuel pump module assembly C463-1, circuit system tester. GO to
VE721 (WH/OG), harness side. B11 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: IPC
DataLogger.
NOTE: It is extremely important to confirm the gauge tester
settings with an ohmmeter to make sure that the gauge tester is in
the correct position. Failure to follow this check may result in
inaccurate test results.
Monitor the IPC fuel level (FUELLEVEL) PID with the gauge tester
set at 180 ohms, 90 ohms, 55 ohms, 30 ohms and 10 ohms.
Does the PID begin at approximately 0%, move to 25%, 50%,
75% then 100%?
B11 CHECK THE FUEL LEVEL SIGNAL AND RETURN CIRCUITS
FOR HIGH RESISTANCE
Ignition OFF. Yes
Disconnect: IPC C220. REMOVE the jumper
Connect a fused jumper wire between the fuel pump module C463- wire. GO to B15 .
1, circuit VE721 (WH/OG), harness side and the fuel pump module
C463-2, circuit VE724 (GY), harness side. No
REPAIR the circuits for
high resistance. TEST
operation.
Measure the resistance between the IPC C220-8, circuit VE724

(GY), harness side and the IPC C220-7, circuit VE721 (WH/OG),
harness side.
B12 CHECK THE FUEL TANK
Check the fuel tank for any damage or deformation. Yes
Is the fuel tank OK? GO to B13 .
No
VERIFY the fuel level
sensor and fuel pump
module are OK.
INSTALL a new fuel
tank. REFER to
operation.
B13 CHECK THE FUEL PUMP MODULE
NOTE: The fuel pump module resistance measures between 10 Yes

ohms ± 2 ohms at the upper stop position and 180 ohms ± 4 ohms CHECK the fuel pump
at the lower stop position. module connector for
corrosion, damaged or
Remove the fuel pump module. Refer to Section 310-01 . pushed out pins and
Measure the resistance between the fuel pump module pin 1, REPAIR as necessary.
component side, and the fuel pump module pin 2, component side, TEST the system for
while moving the float arm from the lower stop position to the upper normal operation.
stop position.
No
GO to B14 .
Does the resistance slowly decrease from approximately 180

ohms to 10 ohms?
B14 CHECK THE FUEL LEVEL SENDER (FLOAT AND CARD)
NOTE: The fuel level sender (float and card) resistance measures Yes
between 180 ohms ± 4 ohms at the lower stop position and 10 INSTALL a new fuel
ohms ± 2 ohms at the upper stop position. pump module. REFER
to Section 310-01 .
Disconnect the fuel level sender (float and card) input wire from the
fuel pump module. CLEAR the DTCs.
Measure the resistance between the fuel level sender (float and REPEAT the self-test.
card) input wire pin 1, harness side, and the fuel level sender (float
and card) return wire pin 2, harness side, while slowly moving the No
float arm from the lower stop position to the upper stop position. INSTALL a new fuel
level sender (float and
card). REFER to
Section 310-01 .
CLEAR the DTCs.
Does the resistance slowly decrease from approximately 180

ohms at the lower stop to 10 ohms at the upper stop?
B15 CHECK FOR CORRECT IPC OPERATION
Disconnect the IPC connectors. Yes
corrosion REFER to Instrument
damaged pins Panel Cluster (IPC) in
pushed-out pins this section. TEST the
Connect the IPC connectors and make sure they seat correctly. system for normal
No
The system is
connector. CLEAR the
DTCs. REPEAT the
self-test.
Pinpoint Test C: The Tachometer Is Inoperative
Normal Operation
The PCM uses the Crankshaft Position (CKP) sensor to measure the engine rpm. The PCM sends the
data to the Instrument Panel Cluster (IPC) over the High Speed Controller Area Network (HS-CAN)
communication bus to command the tachometer according to the data.
If the engine rpm data is invalid for 5 seconds or less or if the IPC does not receive the engine rpm data
for 5 seconds or less, the IPC defaults the tachometer to the last setting, based upon the last known
good rpm message.
If the IPC does not receive the engine rpm data from the PCM for more than 5 seconds, the IPC sets
DTC U0100:00 in continuous memory and defaults the tachometer to 0 rpm. If the engine rpm data
received is deemed invalid by the IPC for 5 seconds or more, the IPC sets DTC U0401:68 and defaults
the tachometer to 0 rpm.
NOTE: If DTC U0100:00 sets in the IPC , other observable symptoms may be an inoperative
speedometer or odometer.
PCM
IPC
PINPOINT TEST C: THE TACHOMETER IS INOPERATIVE

C1 RETRIEVE THE RECORDED DTCs FROM
THE PCM KOEO SELF-TEST
Check the recorded PCM DTCs from the Yes
Key ON Engine OFF (KOEO) self-test. REFER to the Powertrain Control/Emissions
Are any DTCs recorded? Diagnosis (PC/ED) manual.
No
GO to C2 .
C2 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Check for recorded IPC DTCs from the self- Yes
test. For DTC U0100:00, GO to Pinpoint Test AM .
Are any DTCs recorded?
For all other DTCs, REFER to DTC Charts in

this section.
No
GO to C3 .
C3 CARRY OUT THE TACHOMETER ACTIVE
COMMAND USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the INSTALL a new PCM. REFER to Section
scan tool: IPC DataLogger. 303-14 . TEST the system for normal
Select the IPC tachometer (TACH_IND) operation.
active command. Command the tachometer
on then off while monitoring the tachometer. No
Does the tachometer begin at 0 rpm, INSTALL a new IPC . REFER to Instrument
increase to 7,000 rpm then return to 0 Panel Cluster (IPC) in this section. TEST the
rpm? system for normal operation.
Pinpoint Test D: Incorrect Tachometer Indication
Normal Operation
If the engine rpm data is invalid for 5 seconds or less or if the IPC does not receive the engine rpm data
for 5 seconds or less, the IPC defaults the tachometer to the last setting, based upon the last known
good rpm message.
If the IPC does not receive the engine rpm data from the PCM for more than 5 seconds, the IPC sets
DTC U0100:00 in continuous memory and defaults the tachometer to 0 rpm. If the engine rpm data
received is deemed invalid by the IPC for 5 seconds or more, the IPC sets DTC U0401:68 and defaults
the tachometer to 0 rpm.
speedometer or odometer.
PCM concern
IPC
PINPOINT TEST D: INCORRECT TACHOMETER INDICATION

D1 RETRIEVE THE RECORDED DTCs FROM THE PCM
KOEO SELF-TEST
Check the recorded PCM DTCs from the Key ON Yes
Engine OFF (KOEO) self-test. REFER to the Powertrain
Are any DTCs recorded? Control/Emissions Diagnosis
(PC/ED) manual.
No
GO to D2 .
D2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Are any DTCs recorded? For DTC U0100:00, GO to Pinpoint
Test AM .
For all other DTCs, REFER to DTC

Charts in this section.
No
GO to D3 .
D3 CARRY OUT THE TACHOMETER ACTIVE COMMAND
USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to D4 .
IPC DataLogger.
Select the IPC tachometer (TACH_IND) active No
command. Command the tachometer in increments of INSTALL a new IPC . REFER to
10% while monitoring the tachometer. The rpm Instrument Panel Cluster (IPC) in
indicated should increase in increments of this section. TEST the system for
approximately 700 rpm for each 10% change. normal operation.
Does the tachometer indication increase within
specifications?
D4 CHECK THE PCM RPM PIDs
PCM DataLogger. The tachometer is operating
Select the PCM engine rpm (RPM) PID and monitor correctly at this time.
the tachometer while operating the engine at 1,000,
1,500, 2,000 and 2,500 rpm using the PCM PID to set No
the vehicle speed. INSTALL a new IPC . REFER to
Does the tachometer indication range between Instrument Panel Cluster (IPC) in
922-1,078 at 1,000 rpm, 1,422-1,578 rpm at 1,500 this section. TEST the system for
rpm, 1,922-2,078 rpm at 2,000 rpm and 2,422-2,578 normal operation.
rpm at 2,500 rpm?
Pinpoint Test E: The Speedometer Is Inoperative

Normal Operation
The Instrument Panel Cluster (IPC) receives the vehicle speed signal from the PCM over the High
Speed Controller Area Network (HS-CAN) communication bus. The vehicle speed data originates with
the wheel speed sensors. The ABS module provides the wheel speed data to the PCM over the HS-
CAN communication bus. The IPC monitors the vehicle speed input from the PCM and commands the
speedometer with a corresponding movement of the pointer.
If the IPC receives invalid vehicle speed data from the PCM for 5 seconds or less, the IPC defaults the
speedometer to the last setting, based upon the last known good vehicle speed message. If the IPC
does not receive the vehicle speed data from the PCM for more than 5 seconds, the IPC sets DTC
U0100:00 in continuous memory and defaults the speedometer to 0 km/h (0 mph). If the vehicle speed
data received is deemed invalid by the IPC , the IPC sets DTC U0401:68 and defaults the speedometer
to 0 km/h (0 mph).
NOTE: If DTC U0100:00 sets in the IPC , other observable symptoms may be an inoperative tachometer
or odometer.
PCM
IPC
PINPOINT TEST E: THE SPEEDOMETER IS INOPERATIVE

E1 RETRIEVE THE RECORDED DTCs FROM
Check the recorded PCM DTCs from the Key Yes
ON Engine OFF (KOEO) self-test. REFER to the Powertrain
Are any DTCs recorded? Control/Emissions Diagnosis (PC/ED)
manual. TEST the system for normal
operation.
No
GO to E2 .
E2 CARRY OUT THE SPEEDOMETER ACTIVE
Ignition ON. Yes
Enter the following diagnostic mode on the GO to E3 .
scan tool: IPC DataLogger.
Select the IPC speedometer (SPDOMETER) No
active command. Command the speedometer INSTALL a new IPC . REFER to Instrument
on and off while monitoring the speedometer. Panel Cluster (IPC) in this section. TEST
Does the speed begin at 0 km/h (0 mph) the system for normal operation.
move to 209 km/h (130 mph) and return to 0
km/h (0 mph)?
E3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
test. For DTC U0100:00, GO to Pinpoint Test
Are any DTCs recorded? AM . For all other DTCs, REFER to DTC
No
INSTALL a new PCM. REFER to Section
303-14 . TEST the system for normal
operation.
Pinpoint Test F: Incorrect Speedometer Indication
Normal Operation
The Instrument Panel Cluster (IPC) receives the vehicle speed signal from the PCM over the High
Speed Controller Area Network (HS-CAN) communication bus. The vehicle speed data originates with
the wheel speed sensors. The ABS module provides the wheel speed data to the PCM over the HS-
CAN communication bus. The IPC monitors the vehicle speed input from the PCM and commands the
speedometer with a corresponding movement of the pointer.
The IPC provides a tolerance that allows the speed indication to display between 3% below and 7%
above the actual vehicle speed. This means that with an actual vehicle speed of 96.6 km/h (60 mph), the
speedometer may indicate between 93.7-103.3 km/h (58.2-64.2 mph). Incorrect tire size or tire size
configuration could potentially affect the speedometer accuracy.
If the IPC receives invalid vehicle speed data from the PCM for 5 seconds or less, the IPC defaults the
speedometer to the last setting, based upon the last known good vehicle speed message. If the IPC
does not receive the vehicle speed data from the PCM for more than 5 seconds, the IPC sets DTC
U0100:00 in continuous memory and defaults the speedometer to 0 km/h (0 mph). If the vehicle speed
data received is deemed invalid by the IPC , the IPC sets DTC U0401:68 and defaults the speedometer
to 0 km/h (0 mph).
NOTE: If DTC U0100:00 sets in the IPC , other observable symptoms may be an inoperative tachometer
or odometer.
Tire size configuration

PCM concern
IPC
PINPOINT TEST F: INCORRECT SPEEDOMETER INDICATION

F1 CHECK THE TIRE SIZE CONFIGURATION
tool: Module Programming. GO to F2 .
NOTE: The correct tire size can be found on the
vehicle certification label on the LH B-pillar. Refer No
to Section 100-01 . INSTALL the correct size tires or
Verify that the size of the tires installed on the CONFIGURE the correct tire size as
vehicle matches the certification label. required. TEST the system for normal
Verify that the tire size configuration matches the operation.
certification label.
Is the tire size correct and is tire size correctly
configured?
F2 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
manual. TEST the system for normal
operation.
No
GO to F3 .
F3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Test AM . For all other DTCs, REFER
to DTC Charts in this section.
No
GO to F4 .
F4 CARRY OUT THE SPEEDOMETER ACTIVE
Ignition ON. Yes
Enter the following diagnostic mode on the scan GO to F5 .
tool: IPC DataLogger.
Select the IPC speedometer (SPDOMETER) active No
command. Command the speedometer according INSTALL a new IPC . REFER to
to the following tables: Instrument Panel Cluster (IPC) in this
section. TEST the system for normal
Early Build Vehicles and All Vehicles With Part operation.
Number Suffix xF
Command Indication Range
21 km/h (13 mph) 20-22 km/h (13-14 mph)
42 km/h (26 mph) 40-45 km/h (25-28 mph)
63 km/h (39 mph) 61-67 km/h (38-42 mph)
84 km/h (52 mph) 81-90 km/h (50-56 mph)
105 km/h (65 mph) 101-112 km/h (63-70 mph)
126 km/h (78 mph) 121-134 km/h (75-83 mph)
146 km/h (91 mph) 141-157 km/h (88-97 mph)
167 km/h (104 162-179 km/h (100-111
mph) mph)
188 km/h (117 182-201 km/h (113-125
mph) mph)
209 km/h (130 202-224 km/h (125-139
mph) mph)
Late Build Vehicles With Part Number Suffix

xG and xH
Command Indication Range
21 km/h (13 mph) 20-22 km/h (13 mph)
42 km/h (26 mph) 40-43 km/h (25-27 mph)
63 km/h (39 mph) 61-65 km/h (38-40 mph)
84 km/h (52 mph) 81-87 km/h (50-54 mph)
105 km/h (65 mph) 101-108 km/h (63-67 mph)
126 km/h (78 mph) 121-130 km/h (75-81 mph)
146 km/h (91 mph) 141-152 km/h (88-94 mph)
167 km/h (104 162-173 km/h (100-108
mph) mph)
188 km/h (117 182-195 km/h (113-121
mph) mph)
209 km/h (130 202-217 km/h (125-135
mph) mph)
Does the speed indicated increase within the

specified range?
F5 CHECK THE PCM VSS PIDs
tool: PCM DataLogger. GO to F6 .
Select the PCM vehicle speed (VSS) PID and
monitor the PID while driving the vehicle at 32 km/h No
(20 mph), 64 km/h (40 mph) and 97 km/h (60 mph). INSTALL a new IPC . REFER to
Does the speedometer indicate between 31-34 Instrument Panel Cluster (IPC) in this
km/h (19-21 mph), 63-69 km/h (39-43 mph) and section. TEST the system for normal
93-103 km/h (58-64 mph) at the 3 PCM PID operation.
values?
F6 OBSERVE THE SPEEDOMETER OPERATION
Ignition ON. Yes
Observe the speedometer while driving the vehicle The speedometer is operating
at various speeds and stopping frequently. correctly at this time.
Does the speedometer begin at 0 km/h (0 mph)
and fully return to the 0 km/h (0 mph) position No
when the vehicle is stopped? INSTALL a new IPC . REFER to
Instrument Panel Cluster (IPC) in this
operation.
Pinpoint Test G: The Odometer Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the odometer rolling count data from the PCM over the
High Speed Controller Area Network (HS-CAN) communication bus. The IPC monitors the odometer
rolling count input from the PCM and commands the odometer with a display in the integrated circuit
display area.
If the IPC does not receive the odometer rolling count data from the PCM for more than 5 seconds, the
IPC sets DTC U0100:00 in continuous memory and defaults the odometer display to all dashes (-----). If
the odometer rolling count data is deemed invalid by the IPC for 5 seconds or more, the IPC sets DTC
U0401:68 and defaults the odometer display to all dashes (-----).
speedometer or tachometer.
PCM concern
IPC
PINPOINT TEST G: THE ODOMETER IS INOPERATIVE

G1 RETRIEVE THE RECORDED DTCs
FROM THE KOEO PCM SELF-TEST
Check the recorded PCM DTCs Yes
from the Key ON Engine OFF REFER to the Powertrain Control/Emissions
(KOEO) self-test. Diagnosis (PC/ED) manual.
No
GO to G2 .
G2 RETRIEVE THE RECORDED DTCs
FROM THE IPC SELF-TEST
Check for recorded IPC DTCs from Yes
the self-test. For DTC U0100:00, GO to Pinpoint Test AM .
For all other DTCs, REFER to DTC Charts in this
section.
No
INSTALL a new IPC . REFER to Instrument Panel
Cluster (IPC) in this section. TEST the system for
normal operation.
Pinpoint Test H: The Low Oil Pressure Warning Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the engine oil pressure status from the PCM over the High
Speed Controller Area Network (HS-CAN) communication bus. The PCM provides a reference voltage
to the engine oil pressure switch when the ignition key is in the RUN position. With the engine running
and low or no oil pressure, the engine oil pressure switch closes to ground. The PCM detects the
reference voltage pulled low and sends a request to the IPC to illuminate the low oil pressure warning
indicator. With the engine running and sufficient oil pressure, the engine oil pressure switch opens. The
reference voltage remains unchanged or high and sends a request to the IPC to turn off the low oil
pressure warning indicator.
If the IPC fails to receive the oil pressure status from the PCM for 5 seconds or less, the IPC defaults the
low oil pressure warning indicator to the last state (on or off), based upon the last known good oil
pressure status message. If the IPC fails to receive the oil pressure status from the PCM for more than 5
seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the low oil pressure warning
indicator active (on).
speedometer, tachometer, or odometer.

Engine oil pressure switch
Base engine oil pressure concern
PCM
IPC
PINPOINT TEST H: THE LOW OIL PRESSURE WARNING INDICATOR IS NEVER/ALWAYS ON
NOTE: Failure to disconnect the battery when instructed results in false resistance readings. Refer to
Section 414-01 .

H1 CARRY OUT THE IPC INDICATOR LAMP CONTROL ACTIVE
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC If the low oil pressure
DataLogger. warning indicator is
Select the IPC low oil pressure warning indicator (OIL_P_LOW) always on, GO to H2 . If
active command. Command the low oil pressure warning the low oil pressure
indicator on and off. Observe the low oil pressure warning warning indicator is never
indicator. on, GO to H5 .
Does the low oil pressure warning indicator illuminate when
commanded on and turn off when commanded off? No
INSTALL a new IPC .
REFER to Instrument
Panel Cluster (IPC) in
system for normal
operation.
H2 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Is DTC U0100:00 recorded? GO to Pinpoint Test AM .
No
GO to H3 .
H3 CHECK FOR A STUCK CLOSED ENGINE OIL PRESSURE
SWITCH
Ignition OFF. Yes
Disconnect: Engine Oil Pressure Switch C103. INSTALL a new engine
Ignition ON. oil pressure switch.
Observe the low oil pressure indicator. REFER to Section 303-
Does the low oil pressure warning indicator turn off? 01 . TEST the system for
normal operation.
No
GO to H4 .
H4 CHECK THE OIL PRESSURE INPUT CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF. Yes
Disconnect: PCM C175E. GO to H8 .
Measure the resistance between the PCM C175E-25, circuit
CMC24 (GY), harness side and ground. No
REPAIR circuit CMC24
(GY) for a short to
ground. TEST the system
H5 CHECK FOR A STUCK OPEN ENGINE OIL PRESSURE
SWITCH
Ignition OFF. Yes
Disconnect: Engine Oil Pressure Switch C103. REMOVE the jumper
NOTE: Make sure to use a good clean ground for this test step. wire. GO to H7 .
Connect a fused jumper wire between the engine oil pressure
switch C103-1, circuit CMC24 (GY), harness side and ground. No
LEAVE the jumper wire
connected. GO to H6 .
Ignition ON.
Observe the low oil pressure warning indicator.
Does the low oil pressure indicator turn on?
H6 CHECK THE ENGINE OIL PRESSURE INPUT CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. REMOVE the jumper
Disconnect: C175E. wire. GO to H8 .
With the jumper wire in place, measure the resistance between
the PCM C175E-25, circuit CMC24 (GY), harness side and No
ground. REMOVE the jumper
wire. REPAIR circuit
CMC24 (GY) for an open.
TEST the system for
normal operation.
H7 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 switch.
01 . TEST the system for
normal operation.
No
00 to continue diagnosis
of the engine oil
pressure.
H8 RETRIEVE THE RECORDED DTCs FROM THE PCM KOEO
SELF-TEST
Check the recorded PCM DTCs from the Key ON Engine OFF Yes
(KOEO) self-test. REFER to the Powertrain
Are any DTCs recorded? Control/Emissions
Diagnosis (PC/ED)
manual. TEST the
system for normal
operation.
No
GO to H9 .
H9 CHECK FOR CORRECT PCM OPERATION
Disconnect the PCM connectors. Yes
Check for: INSTALL a new PCM.
Connect the PCM connector and make sure it seats correctly.
corroded connector.
Pinpoint Test I: The Engine Over-Temperature Warning Indicator Is Never/Always On
Normal Operation
The PCM uses the Engine Coolant Temperature (ECT) sensor to measure the engine coolant
temperature. The Instrument Panel Cluster (IPC) receives the engine over-temperature request from the
PCM over the High Speed Controller Area Network (HS-CAN) communication bus. When the PCM
detects high engine coolant temperature, the PCM sends a request to the IPC to illuminate the engine
over-temperature warning indicator.
If the engine coolant temperature status message is missing for 5 seconds or less or if the IPC receives
an invalid engine temperature status message for 5 seconds or less, the IPC defaults the engine over-
temperature warning indicator to the last setting (on or off), based upon the last known good request
message.
If the IPC does not receive the engine coolant temperature status message from the PCM for more than
5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the engine over-temperature
warning indicator on. If the engine coolant temperature status message is deemed invalid by the IPC for
5 seconds or more, the IPC sets DTC U0401:68 and defaults the engine over-temperature warning
indicator on.
tachometer, speedometer or odometer.
PCM
IPC
PINPOINT TEST I: THE ENGINE OVER-TEMPERATURE WARNING INDICATOR IS

NEVER/ALWAYS ON

I1 CARRY OUT THE ENGINE OVER-TEMPERATURE
WARNING INDICATOR ACTIVE COMMAND USING THE
SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to I2 .
IPC DataLogger.
Select the IPC engine over-temperature warning No
indicator (COOLANT_LMP) active command. INSTALL a new IPC . REFER to
Command the engine over-temperature warning Instrument Panel Cluster (IPC) in
indicator on and off while monitoring the engine over- this section. TEST the system for
temperature warning indicator. normal operation.
Does the engine over-temperature warning
indicator turn off when commanded off and turn
on when commanded on?
I2 RETRIEVE THE RECORDED DTCs FROM THE PCM
KOEO SELF-TEST
(PC/ED) manual.
No
GO to I3 .
I3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Test AM .
For all other DTCs, REFER to DTC
No
INSTALL a new PCM. REFER to
Section 303-14 . TEST the system
Pinpoint Test J: The Low Fuel Warning Indicator Is Never On
Normal Operation
The low fuel warning indicator illuminates when the Instrument Panel Cluster (IPC) calculation for the
Distance To Empty (DTE) reaches 50 miles (80 km) or less. The DTE is calculated internally by the IPC
from data received from the PCM and the fuel gauge. If the IPC detects a fault in the fuel input (circuitry
or fuel pump module), the IPC defaults the fuel gauge to the empty (E) stop position and illuminates the
low fuel warning indicator.
IPC
PINPOINT TEST J: THE LOW FUEL WARNING INDICATOR IS NEVER ON

J1 CARRY OUT THE IPC INDICATOR LAMP
ACTIVE COMMAND USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the GO to J2 .
Select the IPC low fuel (LOFUELL) active No
command. Command the low fuel warning INSTALL a new IPC . REFER to
indicator on and off. Observe the low fuel Instrument Panel Cluster (IPC) in this
warning indicator. section. TEST the system for normal
Does the low fuel warning indicator operation.
illuminate when commanded on and turn off
when commanded off?
J2 CHECK THE DTE STATUS
Access and observe the message center DTE Yes
displayed mileage. INSTALL a new IPC . REFER to
Does the DTE display indicate 80 km (50 Instrument Panel Cluster (IPC) in this
miles) or less until empty? section. TEST the system for normal
operation.
No
The system is operating correctly at this
time. The low fuel warning message does
not appear until the DTE is 80 km (50
miles) or less.
Pinpoint Test K: The Charging System Warning Indicator Is Never/Always On
Normal Operation
The charging system indicator is controlled by the Instrument Panel Cluster (IPC) based upon data
received from the PCM over the High Speed Controller Area Network (HS-CAN) communication bus.
When a fault is detected in the charging system, the PCM sends the IPC a request to illuminate the
charging system warning indicator.
If the charging system message is missing or invalid for less than 5 seconds, the charging system
warning indicator remains in the last indication mode (on or off) based on the last known good message
received. If the charging system message is missing for more than 5 seconds, the IPC sets DTC
U0100:00 in continuous memory and defaults the charging system warning indicator on. If the charging
data received is deemed invalid by the IPC for 5 seconds or more, the IPC defaults the charging system
warning indicator on.
speedometer, tachometer or odometer.

PCM
IPC
PINPOINT TEST K: THE CHARGING SYSTEM WARNING INDICATOR IS NEVER/ALWAYS ON

K1 CARRY OUT THE IPC INDICATOR LAMP
CONTROL ACTIVE COMMAND USING THE
SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the GO to K2 .
Select the IPC charging system warning No
indicator (CHARGE_LMP) active command. INSTALL a new IPC . REFER to Instrument
Command the charging system warning Panel Cluster (IPC) in this section. TEST the
indicator on and off. Observe the charging system for normal operation.
system warning indicator.
Does the charging system warning
indicator illuminate when commanded
on, and turn off when commanded off?
K2 RETRIEVE THE RECORDED DTCs FROM
Check for recorded PCM DTCs from the Yes
Key ON Engine OFF (KOEO) self-test. REFER to Section 414-00 .
Are any charging system DTCs
recorded? No
GO to K3 .
K3 CHECK THE CHARGING SYSTEM
OPERATION
Check the charging system operation. Refer Yes
to Section 414-00 . GO to K4 .
Does the charging system operate
correctly? No
K4 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
For all other DTCs, REFER to DTC Charts in
this section.
No
If the charging system warning indicator is
always on, INSTALL a new PCM. REFER to
operation. If the charging system warning
indicator is never on, the system is operating
Pinpoint Test L: The Brake Warning Indicator is Never On
Normal Operation
The Instrument Panel Cluster (IPC) uses 3 basic inputs to control the brake warning indicator. The first 2
are the parking brake warning indicator switch and brake fluid level switch. The third is for the Electronic
Brake Distribution (EBD), controlled by the ABS. The parking brake warning indicator switch and brake
fluid level switch are hardwired to the IPC through independent signal circuits. The EBD message is sent
from the ABS module over the High Speed Controller Area Network (HS-CAN) communication bus.
The IPC provides a reference voltage to both the parking brake warning indicator switch and the brake
fluid level switch. When the parking brake is applied, the parking brake warning indicator switch closes
to ground, providing a ground to the IPC and pulling the signal circuit low. When a low brake fluid level
condition exists, the low brake fluid level switch closes to ground pulling the signal circuit low. The IPC
monitors the parking brake and the brake fluid level inputs and illuminates the brake warning indicator
when the parking brake is applied or when the brake fluid level is low. When the ABS module detects a
base brake system concern, other ABS-related or EBD concerns, the ABS module sends a message to
the IPC to illuminate both the ABS warning indicator and the brake warning indicator.

IPC
PINPOINT TEST L: THE BRAKE WARNING INDICATOR IS NEVER ON
Result / Action to
Test Step
Take
L1 CHECK THE OPERATION OF THE IPC
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to L2 .
DataLogger.
Select the IPC brake warning indicator (PBA_LMP) active No
command. Command the brake warning indicator on while INSTALL a new IPC .
observing the brake warning indicator. REFER to Instrument
Does the brake warning indicator illuminate? Panel Cluster (IPC) in
this section. TEST
operation.
L2 CHECK THE OPERATION OF THE BRAKE WARNING INDICATOR
FROM THE PARKING BRAKE SWITCH
Apply the parking brake while monitoring the brake warning Yes
indicator. GO to L5 .
Does the brake warning indicator illuminate?
No
GO to L3 .
L3 CHECK THE PARKING BRAKE WARNING INDICATOR SWITCH
Ignition OFF. Yes
Disconnect: Parking Brake Warning Indicator Switch C306. INSTALL a new
Ignition ON. parking brake
Connect a fused jumper wire between the parking brake warning warning indicator
indicator switch C306-1, circuit CMC25 (WH/VT), harness side and switch. TEST the
ground. system for normal
operation.
No
GO to L4 .
Does the brake warning indicator illuminate?

L4 CHECK THE PARKING BRAKE SIGNAL CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: IPC C220. GO to L8 .
Measure the resistance between the IPC C220-11, circuit CMC25
(WH/VT), harness side and the parking brake warning indicator No
switch C306-1, circuit CMC25 (WH/VT), harness side. REPAIR circuit
CMC25 (WH/VT) for
an open. TEST the
system for normal
operation.

L5 CHECK THE BRAKE FLUID LEVEL INPUT TO THE IPC
NOTE: If the fuse in the jumper wire fails, repair circuit CE908 Yes
(BU/BN) for a short to voltage. GO to L6 .
Ignition OFF.
Disconnect: Brake Fluid Level Switch C124. No
Connect a fused jumper wire between the brake fluid level switch GO to L7 .
C124-2, circuit CE908 (BU/BN), harness side and ground.
Ignition ON.
Monitor the brake warning indicator.
Does the brake warning indicator turn on?
L6 CHECK THE BRAKE FLUID LEVEL INDICATOR SWITCH GROUND
CIRCUIT
Ignition OFF. Yes
Measure the resistance between the brake fluid level switch C124-1, INSTALL a new
circuit GD187 (BK/GN), harness side and ground. brake fluid level
switch. TEST the
system for normal
operation.
No
REPAIR circuit
GD187 (BK/GN) for
an open. TEST the
system for normal
operation.

L7 CHECK BRAKE FLUID LEVEL SIGNAL CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between the IPC C220-16, circuit CE908 GO to L8 .
(BU/BN), harness side and the brake fluid level switch C124-2,
circuit CE908 (BU/BN), harness side. No
REPAIR circuit
CE908 (BU/BN) for
an open. TEST the
system for normal
operation.
L8 CHECK FOR CORRECT IPC OPERATION
pushed-out pins this section. TEST
Connect the IPC connector and make sure it seats correctly. the system for normal
No
The system is
this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test M: The Brake Warning Indicator is Always On
Normal Operation
The Instrument Panel Cluster (IPC) uses 3 basic inputs to control the brake warning indicator. The first 2
are the parking brake warning indicator switch and brake fluid level switch. The third is for the Electronic
Brake Distribution (EBD), controlled by the ABS. The parking brake warning indicator switch and brake
fluid level switch are hardwired to the IPC through independent signal circuits. The EBD message is sent
from the ABS module over the High Speed Controller Area Network (HS-CAN) communication bus.
The IPC provides a reference voltage to both the parking brake warning indicator switch and the brake
fluid level switch. When the parking brake is applied, the parking brake warning indicator switch closes
to ground, providing a ground to the IPC and pulling the signal circuit low. When a low brake fluid level
condition exists, the low brake fluid level switch closes to ground pulling the signal circuit low. The IPC
monitors the parking brake and the brake fluid level inputs and illuminates the brake warning indicator
when the parking brake is applied or when the brake fluid level is low. When the ABS module detects a
base brake system concern, other ABS-related or EBD concerns, the ABS module sends a message to
the IPC to illuminate both the ABS warning indicator and the brake warning indicator.
If the EBD message from the ABS module is missing for less than 5 seconds, the brake warning
indicator remains in the last indication mode (on or off) based on the last known good message
received. If the EBD message from the ABS module is missing or deemed invalid for more than 5
seconds, the IPC sets DTC U0121:00 and defaults the ABS warning indicator on. If the brake warning
message received from the ABS module is deemed invalid by the IPC for 5 seconds or more, the EBD
defaults the brake warning indicator on.
DTC B1048:01 (Brake Fluid Level Switch: General Electrical Failure) — an on-demand DTC that
sets in the IPC if the IPC detects a short to ground on the brake fluid level input circuit.
DTC P1536:01 (Parking Brake Switch Circuit: General Electrical Failure) — an on-demand DTC
that sets when the IPC detects a short to ground on the parking brake warning indicator switch
input circuit during the module self-test.
NOTE: If DTC U0140:00 sets in the IPC , other symptoms may also be present such as Tire Pressure
Monitoring System (TPMS), instrument panel backlighting, and door ajar indication.
NOTE: Both the ABS warning indicator and the brake warning indicator illuminate if the input to turn on
the brake warning indicator is received from the ABS module.

ABS concern
IPC
PINPOINT TEST M: THE BRAKE WARNING INDICATOR IS ALWAYS ON
Result / Action to
Test Step
Take
M1 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES
(DTCs) FROM THE ABS MODULE SELF-TEST
Check for recorded ABS module DTCs from the self-test. Yes
Are any DTCs recorded? REFER to Section
206-09 .
No
GO to M2 .
M2 CHECK THE OPERATION OF THE IPC
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to M3 .
DataLogger.
Select the IPC brake warning indicator active command No
(PBA_LMP). Command the brake warning indicator on then off INSTALL a new IPC .
while observing the brake warning indicator. REFER to Instrument
Does the brake warning indicator illuminate when commanded Panel Cluster (IPC) in
on and turn off when commanded off? this section. TEST the
system for normal
operation.
M3 CHECK THE PARKING BRAKE WARNING INDICATOR SWITCH
Ignition OFF. Yes
Disconnect: Parking Brake Warning Indicator Switch C306. INSTALL a new
Ignition ON. parking brake warning
Monitor the brake warning indicator with the parking brake switch indicator switch. TEST
disconnected. the system for normal
Does the brake warning indicator turn off? operation.
No
GO to M4 .
M4 CHECK THE OPERATION OF THE BRAKE FLUID LEVEL
SWITCH INPUT TO THE IPC
NOTE: Verify that a low brake fluid level condition exists or existed Yes
prior to beginning the brake fluid level switch diagnostics. INSTALL a new brake
fluid level switch.
Ignition OFF. TEST the system for
Disconnect: Brake Fluid Level Switch C124. normal operation.
Ignition ON.
Monitor the brake warning indicator. No
Does the brake warning indicator turn off? GO to M5 .
M5 CHECK THE PARKING BRAKE SIGNAL CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF. Yes
Disconnect: IPC C220. GO to M6 .
Measure the resistance between the parking brake warning
indicator switch C306-1, circuit CMC25 (WH/VT), harness side and No
ground. REPAIR circuit
CMC25 (WH/VT) for a
short to ground. TEST
operation.

M6 CHECK THE BRAKE FLUID LEVEL INPUT CIRCUIT FOR A
SHORT TO GROUND
Measure the resistance between the brake fluid level switch C124- Yes
2, circuit CE908 (BU/BN), harness side and ground. GO to M7 .
No
(BU/BN) for a short to
ground. TEST the
system for normal
operation.

M7 CHECK FOR CORRECT IPC OPERATION
Disconnect all IPC connectors. Yes
Connect all IPC connectors and make sure they seat correctly. system for normal
No
The system is
this time. Concern
may have been
corroded connector.
Pinpoint Test N: The ABS Warning Indicator Is Never/Always On
Normal Operation
The ABS module provides the ABS status to the Instrument Panel Cluster (IPC) over the High Speed
Controller Area Network (HS-CAN) communication bus. If a fault condition exists in the ABS, the ABS
module sends the IPC a command to either flash the ABS warning indicator or to turn it on.
If the ABS status message is missing for less than 5 seconds, the ABS warning indicator remains in the
last indication mode (on or off) based on the last known good message received. If the ABS status
message is missing for more than 5 seconds, the IPC sets DTC U0121:00 and defaults the ABS warning
indicator on. If the ABS data received is deemed invalid by the IPC for 5 seconds or more, the IPC
defaults the ABS warning indicator on.
ABS module
IPC
PINPOINT TEST N: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON

N1 CARRY OUT THE IPC INDICATOR
LAMP CONTROL ACTIVE COMMAND
USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on GO to N2 .
the scan tool: IPC DataLogger.
Select the IPC ABS warning indicator No
(ABS_LAMP) active command. INSTALL a new IPC . REFER to Instrument Panel
Command the ABS warning indicator Cluster (IPC) in this section. TEST the system for
on then off. Observe the ABS warning normal operation.
indicator.
Does the ABS warning indicator turn
off when commanded off?
N2 RETRIEVE THE RECORDED DTCs
Check for recorded IPC DTCs from the Yes
self-test. For DTC U0121:00, GO to Pinpoint Test AO . For
Are any DTCs recorded? all other DTCs, REFER to DTC Charts in this
section.
No
GO to N3 .
N3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE SELF-TEST
Check for recorded ABS module DTCs Yes
from the self-test. REFER to Section 206-09 .
No
If the ABS warning indicator is always on,
INSTALL a new ABS module. REFER to Section
206-09 . TEST the system for normal operation. If
the ABS warning indicator is never on, the system
is operating correctly at this time.
Pinpoint Test O: The Stability/Traction Control Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the stability/traction control data from the ABS module over
the High Speed Controller Area Network (HS-CAN) communication bus. The stability/traction control
indicator flashes when the vehicle traction control is in active mode or is being controlled by the ABS
module. The IPC monitors the stability/traction control message from the ABS module and either flashes
the stability/traction control indicator or turns it on steady depending on the condition.
If the stability/traction control message is invalid for 5 seconds or less or if the IPC does not receive the
stability/traction control message for 5 seconds or less, the IPC defaults the stability/traction control
indicator to the last indication mode (on/off) based upon the last known good message. If the
stability/traction control message is missing for more than 5 seconds, the IPC sets DTC U0121:00 in
continuous memory and defaults the stability/traction control indicator on.
Stability/traction control concern

ABS module
IPC
PINPOINT TEST O: THE STABILITY/TRACTION CONTROL INDICATOR IS NEVER/ALWAYS ON

O1 CARRY OUT THE IPC INDICATOR LAMP
CONTROL ACTIVE COMMAND USING THE
SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the GO to O2 .
Select the IPC stability/traction control No
indicator (TC/IVD/RSCLMP) active INSTALL a new IPC . REFER to Instrument
command. Command the stability/traction Panel Cluster (IPC) in this section. TEST the
control active indicator on and off while system for normal operation.
observing the stability/traction control
indicator.
Does the stability/traction control
indicator illuminate when commanded
on and turn off when commanded off?
O2 RETRIEVE THE RECORDED DTCs FROM

THE IPC SELF-TEST
Check for recorded DTCs from the IPC self- Yes
test. For DTC U0121:00, GO to Pinpoint Test AO .
Are any DTCs recorded? For all other DTCs, REFER to DTC Charts in
this section.
No
GO to O3 .
O3 RETRIEVE THE RECORDED DTCs FROM
THE ABS MODULE SELF-TEST
Check for recorded DTCs from the ABS Yes
module self-test. REFER to Section 206-09 .
No
If the stability/traction control indicator is never
on, the system is operating correctly at this
time. If the stability/traction control indicator is
always on, INSTALL a new ABS module.
REFER to Section 206-09 . TEST the system
Pinpoint Test P: The Malfunction Indicator Lamp (MIL) Is Never/Always On
Normal Operation
The Malfunction Indicator Lamp (MIL) is controlled by the Instrument Panel Cluster (IPC) using data sent
from the PCM over the High Speed Controller Area Network (HS-CAN) communication bus.
If the MIL status message is missing or invalid for less than 5 seconds, the MIL remains in the last
indication mode (on or off) based upon the last known good data message. If the MIL status message is
missing for more than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the
MIL on. If the MIL status message is deemed invalid for more than 5 seconds, the IPC defaults the MIL
on.
PCM
IPC
PINPOINT TEST P: THE MIL IS NEVER/ALWAYS ON

P1 CARRY OUT THE IPC MIL
ACTIVE COMMAND USING THE
SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic GO to P2 .
mode on the scan tool: IPC
DataLogger. No
Select the IPC MIL (MIL) active INSTALL a new IPC . REFER to Instrument Panel Cluster
command. Command the MIL (IPC) in this section. TEST the system for normal
on and off. Observe the MIL . operation.
Does the MIL illuminate when
selected on and turn off when
selected off?
P2 RETRIEVE THE RECORDED
DTCs FROM THE PCM KOEO SELF-
TEST
Check the recorded PCM DTCs Yes
from the Key ON Engine OFF REFER to the Powertrain Control/Emissions Diagnosis
(KOEO) self-test. (PC/ED) manual.
Are any PCM DTCs
recorded? No
GO to P3 .
P3 RETRIEVE THE RECORDED
DTCs FROM THE IPC SELF-TEST
Check for recorded IPC DTCs Yes
from the self-test. GO to Pinpoint Test AM .
Is DTC U0100:00 recorded?
No
If the MIL is never on, the system is operating correctly at
this time. If the MIL is always on, INSTALL a new PCM.
REFER to Section 303-14 . TEST the system for normal
operation.
Pinpoint Test Q: The Powertrain Malfunction (Wrench) Warning Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the powertrain malfunction data from the PCM and the
transmission status from the Transmission Control Module (TCM) over the High Speed Controller Area
Network (HS-CAN) communication bus. When a fault condition exists in the PCM, the PCM sends a
request to the IPC to illuminate the powertrain malfunction (wrench) warning indicator. When a fault
occurs in the transmission, the TCM sends a request to the IPC to illuminate the powertrain malfunction
(wrench) warning indicator.
If the powertrain malfunction (wrench) warning indicator request message is missing from the PCM or
TCM for 5 seconds or less, the powertrain malfunction (wrench) warning indicator remains in the last
indication mode (on or off) based upon the last known good request received. If the powertrain
malfunction (wrench) warning indicator request message is missing from the PCM for more than 5
seconds, the IPC sets DTC U0100:00 and defaults the powertrain malfunction (wrench) warning
indicator on. If the powertrain malfunction (wrench) warning indicator request message is missing from
the TCM for more than 5 seconds, the IPC sets DTC U0101:00 and defaults the powertrain malfunction
(wrench) warning indicator on.
NOTE: If U0100:00 sets in the IPC other symptoms may also be present such as an inoperative
ETC concern
Transmission concern
IPC
PINPOINT TEST Q: THE POWERTRAIN MALFUNCTION (WRENCH) WARNING INDICATOR IS

NEVER/ALWAYS ON
Q1 CARRY OUT THE IPC POWERTRAIN MALFUNCTION
(WRENCH) INDICATOR ACTIVE COMMAND USING THE
SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to Q2 .
IPC DataLogger.
Select the IPC powertrain malfunction (wrench) No
warning indicator (EMS_FAULT) active command. INSTALL a new IPC . REFER to
Command the powertrain malfunction (wrench) Instrument Panel Cluster (IPC) in
warning indicator on and off while observing the this section. TEST the system for
powertrain malfunction (wrench) warning indicator. normal operation.
Does the powertrain malfunction (wrench) warning
indicator illuminate when commanded on, and turn
off when commanded off?
Q2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Is DTC U0100:00 or DTC U0101:00 recorded? For DTC U0100:00, GO to Pinpoint
Test AM . For DTC U0101:00, GO
to Pinpoint Test AN .
No
GO to Q3 .
Q3 RETRIEVE THE RECORDED DTCs FROM THE PCM
KOEO SELF-TEST
Check for recorded PCM DTCs from the Key ON Yes
(PC/ED) manual.
No
diagnose TCM DTCs.
Pinpoint Test R: The Hill Start Assist Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the hill start assist indicator request from the ABS module
over the High Speed Controller Area Network (HS-CAN) communication bus. When the hill start assist is
active, the ABS module sends a request to the IPC to illuminate the hill start assist indicator.
If the hill start assist request is missing or if the data is deemed invalid for less than 5 seconds, the hill
start assist remains in the last indication mode (on or off) based on the last known good request
received. If the hill start assist request is missing or if the data is deemed invalid by the IPC for more
than 5 seconds, the IPC sets DTC U0121:00 in continuous memory and defaults the hill start assist
indicator off.
NOTE: If DTC U0121:00 sets in the IPC , other observable symptoms may be brake, ABS or traction
control warning indication concerns.
Hill start assist function concern

ABS module
IPC
PINPOINT TEST R: THE HILL START ASSIST INDICATOR IS NEVER/ALWAYS ON

R1 CHECK THE OPERATION OF THE HILL
START ASSIST FUNCTION
Verify that the hill start assist function Yes
operates correctly. Refer to Hill Start GO to R2 .
Assist in Section 206-09 .
Does the hill start assist function No
operate correctly? GO to R4 .
R2 CARRY OUT THE IPC DEALER TEST
MODE
Ignition ON. Yes
Enter the IPC dealer test mode. Scroll GO to R3
through the displays until LEd is
displayed. No
Does the hill start assist indicator INSTALL a new IPC . REFER to Instrument
illuminate? Panel Cluster (IPC) in this section. TEST the
R3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
self-test. GO to Pinpoint Test AO .
No
GO to R4 .
R4 RETRIEVE THE RECORDED DTCs FROM
THE ABS MODULE SELF-TEST
Check for recorded ABS module DTCs Yes
No
INSTALL a new ABS module. REFER to
operation.
Pinpoint Test S: The Overdrive Off Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the overdrive off indicator request from the Transmission
Control Module (TCM) over the High Speed Controller Area Network (HS-CAN) communication bus.
When the overdrive off function is selected, the TCM sends a request to the IPC to illuminate the
overdrive off indicator.
If the overdrive off request is missing or if the data is deemed invalid for less than 5 seconds, the
overdrive off indicator remains in the last indication mode (on or off) based on the last known good
request received. If the overdrive off request is missing or if the data is deemed invalid by the IPC for
more than 5 seconds, the IPC sets DTC U0101:00 in continuous memory and defaults the overdrive off
indicator off.
Overdrive function concern

TCM
IPC
PINPOINT TEST S: THE OVERDRIVE OFF INDICATOR IS NEVER/ALWAYS ON

S1 CHECK THE OPERATION OF THE OVERDRIVE
OFF FUNCTION
Verify that the overdrive off function operates Yes
when engaged and turns off when disengaged. GO to S2 .
Refer to Section 307-05 .
Does the overdrive off function operate No
correctly? REFER to Section 307-05 .
S2 CARRY OUT THE IPC OVERDRIVE OFF
INDICATOR ACTIVE COMMAND USING THE SCAN
TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan GO to S3 .
tool: IPC DataLogger.
Select the IPC overdrive off indicator No
(HDC_ACTIVE) active command. Command the INSTALL a new IPC . REFER to
overdrive off indicator on and off while observing Instrument Panel Cluster (IPC) in this
the overdrive off indicator. section. TEST the system for normal
Does the overdrive off indicator illuminate operation.
when commanded on, and turn off when
commanded off?
S3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Is DTC U0100:00 recorded? GO to Pinpoint Test AM .
No
GO to S4 .
S4 RETRIEVE THE RECORDED DTCs FROM THE
TCM SELF-TEST
Check for recorded TCM DTCs from the self-test. Yes
Are any DTCs recorded? REFER to the Powertrain
manual.
No
INSTALL a new TCM . REFER to
Section 307-11 . TEST the system for
normal operation.
Pinpoint Test T: The Upshift Indicator Is Never/Always On
Normal Operation
The upshift indicator informs the driver of shift points that provide the highest fuel economy. The upshift
indicator is controlled by the Instrument Panel Cluster (IPC) based upon an upshift indicator request sent
from the PCM over the High Speed Controller Area Network (HS-CAN) communication bus.
If the upshift indicator request is missing or if the data is deemed invalid for less than 5 seconds, the
upshift indicator remains in the last indication mode (on or off) based on the last known good request
received. If the upshift indicator request is missing or if the data is deemed invalid by the IPC for more
than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the upshift indicator off.
PCM
IPC
PINPOINT TEST T: THE UPSHIFT INDICATOR IS NEVER/ALWAYS ON

T1 CARRY OUT THE IPC UPSHIFT INDICATOR
Ignition ON. Yes
Enter the following diagnostic mode on the GO to T2 .
Select the IPC upshift indicator (SHIFT_LAMP) No
active command. Command the upshift INSTALL a new IPC . REFER to
indicator on and off while observing the upshift Instrument Panel Cluster (IPC) in this
indicator. section. TEST the system for normal
Does the upshift indicator illuminate when operation.
commanded on, and turn off when
commanded off?
T2 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
test. GO to Pinpoint Test AM .
No
GO to T3 .
T3 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Check for recorded PCM DTCs from the Key Yes
manual.
No
operation.
Pinpoint Test U: The Cruise Control Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the cruise control indicator request from the PCM over the
High Speed Controller Area Network (HS-CAN) communication bus. When the cruise control is
engaged, the PCM sends a request to the IPC to illuminate the cruise control indicator.
If the cruise control indicator request is missing or if the data is deemed invalid for less than 5 seconds,
the cruise control indicator remains in the last indication mode (on or off) based on the last known good
request received. If the cruise control indicator request is missing for more than 5 seconds, the IPC sets
DTC U0100:00 in continuous memory and defaults the cruise control indicator off.
PCM
IPC
PINPOINT TEST U: THE CRUISE CONTROL INDICATOR IS NEVER/ALWAYS ON

U1 CHECK THE CRUISE CONTROL OPERATION
Operate the cruise control. Yes
Does the cruise control operate correctly? GO to U2 .
No
U2 CARRY OUT THE IPC INDICATOR LAMP
CONTROL ACTIVE COMMAND USING THE SCAN
TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the GO to U3 .
Select the IPC cruise control indicator No
(CRUISE) active command. Command the INSTALL a new IPC . REFER to
cruise control indicator on and off. Observe the Instrument Panel Cluster (IPC) in this
cruise control indicator. section. TEST the system for normal
Does the cruise control indicator illuminate operation.
when commanded on and turn off when
commanded off?
U3 RETRIEVE AND RECORD THE DTCs FROM
Check for recorded PCM DTCs from the Key Yes
Are any PCM DTCs recorded? Control/Emissions Diagnosis (PC/ED)
manual.
No
GO to U4 .
U4 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
test. For DTC U0100:00, GO to Pinpoint Test
Are any DTCs recorded? AM . For all other DTCs, REFER to DTC
No
operation.
Pinpoint Test V: The Oil Change Minder Indicator Is Never/Always On
Normal Operation
The oil change minder indicator informs the driver that the vehicle requires an oil change. The
Instrument Panel Cluster (IPC) receives the oil change minder indicator request from the PCM over the
High Speed Controller Area Network (HS-CAN) communication bus. When the PCM has determined
that the criteria for vehicle mileage or length of time has been met, the PCM sends a request to the IPC
to illuminate the oil change minder indicator.
If the oil change minder indicator request is missing or if the data is deemed invalid for less than 5
seconds, the oil change minder indicator remains in the last indication mode (on or off) based on the last
known good request received. If the oil change minder indicator request is missing for more than 5
seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the oil change minder
indicator off.
PCM
IPC
PINPOINT TEST V: THE OIL CHANGE MINDER INDICATOR IS NEVER/ALWAYS ON

V1 CARRY OUT THE IPC DEALER TEST
MODE
Ignition ON. Yes
Enter the IPC dealer test mode. Scroll GO to V2 .
through the displays until LEd is displayed.
Does the oil change minder indicator No
illuminate when in the dealer test mode INSTALL a new IPC . REFER to Instrument
and turn off during normal operation? Panel Cluster (IPC) in this section. TEST the
V2 CARRY OUT THE OIL LIFE RESET
PROCEDURE
Reset the oil minder. Refer to Message Yes
Center Configuration in this section. The system is operating correctly at this time.
Does the oil change minder indicator
turn off? No
GO to V3 .
V3 RETRIEVE AND RECORD THE DTCs FROM
Check for recorded PCM DTCs from the Yes
Key ON Engine OFF (KOEO) self-test. REFER to the Powertrain Control/Emissions
Are any PCM DTCs recorded? Diagnosis (PC/ED) manual.
No
GO to V4 .
V4 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Are any DTCs recorded? For all other DTCs, REFER to DTC Charts in
this section.
No
operation.
Pinpoint Test W: The Door Ajar Warning Indicator Is Never/Always On
Normal Operation
The door ajar indicator informs the driver if any of the doors, the luggage compartment lid or the hood is
not completely closed. The door ajar information is sent from the Body Control Module (BCM) to the
Instrument Panel Cluster (IPC) over the Medium Speed Controller Area Network (MS-CAN)
communication bus.
If the door ajar status is missing or if the data is deemed invalid for less than 5 seconds, the door ajar
warning indicator remains in the last indication mode (on or off) based on the last known good request
received. If the door ajar status is missing for more than 5 seconds, the IPC sets DTC U0140:00 in
continuous memory and defaults the door ajar warning indicator off.
Interior lamps concern

Hood ajar concern
Decklid ajar concern
BCM
IPC
PINPOINT TEST W: THE DOOR AJAR WARNING INDICATOR IS NEVER/ALWAYS ON

W1 CHECK THE INTERIOR LIGHTING OPERATION
Open and close each door while monitoring the Yes
courtesy lamps. GO to W2 .
Do the courtesy lamps operate correctly with
each door? No
W2 CARRY OUT THE IPC DOOR AJAR WARNING
INDICATOR ACTIVE COMMAND USING THE SCAN
TOOL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to W3 .
IPC DataLogger.
Select the IPC door ajar warning indicator No
(DOOR_AJAR) active command. Command the door INSTALL a new IPC . REFER to
ajar warning indicator on and off while observing the Instrument Panel Cluster (IPC) in
door ajar warning indicator. this section. TEST the system for
Does the door ajar warning indicator illuminate normal operation.
when commanded on, and turn off when
commanded off?
W3 RETRIEVE THE RECORDED DTCs FROM THE
CONTINUOUS IPC SELF-TEST
Check for recorded IPC DTCs from the continuous Yes
self-test. GO to Pinpoint Test AQ .
No
GO to W4 .
W4 RETRIEVE THE RECORDED DTCs FROM THE BCM
SELF-TEST
Check for recorded DTCs from the BCM self-test. Yes
Are any BCM DTCs recorded? REFER to the Diagnostic Trouble
Code (DTC) Chart in Section 419-
10 .
No
INSTALL a new BCM . REFER to
Pinpoint Test X: The LH/RH Turn Or High Beam Indicator Is Never/Always On
Normal Operation
When the multifunction switch is in the LH or RH TURN position or if the high beams are on, a message
is sent to the Instrument Panel Cluster (IPC) from the Body Control Module (BCM) over the Medium
Speed Controller Area Network (MS-CAN) communication bus. The IPC , upon receipt of the LH/RH turn
or high beam on message, flashes the LH or RH turn signal indicator on and off or illuminates the high
beam indicator.
If the LH/RH TURN or high beam status is missing or if the data is deemed invalid for less than 5
seconds, the LH/RH TURN or high beam indicator remains in the last indication mode (on or off) based
on the last known good request received. If the LH/RH TURN or high beam status is missing for more
than 5 seconds, the IPC sets DTC U0140:00 in continuous memory and defaults the LH/RH TURN or
high beam indicator off.
Turn signal concern

High beam concern
BCM
IPC
PINPOINT TEST X: THE LH/RH OR HIGH BEAM TURN INDICATOR IS NEVER/ALWAYS ON

X1 DETERMINE THE FAULT CONDITION
Place the headlamp switch in the HIGH BEAM position. Yes
Ignition ON. GO to X4 .
Observe the high beam indicator.
Does the high beam indicator illuminate? No
LEAVE the headlamp switch in the
HIGH BEAM position. GO to X2 .
X2 CHECK THE HIGH BEAM HEADLAMPS OPERATION
Observe the high beam headlamps. Yes
Do the high beam headlamps operate correctly? GO to X3 .
No
X3 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to X6 .
IPC DataLogger.
Select the IPC high beam indicator (HIGH_BEAM). No
Command the high beam indicator on and off. Observe INSTALL a new IPC . REFER to
the high beam indicator. Instrument Panel Cluster (IPC) in
Does the high beam indicator illuminate when this section. TEST the system for
commanded on and turn off when commanded off? normal operation.
X4 CHECK THE LH OR RH TURN SIGNAL LAMPS
OPERATION
Ignition ON. Yes
Operate the LH or RH turn signal. Observe the exterior GO to X5 .
LH or RH turn lamps.
Do the turn signal lamps operate correctly? No
X5 CARRY OUT THE IPC INDICATOR LAMP CONTROL
IPC DataLogger. GO to X6 .
Select the IPC RH or LH turn signal indicator
(RH_TURN_L) or (LH_TURN_L) active command. No
Command the RH or LH turn signal indicator on and off. INSTALL a new IPC . REFER to
Observe the LH or RH turn signal indicator. Instrument Panel Cluster (IPC) in
Does the LH or RH turn signal indicator illuminate this section. TEST the system for
when commanded on and turn off when normal operation.
commanded off?
X6 RETRIEVE THE RECORDED DTCs FROM THE BCM
SELF-TEST
Check for recorded BCM DTCs from the self-test. Yes
Are any DTCs recorded? REFER to Section 419-10 .
No
GO to X7 .
X7 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Is DTC U0140:00 recorded? GO to Pinpoint Test AQ .
No
INSTALL a new BCM . REFER to
Pinpoint Test Y: The Tire Pressure Monitoring System (TPMS) Warning Indicator Is Never/Always
On
Normal Operation
The Instrument Panel Cluster (IPC) receives the Tire Pressure Monitoring System (TPMS) messages
from the Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) over the Medium Speed Controller
Area Network (MS-CAN) communication bus. If the TPM / VSM determines that the tire pressure has
exceeded the low tire pressure limits, a message is sent to the IPC to illuminate the TPMS warning
indicator. If a TPMS fault condition exists or if the TPMS is in the tire training mode, the TPM / VSM
sends a message to the IPC to flash the TPMS warning indicator.
If the TPMS status message is missing or invalid for less than 5 seconds, the IPC defaults the TPMS
warning indicator to the last setting (on or off) based upon the last known good message received. If the
TPMS status message is missing for more than 5 seconds, the IPC flashes the TPMS indicator for
approximately 75 seconds then turns the indicator on steady. If the TPMS status message is invalid for
more than 5 seconds, the IPC sets flashes the TPMS indicator for approximately 75 seconds then turns
the indicator on steady.
Tire pressure
TPMS concern
TPM / VSM
IPC
PINPOINT TEST Y: THE TPMS WARNING INDICATOR IS NEVER/ALWAYS ON

Y1 CHECK THE TIRE PRESSURE
Verify that the tire pressure in all tires Yes
meets the recommended tire pressures GO to Y2 .
on the Vehicle Certification (VC) label.
Refer to Section 100-01 . No
Do all the tires meet the CORRECT the tire pressures. TEST the system
recommended tire pressures? for normal operation.
Y2 CARRY OUT THE IPC DEALER TEST
MODE
Ignition ON. Yes
Enter the IPC dealer test mode. Scroll GO to Y3
through the displays until LEd is
displayed. No
Does the TPMS warning indicator INSTALL a new IPC . REFER to Instrument Panel
illuminate? Cluster (IPC) in this section. TEST the system for
normal operation.
Y3 RETRIEVE THE RECORDED DTCs
FROM IPC SELF-TEST
self-test. For DTC U0140:00, GO to Pinpoint Test AQ . For
section.
No
GO to Y4
Y4 RETRIEVE THE RECORDED DTCs
FROM THE TPM / VSM SELF-TEST
Check for recorded TPM / VSM DTCs Yes
from the self-test. REFER to the Diagnostic Trouble Code (DTC)
Are any DTCs recorded? Chart in Section 204-04 .
No
If the TPMS warning indicator is never on, the
system is operating correctly at this time. If the
TPMS warning indicator is always on, INSTALL a
new TPM module Section 204-04 . TEST the
Pinpoint Test Z: The Safety Belt Warning Indicator Is Never/Always On
Normal Operation
The Restraints Control Module (RCM) monitors the safety belt position. The RCM provides the safety
belt status to the Instrument Panel Cluster (IPC) over the High Speed Controller Area Network (HS-
CAN) communication bus.
If the safety belt status is missing or invalid for less than 5 seconds, the IPC defaults the safety belt
warning indicator to the last state (on or off) based upon the last known good message received. If the
IPC does not receive the safety belt buckle switch status from the RCM for more than 5 seconds, the
IPC sets DTC U0151:00 and defaults the safety belt warning indicator off. If the RCM message is
deemed invalid by the IPC for more than 5 seconds, the IPC sets defaults the safety belt warning
indicator off.
RCM
IPC
PINPOINT TEST Z: THE SAFETY BELT WARNING INDICATOR IS NEVER/ALWAYS ON

Z1 RETRIEVE THE RECORDED RCM DTCs
FROM THE SELF-TEST
Check for recorded RCM DTCs from the Yes
self-test. REFER to Section 501-20B .
No
GO to Z2 .
Z2 RETRIEVE THE RECORDED DTCs
self-test. For DTC U0151:00, GO to Pinpoint Test AR . For
section.
No
GO to Z3 .
Z3 CARRY OUT THE IPC INDICATOR
LAMP CONTROL ACTIVE COMMAND
USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on If the safety belt warning indicator is never on, the
the scan tool: IPC DataLogger. system is operating correctly at this time. If the
Select the IPC all warning indicators safety belt warning indicator is always on,
(SBLT_LAMP) active command. INSTALL a new RCM . REFER to Section 501-
Command all the warning indicators on 20B . TEST the system for normal operation.
and off. Observe the safety belt warning
indicator. No
Does the safety belt warning INSTALL a new IPC . REFER to Instrument Panel
indicator illuminate when Cluster (IPC) in this section. TEST the system for
commanded on and turn off when normal operation.
commanded off?
Pinpoint Test AA: The Air Bag Warning Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the Supplemental Restraint System (SRS) status from the
Restraints Control Module (RCM) over the High Speed Controller Area Network (HS-CAN)
communication bus. If an SRS concern is detected, the RCM sets a DTC and sends a request to the IPC
to illuminate the air bag warning indicator.
If the SRS status is missing or invalid for less than 5 seconds, the IPC defaults the air bag warning
indicator to the last state (on or off) based upon the last known good message received. If the SRS
status message is deemed invalid for more than 5 seconds, the IPC defaults the air bag warning
indicator on. If the SRS status message is missing for more than 5 seconds, the IPC sets DTC U0151:00
and defaults the air bag warning indicator on.
RCM
IPC
PINPOINT TEST AA: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON

AA1 CARRY OUT THE IPC RESTRAINTS
OUTPUT CONTROL ACTIVE COMMAND
USING THE SCAN TOOL
Ignition ON. Yes
Enter the following diagnostic mode on GO to AA2 .
the scan tool: IPC DataLogger.
Select the IPC all warning indicators No
(AIRBAG_LMP) active command. INSTALL a new IPC . REFER to Instrument
Command all the warning indicators on Panel Cluster (IPC) in this section. TEST the
and off. Observe the air bag warning system for normal operation.
indicator.
Does the air bag warning indicator
illuminate when commanded on and
turn off when commanded off?
AA2 RETRIEVE THE RECORDED DTCs
FROM THE RCM SELF-TEST
Check for recorded RCM DTCs from the Yes
No
GO to AA3 .
AA3 RETRIEVE THE RECORDED DTCs
self-test. For DTC U0151:00, GO to Pinpoint Test AR .
Are any DTCs recorded? For all other DTCs, REFER to DTC Charts in this
section.
No
If the air bag warning indicator is never on, the
system is operating correctly at this time. If the
air bag warning indicator is always on, INSTALL
a new RCM . REFER to Section 501-20B . TEST
Pinpoint Test AB: The Anti-Theft Indicator Is Never/Always On
Normal Operation
On vehicles not equipped with Intelligent Access (IA), the anti-theft indicator is controlled by the Passive
Anti-Theft System (PATS) housed in the Instrument Panel Cluster (IPC). On vehicles equipped with IA ,
the anti-theft indicator is controlled by the IPC based on a PATS message sent from the Remote
Function Actuator (RFA) module.
PATS concern
IPC
PINPOINT TEST AB: THE ANTI-THEFT INDICATOR IS NEVER/ALWAYS ON

AB1 CARRY OUT THE IPC ANTI-THEFT INDICATOR
Ignition ON. Yes
Enter the following diagnostic mode on the scan For vehicles without IA , GO to AB2 .
tool: IPC DataLogger. For vehicles with IA , GO to AB3 .
Select the IPC anti-theft indicator (THEFT_LMP)
active command. Command the anti-theft indicator No
on and off while observing the anti-theft indicator. INSTALL a new IPC . REFER to
Does the anti-theft indicator illuminate when Instrument Panel Cluster (IPC) in this
commanded on and turn off when commanded section. TEST the system for normal
off? operation.
AB2 RETRIEVE THE RECORDED DTCs FROM THE
Are any PATS -related DTCs recorded?
No
INSTALL a new IPC . REFER to
operation.
CONTINUOUS RFA MODULE SELF-TEST
Check for recorded RFA module DTCs from the Yes
continuous self-test. REFER to Section 419-01B .
Are any PATS -related DTCs recorded?
No
GO to AB4 .
self-test. GO to Pinpoint Test AS .
No
INSTALL a new IPC . REFER to
operation.
Pinpoint Test AC: The Transaxle Range Display is Never On
Normal Operation
The Instrument Panel Cluster (IPC) receives the transaxle range status from the Transmission Control
Module (TCM) over the High Speed Controller Area Network (HS-CAN) communication bus.
If the transaxle range status is missing from the TCM for less than 5 seconds, the transaxle range
indicator displays the last selected range based upon the last good known message. If the transaxle
range status information is missing from the TCM for 5 seconds or more, the IPC sets DTC U0101:00
and the transaxle range indicator is blank.
TCM concern
IPC
PINPOINT TEST AC: THE TRANSAXLE RANGE DISPLAY IS NEVER ON

AC1 VERIFY THE INTEGRATED
CIRCUIT DISPLAY FUNCTIONS
Ignition ON. Yes
Observe the odometer in the GO to AC2 .
integrated display.
Does the odometer display No
illuminate? GO to Pinpoint Test A .
AC2 RETRIEVE THE RECORDED
Check for recorded IPC DTCs Yes
from the self-test. For DTC U0100:00, GO to Pinpoint Test AM . For DTC
Are any DTCs recorded? U0101:00, GO to Pinpoint Test AN .
No
GO to AC3 .
AC3 RETRIEVE THE RECORDED
DTCs FROM THE TCM SELF-TEST
Check for recorded TCM DTCs Yes
No
INSTALL a new IPC . REFER to Instrument Panel
Cluster (IPC) in this section. TEST the system for
normal operation.
Pinpoint Test AD: The Outside Air Temperature Display Does Not Operate Correctly
Normal Operation
The Ambient Air Temperature (AAT) sensor is hardwired to the Instrument Panel Cluster (IPC) through
the input and return circuits. The IPC provides a reference voltage to the AAT sensor and monitors the
change in voltage resulting from changes in resistance as determined by outside air temperature. The
IPC is programmed to update the displayed temperature at different rates depending on several criteria
to prevent false temperature displays due to a condition known as heat soaking. Heat soaking is where
the outside air temperature is hotter in the location of the AAT sensor than the actual outside air
temperature.
The IPC uses the last displayed temperature reading, engine coolant temperature and length of time the
engine is off to determine how the display is updated. The IPC stores the last temperature reading at key
off and then compares the value against the current temperature reading. When the current temperature
reading is below the stored temperature reading, the engine has been off for 2.5 hours or the engine
coolant temperature is below 45°C (32°F), the IPC displays the current outside air temperature as
measured by the AAT sensor.
If the IPC fails any of the above criteria, the display is updated according to the following table:
Early Build Update Rate

Vehicle Speed Display Update Rate
Up to 35 km/h (22 mph) 0.1°C (0.18°F) per minute
Between 35 km/h (22 mph) and 120 km/h (75 mph) 0.55°C (0.99°F) per minute
Between 120 km/h (75 mph) and 300 km/h (186 mph) 1.0°C (1.8°F)
Late Build Update Rate

Vehicle Speed Display Update Rate
Below 25 km/h (16 mph) Not updated
Between 25 km/h (16 mph) and 35 km/h (22 mph) 0.5°C (0.9°F) per minute
Above 100 km/h (62 mph) 4.0°C (7.2°F)
DTC B1A68:11 (Ambient Temperature Sensor: Circuit Short To Ground) — a continuous and on-
demand DTC that sets if the IPC detects a short to ground on the AAT sensor input circuit. If the
IPC detects a short to ground on the outside air temperature input, the IPC defaults the display to
dashes (----).
DTC B1A68:13 (Ambient Temperature Sensor: Circuit Open) — a continuous and on-demand
DTC that sets if the IPC detects an open on the AAT sensor input circuit. If the IPC detects an
open on the outside air temperature input, the IPC defaults the display to dashes (----).

AAT sensor
IPC
PINPOINT TEST AD: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE
CORRECTLY
Result / Action to
Test Step
Take
AD1 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Is IPC DTC B1A68:11 or DTC B1A68:13 recorded? GO to AD4 .
No
VERIFY the vehicle
has been driven to
eliminate any
potential heat soak
condition and cool off
the sensor.
If the outside air

temperature display is
still inaccurate, GO to
AD2 .
AD2 VERIFY THE SPEEDOMETER OPERATION
Operate the vehicle and verify the speedometer operation. Yes
Does the speedometer operate correctly? GO to AD3 .
No
GO to Pinpoint Test
E.
AD3 CHECK THE AMBIENT AIR TEMPERATURE SENSOR
FUNCTION
Ignition OFF. Yes
Disconnect: Ambient Air Temperature Sensor C132. The system is
Measure the resistance between the ambient air temperature operating normally at
sensor C132 pin 2, component side and the ambient air this time. EXPLAIN to
temperature sensor C132 pin 1, component side according to the the customer the
following table. normal operation of
the system.
Ambient Air Ambient Air Temperature Sensor
Temperature Resistance No
CHECK the connector
0-10°C (32-50°F) 5179-3838 ohms for corrosion or
pushed out pins. If the
10-20°C (50-68°F) 3838-2792 ohms
connector is OK,
20-30°C (68-86°F) 2792-1978 ohms INSTALL a new
ambient air
30-40°C (86-104°F) 1978-1392 ohms temperature sensor.
TEST the system for
normal operation.
Does the ambient air temperature sensor resistance match the
ambient air temperature according to the table?
AD4 CLEAR THE DTCs AND RECHECK THE SYSTEM
Clear the DTCs and repeat the IPC self-test. Yes
Is IPC DTC B1A68:11 or DTC B1A68:13 recorded? GO to AD5 .
No
The system is
operating normally at
this time.
AD5 CHECK THE AMBIENT AIR TEMPERATURE SENSOR
FUNCTION
Ignition OFF. Yes
Disconnect: Ambient Air Temperature Sensor C132. INSTALL a new
Ignition ON. ambient air
Measure the voltage between the ambient air temperature sensor temperature sensor.
C132-1, circuit VH407 (YE/GN), harness side and the ambient air CLEAR the DTCs.
temperature sensor C132-2, circuit RH107 (GN/BU), harness side. REPEAT the self-test.
No
GO to AD6 .

AD6 CHECK THE OUTSIDE AIR TEMPERATURE SENSOR INPUT
AND RETURN CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220. REPAIR the circuit in
Ignition ON. question for a short to
Measure the voltage between the IPC C220-20, circuit VH407 voltage. REPEAT the
(YE/GN), harness side and ground; and between the IPC C220-19, self-test. CLEAR the
circuit RH107 (GN/BU), harness side and ground. DTCs.
No
GO to AD7 .
AD7 CHECK THE OUTSIDE AIR TEMPERATURE INPUT CIRCUIT
FOR AN OPEN AND SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the IPC C220-20, circuit VH407 GO to AD8 .
(YE/GN), harness side and the ambient air temperature sensor
C132-1, circuit VH407 (YE/GN), harness side; and between the IPC No
C220-20, circuit VH407 (YE/GN), harness side and ground. REPAIR circuit
VH407 (YE/GN) for
an open or for a short
to ground. TEST the
system for normal
operation.
Is the resistance less than 5 ohms between the IPC and the
ambient air temperature sensor, and greater than 10,000 ohms
between the IPC and ground?
AD8 CHECK THE OUTSIDE AIR TEMPERATURE RETURN CIRCUIT
FOR AN OPEN
Measure the resistance between the IPC C220-19, circuit RH107 Yes
(GN/BU), harness side and the ambient air temperature sensor GO to AD9 .
C132-2, circuit RH107 (GN/BU), harness side.
No
REPAIR circuit
RH107 (GN/BU) for
an open. CLEAR the
DTCs. REPEAT the
self-test.

AD9 CHECK FOR CORRECT IPC OPERATION
Connect all the IPC connectors and make sure they seat correctly. system for normal
No
The system is
may have been
corroded connector.
Pinpoint Test AE: The Trip Computer Switch Is Inoperative
Normal Operation
The trip computer switch is a redundant switch used to control the functions in the integrated circuit
display such as trip computer. The trip computer switch is located in the multifunction switch and
hardwired directly to the Instrument Panel Cluster (IPC) through a single signal circuit with a ground
provide through a separate circuit. When the driver presses the trip computer button, the switch closes
to ground. The IPC detects the change in button state and carries out the chosen function of the
integrated display.
DTC B10BD:01 (Multifunctional Switch: General Electrical Failure) — sets on-demand in the IPC
when the IPC detects a short to ground on the trip computer switch signal circuit.

Message center switch
IPC
PINPOINT TEST AE: THE TRIP COMPUTER SWITCH IS INOPERATIVE
Section 414-01 .
Result / Action to
Test Step
Take
AE1 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Check for recorded DTCs from the IPC self-test. Yes
Are any DTCs recorded? For DTC B10BD:01,
GO to AE6 .
For all other DTCs,
REFER to DTC Charts
in this section.
No
GO to AE2 .
AE2 CHECK THE TRIP COMPUTER SWITCH OPERATION
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to AE3 .
DataLogger.
Select the IPC trip computer switch PID (EXT_TRIP_SW). No
Monitor the PID display while pressing the trip computer switch GO to AE4 .
button.
Does the PID display ON when the button is pressed and OFF
when the button is released?
AE3 RETRIEVE THE RECORDED DTCs FROM THE FCDIM SELF-
TEST
Check for recorded DTCs from the FCDIM self-test. Yes
Is DTC U0155:00 recorded? REFER to Section 415-
00 .
No
INSTALL a new
FCDIM . REFER to
operation.
AE4 CHECK THE TRIP COMPUTER SIGNAL CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220. REPAIR circuit RMC27
Ignition ON. (WH/BN) for a short to
Measure the voltage between the IPC C220-30, circuit RMC27 voltage. TEST the
(WH/BN), harness side and ground. system for normal
operation.
No
GO to AE5 .

AE5 CHECK THE TRIP COMPUTER SIGNAL CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. GO to AE7 .
Measure the resistance between the IPC C220-30, circuit RMC27
(WH/BN), harness side and the multifunction switch C202A-3, No
circuit RMC27 (WH/BN), harness side. REPAIR circuit RMC27
TEST the system for
normal operation.

AE6 CHECK THE TRIP COMPUTER SIGNAL CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. GO to AE7 .
Measure the resistance between the IPC C220-30, circuit RMC27
(WH/BN), harness side and ground. No
REPAIR circuit RMC27
ground. TEST the
system for normal
operation.

AE7 CHECK THE TRIP COMPUTER SWITCH INPUT TO THE IPC
Connect: Multifunction Switch C202A. Yes
Disconnect: Negative Battery Cable. GO to AE8 .
While pressing and releasing the trip computer switch, measure
the resistance between the IPC C220-30, circuit RMC27 (WH/BN), No
harness side and ground. INSTALL a new
multifunction switch.
05 . CLEAR the DTC.
Is the resistance less than 5 ohms with the trip computer

button pressed and greater then 10,000 ohms with the trip
computer button released?
AE8 CHECK FOR CORRECT IPC OPERATION
Connect the IPC connector and make sure it seats correctly. system for normal
Operate the system and determine if the concern is still present. operation.
No
The system is
connector.
Pinpoint Test AF: The Front Control/Display Interface Module (FCDIM) Does Not Display Warning
Messages Or Message Center Warning Indicators
Normal Operation
The message center display is located in the Front Control/Display Interface Module (FCDIM) and
receives the message center data from the Instrument Panel Cluster (IPC) over the High Speed
Controller Area Network (HS-CAN) and Medium Speed Controller Area Network (MS-CAN)
communication bus.
Communication concern
FCDIM
PINPOINT TEST AF: THE FCDIM DOES NOT DISPLAY WARNING MESSAGES OR MESSAGE
CENTER WARNING INDICATORS

AF1 CARRY THE FCDIM DISPLAY OPERATION
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: FCDIM GO to AF2 .
DataLogger.
Select the FCDIM LCD display (LCD_SEG) and message No
center warnings (WARN_AMBER) and (WARN_RED) active INSTALL a new FCDIM .
command. Command the LCD display segments, amber and REFER to Section 415-00 .
red warning displays on. TEST the system for normal
Monitor the FCDIM display. operation.
Do the LCD segments and amber and red warning
displays turn on when commanded on?
AF2 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-
TEST
Are any DTCs recorded? REFER to DTC Charts in
this section.
No
GO to AF3 .
AF3 RETRIEVE THE RECORDED DTCs FROM THE FCDIM
SELF-TEST
Is DTC U0155:00 recorded? REFER to Section 415-00 .
No
INSTALL a new FCDIM .
operation.
Pinpoint Test AG: The VEHICLE NOT IN PARK SELECT P Message Is Inoperative/Always On
(Intelligent Access (IA) Only)
Normal Operation
The park detect switch is hardwired to the Instrument Panel Cluster (IPC) through a single input circuit
and grounded through a separate ground circuit. When the vehicle is in PARK (P), the park detect switch
opens. When the vehicle is not in PARK (P), the park detect switch closes, providing a ground to the IPC
through the park detect input circuit. The IPC receives the driver door ajar data from the Body Control
Module (BCM) over the Medium Speed Controller Area Network (MS-CAN) communication bus. When
the ignition is placed in the off mode with the floor shifter out of the PARK (P) position and the driver
door open, the IPC sends the Front Control/Display Interface Module (FCDIM) a request over the
Controller Area Network (CAN) communication bus to display VEHICLE NOT IN PARK SELECT P in the
message center.
DTC P081C:01 (Park Input Circuit: General Electrical Failure) — an on-demand DTC that sets if
the IPC detects an open on the park input circuit.

Park detect switch
IPC
PINPOINT TEST AG: THE VEHICLE NOT IN PARK SELECT P MESSAGE IS

INOPERATIVE/ALWAYS ON ( IA ONLY)
Section 414-01 .
Result / Action to
Test Step
Take
AG1 CHECK THE PARK DETECT INPUT TO THE IPC
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to AG2 .
DataLogger.
Select the IPC park detect PID (GEAR_PARK). No
Monitor the PID while moving the floor shifter in and out of PARK GO to AG3 .
(P).
Does the PID display TRUE when in PARK (P) and FALSE
when out of PARK (P)?
AG2 RETRIEVE THE RECORDED DTCs FROM THE FCDIM SELF-
TEST
Is DTC U0155:00 recorded? REFER to Section
415-00 .
No
INSTALL a new
FCDIM . REFER to
operation.
AG3 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Are any DTCs recorded? For DTC P081C:01,
GO to AG4 .
For all other DTCs,

REFER to DTC Charts
in this section.
No
GO to AG6 .
AG4 CHECK THE PARK DETECT INPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220. REPAIR circuit CDC41
Disconnect: Remote Function Actuator (RFA) Module C3503C. (WH/BN) for a short to
Ignition ON. voltage. TEST the
Measure the voltage between the IPC C220-25, circuit CDC41 system for normal
(WH/BN), harness side and ground. operation.
No
GO to AG5 .

AG5 CHECK THE PARK DETECT INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Floor Shifter C3245. GO to AG7 .
Measure the resistance between the IPC C220-25, circuit CDC41
(WH/BN), harness side and the floor shifter C3245-2, circuit No
CDC41 (WH/BN), harness side. REPAIR circuit CDC41
TEST the system for
normal operation.
AG6 CHECK THE PARK DETECT INPUT CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: Remote Function Actuator (RFA) Module C3503C. GO to AG7 .
Measure the resistance between the IPC C220-25, circuit CDC41
(WH/BN), harness side and ground. No
ground. TEST the
system for normal
operation.

AG7 CHECK FOR CORRECT IPC OPERATION
Connect the IPC connector and make sure it seats correctly. system for normal
Operate the system and determine if the concern is still present. operation.
No
The system is
may have been
corroded connector.
Pinpoint Test AH: The Chime Sounds When The Driver Door Is Ajar (No Key In Ignition And
Headlamps Off)
Normal Operation
On vehicles without Intelligent Access (IA), the key-in-ignition warning switch is hardwired to the Body
Control Module (BCM) through the key-in-ignition input circuit. When the key is inserted into the ignition
lock cylinder, the key-in-ignition switch opens and removes the ground to the Body Control Module
(BCM). When the BCM detects the key-in-ignition input open with the driver door open, the BCM sends
the IPC a message over the Medium Speed Controller Area Network (MS-CAN) communication bus to
sound the key-in-ignition chime.
On vehicles with IA , the Remote Function Actuator (RFA) module generates an implied key-in-ignition
status from the ignition states and the driver door ajar input. If the vehicle is turned off with the selector
lever out of PARK (P) and the driver door open, the RFA module sends the IPC a message to sound the
key-in-ignition chime.

Key-in-ignition warning switch (without IA )
BCM
PINPOINT TEST AH: THE CHIME SOUNDS WHEN THE DRIVER DOOR IS AJAR (NO KEY IN
IGNITION AND HEADLAMPS OFF)

AH1 CHECK THE INSTRUMENT CLUSTER ILLUMINATION
Close all doors. Yes
Wait one minute. GO to AH2 .
Observe the exterior lights.
Are the headlamps and parking lamps off? No
AH2 CHECK THE INTERIOR LIGHTING OPERATION
Open and close the driver door. Yes
Observe the interior lamps. GO to AH3 .
Do the interior lamps operate correctly from the driver
door? No
AH3 RETRIEVE THE RECORDED DTCs FROM THE BCM SELF-
TEST
Are any DTCs recorded? REFER to Section 419-10
for correct navigation of the
DTC.
No
GO to AH4 .
AH4 CHECK THE KEY-IN-IGNITION SWITCH OPERATION
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to AH6 .
Remove the key from the ignition lock cylinder.
CDC30 (BU/GY), harness side and ground. GO to AH5 .
AH5 CHECK THE KEY-IN-IGNITION INPUT CIRCUIT FOR A
SHORT TO GROUND
Disconnect: Key-In-Ignition Switch C2112. Yes
Measure the resistance between the BCM C2280G-9, circuit INSTALL a new ignition
CDC30 (BU/GY), harness side and ground. switch. REFER to Section
211-05 . TEST the system
No
(BU/GY) short to ground.
TEST the system for
normal operation.

AH6 CHECK FOR CORRECT BCM OPERATION
damaged pins TEST the system for
correctly. No
corroded connector.
Pinpoint Test AI: The Key-In-Ignition Warning Chime Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the key-in-ignition warning status from the Body Control
Module (BCM) over the Medium Speed Controller Area Network (MS-CAN) communication bus.
On vehicles without Intelligent Access (IA), the key-in-ignition warning switch is hardwired to the BCM
through the key-in-ignition input circuit. When the key is inserted into the ignition lock cylinder, the key-
in-ignition switch opens and removes the ground to the BCM . When the BCM detects the key-in-ignition
input open with the driver door open, the BCM sends the IPC a message to sound the key-in-ignition
chime.
On vehicles with IA , the Remote Function Actuator (RFA) module receives the door ajar input from the
BCM-HVTB over the MS-CAN communication bus. The start/stop button is hardwired to the RFA
module. The RFA module generates an implied key-in-ignition status from the start/stop button and the
driver door ajar input. When the ignition is placed in the ON mode (engine off) with the driver door open,
the RFA module sends the IPC a message to sound the key-in-ignition chime.
DTC B100A:23 (Fuel Pump Authorization: Signal Stuck Low) — this DTC sets for a key-in-ignition
fault and sets on-demand in the BCM when the BCM detects a short to ground on the key-in-
ignition output circuit.

Key-in-ignition warning switch (without IA )
BCM (without IA )
RFA module (with IA )
IPC
PINPOINT TEST AI: THE KEY-IN-IGNITION WARNING CHIME IS INOPERATIVE
Result / Action to
Test Step
Take
AI1 CHECK THE SAFETY BELT WARNING CHIME OPERATION
Ignition OFF. Yes
Ignition ON. GO to AI2 .
Monitor the safety belt warning chime when the ignition switch is
transitioned from OFF to RUN. No
Does the safety belt warning chime operate for approximately INSTALL a new IPC .
6 seconds? REFER to Instrument
Panel Cluster (IPC) in
system for normal
operation.
AI2 CHECK THE INTERIOR LAMPS OPERATION
Check the operation of the courtesy lamps from the driver door. Yes
Do the courtesy lamps operate correctly from the driver door? GO to AI3 .
No
REFER to Section
417-02 .
AI3 RETRIEVE THE RECORDED DTCs FROM THE IPC SELF-TEST
Are any DTCs recorded? REFER to DTC
No
For vehicles with IA ,
GO to AI4 . For
vehicles without IA ,
GO to AI5 .
AI4 RETRIEVE THE RECORDED DTCs FROM THE RFA MODULE
SELF-TEST
Check the recorded DTCs from the RFA module self-test. Yes
Are any DTCs present? REFER to Section
419-10 .
No
INSTALL a new RFA
module. REFER to
Section 419-10 .
TEST the system for
normal operation.
AI5 RETRIEVE THE RECORDED DTCs FROM THE BCM SELF-TEST
Check the recorded DTCs from the BCM self-test. Yes
Are any DTCs present? For all other DTCs,
REFER to Section
419-10 . For DTC
B10F1:23, GO to AI6 .
No
GO to AI9 .
AI6 CHECK THE KEY-IN-IGNITION INPUT FOR AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to AI8 .
Insert the key into the ignition lock cylinder.
CDC30 (BU/GY), harness side and ground. GO to AI7 .

AI7 CHECK THE KEY-IN-IGNITION SWITCH OPERATION
Disconnect: Key-In-Ignition Switch C2112. Yes
Measure the resistance between the BCM C2280G-9, circuit INSTALL a new
CDC30 (BU/GY), harness side and the key-in-ignition switch ignition switch.
C2112-1, circuit CDC30 (BU/GY), harness side. REFER to Section
211-05 . TEST the
system for normal
operation.
No
REPAIR circuit
CDC30 (BU/GY) for
an open. TEST the
system for normal
operation.

AI8 CHECK THE KEY-IN-IGNITION GROUND CIRCUIT FOR AN OPEN
Measure the resistance between the key-in-ignition switch C2112-2, Yes
circuit GD115 (BK/GY), harness side and ground. GO to AI10 .
No
REPAIR circuit
GD115 (BK/GY) for an
open. TEST the
system for normal
operation.

AI9 CHECK FOR CORRECT BCM OPERATION
damaged pins Section 419-10 .
pushed-out pins TEST the system for
Connect all the BCM connectors and make sure they seat correctly. normal operation.
The system is
may have been
corroded connector.
AI10 CHECK FOR CORRECT KEY-IN-IGNITION SWITCH OPERATION
Check the key-in-ignition switch C2112 for: Yes
corrosion INSTALL a new
damaged pins ignition switch.
pushed-out pins REFER to Section
Connect the key-in-ignition switch C2112 and make sure it seats 211-05 . TEST the
correctly. system for normal
No
The system is
may have been
corroded connector.
Pinpoint Test AJ: The Headlamps On Warning Chime Is Inoperative
Normal Operation
The Body Control Module (BCM) uses hardwired circuitry to receive the headlamp switch status from the
headlamp switch and the LH front door ajar status from the LH front door ajar switch. The headlamps on
warning chime sounds when the LH front door is opened with the ignition in the OFF state, the key is not
in the ignition lock cylinder (without IA ), and the headlamp switch in the PARK or HEADLAMP ON
position. The BCM communicates the headlamp on chime request to the Instrument Panel Cluster (IPC)
based on headlamp or parking lamp and driver door inputs.
Door ajar indication

BCM
IPC
PINPOINT TEST AJ: THE HEADLAMPS ON WARNING CHIME IS INOPERATIVE

AJ1 CHECK THE SAFETY BELT WARNING
CHIME OPERATION
Ignition OFF. Yes
Ignition ON. GO to AJ2 .
Monitor the safety belt warning chime
when the ignition switch is transitioned No
from OFF to RUN. INSTALL a new IPC . REFER to Instrument
Does the safety belt warning chime Panel Cluster (IPC) in this section. TEST the
operate for approximately 6 seconds? system for normal operation.
AJ2 CHECK THE INTERIOR LAMPS
OPERATION
On vehicles without IA , remove the key Yes
from the ignition lock cylinder. GO to AJ3 .
On vehicles with IA , place the ignition in
the OFF state. No
Open and close the driver door. REFER to Section 417-02 .
Observe the interior lamps.
Do the interior lamps operate correctly
from the driver door?
AJ3 RETRIEVE THE RECORDED DTCs
self-test. For DTC U0140:00, GO to Pinpoint Test AQ .
Are any DTCs recorded? For all other DTCs, REFER to DTC Chart in
this section.
No
GO to AJ4 .
AJ4 RETRIEVE THE RECORDED DTCs
FROM THE BCM SELF-TEST
Check for recorded BCM DTCs from the Yes
self-test. REFER to Section 419-10 for correct
Are any DTCs recorded? navigation of the DTC.
No
INSTALL a new BCM . REFER to Section 419-
Pinpoint Test AK: The Safety Belt Warning Chime Is Inoperative/The Belt-Minder® Feature Does
Not Operate
Normal Operation
The Instrument Panel Cluster (IPC) receives the safety belt and Belt-Minder® requests from the
Restraints Control Module (RCM) over the High Speed Controller Area Network (HS-CAN). The safety
belt warning chime sounds for approximately 6 seconds when the driver safety belt is not fastened and
the ignition is changed from the OFF or ACC state to the RUN or START state.
The Belt-Minder® feature supplements the safety belt warning function and is enabled after the safety
belt warning is complete. The Belt-Minder® simultaneously sounds the chime and illuminates the safety
belt warning lamp in the IPC once the vehicle speed has exceeded 5 km/h (3 mph), and remains active
for 5 minutes from the time it is started.
There are 2 Belt-Minder® strategies used and implemented by the IPC as commanded by the RCM .
The 2 strategies are designed to provide an increased intensity level of the chime. Belt-Minder® A
provides 6 one-second sequences of 0.5-second on/0.5-second off for the first minute of the Belt-
Minder® warning. Belt-Minder® B provides 6 one-second sequences of 0.2-second on/0.2-second off
then 0.3-second on/0.3-second off for the remainder of the Belt-Minder® warning.
NOTE: Make sure the safety belt/Belt-Minder® chime operation is verified with the vehicle moving at
least 9.7 km/h (6 mph).
Belt-Minder® deactivated
Safety belt warning indication concern
Speedometer concern
IPC
PINPOINT TEST AK: THE SAFETY BELT WARNING CHIME IS INOPERATIVE/THE BELT-MINDER®
FEATURE DOES NOT OPERATE

AK1 CHECK THE HEADLAMPS ON
WARNING CHIME OPERATION
Ignition OFF. Yes
Place the headlamp switch in the GO to AK2 .
HEADLAMP position.
Open the LH front door and observe the No
headlamps on warning chime operation. INSTALL a new IPC . REFER to Instrument
Does the headlamps on warning chime Panel Cluster (IPC) in this section. TEST the
operate correctly? system for normal operation.
AK2 CHECK THE DRIVER SAFETY BELT
BUCKLE SWITCH
Ignition ON. Yes
Enter the following diagnostic mode on the GO to AK3 .
scan tool: RCM PIDs.
Monitor the RCM driver safety belt buckle No
PID (SBELT_D_ST) while buckling and REFER to Section 501-20B .
unbuckling the driver safety belt.
Does the PID display BUCKLED with
the safety belt buckled and
UNBUCKLED with the safety belt
unbuckled?
AK3 CHECK THE SAFETY BELT WARNING
INDICATOR FOR CORRECT OPERATION
Ignition ON. Yes
Within one minute, buckle then unbuckle GO to AK4 .
the LH front safety belt.
With the engine running, verify the safety No
belt warning indicator illuminates with the GO to Pinpoint Test Z .
safety belt unbuckled and turns off when
buckled.
Does the safety belt warning indicator
operate correctly?
AK4 CHECK THE SPEEDOMETER
OPERATION
Verify the speedometer is operating Yes
correctly. GO to AK5 .
Does the speedometer operate
correctly? No
AK5 CHECK THE BELT-MINDER®
CONFIGURATION
Verify the Belt-Minder® is activated or Yes
configured on for the seating position in If the Belt-Minder® is always on above 5 km/h
question. Refer to Belt-Minder® (3 mph) with the safety belt unfastened, the
Deactivating/Activating in this section to system is operating normally.
configure without a scan tool.
Is the Belt-Minder® activated for the If the Belt-Minder® is always on with the safety
seating position in question? belt fastened or never on with the safety belt
unfastened above 9.7 km/h (6 mph), INSTALL
a new RCM . REFER to Section 501-20B .
No
ACTIVATE the Belt-Minder® for the seating
position in question. REFER to Belt-Minder®
Deactivating/Activating in this section. TEST
Pinpoint Test AL: The Parking Brake Warning Chime Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) uses vehicle speed data sent from the ABS module over the High
Speed Controller Area Network (HS-CAN) and parking brake switch status input to the IPC to determine
when to turn on the sound the parking brake warning chime.
The parking brake warning chime sounds when the ignition is in the ON state, the parking brake is
engaged, and the vehicle speed is greater than 5 km/h (3 mph). The parking brake warning chime stops
sounding and resets if the parking brake is released, the ignition is not in the ON state, the vehicle speed
is below 5 km/h (3 mph), or after 90 seconds from the time the chime is activated.
NOTE: Make sure the parking brake warning chime operation is verified with the vehicle moving at least
5 km/h (3 mph) with the parking brake slightly applied (just enough to turn the brake warning indicator on
without damaging the rear brakes).
Brake warning indication concern

IPC
PINPOINT TEST AL: THE PARKING BRAKE WARNING CHIME IS INOPERATIVE

AL1 CHECK THE SAFETY BELT WARNING
CHIME OPERATION
Ignition OFF. Yes
Ignition ON. GO to AL2 .
Monitor the safety belt warning chime
when the ignition switch is transitioned No
from OFF to RUN. INSTALL a new IPC . REFER to Instrument
Does the safety belt warning chime Panel Cluster (IPC) in this section. TEST the
operate for approximately 6 seconds? system for normal operation.
AL2 CHECK THE BRAKE WARNING
INDICATOR OPERATION
Ignition ON. GO to AL3 .
Observe the brake warning indicator.
Does the brake warning indicator turn No
on? GO to Pinpoint Test L .
AL3 RETRIEVE THE RECORDED DTCs
self-test. REFER to DTC Chart in this section.
No
INSTALL a new IPC . REFER to Instrument
Panel Cluster (IPC) in this section. TEST the
Pinpoint Test AM: DTC U0100:00 and P1607:87
Normal Operation
DTC U0100:00 (Lost Communication With ECM /PCM "A": No Sub Type Information) — sets in
continuous memory in the Instrument Panel Cluster (IPC) if data messages received from the
PCM over the High Speed Controller Area Network (HS-CAN) are missing for 5 seconds or more.
For a complete list of all network messages, refer to Section 418-00 .
DTC P1607:87 ( MIL Output Circuit: Missing Message) — sets in continuous memory in the IPC
when the MIL message from the PCM is missing for 5 seconds or more.
NOTE: Once the IPC sets DTC U0100:00, multiple gauges or indicators are likely to be inoperative in
the IPC . Other modules that require data from the IPC all set communication DTCs and may also
exhibit system function concerns.
PCM
IPC
PINPOINT TEST AM: DTC U0100:00 AND P1607:87

AM1 VERIFY THE SCAN TOOL CAN
COMMUNICATE WITH THE PCM
Check that a vehicle session can be GO to AM2 .
established using the scan tool.
Can a vehicle session be established? No
REFER to Section 418-00 to diagnose no
communication with the PCM.
AM2 CHECK THE IPC CONTINUOUS
MEMORY DTCs
Ignition ON. Yes
Enter the following diagnostic mode on GO to AM3 .
the scan tool: IPC Self-Test.
Clear the DTCs. No
Wait 10 seconds. The system is operating correctly at this time.
Repeat the IPC self-test. The DTC may have been set due to high
Is DTC U0100:00 or DTC P1607:87 network traffic or an intermittent fault condition.
retrieved again?
AM3 RETRIEVE THE RECORDED DTCs
FROM THE PCM KOEO SELF-TEST
Check for recorded DTCs from the PCM Yes
Key ON Engine OFF (KOEO) self-test. REFER to Section 303-14 .
Is DTC P0562 or P0563 recorded?
No
GO to AM4 .
AM4 RETRIEVE THE RECORDED DTCs
Check for recorded DTCs from the IPC Yes
self-test. For DTC U3006:16, GO to Pinpoint Test AU .
Is DTC U3006:16 or DTC U3006:17 For DTC U3006:17, GO to Pinpoint Test AV .
recorded?
No
GO to AM5 .
AM5 CHECK FOR DTC U0100:00 SET IN
OTHER MODULES
Ignition ON. Yes
Enter the following diagnostic mode on INSTALL a new PCM. REFER to Section 303-
the scan tool: Self-Test. 14 . CLEAR the DTCs. REPEAT the self-test.
Retrieve the continuous memory DTCs
from all modules. No
Is DTC U0100:00 set in the Remote INSTALL a new IPC . REFER to Instrument
Function Actuator (RFA) module or the Panel Cluster (IPC) in this section. TEST the
Restraints Control Module (RCM)? system for normal operation.
Pinpoint Test AN: DTC U0101:00
Normal Operation
DTC U0101:00 (Lost Communication With TCM : No Sub Type Information) — sets in continuous
memory in the Instrument Panel Cluster (IPC) if data messages received from the Transmission
Control Module (TCM) over the High Speed Controller Area Network (HS-CAN) are missing for 5
seconds or more.
TCM
IPC
PINPOINT TEST AN: DTC U0101:00

AN1 VERIFY THE CUSTOMER CONCERN
Ignition ON. Yes
Verify there is an observable symptom present. GO to AN2 .
Is an observable symptom present?
No
The system is operating normally at
this time. The DTC may have been
set due to high network traffic or an
intermittent fault condition.
AN2 CHECK THE COMMUNICATION NETWORK
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to AN3 .
Network Test.
Does the TCM module pass the network test? REFER to Section 418-00 .
AN3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Test AU . For DTC U3006:17, GO
to Pinpoint Test AV .
No
GO to AN4 .
AN4 RECHECK THE IPC DTCs
NOTE: If new modules were installed prior to the DTC Yes

being set, the module configuration may be incorrectly GO to AN5 .
set during the Programmable Module Installation
(PMI) or the PMI may not have been carried out. No
Clear the DTCs. this time. The DTC may have been
Wait 10 seconds. set due to high network traffic or an
Repeat the IPC self-test. intermittent fault condition.
Is DTC U0101:00 still present?
AN5 CHECK FOR DTC U0101:00 SET IN OTHER
MODULES
Clear all DTCs. Yes
Ignition OFF. INSTALL a new TCM . REFER to
Ignition ON. Section 307-11 . CLEAR the DTCs.
Wait 10 seconds. REPEAT the self-test.
Self-Test. No
Retrieve the continuous memory DTCs from all INSTALL a new IPC . REFER to
modules. Instrument Panel Cluster (IPC) in
Is DTC U0101:00 set in the ABS module? this section. TEST the system for
normal operation.
Pinpoint Test AO: DTC U0121:00
Normal Operation
DTC U0121:00 (Lost Communication With Anti-Lock Brake System (ABS) Control Module: No
Sub Type Information) — sets in continuous memory in the Instrument Panel Cluster (IPC) if data
messages received from the ABS module over the High Speed Controller Area Network (HS-
CAN) are missing for 5 seconds or more. For a complete list of all network messages, refer to
Section 418-00 .
ABS module
IPC
PINPOINT TEST AO: DTC U0121:00

AO1 VERIFY THE CUSTOMER CONCERN
Ignition ON. Yes
Verify there is an observable symptom present. GO to AO2 .
No
AO2 CHECK THE COMMUNICATION NETWORK
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to AO3 .
Network Test.
Does the ABS module pass the network test? REFER to Section 418-00 .
AO3 RETRIEVE THE RECORDED DTCs FROM THE ABS
MODULE SELF-TEST
Check for recorded DTCs from the ABS module self- Yes
test. REFER to Section 206-09 .
Is DTC U3003:16 or DTC U3003:17 recorded?
No
GO to AO4 .
AO4 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
No
GO to AO5 .
AO5 RECHECK THE IPC DTCs

being set, the module configuration may be incorrectly INSTALL a new ABS module.
set during the Programmable Module Installation REFER to Section 206-09 . CLEAR
(PMI) or the PMI may not have been carried out. the DTCs. REPEAT the IPC self-
test.
Clear the DTCs.
Wait 10 seconds. No
Repeat the IPC self-test. The system is operating correctly at
Is DTC U0121:00 still present? this time. The DTC may have been
Pinpoint Test AP: DTC U0131:00
Normal Operation
DTC U0131:00 (Lost Communication With Power Steering Control Module: No Sub Type
Information) — sets in continuous memory if data messages received from the Power Steering
Control Module (PSCM) module over the High Speed Controller Area Network (HS-CAN) are
missing for 5 seconds or more. For a complete list of all network messages, refer to Section 418-
00 .
PSCM module
IPC
PINPOINT TEST AP: DTC U0131:00

AP1 VERIFY THE CUSTOMER CONCERN
Ignition ON. Yes
Verify that there is an observable symptom present. GO to AP2 .
No
AP2 CHECK THE COMMUNICATION NETWORK
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to AP3 .
Network Test.
Does the PSCM pass the network test? REFER to Section 418-00 .
AP3 RETRIEVE THE RECORDED DTCs FROM THE
PSCM SELF-TEST
Check for recorded DTCs from the PSCM self-test. Yes
Is DTC U3003:16 or DTC U3003:17 recorded? REFER to Section 211-00 .
No
GO to AP4 .
AP4 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
No
GO to AP5 .
AP5 RECHECK THE IPC DTCs

being set, the module configuration may be incorrectly GO to AP6 .
Clear the DTCs. Repeat the IPC self-test. this time. The DTC may have been
Is DTC U0131:00 still present? set due to high network traffic or an
AP6 CHECK FOR DTC U0131:00 SET IN OTHER
MODULES
Clear all DTCs. Yes
Ignition OFF. INSTALL a new PSCM (part of the
Ignition ON. steering gear). REFER to Section
Wait 10 seconds. 211-02 . CLEAR the DTCs.
Enter the following diagnostic mode on the scan tool: REPEAT the self-test.
Self-Test.
Retrieve the continuous memory DTCs from all No
modules. INSTALL a new IPC . REFER to
Is DTC U0131:00 set in the ABS module? Instrument Panel Cluster (IPC) in
normal operation.
Pinpoint Test AQ: DTC U0140:00
Normal Operation
DTC U0140:00 (Lost Communication With Body Control Module: No Sub Type Information) —
sets in continuous memory in the Instrument Panel Cluster (IPC) if data messages received from
the Body Control Module (BCM) over the High Speed Controller Area Network (HS-CAN) are
missing for 5 seconds or more. For a complete list of all network messages, refer to Section 418-
00 .
BCM
IPC
PINPOINT TEST AQ: DTC U0140:00

AQ1 VERIFY THE CUSTOMER CONCERN
Ignition ON. Yes
Verify there is an observable symptom present. GO to AQ2 .
No
AQ2 CHECK THE COMMUNICATION NETWORK
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to AQ3 .
Network Test.
Does the BCM pass the network test? REFER to Section 418-00 .
AQ3 RETRIEVE THE RECORDED DTCs FROM THE
BCM SELF-TEST
Is DTC U3003:16 or DTC U3003:17 recorded? REFER to Section 419-10 .
No
GO to AQ4 .
AQ4 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
No
GO to AQ5 .
AQ5 RECHECK THE IPC DTCs

being set, the module configuration may be incorrectly GO to AQ6 .
Clear the DTCs. this time. The DTC may have been
Wait 10 seconds. set due to high network traffic or an
Repeat the IPC self-test. intermittent fault condition.
Is DTC U0140:00 still present?
AQ6 CHECK FOR DTC U0140:00 SET IN OTHER
MODULES
Clear all DTCs. Yes
Ignition OFF. INSTALL a new BCM . REFER to
Ignition ON. Section 419-10 . CLEAR the DTCs.
Wait 10 seconds. REPEAT the self-test.
Self-Test. No
Retrieve the continuous memory DTCs from all INSTALL a new IPC . REFER to
modules. Instrument Panel Cluster (IPC) in
Is DTC U0140:00 set in the Audio Control Module this section. TEST the system for
(ACM)? normal operation.
Pinpoint Test AR: DTC U0151:00
Normal Operation
DTC U0151:00 (Lost Communication With Restraints Control Module: No Sub Type Information)
— sets in continuous memory in the Instrument Panel Cluster (IPC) if data messages received
from the Restraints Control Module (RCM) over the High Speed Controller Area Network (HS-
CAN) are missing for 5 seconds or more. For a complete list of all network messages, refer to
Section 418-00 .
RCM
IPC
PINPOINT TEST AR: DTC U0151:00

AR1 VERIFY THE CUSTOMER
CONCERN
Ignition ON. Yes
Verify there is an observable GO to AR2 .
symptom present.
present? The system is operating normally at this time. The
DTC may have been set due to high network traffic
or an intermittent fault condition.
AR2 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Enter the following diagnostic mode GO to AR3 .
on the scan tool: Network Test.
Does the RCM pass the network REFER to Section 418-00 .
test?
AR3 RETRIEVE THE RECORDED DTCs
FROM THE RCM SELF-TEST
Check for recorded DTCs from the Yes
RCM self-test. REFER to Section 501-20B .
Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to AR4 .
AR4 RETRIEVE THE RECORDED DTCs
Check for recorded DTCs from the Yes
IPC self-test. For DTC U3006:16, GO to Pinpoint Test AU . For
Is DTC U3006:16 or DTC U3006:17 DTC U3006:17, GO to Pinpoint Test AV .
recorded?
No
GO to AR5 .
AR5 RECHECK THE IPC DTCs
Clear the DTCs. Yes
Wait 10 seconds. GO to AR6 .
Is DTC U0151:00 still present? No
The system is operating correctly at this time. The
DTC may have been set due to high network traffic
or an intermittent fault condition.
AR6 CHECK FOR DTC U0151:00 SET IN

OTHER MODULES
Clear all DTCs. Yes
Ignition OFF. INSTALL a new RCM . REFER to Section 501-20B .
Ignition ON. CLEAR the DTCs. REPEAT the self-test.
Wait 10 seconds.
Enter the following diagnostic mode No
on the scan tool: Self-Test. INSTALL a new IPC . REFER to Instrument Panel
Retrieve the continuous memory Cluster (IPC) in this section. TEST the system for
DTCs from all modules. normal operation.
Is DTC U0151:00 set in the
Occupant Classification System
Module (OCSM)?
Pinpoint Test AS: DTC U0214:00
Normal Operation
DTC U0214:00 (Lost Communication With Remote Function Actuation: No Sub-Type Information)
— sets in continuous memory in the Instrument Panel Cluster (IPC) if data messages received
from the Remote Function Actuator (RFA) module over the High Speed Controller Area Network
(HS-CAN) are missing for 5 seconds or more. For a complete list of all network messages, refer
to Section 418-00 .
RFA module
IPC
PINPOINT TEST AS: DTC U0214:00

AS1 VERIFY THE CUSTOMER CONCERN
Ignition ON. Yes
Verify that there is an observable symptom present. GO to AS2 .
No
AS2 CHECK THE COMMUNICATION NETWORK
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: GO to AS3 .
Network Test.
Does the RFA module pass the network test? REFER to Section 418-00 .
AS3 RETRIEVE THE RECORDED DTCs FROM THE RFA
MODULE SELF-TEST
Check for recorded DTCs from the RFA module self- Yes
test. REFER to Section 419-10
Is DTC U3003:16 or DTC U3003:17 recorded?
No
GO to AS4 .
AS4 RETRIEVE THE RECORDED DTCs FROM THE IPC

SELF-TEST
No
GO to AS5 .
AS5 RECHECK THE IPC DTCs

being set, the module configuration may be incorrectly INSTALL a new RFA module.
set during the Programmable Module Installation REFER to Section 419-10 . CLEAR
(PMI) or the PMI may not have been carried out. the DTCs. REPEAT the IPC self-
test.
Clear the DTCs. Repeat the IPC self-test.
Pinpoint Test AT: DTC U0257:00
Normal Operation
DTC U0257:00 (Lost Communication With Front Controls / Display Interface Module: No Sub
Type Information) — sets in continuous memory in the Instrument Panel Cluster (IPC) if data
messages received from the Front Control/Display Interface Module (FCDIM) over the High
Speed Controller Area Network (HS-CAN) are missing for 5 seconds or more. For a complete list
of all network messages, refer to Section 418-00 .
FCDIM
IPC
PINPOINT TEST AT: DTC U0257:00

AT1 VERIFY THE CUSTOMER
CONCERN
Ignition ON. Yes
Verify there is an observable GO to AT2 .
symptom present.
present? The system is operating normally at this time. The DTC
may have been set due to high network traffic or an
AT2 CHECK THE COMMUNICATION
NETWORK
Ignition ON. Yes
Enter the following diagnostic GO to AT3 .
mode on the scan tool: Network
Test. No
Carry out the network test. REFER to Section 418-00 .
Does the FCDIM pass the
network test?
AT3 RETRIEVE THE RECORDED
DTCs FROM THE FCDIM SELF-TEST
Check for recorded DTCs from Yes
the FCDIM self-test. REFER to Section 415-00 .
U3006:17 recorded? No
GO to AT4 .
AT4 RETRIEVE THE RECORDED
Check for recorded DTCs from Yes
the IPC self-test. For DTC U3006:16, GO to Pinpoint Test AU . For DTC
Is DTC U3006:16 or DTC U3006:17, GO to Pinpoint Test AV .
U3006:17 recorded?
No
GO to AT5 .
AT5 RECHECK THE IPC DTCs
Clear the DTCs. Yes
Wait 10 seconds. GO to AT6 .
The system is operating correctly at this time. The DTC
may have been set due to high network traffic or an
AT6 CHECK FOR DTC U0212:87 SET
IN OTHER MODULES
Clear all DTCs. Yes
Ignition OFF. INSTALL a new FCDIM . REFER to Section 415-00 .
Ignition ON. CLEAR the DTCs. REPEAT the self-test.
Wait 10 seconds.
Enter the following diagnostic No
mode on the scan tool: Self-Test. INSTALL a new IPC . REFER to Instrument Panel
Retrieve the continuous memory Cluster (IPC) in this section. TEST the system for normal
DTCs from all modules. operation.
Is DTC U0257:00 set in the
Audio Control Module (ACM)?
Pinpoint Test AU: DTC U3006:16
Normal Operation
DTC U3006:16 (Control Module Input Power "A": Circuit Voltage Below Threshold) — sets in the
Instrument Panel Cluster (IPC) in continuous memory if the IPC detects battery voltage below 8
volts on the hot at all times B+ voltage supply circuit for more than one second after the engine
has been running for longer than one second.

High circuit resistance
IPC
PINPOINT TEST AU: DTC U3006:16
correct probe adapter(s) may damage the connector
Section 414-01 .

AU1 RECHECK THE IPC DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: IPC GO to AU2 .
Self-Test.
Clear the DTCs. No
Wait 10 seconds. The system is operating
Repeat the IPC self-test. correctly at this time. The
Is DTC U3006:16 still present? DTC may have been set
due to a previous low
battery voltage condition.
AU2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
Self-Test. REFER to Section 414-00 .
Carry out the PCM Key ON Engine OFF (KOEO) self-test.
Retrieve the continuous memory DTCs from all modules. No
Is DTC P0469, P065B, P065C, or P0A3B set in the PCM? GO to AU3 .
AU3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
Check the battery condition and verify the battery is fully Yes
charged. Refer to Section 414-01 . GO to AU4 .
Is the battery OK and fully charged?
No
AU4 CHECK THE IPC VOLTAGE PID
Ignition ON. Yes
Measure and record the voltage at the battery. GO to AU7 .
Enter the following diagnostic mode on the scan tool: IPC
DataLogger. No
Monitor the IPC voltage PID (MAINECUV). GO to AU5 .
Is the voltage within 0.2 volt of the recorded battery
voltage?
AU5 CHECK THE IPC VOLTAGE SUPPLY
Ignition OFF. Yes
Disconnect: IPC C220. GO to AU6 .
Ignition ON.
Measure the voltage between the IPC C220-32, circuit SBP03 No
(BU/RD), harness side and ground. REPAIR circuit SBP03
(BU/RD) for high resistance.
CLEAR the DTC. REPEAT
the self-test.
voltage?
AU6 CHECK THE IPC GROUND CIRCUIT
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to AU7 .
Measure the resistance between the IPC C220-6, circuit
GD115 (BK/GY), harness side and ground. No
(BK/GY) for high resistance.
the self-test.

AU7 CHECK FOR CORRECT IPC OPERATION
corrosion REFER to Instrument Panel
damaged pins Cluster (IPC) . TEST the
pushed-out pins system for normal
Connect the IPC connector and make sure it seats correctly. operation.
corroded connector.
Pinpoint Test AV: DTC U3006:17
Normal Operation
DTC U3006:17 (Control Module Input Power "A": Circuit Voltage Above Threshold) — sets in the
Instrument Panel Cluster (IPC) in continuous memory if the IPC detects battery voltage above 16
volts on the hot at all times B+ voltage supply circuit for more than one second after the engine
has been running for longer than one second.

IPC
PINPOINT TEST AV: DTC U3006:17
NOTE: DTC U3006:17 may be stored in the module memory due to past battery charging or vehicle
jump starting events.

AV1 CHECK FOR DTC B1317, B1676,
P0563 (PCM) OR U3003:17 SET IN OTHER
MODULES
Ignition ON. Yes
Enter the following diagnostic mode on REFER to Section 414-00 to diagnose an
the scan tool: Self-Test. overcharging condition.
Retrieve the continuous memory DTCs
from all modules. No
Is DTC B1317, B1676, P065B (PCM) GO to AV2 .
or U3003:17 set in more than one
module?
AV2 CHECK THE BATTERY VOLTAGE
Turn off all interior/exterior lights and Yes
accessories. REFER to Section 414-00 to diagnose an
Start and run the engine at overcharging condition.
approximately 2,000 rpm for 3 minutes
while monitoring the battery voltage. No
Does the battery voltage rise to 15.5 GO to AV3 .
volts or higher?
AV3 RECHECK FOR DTC U3006:17
Turn the engine off. Yes
Ignition ON. INSTALL a new IPC . REFER to Instrument Panel
Enter the following diagnostic mode on Cluster (IPC) in this section. TEST the system for
the scan tool: Self-Test. normal operation.
Clear the continuous memory DTCs.
Carry out the IPC self-test. No
Is DTC U3006:17 present? The system is operating normally at this time. The
DTC may have been set previously during battery
charging or while jump starting the vehicle.
Pinpoint Test AW: DTC U3010:01
Normal Operation
DTC U3010:01 (Ignition Input Start: General Electrical Failure) — sets on-demand in the
Instrument Panel Cluster (IPC) if the IPC detects voltage on the START input circuit during the
self-test.

IPC
PINPOINT TEST AW: DTC U3010:01

AW1 CHECK FOR VEHICLE OPTION CONTENT
Check if the vehicle is equipped with Intelligent Access (IA). Yes
Is the vehicle equipped with IA ? GO to AW2 .
No
GO to AW3 .
AW2 CHECK THE RFA MODULE
Ignition OFF. Yes
Disconnect: RFA Module C3503C. GO to AW4 .
Ignition ON.
Clear the IPC DTCs. No
Enter the following diagnostic mode on the scan tool: Self- REFER to Section 303-06
Test. to diagnose the PCM starter
Repeat the IPC self-test. inhibit function.
AW3 CHECK THE PCM
Ignition OFF. Yes
Disconnect: PCM C175B. GO to AW4 .
Ignition ON.
Clear the IPC DTCs. No
Enter the following diagnostic mode on the scan tool: Self- REFER to Section 303-06
Test. to diagnose the PCM starter
Repeat the IPC self-test. inhibit function.
AW4 CHECK THE START INPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: IPC C220. REPAIR circuit CDC54
Ignition ON. (WH/GN) for a short to
Measure the voltage between the IPC C220-9, circuit CDC54 voltage. TEST the system
(WH/GN), harness side and ground. for normal operation.
No
INSTALL a new IPC .
REFER to Instrument Panel
Cluster (IPC) in this section.
operation.
Belt-Minder® Deactivating/Activating
Preparation
NOTE: The driver and front passenger Belt-Minder® are deactivated/activated independently. When
deactivating/activating one seating position, do not buckle the other position, as this terminates the
procedure.
NOTE: The Belt-Minder® can also be deactivated/activated using the scan tool.
1. Before deactivating/activating the Belt-Minder®, set the parking brake (manual transaxle).
2. Place the transmission selector lever in PARK (automatic transaxle).

For vehicles with push-button start, push the start/stop switch to turn the vehicle off
completely.
4. Unbuckle the driver and front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the RUN position (do not start the engine).
For vehicles with push-button start, push the start/stop switch and release quickly, do not
attempt to start the engine.
2. Wait approximately 1 minute until the safety belt warning indicator turns off.
3. NOTE: Complete Step 3 within 50 seconds after the safety belt warning indicator turns off.
NOTE: Buckle and unbuckle the safety belt at a moderate rate. If the safety belt
buckle/unbuckle/buckle sequence is carried out too quickly, the Restraints Control Module (RCM)
can fail to recognize one of the sequences and the procedure must be repeated.
To disable the seating position, buckle then unbuckle the safety belt 3 times, ending in the
unbuckled state.
After Step 3, the safety belt warning indicator illuminates for 3 seconds then turns off.
4. Within 7 seconds of the indicator turning off, buckle then unbuckle the safety belt.
If currently enabled this disables the Belt-Minder® feature for that seating position. As
confirmation, the safety belt warning indicator flashes 1 time per second for 3 seconds.
If currently disabled this enables the Belt-Minder® feature for that seating position. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds,
followed by 3 seconds with the indicator ff, then followed by the safety belt warning
indicator flashing 1 times per second for 3 seconds again.
Message Center Configuration
Oil Life Reset
NOTE: This procedure resets the oil life telltale in the Instrument Panel Cluster (IPC), and the oil change
reminder message in the message center display.
1. Press the brake and accelerator pedals at the same time.
2. Turn the ignition switch to the RUN position (do not start the engine).
For vehicles with push-button start, push the start/stop switch and release quickly, do not
attempt to start the engine.
3. Keep the pedals fully depressed for a minimum of 20 seconds.
4. Rotate the key to the OFF position.

For vehicles with push-button start, push the start/stop switch to turn the vehicle off
completely.
5. Start the vehicle. Make sure that the oil life telltale is not illuminated in the IPC , and the oil
change reminder message is no longer displayed in the message center.
NOTE: Steering wheel removed for clarity.

1 — IPC finish panel
2 W707628 IPC screws (3 required)
3 10849 IPC
4 — IPC electrical connector (part of 14K024)
Removal
NOTE: If installing a new Instrument Panel Cluster (IPC), all vehicle keys are erased during the parameter reset
procedure. Verify at least 2 of the vehicle keys are available prior to carrying out this procedure.
NOTE: If a new non-Intelligent Access (IA) IPC is installed, the IPC and the PCM require a parameter reset to
allow the IPC and the PCM to recognize each other. Failure to carry out the parameter reset to the IPC and the
PCM may result in a no start condition.
1. If installing a new IPC , upload the IPC configuration information to the scan tool. For additional
information, refer to Programmable Module Installation (PMI) in Section 418-01 .
2. Lower the tilt steering column to the lowest setting.
3. Remove the IPC center bolt cover and bolt.

4. Position back the instrument cluster finish panel.
5. Remove the two lower IPC bolts and the IPC .

Installation
1. Position the IPC in the instrument panel, connect the electrical connector and install the 2 lower IPC
screws.
2. Reposition the instrument cluster finish panel.
3. Install the IPC center bolt cover and bolt.

4. If installing a new IA IPC remove relay R7 from the Central Junction Box (CJB) and jumper pins 3 and 5
together. Download the IPC configuration information from the scan tool into the new IPC . For additional
information, refer to PMI in Section 418-01 .
After configuration, remove the jumper and reinstall relay R7.
5. If installing a new non- IA IPC , carry out the parameter reset procedure. For additional information, refer
to Section 418-01 .
6. If installing a new non- IA IPC , carry out the key programming procedure. For additional information,
refer to Section 419-01B .
SECTION 413-06: Horn 2011 Fiesta Workshop Manual
Horn bracket bolt 9 80
Horn
The horn system consists of the following components:

Clockspring
Horn relay (integral to the BCM )
Horn (located below the RH headlamp and behind the RH fender)
Horn
Special Tool(s)

tool
Flex Probe Kit

The Battery Junction Box (BJB) supplies the switched and control voltage to the horn relay (part of the
Body Control Module (BCM)). When the driver air bag module is pressed, the horn switch (which is
integrated into the driver air bag module) is closed and ground is supplied to the BCM which is routed
through the clockspring. The horn relay then energizes, sending voltage to the horn, enabling the horn to
sound.
The horn switch is not a single component, but consists of contact points located on the steering wheel
and driver air bag module. The contact points are separated by springs. One set of contacts is part of
the steering wheel itself and the other set is part of a metal plate mounted to the rear of the driver air bag
module. Springs mounted to the metal plate are isolated by plastic seats on the steering wheel. When
the driver air bag module is pressed against the steering wheel, the contacts on the driver air bag
module and the steering wheel touch to complete the circuit.
Anti-Theft Horn
On vehicles equipped with perimeter alarm, the vehicle has a separate anti-theft horn. Refer to Section
419-01A , for information on the perimeter alarm and anti-theft horn.

Horn Battery Junction Box (BJB) fuse 32 (20A)
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart
Symptom Chart
Symptom Chart
The horn is Fuse GO to Pinpoint
inoperative Wiring, terminals or connectors Test A .
Horn
Clockspring
The horn is Wiring, terminals or connectors GO to Pinpoint
always on Steering wheel harness Test B .
Clockspring
BCM
Tire Pressure Monitor (TPM)/Vehicle
Security Module (VSM)
Pinpoint Tests
Pinpoint Test A: The Horn Is Inoperative
Refer to Wiring Diagrams Cell 44 , Horn/Cigar Lighter for schematic and connector information.
Normal Operation
When the driver air bag module is pressed, the normally open horn switch (which is part of the driver air
bag module) is closed and ground is routed through the clockspring to the horn relay, energizing the
horn relay. The Battery Junction Box (BJB) supplies the switched and control voltage to the horn relay,
which is integrated into the Body Control Module (BCM). The horn relay then provides voltage to the
horn, enabling the horn to sound.
Fuse
Horn
Clockspring
BCM
PINPOINT TEST A: THE HORN IS INOPERATIVE

A1 CHECK FOR VOLTAGE TO THE HORN
Ignition OFF. Yes
Disconnect: Horn C131. GO to A2 .
While pressing the horn switch, measure the voltage between
the horn C131-2, circuit CRH04 (VT/GN), harness side and No
ground. GO to A3 .

A2 CHECK FOR VOLTAGE TO THE HORN USING THE
CONNECTOR GROUND
While pressing the horn switch, measure the voltage between Yes
the horn C131-2, circuit CRH04 (VT/GN), harness side and the INSTALL a new horn.
horn C131-1, circuit GD123 (BK/GY), harness side. REFER to Horn in this
section. TEST the system
No
TEST the system for
normal operation.

A3 CHECK FOR VOLTAGE TO THE BCM
Connect: Horn C131. Yes
GO to A4 .
Measure the voltage between the BCM C2280A-2, circuit No
SBB32 (VT/RD), harness side and ground. VERIFY the BJB fuse 32
(20A) is OK. If OK,
(VT/RD) for an open. If not
Diagrams manual to
TEST the system for
normal operation.

A4 BYPASS THE BCM
Connect a fused jumper wire between the BCM C2280A-2, Yes
circuit SBB32 (VT/RD), harness side and the BCM C2280A-3, REMOVE the jumper wire.
circuit CRH04 (VT/GN), harness side. GO to A5 .
No
REPAIR circuit CRH04
(VT/GN) for an open.
TEST the system for
normal operation.
Does the horn sound?

A5 CHECK FOR VOLTAGE TO THE CLOCKSPRING
Disconnect: Clockspring C218B . GO to A7 .
Measure the voltage between the clockspring C218B-11, circuit
CRH03 (BN), harness side and ground. No
GO to A6 .

A6 CHECK HORN RELAY COIL GROUND CONTROL CIRCUIT
FOR AN OPEN
Measure the resistance between the clockspring C218B-11, GO to A10 .
circuit CRH03 (BN), harness side and the BCM C2280E-21,
circuit CRH03 (BN), harness side. No
REPAIR circuit CRH03
(BN) for an open. TEST
operation.

A7 CHECK FOR VOLTAGE TO THE CLOCKSPRING USING THE
CONNECTOR GROUND
Measure the voltage between the clockspring C218B-11, circuit Yes
CRH03 (BN), harness side and the clockspring C218B-15, GO to A8 .
circuit GD115 (BK/GY), harness side.
No
TEST the system for
normal operation.

A8 CHECK FOR VOLTAGE TO THE HORN SWITCH
CONNECTOR
Connect: BCM C2280E. Yes
Connect: Clockspring C218B. INSTALL a new driver air
Remove the driver air bag module. Refer to Section 501-20B . bag module. REFER to
Disconnect: Horn Switch C217A. Section 501-20B . TEST
Disconnect: Horn Switch C217B. the system for normal
Measure the voltage between the horn switch C217A-1, circuit operation.
(RD), harness side and the horn switch C217B-1, circuit (VT),
harness side. No
GO to A9 .
A9 CHECK FOR VOLTAGE TO THE CLOCKSPRING
Disconnect: Clockspring C218C. Yes
Measure the voltage between the clockspring connector C218C The steering wheel
pin 4, component side and the clockspring C218C pin 8 harness has an open
component side. circuit. INSTALL a new
steering wheel. REFER to
system for normal
operation.
No
INSTALL a new
Section 501-20B . TEST
operation.

correctly. No
corroded connector.
Pinpoint Test B: The Horn Is Always On
Refer to Wiring Diagrams Cell 44 , Horn/Cigar Lighter for schematic and connector information.
Normal Operation
When the driver air bag module is pressed, the normally open horn switch (which is part of the driver air
bag module) is closed and ground is routed through the clockspring to the horn relay, energizing the
horn relay. The Battery Junction Box (BJB) supplies the switched and control voltage to the horn relay,
which is integrated into the Body Control Module (BCM). The horn relay then provides voltage to the
horn, enabling the horn to sound. If incorrectly installed, the horn pad can cause the horn switch to be
closed at all times.
The Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) is also wired to the horn relay coil
controlled circuit. The TPM / VSM sounds the horn during TPMS sensor training.

Clockspring
BCM
TPM / VSM
PINPOINT TEST B: THE HORN IS ALWAYS ON

B1 CHECK THE HORN SWITCH
INPUT TO THE BCM
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to B2 .
Ignition ON. No
Does the horn continue to GO to B3 .
sound?
B2 CHECK THE HORN CIRCUIT FOR
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280A. REPAIR circuit CHR04 (VT/GN) for a short to voltage.
Ignition ON. TEST the system for normal operation.
Does the horn continue to
sound? No
GO to B7 .
B3 CHECK THE TPM / VSM
Ignition OFF. Yes
Connect: BCM C2280E. GO to B4 .
Connect: BCM C2280D.
Disconnect: TPM / VSM C4321B. No
Does the horn continue to GO to B8 .
sound?
B4 CHECK THE HORN SWITCH
INPUT CIRCUIT FOR A SHORT TO
GROUND
Disconnect: Clockspring C218B. Yes
Does the horn continue to REPAIR circuit CRH03 (BN) for a short to ground.
sound? TEST the system for normal operation.
No
GO to B5 .
B5 CHECK HORN SWITCH
Connect: Clockspring C218B. Yes
Remove the driver air bag module. GO to B6 .
Refer to Section 501-20B .
Disconnect: Horn Switch C217A. No
Does the horn continue to INSTALL a new driver air bag module. REFER to
sound? Section 501-20B . TEST the system for normal
operation.
B6 CHECK THE CLOCKSPRING FOR
A SHORT TO GROUND
Disconnect: Clockspring C218C. Yes
Does the horn continue to INSTALL a new clockspring. REFER to Section 501-
sound? 20B . TEST the system for normal operation.
No
The steering wheel harness has a short circuit.
INSTALL a new steering wheel. REFER to Section
211-04 . TEST the system for normal operation.
B7 CHECK FOR CORRECT BCM
OPERATION
Disconnect all the BCM Yes
connectors. INSTALL a new BCM . REFER to Section 419-10 .
Check for: TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time. The
Connect all the BCM connectors concern may have been caused by a loose or corroded
and make sure they seat correctly. connector.
B8 CHECK FOR CORRECT TPM /
VSM OPERATION
Disconnect all the TPM / VSM Yes
connectors. INSTALL a new TPM module. REFER to Section 204-
corrosion
damaged pins No
Connect all the TPM / VSM concern may have been caused by a loose or corroded
connectors and make sure they connector.
seat correctly.
Horn

1 — Horn electrical connector (part of 14K012)
2 13832 Horn
2 W702498 Horn bracket bolt
3. Remove the horn bracket bolt and the horn.


SECTION 414-00: Charging System 2011 Fiesta Workshop Manual
Item Specification
Generator
Generator pulley ratio 2.62:1
Rating 81 amps @ 750 rpm (min) - 124 amps @ 2,300 rpm (max)
Voltage regulator type Electronic internal with generator
Generator B+ terminal nut 15 — 133
Generator nut 48 35 —
Generator stud bolt 10 — 89
Lower generator bolt 48 35 —
Upper generator bolt 48 35 —
Charging System
The charging system is a negative ground system consisting of:
a generator with an internal voltage regulator.

a charging system warning indicator.
a battery.
circuitry and cables.
a PCM.
The generator is driven by the accessory drive belt. When the engine is started, the generator begins to
generate AC voltage which is internally converted to DC voltage. The DC voltage is controlled by the
voltage regulator (located on the rear of the generator) and supplied to the battery. The PCM controls
the voltage regulator set point, communicating with the generator internal voltage regulator over a
dedicated Local Interconnect Network (LIN) communication circuit.
The PCM-controlled charging system, or Smart Charge charging system, determines the optimal voltage
setpoint for the charging system and communicates this information to the voltage regulator. The Smart
Charge charging system is designed to set 1 of 9 DTCs any time a charging system fault is present. All
of the DTCs can set continuous faults, but not all DTCs set as on-demand faults.
DTC Key ON Engine OFF (KOEO) Key ON Engine Running (KOER) Continuous
P065B:09 X X
P065C:09 X X
P0A3B:09 X X
P1794:16 X X X
P1794:17 X X X
U0120:13 X X X
U0469:09 X X
U3003:16 X X X
U3003:17 X X X
This system uses a dedicated Local Interconnect Network (LIN) communication circuit. The generator
uses this LIN circuit to communicate the desired setpoint from the PCM to the voltage regulator. The
generator also uses this LIN circuit to communicate the generator load and error conditions to the PCM.
The PCM simultaneously controls and monitors the output of the generator. When the usage of current
is high or the battery is discharged, the PCM raises engine speed as needed to increase generator
output. The generator charges the battery and at the 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 uses the measurement from the Intake Air
Temperature (IAT) sensor to adjust the charging voltage according to the battery temperature. The PCM
also uses other inputs to control charging system voltage such as the Vehicle Speed Sensor (VSS) and
Engine Coolant Temperature (ECT) sensor. The voltage setpoint is calculated by the PCM and
communicated to the voltage regulator by the LIN circuit based on the needs of the vehicle and the
operating conditions.
The PCM turns off the generator during cranking to reduce the generator load and improve cranking
speed. Once the engine starts, the PCM slowly increases generator output to desired voltage.
The PCM controls the charging system warning indicator by sending a message over the High Speed
Controller Area Network (HS-CAN) to the Instrument Panel Cluster (IPC) module. The IPC module
controls the charging system warning indication based on the message from the PCM. The IPC module
controls the charging system indication based on the message from the PCM, turning it on or off. If
equipped with a Front Control/Display Interface Module (FCDIM) (message center), the IPC module
displays a CHECK CHARGING SYSTEM message. When the ignition is on and the engine is off on
vehicles equipped with a message center, the CHECK CHARGING SYSTEM message may not be
displayed. For additional information regarding the IPC module, refer to Section 413-01 . For additional
information regarding the FCDIM , refer to Section 415-00 .
Under certain circumstances the charging system may have a concern but still keep the battery charged
and the vehicle running. The LIN normally initiates charging from the PCM, but the generator may
continue charging when a fault is present on this circuit. If the engine is operated at greater than 2,000
rpm momentarily, the generator may self-excite or start charging on its own. The charging system
warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed, and the
generator operates in a default mode (approximately 13.5 volts) until the engine is turned off. When the
engine is restarted and the engine is operated at greater than 2,000 rpm momentarily, the generator
may again self-excite and again the charging system warning indicator is illuminated and/or CHECK
CHARGING SYSTEM message is displayed.
The PIDs and their associated descriptions used in the charging system diagnosis are listed below:
PID Chart
Associated Connector,
PID Description Normal Display Circuit Name Circuit
GENVDSD Generator Voltage varies by vehicle needs - — —
Voltage Desired May be controlled by an output
state control
VPWR Module Supply Within 0.5 volt of battery voltage — —
Voltage
Special Tool(s)
tool
NOTICE: Do not make jumper connections except as directed. Incorrect connections may
damage the voltage regulator test terminals or fuses.
NOTICE: Do not allow any metal object to come in contact with the generator housing and
internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out any pinpoint test, disregard any DTCs set while following a specific pinpoint
test. After the completion of a test, be sure to clear all DTCs in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise
specified.

Battery Wiring, terminals or connectors
Front End Accessory Drive (FEAD) belt Cables
Generator pulley Battery
Generator
Fuses
4. Verify the battery condition. Refer to Section 414-01 .

tool.

The air bag warning indicator prove-out (other indicators may NOT prove ignition is
on) confirms ignition on. If ignition does not turn on, refer to Section 211-05 to
refer to Section 418-00 , Inspection and Verification, to establish a scan tool session
(without the ignition on).

418-00 .
NOTE: Use the Integrated Diagnostic System (IDS) feature that retrieves all Continuous Memory
Diagnostic Trouble Codes (CMDTCs) from all modules at one time.
9. Retrieve CMDTCs from all modules.
10. NOTE: If no charging system DTCs are present, the charging system is operating correctly. If the
charging system has a concern, it usually sets a charging system DTC.
If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Chart
in this section. For all other DTCs, refer to the Master DTC Chart in Section 419-10 or Powertrain
11. If no DTCs related to the concern are retrieved, go to the Symptom Chart in this section.
Diagnostic Trouble Code (DTC) Chart
DTCs Description Source Action

P065B:09 Generator Control Circuit PCM INSTALL a new generator. Refer to Generator
Range/Performance: in this section. CLEAR the DTCs. REPEAT
Component Failure the self-test. TEST the system for normal
operation.
P065C:09 Generator Mechanical PCM GO to Pinpoint Test D .
Performance: Component
Failure
P0A3B:09 Generator Over Temperature: PCM INSTALL a new generator. Refer to Generator
Component Failure in this section. CLEAR the DTCs. REPEAT
the self-test. TEST the system for normal
operation.
P1794:16 Battery Voltage Circuit: Circuit PCM GO to Pinpoint Test B .
P1794:17 Battery Voltage Circuit: Circuit PCM GO to Pinpoint Test A .
U0120:13 Lost Communication with PCM GO to Pinpoint Test C .
Starter/Generator Control
Module: Circuit Open
U0469:09 Invalid Data Received From PCM INSTALL a new generator. Refer to Generator
Starter/Generator Control in this section. CLEAR the DTCs. REPEAT
Module: Component Failure the self-test. TEST the system for normal
operation.
U3003:16 Battery Voltage: Circuit Voltage PCM GO to Pinpoint Test B .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage PCM GO to Pinpoint Test A .
Above Threshold
All other — Various REFER to the Section 303-14 or the
DTCs Modules Powertrain Control/Emissions Diagnosis
(PC/ED) manual. If directed to this section
from another section, GO to Symptom Chart
in this section.
Symptom Chart
Symptom Chart
System voltage Engine, generator GO to Pinpoint Test A .
high and battery
grounds
connectors
Battery
Generator
PCM
System voltage High-current fuse GO to Pinpoint Test B .
low or battery is assembly
discharged Abnormal ignition-
off current drain(s)
Engine, generator
and battery
grounds
Positive battery
cable
connectors
Battery
Generator
PCM
The generator is Front End GO to Pinpoint Test D .
noisy Accessory Drive
(FEAD) belt
Loose
bolts/brackets
Generator/pulleys
Radio Generator GO to Pinpoint Test E .
interference Wiring, terminals or
connectors
In-vehicle
entertainment
system
Charging Wiring, terminals or RETRIEVE Continuous Memory
system warning connectors Diagnostic Trouble Codes
indicator is IPC (CMDTCs) from all modules. If
never/always on Generator any charging system DTCs are
PCM found, REFER to the Diagnostic
Trouble Code (DTC) Chart in
this section. If no charging
system DTCs are found, REFER
to Section 413-01 .
Pinpoint Test
Special Tool(s)

tool
Pinpoint Test A: System Voltage High
Refer to Wiring Diagrams Cell 12 , Charging System for schematic and connector information.
NOTE: DTC P1794:17 or U3003:17 can set if the vehicle has been recently jump started, the battery has
been recently charged or the battery has been discharged. The battery may become discharged due to
excessive load(s) on the charging system from aftermarket accessories or if vehicle accessories have
been operating for an extended period of time without the engine running.
Normal Operation
With the engine running, the charging system supplies voltage to the battery and the vehicle electrical
system through the battery B+ cable. The voltage that is supplied to the vehicle electrical system
operates of the various vehicle systems and modules. Many modules monitor this voltage and set a DTC
if the voltage exceeds their calibrated setpoint.
DTC P1794:17 (Battery Voltage Circuit: Circuit Voltage Above Threshold) — Sets when the
module senses battery voltage is greater than 16 volts.
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — Sets when the module
senses battery voltage is greater than 16 volts.

Engine, generator and battery grounds
Battery
Generator
PCM
PINPOINT TEST A: SYSTEM VOLTAGE HIGH
NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.
NOTE: Do not have a battery charger attached during vehicle testing.

A1 CHECK BATTERY CONDITION
Refer to Section 414-01 and carry out Pinpoint Test A: Yes
Battery Condition Test to determine if the battery can hold a GO to A2 .
charge and is OK for use.
Does the battery pass the condition test? No
A2 MONITOR PCM PID GENERATOR VOLTAGE DESIRED
(GENVDSD)
Enter the following diagnostic mode on the scan tool: PCM GO to A3 .
DataLogger.
Monitor the GENVDSD PID. No
Does the GENVDSD PID indicate 15.9 volts or less? GO to A8 .
(GENVDSD)
With the engine still running at idle, measure battery voltage Yes
and record. The fault is not present at
this time. CHECK generator
connections for corrosion,
loose connections and/or
bent terminals. REPAIR as
necessary. CLEAR the
normal operation.
No
GO to A4 .
Monitor the GENVDSD PID.

Is battery voltage within ±0.6 volt of the PID GENVDSD?
(GENVDSD) WHILE COMMANDED
Monitor the GENVDSD PID. Yes
Using the active command, set GENVDSD PID to 14 volts. GO to A5 .
With the engine still running at idle, measure battery voltage
and record. No
INSTALL a new generator.
REFER to Generator in this
operation.
Is battery voltage within ±0.6 volt of the PID GENVDSD?
A5 CHECK THE GENERATOR OUTPUT
Increase engine rpm until generator starts to generate output. Yes
With the engine running, measure battery voltage and record. INSTALL a new generator.
operation.
No
GO to A6 .

A6 COMPARE PCM SUPPLY VOLTAGE (VPWR) PID TO
BATTERY VOLTAGE
With the engine still running at idle, measure the battery Yes
voltage at the battery and monitor the PCM VPWR PID. INSTALL a new generator.
operation.
No
GO to A7 .
Does PCM VPWR PID accurately display battery voltage

within ±0.5 volt?
A7 CHECK PCM SUPPLY VOLTAGE CIRCUITS
Ignition OFF. Yes
Inspect the connector pins for damage. Measure resistance
between Battery Junction Box (BJB) fuse 16 (15A), output No
side and: REPAIR high resistance or
PCM C175B-11, circuit CBB16 (BU/GN), harness side. loose connections in the
PCM C175B-12, circuit CBB16 (BU/GN), harness side. affected circuit(s). CLEAR
normal operation.

A8 CHECK FOR CORRECT PCM OPERATION
Ignition OFF. Yes
Check the PCM harness and component side connectors for: INSTALL a new PCM.
pushed-out/bent pins. CLEAR the DTCs. REPEAT
Connect the PCM and generator, make sure the connectors the self-test. TEST the
seat correctly. system for normal operation.
Operate the system and determine if the concern is still
present.
normal operation.
Pinpoint Test B: System Voltage Low or Battery is Discharged
Normal Operation
With the engine running, the charging system supplies voltage to the battery and the vehicle electrical
system through the battery B+ cable. The voltage that is supplied to the vehicle electrical system
operates the various vehicle systems and modules. Many modules monitor this voltage and set a DTC if
the voltage drops below their calibrated setpoint.
DTC P1794:16 (Battery Voltage Circuit: Circuit Voltage Below Threshold) — Sets when the
module senses battery voltage is less than 9 volts.
DTC P065B:09 (Generator Control Circuit Range/Performance: Component Failure) — Sets
when the generator reports an internal regulator failure.
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — Sets when the module
senses battery voltage is less than 9 volts.

High-current fuse assembly
Abnormal ignition-off current drain(s)
Engine, generator and battery grounds
Positive battery cable
Battery
Generator
PCM
PINPOINT TEST B: SYSTEM VOLTAGE LOW OR BATTERY IS DISCHARGED

B1 CHECK THE PCM DTCs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: Self- INSTALL a new generator.
Test — PCM. REFER to Generator in this
Check the PCM for DTCs. section. CLEAR the DTCs.
Is DTC P065B:09 present? REPEAT the self-test. TEST
operation.
No
GO to B2 .
B2 CHECK BATTERY CONDITION
Refer to Section 414-01 and carry out Pinpoint Test A: Yes
Battery Condition Test to determine if the battery can hold a GO to B3 .
charge and is OK for use.
Does the battery pass the condition test? No
operation.
B3 CHECK THE GENERATOR CONNECTIONS
Ignition OFF. Yes
Inspect generator C102A connection. Connector should be GO to B4 .
installed correctly and tight.
Inspect generator C102A for bent and/or pushed-out pins. No
Inspect generator C102B, B+ circuit SBF01 (RD) TIGHTEN or INSTALL a new
connection. The connection should be tight. C102B (B+ nut) or REPAIR
Measure the battery voltage. connection as needed.
REFER to Specifications in
this section. VERIFY the high
current fuse assembly is OK.
If the fuse assembly is OK,
REPAIR circuit SBF01 (RD). If
the fuse assembly is not OK,
REFER to the Wiring
operation.
Measure the voltage between generator C102B, B+ circuit

SBF01 (RD) and ground.
Is the generator C102B connection tight and does the

generator B+ measure battery voltage within ±0.5 volt?
B4 CHECK THE VOLTAGE DROP IN THE B+ CIRCUIT
With the engine running at idle, headlamps on and blower GO to B5 .
on high, measure the voltage drop between generator B+
C102B, circuit SBF01 (RD) and the positive battery No
terminal. INSPECT and REPAIR any
corrosion in the B+ circuit
SBF01 (RD) or positive
battery cable connections.
Carry out a wiggle test of the generator wiring and

connections while measuring voltage drop.
Is the voltage drop less than 0.5 volt?
B5 CHECK THE VEHICLE GROUNDS
With the engine running at idle, headlamps on and heater GO to B6 .
blower on high, measure the voltage drop between the
generator housing and the negative battery terminal. No
INSPECT and REPAIR the
engine ground, generator
ground or the battery ground
for corrosion. CLEAR the
operation.
Is the voltage drop less than 0.5 volt?

B6 COMPARE PCM SUPPLY VOLTAGE (VPWR) PID
DataLogger. GO to B7 .
Monitor PCM VPWR PID.
With the engine still running at idle, headlamps on and No
blower on high, measure the battery voltage at the battery REPAIR high resistance or
and monitor the PCM VPWR PID. loose connections in the
affected PCM power circuit(s).
Does PCM VPWR PID display battery voltage within

±0.5 volt?
B7 CHECK PCM GROUND FOR HIGH RESISTANCE
Monitor PCM VPWR PID. Yes
With the engine still running at idle, turn off all accessory GO to B8 .
loads, measure the battery voltage at the battery and note
the PCM VPWR PID. No
REPAIR the affected PCM
ground circuits. CLEAR the
operation.
With the engine still running at idle, turn headlamps on and
blower on high, measure the battery voltage at the battery
and monitor the PCM VPWR PID.
Does the VPWR PID read within ±0.5 volt with

accessory loads on as compared to accessory loads
off?
B8 MONITOR PID VPWR AT WOT
With the engine still running at idle, turn off all accessory Yes
loads, measure the battery voltage at the battery and CARRY OUT the Component
monitor the PCM VPWR PID. Test, Battery — Drain Test.
No
INSTALL a new PCM. REFER
to Section 303-14 . CLEAR
normal operation.
Monitor the VPWR PID and momentarily accelerate the

engine to WOT and release. Repeat this step 4-5 times
while continuing to monitor the VPWR PID.
Does the VPWR PID stay within 0.5 volt of battery
voltage when the engine rpms are increased?
Pinpoint Test C: DTC U0120:13

Normal Operation
The charging system supplies voltage to the battery and the vehicle electrical system through the battery
B+ cable. The PCM monitors the generator output through a dedicated Local Interconnect Network (LIN)
communication circuit. The generator uses this LIN circuit to communicate the desired voltage setpoint
from the PCM to the voltage regulator. The generator also uses this LIN circuit to communicate the
generator load and error conditions to the PCM.
DTC U0120:13 (Lost Communication with Starter/Generator Control Module: Circuit Open) —
Sets when the PCM does not detect communication through the LIN circuit. This can be a result
of an open or short in the LIN circuit. This DTC also sets if the B+ circuit is open.

Generator
PCM
PINPOINT TEST C: DTC U0120:13

C1 CHECK THE GENERATOR CONNECTIONS
Ignition OFF. Yes
Inspect generator C102A connection. Connector should be GO to C2 .
installed correctly and tight.
Inspect generator C102A for bent and/or pushed-out pins. No
Inspect generator C102B, B+ circuit SBF01 (RD) TIGHTEN or INSTALL a new
connection. The connection should be tight. C102B (B+ nut) or REPAIR
Measure the battery voltage. connection as needed. REFER
to Specifications in this section.
VERIFY the high current fuse
assembly is OK. If the fuse
assembly is OK, REPAIR
circuit SBF01 (RD). If the fuse
assembly is not OK, REFER to
identify the possible causes of
the circuit short. CLEAR the
operation.
Measure the voltage between generator C102B, B+ circuit

SBF01 (RD) and ground.
Is the generator C102B connection tight and does the
generator B+ measure battery voltage within ±0.5 volt?
C2 CHECK THE GENERATOR LIN CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition OFF. Yes
Disconnect: Generator C102A. REPAIR circuit CDC15 (VT) for
Disconnect: PCM C175E. a short to voltage. CLEAR the
Ignition ON. DTCs. REPEAT the self-test.
Measure the voltage between generator C102A-1, circuit TEST the system for normal
CDC15 (VT), harness side and ground. operation.
No
GO to C3 .

C3 CHECK THE GENERATOR LIN CIRCUIT FOR A SHORT
TO GROUND
Ignition OFF. Yes
Measure the resistance between the generator C102A-1, GO to C4 .
circuit CDC15 (VT), harness side and ground.
No
REPAIR circuit CDC15 (VT) for
operation.

C4 CHECK THE GENERATOR LIN CIRCUIT FOR AN OPEN
Inspect the following harness connectors for damaged or Yes
pushed-out pins: INSTALL a new generator.
PCM C175E-39, circuit CDC15 (VT) Refer to Generator in this
Generator C102A-1, circuit CDC15 (VT) section. CLEAR the DTCs.
Measure the resistance between PCM C175E-39, circuit REPEAT the self-test. TEST
CDC15 (VT), harness side and generator C102A-1, circuit the system for normal
CDC15 (VT), harness side. operation.
If DTC U0120:13 returns,

INSTALL a new PCM. Refer to
No
REPAIR circuit CDC15 (VT) for
an open. CLEAR the DTCs.
operation.
Are the connectors and pins free of damage and is the

resistance less than 5 ohms?
Pinpoint Test D: The Generator is Noisy
Normal Operation
The generator is belt-driven by the engine accessory drive system. Sources of generator noise include
bearing noise, electrical fault noise and generator or belt pulley misalignment. A generator with certain
types of diode or stator failures may also produce an audible noise.
DTC P065C:09 (Generator Mechanical Performance: Component Failure) — Sets when the
generator reports an internal mechanical failure. This DTC also sets if the generator has a bad
bearing, pulley, axle or belt.

Front End Accessory Drive (FEAD) drive belt
Loose bolts/brackets
Generator/pulley
PINPOINT TEST D: THE GENERATOR IS NOISY

D1 CHECK FOR ACCESSORY DRIVE BELT
NOISE AND LOOSE MOUNTING BRACKETS
Ignition OFF. Yes
Check the accessory drive belt and tensioner GO to D2 .
for damage and correct installation. Refer to
Section 303-05 . No
Check the accessory mounting brackets and REPAIR as necessary. REFER to Section
generator pulley for looseness or misalignment. 303-05 for diagnosis and testing of the
Is the accessory drive OK? accessory drive system. TEST the system
D2 CHECK THE GENERATOR MOUNTING
Check the generator mounting for loose bolts or Yes
misalignment. GO to D3 .
Is the generator mounted correctly?
No
REPAIR as necessary. TEST the system
D3 CHECK THE GENERATOR FOR NOISE
With the engine running, use a stethoscope or Yes
equivalent listening device to probe the INSTALL a new generator. REFER to the
generator and the accessory drive area for Generator in this section.
unusual mechanical noise.
Is the generator the noise source? No
REFER to Section 303-00 to diagnose the
source of the engine noise.
Pinpoint Test E: Radio Interference
Normal Operation
The generator radio suppression equipment reduces interference transmitted through the audio system
speakers by the vehicle electrical system.

Generator
In-vehicle entertainment system
PINPOINT TEST E: RADIO INTERFERENCE
NOTE: If the OEM audio unit has been replaced with an aftermarket unit, the vehicle may not pass this
test. Return the vehicle to OEM condition before carrying out this pinpoint test.
NOTE: If the engine is operated at greater than 2,000 rpm momentarily, the generator self-excites. Make
sure the engine rpm remains below 2,000 rpm when the generator is disconnected. If it rises above
2,000 rpm, turn the ignition to the OFF position and restart the test.
NOTE: Inspect for any aftermarket accessories that have been added to the vehicle. Check the wiring
for these accessories and be sure they have not been attached to the generator circuits and are
positioned away from the generator wiring.

E1 VERIFY THE GENERATOR IS THE
SOURCE OF THE RADIO INTERFERENCE
Start the engine and allow the engine to Yes
idle. REFER to Section 415-00 for diagnosis and
Tune the audio unit to a station where the testing of the in-vehicle entertainment system.
interference is present.
Ignition OFF. No
Disconnect: Generator C102B. INSTALL a new generator. REFER to
Start the engine and allow the engine to Generator in this section. TEST the system for
idle, determine if the interference is still normal operation.
present.
Is the interference present with the
generator disconnected?
Generator

1 W703175 Generator stud bolt
2 W715065 Lower generator bolt
3 10346 Generator
4 — Generator electrical connector (part of 12A522)
5 W707759 Generator B+ terminal nut (part of 10346)
6 10A375 Generator B+ terminal protective cover
7 — Generator B+ terminal (part of 12A522)
8 W703957 Upper generator bolt
9 W520103 Generator nut
Removal
1. Disconnect the battery. For additional information, refer to Section 414-01 .
3. Remove the generator B+ terminal protective cover and nut. Position the generator B+ terminal aside.
4. Disconnect the generator electrical connector.
5. Detach the upper degas bottle hose from the fuel rail and position aside.
6. Remove the generator nut and the stud bolt.

7. Remove the upper and lower generator bolts.
8. Remove the generator.
Installation
1. Install the generator and generator upper and lower bolts. Hand-tighten the bolts. Do not torque the bolt
at this time.
2. Install the generator stud bolt.

3. Install the generator nut.

4. Tighten the generator upper and lower bolts.

5. Attach the upper degas bottle hose to the fuel rail.
6. Connect the generator electrical connector.
7. Position the generator B+ terminal on the generator and install the nut.
Tighten the nut to 15 Nm (133 lb-in).
Install the generator B+ terminal protective cover.
9. Connect the battery. For additional information, refer to Section 414-01 .

SECTION 414-01: Battery, Mounting and Cables 2011 Fiesta Workshop Manual
Item Specification
Battery
Cold Cranking Amps (CCA) measured at -18°C (0°F) 500 CCA
Battery ground cable body terminal bolt 13 — 115
Battery hold-down bracket nuts 5 — 44
Battery terminal nuts 5 — 44
High current battery junction box side terminal nuts 5 — 44
High current battery junction box upper terminal nuts 10 — 89
Battery and Cables
Vehicles are equipped with a 12-volt, maintenance-free battery.
The battery and cable system consists of the following components:
Battery
Battery cable assembly
Battery tray
The battery is a 12V DC source connected in a negative ground system. The battery case is sealed with 2
vent holes to release gases. The battery has 3 major functions:
Engine cranking power source

Voltage stabilizer for the electrical system
Temporary power source when electrical loads exceed the generator output current
Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling
facility for disposal.
Battery Eye Operation
The battery eye indicates the state-of-charge of the battery by responding to the specific gravity of a
single battery cell electrolyte. The battery eye has a viewing plate, 2 colored balls of different specific
gravity and a small passage. As the state-of-charge and specific gravity changes, the balls change their
position in the passageway and subsequently display a different color in the viewing eye. The primary
purpose of the battery is to be a quick indicator of state-of-charge for assembly plants and dealership
pre-delivery processes.
The color of the battery eye indicates the approximate state-of-charge.
Red — indicates low state-of-charge.

Yellow/Black — indicates between high and low state-of-charge.
Green — indicates high state-of-charge.
No color can occur after the battery has been in service for several years and some of the plate
material has coated the balls.
A clear battery eye can occur if the battery case becomes damaged and the electrolyte has fallen
below the plates.
NOTE: The battery eye may remain red for a period of time (up to several days), even after the battery is
fully charged, because the acid is not yet fully mixed.
Do not install a new battery based solely on the indication of the battery eye. The battery eye color
simply indicates the battery state-of-charge, not its condition. For example, a red or yellow/black battery
eye usually indicates the battery is discharged, not defective. If the battery eye indicates the battery may
be discharged, it is necessary to recharge the battery before testing its condition.
Charging a Battery
Batteries discharge while the vehicle is on the dealer lot or parked by the customer for an extended
period of time due to normal parasitic key-off loads. Also, vehicles still in dealer inventory or in long-term
storage may be driven short distances with heavy electrical loads. Over a period of time (30 days or
more), this could result in vehicles having shallow or deeply discharged batteries.
Deeply discharged — A battery that is drained over a prolonged period of time, such as an unsold
vehicle or a vehicle in storage, to the point the battery is dead.
Shallow discharge — A battery that is drained by leaving an accessory on for several hours or a
few days and has a very low charge.
The vehicle charging system is designed to supply the electrical power needed to maintain the battery
near full charge during normal vehicle use. The charging system is not capable of bringing a deeply
discharged battery back to near full charge in a short amount of time such as allowing the vehicle to idle
for 15 minutes to "recharge the battery". Discharged batteries should be charged using an external
charger.
NOTE: Battery chargers have improved greatly with the addition of the new generation pulse chargers.
These chargers pulse current into the battery, breaking down the sulfation layer on the battery plates
and generally reduce charging times to less than an hour.
NOTE: Cold batteries will not readily accept a charge. Therefore, batteries should be allowed to warm to
approximately 5°C (41°F) before charging. This may require 4 to 8 hours at room temperature.
The following chart summarizes 2 recommended methods of charging.
Type of Battery
Discharge Pulse Charger Standard Charger
Deeply discharged Follow directions supplied with 2 to 8 hours and may take up to an hour to
the pulse charger accept initial charge
Shallow discharge 45 minutes to an hour charge 2 hours below (40A) on manual setting or
medium automatic setting

Battery Battery cables
Battery mounting Battery posts
4. If the fault is not visually evident, GO to Pinpoint Test A in the Pinpoint Test procedure.
Pinpoint Test
Special Tool(s)
Micro 490 Digital Battery
Analyzer
Pinpoint Test A: Battery Condition Test
Normal Operation
Battery condition is determined by measuring battery terminal voltage after a specific discharge current
is applied for a specified time period.

Battery charge
Battery
PINPOINT TEST A: BATTERY CONDITION TEST

A1 TEST THE BATTERY CONDITION
NOTE: A red test-eye indicates the battery Yes

is discharged, not necessarily defective. If the meter reads GOOD BATTERY,
RETURN the battery to service.
NOTE: Failure to fully charge the battery
before retesting may cause false readings. If the meter reads GOOD-RECHARGE,
Verify the battery condition using the Micro CHARGE the battery and RETURN it to
490 Digital Battery Analyzer. service.
Is the battery OK?
If the meter reads CHARGE & RETEST, fully
CHARGE and RETEST the battery.
No
If the meter reads REPLACE BATTERY,
If the meter reads BAD CELL-REPLACE,

Component Test
Battery — Drain Tests
NOTICE: To prevent damage to the meter, do not crank the engine or operate accessories that
draw more than 10A.
NOTE: No factory-equipped vehicle should have more than a 50 mA (0.050 amp) draw.
Check for current drains on the battery in excess of 50 mA (0.050 amp) with all the electrical accessories
off and the vehicle at rest for at least 40 minutes. Current drains can be tested with the following
procedure.
NOTE: Many electronic modules draw 10 mA (0.010 amp) or more continuously.
NOTE: Typically, a drain of approximately 1 amp is attributed to an engine compartment lamp, glove
compartment lamp or interior lamp staying on continually. Other component failures or wiring shorts are
located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is
found, the meter reading falls to an acceptable level. If the drain is still not located after checking all the
fuses, it may be due to the generator. Disconnect the generator and retest.
NOTE: To accurately test the drain on a battery, an in-line ammeter must be used between the negative
battery post and its respective cable. Use of a test lamp or voltmeter is not an accurate method.
1. Make sure the junction box(es)/fuse panel(s) is accessible without turning on the interior lights or
the underhood lights.
2. Drive the vehicle at least 5 minutes and over 48 km/h (30 mph) to turn on and activate the vehicle
systems.
3. Allow the vehicle to sit with the key out of the ignition for at least 40 minutes to allow the modules
to time out/power down.
4. Connect a fused jumper wire (30A) between the negative battery cable and the negative battery
post to prevent modules from resetting.
5. Disconnect the negative battery cable from the negative battery post without breaking the
connection of the jumper wire.
6. NOTE: It is very important that continuity is not broken between the battery and the negative
battery cable when connecting the meter. If this happens, the entire 40-minute procedure must be
repeated.
Connect the battery tester between the negative battery cable and the post. The meter must be
capable of reading milliamps and should have a 10-amp capability.
7. NOTE: If the meter settings need to be switched or the test leads need to be moved to another
jack, the jumper wire must be reinstalled to avoid breaking continuity.
Remove the jumper wire.
8. Note the amperage draw. Draw varies from vehicle to vehicle depending on the equipment
package. Compare to a similar vehicle for reference.
NOTE: If the vehicle sits for an extended period of time and the battery drains, there is the possibility of
a control module staying alive and not going into sleep mode. If a module does stay alive, it can also
result in battery drain. If a module is suspect, isolate individual modules by disconnecting each module
one at a time and note if the excessive draw goes away.
NOTE: For vehicles equipped with aftermarket bodies or boxes which contain electrical connections,
disconnect the aftermarket to factory connections to isolate the body from the chassis.
9. If the current draw is excessive, remove the fuses from the Battery Junction Box (BJB) one at a
time and note the current drop. When the current level drops to an acceptable level after
removing a fuse, the circuit containing the excessive draw has been located. The excessive draw
can be isolated by continuing to pull sub system fuses. Do not reinstall the fuses until testing is
finished. To correctly isolate each of the circuits, all of the fuses may need to be removed, then
install one fuse and note the amperage draw, remove the fuse and install the next fuse. Continue
this process with each fuse.
Once the main circuit is identified, continue to remove the fuses from the Smart Junction
Box (SJB) one at a time and note the current reading. Do not reinstall the fuses until
testing is finished. To correctly isolate each of the circuits, all of the fuses may need to be
removed, then install one fuse and note the amperage draw, remove the fuse and install
the next fuse. Continue this process with each fuse.
10. Check the wiring diagrams for any circuits that run from the battery without passing through the
BJB or the SJB . If the current draw is still excessive, disconnect these circuits until the draw is
found. Also, disconnect the generator electrical connections and retest if the draw cannot be
located. The generator may be internally shorted, causing the current drain.
Battery Disconnect
WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag supplemental restraint system (SRS) component and before servicing,
removing, installing, adjusting or striking components near the front or side impact sensors or
the restraints control module (RCM). Nearby components include doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Refer to the Description and Operation portion of Section 501-20B for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of
an accidental deployment.
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.
NOTE: When disconnecting the battery ground cable to interrupt power to the vehicle electrical system,
disconnect the battery ground cable only. It is not necessary to disconnect the positive battery cable.
NOTE: Wait one minute between ignition OFF and disconnecting the negative battery cable or the ABS
module sets DTC U3000:41.
1. Disconnect the battery ground terminal.

To connect, tighten to 5 Nm (44 lb-in).
2. Disconnect the positive battery terminal.

To connect, tighten to 5 Nm (44 lb-in).
3. To connect, reverse the disconnect procedure.

Battery and Battery Tray — Exploded View

1 W520412 Battery hold-down bracket nut (2 required)
2 10718 Battery hold-down bracket
3 10757 Battery heat shield
4 10655 Battery
5 W701695 Battery tray bolt (3 required)
6 10732 Battery tray
7 10732 Battery tray support bracket
removal.
Battery Cables — Exploded View
Part
1 — Battery ground cable terminal nut (part of 14301)
2 14301 Battery ground cable
3 — Battery ground cable body terminal (part of 14301)
4 W505253 Battery ground cable body terminal bolt
5 — Battery positive terminal nut (part of 14450)
6 14450 Battery positive terminal
7 W520101 Engine harness wire terminal-to-high current battery
junction box terminal nut
8 — Engine harness wire terminal (part of 12A522)
9 — Engine compartment harness wire terminal (part of
14K012)
10 W705790 Engine compartment harness wire terminal-to-high
current battery junction box side terminal nuts (2
required)
11 — Engine compartment harness wire terminal (part of
14K012)
12 67010 High current battery junction box
13 W711953 High current battery junction box-to-battery positive
terminal nut
14 14A003 High current battery junction box cover
removal.
SECTION 415-00: Information and Entertainment Systems 2011 Fiesta Workshop Manual
Antenna cable bolt (part of the antenna cable) 9 80
Door subwoofer bolts 3 27
Information and Entertainment System
Functional Components
The functional components of the audio system (and their locations) are as follows:
Audio Control Module (ACM)

Accessory Protocol Interface Module (APIM) (if equipped), located under the RH side of the
instrument panel
Global Positioning System Module (GPSM) (if equipped), located in the top center area of the
instrument panel
Speakers (see Audio Line-Up for locations)
Antenna (either AM/FM, or combination AM/FM/satellite)
Antenna cables
Clockspring
Audio input jack
Steering wheel controls (if equipped)
Universal Serial Bus (USB) port and cable (if equipped)
Microphone (if equipped)
Audio Line-Up
The vehicle is equipped with one of the following audio systems:
Base
AM/FM stereo (CD with MP3 optional)
Four speakers (2 front door woofers, 2 front door tweeters)
High
AM/FM/Single CD with MP3
Six speakers (2 front door woofers, 2 front door tweeters, 2 rear door full-range speakers)
All audio systems include the following features:
Audio input jack
The following options are also available:
Steering wheel controls

Satellite radio system
Provides satellite broadcast audio channels
SYNC system
Provides mobile phone and media device functionality with the vehicle audio system
Antenna
All vehicles utilize a fixed-mast antenna for AM/FM reception. If the vehicle is equipped with satellite
radio, a combination AM/FM/satellite radio antenna is utilized.
Satellite Radio
The satellite radio system is comprised of the following:
Satellite radio receiver (built-in to the ACM )

Antenna
Antenna cables
SYNC System
The SYNC system is comprised of the following:
APIM
SYNC-specific steering wheel controls
Microphone
USB port and cable
Audio input jack
GPSM
SYNC is a hands-free communications and entertainment system that allows the following interactions:
Send and receive phone calls via a Bluetooth-enabled phone

Send and receive text messages via a Bluetooth-enabled phone
Connect media devices (such as an iPod® or USB flash device) in order to play audio files
Play media files via a Bluetooth-enabled media audio device
Produce vehicle health reports
Initiate an emergency call (eCall) when the air bags deploy
Provide turn-by-turn traffic directions through the use of the signal received by the GPSM
Not all features are available with every phone.
For additional information on audio system operation, including the SYNC system, refer to the Owner's
Literature.
Information and Entertainment System
Special Tool(s)

tool
Flex Probe Kit

Backprobe Pins
POM6411 or equivalent
Universal Serial Bus (USB)

Male-A to Male-A Cable
CCMUSB2-AM-AM-10 or
equivalent
Multi-Media Interface Tester

105-00120
The Audio Control Module (ACM) can be operated while the key is in RUN or ACC. Additionally, the one
hour mode feature allows the audio system to be operated for 1 hour when the ignition is transitioned to
OFF and the ON/OFF button is pressed.
The ACM can produce its own DTCs, which can be communicated to the scan tool. The ACM
communicates on the Infotainment Controller Area Network (I-CAN), with the Front Control/Display
Interface Module (FCDIM) acting as the gateway to the Medium Speed Controller Area Network (MS-
CAN).
The Front Controls Interface Module (FCIM) is the customer interface to the audio system. It is separate
from the ACM , and utilizes a dedicated Local Interconnect Network (LIN) with the FCDIM to transmit
button press information.
The FCDIM is a stand-alone module. It receives messages for all of its displays, which include:
Audio information
Warning and information messages
The FCDIM acts as the gateway between the MS-CAN and the I-CAN .
Satellite Audio
The satellite audio system consists of the ACM , the AM/FM/satellite radio combination antenna, and the
antenna cables. The antenna receives digital audio signals and sends them to the ACM .
Antenna
The fixed-mast antenna receives AM/FM radio waves and sends them to the ACM via the antenna co-
axial cable. If the vehicle is equipped with satellite audio, a combination AM/FM/satellite radio antenna is
utilized.
The antenna receives voltage from the ACM in order to amplify the audio signals.
SYNC® System
The SYNC® system allows interaction with several types of customer devices, including mobile phones
and media devices. The system is comprised of the Accessory Protocol Interface Module (APIM), a
microphone, the Universal Serial Bus (USB) cable and port, and the audio input jack. The APIM contains
an on-board Bluetooth® chipset, which enables certain wireless devices to interact with the system.
The APIM consists of 2 internal modules: the Consumer Interface Processor (CIP) and the Vehicle
Interface Processor (VIP). The modules are not replaceable individually, but can be flashed
independently, if required.
The CIP interfaces with all of the customer inputs to the APIM . The CIP contains an analog-to-digital-to-
analog converter, as well as the Bluetooth® chipset. Any consumer-available application upgrades that
are available are loaded directly to the CIP through the USB port.
The VIP provides an interface between the CIP and the vehicle. The main functions of the VIP are
controlling the APIM power management and translating both inbound and outbound signals over the
CAN .
The APIM can receive inputs from the following sources:
USB port
Audio input jack
Bluetooth®
The USB port can be used for connecting a media device (such as an iPod®) with the device's available
cable, or for directly plugging in a portable mass storage device (such as a "thumb drive"). When playing
media files stored on a mass storage device, the SYNC® system only plays files that do not have Digital
Rights Management (DRM) protection. The USB port can also be used for uploading vehicle application
upgrades.
The USB port is powered by the APIM , so no external power source is needed to power a device
plugged into the USB port.
The audio input jack can be used for connecting a media device (such as an iPod®) utilizing a 1/8-inch
audio jack. When a device is connected through the audio input jack, only the speaker volume can be
controlled by the ACM . All other functions (such as seek, fast forward, pause, etc.) must be carried out
on the device itself.
The Bluetooth® interface can accommodate both Bluetooth®-enabled mobile phones and Bluetooth®-
enabled media devices. Any Bluetooth® device used with the SYNC® system must first be paired with
the system before it is operational.
Bluetooth® is a secure, short-range radio frequency that allows devices to communicate wirelessly
through radio waves. The operating range of a Bluetooth® signal is a maximum of 32 feet.
Only one Bluetooth® phone and one Bluetooth® media device can be connected to the system at any
one time. If an additional device of either type is paired with the system and made active, the APIM
disconnects any active connections and establishes a connection with the new device.
It is important to understand that not all mobile phones have the same level of features when interacting
with the SYNC® system. For a list of compatible phones, refer to the SyncMyRide website .
In addition to audio information, metadata may also be sent to the APIM from a device plugged into the
USB port. Metadata consists of such information as artist, album title, song title, and genre. The
metadata is used by the APIM to create indexes that can be used to sort for particular music, based on
customer preference. Not all USB devices send metadata to the APIM ; also, no metadata is transferred
when a device is connected through the audio input jack. When a new media device is connected to the
SYNC® system, the APIM automatically indexes the information. This can take up to several minutes
(depending on the amount of data on the device), and is considered normal operation. When a device
that was previously connected to the SYNC® system is reconnected, the APIM updates the index (rather
than creating a new one), which reduces the amount of time needed to create the index.
The APIM receives both stereo and mono sound inputs, and can also transmit both stereo and mono
sound. The mono function is used to receive the microphone input, and to send sound to the ACM for
voice prompts, the Text-To-Speech (TTS) feature, ringtones, and any audio received through a
connected mobile phone. The TTS feature speaks information so that it does not have to be read from
the display.
The Global Positioning System Module (GPSM) provides vehicle location for real-time traffic reports and
re-routing, and for identifying vehicle location in the event of a collision (part of the e911 feature). The
vehicle location information is broadcast to the APIM over the CAN .
The APIM communicates via the I-CAN and High Speed Controller Area Network (HS-CAN).
Communication with the scan tool is established through the HS-CAN .
Steering Wheel Controls
The steering wheel controls consist of a series of resistors. Each steering wheel controls switch function
corresponds with a specific resistance value within the switch. When a switch is pressed, the FCDIM (or
the APIM ) monitors the change in reference voltage to determine the requested function.
On vehicles equipped with the SYNC® system, the PUSH-TO-TALK (an icon of a person speaking)
switch interfaces directly with the APIM , while the other audio steering wheel controls interface with the
FCDIM .
Audio Input Jack
The audio input jack allows for a portable MP3 audio device to be connected to the vehicle audio
system. When a portable MP3 player is connected, audio from the MP3 audio device can be played
through the vehicle speakers. The audio stream from the audio input jack routes to the APIM if the
vehicle is equipped with the SYNC® system, or directly to the ACM if the vehicle is not equipped with the
SYNC® system.
Audio Signals
Stereo signals contain left and right channel information, and are used for most audio signals.
A mono signal is used for the microphone input to the APIM . A mono signal is also used for the voice
prompts, the TTS feature, ringtones, and any audio received through a connected mobile phone. These
audio signals are output from the APIM to the ACM . The mono and stereo outputs from the APIM utilize
separate circuits.
A digital signal is used to transmit data from a media device connected through the USB port to the
APIM . The APIM then converts the signal to analog and relays the signal to the ACM .
A wireless signal is used to broadcast audio signals from a Bluetooth® device to the APIM . As with a
digital signal sent through the USB port, the APIM converts the wireless audio signal to analog and
relays it to the ACM .
Network Communication
There are numerous messages internal to the audio system. The functions of these message include
(but are not limited to):
Changing the audio source

Updating the FCDIM display
In addition, the numerous messages are utilized by the audio system in conjunction with systems
outside of the audio system. Refer to Section 418-00 for a complete list of network messages.

Front Control/Display Interface Module (FCDIM) Body Control Module (BCM) fuse(s):
Front Controls Interface Module (FCIM) 7 (7.5A)
Antenna 10 (15A)
Universal Serial Bus (USB) port 16 (15A)
Audio input jack 19 (7.5A)
Steering wheel controls Wiring, terminals or connectors
Speaker mounting/speaker cones
Trim panels
3. If the fault is visually evident, correct the cause (if possible) before proceeding to the next step.

Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan
tool.

Verify the ignition key is in the ON position.
Verify the scan tool operation with a known good vehicle.
Refer to Section 418-00 to diagnose no response from the PCM.
7. NOTE: Do not press any buttons on the FCIM while the ACM is carrying out the self-test.
Carry out the network test.

418-00 .
9. If no DTCs related to the concern are retrieved, refer to the Symptom Charts.
DTC Charts
Audio Control Module (ACM) DTC Chart
type code provides information about specific fault conditions such as opens, or shorts to ground.
Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in
determining DTC history.

B1A01:01 Speaker #1: General Electrical GO to Pinpoint Test F .
Failure
B1A01:11 Speaker #1: Circuit Short to GO to Pinpoint Test F .
Ground
Battery
B1A01:13 Speaker #1: Circuit Open GO to Pinpoint Test F .
Failure
Ground
Battery
Failure
Ground
Battery
Failure
Ground
Battery
B1A56:1D Antenna: Circuit Current Out of GO to Pinpoint Test A .
Range
B1A56:21 Antenna: Signal Amplitude 〈 GO to Pinpoint Test A .
Minimum
B1A89:11 Satellite Antenna: Circuit Short to GO to Pinpoint Test B .
Ground
B1A89:13 Satellite Antenna: Circuit Open GO to Pinpoint Test B .
B1D19:4B Compact Disc Unit: Over The ACM was over-temperature. This may occur during
Temperature extended use. Audio operation can resume after the
ACM cools. CLEAR the DTCs. This is normal operation.
U0074:00 Control Module Communication REFER to Section 418-00 .
Bus "B" Off: No Sub Type
Information
U0140:00 Lost Communication With Body GO to Pinpoint Test P .
Information
U0253:00 Lost Communication With GO to Pinpoint Test Q .
Accessory Protocol Interface
Module: No Sub Type Information
U0257:00 Lost Communication With Front GO to Pinpoint Test R .
Controls/Display Interface
Module: No Sub Type Information
U2100:00 Initial Configuration Not REPROGRAM the Audio Control Module (ACM).
Complete: No Sub Type REFER to the Programmable Module Installation (PMI)
Information procedure in Section 418-01 . TEST the system for
normal operation.
U2101:00 Control Module Configuration REPROGRAM the ACM . REFER to the PMI procedure
Incompatible: No Sub Type in Section 418-01 . TEST the system for normal
U3000:41 Control Module: General CLEAR the DTCs. REPEAT the self-test. If DTC
Checksum Failure U3000:41 is retrieved again, INSTALL a new ACM .
REFER to Audio Control Module (ACM) in this section.
U3000:42 Control Module: General Memory CLEAR the DTCs. REPEAT the self-test. If DTC
Failure U3000:41 is retrieved again, INSTALL a new ACM .
U3000:49 Control Module: Internal CLEAR the DTCs. REPEAT the self-test. If DTC
Electronic Failure U3000:49 is retrieved again, INSTALL a new ACM .
U3000:96 Control Module: Component GO to Pinpoint Test C .
Internal Failure
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test S .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test T .
Above Threshold
Front Control/Display Interface Module (FCDIM) DTC Chart

B10BD:11 Multifunctional Switch: Circuit Short to GO to Pinpoint Test D .
Ground
B10BD:13 Multifunctional Switch: Circuit Open GO to Pinpoint Test D .
B10BD:23 Multifunctional Switch: Signal Stuck GO to Pinpoint Test D .
Low
U0010:88 Medium Speed CAN Communication REFER to Section 418-00 .
Bus: Bus Off
U0074:88 Control Module Communication Bus REFER to Section 418-00 .
"B" Off: Bus Off
U1A00:00 Private Communication Network: No GO to Pinpoint Test Y .
Information
U0155:00 Lost Communication With Instrument GO to Pinpoint Test U .
Panel Cluster (IPC) Control Module:
U0193:00 Lost Communication With "Digital GO to Pinpoint Test X .
Audio Control Module A": No Sub
Type Information
U0423:68 Invalid Data Received From RETRIEVE and FOLLOW other DTCs present in
Instrument Panel Cluster Control the FCDIM or IPC .
Module: Event Information
U2100:00 Initial Configuration Not Complete: No PROGRAM the FCDIM . REFER to the
Sub Type Information Programmable Module Installation (PMI) procedure
in Section 418-01 . TEST the system for normal
operation.
U3000:00 Control Module: No Sub Type INSTALL a new FCDIM . REFER to Front
Information Controls/Display Interface Module (FCDIM) in this
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AE .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AF .
Above Threshold
Accessory Protocol Interface Module (APIM) DTC Chart

B1201:1C Steering Wheel Audio Switch Pack GO to Pinpoint Test I .
2: Circuit Voltage Out of Range
B1201:63 Steering Wheel Audio Switch Pack GO to Pinpoint Test I .
2: Circuit / Component Protection
Time-Out
B1252:04 USB Port: System Internal Failure GO to Pinpoint Test H .
B1252:11 USB Port: Circuit Short to Ground GO to Pinpoint Test H .
B1D79:01 Microphone Input: General Electrical GO to Pinpoint Test I .
Failure
U0100:00 Lost Communication With GO to Pinpoint Test Z .
ECM /PCM "A": No Sub Type
Information
Information
U0151:00 Lost Communication With Restraints GO to Pinpoint Test AA .
Information
U0155:00 Lost Communication With GO to Pinpoint Test U .
Instrument Panel Cluster ( IPC ): No
U016A:00 Lost Communication With Global GO to Pinpoint Test AB .
Positioning System Module: No Sub
Type Information
U0184:00 Lost Communication With Radio: No GO to Pinpoint Test X .
U0255:00 Lost Communication With Front GO to Pinpoint Test R .
Display Interface Module: No Sub
Type Information
U0422:00 Invalid Data Received From Body RETRIEVE and FOLLOW other DTCs present in the
Control Module: No Sub Type Accessory Protocol Interface Module (APIM) or Body
Information Control Module (BCM).
U0423:00 Invalid Data Received From RETRIEVE and FOLLOW other DTCs present in the
Instrument Panel Control Module: APIM or Instrument Panel Cluster (IPC).
U046B:00 Invalid Data Received From Global RETRIEVE and FOLLOW other DTCs present in the
Positioning System Module: No Sub APIM or Global Positioning System Module (GPSM).
Type Information
U0485:00 Invalid Data Received From Radio: RETRIEVE and FOLLOW other DTCs present in the
No Sub Type Information APIM or Audio Control Module (ACM).
U2100:00 Initial Configuration Not Complete: PROGRAM the APIM . REFER to the Programmable
No Sub Type Information Module Installation (PMI) procedure in Section 418-
U2101:00 Control Module Configuration PROGRAM the APIM . REFER to the PMI procedure
Incompatible: No Sub Type in Section 418-01 . TEST the system for normal
U3000:04 Control Module: System Internal GO to Pinpoint Test M .
Failure
U3000:41 Control Module: General Checksum INSTALL a new APIM . REFER to Accessory
Failure Protocol Interface Module (APIM) in this section.
U3000:42 Control Module: General Memory INSTALL a new APIM . REFER to Accessory
Failure Protocol Interface Module (APIM) in this section.
U3000:88 Control Module: Bus Off REFER to Section 418-00 .
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AC .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AD .
Above Threshold
Global Positioning System Module (GPSM) DTC Chart

Information
U0155:00 Lost Communication With Instrument GO to Pinpoint Test U .
Panel Cluster ( IPC ): No Sub Type
Information
U0422:00 Invalid Data Received From Body RETRIEVE and FOLLOW other DTCs present in
Control Module: No Sub Type the Global Positioning System Module (GPSM) or
Information Body Control Module (BCM).
U0423:00 Invalid Data Received From Instrument RETRIEVE and FOLLOW other DTCs present in
Panel Control Module: No Sub Type the GPSM or Instrument Panel Cluster (IPC).
Information
U3000:09 Control Module: Component Failure INSTALL a new GPSM . REFER to Global
Positioning System Module (GPSM) in this section.
U3000:41 Control Module: General Checksum INSTALL a new GPSM . REFER to Global
Failure Positioning System Module (GPSM) in this section.
U3000:42 Control Module: General Memory INSTALL a new GPSM . REFER to Global
Failure Positioning System Module (GPSM) in this section.
U3003:16 Battery Voltage: Circuit Voltage Below GO to Pinpoint Test AG .
Threshold
U3003:17 Battery Voltage: Circuit Voltage Above GO to Pinpoint Test AH .
Threshold
Symptom Chart — General Audio System
General Audio System

The Audio Control Fuse REFER to Section 418-00 .
Module (ACM) does Wiring, terminals
not respond to the or connectors
scan tool Front
Control/Display
Interface Module
(FCDIM)
ACM
The Front Fuse REFER to Section 418-00 .
Control/Display Wiring, terminals
Interface Module or connectors
(FCDIM) does not FCDIM
respond to the scan
tool
The Accessory Fuse REFER to Section 418-00 .
Protocol Interface Wiring, terminals
Module (APIM) does or connectors
not respond to the APIM
scan tool
The Global Fuse REFER to Section 418-00 .
Positioning System Wiring, terminals
Module (GPSM) or connectors
does not respond to FCDIM
the scan tool GPSM
The entire audio Communication GO to Pinpoint Test K .
system is network concern
inoperative FCIM
FCDIM
ACM
The steering wheel Wiring, terminals For the VOICE switch, GO to
controls are or connectors Pinpoint Test I .
inoperative/do not Steering wheel For all other switches, GO to
operate correctly controls Pinpoint Test D .
Steering column
multifunction
switch (vehicles
with SYNC®)
FCDIM
ACM
APIM (if
equipped)
The speed sensitive Speed sensitive GO to Pinpoint Test W .
volume does not volume setting
operate correctly Vehicle Speed
Sensor (VSS)
signal concern
ACM
The audio input jack Wiring, terminals GO to Pinpoint Test E .
is inoperative/does or connectors
not operate correctly Audio input jack
ACM
APIM (if
equipped)
An individual Front FCIM INSTALL a new FCIM .
Controls Interface REFER to Front Controls
Module (FCIM) Interface Module (FCIM) in
button is this section. TEST the system
inoperative/does not for normal operation.
operate correctly
The audio system Wiring, terminals GO to Pinpoint Test Y .
does not operate or connectors
correctly from the FCIM
Front Controls FCDIM
Interface Module
(FCIM)
The Front Controls Backlighting CHECK the operation of the
Interface Module system concern audio system from the FCIM
(FCIM) illumination FCIM by turning the system on,
does not operate adjusting the volume, and
correctly selecting several different
presets.
If the audio system
does not operate
correctly from the
FCIM , GO to Pinpoint
Test Y .
If the illumination is the
only concern, REFER
to Section 413-00 .
One or more Front FCDIM GO to Pinpoint Test V .
Control/Display ACM
Interface Module Instrument Panel
(FCDIM) displays is Cluster (IPC)
inoperative/does not concern
operate correctly APIM (if
equipped)
The Front Fuse CARRY OUT the FCDIM self-
Control/Display Wiring, terminals test.
Interface Module or connectors If the scan tool cannot
(FCDIM) screen is FCDIM communicate with the
completely FCDIM , REFER to
inoperative Section 418-00 .
If the scan tool does
communicate with the
FCDIM , INSTALL a
new FCDIM . REFER to
Front Controls/Display
Interface Module
(FCDIM) in this section.
TEST the system for
normal operation.
The Front Backlighting GO to Pinpoint Test L .
Control/Display system concern
Interface Module FCDIM
(FCDIM) illumination
does not operate
correctly
Symptom Chart — Sound Quality
Sound Quality
Poor reception — AM/FM Antenna GO to
Antenna cable Pinpoint
Charging system Test A .
Ignition system
Audio Control
Module (ACM)
Continuous seek/scan in AM/FM Antenna GO to
Antenna cable Pinpoint
ACM Test A .
Poor quality/distorted/no sound from Wiring, terminals or GO to
one or more speakers (not all connectors Pinpoint
speakers) Speaker Test F .
ACM
Poor quality/distorted/no sound from Wiring, terminals or GO to
all speakers connectors Pinpoint
ACM Test G .
Poor reception — satellite radio Obstructions to the GO to
antenna line of sight Pinpoint
Antenna Test B .
Antenna cable
ACM
Continuous seek/scan — satellite Obstructions to the GO to
radio antenna line of sight Pinpoint
No channel found in Test B .
the selected
category
Antenna
Antenna cable
ACM
Poor sound quality/no sound while in Antenna GO to
satellite radio mode — all other Antenna cable Pinpoint
functions operate correctly ACM Test B .
Poor quality/distorted/no sound while Wiring, terminals or GO to
in SYNC® mode connectors Pinpoint
Accessory Protocol Test J .
Interface Module
(APIM)
ACM
Symptom Chart — Satellite Radio
Satellite Radio
Poor reception Obstructions to the GO to
antenna line of sight Pinpoint
Antenna Test B .
Antenna cable
Audio Control
Module (ACM)
Continuous seek/scan No channel found in GO to
the selected Pinpoint
category Test B .
Obstructions to the
antenna line of sight
Antenna
Antenna cable
ACM
Poor sound quality/no sound while in Antenna GO to
satellite radio mode — all other Antenna cable Pinpoint
functions operate correctly ACM Test B .
The satellite radio is Subscription status GO to
inoperative/does not operate Satellite radio Pinpoint
correctly system concern Test C .
ACM
Symptom Chart — SYNC® System
SYNC® System
The SYNC® system is Audio system GO to Pinpoint Test M .
completely inoperative concern
Communication
network concern
Customer error
Customer device
Accessory
Protocol Interface
Module (APIM)
Poor Wiring, terminals GO to Pinpoint Test J .
quality/distorted/no or connectors
sound while in SYNC® APIM
mode ACM
Unable to pair Incompatible GO to Pinpoint Test N .
Bluetooth® device Bluetooth®
device
Customer error
Customer
Bluetooth®
device
APIM
An individual Customer device NOTE: If a Bluetooth®
Bluetooth® device compatibility device is able to pair with
feature is inoperative the SYNC® system, there
are no concerns with the
APIM .
INSTRUCT the customer

to review the device
compatibility list on the
SyncMyRide website . Not
all phone features are
available through SYNC®.
This is normal operation.
The Universal Serial Customer USB GO to Pinpoint Test H .
Bus (USB) port is device
inoperative/does not USB cable and
operate correctly port
APIM
The steering wheel Wiring, terminals For the VOICE switch, GO
controls are or connectors to Pinpoint Test I .
inoperative/do not Steering wheel For all other switches, GO
operate correctly controls to Pinpoint Test D .
Multifunction
switch
FCDIM
ACM
APIM
The audio input jack is Wiring, terminals GO to Pinpoint Test E .
inoperative/does not or connectors
operate correctly Audio input jack
APIM
The SYNC® system Customer setting NOTE: The audible
audible prompts are Wiring, terminals prompts include the Text-
inoperative/do not or connectors To-Speech (TTS) feature,
operate correctly ACM voice prompts, and
APIM ringtones.
GO to Pinpoint Test O .
During a phone call, no Customer setting GO to Pinpoint Test O .
incoming audio is heard Wiring, terminals
in the vehicle or connectors
ACM
APIM
Voice recognition is Wiring, terminals GO to Pinpoint Test I .
inoperative/does not or connectors
operate correctly Microphone
Steering column
multifunction
switch
APIM
During a phone call, no Wiring, terminals GO to Pinpoint Test I .
outgoing audio is heard or connectors
on the outside device Microphone
APIM
Pinpoint Tests
Pinpoint Test A: Poor Reception — AM/FM
Normal Operation
The antenna receives AM and FM radio waves and sends them to the Audio Control Module (ACM)
through the antenna cable. The ACM powers the antenna in order to amplify the AM signal.
DTC B1A56:1D (Antenna: Circuit Current Out of Range) — sets continuously when the antenna
enable circuit current is outside of limits. The current is checked once every 5 seconds.
DTC B1A56:21 (Antenna: Signal Amplitude 〈 Minimum) — sets on-demand when no signal is
detected from the antenna.
Antenna
Antenna cable
Charging system
Ignition system
ACM
PINPOINT TEST A: POOR RECEPTION — AM/FM

A1 CHECK THE AUDIO SYSTEM RECEPTION
Operate the audio system in radio tuner (AM/FM) mode. Yes
Check the reception with the engine running, and with the GO to A2 .
engine off.
Does the poor reception only occur with the engine No
running? GO to A4 .
A2 CHECK THE GENERATOR
Ignition OFF. Yes
Disconnect the wiring harness from the generator voltage INSTALL a new generator.
regulator. REFER to Section 414-00 .
Start the engine. TEST the system for normal
Operate the audio system in radio tuner (AM/FM) mode. operation.
Is the reception OK?
No
GO to A3 .
A3 CHECK THE IGNITION CIRCUITS
Ignition OFF. Yes
Connect the wiring harness to the voltage regulator. USE a jumper cable to
Visually inspect the engine compartment and make sure all ground various parts of the
ignition coils are correctly and securely connected, and that vehicle to the frame (for
there are no visible cracks in the coil housings. example: engine, fenders,
Inspect all the wiring harnesses and connectors for damaged quarter panels, stone
insulation and loose or broken conditions. deflectors, air cleaner, body
Are the ignition components OK? sheet metal). When the
noise is eliminated,
PROVIDE a permanent
ground where necessary.
operation.
No
REPAIR the ignition system
as necessary. TEST the
system for normal
operation.
A4 CHECK THE ANTENNA ENABLE CIRCUIT
Ignition OFF. Yes
Disconnect: Antenna C9021. GO to A6 .
Operate the audio system in radio tuner (AM/FM) mode.
Measure the voltage between the antenna C9021-1, circuit No
CME44 (BU), harness side and ground. GO to A5 .

A5 CHECK THE ANTENNA ENABLE CIRCUIT FOR AN OPEN
OR SHORT TO GROUND
Ignition OFF. Yes
Disconnect: ACM C240A. GO to A9 .
Measure the resistance between the ACM C240A-2, circuit
CME44 (BU), harness side and the antenna C9021-1, circuit No
CME44 (BU); and between the ACM C240A-2, circuit CME44 REPAIR the circuit. TEST
(BU), harness side and ground. the system for normal
operation.
Is the resistance less than 5 ohms between the ACM and

the antenna, and greater than 10,000 ohms between the
ACM and ground?
A6 CHECK THE AM/FM ANTENNA CABLE
Ignition OFF. Yes
Disconnect: AM/FM Antenna In-Line Connection At RH Kick GO to A7 .
Panel.
Disconnect: AM/FM Antenna Cable At ACM . No
Measure the resistance of the rear AM/FM antenna cable core INSTALL a new front or
between the antenna and the front AM/FM antenna cable in- rear AM/FM antenna cable.
line connection; and between the rear AM/FM antenna cable REFER to Antenna Cable
core and shield. — AM/FM/Satellite Radio in
Measure the resistance of the front AM/FM antenna cable this section. TEST the
core between the ACM and the rear AM/FM antenna cable in- system for normal
line connection; and between the front AM/FM antenna cable operation.
core and shield.
Is the resistance of each AM/FM antenna cable core less
than 2 ohms, and the resistance between the core and
shield of each AM/FM antenna cable greater than 10,000
ohms?
A7 ISOLATE THE ANTENNA
Connect: AM/FM Antenna In-Line Connection At RH Kick Yes
Panel. The concern was caused by
Connect: AM/FM Antenna Cable At ACM . an inoperative AM/FM
Install a new antenna. Refer to Antenna in this section. antenna. The system is now
Operate the audio system in radio tuner (AM/FM) mode. operating correctly.
Is the reception OK?
No
GO to A8 .
A8 ISOLATE THE ANTENNA CABLE
Ignition OFF. Yes
Substitute each antenna cable by routing a new component. INSTALL a new antenna
Do not remove the original antenna cable at this time. cable for the inoperative
Operate the audio system in radio tuner (AM/FM) mode. cable. REFER to Antenna
Is the reception OK? Cable — AM/FM/Satellite
Radio in this section. TEST
operation.
No
REMOVE the substitute
antenna cable. GO to A9 .
A9 CHECK FOR CORRECT ACM OPERATION
Disconnect all the ACM connectors. Yes
Check for: INSTALL a new ACM .
corrosion REFER to Audio Control
damaged pins Module (ACM) in this
pushed-out pins section. TEST the system
Connect all the ACM connectors and make sure they seat for normal operation.
correctly.
corroded connector.
Pinpoint Test B: Poor Reception/Poor Sound Quality/No Sound — Satellite Radio
Normal Operation
Digital signals are received by the satellite radio antenna and sent to the Audio Control Module (ACM)
through the satellite radio antenna cable.
A short to ground in the satellite radio antenna typically has no effect on the antenna signal. However,
an open in the antenna circuit results in no sound from the satellite radio system. A short to voltage in
the antenna circuit can have varying effects on the system.
Obstructions to the antenna line of sight can affect reception, but this is considered normal operation.
Possible obstructions include hills, tall buildings, tunnels, and being parked inside a garage. Make sure
the vehicle is in a clear area, free of obstructions, before testing satellite radio reception.
DTC B1A89:11 (Satellite Antenna: Circuit Short to Ground) — sets when the satellite radio
antenna circuit is shorted to voltage or ground for greater than 250 ms. This DTC can be either
continuous or on-demand.
DTC B1A89:13 (Satellite Antenna: Circuit Open) — sets when an open is detected in the satellite
radio antenna circuit for greater than 250 ms. This DTC can be either continuous or on-demand.
Obstructions to the antenna line of sight

No channel found in the selected category
Antenna
Antenna cable
ACM
PINPOINT TEST B: POOR RECEPTION/POOR SOUND QUALITY/NO SOUND — SATELLITE RADIO

B1 CHECK THE RECEPTION AND CATEGORY
FILTER SETTING
Turn the category filter function off. For additional Yes
information, refer to the Owner's Literature. The system is operating correctly at
Drive the vehicle to an open location, free of this time. The concern was a result of
obstacles. no channel being found in the selected
Scan for a good channel. category or obstructions to the antenna
Does the satellite audio system find a good line of sight.
channel with normal reception?
No
GO to B2 .
B2 CHECK THE SATELLITE SIGNAL PID
(SAT_SIG_STR)
tool: ACM DataLogger. GO to B3 .
Monitor the ACM satellite signal strength PID
(SAT_SIG_STR). No
Does the PID indicate "No Signal"? GO to Pinpoint Test C .
B3 CHECK THE SATELLITE RADIO ANTENNA
CABLE RESISTANCE
Ignition OFF. Yes
Disconnect: Satellite Radio Antenna Connection At GO to B4 .
ACM .
Disconnect: Satellite Radio Antenna Cable In-Line No
Connection At RH Kick Panel. INSTALL a new antenna cable.
Disconnect: Antenna C9021. REFER to Antenna Cable —
Measure the resistance of the front satellite radio AM/FM/Satellite Radio in this section.
antenna cable core between the ACM and the CLEAR any DTCs present. TEST the
satellite radio antenna in-line connection; and system for normal operation.
between the front satellite radio antenna cable core
and shield.
Measure the resistance of the rear satellite radio
antenna cable core between the antenna C9021,
harness side and the satellite radio antenna cable
in-line connection; and between the rear satellite
radio antenna cable core and shield.
Is the resistance of each satellite radio antenna
cable core less than 2 ohms, and the resistance
between the core and shield of each satellite
radio antenna cable greater than 10,000 ohms?
B4 ISOLATE THE ANTENNA
Connect: Satellite Radio Antenna Connection At Yes
ACM . The concern was caused by an
Connect: Satellite Radio Antenna Cable In-Line inoperative antenna. The system is
Connection At RH Kick Panel. now operating correctly. CLEAR any
Install a new antenna. Refer to Antenna in this DTCs present. TEST the system for
section. normal operation.
Operate the audio system in satellite radio mode.
Is the reception OK? No
GO to B5 .
B5 CHECK FOR CORRECT ACM OPERATION
Check for: INSTALL a new ACM . REFER to
corrosion Audio Control Module (ACM) in this
damaged pins section. TEST the system for normal
Connect all the ACM connectors and make sure
they seat correctly. No
Operate the system and verify the concern is still The system is operating correctly at
present. this time. The concern may have been
Is the concern still present? caused by a loose or corroded
connector.
Pinpoint Test C: The Satellite Radio Is Inoperative/Does Not Operate Correctly
Normal Operation
Digital signals are received by the antenna and sent to the Audio Control Module (ACM) through the
satellite radio antenna. The satellite radio receiver is internal to the ACM .
When a satellite radio subscription is activated, the Electronic Serial Number (ESN) of the built-in
satellite radio receiver is associated with the Vehicle Identification Number (VIN). As a result, the ACM
cannot be swapped from one vehicle to another.
DTC U3000:96 (Control Module: Component Internal Failure) — sets when the ACM detects an
internal failure with the built-in satellite radio receiver.
Subscription status
Satellite radio system concern
ACM
PINPOINT TEST C: THE SATELLITE RADIO IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

C1 VERIFY AN ACTIVE SUBSCRIPTION
Operate the audio system in satellite Yes
radio mode and observe the display. The subscription has expired. INFORM the
Does the display indicate the customer to contact Sirius to re-activate the
subscription has expired? subscription.
No
GO to C2 .
C2 CHECK THE SATELLITE SIGNAL PID
(SAT_SIG_STR)
on the scan tool: ACM DataLogger. GO to Pinpoint Test B .
Monitor the ACM satellite signal
strength PID (SAT_SIG_STR). No
Does the PID indicate "No Signal"? GO to C3 .
C3 CHECK FOR CORRECT ACM
OPERATION
Ignition OFF. Yes
Disconnect all the ACM connectors. INSTALL a new ACM . REFER to Audio Control
Check for: Module (ACM) in this section. TEST the system for
corrosion normal operation.
damaged pins
pushed-out pins No
Connect all the ACM connectors and The system is operating correctly at this time. The
make sure they seat correctly. concern may have been caused by a loose or
Operate the system and determine if corroded connector.
the concern is still present.
Pinpoint Test D: The Steering Wheel Controls Are Inoperative/Do Not Operate Correctly
Refer to Wiring Diagrams Cell 130 , Audio System for schematic and connector information.
Normal Operation
A reference voltage is sent from the appropriate module to the steering wheel controls. When a switch is
pressed, the voltage is routed through a specific resistor value for each function, then to ground through
the module. The module uses this voltage signal to determine which control input function has been
selected.
All switches are wired to the Front Control/Display Interface Module (FCDIM) except for the VOICE
switch, which is wired directly to the Accessory Protocol Interface Module (APIM) for vehicles with the
SYNC® system. If the VOICE switch is inoperative, the entire voice recognition system is inoperative. To
diagnose this concern, GO to Pinpoint Test I .
B10BD:11 (Multifunctional Switch: Circuit Short to Ground) — sets when a short to ground is
detected in the steering wheel controls circuit.
B10BD:13 (Multifunctional Switch: Circuit Open) — sets when an open is detected in the steering
wheel controls circuit.
B10BD:23 (Multifunctional Switch: Signal Stuck Low) — sets in continuous memory when the
FCDIM detects a steering wheel controls switch stuck for more than 2 minutes during normal
operation.

Steering wheel controls
Clockspring
ACM
PINPOINT TEST D: THE STEERING WHEEL CONTROLS ARE INOPERATIVE/DO NOT OPERATE
CORRECTLY

D1 CHECK THE DTCs
Carry out the FCDIM self-test. Yes
Is DTC B10BD:23 retrieved? INSTALL new steering
wheel controls. REFER to
in this section. CLEAR
the DTCs. TEST the
system for normal
operation.
No
GO to D2 .
D2 MONITOR THE STEERING WHEEL CONTROLS PIDs ( FCDIM -
CONTROLLED SWITCHES)
Enter the following diagnostic mode on the scan tool: FCDIM Yes
DataLogger. GO to D13 .
Monitor the steering wheel controls PIDs while pressing each
steering wheel controls switch as follows: No
If only one PID value is
Steering Wheel Controls Switch PID incorrect or the PID value
always reads one
VOL- SCS_VOLDOWN particular switch position,
INSTALL new steering
VOL+ SCS_VOLUP
wheel controls. REFER to
SEEK- SCS_SEEKMINUS Steering Wheel Controls
SEEK+ SCS_SEEKPLUS any DTCs present. TEST
MODE SCS_MODE the system for normal
operation.
Do the PID values agree with the switch positions?
Otherwise, GO to D3 .
D3 CHECK THE STEERING WHEEL CONTROLS REFERENCE
VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: FCDIM C2123 . TURN the parking lamps
Ignition ON. off. GO to D4 .
Turn the parking lamps on.
Measure the voltage between the FCDIM C2123-10, circuit No
VME14 (GY/YE), harness side and ground. TURN the parking lamps
off. GO to D7 .
D4 CHECK THE STEERING WHEEL CONTROLS REFERENCE
VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE WITH THE
CLOCKSPRING DISCONNECTED
Ignition OFF. Yes
Disconnect: Clockspring C218B . REPAIR the circuit.
Ignition ON. CLEAR any DTCs
Turn the parking lamps on. present. TEST the
Measure the voltage between the FCDIM C2123-10, circuit system for normal
VME14 (GY/YE), harness side and ground. operation.
No
TURN the parking lamps
off. GO to D5 .

D5 CHECK THE CLOCKSPRING FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Connect: Clockspring C218B . INSTALL a new
WARNING: Make sure no one is in the vehicle and Section 501-20B .
there is nothing blocking or placed in front of any air bag CLEAR any DTCs
module when the battery is connected. Failure to follow present. TEST the
these instructions may result in serious personal injury in system for normal
the event of an accidental deployment. operation.
Remove the driver air bag module. Refer to Section 501-20B .
Disconnect: Clockspring C218C . No
Connect the battery. GO to D6 .
Ignition ON.
Turn the parking lamps on.
Measure the voltage between the FCDIM C2123-10, circuit
VME14 (GY/YE), harness side and ground.
D6 CHECK THE STEERING WHEEL CONTROLS CIRCUITRY FOR
A SHORT TO THE ILLUMINATION CIRCUIT
Ignition OFF. Yes
Disconnect: Steering Wheel Controls C2998 . INSTALL new steering
Measure the resistance between the steering wheel controls wheel controls. REFER to
C2998-2, harness side and the steering wheel controls C2998-3, Steering Wheel Controls
harness side; and between the steering wheel controls C2998-4, in this section. CLEAR
harness side and the steering wheel controls C2998-3, harness any DTCs present. TEST
side. the system for normal
operation.
No
REPAIR the steering
wheel harness or
INSTALL a new steering
wheel. REFER to Section
211-04 . TEST the
system for normal
operation.

D7 CHECK THE STEERING WHEEL CONTROLS CIRCUITRY FOR
A SHORT TO GROUND
Ignition OFF. Yes
Remove the driver air bag module. Refer to Section 501-20B . GO to D10 .
Disconnect: Steering Wheel Controls C2998 .
Measure the resistance between the FCDIM C2123-10, circuit No
VME14 (GY/YE), harness side and ground; and between the GO to D8 .
FCDIM C2123-9, circuit RME24 (BU/WH), harness side and
ground
D8 CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
Disconnect: Clockspring C218B . Yes
Measure the resistance between the FCDIM C2123-10, circuit GO to D9 .
VME14 (GY/YE), harness side and ground; and between the
FCDIM C2123-9, circuit RME24 (BU/WH), harness side and No
ground REPAIR the circuit in
question. CLEAR any
DTCs present. TEST the
system for normal
operation.

D9 CHECK THE STEERING WHEEL HARNESS FOR A SHORT TO
GROUND
Connect: Clockspring C218B . Yes
Disconnect: Clockspring C218C . REPAIR the steering
Measure the resistance between the FCDIM C2123-10, circuit wheel harness or
VME14 (GY/YE), harness side and ground; and between the INSTALL a new steering
FCDIM C2123-9, circuit RME24 (BU/WH), harness side and wheel. REFER to Section
ground 211-04 . TEST the
system for normal
operation.
No
INSTALL a new
Section 501-20B .
CLEAR any DTCs
present. TEST the
system for normal
operation.

D10 CHECK THE STEERING WHEEL CONTROLS CIRCUITRY
FOR AN OPEN
Disconnect: Clockspring C218B . Yes
Measure the resistance between the FCDIM C2123-10, circuit GO to D11 .
VME14 (GY/YE), harness side and the clockspring C218B-12,
circuit VME14 (GY/YE), harness side. No
REPAIR the circuit in
question. CLEAR any
DTCs present. TEST the
system for normal
operation.
Measure the resistance between the FCDIM C2123-9, circuit

RME24 (BU/WH), harness side and the clockspring C218B-14,
circuit RME24 (BU/WH), harness side.

D11 CHECK THE CLOCKSPRING FOR AN OPEN
Measure the resistance between the clockspring C218B-12, GO to D12 .
component side and the clockspring C218C-7, component side.
No
INSTALL a new
Section 501-20B .
CLEAR any DTCs
present. TEST the
system for normal
operation.
Measure the resistance between the clockspring C218B-14,

component side and the C218C-5, component side.
D12 CHECK THE STEERING WHEEL HARNESS FOR AN OPEN
Measure the resistance between the clockspring C218C-7, INSTALL new steering
harness side and the steering wheel controls C2998-2, harness wheel controls. REFER to
side. Steering Wheel Controls
any DTCs present. TEST
operation.
No
REPAIR the steering
wheel harness or
INSTALL a new steering
wheel. REFER to Section
211-04 . TEST the
system for normal
operation.
Measure the resistance between the clockspring C218C-5,

harness side and the steering wheel controls C2998-4, harness
side.

D13 CHECK FOR CORRECT FCDIM OPERATION
Connect: All Disconnected Connectors. Yes
Disconnect the FCDIM connector. INSTALL a new FCDIM .
Check for: REFER to Front
corrosion Controls/Display Interface
damaged pins Module (FCDIM) in this
Connect the FCDIM connector and make sure it seats correctly. for normal operation.
Operate the system and determine if the concern is still present.
corroded connector.
CLEAR any DTCs
present. TEST the
system for normal
operation.
Pinpoint Test E: The Audio Input Jack Is Inoperative/Does Not Operate Correctly
Normal Operation — Vehicles Without the SYNC® System
Audio signals are sent from the audio input jack to the Audio Control Module (ACM). There are no
external power or ground circuits to the audio input jack.
Vehicles With the SYNC® System
Audio signals are sent from the audio input jack to the Accessory Protocol Interface Module (APIM). The
signals are then sent to the ACM . There are no external power or ground circuits to the audio input jack.

Audio input jack
ACM
APIM (if equipped)
PINPOINT TEST E: THE AUDIO INPUT JACK IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: Before carrying out this pinpoint test, make sure the MP3 device is operating correctly.
Result / Action to
Test Step
Take
E1 CHECK THE AUDIO INPUT JACK AUDIO
Connect: Multi-Media Interface Tester. Yes
Using the Multi-Media Interface Tester, attempt to play an audio file The system is
using the audio input jack. operating correctly at
Does the file play correctly? this time. The concern
may be with the
customer device.
No
GO to E2 .
E2 DETERMINE THE VEHICLE CONTENT
Determine if the vehicle is equipped with the SYNC® system. Yes
Is the vehicle equipped with the SYNC® system? GO to E3 .
No
GO to E4 .
E3 CHECK THE APIM AUDIO OUTPUT
Using the Multi-Media Interface Tester, attempt to play an audio file Yes
using either the Universal Serial Bus (USB) port or Bluetooth®. GO to E4 .
Is the audio output OK for the USB port or Bluetooth®?
No
GO to Pinpoint Test
M.
E4 CHECK THE AUDIO INPUT JACK CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: Audio Input Jack C3312. REPAIR the circuit in
Disconnect: ACM C240B or APIM C2383 (If Equipped). question. TEST the
Measure the voltage between the audio input jack, harness side operation.
and ground as follows:
No
Positive Meter Lead Negative Meter Lead GO to E5 .
C3312-1 Ground
VME46 (BU/GN)
C3312-2 Ground
RME46 (WH/GN)
C3312-4 Ground
RME45 (YE/GN)

E5 CHECK THE AUDIO INPUT JACK CIRCUITS FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the audio input jack, harness side GO to E6 .
and the ACM (or APIM , if equipped), harness side; and between
the audio input jack, harness side and ground follows: No
Positive Meter question. TEST the
Lead Negative Meter Lead Circuit system for normal
operation.
C3312-1 C240A-18 or C2383-47, then VME46
ground (BU/GN)
C3312-2 C240A-6 or C2383-48, then RME45
ground (YE/GN)
C3312-4 C240A-17 or C2383-45, then VME45 (BU)
ground
Is the resistance less than 5 ohms between the audio input

jack and the ACM (or APIM ), and greater than 10,000 ohms
between the audio input jack and ground?
E6 ISOLATE THE AUDIO INPUT JACK
Disconnect: ACM C240A or APIM C2383 (If Equipped). Yes
Install a new audio input jack. Refer to Audio Input Jack in this The concern was
section. caused by an
Connect: Multi-Media Interface Tester. inoperative audio input
Using the Multi-Media Interface Tester, attempt to play an audio file jack. The system is
using the audio input jack. now operating
Does the file play correctly? correctly.
No
For vehicles without
the SYNC® system,
GO to E7 .
For vehicles with the

SYNC® system, GO
to E8 .
E7 CHECK FOR CORRECT ACM OPERATION
Ignition OFF. Yes
Connect: Audio Input Jack C2401. INSTALL a new ACM .
Disconnect all the ACM connectors. REFER to Audio
Check for: Control Module (ACM)
corrosion in this section. TEST
damaged pins the system for normal
Connect all the ACM connectors and make sure they seat correctly.
Operate the system and determine if the concern is still present. No
may have been
corroded connector.
E8 CHECK FOR CORRECT APIM OPERATION
Ignition OFF. Yes
Connect: Audio Input Jack C2401. INSTALL a new
Disconnect the APIM connector. APIM . REFER to
Check for: Accessory Protocol
corrosion Interface Module
damaged pins (APIM) in this section.
Connect the APIM connector and make sure it seats correctly. normal operation.
Turn the radio on and press the PUSH-TO-TALK button.
Wait 2 minutes for the APIM to re-initalize. No
Operate the system and determine if the concern is still present. The system is
may have been
corroded connector.
Pinpoint Test F: Poor Quality/Distorted/No Sound From One Or More Speakers (Not All Speakers)
Normal Operation
The Audio Control Module (ACM) directs audio signals to the speakers in the form of a fluctuating AC
voltage. The ACM has an overload protection function that protects the ACM if an over-current condition
is present. As a result, if there is a short to ground on the circuitry to any of the interior speakers, the
ACM can mute the sound to all of the interior speakers.
Root DTC Failure

Description Types Fault Trigger Conditions
B1A01 — 01, 11, 12, Sets when an open, short to ground, or short to voltage is detected in
Speaker #1 13 the LF speaker circuits. The test period is typically 100 ms.
Speaker #2 13 the RF speaker circuits. The test period is typically 100 ms.
Speaker #3 13 the LR speaker circuits. The test period is typically 100 ms.
Speaker #4 13 the LR speaker circuits. The test period is typically 100 ms.

Speaker
ACM
PINPOINT TEST F: POOR QUALITY/DISTORTED/NO SOUND FROM ONE OR MORE SPEAKERS

(NOT ALL SPEAKERS)
Result / Action to
Test Step
Take
F1 DETERMINE THE INOPERATIVE SPEAKER
NOTE: For vehicles with a 4-speaker system, proceed directly to Yes

Step F5. GO to F2 .
Manually adjust the fade/balance to test for sound at each No
individual speaker. GO to F5 .
Is there a concern with a front door tweeter speaker?
F2 CHECK THE AUDIO SIGNAL TO THE TWEETER SPEAKER
Ignition OFF. Yes
Disconnect: Suspect Speaker. INSTALL a new
Operate the audio system in radio tuner (AM/FM) mode. tweeter speaker.
Measure the AC voltage between the suspect tweeter speaker REFER to Speaker —
pins, harness side as follows: Tweeter in this section.
CLEAR any DTCs
Suspect Tweeter Positive Meter Negative Meter present. TEST the
Speaker Lead Lead system for normal
operation.
LH C513-1 C513-3
No
VME08 (GN/OG) RME08 (GY/OG) GO to F3 .
RH C613-1 C613-3
VME11 (VT/OG) RME11 (YE/OG)

Is a fluctuating AC voltage present?
F3 CHECK THE AUDIO CIRCUITS TO THE TWEETER FOR A SHORT
TO VOLTAGE
Ignition OFF. Yes
Disconnect: LF Door Speaker C536 (LH Speaker Concern) or RF REPAIR the circuit in
Door Speaker C628 (RH Speaker Concern). question. CLEAR any
Ignition ON. DTCs present. TEST
Measure the voltage between the suspect tweeter speaker, the system for normal
harness side and ground as follows: operation.
Suspect Tweeter Positive Meter Negative Meter No

Speaker Lead Lead GO to F4 .
LH C513-1 Ground
VME08 (GN/OG)
C513-3 Ground
RME08 (GY/OG)
RH C613-1 Ground
VME11 (VT/OG)
C613-3 Ground
RME11 (YE/OG)

F4 CHECK THE AUDIO CIRCUITS TO THE TWEETER FOR AN OPEN
OR SHORT TO GROUND
Measure the resistance between the suspect tweeter speaker, Yes
harness side and the corresponding door speaker, harness side; GO to F8 .
and between the suspect tweeter speaker, harness side and
ground as follows: No
Suspect Tweeter Positive Negative question. CLEAR any
Speaker Meter Lead Meter Lead Circuit DTCs present. TEST
LH C513-1 C536-2, then VME08 operation.
ground (GN/OG)
C513-3 C536-3, then RME08
ground (GY/OG)
RH C613-1 C628-2, then VME11
ground (VT/OG)
C613-3 C628-3, then RME11
ground (YE/OG)
Are the resistances less than 5 ohms between the suspect

tweeter speaker and the corresponding door speaker, and
greater than 10,000 ohms between the suspect tweeter
speaker and ground?
F5 CHECK THE AUDIO SIGNAL TO THE SUSPECT SPEAKER
Ignition OFF. Yes
Disconnect: Suspect Speaker. INSTALL a new door
Operate the audio system in radio tuner (AM/FM) mode. speaker. REFER to
Measure the AC voltage between the suspect speaker pins, Speaker — Front Door
harness side as follows: or Speaker — Rear
Suspect Speaker Positive Meter Lead Negative Meter Lead CLEAR any DTCs
present. TEST the
LF door C536-1 C536-4 system for normal
operation.
VME07 (WH) RME07 (WH/BN)
No
RF door C628-1 C628-4
GO to F6 .
VME10 (WH/VT) RME10 (WH/OG)
LR door C702-1 C702-4
VME09 (WH/GN) RME09 (BN/YE)

RR door C802-1 C802-4
VME12 (BN/WH) RME12 (BN/BU)

Is a fluctuating AC voltage present?
F6 CHECK THE AUDIO CIRCUITS TO THE SUSPECT SPEAKER
Ignition OFF. Yes
Disconnect: ACM C240A. REPAIR the circuit in
Ignition ON. question. CLEAR any
Measure the voltage between the suspect speaker, harness side DTCs present. TEST
and ground as follows: the system for normal
operation.
Suspect Speaker Positive Meter Lead Negative Meter Lead
No
LF door C536-1 Ground GO to F7 .
VME07 (WH)
C536-4 Ground
RME07 (WH/BN)
RF door C628-1 Ground
VME10 (WH/VT)
C628-4 Ground
RME10 (WH/OG)
LR door C702-1 Ground
VME09 (WH/GN)
C702-4 Ground
RME09 (BN/YE)
RR door C802-1 Ground
VME12 (BN/WH)
C802-4 Ground
RME12 (BN/BU)
F7 CHECK THE AUDIO CIRCUITS TO THE SUSPECT SPEAKER
Measure the resistance between the suspect speaker, harness Yes
side and the ACM , harness side; and between the suspect GO to F8 .
speaker, harness side and ground as follows:
No
Suspect Positive Meter Negative Meter REPAIR the circuit in
Speaker Lead Lead Circuit question. CLEAR any
DTCs present. TEST
LF door C536-1 C240A-22, then VME07 (WH) the system for normal
ground operation.
C536-4 C240A-10, then RME07
ground (WH/BN)
RF door C628-1 C240A-23, then VME10
ground (WH/VT)
C628-4 C240A-11, then RME10
ground (WH/OG)
LR door C702-1 C240A-21, then VME09
ground (WH/GN)
C702-4 C240A-9, then RME09
ground (BN/YE)
RR door C802-1 C240A-24, then VME12
ground (BN/WH)
C802-4 C240A-12, then RME12
ground (BN/BU)
Are the resistances less than 5 ohms between the suspect

speaker and the ACM , and greater than 10,000 ohms between
the suspect speaker and ground?
F8 CHECK FOR CORRECT ACM OPERATION
Disconnect all the ACM connectors. INSTALL a new ACM .
Check for: REFER to Audio
corrosion Control Module (ACM)
damaged pins in this section. TEST
pushed-out pins the system for normal
Connect all the ACM connectors and make sure they seat operation.
correctly.
may have been
corroded connector.
Pinpoint Test G: Poor Quality/Distorted/No Sound From All Speakers
Normal Operation
The Audio Control Module (ACM) receives the START signal through the Controller Area Network
(CAN). When it receives this signal, it mutes the audio output to prevent voltage spikes from producing a
popping noise through the speakers during engine cranking.
If the ACM loses power or ground, the scan tool cannot communicate with it. Refer to Section 418-00 to
continue diagnosis.
If a speaker fault DTC is set in the ACM , the cause of the concern is likely a short to ground or short to
voltage in the circuitry to an individual speaker, which has caused the ACM overload protection to
activate.

ACM
PINPOINT TEST G: POOR QUALITY/DISTORTED/NO SOUND FROM ALL SPEAKERS

G1 CHECK FOR SPEAKER DTCs
Ignition ON. Yes
Carry out the ACM self-test. GO to Pinpoint Test F .
Are any speaker fault DTCs
present? No
GO to G2 .
G2 CHECK FOR CORRECT ACM
OPERATION
Ignition OFF. Yes
Disconnect all the ACM connectors. INSTALL a new ACM . REFER to Audio Control
Check for: Module (ACM) in this section. TEST the system for
corrosion normal operation.
damaged pins
pushed-out pins No
Connect all the ACM connectors and The system is operating correctly at this time. The
make sure they seat correctly. concern may have been caused by a loose or
Operate the system and determine if corroded connector.
Pinpoint Test H: The Universal Serial Bus (USB) Port Is Inoperative/Does Not Operate Correctly
Normal Operation
The Universal Serial Bus (USB) port is connected to the Accessory Protocol Interface Module (APIM)
through the USB cable. The USB port can be used to play audio files or upload software from mass
storage devices, or for connecting a media device.
If supported by the user device, the USB can provide charging. Because of this feature, when a USB
device is plugged into the USB port, the SYNC® system does not automatically switch to the device.
If a USB mass storage device is used to play an audio file, the SYNC® system only plays audio files that
do not have Digital Rights Management (DRM) protection.
The USB cable and port are not serviceable separately.
DTC B1252:04 (USB Port: System Internal Failure) — sets when the APIM detects an over-
temperature condition in the USB circuit. This can be caused by a fault in the USB cable and port,
or by the customer USB device.
DTC B1252:11 (USB Port: Circuit Short to Ground) — sets when the APIM detects an over-
current condition in the USB circuit. This can be caused by a fault in the USB cable and port, or
by the customer USB device.
Customer USB device

USB cable and port
APIM
PINPOINT TEST H: THE USB PORT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

H1 CHECK THE USB CONNECTION
Using the Multi-Media Interface Tester, The SYNC® system is operating correctly.
attempt to play a file using the USB port. REVIEW the operation of the USB port with the
Does the audio file play successfully customer. If the customer device still does not
using the USB connection? operate correctly, the fault is with the customer
device.
No
GO to H2 .
H2 INSPECT THE USB CABLE
Ignition OFF. Yes
Disconnect: USB Cable At APIM . The concern was caused by the USB
Inspect the USB cable for damage. connection not being seated correctly. The
Connect: USB Cable At APIM . system is now operating correctly.
Ignition ON.
Connect: Multi-Media Interface Tester. No
Using the Multi-Media Interface Tester, GO to H3 .
attempt to play a file using the USB port.
Does the audio file play successfully
using the USB connection?
H3 RESET THE APIM AND RECHECK
SYNC® SYSTEM OPERATION
NOTE: Carrying out a Master Reset Yes

returns all preference settings to the The SYNC® system is operating correctly at
factory defaults, erases all the phone this time. CARRY OUT a SYNC® system
book and call histories, and deletes any Master Reset. REFER to the Owner's
devices paired with the SYNC® system. Literature.
Carry out an APIM power reset by REVIEW the SYNC® system operation with the
disconnecting the battery for 5 minutes, customer. If the customer device still does not
then reconnecting it. operate correctly, the fault is with the customer
Connect: Multi-Media Interface Tester. device.
Using the Multi-Media Interface Tester,
test the audio output for the audio input No
jack, USB port, and Bluetooth connection If only the USB port is inoperative, GO to H4 . If
using the VOICE switch on the steering additional inputs are inoperative, GO to
wheel controls to enter each mode. Symptom Chart to diagnose the observed
Do all of the SYNC® inputs function symptom. If all inputs are inoperative, INSTALL
correctly? a new APIM . REFER to Accessory Protocol
Interface Module (APIM) in this section.
H4 ISOLATE THE USB CABLE AND PORT
Install a new USB cable and port. Refer to Yes
Universal Serial Bus (USB) Cable and The concern was caused by an inoperative
Port in this section. USB cable. The system is now operating
Connect: Multi-Media Interface Tester. correctly.
attempt to play a file using the USB port. No
Does the audio file play successfully GO to H5 .
using the USB connection?
H5 CHECK FOR CORRECT APIM
OPERATION
Disconnect the APIM connector. Yes
Check for: INSTALL a new APIM . REFER to Accessory
corrosion Protocol Interface Module (APIM) in this
damaged pins section. TEST the system for normal operation.
pushed-out pins
Connect the APIM connector and make No
sure it seats correctly. The system is operating correctly at this time.
Wait 2 minutes for the APIM to re-initalize. The concern may have been caused by a loose
Operate the system and verify the or corroded connector. CLEAR any DTCs
concern is still present. present.
Pinpoint Test I: Voice Recognition Is Inoperative/Does Not Operate Correctly
Normal Operation
When the VOICE switch is pressed, it changes a reference voltage signal and the audio system enters
voice recognition mode. The VOICE switch is wired to the Accessory Protocol Interface Module (APIM).
The microphone receives the voice command and sends a signal to the APIM . The microphone is also
used to detect outgoing audio during a phone call.
DTC B1201:1C (Steering Wheel Audio Switch Pack 2: Circuit Voltage Out of Range) — sets
when the APIM detects the VOICE switch circuit out-of-range for greater than 250 ms.
DTC B1201:63 (Steering Wheel Audio Switch Pack 2: Circuit / Component Protection Time-Out)
— sets when the APIM detects the VOICE switch stuck within range for greater than 120 seconds
during normal operation, or for greater than 3 seconds during the on-demand self-test.
DTC B1D79:01 (Microphone Input: General Electrical Failure) — sets during the on-demand self-
test if the APIM does not detect the microphone.

Steering column multifunction switch
Microphone
APIM
PINPOINT TEST I: VOICE RECOGNITION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to
Section 414-01 .

I1 CHECK THE OPERATION OF THE VOICE SWITCH
Operate the audio system in radio tuner (AM/FM) mode. Yes
Adjust the audible prompt volume to an acceptable range. Refer GO to I6 .
to the Owner's Literature.
Press the VOICE switch. No
Does the audio system enter voice recognition mode? GO to I2 .
I2 MONITOR THE VOICE SWITCH PID
Enter the following diagnostic mode on the scan tool: APIM Yes
DataLogger. GO to I11 .
Monitor the VOICE switch PID (SCS_VOICE) while pressing and
releasing the VOICE switch. No
Does the PID value agree with the switch position? If the switch always
reads active, INSTALL a
new steering column
05 . CLEAR any DTCs
present. TEST the
system for normal
operation.
For all other PID values,

GO to I3 .
I3 CHECK THE REFERENCE VOLTAGE CIRCUIT TO THE VOICE

SWITCH FOR A SHORT TO VOLTAGE
Disconnect: Steering Column Multifunction Switch C202A. Yes
Disconnect: APIM C2383 . REPAIR the circuit.
Ignition ON. CLEAR any DTCs
Measure the voltage between the steering column multifunction present. TEST the
switchC202A-2, circuit VME14 (GY/YE), harness side and system for normal
ground. operation.
No
GO to I4 .

I4 CHECK THE CIRCUITS TO THE VOICE SWITCH FOR AN OPEN
OR SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the steering column GO to I5 .
multifunction switch, harness side and the APIM , harness side;
and between the steering column multifunction switch, harness No
side and ground as follows: REPAIR the circuit in
question. CLEAR any
Positive Meter DTCs present. TEST
Lead Negative Meter Lead Circuit the system for normal
operation.
C202A-2 C2383-15, then VME14 (GY/YE)
ground
C202A-7 C2383-14, then RME24
ground (BU/WH)
Is the resistance less than 5 ohms between the steering

column multifunction switch and the APIM , and greater than
10,000 ohms between the steering column multifunction
switch and ground?
I5 ISOLATE THE VOICE SWITCH
Connect: APIM C2383. Yes
Install a new steering column multifunction switch. Refer to GO to I11 .
Section 211-05 .
The concern was
caused by an
inoperative steering
column multifunction
switch. CLEAR any
DTCs present.
I6 CHECK THE OPERATION OF THE VOICE RECOGNITION
Press the VOICE switch. Yes
Wait for the SYNC® system to acknowledge the VOICE switch The system is operating
being pressed. correctly at this time.
While still in voice recognition mode, speak the command ADVISE the customer
"PHONE", and observe the audio system. on the correct operation
Does the SYNC® system acknowledge the command of the voice recognition
"PHONE"? system.
No
GO to I7 .
I7 CHECK THE MICROPHONE SHIELD CIRCUIT FOR CONTINUITY
TO GROUND
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to I8 .
Disconnect: Microphone C9221.
Measure the resistance between the microphone C9221-3, circuit No
GD111, harness side and ground. REPAIR the circuit.
TEST the system for
normal operation.

I8 CHECK THE MICROPHONE CIRCUITS FOR A SHORT TO
VOLTAGE
Connect: Negative Battery Cable. Yes
Disconnect: APIM 2383. REPAIR the circuit in
Ignition ON. question. CLEAR any
Measure the voltage between the microphone C9221-1, circuit DTCs present. TEST
VMT02 (GN/OG), harness side and ground; and between the the system for normal
microphone C9221-2, circuit VMM13 (YE/GN), harness side and operation.
ground.
No
GO to I9 .
I9 CHECK THE MICROPHONE CIRCUITS FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the microphone, harness side GO to I10 .
and the APIM , harness side as follows:
No
Positive Meter Lead Negative Meter Lead Circuit REPAIR the circuit in
question. TEST the
C9221-1 C2383-18, then ground VMT02 (GN/OG) system for normal
operation.
C9221-2 C2383-5, then ground VMM13 (YE/GN)
Are the resistances less than 5 ohms between the

microphone and the APIM , and greater than 10,000 ohms
between the microphone and ground?
I10 ISOLATE THE MICROPHONE
Connect: APIM C2383. Yes
Install a new microphone. Refer to Microphone in this section. The fault was caused by
Operate the audio system in radio tuner (AM/FM) mode. an inoperative
Press the VOICE switch and attempt several voice commands. microphone. The
Does the voice recognition operate correctly? system is now operating
correctly.
No
GO to I11 .
I11 RESET THE APIM AND RECHECK SYNC® SYSTEM
OPERATION
NOTE: Carrying out a Master Reset returns all preference Yes

settings to the factory defaults, erases all the phone book and call The SYNC® system is
histories, and deletes any devices paired with the SYNC® operating correctly at
system. this time. CARRY OUT
Carry out an APIM power reset by disconnecting the battery for 5 a SYNC® system
minutes, then reconnecting it. Master Reset. REFER
Connect: Multi-Media Interface Tester. to the Owner's
Using the Multi-Media Interface Tester, test the audio output for Literature.
the audio input jack, USB port, and Bluetooth connection using
the VOICE switch on the steering wheel controls to enter each REVIEW the SYNC®
mode. system operation with
Do all of the SYNC® inputs function correctly? the customer. If the
customer device still
does not operate
correctly, the fault is
with the customer
device.
No
GO to I12 .
I12 CHECK FOR CORRECT APIM OPERATION
Check for: INSTALL a new APIM .
corrosion REFER to Accessory
damaged pins Protocol Interface
pushed-out pins Module (APIM) in this
Connect the APIM connector and make sure it seats correctly. section. TEST the
Turn the radio on and press the PUSH-TO-TALK button. system for normal
Wait 2 minutes for the APIM to re-initalize. operation.
Pinpoint Test J: Poor Quality/Distorted/No Sound While In SYNC® Mode
Refer to Wiring Diagrams Cell 130 , Audio System/Navigation for schematic and connector information.
Normal Operation
The Accessory Protocol Interface Module (APIM) transmits left and right channel analog audio signals to
the Audio Control Module (ACM). These signals include inputs from the Universal Serial Bus (USB) port,
the audio input jack, and a Bluetooth® media device.
If a USB mass storage device is used to play an audio file, the SYNC® system only plays audio files that
do not have Digital Rights Management (DRM) protection.

ACM
APIM
PINPOINT TEST J: POOR QUALITY/DISTORTED/NO SOUND WHILE IN SYNC® MODE


J1 VERIFY THE OPERATION OF THE SYNC® SYSTEM AUDIO
SOURCES
Using the Multi-Media Interface Tester, test the audio output for GO to J2 .
the audio input jack, USB port and Bluetooth®.
Is there poor quality/distorted/no sound from each SYNC® No
audio source? If the concern is only with
some of the audio
sources, GO to Symptom
Chart - SYNC® System to
diagnose the observed
symptom.
If all audio sources

operate correctly, the
concern is with the
customer device.
J2 CHECK THE AUDIO CIRCUITS FROM THE APIM FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: ACM C240B. REPAIR the circuit in
Disconnect: APIM C2383. question. TEST the
Measure the voltage between the APIM , harness side and operation.
ground as follows:
No
Positive Meter Lead Negative Meter Lead GO to J3 .
C2383-23 Ground
VME53 (VT/GN)
C2383-24 Ground
RME53 (BN/WH)
C2383-25 Ground
VME52 (BU)
C2383-26 Ground
RME52 (GY/OG)
J3 CHECK THE CIRCUITS FROM THE APIM FOR AN OPEN OR
SHORT TO GROUND
Ignition OFF. Yes
Measure the resistance between the ACM , harness side, and GO to J4 .
the APIM , harness side; and between the ACM , harness side
and ground as follows: No
Positive Meter question. TEST the
Lead Negative Meter Lead Circuit system for normal
operation.
C240B-13 C2383-23, then VME53 (VT/GN)
ground
C240B-26 C2298-24, then RME53
ground (BN/WH)
C240B-12 C2298-25, then VME52 (BU)
ground
C240B-25 C2298-26, then RME52
ground (GY/OG)
Are the resistances less than 5 ohms between the ACM and
the APIM , and greater than 10,000 ohms between the ACM
and ground?
J4 CHECK FOR CORRECT APIM OPERATION
Disconnect the APIM connector. INSTALL a new APIM .
Check for: REFER to Accessory
corrosion Protocol Interface Module
damaged pins (APIM) in this section.
Connect the APIM connector and make sure it seats correctly. normal operation. If the
Turn the radio on and press the PUSH-TO-TALK button. concern is still present,
Wait 2 minutes for the APIM to re-initalize. GO to J5 .
corroded connector.
J5 CHECK FOR CORRECT ACM OPERATION
corrosion REFER to Audio Control
damaged pins Module (ACM) in this
Connect all the ACM connectors and make sure they seat for normal operation.
correctly.
corroded connector.
Pinpoint Test K: The Entire Audio System is Inoperative
Normal Operation
With the ignition in RUN or ACC, the audio system can be powered on. When the ON button is pressed
on the Front Controls Interface Module (FCIM) (or the ignition is turned to RUN or ACC and the audio
system was on when the ignition was turned off), a wake-up signal is provided to the Front
Control/Display Interface Module (FCDIM) via the dedicated Local Interconnect Network (LIN) line. The
FCDIM then broadcasts a message over the Infotainment Controller Area Network (I-CAN) to the other
modules in the audio system.
When a button is pressed on the FCIM , there is a corresponding display on the FCDIM . The FCDIM
displays base audio system information, warning message and icons, SYNC® information (if equipped),
and satellite radio information (if equipped). The information is sent to the FCDIM via the MS-CAN .
Communication network concern

FCIM
FCDIM
ACM
PINPOINT TEST K: THE ENTIRE AUDIO SYSTEM IS INOPERATIVE

K1 CHECK FOR SCAN TOOL
COMMUNICATION
Carry out the network test with the scan Yes
tool. REFER to Section 418-00 to diagnose The
Do either the ACM or the FCDIM fail to ACM Does Not Respond To The Scan Tool or
communicate with the scan tool? The FCDIM Does Not Respond To The Scan
Tool.
No
GO to K2 .
K2 CHECK THE POWER SWITCH INPUT TO
THE FCDIM
Enter the following diagnostic mode on the Yes
scan tool: FCDIM DataLogger. GO to K3 .
Monitor the FCDIM power switch PID
(BTN_POWER) while pressing and No
releasing the power switch on the FCIM . GO to Pinpoint Test Y .
Does the PID display the correct the
power switch positions?
K3 CHECK FOR LOST COMMUNICATION
DTCs
Using the scan tool, clear the ACM and Yes
FCDIM continuous DTCs. REFER to DTC Charts in this section.
Ignition OFF.
Ignition ON. No
Wait at least 10 seconds. GO to K4 .
Repeat the ACM and FCDIM self-tests.
Is DTC U0140:00, U0193:00, or U0257:00
present in either module?
K4 CHECK FOR CORRECT ACM OPERATION
Check for: INSTALL a new ACM . REFER to Audio
corrosion Control Module (ACM) in this section. CLEAR
damaged pins any DTCs present. TEST the system for
Connect all the ACM connectors and make
sure they seat correctly. No
Operate the system and verify the concern The system is operating correctly at this time.
is still present. The concern may have been caused by a
Is the concern still present? loose or corroded connector. CLEAR any
DTCs present.
Pinpoint Test L: The Front Control/Display Interface Module (FCDIM) Illumination Does Not
Operate Correctly
Normal Operation
The Front Control/Display Interface Module (FCDIM) receives the illumination signal from the Body
Control Module (BCM) and dims the illumination based on the position of the dimmer switch. In the event
this signal is lost, the FCDIM defaults to full nighttime brightness, resulting in a symptom of the FCDIM
being unable to dim.
Backlighting system concern

FCDIM
PINPOINT TEST L: THE FDIM ILLUMINATION DOES NOT OPERATE CORRECTLY

L1 CHECK FOR DTC U0140:00
Is DTC U0140:00 present? GO to Pinpoint Test P .
No
GO to L2 .
L2 CHECK FOR CORRECT FCDIM
OPERATION
Disconnect the FCDIM Yes
connector. INSTALL a new FCDIM . REFER to Front
Check for: Controls/Display Interface Module (FCDIM) in this section.
damaged pins
pushed-out pins No
Connect the FCDIM connector The system is operating correctly at this time. The
and make sure it seats concern may have been caused by a loose or corroded
correctly. connector.
Operate the system and
determine if the concern is still
present.
Pinpoint Test M: The SYNC® System Is Completely Inoperative
Normal Operation
The Accessory Protocol Interface Module (APIM) takes action based on network message it receives
from other audio system modules, and from the VOICE switch (part of the multifunction switch). The
APIM sends display data to the Front Control/Display Interface Module (FCDIM) in order to update the
display screen.
DTC U3000:04 (Control Module: System Internal Failure) — sets when the APIM detects a fault
due to a device conflict or an internal failure.
Audio system concern

Customer error
Customer device
APIM
PINPOINT TEST M: THE SYNC® SYSTEM IS COMPLETELY INOPERATIVE

M1 CHECK FOR SCAN TOOL
COMMUNICATION WITH THE APIM
Carry out the network test using the Yes
scan tool. GO to M2 .
Does the APIM pass the network
test? No
M2 CHECK THE SYNC® SYSTEM
OPERATION
NOTE: Carrying out a Master Reset Yes

returns all preference settings to the The SYNC® system is operating correctly at this
factory defaults, erases all the phone time. CARRY OUT a SYNC® system Master
book and call histories, and deletes any Reset. REFER to the Owner's Literature.
devices paired with the SYNC® system.
REVIEW the SYNC® system operation with the
Connect: Multi-Media Interface Tester. customer. If the customer device still does not
Using the Multi-Media Interface Tester, operate correctly, the fault is with the customer
test the audio output for the audio input device.
jack, USB port, and Bluetooth
connection using the VOICE switch on No
the steering wheel controls to enter each GO to M3 .
mode.
Do all of the SYNC® inputs function
correctly?
M3 RESET THE APIM AND RECHECK
SYNC® SYSTEM OPERATION
Carry out an APIM power reset by Yes
disconnecting the battery for 5 minutes, The SYNC® system is operating correctly at this
then reconnecting it. time. CARRY OUT a SYNC® system Master
Connect: Multi-Media Interface Tester. Reset. REFER to the Owner's Literature.
test the audio output for the audio input REVIEW the SYNC® system operation with the
jack, USB port, and Bluetooth customer. If the customer device still does not
connection using the VOICE switch on operate correctly, the fault is with the customer
the steering wheel controls to enter each device.
mode.
Do all of the SYNC® inputs function No
correctly? If only some (but not all) of the inputs are
inoperative, GO to Symptom Chart to diagnose
the observed symptom. If all inputs are
inoperative and/or DTC U3000:04 is present,
INSTALL a new APIM . REFER to Accessory
Protocol Interface Module (APIM) in this section.
Pinpoint Test N: Unable To Pair Bluetooth® Device
Normal Operation
When a new Bluetooth® device is added, the Accessory Protocol Interface Module (APIM) and the
Bluetooth® device must be paired together. Most Bluetooth® devices can pair with the SYNC® system,
although functionality varies. To determine if a Bluetooth® device is supported, retrieve the Consumer
Interface Processor (CIP) software level using the Accessory Protocol Interface Module (APIM) Software
Level Check in this section, and verify the customer device is on the compatibility list for the current CIP
software level.
Pairing a Bluetooth® device is accomplished through the "Add Device" selection of the phone menu.
When pairing a device, the SYNC® system generates a unique Personal Identification Number (PIN)
that must be entered on the Bluetooth® device in order for the pairing process to be successful. There
are also some device-specific actions that must take place. For additional information on the pairing
process, refer to the Owner's Literature.
Incompatible Bluetooth® device

Customer error
Customer Bluetooth® device
APIM
PINPOINT TEST N: UNABLE TO PAIR Bluetooth® DEVICE

N1 CHECK THE BLUETOOTH® CONNECTION
NOTE: Carrying out a Master Reset returns all Yes

preference settings to the factory defaults, erases all The SYNC® system is operating
the phone book and call histories and deletes any correctly at this time. CARRY OUT a
devices paired with the SYNC® system. SYNC® system Master Reset.
REFER to the Owner's Literature.
Connect: Multi-Media Interface Tester.
Using the Multi-Media Interface Tester, connect to REVIEW the pairing process with the
the SYNC® system using Bluetooth®. Follow the tool customer. If the customer device still
instructions. does not pair, the fault is with the
Enter the following diagnostic mode on the scan tool: customer device.
APIM DataLogger.
Monitor the Bluetooth® device paired PID (BT_PAIR) No
and the Bluetooth® device connected PID GO to N2 .
(BT_CONN).
Do the PIDs both read "Yes"?
N2 CHECK FOR CORRECT APIM OPERATION
Ignition OFF. Yes
Disconnect the APIM connector. INSTALL a new APIM . REFER to
Check for: Accessory Protocol Interface Module
corrosion (APIM) in this section. TEST the
damaged pins system for normal operation.
pushed-out pints
Connect the APIM connector and make sure it seats No
correctly. The system is operating correctly at
Turn the radio on and press the PUSH-TO-TALK this time. The concern may have
button. been caused by a loose or corroded
Wait 2 minutes for the APIM to re-initalize. connector.
Operate the system and verify the concern is still
present.
Pinpoint Test O: The SYNC® System Audible Prompts Are Inoperative/Do Not Operate Correctly
Normal Operation
The Text-To-Speech (TTS) and voice prompt features speak certain text information and interaction
requests in order to minimize driver distraction while driving. The ringtone alerts the driver to an
incoming call.
Audible prompts can range from a simple tone to more elaborate spoken text, based on the customer
setting. When interaction mode is set to standard, detailed guidance is provided. When interaction mode
is set to advanced, most prompts are tones only and minimal audible guidance is provided. Refer to the
Owner's Literature for further information on voice interaction.
The audio signals for the TTS and voice prompt features, the ringtones, and audio from an outside
device during a phone call, are sent from the Accessory Protocol Interface Module (APIM) to the Audio
Control Module (ACM).
Customer setting
ACM
APIM
PINPOINT TEST O: THE SYNC® SYSTEM AUDIBLE PROMPTS ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
Result / Action
Test Step
to Take
O1 CHECK THE AUDIBLE PROMPT SETTING
Operate the audio system in SYNC® mode. Yes
Verify the audible prompts are enabled. Refer to "SYNC® Voice The system is
Recognition Feature" in the Owner's Literature. operating
Press the VOICE button on the steering wheel controls and observe the correctly at this
SYNC® audible prompt. time. The
Does the SYNC® system produce an audible prompt correctly? concern was
caused by a
customer setting.
INSTRUCT the
customer in the
correct operation
of the audible
prompt feature.
No
GO to O2 .
O2 CHECK FOR A VOLTAGE SIGNAL FROM THE APIM
NOTICE: This pinpoint test step directs testing circuits using a Yes
back-probe method. Use the special back-probe tool specified in GO to O6 .
the tool list in this section. Do not force test leads or other probes
into connectors. Adequate care must be exercised to avoid No
connector terminal damage while ensuring that good electrical GO to O3 .
contact is made with the circuit or terminal. Failure to follow these
instructions may cause damage to wiring, terminals, or connectors
and subsequent electrical faults.
Operate the audio system in SYNC® mode.
While pressing the VOICE button repeatedly, measure the AC voltage by
backprobing between the ACM C240B-8, circuit VMN14 (WH/VT),
harness side and the ACM C240B-21, circuit RMN14 (GY/BN), harness
side.
Is an AC voltage produced each time the VOICE switch is pressed?
O3 CHECK THE AUDIBLE PROMPT CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: ACM C240B. REPAIR the
Disconnect: APIM C2383. circuit in
Ignition ON. question. TEST
Measure the voltage between the APIM C2383-3, circuit VMN14 the system for
(WH/VT), harness side and ground; and between the APIM C2383-4, normal operation.
circuit RMN14 (GY/BN), harness side and ground.
No
GO to O4 .

O4 CHECK THE AUDIBLE PROMPT CIRCUITS FOR AN OPEN OR SHORT
TO GROUND
Ignition OFF. Yes
Measure the resistance between the APIM , harness side and the ACM , GO to O5 .
harness side; and between the APIM , harness side and ground as
follows: No
REPAIR the
Positive Meter Lead Negative Meter Lead Circuit circuit in
question. TEST
C2383-3 C240B-8, then ground VMN14 (WH/VT) the system for
C2383-4 C240B-21, then ground RMN14 (GY/BN) normal operation.
Are the resistances less than 5 ohms between the APIM and the
ACM , and greater than 10,000 ohms between the APIM and
ground?
O5 CHECK FOR CORRECT APIM OPERATION
Ignition OFF. Yes
Connect: ACM C240B. INSTALL a new
Disconnect the APIM connector. APIM . REFER to
Check for: Accessory
corrosion Protocol
damaged pins Interface Module
pushed-out pins (APIM) in this
Connect the APIM connector and make sure it seats correctly. section. TEST
Turn the radio on and press the PUSH-TO-TALK button. the system for
Wait 2 minutes for the APIM to re-initalize. normal operation.
No
The system is
operating
correctly at this
time. The
concern may
have been
caused by a
loose or corroded
connector.
O6 CHECK FOR CORRECT ACM OPERATION
Ignition OFF. Yes
Disconnect all the ACM connectors. INSTALL a new
Check for: ACM . REFER to
corrosion Audio Control
damaged pins Module (ACM) in
pushed-out pins this section.
Connect all the ACM connectors and make sure they seat correctly. TEST the system
Operate the system and verify the concern is still present. for normal
No
The system is
operating
correctly at this
time. The
concern may
have been
caused by a
loose or corroded
connector.
Pinpoint Test P: DTC U0140:00
Normal Operation
Several audio system modules receive network messages from the Body Control Module (BCM) via the
Medium Speed Controller Area Network (MS-CAN). The following information is included in the
messages:
Light and chime request

Illumination dimmer control
As more than one module receives these messages, all modules receiving a particular message should
exhibit a symptom if the message is missing.
DTC U0140:00 (Lost Communication With Body Control Module: No Sub Type Information) — set
by the Audio Control Module (ACM), the Front Control/Display Interface Module (FCDIM), the
Accessory Protocol Interface Module (APIM), or the Global Positioning System Module (GPSM)
when network messages are missing from the BCM for greater than 5 seconds with the ignition in
RUN.

BCM
PINPOINT TEST P: DTC U0140:00

P1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs GO to P2 .
from all modules.
Ignition OFF. No
Ignition ON. The system is operating correctly at this time. The DTC may
Wait at least 10 seconds. been set due to an intermittent fault in the network wiring.
Retrieve all continuous
DTCs from all modules.
Is DTC U0140:00 set in
any audio system
module?
P2 CHECK FOR BATTERY
VOLTAGE OUT-OF-RANGE
DTCs
Carry out the self-test for Yes
the following modules: For an audio system module, REFER to DTC Charts in this
ACM section.
FCDIM
APIM For the BCM , REFER to Section 419-10 .
GPSM
BCM No
Is DTC U3003:16 or DTC GO to P3 .
U3003:17 recorded in any
module?
P3 CHECK FOR DTC U0140:00
SET IN MULTIPLE MODULES
Review the recorded results Yes
from the self-test. If all audio system modules except the FCDIM set DTC
Is DTC U0140:00 set in U0140:00, INSTALL a new FCDIM . REFER to Front
more than one audio Controls/Display Interface Module (FCDIM) in this section.
system module? TEST the system for normal operation.
Otherwise, GO to P4 .
No
If there is an observable symptom, GO to Symptom Chart -
General Audio System to diagnose the observed symptom.
If there is no observable symptom, the system is operating

correctly at this time. The DTC may have been set due to high
network traffic or an intermittent fault condition.
P4 CHECK FOR CORRECT
BCM OPERATION
Ignition OFF. Yes
Disconnect all the BCM INSTALL a new BCM . REFER to Section 419-10 . CLEAR all
connectors. continuous DTCs. TEST the system for normal operation.
Check for:
corrosion No
damaged pins The system is operating correctly at this time. The concern
pushed-out pints may have been caused by a loose or corroded connector.
Connect all the BCM CLEAR all continuous DTCs. REPEAT the self-test for the
connectors and make sure module(s) that set DTC U0140:00.
they seat correctly.
verify the concern is still
present.
Is the concern still
present?
Pinpoint Test Q: DTC U0253:00
DTC U0253:00 (Lost Communication With Accessory Protocol Interface Module: No Sub Type
Information) — set by the Audio Control Module (ACM) when network messages are missing from
the Accessory Protocol Interface Module (APIM) over the Medium Speed Controller Area Network
(MS-CAN) for greater than 5 seconds with the ignition in RUN.

APIM
PINPOINT TEST Q: DTC U0253:00

Q1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs from GO to Q2 .
all modules.
Ignition OFF. No
Wait at least 10 seconds. been set due to an intermittent fault in the network wiring.
Retrieve all continuous DTCs
from all modules.
U0197:00 set in any
module?
Q2 CHECK FOR BATTERY
VOLTAGE OUT-OF-RANGE DTCs
Carry out the self-test for the Yes
following modules: REFER to DTC Charts in this section.
ACM
APIM No
Is DTC U3003:16 or DTC GO to Q3 .
U3003:17 recorded in any
module?
Q3 CHECK FOR DTC U0253:00
OR DTC U0197:00 SET IN
MULTIPLE MODULES
from the self-test. GO to Q4 .
Are DTC U0253:00 or DTC
U0197:00 set in more than No
one module? If there is an observable symptom, GO to Symptom Chart -
correctly at this time. The DTC may have been set due to
high network traffic or an intermittent fault condition.
Q4 CHECK FOR CORRECT APIM
OPERATION
Ignition OFF. Yes
Disconnect the APIM INSTALL a new APIM . REFER to Accessory Protocol
connector. Interface Module (APIM) in this section. CLEAR all
Check for: continuous DTCs. TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pints The system is operating correctly at this time. The concern
Connect the APIM connector may have been caused by a loose or corroded connector.
and make sure it seats CLEAR all continuous DTCs. REPEAT the self-test for the
correctly. module(s) that set DTC U0197:00 or DTC U0253:00.
Operate the system and verify
Pinpoint Test R: DTC U0255:00 Or DTC U0257:00
DTC U0255:00 (Lost Communication With Front Display Interface Module: No Sub Type
Information) — set by the Accessory Protocol Interface Module (APIM) when network messages
are missing from the Front Control/Display Interface Module (FCDIM) for greater than 5 seconds
with the ignition in RUN.
DTC U0257:00 (Lost Communication With Front Controls/Display Interface Module: No Sub Type
Information) — set by the Audio Control Module (ACM) when network messages are missing from
the FCDIM for greater than 5 seconds with the ignition in RUN.

ACM
APIM
FCDIM
PINPOINT TEST R: DTC U0255:00 OR DTC U0257:00
NOTE: Disregard the pinpoint test steps for the APIM if the concern is on a vehicle without the SYNC®
system.

R1 CHECK FOR LOST COMMUNICATION DTCs
NOTE: If new modules were installed prior to Yes

the DTC being set, the module configuration GO to R2 .
may be incorrectly set during Programmable
Module Installation (PMI) or the PMI may not No
have been carried out. The system is operating correctly at this time.
The DTC may have been set due to an
Ignition ON. intermittent fault in the network wiring.
Clear the ACM and APIM DTCs.
Ignition OFF.
Ignition ON.
Wait at least 10 seconds.
Repeat the ACM and APIM self-test.
Is DTC U0255:00 or DTC U0257:00 still
present?
R2 VERIFY THE CUSTOMER CONCERN
Operate the audio system in various modes Yes
(radio tuner, SYNC®, etc.). GO to R3 .
Verify there is an observable symptom
present. No
Is an observable symptom present? The system is operating correctly at this time.
The DTC may have been set due to an
intermittent fault in the network wiring.
CHECK the network wiring between the
FCDIM and the module in question for an
intermittent fault.
R3 CHECK THE COMMUNICATION NETWORK
Carry out the network test using the scan Yes
tool. GO to R4 .
Does the FCDIM pass the network test?
No
REFER to The FCDIM Does Not Respond
To The Scan Tool in Section 418-00 .
R4 CHECK FOR BATTERY VOLTAGE OUT-OF-
RANGE DTCs
Carry out the self-test for the following Yes
modules: REFER to DTC Charts in this section.
ACM
APIM No
FCDIM INSTALL a new FCDIM . REFER to Front
Are any low or high voltage DTCs Controls Interface Module (FCIM) in this
recorded in any module? section. CLEAR the ACM and APIM DTCs.
REPEAT the ACM and APIM self-tests.
If DTC U0257:00 is still present in the ACM ,

INSTALL a new ACM . REFER to Audio
Control Module (ACM) in this section. TEST
If DTC U0255:00 is still present in the APIM ,

INSTALL a new APIM . REFER to Accessory
Protocol Interface Module (APIM) in this
operation.
Pinpoint Test S: DTC U3003:16 (Audio Control Module (ACM))
Normal Operation
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — set by the Audio Control
Module (ACM) as a continuous or on-demand DTC when the supply voltage falls below 10 volts
for at least 10 seconds during normal operation, or for greater than 250 milliseconds during the
self-test.

ACM
PINPOINT TEST S: DTC U3003:16 ( ACM )
Section 414-01 .

S1 RECHECK THE ACM DTCs
Clear the ACM DTCs. Yes
Ignition OFF. GO to S2 .
Ignition ON.
Wait 10 seconds. No
Repeat the ACM self-test. The system is operating
Is DTC U3003:16 still present? correctly at this time. The
DTC may have been set
S2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
Retrieve the continuous memory DTCs from all modules. Yes
Are any voltage-related DTCs set in the PCM? REFER to Section 414-00 .
No
GO to S3 .
S3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
Check the battery condition and verify that the battery is fully Yes
charged. Refer to Section 414-01 . GO to S4 .
No
S4 CHECK THE ACM VOLTAGE SUPPLY
Ignition OFF. Yes
Measure and record the voltage at the battery. GO to S5 .
Disconnect: ACM C240A.
Ignition ON. No
Measure the voltage between the ACM C240A-1, circuit REPAIR the circuit for high
SBP10 (YE/RD), harness side and ground. resistance. CLEAR the
DTC. REPEAT the self-test.
voltage?
S5 CHECK THE ACM GROUND CIRCUIT FOR CONTINUITY
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to S6 .
Measure the resistance between the ACM C240A-13, circuit
GD111 (BK/BU), harness side and ground. No
REPAIR the circuit for high
resistance. CLEAR the
test.

S6 CHECK FOR CORRECT ACM OPERATION
Disconnect all the ACM connectors. INSTALL a new ACM .
Check for: REFER to Audio Control
corrosion Module (ACM) in this
damaged pins section. TEST the system
Connect all the ACM connectors and make sure they seat
correctly. No
corroded connector.
Pinpoint Test T: DTC U3003:17 (Audio Control Module (ACM))
Normal Operation
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — set by the Audio Control
Module (ACM) when the supply voltage is greater than 15.8 volts for more than 250 milliseconds
during normal operation or the self-test.

ACM
PINPOINT TEST T: DTC U3003:17 ( ACM )
T1 CHECK FOR HIGH VOLTAGE DTCs
SET IN OTHER MODULES
Ignition ON. Yes
Retrieve all continuous DTCs from all REFER to Section 414-00 to diagnose an
modules. overcharging condition.
Are high voltage DTCs (e.g., B1317,
U3003:17, P0563) set in more than No
one module? GO to T2 .
T2 CHECK THE BATTERY VOLTAGE
accessories. REFER to Section 414-00 to diagnose an
Start and run the engine at overcharging condition.
approximately 2,000 rpm for 3 minutes
while monitoring the battery voltage. No
Does the battery voltage rise to 15.5 GO to T3 .
volts or higher?
T3 RECHECK FOR DTC U3003:17
Ignition OFF. Yes
Ignition ON. INSTALL a new ACM . REFER to Audio Control
Clear the ACM DTCs. Module (ACM) in this section. TEST the system
Repeat the ACM self-test. for normal operation.
No
Pinpoint Test U: DTC U0155:00
Normal Operation
Several audio system modules receive network messages from the Instrument Panel Cluster (IPC) via
the Medium Speed Controller Area Network (MS-CAN). The following information is included in the
messages:
Date/time data
Ignition switch position
Vehicle speed data
Warning indicator status
As more than one module receives these messages, all modules receiving a particular message can
DTC U0155:00 (Lost Communication With Instrument Panel Cluster ( IPC ) Control Module: No
Sub Type Information) — set by the Front Control/Display Interface Module (FCDIM), the
Accessory Protocol Interface Module (APIM), or the Global Positioning System Module (GPSM)
when network messages are missing from the IPC for greater than 5 seconds with the ignition in
RUN.

IPC
PINPOINT TEST U: DTC U0155:00

U1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs from GO to U2 .
all modules.
Ignition OFF. No
Wait at least 10 seconds. have been set due to an intermittent fault in the network
Retrieve all continuous wiring.
DTCs from all modules.
Is DTC U0155:00 set in any
audio system module?
U2 CHECK FOR BATTERY
following modules: For an audio system module, REFER to DTC Charts in this
FCDIM section.
APIM (if equipped)
GPSM (if equipped) For the IPC , REFER to Section 413-01 .
IPC
Are any low or high No
voltage DTCs recorded in GO to U3 .
any module?
U3 CHECK FOR DTC U0155:00
SET IN MULTIPLE MODULES
from the self-test. GO to U4 .
Is DTC U0155:00 set in
more than one audio No
system module? If there is an observable symptom, GO to Symptom Chart -

U4 CHECK FOR CORRECT IPC
OPERATION
Ignition OFF. Yes
Disconnect the IPC INSTALL a new IPC . REFER to Section 413-01 . CLEAR all
connector. continuous DTCs. TEST the system for normal operation.
Check for:
corrosion No
damaged pins The system is operating correctly at this time. The concern
pushed-out pins may have been caused by a loose or corroded connector.
Connect the IPC connector CLEAR all continuous DTCs. REPEAT the self-test for the
and make sure it seats module(s) that set DTC U0155:00.
correctly.
determine if the concern is
still present.
Is the concern still
present?
Pinpoint Test V: One Or More Front Control/Display Interface Module (FCDIM) Displays Is
Inoperative/Does Not Operate Correctly
Normal Operation
All of the displays on the Front Control/Display Interface Module (FCDIM) screen are controlled through
network messages. The modules sending display data to the FCDIM are:
Audio Control Module (ACM): audio system information (including satellite radio information)
Instrument Panel Cluster (IPC): warning messages and indicators
Accessory Protocol Interface Module (APIM): SYNC® system information
If the FCDIM loses the signal from any of these modules, only those specific displays are inoperative.

ACM
IPC
APIM (if equipped)
FCDIM
PINPOINT TEST V: ONE OR MORE FCDIM DISPLAYS IS INOPERATIVE/DOES NOT OPERATE

CORRECTLY

V1 CHECK FOR SCAN TOOL COMMUNICATION WITH THE
FCDIM
Carry out the network test using the scan tool. Yes
Does the scan tool communicate with the FCDIM ? GO to V2 .
No
REFER to The FCDIM Does Not
Respond To The Scan Tool in
Section 418-00 .
V2 CHECK FOR LOST COMMUNICATION DTCs SET IN
THE FCDIM
Using the scan tool, retrieve all continuous DTCs. Yes
Is DTC U0155:00 or U0193:00 present in the FCDIM ? REFER to DTC Charts in this
section.
No
GO to V3 .
V3 CHECK THE FCDIM DISPLAY SEGMENTS
FCDIM DataLogger. GO to V4 .
Command all of the LCD segments on using the FCDIM
active command LCD_SEG (All LCD Segments). No
Do all of the FDIM segments illuminate? GO to V5 .
V4 OBSERVE THE SPECIFIC INOPERATIVE DISPLAY
Observe the inoperative FCDIM display while carrying out Yes
the indicated diagnostic method as follows: The system is operating
correctly at this time. INFORM
Inoperative Expected the customer on the operation of
Display Diagnostic Method Results the FCDIM display.
Audio system Turn the audio The FCDIM No

system on, press display updates to For a warning message or
the AM/FM button, show the change indicator concern, REFER to
and tune to several in audio setting. Section 413-01 .
channels.
For all other display concerns,
SYNC® Turn the audio The FCDIM
GO to V5 .
system (if system on, press display shows
equipped) the phone button, information
and observe the relating to the
display. phone.
Does the suspect display operate correctly based on

the expected results?
V5 CHECK FOR CORRECT FCDIM OPERATION
Ignition OFF. Yes
damaged pins Module (FCDIM) in this section.
Connect the FCDIM connector and make sure it seats operation.
correctly.
Operate the system and determine if the concern is still No
present. The system is operating
concern may have been caused
connector.
Pinpoint Test W: The Speed Sensitive Volume Does Not Operate Correctly
Normal Operation
The speed sensitive volume function adjusts the volume based on the Vehicle Speed Sensor (VSS)
signal, which is received over the Controller Area Network (CAN) Other modules also receive this signal
and should exhibit symptoms if the signal is lost.
Speed sensitive volume setting

VSS signal concern
ACM
PINPOINT TEST W: THE SPEED SENSITIVE VOLUME DOES NOT OPERATE CORRECTLY

W1 CHECK THE SPEEDOMETER OPERATION
Drive the vehicle and observe the speedometer. Yes
Does the speedometer operate correctly? GO to W2 .
No
W2 CHECK THE SPEED SENSITIVE VOLUME SETTING
Turn the speed sensitive volume off. Refer to the Yes
Owner's Literature. The system is operating correctly at
Operate the audio system in radio tuner (AM/FM) this time. INSTRUCT the customer in
mode. the correct usage of the speed
Drive the vehicle at various speeds and observe the sensitive volume feature.
speaker volume.
Set the speed sensitive volume to maximum No
compensation. Refer to the Owner's Literature. GO to W3 .
Operate the audio system in radio tuner (AM/FM)
mode.
Drive the vehicle at various speeds and observe the
speaker volume.
Does the volume remain constant with the speed
sensitive volume turned off, and increase and
decrease with vehicle speed with the speed
sensitive volume set to maximum?
W3 CHECK FOR DTC U0155:00 SET IN THE FCDIM
Is DTC U0155:00 present? GO to Pinpoint Test U .
No
GO to W4 .
W4 CHECK FOR CORRECT ACM OPERATION
Check for: INSTALL a new ACM . REFER to
corrosion Audio Control Module (ACM) in this
damaged pins section. TEST the system for normal
Connect all the ACM connectors and make sure they
seat correctly. No
Operate the system and determine if the concern is The system is operating correctly at
still present. this time. The concern may have
Is the concern still present? been caused by a loose or corroded
connector.
Pinpoint Test X: DTC U0184:00 Or DTC U0193:00
Normal Operation
Several audio system modules receive network messages from the Audio Control Module (ACM). These
messages consist mainly of audio setting information.
As more than one module receives each of these messages, all modules receiving a particular message
can exhibit a symptom if the message is missing.
DTC U0184:00 (Lost Communication With Radio: No Sub Type Information) — set by the
Accessory Protocol Interface Module (APIM) when network messages are missing from the ACM
for greater than 5 seconds with the ignition in RUN.
DTC U0193:00 (Lost Communication With "Digital Audio Control Module A": No Sub Type
Information) — set by the Front Control/Display Interface Module (FCDIM) when network
messages are missing from the ACM for greater than 5 seconds with the ignition in RUN.

ACM
PINPOINT TEST X: DTC U0184:00 OR DTC U0193:00

X1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs from GO to X2 .
all modules.
Ignition OFF. No
Ignition ON. The system is operating correctly at this time. The DTC
Wait at least 10 seconds. may have been set due an intermittent fault in the network
Retrieve all continuous DTCs wiring.
from all modules.
U0193:00 set in any audio
system module?
X2 CHECK FOR BATTERY
following modules: REFER to DTC Charts in this section.
ACM
FCDIM No
APIM (if equipped) GO to X3 .
Are any low or high voltage
DTCs recorded in any
module?
X3 CHECK FOR DTC U0184:00
OR DTC U0193:00 SET IN
MULTIPLE MODULES
from the self-test. GO to X4 .
U0193:00 set in more than No
one module? If there is an observable symptom, GO to Symptom Chart -

X4 CHECK FOR CORRECT ACM
OPERATION
Ignition OFF. Yes
Disconnect all the ACM INSTALL a new ACM . REFER to Audio Control Module
connectors. (ACM) in this section. CLEAR all continuous DTCs. TEST
Check for: the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time. The concern
Connect all the ACM may have been caused by a loose or corroded connector.
connectors and make sure CLEAR all continuous DTCs. REPEAT the self-test for the
they seat correctly. module(s) that set DTC U0184 or DTC U0184:00.
determine if the concern is still
present.
Pinpoint Test Y: The Audio System Does Not Operate Correctly From The Front Controls
Interface Module (FCIM)
Normal Operation
The Front Controls Interface Module (FCIM) exchanges information with the Front Control/Display
Interface Module (FCDIM) over the Local Interconnect Network (LIN). This information includes (among
others) button press data and display data.
DTC U1A00:00 (Private Communication Network: No Sub Type Information) — sets when the
FCDIM does not receive information from the FCIM over the LIN for greater than 2 seconds. This
does not necessarily indicate a fault in the LIN wiring, as a loss of power or ground to the FCIM
can also cause a lack of communication.

FCIM
FCDIM
PINPOINT TEST Y: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FCIM
Section 414-01 .

Y1 CHECK THE FCDIM BUTTON PIDs
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: FCDIM GO to Y6 .
DataLogger.
NOTE: The button PIDs begin with the prefix "BTN_" and end with No
the indicated button. For example, PID BTN_FM correlates with GO to Y2 .
the FM button on the FCIM .
Monitor several of the FCDIM button PIDs.
Do the PID states agree with the button presses?
Y2 CHECK FOR VOLTAGE TO THE FCIM
Ignition OFF. Yes
Disconnect: FCIM C2402. GO to Y3 .
Ignition ON.
Measure the voltage between the FCIM C2402-8, circuit SBP07 No
(WH/RD), harness side and ground. REPAIR the circuit.
TEST the system for
normal operation.
Y3 CHECK THE FCIM GROUND CIRCUIT FOR CONTINUITY
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to Y4 .
Measure the resistance between the FCIM C2402-5, circuit
GD115 (BK/GY), harness side and ground. No
REPAIR the circuit.
TEST the system for
normal operation.

Y4 CHECK THE LIN CIRCUIT FOR A SHORT TO VOLTAGE
Disconnect: FCDIM C2123. Yes
Measure the voltage between the FCIM C2402-7, circuit VDB21 REPAIR the circuit.
(OG), harness side and ground. CLEAR any DTCs
present. TEST the
system for normal
operation.
No
GO to Y5 .

Y5 CHECK THE LIN CIRCUIT FOR AN OPEN OR SHORT TO
GROUND
Measure the resistance between the FCIM C2402-7, circuit Yes
VDB21 (OG), harness side and the FCDIM C2123-8, circuit INSTALL a new FCIM .
VDB21 (OG), harness side; and between the FCIM C2402-7, REFER to Front
circuit VDB21 (OG), harness side and ground. Controls Interface
Module (FCIM) in this
section . TEST the
system for normal
operation. GO to Y6 .
No
REPAIR the circuit.
CLEAR any DTCs
present. TEST the
system for normal
operation.
Is the resistance less than 5 ohms between the FCIM and the
FCDIM , and greater than 10,000 ohms between the FCIM and
ground?
Y6 CHECK FOR CORRECT FCDIM OPERATION
Disconnect the FCDIM connector. INSTALL a new
Check for: FCDIM . REFER to
corrosion Front Controls/Display
pushed-out pins (FCDIM) in this section.
Connect the FCDIM connector and make sure it seats correctly. TEST the system for
Operate the system and determine if the concern is still present. normal operation.
No
Pinpoint Test Z: DTC U0100:00
Normal Operation
The Accessory Protocol Interface Module (APIM) receives network messages from the PCM via the
High Speed Controller Area Network (HS-CAN). These messages include the odometer reading and the
fuel level.
As other modules outside of the audio system also receive these messages, all modules receiving a
particular message can exhibit a symptom if the message is missing.
DTC U0100:00 (Lost Communication With ECM /PCM "A": No Sub Type Information) — set by
the APIM when it is missing messages from the PCM over the HS-CAN for greater than 5
seconds with the ignition in the RUN position.

PCM
PINPOINT TEST Z: DTC U0100:00

Z1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs from all GO to Z2 .
modules.
Ignition OFF. No
Wait at least 10 seconds. may have been set due to an intermittent fault in the
Retrieve all continuous DTCs network wiring.
from all modules.
Is DTC U0100 or DTC U0100:00
set in any modules?
Z2 CHECK FOR BATTERY
following modules: For the APIM , REFER to DTC Charts in this section.
APIM
PCM For all other modules, REFER to the Diagnostic Trouble
Instrument Panel Cluster Code (DTC) Chart in Section 419-10 .
(IPC)
Are any low or high voltage No
DTCs recorded in any module? GO to Z3 .
Z3 CHECK FOR DTC U0100 OR DTC
U0100:00 SET IN MULTIPLE
MODULES
Review the recorded results from Yes
the self-test. GO to Z4 .
set in more than one module? No
If there is an observable symptom, GO to Symptom
Chart - General Audio System to diagnose the observed
symptom.
If there is no observable symptom, the system is

operating correctly at this time. The DTC may have been
set due to high network traffic or an intermittent fault
condition.
Z4 CHECK FOR CORRECT PCM
OPERATION
Disconnect all the PCM Yes
connectors. INSTALL a new PCM. REFER to Section 303-14 .
Check for: CLEAR all continuous DTCs. REPEAT the APIM self-
corrosion test.
damaged pins
pushed-out pins No
Connect all the PCM connectors The system is operating correctly at this time. The
and make sure they seat concern may have been caused by a loose or corroded
correctly. connector. CLEAR all continuous DTCs. REPEAT the
Is the concern still present? APIM self-test.
Pinpoint Test AA: DTC U0151:00
Normal Operation
The Accessory Protocol Interface Module (APIM) receives the emergency call notification message from
the Restraints Control Module (RCM) via the High Speed Controller Area Network (HS-CAN). The APIM
uses this message to activate the emergency call system.
As other modules outside of the audio system also receive this message, all modules receiving it can
DTC U0151:00 (Lost Communication With Restraints Control Module: No Sub Type Information)
— set by the APIM when it is missing the air bag deployment notification message from the RCM
over the HS-CAN for greater than 5 seconds with the ignition in the RUN position.

Restraints system concern
PINPOINT TEST AA: DTC U0151:00

AA1 CHECK FOR LOST
COMMUNICATION DTCs
Ignition ON. Yes
Clear continuous DTCs from all GO to AA2 .
modules.
Ignition OFF. No
Wait at least 10 seconds. may have been set due to an intermittent fault in the
Retrieve all continuous DTCs network wiring.
from all modules.
set in any modules?
AA2 CHECK FOR BATTERY
following modules: For the APIM , REFER to DTC Charts in this section.
APIM
PCM For all other modules, REFER to the Diagnostic Trouble
RCM Code (DTC) Chart in Section 419-10 .
(IPC) No
Are any low or high voltage GO to AA3 .
DTCs recorded in any module?
AA3 CHECK FOR DTC U0151 OR
DTC U0151:00 SET IN MULTIPLE
MODULES
Review the recorded results from Yes
the self-test. GO to AA4 .
set in more than one module? No
If there is an observable audio system symptom, GO to
Symptom Chart - General Audio System to diagnose the
observed symptom.
If there is an observable restraints system symptom,

REFER to Section 501-20B to diagnose the symptom.
If there is no observable symptom, the system is
operating correctly at this time. The DTC may have
been set due to high network traffic or an intermittent
fault condition.
AA4 CHECK FOR CORRECT RCM
OPERATION
Disconnect all the RCM Yes
connectors. INSTALL a new RCM . REFER to Section 501-20B .
Check for: CLEAR all continuous DTCs. REPEAT the APIM self-
corrosion test.
damaged pins
pushed-out pins No
Connect all the RCM connectors The system is operating correctly at this time. The
and make sure they seat concern may have been caused by a loose or corroded
correctly. connector. CLEAR all continuous DTCs. REPEAT the
Is the concern still present? APIM self-test.
Pinpoint Test AB: DTC U016A:00
DTC U016A:00 (Lost Communication With Global Positioning System Module: No Sub Type
Information) — set by the Accessory Protocol Interface Module (APIM) when it is missing network
messages from the Global Positioning System Module (GPSM) over the Medium Speed
Controller Area Network (MS-CAN) for greater than 5 seconds with the ignition in the RUN
position.

GPSM
APIM
PINPOINT TEST AB: DTC U016A:00

AB1 CHECK THE APIM DTCs
NOTE: If new modules were installed prior to Yes

the DTC being set, the module configuration GO to AB2 .
may be incorrectly set during Programmable
Module Installation (PMI) or the PMI may not No
have been carried out. The system is operating correctly at this
time. The DTC may have been set due to
Ignition ON. an intermittent fault in the network wiring.
Clear the APIM DTCs.
Ignition OFF.
Ignition ON.
Wait at least 10 seconds.
Retrieve the APIM self-test.
Is DTC U016A:00 still present?
AB2 VERIFY THE CUSTOMER CONCERN
Operate the audio system in various modes Yes
(radio tuner, SYNC®, etc.). GO to AB3 .
Observe the compass display for normal
operation. No
Is an observable symptom present? The system is operating correctly at this
time. The DTC may have been set due to
an intermittent fault in the network wiring.
CHECK the MS-CAN wiring between the
APIM and the GPSM for an intermittent
fault.
AB3 CHECK THE COMMUNICATION NETWORK
Carry out the network test using the scan tool. Yes
Does the GPSM pass the network test? GO to AB4 .
No
REFER to The GPSM Does Not Respond
To The Scan Tool in Section 418-00 .
AB4 CHECK FOR BATTERY VOLTAGE OUT-OF-
RANGE DTCs
Carry out the self-test for the following Yes
modules: REFER to DTC Charts in this section.
APIM
GPSM No
Is DTC U3003:16 or DTC U3003:17 INSTALL a new GPSM . REFER to Global
recorded in either module? Positioning System Module (GPSM) in this
section. CLEAR the APIM DTCs. REPEAT
the APIM self-test.
If DTC U016A:00 is still present, INSTALL a

new APIM . REFER to Accessory Protocol
Interface Module (APIM) in this section.
Pinpoint Test AC: DTC U3003:16 (Accessory Protocol Interface Module (APIM))
Normal Operation
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — set by the Accessory
Protocol Interface Module (APIM) when the supply voltage falls below 10 volts for at least 10
seconds during normal operation, or for more than 250 ms during the self-test.

APIM
PINPOINT TEST AC: DTC U3003:16 ( APIM )
Section 414-01 .
Result / Action to
Test Step
Take
AC1 RECHECK THE APIM DTCs
Clear the APIM DTCs. Yes
Ignition OFF. GO to AC2 .
Ignition ON.
Wait 10 seconds. No
Repeat the APIM self-test. The system is
Is DTC U3003:16 still present? operating correctly at
this time. The DTC
may have been set
battery voltage
condition.
AC2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
Are any low voltage DTCs set in the PCM? REFER to Section
414-00 .
No
GO to AC3 .
AC3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE
charged. Refer to Section 414-01 . GO to AC4 .
No
REFER to Section
414-01 .
AC4 CHECK THE APIM VOLTAGE SUPPLY
Ignition OFF. Yes
Measure and record the voltage at the battery. GO to AC5 .
Disconnect: APIM C2383.
Ignition ON. No
Measure the voltage between the APIM C2383-1, circuit SBP10 REPAIR the circuit for
(YE/RD), harness side and ground. high resistance.
CLEAR the DTC.
Is the voltage within 0.2 volt of the recorded battery voltage?

AC5 CHECK THE APIM GROUND CIRCUIT FOR CONTINUITY
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to AC6 .
Measure the resistance between the APIM C2383-37, circuit
GD111 (BK/BU), harness side and ground; and between the APIM No
C2383-38, circuit GD111 (BK/BU), harness side and ground. REPAIR the circuit in
question for high
resistance. CLEAR
the DTCs. REPEAT
the self-test.
AC6 CHECK FOR CORRECT APIM OPERATION
Disconnect the APIM connector. INSTALL a new
Check for: APIM . REFER to
corrosion Accessory Protocol
pushed-out pins (APIM) in this section.
Connect the APIM connector and make sure it seats correctly. TEST the system for
No
The system is
may have been
corroded connector.
Pinpoint Test AD: DTC U3003:17 (Accessory Protocol Interface Module (APIM))
Normal Operation
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — set by the Accessory
Protocol Interface Module (APIM) when the supply voltage is greater than 15.8 volts for greater
than 250 milliseconds during normal operation or the self-test.

APIM
PINPOINT TEST AD: DTC U3003:17 ( APIM )

AD1 CHECK FOR HIGH VOLTAGE DTCs
Ignition ON. Yes
Retrieve the continuous memory DTCs REFER to Section 414-01 to diagnose an
from all modules. overcharging.
one module? GO to AD2 .
AD2 CHECK THE BATTERY VOLTAGE
accessories. REFER to Section 414-00 .
Start and run the engine at
approximately 2,000 rpm for 3 minutes No
while monitoring the battery voltage. GO to AD3 .
Does the battery voltage rise to 15.5
volts or higher?
AD3 RECHECK FOR DTC U3003:17
Ignition OFF. Yes
Ignition ON. INSTALL a new APIM . REFER to Accessory
Clear the APIM DTCs. Protocol Interface Module (APIM) in this section.
Repeat the APIM self-test. TEST the system for normal operation.
No
Pinpoint Test AE: DTC U3003:16 (Front Control/Display Interface Module (FCDIM))
Normal Operation
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — set by the Front
Control/Display Interface Module (FCDIM) when the supply voltage falls below 9 volts for greater
than 1 second during normal operation.

FDIM
PINPOINT TEST AE: DTC U3003:16 ( FCDIM )
Section 414-01 .

AE1 RECHECK THE FCDIM DTCs
Clear the FCDIM DTCs. Yes
Ignition OFF. GO to AE2 .
Ignition ON.
Wait 10 seconds. No
Repeat the FCDIM self-test. The system is operating
Is DTC U3003:16 still present? correctly at this time. The
DTC may have been set
AE2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
Are any low voltage DTCs set in the PCM? REFER to Section 414-00 .
No
GO to AE3 .
AE3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
charged. Refer to Section 414-01 . GO to AE4 .
No
AE4 CHECK THE TCIL VOLTAGE SUPPLY
Ignition OFF. Yes
Measure and record the voltage at the battery. GO to AE5 .
Disconnect: FCDIM C2123.
Ignition ON. No
Measure the voltage between the FCDIM C2123-1, circuit REPAIR the circuit for high
SBP07 (WH/RD), harness side and ground. resistance. CLEAR the
DTC. REPEAT the self-
test.

voltage?
AE5 CHECK THE FCDIM GROUND CIRCUIT FOR CONTINUITY
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to AE6 .
For vehicles built up to 1/14/2011, measure the resistance
between the FCDIM C2123-7, circuit GD115 (BK/GY), harness No
side and ground. REPAIR the circuit for high
resistance. CLEAR the
test.
For vehicles built after 1/14/2011, measure the resistance
between the FCDIM C2123-9, circuit GD115 (BK/GY), harness
side and ground.

AE6 CHECK FOR CORRECT FCDIM OPERATION
damaged pins Module (FCDIM) in this
Connect the FCDIM connector and make sure it seats for normal operation.
correctly.
corroded connector.
Pinpoint Test AF: DTC U3003:17 (Front Control/Display Interface Module (FCDIM))
Normal Operation
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — set by the Front
Control/Display Interface Module (FCDIM) when the supply voltage is greater than 16 volts for
greater than 1 second during normal operation.

FCDIM
PINPOINT TEST AF: DTC U3003:17 ( FCDIM )

AF1 CHECK FOR HIGH VOLTAGE DTCs
Ignition ON. Yes
one module? GO to AF2 .
AF2 CHECK THE BATTERY VOLTAGE
while monitoring the battery voltage. GO to AF3 .
volts or higher?
AF3 RECHECK FOR DTC U3003:17
Ignition OFF. Yes
Ignition ON. INSTALL a new FCDIM . REFER to Front
Clear the FCDIM DTCs. Controls/Display Interface Module (FCDIM) in this
Repeat the FCDIM self-test. section. TEST the system for normal operation.
No
Pinpoint Test AG: DTC U3003:16 (Global Positioning System Module (GPSM))
Normal Operation
DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) — set by the Global
Positioning System Module (GPSM) when the supply voltage falls below 10 volts for at least 10
seconds during normal operation or for greater than 250 milliseconds during the self-test.
Wiring, terminal or connectors

GPSM
PINPOINT TEST AG: DTC U3003:16 ( GPSM )

NOTICE: Use the correct probe adaptor(s) when making measurements. Failure to use the
correct probe adaptor(s) may damage the connector.
Section 414-01 .
Result / Action to
Test Step
Take
AG1 RECHECK THE GPSM DTCs
Clear the GPSM DTCs. Yes
Ignition OFF. GO to AG2 .
Ignition ON.
Wait at least 15 seconds. No
Repeat the GPSM self-test. The system is
Is DTC U3003:16 still present? operating correctly at
this time. The DTC
may have been set
battery voltage
condition.
AG2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
Are any low voltage DTCs set in the PCM? REFER to Section
414-00 .
No
GO to AG3 .
AG3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE
charged. Refer to Section 414-01 . GO to AG4 .
No
REFER to Section
414-01 .
AG4 CHECK THE GPSM VOLTAGE SUPPLY
Ignition OFF. Yes
Measure and record the voltage at the battery. GO to AG5 .
Disconnect: GPSM C2398.
Measure the voltage between the GPSM C2398-1, circuit SBP16 No
(VT/RD) for vehicles built up to 1/14/2011, or circuit SBP10 (YE/RD) REPAIR the circuit for
for vehicles built after 1/14/2011, harness side and ground. high resistance.
CLEAR the DTC.
Is the voltage within 0.2 volt of the recorded battery voltage?

AG5 CHECK THE GPSM GROUND CIRCUIT FOR CONTINUITY
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to AG6 .
Measure the resistance between the GPSM C2398-6, circuit GD111
(BK/BU), harness side and ground. No
high resistance.
CLEAR the DTC.

AG6 CHECK FOR CORRECT GPSM OPERATION
Disconnect the GPSM connector. Yes
Connect: Negative Battery Cable. INSTALL a new
Check for: GPSM . REFER to
corrosion Global Positioning
damaged pins System Module
pushed-out pins (GPSM) in this
Connect the GPSM connector and make sure it seats correctly. section. TEST the
Is the concern still present? system for normal
operation.
No
The system is
may have been
corroded connector.
Pinpoint Test AH: DTC U3003:17 (Global Positioning System Module (GPSM))
Normal Operation
DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) — set by the Global
Positioning System Module (GPSM) when the supply voltage is greater than 15.8 volts for greater
than 250 milliseconds during normal operation or the self-test.

GPSM
PINPOINT TEST AH: DTC U3003:17 ( GPSM )
AH1 CHECK FOR HIGH VOLTAGE DTCs
Ignition ON. Yes
one module? GO to AH2 .
AH2 CHECK THE BATTERY VOLTAGE
while monitoring the battery voltage. GO to AH3 .
volts or higher?
AH3 RECHECK FOR DTC U3003:17
Ignition OFF. Yes
Ignition ON. INSTALL a new GPSM . REFER to Global
Clear the GPSM DTCs. Positioning System Module (GPSM) in this
Repeat the GPSM self-test. section. TEST the system for normal operation.
No
Accessory Protocol Interface Module (APIM) Software Level Check
Special Tool(s)
tool
Universal Serial Bus (USB)

Male-A to Male-A Cable
CCMUSB2-AM-AM-10 or
equivalent
NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software
level. To program the APIM , refer to Accessory Protocol Interface Module (APIM) Programming in
Section 418-01 .
1. Turn the Audio Control Module (ACM) on.
2. Connect the scan tool to the Data Link Connector (DLC).
3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool.
4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port.
5. From the technician service publication website, run On-Line Automotive Service Information
System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number
(VIN).
6. From the OASIS tab, select the "Sync/APIM" bullet.
7. Select the "Read APIM" button to verify the current APIM software level.
The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface
Processor (CIP) software levels.
8. The scan tool displays the following information:

Last Recorded State — Hardware
VIN : vehicle identification number associated with the current APIM
Installed date: date the APIM was installed
Radio: currently identified ACM in the vehicle
HW Part No.: APIM hardware part number
Un-installed date: date (if any) the APIM was uninstalled
S/N: APIM serial number
Last Recorded State — Software
Date/Time: date and time of last recorded software installation
VIP : VIP software that was installed at that time
CIP : CIP software that was installed at that time
Description: a description of the content of the software revision
History — Software
Date/Time: date and time of any recorded software installation
VIP : VIP software that was installed at that time
CIP : CIP software that was installed at that time
Available Software for Programming
Select: allows the software package to be selected
Lineage: the original software release, if the software available is a revision
VIP : VIP software level that is available with the selection
CIP : CIP software level that is available with the selection
9. Click a CIP software level to view the device compatibility list associated with the CIP software
level, if desired.
10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port,
or exit the OASIS screen.
Satellite Radio Receiver Electronic Serial Number (ESN) Retrieval
Satellite Radio Electronic Serial Number (ESN) Retrieval
NOTE: If the SDARS is inoperable the Electronic Serial Number (ESN) may be obtained from a label
affixed to the chassis.
1. Operate the audio system in satellite radio mode.
2. Depending on vehicle configuration, press and hold the AUX button and preset button 1 or the
SIRIUS button and preset button 1, simultaneously.
The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number
(ESN) displays on the screen.
3. Record the SDARS module ESN .
4. Turn the audio system off.

Antenna
Early Build

1 18813 Antenna mast
2 18936 Antenna
3 — Antenna cable bolt (part of 18812)
4 18812 Antenna cable
Late Build
1 18813 Antenna mast
2 18936 Antenna
3 18812 Antenna cable
4 — Antenna cable bolt (part of 18936)
5 — Antenna pigtail (part of 18936)
6 — Antenna retainers (part of 18936)
All
Early build
2. Remove the bolt from the antenna base and remove the antenna cable connector from the antenna
base.
To install, tighten to 9Nm (80 lb-in).
Late build
3. Disconnect the antenna cable electrical connectors. Remove the bolt from the antenna base and remove
the antenna base retainers.
To install, tighten to 9Nm (80 lb-in).
All
4. Remove the satellite radio antenna from the top of the roof.

Antenna Cable — AM/FM/Satellite Radio
Cable Routing — Rear

1 18812 AM/FM/Satellite radio rear antenna cable
Cable Connection
1 18812 AM/FM/Satellite radio rear antenna cable
Cable Routing — Front

2 18812 AM/FM/Satellite radio front antenna cable
Removal
NOTE: The AM/FM/Satellite radio antenna cables are part of the vehicle wiring harness. Because the cables
cannot be removed from the harness, this procedure applies to replacement of the cables only.
Front cable
1. Remove the Audio Control Module (ACM) and disconnect the AM/FM/Satellite radio antenna cable
connection(s). For additional information, refer to Audio Control Module (ACM) in this section.
2. Remove the glove compartment. For additional information, refer to Section 501-12 .
3. Remove the right lower cowl side trim panel. For additional information, refer to Section 501-05 .
4. Disconnect the AM/FM/Satellite radio front antenna cable in-line connection(s) at the lower right side of
the cowl.
Rear cable
5. Remove the headliner, C-pillar upper trim panel, C-pillar lower trim panel, rear scuff plate, B-pillar lower
trim panel, front scuff plate and the RH side cowl side trim panel. For additional information, refer to
Section 501-05 .
6. Remove the AM/FM/Satellite radio antenna cable bolt, and disconnect the AM/FM/Satellite radio rear
antenna cable from the antenna base.
7. Disconnect the AM/FM/Satellite radio rear antenna cable in-line connection(s) at the lower right side of
the cowl.
Installation
Front cable
1. Overlay the new AM/FM/Satellite radio front antenna cable on the vehicle wiring harness, following the
routing of the original cable.
2. Secure the new AM/FM/Satellite radio front antenna cable to the wiring harness with tape or zip ties as
necessary.
3. Connect the AM/FM/Satellite radio front antenna cable in-line connection(s) at the lower right side of the
cowl.
4. Install the right lower cowl side trim panel. For additional information, refer to Section 501-05 .
5. Install the glove compartment. For additional information, refer to Section 501-12 .
6. Install the Audio Control Module (ACM) and connect the AM/FM/Satellite radio front antenna cable
connection(s). For additional information, refer to Audio Control Module (ACM) in this section.
Rear cable
7. Overlay the new AM/FM/Satellite radio rear antenna cable on the vehicle wiring harness, following the
routing of the original cable.
8. Secure the new AM/FM/Satellite radio rear antenna cable to the wiring harness with tape or zip ties as
necessary.
9. Connect the AM/FM/Satellite radio rear antenna cable to the AM/FM/Satellite radio antenna cable base
and install the antenna cable bolt.
10. Connect the AM/FM/Satellite radio rear antenna cable in-line connection(s) at the lower right side of the
cowl and at the right side quarter trim panel.
11. Install the headliner, C-pillar upper trim panel, C-pillar lower trim panel, rear scuff plate, B-pillar lower
trim panel, front scuff plate and the RH side cowl side trim panel. For additional information, refer to
Section 501-05 .
Audio Input Jack

1 19C149 Console bezel
2 19A164 Audio input jack
3 14D202 Universal Serial Bus (USB) port and cable
1. Remove the instrument panel lower finish panel. For additional information, refer to Section 501-12 .
2. With a non-marring tool, lift the corners of the console bezel upward to release the retaining clips.
3. Disconnect the electrical connector from the audio input jack.
4. Release the tabs and remove the audio input jack from the bezel.

1 18K810 / 18C869 ACM
2 — ACM electrical connectors (part of 14K024)
1. Remove the instrument panel upper finish panel. For additional information, refer to Section 501-12 .
2. Remove the 4 Front Controls Interface Module (FCIM) finish panel screws and rotate upwards from the bottom
to release the 3 clips. Remove the Front Controls Interface Module (FCIM) finish panel.
3. Remove the ACM .
Disconnect the ACM electrical connectors.

Global Positioning System Module (GPSM)

3 10E893 Global Positioning System Module (GPSM)
4 — GPSM electrical connector (part of 14K024)
2. Slide the GPSM and bracket rearward and remove.


Speaker — Rear Door

1 W506964-S Speaker screws (3 required)
2 18808C Door speaker
3 — Door speaker electrical connector (part of 14631)
2. Remove the 3 screws from the rear door speaker and remove the speaker.


2 — Steering wheel finish panel
3 9C888 Audio control switch
4 9C888 Cruise control switch
5 — Switch screws (3 required)
7 — Steering wheel finish panel screws (2 required)
1. Remove the driver air bag module. For additional information, refer to Section 501-20B .
2. Remove the 2 steering wheel finish panel screws on the back of the steering wheel and remove the
steering wheel finish panel.
3. Remove the 3 screws on the steering wheel control switch and remove the switch from the steering
wheel finish panel.

Speaker — Front Door
Speaker — subwoofer

1 W506964-S Speaker screws (3 required)
2 18808A Speaker
3 — Speaker electrical connector (part of 14631)
2. Remove the 3 speakers screws and remove the speaker.


Front Controls/Display Interface Module (FCDIM)

3 N806272 FCDIM screws (2 required)
4 10D885 FCDIM
5 — FCDIM electrical connector (part of 14K024)
2. Remove the two screws and remove the FCDIM .

Disconnect the FCDIM electrical connectors.

5 18A802 Finish panel
6 — Finish panel clip (2 required)
7 18812 FCIM electrical connector (part of 14K024)
8 W506962 FCIM screws (4 required)
9 18842 FCIM
1. Remove the upper finish panel. For additional information, refer to Section 501-12 .
2. Remove the 4 Front Controls Interface Module (FCIM) finish panel screws and rotate upwards from the bottom
to release the 3 clips. Remove the FCIM finish panel.
Disconnect the electrical connector and release the Passenger Air Bag Deactivation (PAD) indicator
from the FCIM finish panel.
3. Remove the 4 screws from the FCIM and remove the FCIM from the finish panel.

Accessory Protocol Interface Module (APIM)

1 W505156 APIM screws (4 required)
2 14D212 APIM
3 — APIM connector (part of 14K024)
1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and
hardware level when a new APIM is being installed to make sure that the new component is the same
version as the component being replaced.
Retrieve and record the current APIM software and hardware level. For additional information, refer to
Accessory Protocol Interface Module (APIM) Software Level Check in this section.
2. Disengage the two push pins and remove the hush panel from the lower right side of the instrument
panel.
3. Remove the 4 screws and the APIM .
Disconnect the electrical connector and the Universal Serial Bus (USB) cable.

If a new APIM is being installed, program the APIM to the correct software level. For additional
Universal Serial Bus (USB) Cable and Port
USB Port

1 19C149 Console bezel
2 19A164 Audio input jack
3 14D202 Universal Serial Bus (USB) port and cable
USB Cable — Console

1 14D202 USB cable — console
Removal
NOTE: The Universal Serial Bus (USB) cable is a two piece cable. The USB cable routed through the floor
console can be removed and replaced. The USB cable routed through the instrument panel is taped into the
wiring harness. Because the instrument panel USB cable cannot be removed from the harness, this procedure
applies to replacement of that cable only.
USB Port and Cable — Console
1. Remove the instrument panel lower finish panel and the RH floor console side panel. For additional
2. Release the push-pins and remove the Universal Serial Bus (USB) port and cable from the floor console
bezel.
3. Disconnect the floor console to instrument panel USB cable electrical connector and remove the USB
cable.
USB Cable Cable — Instrument panel
4. Remove the instrument panel lower finish panel and the RH floor console side panel. For additional
5. Disconnect the floor console to instrument panel USB cable electrical connector and push pin.
6. Disconnect the USB cable at the Accessory Protocol Interface Module (APIM). For additional
Installation
USB Port and Cable — Console

1. Route the USB cable through the floor console. Connect the floor console to instrument panel USB cable
electrical connector.
2. Connect the USB port and cable to the floor console bezel.
3. Install the instrument panel lower finish panel and the RH floor console side panel. For additional
USB Cable Cable — Instrument panel
4. Overlay the new USB cable on the vehicle wiring harness, following the routing of the original cable.
5. Secure the new USB cable to the wiring harness with tape or zip ties as necessary.
6. Connect the floor console to instrument panel USB cable electrical connector and push pin.
7. Connect the USB cable at the Accessory Protocol Interface Module (APIM). For additional information,
8. Install the instrument panel lower finish panel and the RH floor console side panel. For additional
Microphone
Microphone — SYNC

1 19A391 Microphone
2 W713933 Microphone connector (Part of 14335)
Removal
NOTE: If the microphone is removed from the headliner, a new microphone must be installed.
1. Using a suitable tool, (such as a thin small flat head screwdriver) twist and pry the microphone bezel
from the headliner metal mounting bracket.
2. Remove the microphone from the headliner by grasping the microphone pigtail.
Disconnect the microphone electrical connector.
Installation
1. Reconnect the microphone electrical connector.
2. Wrap the connection with anti-rattle tape.
3. Feed the microphone pigtail into the headliner through the microphone hole.
Verify the microphone pigtail points towards the front of the vehicle.
4. Snap the microphone into the headliner mounting bracket.

Verify the mounting bracket and microphone are snug to the headliner.
Speaker — Tweeter

1 22600 RH/ 22601 LH Interior door handle
2 18808B Speaker
3 — Speaker connector (part of 14631)
1. Remove the front interior door handle. For additional information, refer to Section 501-14 .
2. Release the 3 tabs and remove the speaker from the front interior door handle.

SECTION 417-01: Exterior Lighting 2011 Fiesta Workshop Manual
Headlamp assembly bolts 5 44
High mounted stoplamp screws (5-door hatchback) 1 9
Reversing lamp switch 14 124
Exterior Lighting
The exterior lighting system consists of the following components:
Headlamp assemblies
Body Control Module (BCM) (located under the glove compartment)
Stoplamp switch
Low beam relay
High beam relay
Reversing lamp relay
Daytime Running Lamps (DRL) relay (if equipped)
Headlamp switch
Multifunction switch
Reversing lamp switch (manual transaxle)
Exterior mirror turn lamps
High mounted stoplamp
Rear lamp assemblies
License plate lamps
Lamp Assembly Condensation
Exterior lamps are vented to accommodate normal changes in pressure. Condensation can be a natural
by-product of this design. When moist air enters the lamp assembly through the vents, there is a
possibility that condensation can occur if the temperature is cold. When normal condensation occurs, a
thin mist forms on the interior of the lens. The thin mist eventually clears and exits through the vents
during normal operation. The amount of time it takes to clear the lens of acceptable mist varies with
ambient humidity and lamp types. Normal condensation clears from any lamp in 48 hours under dry
conditions.
Do not replace a lamp assembly with acceptable levels of condensation such as:
presence of thin mist (no streaks, drip marks or droplets are present)
fine mist covers less than 50% of the lens
Examples of unacceptable moisture (usually caused by a lamp housing leak):
water puddling inside the lamp

large water droplets, drip marks or streaks present on the interior of the lens
Headlamps
The headlamp system is a quad-beam pattern system. It consists of replaceable low and high beam
bulbs. The headlamp assembly has the park/turn indicator and side marker lamp integrated into the
headlamp assembly. The headlamps do not illuminate when the ignition is OFF or in ACC and the
headlamp switch is in the HEADLAMPS ON position.
If the headlamps are in the high beam mode when the headlamp switch is turned off, the BCM defaults
the headlamps to the low beam mode the next time the headlamp switch is placed in the HEADLAMPS
ON position.
Flash-to-Pass and High Beam

When the ignition is in RUN, the high beams are illuminated when the multifunction switch is placed in
the FLASH-TO-PASS position and remain illuminated until the multifunction switch is released.
If the low beams are on when the multifunction switch is placed in the HIGH BEAM position, the high
beams are illuminated in addition to the low beams (high beam mode). The high beams turn off (low
beam mode) when the multifunction switch is placed in the HIGH BEAM position again or the headlamp
switch is switched out of the HEADLAMPS ON position.
Headlamp Exit Delay
When the ignition is OFF or in ACC and the multifunction switch is placed in the FLASH-TO-PASS
position and released, the parking lamps and low beams are illuminated. They remain illuminated until
one of the following occurs:
3 minutes have elapsed with a door open

30 seconds have elapsed after all doors are closed
the multifunction switch is placed in the FLASH-TO-PASS position again
the ignition changes to RUN
With all the doors closed, but within the 30 second delay, opening any door results in the 3 minute timer
restarting.
Daytime Running Lamps (DRL)
If the vehicle is equipped with Daytime Running Lamps (DRL), the BCM is configured for this feature.
The DRL feature illuminates the low beam headlamps at a reduced intensity when the ignition is in RUN
and the headlamp switch is in the OFF position.
The DRL feature is inactive when the flash-to-pass feature is active.
The DRL feature is not a programmable parameter for this vehicle.
Stoplamps
The stoplamp switch is located on the brake pedal assembly. The stoplamps illuminate when the brake
pedal is applied. The rear lamps are combination stop/turn lamps on 4-door vehicles.
Turn Signal/Hazard Lamps
The front turn signal lamps are located within the headlamp assemblies. The rear lamps on 4-door
vehicles share functionality with the stoplamps (combination stop/turn lamps). If equipped, there are turn
signal lamps located within the exterior mirrors.
When the multifunction switch is place in the LH or RH LANE CHANGE position (first detent down or up)
and released, the turn signals flash 1 or 3 times. This setting is programmed by the driver from the
center display (Front Control/Display Interface Module (FCDIM)) in the instrument panel.
When the multifunction switch is placed in the LH or RH TURN position (second detent down or up), the
BCM cycles the voltage on and off approximately 75 times per minute. If a front or rear turn bulb is
inoperative, the BCM cycles the voltage on and off approximately 150 times per minute.
The hazard flasher switch is integrated into the Front Controls Interface Module (FCIM). When the
hazard flasher switch is pressed, the BCM cycles the voltage on and off to all the turn lamps
approximately 75 times per minute.
Parking Lamps
The BCM supplies voltage to the parking lamps when demanded. The parking lamp system includes the
following:
Front parking lamps
Front side marker lamps
Rear parking lamps
License plate lamps
Reversing Lamps
When the transaxle is placed in REVERSE (R) with the ignition in RUN, the reversing lamp relay
(automatic transaxle) or the reversing lamp switch (manual transaxle) provides voltage to the reversing
lamps. The reversing lamps are located within the rear lamp assemblies.
Diagnostic Trouble Code (DTC) Chart

B1007:92 High-Beam Headlamp Switch: GO to Pinpoint Test D .
Performance Or Incorrect Operation
B1092:12 Daytime Running Light Relay: Circuit GO to Pinpoint Test F .
Short To Battery
B1092:14 Daytime Running Light Relay: Circuit If the Daytime Running Lamps (DRL) are
Short To Ground Or Open inoperative, GO to Pinpoint Test F .
If the DRL are on with the ignition off, GO to

Pinpoint Test G .
B1098:11 Left Position Light: Circuit Short To GO to Pinpoint Test P .
Ground
B1098:15 Left Position Light: Circuit Short To If the parking lamps are inoperative, GO to
Battery Or Open Pinpoint Test P .
If the parking lamps are always on, GO to

Pinpoint Test Q .
B1099:11 Right Position Light: Circuit Short To GO to Pinpoint Test P .
Ground
B1099:15 Right Position Light: Circuit Short To If the parking lamps are inoperative, GO to

Pinpoint Test Q .
B109A:12 High Beam Relay: Circuit Short To GO to Pinpoint Test B .
Battery
B109A:14 High Beam Relay: Circuit Short To If the high beams are inoperative, GO to
Ground Or Open Pinpoint Test B .
If the high beams are always on, GO to

Pinpoint Test D .
B10A6:92 Main Light Switch: Performance Or GO to Pinpoint Test C .
Incorrect Operation
B10A8:12 Low Beam Relay: Circuit Short To GO to Pinpoint Test A .
Battery
B10A8:14 Low Beam Relay: Circuit Short To If the low beams are inoperative, GO to
Ground Or Open Pinpoint Test A .
If the low beams are always on, GO to

Pinpoint Test C .
B1118:11 Left Rear Sidemarker: Circuit Short To GO to Pinpoint Test P .
Ground
B1118:15 Left Rear Sidemarker: Circuit Short To If the parking lamps are inoperative, GO to

Pinpoint Test Q .
B132B:12 Left Stop/Turn Lamp: Circuit Short To GO to Pinpoint Test M .
Battery
B132B:14 Left Stop/Turn Lamp: Circuit Short To If the LH stoplamp is inoperative, GO to
Ground Or Open Pinpoint Test I .
If the LH rear turn lamp function is

inoperative, GO to Pinpoint Test M .
B132C:12 Right Stop/Turn Lamp: Circuit Short To GO to Pinpoint Test M .
Battery
B132C:14 Right Stop/Turn Lamp: Circuit Short To If the RH stoplamp is inoperative, GO to
Ground Or Open Pinpoint Test I .
If the RH rear turn lamp function is

inoperative, GO to Pinpoint Test M .
B1D06:11 Left Turn Indicator: Circuit Short To For 4-door vehicles, GO to Pinpoint Test M .
Ground
For 5-door vehicles, GO to Pinpoint Test N .
B1D06:15 Left Turn Indicator: Circuit Short To For 4-door vehicles, GO to Pinpoint Test M .
Battery Or Open
B1D07:11 Right Turn Indicator: Circuit Short To For 4-door vehicles, GO to Pinpoint Test M .
Ground
B1D07:15 Right Turn Indicator: Circuit Short To For 4-door vehicles, GO to Pinpoint Test M .
Battery Or Open
B1D35:23 Hazard Switch: Signal Stuck Low GO to Pinpoint Test O .
B1D36:92 Turn Indicator Switch: Performance Or GO to Pinpoint Test L .
Incorrect Operation
C1137:24 Reverse Gear Switch: Signal Stuck High GO to Pinpoint Test T .
All other — REFER to Section 419-10 .
DTCs
Headlamps
Special Tool(s)

tool
Flex Probe Kit

Exterior Lighting
The Body Control Module (BCM) monitors the headlamp switch position by sending voltage signals on
multiple circuits to the headlamp switch. There is one circuit for each headlamp switch position. At any
given time, one of the signal circuits is switched to ground to indicate the headlamp switch position.
If, when the ignition is in RUN, the BCM does not detect any active inputs from the headlamp switch or if
the BCM detects multiple headlamp switch input circuits short to ground, the BCM turns the parking
lamps and headlamps on and keeps them on until the ignition is transitioned OFF.
If either situation occurs, the BCM cannot be ruled immediately as being at fault. This is normal
behavior of the BCM design as a fault has been detected with the inputs from the headlamp switch.
Flash-to-Pass and High Beam
The BCM monitors the multifunction switch for a flash-to-pass or high beam request. With the ignition in
RUN and the multifunction switch in the FLASH-TO-PASS position, the BCM energizes the high beam
relay until the multifunction switch is released.
If the low beams are on when the BCM detects the multifunction switch is in the HIGH BEAM position,
the BCM energizes the high beam relay to provide voltage to the high beams (high beam mode). The
BCM defaults to low beam mode if the headlamps are turned off using the headlamp switch or the
ignition transitions out of RUN.

A Field-Effect Transistor (FET) is a type of transistor that, when used with module software, monitors
and controls current flow on module outputs. The FET protection strategy prevents module damage in
the event of excessive current flow.
The BCM utilizes a FET protective circuit strategy for many of its outputs (such as a turn lamp output
circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are
shut down when a fault event is detected. A short circuit DTC sets when the fault event occurs.
The circuit remains off until the fault is corrected and the ignition is cycled off and then back on, the
module resets the FET protection and allows the circuit to function.
The FET protected circuits for the headlamp system are the low and high beam relay coil ground
circuits.

Headlamp switch Battery Junction Box (BJB) fuse(s):
Multifunction switch 12 (10A) (LH high beam)
13 (10A) (RH high beam)
14 (10A) (LH low beam)
15 (10A) (RH low beam)
23 (7.5A) (low beam relay coil)
31 (20A) (low beam relay)
Central Junction Box (CJB) fuse 21 (10A) (ignition ON input)
Low beam relay
High beam relay
Bulb(s)

tool.

not prove ignition ON). If the ignition does not turn on, refer to Section 211-05 to

418-00 .
9. If the DTCs retrieved are related to the concern, refer to Diagnostic Trouble Code (DTC) Chart in
this section. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Section 419-
10 .
Symptom Chart
Symptom Chart
One or both low Fuse VERIFY the bulbs are
beams are Wiring, terminals or OK. If OK, GO to
inoperative connectors Pinpoint Test A .
Low beam relay
Headlamp assembly
Body Control Module
(BCM)
One or both high Fuse VERIFY the bulbs are
beams are Wiring, terminals or OK. If OK, GO to
inoperative connectors Pinpoint Test B .
High beam relay
Headlamp assembly
Battery Junction Box
(BJB)
BCM
The low beam are Wiring, terminals or GO to Pinpoint Test C .
always on connectors
Low beam relay
Daytime Running
Lamps (DRL) system
concern
Headlamp switch
BCM
The high beams are Wiring, terminals or GO to Pinpoint Test D .
always on connectors
High beam relay
BCM
The flash-to-pass Wiring, terminals or GO to Pinpoint Test E .
feature is connectors
inoperative Multifunction switch
BCM
Pinpoint Tests
Pinpoint Test A: One Or Both Low Beams Are Inoperative
Refer to Wiring Diagrams Cell 85 , Headlamps for schematic and connector information.
Normal Operation
The low beams do not turn on unless the ignition is in RUN. The Body Control Module (BCM) monitors a
circuit that is provided voltage when the ignition is in RUN.
Voltage is provided at all times to the switch and coil sides of the low beam relay. When the BCM
detects the headlamp switch in the HEADLAMPS ON position, the BCM provides ground for the low
beam relay coil. When the low beam relay energizes, voltage is routed through Battery Junction Box
(BJB) fuses 14 (10A) (LH low beam) and 15 (10A) (RH low beam) to the headlamps.
DTC B10A8:12 (Low Beam Relay: Circuit Short To Battery) — a continuous and on-demand DTC
that sets when the BCM detects a short to voltage from the low beam relay coil ground controlled
circuit.
DTC B10A8:14 (Low Beam Relay: Circuit Short To Ground Or Open) — a continuous and on-
demand DTC that sets when the BCM detects an open from the low beam relay coil ground
controlled circuit.
Fuse
Low beam relay
Headlamp assembly
BCM
PINPOINT TEST A: ONE OR BOTH LOW BEAMS ARE INOPERATIVE
Result / Action to
Test Step
Take
A1 DETERMINE IF BOTH HEADLAMPS ARE INOPERATIVE
Ignition ON. Yes
Place the headlamp switch in the HEADLAMPS ON position and VERIFY the BJB
observe the headlamps. fuses 23 (7.5A) and
Are both headlamps inoperative? 31 (20A) are OK. If
OK, GO to A5 . If not
OK, REFER to the
Wiring Diagrams
manual to identify
the possible causes
of the circuit short.
No
VERIFY the BJB
fuse 14 (10A) (LH
low beam) or fuse 15
(10A) (RH low beam)
is OK. If OK, GO to
A2 . If not OK,
REFER to the Wiring
Diagrams manual to
short.
A2 CHECK FOR VOLTAGE TO THE HEADLAMP
Place the headlamp switch in the HEADLAMPS OFF position. Yes
Disconnect: Inoperative Headlamp.
Ignition ON. No
Place the headlamp switch in the HEADLAMPS ON position. GO to A4 .
Measure the voltage between the LH headlamp C1021-1, circuit
CBB14 (VT/OG), harness side and ground; or between the RH
headlamp C1041-1, circuit CBB15 (BN/BU), harness side and
ground.

A3 CHECK THE HEADLAMP GROUND CIRCUIT FOR AN OPEN
Measure the voltage between the LH headlamp C1021-1, circuit Yes
CBB14 (VT/OG), harness side and the LH headlamp C1021-2, circuit REPAIR or INSTALL
GD123 (BK/GY), harness side; or between the RH headlamp C1041- a new headlamp
1, circuit CBB15 (BN/BU), harness side and the RH headlamp assembly. REFER to
C1041-2, circuit GD188 (BK/YE), harness side. Headlamp Assembly
in this section. TEST
the system for
normal operation.
No
REPAIR the circuit
GD123 (BK/GY) (LH
headlamp) or circuit
GD188 (BK/YE) (RH
headlamp) for an
open. TEST the
system for normal
operation.

A4 CHECK FOR VOLTAGE TO THE LOW BEAM FUSE
Disconnect: BJB Fuse 14 (10A) (LH low beam) or Fuse 15 (10A) (RH Yes
low beam) . REPAIR circuit
Measure the voltage between the BJB fuse 14 (10A) (LH low beam), CBB14 (VT/OG) (LH
circuit CLF09 (BU/GY), input side and ground; or between the BJB headlamp) or circuit
fuse 15 (10A) (RH low beam), circuit CLF09 (BU/GY), input side and CBB15 (BN/BU) (RH
ground. headlamp) for an
open. TEST the
system for normal
operation.
No
REPAIR circuit
CLF09 (BU/GY) for
an open. TEST the
system for normal
operation.

A5 CHECK THE LOW BEAM RELAY
Ignition OFF. REMOVE the known
Disconnect: Low Beam Relay. good relay. INSTALL
Substitute a known good relay. a new low beam
Ignition ON. relay. TEST the
Place the headlamp switch in the HEADLAMPS ON position. system for normal
Do the headlamps illuminate? operation.
No
REMOVE the known
good relay. GO to
A6 .
A6 CHECK FOR VOLTAGE TO THE LOW BEAM RELAY
Ignition OFF. Yes
Measure the voltage between the low beam relay pin 5, circuit GO to A7 .
SBB31 (WH/RD), BJB face side and ground.
No
REPAIR circuit
SBB31 (WH/RD) for
an open. TEST the
system for normal
operation.

A7 BYPASS THE LOW BEAM RELAY
Connect a fused jumper wire between the low beam relay pin 5, Yes
circuit SBB31 (WH/RD), BJB face side and the low beam relay pin 3, REMOVE the jumper
circuit CLF09 (BU/GY), BJB face side. wire. GO to A8 .
No
REMOVE the jumper
CLF09 (BU/GY) for
an open. TEST the
system for normal
operation.
Do the headlamps illuminate?

A8 CHECK FOR VOLTAGE TO THE LOW BEAM RELAY COIL
Measure the voltage between the low beam relay pin 1, circuit Yes
SBB23 (WH/RD), BJB face side and ground. GO to A9 .
No
REPAIR circuit
SBB23 (WH/RD) for
an open. CLEAR the
DTCs. TEST the
system for normal
operation.

A9 CHECK THE LOW BEAM RELAY COIL GROUND CONTROLLED
Ignition OFF. Yes
Disconnect: BCM C2280D. REPAIR circuit
Ignition ON. CLF04 (BN/BU) for a
Measure the voltage between the BCM C2280D-5, circuit CLF04 short to voltage.
(BN/BU), harness side and ground. CYCLE the ignition
ON then OFF.
CLEAR the DTCs.
TEST the system for
normal operation.
No
GO to A10 .

A10 CHECK THE LOW BEAM RELAY COIL GROUND CONTROLLED
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Connect: Low Beam Relay. GO to A11 .
Ignition ON.
Measure the voltage between the BCM C2280D-5, circuit CLF04 No
(BN/BU), harness side and ground. REPAIR circuit
CLF04 (BN/BU) for
an open. CLEAR the
DTCs. TEST the
system for normal
operation.

A11 CHECK THE IGNITION RUN INPUT CIRCUIT FOR AN OPEN
Measure the voltage between the BCM C2280B-4, circuit CBP21
(BU/GY), harness side and ground. No
REPAIR circuit
CBP21 (BU/GY) for
an open. CLEAR the
DTCs. TEST the
system for normal
operation.

The system is
this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test B: One or Both High Beams are Inoperative

Normal Operation
Voltage is provided at all times to the switch and coil sides of the high beam relay. The Body Control
Module (BCM) sends a voltage signal to the multifunction switch to monitor for a high beam request. The
multifunction switch routes the voltage signal to ground when placed in the HIGH BEAM position. When
the headlamps are on and the BCM detects a request for the high beams, the BCM provides ground for
the high beam relay coil. When the high beam relay energizes, voltage is routed through Battery
Junction Box (BJB) fuses 12 (10A) (LH low beam) and 13 (10A) (RH low beam) to the headlamps.
DTC B109A:12 (High Beam Relay: Circuit Short To Battery) — a continuous and on-demand DTC
that sets when the BCM detects a short to voltage from the high beam relay coil ground controlled
circuit.
DTC B109A:14 (High Beam Relay: Circuit Short To Ground Or Open) — a continuous and on-
demand DTC that sets when the BCM detects an open from the high beam relay coil ground
controlled circuit.
Fuse
High beam relay
Headlamp assembly
BJB
BCM
PINPOINT TEST B: ONE OR BOTH HIGH BEAMS ARE INOPERATIVE

B1 CHECK THE LOW BEAM OPERATION
Ignition ON. Yes
Place the headlamp switch in the HEADLAMPS ON position. If an individual high beam
Do both low beams illuminate? is inoperative, VERIFY the
BJB fuse 12 (10A) (LH
high beam) or fuse 13
(10A) (RH high beam) is
OK. If OK, GO to B2 . If
If both high beams are
inoperative, GO to B4 .
No
B2 CHECK FOR VOLTAGE TO THE HEADLAMP
Ignition OFF. REPAIR or INSTALL a
Disconnect: Inoperative Headlamp. new headlamp assembly.
Ignition ON. REFER to Headlamp
Place the headlamp switch in the HEADLAMPS ON position Assembly in this section.
and the multifunction switch in the HIGH BEAM position. TEST the system for
Measure the voltage between the LH headlamp C1021-3, normal operation.
circuit CBB12 (GN/WH), harness side and ground; or between
the RH headlamp C1041-3, circuit CBB13 (GY/BN), harness No
side and ground. GO to B3 .

B3 CHECK FOR VOLTAGE TO THE HIGH BEAM FUSE
Ignition OFF. Yes
Disconnect: BJB Fuse 12 (10A) (LH high beam) or Fuse 13 REPAIR circuit CBB12
(10A) (RH high beam). (GN/WH) (LH headlamp)
Measure the voltage between the BJB fuse 12 (10A) (LH high or circuit CBB13 (GY/BN)
beam), circuit CLF08 (YE/VT), input side and ground; or (RH headlamp) for an
between the BJB fuse 13 (10A) (RH high beam), circuit CLF08 open. TEST the system for
(YE/VT), input side and ground. normal operation.
No
REPAIR circuit CLF08
(YE/VT) for an open. TEST
operation.

B4 CHECK THE BCM MULTIFUNCTION SWITCH PID
DataLogger. GO to B5 .
Monitor the BCM multifunction switch input PID
(HIGH_BEAM_SW) while placing the multifunction switch in No
the HIGH BEAM position. GO to B10 .
Does the PID indicate a request for high beams?
B5 CHECK THE HIGH BEAM RELAY
Ignition OFF. REMOVE the known good
Disconnect: High Beam Relay. relay. INSTALL a new high
Substitute a known good relay. beam relay. TEST the
Place the headlamp switch in the HEADLAMPS ON position operation.
and the multifunction switch in the HIGH BEAM position.
Do the high beams illuminate? No
REMOVE the known good
relay. GO to B6 .
B6 CHECK FOR VOLTAGE TO THE HIGH BEAM RELAY
Ignition OFF. Yes
Measure the voltage between the high beam relay pin 1, BJB GO to B7 .
face side and ground; and between the high beam relay pin 5,
BJB face side and ground. No
INSTALL a new BJB .
CLEAR the DTCs. TEST
operation.

B7 BYPASS THE HIGH BEAM RELAY
Connect a fused jumper wire between the high beam relay pin Yes
5, BJB face side and the high beam relay pin 3, circuit CLF08 REMOVE the jumper wire.
(YE/VT), BJB face side. GO to B8 .
No
(YE/VT) for an open. TEST
operation.
Do the high beams illuminate?

B8 CHECK THE HIGH BEAM RELAY COIL GROUND
CONTROLLED CIRCUIT FOR A SHORT TO VOLTAGE
Disconnect: BCM C2280D . Yes
Ignition ON. REPAIR circuit CLF02
Measure the voltage between the BCM C2280D-11, circuit (GY/BN) for a short to
CLF02 (GY/BN), harness side and ground. voltage. CYCLE the
ignition ON then OFF.
operation.
No
GO to B9 .
B9 CHECK THE HIGH BEAM RELAY COIL GROUND
CONTROLLED CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Connect: High Beam Relay. GO to B13 .
Ignition ON.
Measure the voltage between the BCM C2280D-11, circuit No
CLF02 (GY/BN), harness side and ground. REPAIR circuit CLF02
operation.

B10 BYPASS THE MULTIFUNCTION SWITCH
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. REMOVE the jumper wire.
Ignition ON. INSTALL a new
Connect a fused jumper wire between the multifunction switch multifunction switch.
C202A-10, circuit CLF17 (WH/OG), harness side and the REFER to Section 211-
multifunction switch C202A-9, circuit GD115 (BK/GY), harness 05 . TEST the system for
side. normal operation.
No
GO to B11 .
Enter the following diagnostic mode on the scan tool: BCM
DataLogger.
(HIGH_BEAM_SW).
B11 BYPASS THE MULTIFUNCTION SWITCH GROUND CIRCUIT
Connect a fused jumper wire between the multifunction switch Yes
C202D-10, circuit CLF17 (WH/OG), harness side and ground. REMOVE the jumper wire.
TEST the system for
normal operation.
No
GO to B12 .

DataLogger .
(HIGH_BEAM_SW).
B12 CHECK THE HIGH BEAM REQUEST INPUT CIRCUIT FOR
AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280F . GO to B13 .
Measure the resistance between the multifunction switch
C202A-10, circuit CLF17 (WH/OG), harness side and the BCM No
C2280F-10, circuit CLF17 (WH/OG), harness side. REPAIR circuit CLF17
(WH/OG) for an open.
TEST the system for
normal operation.

correctly. No
corroded connector.
Pinpoint Test C: The Low Beams Are Always On
Normal Operation
The Body Control Module (BCM) sends voltage signals to the headlamp switch through the headlamp
switch input circuits (off, parking lamps, headlamps). At any given time, the headlamp switch routes one
of the input circuits to ground, indicating the headlamp switch position to the BCM . When the BCM
detects the headlamp switch in the HEADLAMPS ON position, the BCM provides ground for the low
beam relay coil. When the low beam relay energizes, voltage is routed through Battery Junction Box
(BJB) fuses 14 (10A) (LH low beam) and 15 (10A) (RH low beam) to the headlamps.
If the BCM detects multiple or no active headlamp switch inputs, the BCM defaults the exterior lamps on.
Vehicles equipped with Daytime Running Lamps (DRL) utilize a separate relay in conjunction with the
existing headlamp circuitry to illuminate the low beams at a reduced intensity when the ignition is in
RUN.
DTC B10A6:92 (Main Light Switch: Performance Or Incorrect Operation) — a continuous and on-
demand DTC that sets when the BCM detects a no inputs from the headlamp switch are active
(circuits open) or more than one headlamp switch input circuits are active (short to ground).
DTC B10A8:14 (Low Beam Relay: Circuit Short To Ground Or Open) — a continuous and on-
demand DTC that sets when the BCM detects a short to ground from the low beam relay coil
ground controlled circuit.

Low beam relay
DRL system concern
Headlamp switch
BCM
PINPOINT TEST C: THE LOW BEAMS ARE ALWAYS ON
Result / Action to
Test Step
Take
C1 CHECK THE BCM HEADLAMP SWITCH PIDs
NOTE: Make sure the headlamp switch is aligned in the correct Yes
position when monitoring the PIDs. GO to C7 .
NOTE: Only one PID should indicate ON at each headlamp switch No
position. GO to C2 .
Ignition ON.
DataLogger.
While moving the headlamp switch through all positions (OFF,
PARKING LAMPS and HEADLAMPS), monitor the BCM headlamp
switch input PIDs (LIGHTNG_MODE, PARK_LMP_SW,
LOW_BEAM_SW).
Do the headlamp switch positions agree with the PIDs (with
only one PID indicating ON in each position?
C2 CHECK THE HEADLAMP SWITCH
Ignition OFF. Yes
Disconnect: Headlamp Switch C205. GO to C3 .
Carry out the headlamp switch component test.
No
headlamp switch.
REFER to Headlamp
Does the headlamp switch pass the component test? Switch in this section.
CLEAR the DTCs.
TEST the system for
normal operation.
C3 DETERMINE IF A HEADLAMP SWITCH INPUT IS SHORT TO
GROUND
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: BCM GO to C4 .
DataLogger.
Monitor the BCM headlamp switch input PIDs (LIGHTNG_MODE, No
PARK_LMP_SW, LOW_BEAM_SW). GO to C5 .
Do any of the headlamp switch PIDs indicate ON?
C4 CHECK THE HEADLAMP SWITCH INPUT CIRCUITS FOR A
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to C12 .
Measure the resistance between the headlamp switch, harness
side and ground as follows: No
Headlamp Switch Connector-Pin Circuit question for a short to
ground. CLEAR the
C205-6 CLF23 (WH/VT) DTCs. TEST the
system for normal
C205-2 CLF24 (YE/BU)
operation.
C205-7 CLF18 (BU/WH)

C5 DETERMINE IF A HEADLAMP SWITCH INPUT IS OPEN
DataLogger. REPAIR circuit GD115
Monitor the BCM headlamp switch input PIDs while connecting a (BK/GY) for an open.
fused jumper wire between the headlamp switch pins and ground CLEAR the DTCs.
as follows: TEST the system for
normal operation.
Headlamp Switch
PID to Monitor Connector-Pin Circuit No
GO to C6 .
LIGHTNG_MODE C205-6 CLF23
(WH/VT)
PARK_LMP_SW C205-2 CLF24
(YE/BU)
LOW_BEAM_SW C205-7 CLF18
(BU/WH)
Do the PIDs indicate ON with each corresponding

connection?
C6 CHECK THE HEADLAMP SWITCH INPUT CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to C12 .
Measure the resistance between the headlamp switch, harness
side and the BCM , harness side as follows: No
Headlamp Switch BCM Connector- question for an open.
Connector-Pin Pin Circuit CLEAR the DTCs.
TEST the system for
C205-6 C2280E-3 CLF23 normal operation.
(WH/VT)
C205-2 C2280E-9 CLF24
(YE/BU)
C205-7 C2280E-13 CLF18
(BU/WH)
C7 CHECK THE LOW BEAM RELAY OUTPUT
Ignition OFF. Yes
Disconnect: Low Beam Relay. GO to C8 .
Ignition ON.
Do the low beams continue to illuminate? No
If equipped with DRL ,
GO to C9 . If not
equipped with DRL ,
GO to C10 .
C8 ISOLATE THE SHORT TO VOLTAGE
Disconnect: BJB Fuses 14 (10A) and 15 (10A). Yes
Does either low beam continue to illuminate? REPAIR circuit CBB14
(VT/OG) (LH
CBB15 (BN/BU) (RH
headlamp) for a short
to voltage as
necessary. TEST the
system for normal
operation.
No
(BU/GY) for a short to
voltage. TEST the
system for normal
operation.
C9 CHECK THE DRL SYSTEM
Ignition OFF. Yes
Measure the voltage between the low beam relay pin 4, circuit GO to Pinpoint Test
CLF13 (YE/BU), BJB face side and ground. G.
No
GO to C10 .
C10 CHECK THE LOW BEAM RELAY
Ignition OFF. Yes
Substitute a known good relay. REMOVE the known
Ignition ON. good relay. GO to
Do the low beams continue to illuminate? C11 .
No
REMOVE the known
good relay. INSTALL a
new low beam relay.
TEST the system for
normal operation.
C11 CHECK THE LOW BEAM RELAY COIL GROUND CONTROLLED
Ignition OFF. Yes
Disconnect: BCM C2280D. GO to C12 .
Measure the resistance between the low beam relay pin 2, circuit
CLF04 (BN/BU), BJB face side and ground. No
(BN/BU), for a short to
ground. CLEAR the
DTCs. TEST the
system for normal
operation.

damaged pins 419-10 . TEST the
Connect all the BCM connectors and make sure they seat operation.
correctly.
may have been
corroded connector.
Pinpoint Test D: The High Beams Are Always On
Normal Operation
Voltage is provided at all times to the switch and coil sides of the high beam relay. The Body Control
Module (BCM) sends two voltage signals to the multifunction switch. One is to monitor for a high beam
request and the other for a flash-to-pass request. The multifunction switch routes the corresponding
voltage signal to ground when placed in the HIGH BEAM or FLASH-TO-PASS position. When the
headlamps are on and the BCM detects a request for the high beams or flash-to-pass feature, the BCM
provides ground for the high beam relay coil. When the high beam relay energizes, voltage is routed
through Battery Junction Box (BJB) fuses 12 (10A) (LH high beam) and 13 (10A) (RH high beam) to the
headlamps.
DTC B1007:92 (High-Beam Headlamp Switch: Performance Or Incorrect Operation) — an on-

demand DTC that sets when the BCM detects a short to ground from the high beam or flash-to-
pass request input circuits.
DTC B109A:14 (High Beam Relay: Circuit Short To Ground Or Open) — a continuous and on-
demand DTC that sets when the BCM detects a short to ground from the high beam relay coil

High beam relay
BCM
PINPOINT TEST D: THE HIGH BEAM(S) ARE ALWAYS ON
Result / Action to
Test Step
Take
D1 CHECK THE MULTIFUNCTION SWITCH INPUT
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: BCM GO to D2 .
DataLogger.
Monitor the BCM multifunction switch high beam and flash-to-pass No
PIDs (HIGH_BEAM_SW, FLASH-to-PASS). GO to D4 .
Does either PID indicate a high beam or flash-to-pass
request?
D2 CHECK THE MULTIFUNCTION SWITCH
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. GO to D3 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: BCM No
DataLogger. INSTALL a new
Monitor the BCM multifunction switch high beam and flash-to-pass multifunction switch.
PIDs (HIGH_BEAM_SW, FLASH-to-PASS). REFER to Section 211-
Does either PID indicate a high beam or flash-to-pass 05 . TEST the system
request? for normal operation.
D3 CHECK THE HIGH BEAM AND FLASH-TO-PASS INPUT
Ignition OFF. Yes
Disconnect: BCM C2280E and C2280F . GO to D8 .
Measure the resistance between the multifunction switch C202A-
5, circuit CLF27 (GN/BN), harness side and ground; and between No
the multifunction switch C202A-10, circuit CLF17 (WH/OG), REPAIR circuit CLF27
harness side and ground. (GN/BN) (flash-to-pass)
or circuit CLF17
(WH/OG) (high beam)
for a short to ground.
TEST the system for
normal operation.

D4 CHECK THE HIGH BEAM RELAY OUTPUT
Ignition OFF. Yes
Disconnect: High Beam Relay. GO to D5 .
Ignition ON.
Do the high beams continue to illuminate? No
GO to D6 .
D5 ISOLATE THE SHORT TO VOLTAGE
Disconnect: BJB Fuses 12 (10A) and 13 (10A). Yes
Does either high beam continue to illuminate? REPAIR circuit CBB12
(GN/WH) (LH
CBB13 (GN/BN) (RH
headlamp) for a short
to voltage as
necessary. TEST the
system for normal
operation.
No
(YE/VT) for a short to
voltage. TEST the
system for normal
operation.
D6 CHECK THE HIGH BEAM RELAY
Ignition OFF. Yes
Substitute a known good relay. REMOVE the known
Ignition ON. good relay. GO to D7 .
Do the high beams continue to illuminate?
No
REMOVE the known
good relay. INSTALL a
new high beam relay.
TEST the system for
normal operation.
D7 CHECK THE HIGH BEAM RELAY COIL GROUND CONTROLLED
Ignition OFF. Yes
Disconnect: BCM C2280D. GO to D8 .
Measure the resistance between the high beam relay pin 2, circuit
CLF02 (GY/BN), BJB face side and ground. No
(BN/BU), for a short to
ground. CLEAR the
DTCs. TEST the
system for normal
operation.

correctly. No
Operate the system and verify the concern is still present. The system is
connector.
Pinpoint Test E: The Flash-To-Pass Feature Is Inoperative
Normal Operation
The Body Control Module (BCM) sends a voltage signal to the multifunction switch to monitor for a flash-
to-pass feature request. The multifunction switch routes the voltage signal to ground when placed in the
FLASH-TO-PASS position. When the headlamps are on and the BCM detects a request for the flash-to-
pass feature, the BCM activates the high beams.

BCM
PINPOINT TEST E: THE FLASH-TO-PASS FEATURE IS INOPERATIVE
Result / Action to
Test Step
Take
E1 VERIFY THE HIGH BEAM HEADLAMP OPERATION
Ignition ON. Yes
Place the headlamp switch in the HEADLAMPS ON position. GO to E2 .
Place the multifunction switch in the HIGH BEAM position while
observing the headlamps. No
Do the high beams illuminate? GO to Pinpoint Test B .
E2 BYPASS THE MULTIFUNCTION SWITCH
Ignition OFF. REMOVE the jumper
Disconnect: Multifunction Switch C202A. wire. INSTALL a new
Ignition ON. multifunction switch.
Connect a fused jumper wire between the multifunction switch REFER to Section 211-
C202A-5, circuit CLF27 (GN/BN), harness side and the 05 . TEST the system
multifunction switch C202A-9, circuit GD115 (BK/GY), harness for normal operation.
side.
No
REMOVE the jumper
wire. GO to E3 .
Do the high beams illuminate?

E3 CHECK THE FLASH-TO-PASS INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to E4 .
Measure the resistance between the multifunction switch C202A-5,
circuit CLF27 (GN/BN), harness side and the BCM C2280E-22, No
circuit CLF27 (GN/BN), harness side. REPAIR circuit CLF27
(GN/BN) for an open.
TEST the system for
normal operation.
correctly. No
connector.
Daytime Running Lamps (DRL)
Special Tool(s)

tool
Flex Probe Kit

The Body Control Module (BCM) controls the Daytime Running Lamps (DRL) by energizing the DRL
relay when the ignition is in RUN and the headlamp switch is not in the HEADLAMPS ON position.
When the DRL relay is energized, voltage is routed through a resistor wire to the low beam relay. The
voltage passes through the low beam relay to the existing circuitry for the low beams. The voltage
passes through a resistor wire to illuminate the low beams at reduced intensity.
The DRL is not a programmable parameter for this vehicle.
The FET protected circuit for the DRL system is the DRL relay coil ground circuit.

Electrical
Battery Junction Box (BJB) fuse 25 (15A) ( DRL relay)
Central Junction Box (CJB) fuse 21 (10A) (ignition input)
Daytime Running Lamps (DRL) relay

tool.


418-00 .
9. If the DTCs retrieved are related to the concern, refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual or the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
Symptom Chart
Symptom Chart
The Daytime Running Lamps Fuse GO to Pinpoint
(DRL) are inoperative Wiring, terminals or Test F .
connectors
DRL relay
Body Control
Module (BCM)
The Daytime Running Lamps Wiring, terminals or GO to Pinpoint
(DRL) are on with the ignition off connectors Test G .
DRL relay
Body Control
Module (BCM)
Pinpoint Tests
Pinpoint Test F: The Daytime Running Lamps (DRL) Are Inoperative
Normal Operation
Voltage at all times to the switch and coil sides of the Daytime Running Lamps (DRL) relay. When the
ignition is in RUN, voltage the is supplied Body Control Module (BCM) from an ignition switch input
circuit.
When the headlamps are not on and the BCM detects the ignition in RUN, the BCM provides ground for
the DRL relay coil, energizing the relay. The DRL relay provides voltage to the low beam relay through a
resistor wire. The voltage passes through the low beam relay and on to the existing low beam circuitry,
illuminating the headlamps at a reduced intensity.
DTC B1092:12 (Daytime Running Light Relay: Circuit Short To Battery) — a continuous and on-
demand DTC that sets when the BCM detects a short to voltage from the DRL relay coil ground
controlled circuit.
DTC B1092:14 (Daytime Running Light Relay: Circuit Short To Ground Or Open) — a continuous
and on-demand DTC that sets when the BCM detects an open from the DRL relay coil ground
controlled circuit.
Fuse
DRL relay
BCM
PINPOINT TEST F: THE DRL ARE INOPERATIVE

F1 CHECK THE LOW BEAM OPERATION
Ignition ON. Yes
Place the headlamp switch in the HEADLAMPS ON position. VERIFY the BJB fuse 25
Do both low beams illuminate? (15A) is OK. If OK, GO to
F2 . If not OK, REFER to
the Wiring Diagrams
circuit short.
No
F2 CHECK THE DRL RELAY
Ignition OFF. REMOVE the known good
Disconnect: DRL Relay. relay. INSTALL a new
Substitute a known good relay. DRL relay. TEST the
Do the headlamps illuminate? operation.
No
relay. GO to F3 .
F3 CHECK FOR VOLTAGE TO THE DRL RELAY
Ignition OFF. Yes
Measure the voltage between the DRL relay pin 1, circuit GO to F4 .
SBB25 (RD), BJB face side and ground; and between the DRL
relay pin 3, circuit SBB25 (RD), BJB face side and ground. No
(RD) for an open. TEST
operation.

F4 BYPASS THE DRL RELAY
Connect a fused jumper wire between the DRL relay pin 3, Yes
circuit SBB25 (RD), BJB face side and the DRL relay pin 5, REMOVE the jumper wire.
circuit CLF13 (YE/BU), BJB face side. GO to F6 .
No
connected. GO to F5 .
Do the headlamps illuminate?

F5 CHECK THE LOW BEAM RELAY
Disconnect: Low Beam Relay. Yes
Substitute a known good relay. REMOVE the jumper wire
Do the headlamps illuminate? and the known good relay.
INSTALL a new low beam
relay. TEST the system
No
REMOVE the jumper wire
and the known good relay.
(YE/BU) for an open.
TEST the system for
normal operation.
F6 CHECK THE DRL RELAY COIL GROUND CONTROLLED
Disconnect: BCM C2280D. Yes
Ignition ON. REPAIR circuit CLF10
Measure the voltage between the BCM C2280D-8, circuit (GN/OG) for a short to
CLF10 (GN/OG), harness side and ground. voltage. CYCLE the
ignition ON then OFF.
operation.
No
GO to F7 .

F7 CHECK THE DRL RELAY COIL GROUND CONTROLLED
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Connect: DRL Relay. GO to F8 .
Ignition ON.
Measure the voltage between the BCM C2280D-8, circuit No
CLF10 (GN/OG), harness side and ground. REPAIR circuit CLF10
(GN/OG) for an open.
operation.

F8 CHECK THE IGNITION ON INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280B. GO to F9 .
Ignition ON.
Measure the voltage between the BCM C2280B-4, circuit No
CBP21 (BU/GY), harness side and ground. VERIFY the CJB fuse 21
(10A) is OK. If OK,
(BU/GY) for an open.
TEST the system for
normal operation. If not
Diagrams manual to

F9 CHECK FOR CORRECT BCM OPERATION
correctly. No
corroded connector.
Pinpoint Test G: The Daytime Running Lamps (DRL) Are On With The Ignition Off
Normal Operation
Voltage at all times to the switch and coil sides of the Daytime Running Lamps (DRL) relay. Voltage is
supplied from an ignition switch input circuit to the Body Control Module (BCM) when the ignition is in
RUN.
When the headlamps are not on and the BCM detects the ignition in RUN, the BCM provides ground for
the DRL relay coil, energizing the relay. The DRL relay provides voltage to the low beam relay through a
resistor wire. The voltage passes through the low beam relay and on to the existing low beam circuitry,
illuminating the headlamps at a reduced intensity.
DTC B1092:14 (Daytime Running Light Relay: Circuit Short To Ground Or Open) — a continuous
and on-demand DTC that sets when the BCM detects a short to ground from the DRL relay coil

DRL relay
BCM
PINPOINT TEST G: THE DRL ARE ON WITH THE IGNITION OFF

G1 CHECK THE DRL RELAY OUTPUT
Ignition OFF. Yes
Disconnect: DRL Relay. GO to G2 .
Do the headlamps continue to illuminate?
No
GO to G3 .
G2 CHECK THE DRL RELAY OUTPUT CIRCUIT FOR A SHORT
TO VOLTAGE
Disconnect: Low Beam Relay. Yes
Measure the voltage between the DRL relay pin 5, circuit REPAIR circuit CLF13
CLF13 (YE/BU), BJB face side and ground. (YE/BU) for a short to
voltage. TEST the system
No
GO to Pinpoint Test C .

G3 CHECK THE DRL RELAY
Substitute a known good relay. Yes
Do the headlamps continue to illuminate? REMOVE the known good
relay. GO to G4 .
No
relay. INSTALL a new DRL
relay. TEST the system for
normal operation.
G4 CHECK THE DRL RELAY COIL GROUND CONTROLLED
Measure the resistance between the BCM C2280D-8, circuit GO to G5 .
CLF10 (GN/OG), harness side and ground.
No
(GN/OG) for a short to
TEST the system for
normal operation.
G5 CHECK FOR CORRECT BCM OPERATION
correctly. No
corroded connector.
Stoplamps
Special Tool(s)

tool
Flex Probe Kit

4-Door Vehicles
The stoplamp switch is provided voltage at all times. When the brake pedal is applied, voltage is routed
to the high mounted stoplamp and to the LH and RH turn relays. The voltage passes through the turn
relays, on to the LH and RH stoplamps. The stoplamps are combination rear stop/turn lamps.
5-Door Vehicles
The stoplamp switch is provided voltage at all times. When the brake pedal is applied, voltage is routed
to all of the stoplamps.

Stoplamp switch Central Junction Box (CJB) fuse 18 (10A) (stoplamp switch)
Bulb
Bulb socket

tool.


418-00 .
10 .
Symptom Chart
Symptom Chart
All the stoplamps are Fuse VERIFY the bulbs are OK.
inoperative Wiring, terminals If OK, GO to Pinpoint Test
or connectors H.
Stoplamp switch
One or more Wiring, terminals VERIFY the bulbs are OK.
stoplamps are or connectors If OK, GO to Pinpoint Test
inoperative Bulb socket I.
High mounted
stoplamp
Turn relay
Body Control
Module (BCM)
The stoplamps are on Wiring, terminals GO to Pinpoint Test J .
continuously or connectors
Stoplamp switch
PCM
Pinpoint Tests
Pinpoint Test H: All The Stoplamps Are Inoperative
Refer to Wiring Diagrams Cell 90 , Turn Signal/Stop/Hazard Lamps for schematic and connector
information.
Normal Operation
The stoplamp switch is provided voltage at all times from the Central Junction Box (CJB) fuse 18 (10A).
The stoplamps are combination rear stop/turn lamps.
On 4-door vehicles, when the brake pedal is applied, voltage is routed to the high mounted stoplamp
and to the LH and RH turn relays. The voltage passes through the turn relays, to the LH and RH
stoplamps.
On 5-door vehicles, when the brake pedal is applied, voltage is routed to all of the stoplamps.
Fuse
Stoplamp switch
PINPOINT TEST H: ALL THE STOPLAMPS ARE INOPERATIVE
Result / Action to
Test Step
Take
H1 CHECK FOR VOLTAGE TO THE STOPLAMP SWITCH
Ignition OFF. Yes
Disconnect: Stoplamp Switch C2314. GO to H2 .
Measure the voltage between the stoplamp switch C2314-1, circuit
SBP18 (YE/RD), harness side and ground. No
VERIFY the CJB fuse
18 (10A) is OK. If OK,
GO to H2 . If not OK,
REFER to the Wiring
Diagrams manual to
short.
H2 BYPASS THE STOPLAMP SWITCH
Connect a fused jumper wire between the stoplamp switch C2314- Yes
1, circuit SBP18 (YE/RD), harness side and the stoplamp switch REMOVE the jumper
C2314-2, circuit CCA26 (BU/GY), harness side. wire. INSTALL a new
stoplamp switch.
REFER to Stoplamp
TEST the system for
normal operation.
No
REMOVE the jumper
CCA26 (BU/GY) for an
Are the stoplamps illuminated?
Pinpoint Test I: One Or More Stoplamps Are Inoperative
information.
Normal Operation — 4-Door
When the brake pedal is applied, voltage is routed to the high mounted stoplamp and to the LH and RH
turn relays. The voltage passes through the turn relays, on to the LH and RH stoplamps. When a turn
relay is energized (during turn lamp operation), voltage from the stoplamp switch is interrupted. The
stoplamps are combination rear stop/turn lamps.
5-Door
On 5-door vehicles, when the brake pedal is applied, voltage is routed to all of the stoplamps.
DTC B132B:14 (Left Stop/Turn Lamp: Circuit Short To Ground Or Open) — a continuous and on-
demand DTC that sets when the BCM detects a short to ground from the LH rear turn lamp relay
coil ground controlled circuit.
DTC B132C:14 (Right Stop/Turn Lamp: Circuit Short To Ground Or Open) — a continuous and
on-demand DTC that sets when the BCM detects a short to ground from the RH rear turn lamp
relay coil ground controlled circuit.

Bulb socket
High mounted stoplamp
Turn relay
BCM
PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE
Result / Action to
Test Step
Take
I1 DETERMINE THE INOPERATIVE STOPLAMP
Ignition OFF. Yes
Apply the brake pedal and observe the stoplamps. GO to Pinpoint
Are all the stoplamps inoperative? Test H .
No
For an inoperative
high mounted
stoplamp, GO to
I2 .
For an inoperative
rear lamp on a 5-
door vehicle, GO to
I4 .
For an inoperative
rear lamp on a 4-
door vehicle, GO to
I6 .
I2 CHECK FOR VOLTAGE TO THE HIGH MOUNTED STOPLAMP
Disconnect: High Mounted Stoplamp C904 or C9040. Yes
For 4-door vehicles, while applying the brake pedal, measure the GO to I3 .
voltage between the high mounted stoplamp C904-1, circuit CCA26
(BU/GY), harness side and ground. No
REPAIR circuit
CCA26 (BU/GY) for
an open. TEST the
system for normal
operation.
For 5-door vehicles, while applying the brake pedal, measure the
(BU/GY), harness side and ground.

I3 CHECK THE HIGH MOUNTED STOPLAMP GROUND CIRCUIT FOR
AN OPEN
For 4-door vehicles, while applying the brake pedal, measure the Yes
voltage between the high mounted stoplamp C904-1, circuit CCA26 INSTALL a new
(BU/GY), harness side and the high mounted stoplamp C904-2, circuit high mounted
GD143 (BK/VT), harness side. stoplamp. REFER
to High Mounted
Stoplamp in this
section. TEST the
system for normal
operation.
No
REPAIR circuit
GD143 (BK/VT) for
an open. TEST the
system for normal
operation.
For 5-door vehicles, while applying the brake pedal, measure the
(BU/GY), harness side and the high mounted stoplamp C9040-2,
circuit GD143 (BK/VT), harness side.

I4 CHECK FOR VOLTAGE TO THE REAR LAMP
Disconnect: Inoperative Rear Lamp. Yes
While applying the brake pedal, measure the voltage between the LH GO to I5 .
rear lamp C414-3, circuit CCA26 (BU/GY), harness side and ground;
or between the RH rear lamp C417-3, circuit CCA26 (BU/GY), harness No
side and ground. REPAIR circuit
CCA26 (BU/GY) for
an open. TEST the
system for normal
operation.

I5 CHECK THE REAR LAMP GROUND CIRCUIT FOR AN OPEN
While applying the brake pedal, measure the voltage between the LH Yes
rear lamp C414-3, circuit CCA26 (BU/GY), harness side and the LH REPAIR or
rear lamp C414-1, circuit GD143 (BK/VT), harness side; or between INSTALL a new
the RH rear lamp C417-3, circuit CCA26 (BU/GY), harness side and rear lamp harness.
the RH rear lamp C417-1, circuit GD145 (BK/BU), harness side. TEST the system
for normal
operation.
No
REPAIR circuit
GD143 (BK/VT)
(LH rear lamp) or
circuit GD145
(BK/BU) (RH rear
lamp) for an open.
TEST the system
for normal
operation.

I6 CHECK FOR VOLTAGE TO THE BULB SOCKET
While applying the brake pedal, measure the voltage between the LH GO to I7 .
rear lamp C412-3, circuit CLS55 (GN/BU), harness side and ground;
or between the RH rear lamp C415-3, circuit CLS54 (BU/OG), harness No
side and ground. GO to I8 .
I7 CHECK THE REAR LAMP GROUND CIRCUIT FOR AN OPEN
While applying the brake pedal, measure the voltage between the LH Yes
rear lamp C412-3, circuit CLS55 (GN/BU), harness side and the LH INSTALL a new
rear lamp C412-1, circuit GD143 (BK/VT), harness side; or between bulb socket. TEST
the RH rear lamp C415-3, circuit CLS54 (BU/OG), harness side and the system for
the RH rear lamp C415-1, circuit GD145 (BK/BU), harness side. normal operation.
No
REPAIR circuit
GD143 (BK/VT)
(LH rear lamp) or
circuit GD145
(BK/BU) (RH rear
lamp) for an open.
TEST the system
for normal
operation.

I8 CHECK THE TURN RELAY
Connect: Inoperative Rear Lamp. Yes
Disconnect: Suspect Turn Relay. REMOVE the
Substitute a known good relay. known good relay.
Apply the brake pedal and observe the stoplamps. INSTALL a new
Does the stoplamp in question illuminate? turn relay. TEST
the system for
normal operation.
No
REMOVE the
known good relay.
GO to I9 .
I9 CHECK FOR VOLTAGE TO THE TURN RELAY
For the LH stoplamp, while applying the brake pedal, measure the Yes
voltage between the LH turn relay pin 4, circuit CCA26 (BU/GY), CJB GO to I10 .
face side and ground.
No
REPAIR circuit
CCA26 (BU/GY) for
an open. TEST the
system for normal
operation.
For the RH stoplamp, while applying the brake pedal, measure the
voltage, between the RH turn relay pin 4, circuit CCA26 (BU/GY), CJB
face side and ground.

I10 BYPASS THE TURN RELAY
For the LH stoplamp, connect a fused jumper wire between the LH Yes
turn relay pin 4, circuit CCA26 (BU/GY), CJB face side and the LH turn REMOVE the
relay pin 3, circuit CLS55 (GN/BU), CJB face side. jumper wire. GO to
I11 .
No
REMOVE the
jumper wire.
REPAIR circuit
CLS55 (GN/BU)
(LH rear lamp) or
circuit CLS54
(BU/OG) (RH rear
lamp) for an open.
TEST the system
for normal
operation.
For the RH stoplamp, connect a fused jumper wire between the RH

turn relay pin 4, circuit CCA26 (BU/GY), CJB face side and the LH turn
relay pin 3, circuit CLS54 (BU/OG), CJB face side.
Apply the brake pedal and observe the stoplamps.
Does the stoplamp in question illuminate?
I11 CHECK THE TURN RELAY COIL GROUND CIRCUIT FOR A SHORT
TO GROUND
For the LH stoplamp, measure the resistance between the LH turn GO to I12 .
relay pin 2, circuit CLS51 (WH/GN), harness side and the ground.
No
REPAIR circuit
CLS51 (WH/GN)
(LH stoplamp) or
circuit CLS53
(GY/VT) for a short
to ground. CLEAR
the DTCs. TEST
the system for
normal operation.
For the RH stoplamp, measure the resistance between the RH turn

relay pin 2, circuit CLS53 (GY/VT), harness side and the ground.

I12 CHECK FOR CORRECT BCM OPERATION
pushed-out pins TEST the system
Connect all the BCM connectors and make sure they seat correctly. for normal
No
The system is
operating correctly
at this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test J: The Stoplamps Are On Continuously
Normal Operation
On 4-door vehicles, when the brake pedal is applied, voltage is routed to the PCM, the high mounted
stoplamp and to the LH and RH turn relays. The voltage passes through the turn relays, on to the LH
and RH stoplamps.
On 5-door vehicles, when the brake pedal is applied, voltage is routed to the PCM and all of the
stoplamps.

Stoplamp switch
PCM
PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY

J1 CHECK THE STOPLAMP SWITCH
Disconnect: Stoplamp Switch Yes
C2314. GO to J2 .
Do the stoplamps continue to
illuminate? No
INSTALL a new stoplamp switch. REFER to Stoplamp
Switch in this section. TEST the system for normal
operation.
J2 CHECK THE PCM
Do the stoplamps continue to For 4-door vehicles, GO to J3 .
illuminate?
For 5-door vehicles, REPAIR circuit CCA26 (BU/GY)
for a short to voltage. TEST the system for normal
operation.
No
GO to J4 .
J3 ISOLATE THE SHORT TO
VOLTAGE
Disconnect: LH and RH Turn Yes
Relays. REPAIR circuit CCA26 (BU/GY) for a short to voltage.
Does the high mounted TEST the system for normal operation.
stoplamp continue to
illuminate? No
REPAIR circuit CLS55 (GN/BU) (LH stoplamp) or
circuit CLS54 (BU/OG) for a short to voltage. TEST the
J4 CHECK FOR CORRECT PCM
OPERATION
Disconnect all the PCM Yes
connectors. INSTALL a new PCM. REFER to Section 303-14 .
corrosion
damaged pins No
Connect all the PCM connectors concern may have been caused by a loose or corroded
and make sure they seat correctly. connector.
Turn Signal and Hazard Lamps
Special Tool(s)

tool
Flex Probe Kit

The Body Control Module (BCM) monitors the multifunction switch position by sending voltage signals to
the multifunction switch and the Front Controls Interface Module (FCIM). When the multifunction switch
is in the LH or RH TURN position, or the hazard flasher lamp switch is pressed, that input signal is
routed to ground.
When the BCM receives a request for a turn signal or hazard lamp function, the BCM supplies on/off
voltage to the appropriate turn lamps.
On 4-door vehicles, turn relays interrupt the stoplamp switch output and allow the BCM to control voltage
to the combination stop/turn lamps.
The timed on/off cycle for the turn lamps is determined by the BCM and is set to flash approximately 75
times per minute if both the front and rear turn lamps operate correctly. If an individual turn lamp is
inoperative, the BCM flashes the remaining turn lamp approximately 150 times per minute.
The timed on/off cycle for the hazard lamp function is set to flash all the turn lamps approximately 75
times per minute.
The FET protected circuits for the turn lamp system are the turn relay coil ground circuits and the front
and rear turn lamp voltage supply circuits.

Multifunction switch Bulb
Front Controls Interface Module (FCIM) Bulb socket(s)

tool.


418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the Body Control Module
(BCM).
10 .
Symptom Chart
Symptom Chart
The turn signal function is Wiring, VERIFY the
inoperative terminals or bulbs are OK. If
connectors OK, GO to
Multifunction Pinpoint Test K .
switch
Body Control
Module (BCM)
The turn signal function is always Wiring, GO to Pinpoint
on terminals or Test L .
connectors
Multifunction
switch
BCM
NOTE: NOTE: LED lamps draw low Bulb(s) INSTALL a
current compared to an correct bulbs as
incandescent bulb. The Smart necessary. TEST
Junction Box (SJB) interprets this the system for
as a bulb out and fast flashes (bulb normal operation.
outage mode) the turn lamps.
The turn signal lamps fast flash and

no bulbs are inoperative
One turn signal/hazard lamp is Wiring, VERIFY the bulb
inoperative/always on (4-door) terminals or is OK. If OK, GO
connectors to Pinpoint Test
Bulb socket M.
Turn relay
BCM
One turn signal/hazard lamp is Wiring, VERIFY the bulb
inoperative/always on (5-door) terminals or is OK. If OK, GO
connectors to Pinpoint Test
Bulb socket N.
BCM
The hazard lamp function is Wiring, GO to Pinpoint
inoperative/always on terminals or Test O .
connectors
Front Controls
Interface
Module (FCIM)
BCM
Pinpoint Tests
Pinpoint Test K: The Turn Signal Function Is Inoperative
information.
Normal Operation
The Body Control Module (BCM) sends voltage signals to the multifunction switch to monitor the LH and
RH turn input circuits. The voltage signal is routed to ground when the multifunction switch is placed in
the LH or RH TURN position. When the BCM detects the multifunction switch is in the LH or RH TURN
position, the BCM sends voltage to the appropriate turn lamps.

BCM
PINPOINT TEST K: THE TURN SIGNAL FUNCTION IS INOPERATIVE
Result / Action to
Test Step
Take
K1 CHECK FOR CORRECT HIGH BEAM OPERATION
Place the headlamp switch in the HEADLAMPS ON position. Yes
Place the multifunction switch in the HIGH BEAM position while GO to K2 .
observing the high beam headlamps.
Do the high beams operate correctly? No
REFER to Headlamps
in this section.
K2 BYPASS THE MULTIFUNCTION SWITCH
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. REMOVE the jumper
For an inoperative LH turn signal, connect a fused jumper wire wire. INSTALL a new
between the multifunction switch C202A-4, circuit CLS39 (VT/WH), multifunction switch.
harness side and the multifunction switch C202A-9, circuit GD115 REFER to Section
(BK/GY), harness side. 211-05 . TEST the
system for normal
operation.
No
REMOVE the jumper
wire. GO to K3 .
For an inoperative RH turn signal, connect a fused jumper wire

between the multifunction switch C202A-8, circuit CLS41 (GY/YE),
harness side and the multifunction switch C202A-9, circuit GD115
(BK/GY), harness side.
Ignition ON.
Do the turn signals in question flash on and off?
K3 CHECK THE TURN LAMP REQUEST INPUT CIRCUIT FOR AN
OPEN
For an inoperative LH turn signal, measure the resistance between GO to K4 .
the multifunction switch C202A-4, circuit CLS39 (VT/WH), harness
side and the BCM C2280E-7, circuit CLS39 (VT/WH), harness side. No
REPAIR circuit
CLS39 (VT/WH) (LH
turn) or circuit CLS41
(GY/YE) (RH turn) for
an open. TEST the
system for normal
operation.
For an inoperative RH turn signal, measure the resistance between

the multifunction switch C202A-8, circuit CLS41 (GY/YE), harness
side and the BCM C2280E-8, circuit CLS41 (GY/YE), harness side.

K4 CHECK FOR CORRECT BCM OPERATION
The system is
may have been
corroded connector.
Pinpoint Test L: The Turn Signal Function Is Always On
information.
Normal Operation
The Body Control Module (BCM) sends voltage signals to the multifunction switch to monitor the LH and
RH turn input circuits. The voltage signal is routed to ground when the multifunction switch is placed in
the LH or RH TURN position. When the BCM detects the multifunction switch is in the LH or RH TURN
position, the BCM sends voltage to the appropriate turn lamps.
DTC B1D36:92 (Turn Indicator Switch: Performance Or Incorrect Operation) — a continuous and
on-demand DTC that sets when the BCM detects a short to ground from the LH and/or the RH
turn signal switch input.

BCM
PINPOINT TEST L: THE TURN SIGNAL FUNCTION IS ALWAYS ON
Result / Action to
Test Step
Take
L1 CHECK THE MULTIFUNCTION SWITCH
Ignition OFF. Yes
Disconnect: Multifunction Switch C202A. GO to L2 .
Ignition ON.
Do the turn lamps continue to flash on and off? No
INSTALL a new
REFER to Section
211-05 . TEST the
system for normal
operation.
L2 CHECK THE TURN LAMP REQUEST INPUT CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to L3 .
Measure the resistance between the multifunction switch C202A-4
(LH turn lamps), circuit CLS39 (VT/WH), harness side and ground; No
or between the multifunction switch C202A-8 (RH turn lamps), circuit REPAIR circuit
CLS41 (GY/YE), harness side and ground. CLS39 (VT/WH) (LH
(GY/YE) (RH turn) for
a short to ground.
TEST the system for
normal operation.

L3 CHECK FOR CORRECT BCM OPERATION
The system is
this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test M: One Turn Signal/Hazard Lamp Is Inoperative/Always On (4-Door)
information.
Normal Operation
When the Body Control Module (BCM) detects the multifunction switch is in the LH TURN position, the
BCM provides ground for the LH turn relay coil to interrupt the stoplamp switch output to the LH rear
lamp, and simultaneously provides on/off voltage to the LH front turn lamp on one output circuit, and to
the LH turn relay (switch side) and LH exterior mirror turn lamp (if equipped) on another circuit.
When the Body Control Module (BCM) detects the multifunction switch is in the RH TURN position, the
BCM provides ground for the RH turn relay coil to interrupt the stoplamp switch output to the RH rear
lamp, and simultaneously provides on/off voltage to the RH front turn lamp on one output circuit, and to
the RH turn relay (switch side) and RH exterior mirror turn lamp (if equipped) on another circuit.
The rear lamps are combination stop/turn lamps and are controlled through the rear stoplamp circuitry.
B132B:12 — Left Stop/Turn A continuous and on-demand DTC that sets when the BCM
Lamp: Circuit Short To Battery detects a short to voltage from the LH turn relay coil ground
controlled circuit.
B132B:14 — Left Stop/Turn A continuous and on-demand DTC that sets when the BCM
Lamp: Circuit Short To Ground detects an open or short to ground from the LH turn relay coil
Or Open ground controlled circuit.
B132C:12 — Right Stop/Turn A continuous and on-demand DTC that sets when the BCM
Lamp: Circuit Short To Battery detects a short to voltage from the RH turn relay coil ground
controlled circuit.
B132C:14 — Right Stop/Turn A continuous and on-demand DTC that sets when the BCM
Lamp: Circuit Short To Ground detects an open or short to ground from the RH turn relay coil
Or Open ground controlled circuit.
B1D06:11 — Left Turn A continuous and on-demand DTC that sets when the BCM
Indicator: Circuit Short To detects a short to ground from the LH front or LH rear turn
Ground lamp voltage supply circuits.
Indicator: Circuit Short To detects an open or short to voltage from the LH front or LH rear
Battery Or Open turn lamp voltage supply circuits.
B1D07:11 — Right Turn A continuous and on-demand DTC that sets when the BCM
Indicator: Circuit Short To detects a short to ground from the RH front or RH rear turn
Indicator: Circuit Short To detects an open or short to voltage from the RH front or RH
Battery Or Open rear turn lamp voltage supply circuits.

Bulb socket
Turn relay
BCM
PINPOINT TEST M: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON (4-DOOR)

M1 CHECK THE STOPLAMPS
Ignition OFF. Yes
Apply and release the brake pedal while observing the GO to M2 .
stoplamps.
Do the stoplamps operate correctly? No
REFER to Stoplamps in
this section.
M2 DETERMINE IF A TURN LAMP IS ALWAYS ON
NOTE: If the turn lamps are flashing, GO to Pinpoint Test L . Yes

GO to M3 .
Ignition ON.
Activate the hazard lamp function and monitor the turn lamps. No
Is any turn lamp on? For a front turn lamp, GO to
M4 . For a rear or exterior
mirror turn lamp, GO to
M9 .
M3 CHECK THE BCM TURN LAMP OUTPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Deactivate the hazard lamp function . Yes
Ignition OFF. For the LH front turn lamp,
Disconnect: BCM C2280A (Front Turn Lamp). REPAIR circuit CLS21
Disconnect: BCM C2280C (Rear or Exterior Mirror Turn (BU/GN) for a short to
Lamp). voltage. CLEAR the DTCs.
Activate the hazard lamp function . normal operation. For the
Does the turn lamp in question continue to illuminate? RH front turn lamp,
REPAIR circuit CLS25
voltage. CLEAR the DTCs.
TEST the system for
normal operation. For the
LH rear or exterior mirror
turn lamp, REPAIR circuit
CLS23 (GY/OG) for a short
to voltage. CLEAR the
DTCs. TEST the system for
RH rear or exterior mirror
CLS27 (GN/OG) for a short
normal operation.
No
GO to M19 .
M4 CHECK FOR VOLTAGE TO THE FRONT TURN LAMP
Ignition OFF. Yes
Disconnect: Inoperative Front Lamp. GO to M5 .
Activate the hazard lamp function .
Measure the voltage between the LH front turn lamp C1023-3, No
circuit CLS21 (BU/GN), harness side and ground; or between GO to M6 .
the RH front turn lamp C1043-3, circuit CLS25 (YE/VT),
Does the voltage alternate between 0 volts and greater

than 10 volts?
M5 CHECK THE FRONT TURN LAMP GROUND CIRCUIT FOR
AN OPEN
Measure the voltage between the LH front turn lamp C1023-3, Yes
circuit CLS21 (BU/GN), harness side and the LH front lamp INSTALL a new bulb
C1023-1, circuit GD188 (BK/YE), harness side; or between the socket. CLEAR the DTCs.
RH front turn lamp C1043-3, circuit CLS25 (YE/VT), harness TEST the system for
side and the RH front lamp C1043-1, circuit GD123 (BK/GY), normal operation.
harness side.
No
(BK/YE) (LH turn) or circuit
GD123 (BK/GY) (RH turn)
normal operation.

than 10 volts?
M6 CHECK THE FRONT TURN LAMP BULB SOCKET FOR A
SHORT TO GROUND
Cycle the ignition on then off. INSTALL a new bulb
Activate the hazard lamp function . socket. CLEAR the DTCs.
Measure the voltage between the LH front turn lamp C1023-3, TEST the system for
circuit CLS21 (BU/GN), harness side and ground; or between normal operation.
GO to M7 .

than 10 volts?
M7 CHECK THE FRONT TURN LAMP VOLTAGE CIRCUIT FOR A
SHORT TO GROUND
Disconnect: BCM C2280A. GO to M8 .
Measure the resistance between the LH front turn lamp
C1023-3, circuit CLS21 (BU/GN), harness side and ground; or No
between the RH front turn lamp C1043-3, circuit CLS25 REPAIR circuit CLS21
(YE/VT), harness side and ground. (BU/GN) (LH turn) or
CLS25 (YE/VT) (RH turn)
CLEAR the DTCs. CYCLE
the ignition. TEST the
system for normal
operation.

M8 CHECK THE FRONT TURN LAMP VOLTAGE CIRCUIT FOR
AN OPEN
Measure the resistance between the LH front turn lamp Yes
C1023-3, circuit CLS21 (BU/GN), harness side and the BCM GO to M19 .
C2280A-5, circuit CLS21 (BU/GN), harness side; or between
the RH front turn lamp C1043-3, circuit CLS25 (YE/VT), No
harness side and the BCM C2280A-6, circuit CLS25 (YE/VT), REPAIR circuit CLS21
harness side. (BU/GN) (LH turn) or
normal operation.

M9 USE THE RECORDED DTCs FROM THE BCM SELF-TEST
Deactivate the hazard lamp function. Yes
Check the recorded results from the BCM on-demand self- If equipped with exterior
test. mirror turn lamps, GO to
Is DTC B1D06:11 or DTC B1D07:11 present? M10 . If not equipped with
exterior mirror turn lamps,
GO to M11 .
No
GO to M12 .
M10 CHECK THE EXTERIOR MIRROR FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: LH Exterior Mirror C521 (DTC B1D06:11). INSTALL a new exterior
Disconnect: RH Exterior Mirror C601 (DTC B1D07:11). mirror. REFER to Section
Cycle the ignition on and then off. 501-09 . TEST the system
Activate the hazard lamp function. for normal operation.
Does the rear lamp flash on and off?
No
GO to M11 .
M11 CHECK THE BCM REAR TURN LAMP OUTPUT CIRCUIT
Disconnect: Corresponding LH or RH Turn Relay. GO to M19 .
Disconnect: BCM C2280C.
Measure the resistance between the BCM C2280C-12 (DTC No
B1D06:11), circuit CLS23 (GY/OG), harness side and ground; REPAIR circuit CLS23
or between the BCM C2280C-13 (DTC B1D07:11), circuit (GY/OG) (LH turn) or circuit
CLS27 (GN/OG), harness side and ground. CLS27 (GN/OG) (RH turn)
system for normal
operation.

M12 CHECK FOR VOLTAGE TO THE TURN RELAY OR
EXTERIOR MIRROR
NOTE: If both the rear turn and exterior mirror turn lamps are Yes
inoperative, follow the diagnostics for the rear turn lamp. For an inoperative exterior
Ignition OFF. M13 . For an inoperative
Disconnect: Suspect Turn Relay or Exterior Mirror. rear turn lamp, GO to M15 .
Activate the hazard lamp function.
For an inoperative rear turn lamp, measure the voltage
between the LH turn relay pin 5, CJB face side, circuit CLS23 No
(GY/OG), harness side and ground; or between the RH turn For an inoperative exterior
relay pin 5, CJB face side, circuit CLS27 (GN/OG), harness mirror turn lamp, REPAIR
side and ground. circuit CLS23 (GY/OG) (LH
(GN/OG) (RH turn) for an
normal operation. For an
inoperative rear turn lamp,
GO to M14 .
For an inoperative exterior mirror turn lamp, measure the

voltage between the LH exterior mirror, C521-8, circuit CLS23
(GY/OG), harness side and ground; or between the RH
exterior mirror, C601-8, circuit CLS27 (GN/OG), harness side
and ground.
than 10 volts?
M13 CHECK THE EXTERIOR MIRROR GROUND CIRCUIT FOR
AN OPEN
Measure the voltage between the LH exterior mirror C521-8, Yes
circuit CLS23 (GY/OG), harness side and the LH exterior INSTALL a new exterior
mirror C521-2, circuit GD143 (BK/VT), harness side; or mirror. REFER to Section
between RH exterior mirror, C601-8, circuit CLS27 (GN/OG), 501-09 . TEST the system
harness side and the RH exterior mirror C601-2, circuit GD145 for normal operation.
(BK/BU), harness side.
No
REPAIR the circuit GD143
(BK/VT) (LH turn) or circuit
GD145 (BK/BU) (RH turn)
system for normal
operation.

than 10 volts?
M14 CHECK THE BCM REAR TURN LAMP OUTPUT CIRCUIT
FOR AN OPEN
Disconnect: BCM C2280C. GO to M19 .
For an inoperative LH rear turn lamp, measure the resistance
between the LH turn relay pin 5, circuit CLS23 (GY/OG), CJB No
face side and the BCM C2280C-12, circuit CLS23 (GY/OG), REPAIR circuit CLS23
harness side. (GY/OG) (LH turn) or circuit
CLS27 (GN/OG) (RH turn)
normal operation.
For an inoperative RH rear turn lamp, measure the resistance
between the RH turn relay pin 5, circuit CLS27 (GN/OG), CJB
face side and the BCM C2280C-13, circuit CLS27 (GN/OG),
harness side.

M15 CHECK THE TURN RELAY
Substitute a known good relay. REMOVE the known good
Activate the hazard lamp function. relay. INSTALL a new turn
Does the suspect rear turn lamp flash on and off? relay. TEST the system for
normal operation.
No
relay. GO to M16 .
M16 CHECK THE FOR VOLTAGE TO THE TURN RELAY
Measure the voltage between the LH turn relay pin 1, circuit GO to M17 .
SBP18 (YE/RD), CJB face side and ground; or between the
RH turn relay pin 1, circuit SBP18 (YE/RD), CJB face side and No
ground. REPAIR circuit SBP18
(YE/RD) for an open. TEST
operation
M17 CHECK THE TURN RELAY GROUND CONTROLLED
Ignition ON. REPAIR circuit CLS51
Measure the voltage between the LH turn relay pin 2, circuit (WH/GN) (LH turn) or
CLS51 (WH/GN), CJB face side and ground; or between the circuit CLS53 (GY/VT) (RH
RH turn relay pin 2, circuit CLS53 (GY/VT), CJB face side and turn) for a short to voltage.
ground. CLEAR the DTCs. CYCLE
system for normal
operation.
No
GO to M18 .

M18 CHECK THE TURN RELAY GROUND CONTROLLED
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Connect: Suspect Turn Relay. GO to M19 .
Measure the voltage between the BCM C2280D-6 (LH turn),
circuit CLS51 (WH/GN), harness side and ground; or between No
the BCM C2280D-7 (RH turn), circuit CLS53 (GY/VT), harness REPAIR circuit CLS51
side and ground. (WH/GN) (LH turn) or
circuit CLS53 (GY/VT) (RH
turn) for an open. CLEAR
the DTCs. TEST the
system for normal
operation.
M19 CHECK FOR CORRECT BCM OPERATION
correctly. No
corroded connector.
Pinpoint Test N: One Turn Signal/Hazard Lamp Is Inoperative/Always On (5-Door)
information.
Normal Operation
When the Body Control Module (BCM) detects the multifunction switch is in the LH TURN position, the
BCM provides on/off voltage to the LH front turn lamp on one output circuit, and to the LH rear and LH
exterior mirror turn lamp (if equipped) on another circuit.
When the BCM detects the multifunction switch is in the RH TURN position, the BCM provides on/off
voltage to the RH front turn lamp on one output circuit, and to the RH rear and RH exterior mirror turn
lamp (if equipped) on another circuit.

Indicator: Circuit Short To detects a short to ground from the LH front or LH rear turn lamp
Ground voltage supply circuits.
Indicator: Circuit Short To detects an open or short to voltage from the LH front or LH rear
Indicator: Circuit Short To detects a short to ground from the RH front or RH rear turn
Indicator: Circuit Short To detects an open or short to voltage from the RH front or RH rear

Bulb socket
BCM
PINPOINT TEST N: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON (5-DOOR)

N1 CHECK THE STOPLAMPS
Ignition OFF. Yes
Apply and release the brake pedal while observing the GO to N2 .
stoplamps.
Do the stoplamps operate correctly? No
REFER to Stoplamps in
this section.
N2 DETERMINE IF A TURN LAMP IS ALWAYS ON
NOTE: If the turn lamps are flashing, GO to Pinpoint Test L . Yes

GO to N3 .
Ignition ON.
Is any turn lamp on? No
For a front turn lamp, GO to
N4 . For a rear or exterior
N9 .
N3 CHECK THE BCM TURN LAMP OUTPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF. For the LH front turn lamp,
Disconnect: BCM C2280A (Front Turn Lamp). REPAIR circuit CLS21
Disconnect: BCM C2280C (Rear or Exterior Mirror Turn (BU/GN) for a short to
Lamp). voltage. CLEAR the DTCs.
Does the turn lamp in question continue to illuminate? normal operation. For the
RH front turn lamp,
voltage. CLEAR the DTCs.
TEST the system for
LH rear or exterior mirror
CLS23 (GY/OG) for a short
RH rear or exterior mirror
CLS27 (GN/OG) for a short
normal operation.
No
GO to N16 .
N4 CHECK FOR VOLTAGE TO THE FRONT TURN LAMP
Ignition OFF. Yes
Disconnect: Inoperative Front Lamp. GO to N5 .
Activate the hazard lamp function.
Measure the voltage between the LH front turn lamp C1023-3, No
circuit CLS21 (BU/GN), harness side and ground; or between GO to N6 .

than 10 volts?
N5 CHECK THE FRONT TURN LAMP GROUND CIRCUIT FOR
AN OPEN
Measure the voltage between the LH front turn lamp C1023-3, Yes
circuit CLS21 (BU/GN), harness side and the LH front lamp INSTALL a new bulb
C1023-1, circuit GD188 (BK/YE), harness side; or between the socket. CLEAR the DTCs.
RH front turn lamp C1043-3, circuit CLS25 (YE/VT), harness TEST the system for
side and the RH front lamp C1043-1, circuit GD123 (BK/GY), normal operation.
harness side.
No
(BK/YE) (LH turn) or circuit
GD123 (BK/GY) (RH turn)
normal operation.

than 10 volts?
N6 CHECK THE FRONT TURN LAMP BULB SOCKET FOR A
SHORT TO GROUND
Cycle the ignition on then off. INSTALL a new bulb
Activate the hazard lamp function. socket. CLEAR the DTCs.
Measure the voltage between the LH front turn lamp C1023-3, TEST the system for
circuit CLS21 (BU/GN), harness side and ground; or between normal operation.
GO to N7 .

than 10 volts?
N7 CHECK THE FRONT TURN LAMP VOLTAGE CIRCUIT FOR A
SHORT TO GROUND
Disconnect: BCM C2280A. GO to N8 .
Measure the resistance between the LH front turn lamp
C1023-3, circuit CLS21 (BU/GN), harness side and ground; or No
between the RH front turn lamp C1043-3, circuit CLS25 REPAIR circuit CLS21
(YE/VT), harness side and ground. (BU/GN) (LH turn) or
system for normal
operation.

N8 CHECK THE FRONT TURN LAMP VOLTAGE CIRCUIT FOR
AN OPEN
Measure the resistance between the LH front turn lamp Yes
C1023-3, circuit CLS21 (BU/GN), harness side and the BCM GO to N16 .
C2280A-5, circuit CLS21 (BU/GN), harness side; or between
the RH front turn lamp C1043-3, circuit CLS25 (YE/VT), No
harness side and the BCM C2280A-6, circuit CLS25 (YE/VT), REPAIR circuit CLS21
harness side. (BU/GN) (LH turn) or
normal operation.
N9 USE THE RECORDED DTCs FROM THE BCM SELF-TEST
Check the recorded results from the BCM on-demand self- If equipped with exterior
test. mirror turn lamps, GO to
Is DTC B1D06:11 or DTC B1D07:11 present? N10 . If not equipped with
exterior mirror turn lamps,
GO to N11 .
No
GO to N13 .
N10 CHECK THE EXTERIOR MIRROR FOR A SHORT TO
GROUND
Ignition OFF. Yes
Disconnect: LH Exterior Mirror C521 (DTC B1D06:11). INSTALL a new exterior
Disconnect: RH Exterior Mirror C601 (DTC B1D07:11). mirror. REFER to Section
Cycle the ignition on and then off. 501-09 . TEST the system
Activate the hazard lamp function. for normal operation.
Does the rear lamp flash on and off?
No
GO to N11 .
N11 CHECK THE REAR TURN LAMP BULB SOCKET FOR A
SHORT TO GROUND
Deactivate the hazard lamp function. INSTALL a new bulb
Cycle the ignition on then off. socket. CLEAR the DTCs.
Activate the hazard lamp function. CYCLE the ignition. TEST
Measure the voltage between the LH rear turn lamp C414-5, the system for normal
circuit CLS23 (GY/OG), harness side and ground; or between operation.
the RH rear turn lamp C417-5, circuit CLS27 (GN/OG),
GO to N12 .
than 10 volts?
N12 CHECK THE BCM REAR TURN LAMP OUTPUT CIRCUIT
Disconnect: BCM C2280C. GO to N16 .
Measure the resistance between the BCM C2280C-12 (LH
turn), circuit CLS23 (GY/OG), harness side and ground; or No
between the BCM C2280D-13(RH turn), circuit CLS27 REPAIR circuit CLS23
(GN/OG), harness side and ground. (GY/OG) (LH turn) or circuit
CLS27 (GN/OG) (RH turn)
system for normal
operation.

N13 CHECK FOR VOLTAGE TO THE REAR TURN LAMP OR
EXTERIOR MIRROR
NOTE: If both the rear turn and exterior mirror turn lamps are Yes
inoperative, follow the diagnostics for the rear turn lamp. For an inoperative exterior
Ignition OFF. N14 . For an inoperative
Disconnect: Inoperative Rear Lamp or Exterior Mirror. rear turn lamp, REPAIR or
Activate the hazard lamp function. INSTALL a new rear lamp
For an inoperative rear turn lamp, measure the voltage harness. CLEAR the DTCs.
between the LH rear turn lamp C414-5, circuit CLS23 TEST the system for
(GY/OG), harness side and ground; or between the RH rear normal operation.
turn lamp C417-5, circuit CLS27 (GN/OG), harness side and
ground. No
For an inoperative exterior
mirror turn lamp, REPAIR
circuit CLS23 (GY/OG) (LH
(GN/OG) (RH turn) for an
normal operation. For an
inoperative rear turn lamp,
GO to N15 .
For an inoperative exterior mirror turn lamp, measure the

voltage between the LH exterior mirror, C521-8, circuit CLS23
(GY/OG), harness side and ground; or between the RH
exterior mirror, C601-8, circuit CLS27 (GN/OG), harness side
and ground.
than 10 volts?
N14 CHECK THE EXTERIOR MIRROR GROUND CIRCUIT FOR
AN OPEN
Measure the voltage between the LH exterior mirror C521-8, Yes
circuit CLS23 (GY/OG), harness side and the LH exterior INSTALL a new exterior
mirror C521-2, circuit GD143 (BK/VT), harness side; or mirror. REFER to Section
between RH exterior mirror, C601-8, circuit CLS27 (GN/OG), 501-09 . TEST the system
harness side and the RH exterior mirror C601-2, circuit GD145 for normal operation.
(BK/BU), harness side.
No
REPAIR the circuit GD143
(BK/VT) (LH turn) or circuit
GD145 (BK/BU) (RH turn)
system for normal
operation.

than 10 volts?
N15 CHECK THE BCM REAR TURN LAMP OUTPUT CIRCUIT
FOR AN OPEN
Disconnect: BCM C2280C. GO to N16 .
Measure the resistance between the LH rear turn lamp C414-
5, circuit CLS23 (GY/OG), harness side and the BCM No
C2280C-12, circuit CLS23 (GY/OG), harness side; or between REPAIR circuit CLS23
the RH rear turn lamp C417-5, circuit CLS27 (GN/OG), (GY/OG) (LH turn) or circuit
harness side and the BCM C2280C-13, circuit CLS27 CLS27 (GN/OG) (RH turn)
(GN/OG), harness side. for an open. CLEAR the
normal operation.
N16 CHECK FOR CORRECT BCM OPERATION
correctly. No
corroded connector.
Pinpoint Test O: The Hazard Lamp Function Is Inoperative/Always On
information.
Normal Operation
The Body Control Module (BCM) sends a voltage signal to the Front Controls Interface Module (FCIM).
The voltage signal is routed to ground when the hazard flasher lamp switch is activated. When the BCM
detects a request for the hazard lamps, the BCM provides on/off voltage to all the turn lamps.
DTC B1D35:23 (Hazard Switch: Signal Stuck Low) — a continuous and on-demand DTC that
sets when the BCM detects a short to ground from the hazard flasher lamp switch input circuit.

FCIM
BCM
PINPOINT TEST O: THE HAZARD LAMP FUNCTION IS INOPERATIVE/ALWAYS ON

Take
O1 CHECK THE RECORDED DTCs FROM THE BCM SELF-TEST
Check the recorded DTCs from the BCM self-test. Yes
Is DTC B1D35:23 present? GO to O2 .
No
GO to O4 .
O2 CHECK THE FCIM
Ignition OFF. Yes
Disconnect: FCIM C2402. GO to O3 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: BCM Self- No
Test. GO to O6 .
Clear the DTCs and repeat the BCM self-test.
Is DTC B1D35:23 still present?
O3 CHECK THE HAZARD LAMP REQUEST INPUT CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280F. GO to O7 .
Measure the resistance between the FCIM C2402-1, circuit CLS32
(BN/YE), harness side and ground. No
ground. CLEAR the
DTCs. TEST the
system for normal
operation.

O4 BYPASS THE FCIM
Ignition OFF. Yes
Disconnect: FCIM C2402. GO to O6 .
Connect and remove a fused jumper wire between the FCIM
C2402-1, circuit CLS32 (BN/YE), harness side and ground. No
GO to O5 .
Does the hazard lamp function operate?

O5 CHECK THE HAZARD LAMP REQUEST INPUT CIRCUIT FOR AN
OPEN
Measure the resistance between the BCM C2280F-4, circuit GO to O7 .
CLS32 (BN/YE), harness side and the FCIM C2402-1, circuit
CLS32 (BN/YE), harness side. No
TEST the system for
normal operation.

O6 CHECK FOR CORRECT FCIM OPERATION
Disconnect all the FCIM connectors. Yes
Check for: INSTALL a new FCIM .
Connect all the FCIM connectors and make sure they seat
correctly. No
connector.
O7 CHECK FOR CORRECT BCM OPERATION
correctly. No
connector.
Parking, Rear and License Plate Lamps
Special Tool(s)

tool
Flex Probe Kit

The Body Control Module (BCM) monitors the headlamp switch position by sending voltage signals on
multiple circuits to the headlamp switch. There is one circuit for each headlamp switch position. At any
given time, one of the signal circuits is switched to ground to indicate the headlamp switch position.
If, when the ignition is in RUN, the BCM does not detect any active inputs from the headlamp switch or if
the BCM detects multiple headlamp switch input circuits short to ground, the BCM turns the parking
lamps and headlamps on and keeps them on until the ignition is transitioned OFF.
If either situation occurs, the BCM cannot be ruled immediately as being at fault. This is normal
behavior of the BCM design as a fault has been detected with the inputs from the headlamp switch.
When the BCM receives an input from the headlamp switch indicating a request for the parking lamps,
the supplies voltage to the exterior lamps.
The FET protected circuits for the parking lamp system are the LH rear (and license plate lamps), the
RH rear, LH front, RH front and front marker lamp voltage supply circuits.

Headlamp switch Battery Junction Box (BJB) fuse 22 (15A)
Bulb(s)
Bulb socket(s)
Auxiliary parking lamp(s)

tool.


418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB .
10 .

Symptom Chart
Symptom Chart
One or more parking, rear Fuse VERIFY the bulbs are
or license plate lamps is Wiring, terminals OK. If OK, GO to
inoperative or connectors Pinpoint Test P .
Bulb socket
Auxiliary parking
lamp
Body Control
Module (BCM)
The parking, rear or license Wiring, terminals GO to Pinpoint Test Q .
plate lamps are on or connectors
continuously BCM
Pinpoint Tests
Pinpoint Test P: One Or More Parking, Rear or License Plate Lamps Is Inoperative
Refer to Wiring Diagrams Cell 92 , Parking, Rear and License Lamps for schematic and connector
information.
Normal Operation
The Battery Junction Box (BJB) fuse 22 (15A) provides voltage to the Body Control Module (BCM) for
the parking lamps. When the headlamp switch is placed in the PARKING LAMPS ON position, the BCM
provides voltage on 5 separate circuits to the front and rear parking and license plate lamps.
If a fault exists with the headlamp switch input, the BCM faults the parking lamps and low beam
headlamps on.

B1098:11 — Left Position Light: A continuous and on-demand DTC that sets when the BCM
Circuit Short To Ground detects a short to ground from the LH front or LH rear parking
lamp voltage supply circuits.
Circuit Short To Battery Or detects an open from the LH front or LH rear parking lamp
Open voltage supply circuits.
B1099:11 — Right Position A continuous and on-demand DTC that sets when the BCM
Light: Circuit Short To Ground detects a short to ground from the RH front or RH rear
parking lamp voltage supply circuits.
Light: Circuit Short To Battery detects an open from the RH front or RH rear parking lamp
Or Open voltage supply circuits.
B1118:11 — Left Rear A continuous and on-demand DTC that sets when the BCM
Sidemarker: Circuit Short To detects a short to ground from the front side marker lamps
Ground voltage supply circuit.
Sidemarker: Circuit Short To detects an open from the front side marker lamps voltage
Battery Or Open supply circuit.
Fuse
Bulb socket
Auxiliary parking lamp
BCM
PINPOINT TEST P: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMPS IS

INOPERATIVE

P1 DETERMINE IF ALL THE PARKING LAMPS ARE
INOPERATIVE
Ignition OFF. Yes
Place the headlamp switch in the PARKING LAMPS ON VERIFY the BJB fuse 22
position. (15A) is OK. If OK, GO to
Are all the parking lamps inoperative? P2 . If not OK, REFER to the
of the circuit short.
No
GO to P3 .
P2 CHECK FOR VOLTAGE TO THE BCM
Disconnect: BCM C2280A. GO to P6 .
Measure the voltage between the BCM C2280A-7, circuit
SBB22 (BN/RD), harness side and ground. No
(BN/RD) for an open. TEST
operation.

P3 CHECK FOR VOLTAGE TO THE INOPERATIVE PARKING
LAMP
NOTE: If the LH rear and both license plate lamps are Yes
inoperative, follow the diagnostics for the rear lamp. For a license plate lamp,
Place the headlamp switch in the OFF position. REPAIR circuit GD143
Disconnect: Inoperative Lamp. (BK/VT) for an open. TEST
Place the headlamp switch in the PARKING LAMPS ON the system for normal
position. operation. For all other
Measure the voltage between the inoperative lamp, harness lamps, GO to P4 .
side and ground as follows:
No
For a license plate lamp,
Inoperative Lamp Connector-Pin Circuit REPAIR circuit CLS08
LH front C1023-2 CLS06 (GN/OG) (VT/GN) for an open. TEST
RH front C1043-2 CLS07 (BN/YE) operation. If an individual
LH front side marker C1127-2 CLS12 (WH/VT) front side marker lamp or
either front auxiliary parking
RH front side marker C1126-2 CLS12 (WH/VT) lamp is inoperative, REPAIR
LH front auxiliary C1445-1 CLS12 (WH/VT) circuit CLS12 (WH/VT) for
an open. TEST the system
RH front auxiliary C1446-1 CLS12 (WH/VT) for normal operation. For all
other lamp concerns, GO to
LH rear (4-door) C412-2 CLS08 (VT/GN)
P5 .
RH rear (4-door) C415-2 CLS09 (WH/OG)
LH rear (5-door) C414-2 CLS08 (VT/GN)
RH rear (5-door) C417-2 CLS09 (WH/OG)
LH license plate C452-1 CLS08 (VT/GN)
RH license plate C462-1 CLS08 (VT/GN)

P4 CHECK THE PARKING LAMP GROUND CIRCUIT FOR AN
OPEN
Measure the voltage between the inoperative lamp pins, Yes
harness side as follows: For a front parking or side
marker lamp, INSTALL a
Inoperative Connector-Pin/ Connector-Pin/ new bulb socket. TEST the
Lamp Circuit Circuit system for normal operation.
For a front auxiliary parking
LH front C1023-2 C1023-1 lamp, INSTALL a new
auxiliary parking lamp.
CLS06 (GN/OG) GD188 (BK/YE) REFER to Parking Lamp —
Auxiliary in this section.
RH front C1043-2 C1043-1
operation. For a rear parking
CLS07 (BN/YE) GD123 (BK/GY)
lamp (4-door), INSTALL a
LH front side C1127-2 C1127-1 new bulb socket. TEST the
marker system for normal operation.
CLS12 (WH/VT) GD188 (BK/YE) For a rear parking lamp (5-
door), REPAIR or INSTALL
RH front side C1126-2 C1126-1 a new rear lamp harness .
marker
CLS12 (WH/VT) GD123 (BK/GY) operation.
LH front auxiliary C1445-1 C1445-2
No
CLS12 (WH/VT) GD188 (BK/YE) REPAIR the ground circuit in
question for an open.
RH front auxiliary C1446-1 C1446-1 CLEAR the DTCs. TEST the
CLS12 (WH/VT) GD123 (BK/GY)
LH rear (4-door) C412-2 C412-1
CLS08 (VT/GN) GD143 (BK/VT)
RH rear (4-door) C415-2 C415-1
CLS09 (WH/OG) GD145 (BK/BU)

LH rear (5-door) C414-2 C414-1
CLS08 (VT/GN) GD143 (BK/VT)

RH rear (5-door) C417-2 C417-1
CLS09 (WH/OG) GD145 (BK/BU)

P5 BYPASS THE BCM
NOTE: If both LH (front and rear) or RH (front and rear) Yes

lamps are inoperative, the test must be checked at both REMOVE the jumper wire.
lamps to eliminate the circuitry as the cause of the concern. GO to P6 .
NOTE: If the fuse in the jumper wire fails, refer to the Wiring No
Diagrams manual to identify the possible causes of the circuit REMOVE the jumper wire.
short. After the repair, cycle the ignition to reset the driver REPAIR the parking lamp
within the BCM . Test the system for normal operation. voltage supply circuit in
Disconnect: BCM C2280C (Front Side Marker Lamps). question for an open.
Disconnect: BCM C2280D (Front Parking Lamps). CLEAR the DTCs. TEST the
Disconnect: BCM C2280G (Rear Parking Lamps). system for normal operation.
For the front side marker lamps, connect a fused jumper wire
between the BCM C2280C-14, circuit CLS12 (WH/VT),
harness side and battery positive.
For a front parking lamp, connect a fused jumper wire

between the BCM C2280D-24 (LH), circuit CLS06 (GN/OG),
harness side and battery positive; or between the BCM
C2280D-23 (RH), circuit CLS07 (BN/YE), harness side and
battery positive.
For a rear parking lamp, connect a fused jumper wire
between the BCM C2280G-13 (LH), circuit CLS08 (VT/GN),
harness side and battery positive; or between the BCM
C2280G-1 (RH), circuit CLS09 (WH/OG), harness side and
battery positive.
Does the parking lamp(s) in question illuminate?

P6 CHECK FOR CORRECT BCM OPERATION
correctly. No
corroded connector.
Pinpoint Test Q: The Parking, Rear Or License Plate Lamps Are On Continuously
Refer to Wiring Diagrams Cell 92 , Parking, Rear and License Lamps for schematic and connector
information.
Normal Operation
The Battery Junction Box (BJB) fuse 22 (15A) provides voltage to the Body Control Module (BCM) for
the parking lamps. When the headlamp switch is placed in the PARKING LAMPS ON position, the BCM
provides voltage on 5 separate circuits to the front and rear parking and license plate lamps.
If a fault exists with the headlamp switch input, the BCM faults the parking lamps and low beam
headlamps on.

Circuit Short To Battery Or detects a short to voltage from the LH front or LH rear parking
Open lamp voltage supply circuits.
Light: Circuit Short To Battery detects a short to voltage from the RH front or RH rear
Or Open parking lamp voltage supply circuits.
Sidemarker: Circuit Short To detects a short to voltage from the front side marker lamps
Battery Or Open voltage supply circuit.

BCM
PINPOINT TEST Q: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY

Q1 USE THE RECORDED DTCs FROM
THE BCM SELF-TEST
Check the recorded results from the Yes
BCM self-test. GO to Pinpoint Test C .
Was DTC B10A6:92 recorded?
No
GO to Q2 .
Q2 CHECK THE BCM PARKING LAMP
OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280C (Front Side REPAIR the parking lamp voltage supply circuit in
Marker and Auxiliary Lamps). question for a short to voltage. CLEAR the DTCs.
Disconnect: BCM C2280D (Front TEST the system for normal operation.
Parking Lamps).
Disconnect: BCM C2280G (Rear No
Parking Lamps). GO to Q3 .
Ignition ON.
Does the parking lamp(s) in
question continue to illuminate?
Q3 CHECK FOR CORRECT BCM
OPERATION
Ignition OFF. Yes
Disconnect all the BCM connectors. INSTALL a new BCM . REFER to Section 419-10 .
corrosion
damaged pins No
Connect all the BCM connectors and concern may have been caused by a loose or
make sure they seat correctly. corroded connector.
Reversing Lamps
Special Tool(s)

tool
Flex Probe Kit

Automatic Transaxle
The reversing lamps are provided voltage from the reversing lamps relay. Voltage is supplied to the
reversing lamps relay when the ignition is in RUN. The Transmission Control Module (TCM) monitors the
transaxle gear status. When the TCM detects the transaxle is in REVERSE (R), the TCM provides a
ground for the reversing lamps relay coil. When the relay is energized, voltage is supplied to the
reversing lamps.
Manual Transaxle
Voltage is supplied to the reversing lamp switch when the ignition is in RUN. When the transaxle is in
REVERSE (R), the reversing lamp switch routes voltage to the reversing lamps.
2. Visually inspect for obvious signs of electrical damage.

Electrical
Central Junction Box (CJB) fuse 6 (10A)
Bulb
Reversing lamps relay (automatic transaxle)

tool.


418-00 .
(BCM).
10 .
Symptom Chart
Symptom Chart
Both reversing Fuse VERIFY the bulbs are
lamps are Wiring, terminals or OK. If OK, GO to
inoperative connectors Pinpoint Test R .
Reversing lamps relay
(automatic transaxle)
Reversing lamp switch
(manual transaxle)
Transmission Control
Module (TCM) (automatic
transaxle)
An individual Wiring, terminals or VERIFY the bulb is
reversing lamp is connectors OK. If OK, GO to
inoperative Bulb socket Pinpoint Test S .
The reversing lamps Wiring, terminals or GO to Pinpoint Test
are on continuously connectors T.
Reversing lamps relay
(automatic transaxle)
Reversing lamp switch
(manual transaxle)
Auto-dimming interior rear
view mirror
Global Positioning
System Module (GPSM)
Body Control Module
(BCM)
TCM (automatic
transaxle)
Pinpoint Tests
Pinpoint Test R: Both Reversing Lamps Are Inoperative
Refer to Wiring Diagrams Cell 93 , Reversing Lamps for schematic and connector information.
Normal Operation — Automatic Transaxle
reversing lamps.
Manual Transaxle
NOTE: The reversing lamps on 4-door vehicles share the same ground circuit.
Fuse
PINPOINT TEST R: BOTH REVERSING LAMPS ARE INOPERATIVE

Result / Action to
Test Step
Take
R1 DETERMINE THE TRANSAXLE TYPE
Ignition OFF. Yes
Check the vehicle for a manual transaxle. VERIFY the CJB fuse 6
Is the vehicle equipped with a manual transaxle? (10A) is OK. If OK, GO
to R2 . If not OK,
REFER to the Wiring
Diagrams manual to
short.
No
(10A) is OK. If OK, GO
to R4 . If not OK,
REFER to the Wiring
Diagrams manual to
short.
R2 CHECK FOR VOLTAGE TO THE REVERSING LAMP SWITCH
Disconnect: Reversing Lamp Switch C169. Yes
Ignition ON. GO to R3 .
Measure the voltage between the reversing lamp switch C169-1,
circuit CBP06 (WH/BU), harness side and ground. No
(WH/BU) for an open.
TEST the system for
normal operation.

R3 BYPASS THE REVERSING LAMP SWITCH
Connect a fused jumper wire between the reversing lamp switch Yes
C169-1, circuit CBP06 (WH/BU), harness side and the reversing REMOVE the jumper
lamp switch C169-2, circuit CET47 (BU), harness side. wire. INSTALL a new
reversing lamp switch.
REFER to Reversing
Lamp Switch in this
section. TEST the
system for normal
operation.
No
For 4-door vehicles,
connected. GO to R7 .
REMOVE the jumper
CET47 (BU) for an
Do the reversing lamps illuminate?

R4 CHECK THE REVERSING LAMPS RELAY
Disconnect: Reversing Lamps Relay. Yes
Ignition ON. REMOVE the known
Substitute a known good relay and recheck the reversing lamps good relay. INSTALL a
operation. new reversing lamps
Do the reversing lamps operate correctly? relay. TEST the system
No
REMOVE the known
good relay. GO to R5 .
R5 CHECK FOR VOLTAGE TO THE REVERSING LAMPS RELAY
Ignition ON. Yes
Measure the voltage between the reversing lamps relay pin 1, GO to R6 .
circuit CBP06 (WH/BU), BJB face side and ground; and between
the reversing lamps relay pin 3, circuit CBP06 (WH/BU), BJB face No
side and ground. REPAIR circuit CBP06
TEST the system for
normal operation.

R6 BYPASS THE REVERSING LAMPS RELAY
Connect a fused jumper wire between the reversing lamps relay Yes
pin 3, circuit CBP06 (WH/BU), BJB face side and the reversing REMOVE the jumper
lamps relay pin 5, circuit CET47 (BU), BJB face side. wire. GO to R8 .
No
connected. GO to R7 .
REMOVE the jumper
CET47 (BU) for an
Do the reversing lamps illuminate?

R7 CHECK FOR VOLTAGE TO THE LH REVERSING LAMP
Ignition OFF. Yes
Disconnect: LH Reverse Lamp C487. REMOVE the jumper
Ignition ON. wire. REPAIR circuit
Measure the voltage between the LH reversing lamp C487-1, GD143 (BK/VT) for an
circuit CET47 (BU), harness side and ground. open. TEST the system
No
REMOVE the jumper
CET47 (BU) for an

R8 CHECK THE REVERSING LAMPS RELAY COIL GROUND
CONTROLLED CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: TCM C1750A. REPAIR circuit CLS28
Ignition ON. (BU/WH) for a short to
Measure the voltage between the reversing lamps relay pin 2, voltage. TEST the
circuit CLS28 (BU/WH), BJB face side and ground. system for normal
operation.
No
GO to R9 .

R9 CHECK THE REVERSING LAMPS RELAY COIL GROUND
Ignition OFF. Yes
Connect: Reversing Lamps Relay. GO to R10 .
Ignition ON.
Measure the voltage between the TCM C1750A-40, circuit CLS28 No
(BU/WH), harness side and ground. REPAIR circuit CLS28
(BU/WH) for an open.
TEST the system for
normal operation.

R10 CHECK THE TCM GEAR STATUS INPUT PID
Ignition OFF. Yes
Connect: TCM C1750A. GO to R11 .
Ignition ON.
Enter the following diagnostic mode on the scan tool: TCM No
DataLogger. REFER to Section 307-
Monitor the TCM gear status PID (GEAR_ENGAGED) while 11 to continue
placing the gear selector lever through all its positions. diagnosis of the gear
Does the PID agree with the gear selections? input.
R11 CHECK FOR CORRECT TCM OPERATION
Ignition OFF. Yes
Disconnect all the TCM connectors. INSTALL a new TCM .
corrosion 11 . TEST the system
damaged pins for normal operation.
pushed-out pins
Connect all the TCM connectors and make sure they seat No
correctly. The system is operating
Operate the system and verify the concern is still present. correctly at this time.
Is the concern still present? The concern may have
Pinpoint Test S: The Individual Reversing Lamp Is Inoperative
Normal Operation
Voltage is routed to the reversing lamps when the reversing lamps relay is energized.

Bulb socket
PINPOINT TEST S: THE INDIVIDUAL REVERSING LAMP IS INOPERATIVE
Result / Action
Test Step
to Take
S1 CHECK FOR VOLTAGE TO THE INOPERATIVE REVERSING LAMP
Disconnect: Inoperative Reversing Lamp. GO to S2 .
Ignition ON.
Select REVERSE. No
For 4-door vehicles, measure the voltage between the LH reversing lamp REPAIR circuit
C487-1, circuit CET47 (BU), harness side and ground; or between the RH CET47 (BU) for
reversing lamp C488-1, circuit CET47 (BU), harness side and ground. an open. TEST
the system for
normal
operation.
For 5-door vehicles, measure the voltage between the LH reversing lamp
C414-4, circuit CET47 (BU), harness side and ground; or between the RH
reversing lamp C417-4, circuit CET47 (BU), harness side and ground.

S2 CHECK THE REVERSING LAMP GROUND CIRCUIT FOR AN OPEN
For 4-door vehicles, measure the voltage between the LH reversing lamp Yes
C487-1, circuit CET47 (BU), harness side and the LH reversing lamp INSTALL a new
C487-2, circuit GD143 (BK/VT), harness side; or between the RH bulb socket.
reversing lamp C488-1, circuit CET47 (BU), harness side and the RH TEST the
reversing lamp C488-2, circuit GD143 (BK/VT), harness side. system for
normal
operation.
No
REPAIR circuit
GD143 (BK/VT)
or circuit GD143
(BK/VT) for an
open. TEST the
system for
normal
operation.
For 5-door vehicles, measure the voltage between the LH reversing lamp
C414-4, circuit CET47 (BU), harness side and the LH reversing lamp
C414-1, circuit GD143 (BK/VT), harness side; or between the RH
reversing lamp C417-4, circuit CET47 (BU), harness side and the RH
reversing lamp C417-1, circuit GD143 (BK/BU), harness side.
Pinpoint Test T: The Reversing Lamps Are On Continuously
Normal Operation
The reversing lamps are illuminated, voltage is also provided to the Body Control Module (BCM), the
auto-dimming interior rear view mirror and the Global Positioning System Module (GPSM) if equipped.
Automatic Transaxle
reversing lamps.
Manual Transaxle
DTC C1137:24 (Reverse Gear Switch: Signal Stuck High) — A continuous and on-demand DTC
that sets when the BCM detects a short to voltage from the reversing lamp voltage supply circuit.

Auto-dimming interior rear view mirror
BCM
GPSM
PINPOINT TEST T: THE REVERSING LAMPS ARE ON CONTINUOUSLY

T1 DETERMINE THE TRANSAXLE TYPE
Ignition OFF. Yes
Check the vehicle for a manual GO to T2 .
transaxle.
Is the vehicle equipped with a No
manual transaxle? GO to T3 .
T2 CHECK THE REVERSING LAMP
SWITCH
Ignition OFF. Yes
Disconnect: Reversing Lamp Switch If equipped with a GPSM , GO to T4 . If not
C169. equipped with a GPSM , GO to T5 .
Ignition ON.
Do the reversing lamps continue to No
illuminate? INSTALL a new reversing lamp switch. REFER to
Reversing Lamp Switch in this section. TEST the
T3 CHECK THE REVERSING LAMPS
RELAY OUTPUT
Ignition OFF. Yes
Disconnect: Reversing Lamps Relay. If equipped with a GPSM , GO to T4 . If not
Ignition ON. equipped with a GPSM , GO to T5 .
Do the reversing lamps continue to
illuminate? No
GO to T7 .
T4 CHECK THE GPSM FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: GPSM C2398. GO to T5 .
Ignition ON.
illuminate? GO to T10 .
T5 CHECK THE BCM FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280D. If equipped with an auto-dimming interior rear view
Ignition ON. mirror, GO to T6 . If not equipped with an auto-
Do the reversing lamps continue to dimming interior rear view mirror, REPAIR circuit
illuminate? CET47 (BU) for a short to voltage. TEST the
No
GO to T11 .
T6 CHECK THE AUTO-DIMMING
INTERIOR REAR VIEW MIRROR FOR A
SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Auto-Dimming Interior REPAIR circuit CET47 (BU) for a short to voltage.
Rear View Mirror C911. TEST the system for normal operation.
Ignition ON.
illuminate? INSTALL a new auto-dimming interior rear view
mirror. REFER to Section 501-09 . TEST the
RELAY
Ignition OFF. Yes
Substitute a known good relay. REMOVE the known good relay. GO to T8 .
Ignition ON.
illuminate? REMOVE the known good relay. INSTALL a new
reversing lamps relay. TEST the system for normal
operation.
RELAY COIL GROUND CONTROLLED
Ignition OFF. Yes
Connect: Reversing Lamps Relay. REPAIR circuit CLS28 (BU/WH) for a short to
Disconnect: TCM C1750A. ground. TEST the system for normal operation.
Ignition ON.
illuminate? GO to T9 .
T9 CHECK THE TCM GEAR STATUS
INPUT PID
Ignition OFF. Yes
Connect: TCM C1750A. GO to T12 .
Ignition ON.
Enter the following diagnostic mode on No
the scan tool: TCM DataLogger. REFER to Section 307-11 to continue diagnosis of
Monitor the TCM gear status PID the gear input.
(GEAR_ENGAGED) while placing the
gear selector lever through all its
positions.
Does the PID agree with the gear
selections?
T10 CHECK FOR CORRECT GPSM
OPERATION
Ignition OFF. Yes
Disconnect all the GPSM connectors. INSTALL a new GPSM . REFER to Section 415-
corrosion
damaged pins No
Connect all the GPSM connectors and concern may have been caused by a loose or
T11 CHECK FOR CORRECT BCM
OPERATION
Ignition OFF. Yes
Disconnect all the BCM connectors. INSTALL a new BCM . REFER to Section 419-10 .
corrosion
damaged pins No
Connect all the BCM connectors and concern may have been caused by a loose or
T12 CHECK FOR CORRECT TCM
OPERATION
Ignition OFF. Yes
Disconnect all the TCM connectors. INSTALL a new TCM . REFER to Section 307-11 .
corrosion
damaged pins No
Connect all the TCM connectors and concern may have been caused by a loose or
Headlamp Adjustment
Special Tool(s)
Vision 100 Headlamp Aimer
Headlamp Aiming
NOTE: For the photometric aiming procedure, refer to the appropriate photometric headlamp aimer
instruction manual.
NOTE: Mechanical aimers cannot be used with VOR- or VOL-type headlamps.
NOTE: Consult your state vehicle inspection manual for recommended tolerance ranges for visual
aiming.
NOTE: Horizontal aim is not adjustable.
1. The headlamp aiming procedure depends on what type of beam pattern the headlamp is
equipped with. Vehicles may come equipped with visually optically aligned left (VOL) or visually
optically aligned right (VOR) headlamps. To identify the headlamp beam pattern, look on the
headlamp lens. Molded in small letters on the headlamp lens is one of the following:
VOL and SAE
VOR and SAE
2. Once the headlamp beam pattern is identified, aim the headlamps using one of the following
methods as applicable.
Photometric aimers can aim VOL- and VOR- headlamps. This is the preferred method of
headlamp aiming.
Visual or screen method aiming can be used to aim VOL- and VOR- headlamps.
Mechanical aimers cannot be used with VOR- or VOL-type headlamps. Aerodynamic
lamps that can be aimed mechanically have 3 nibs molded into the lens of the lamp.
3. Before starting headlamp adjustment:

check that the vehicle is on level ground.
check the tire inflation.
check that no other load is in the vehicle other than a half tank of fuel.
check that the headlamps are clean.
check for correct headlamp operation.
if the vehicle is equipped with air suspension, make sure that the switch is on.
4. NOTE: The vertical wall or screen must be a minimum of 2.4 m (8 ft) wide.
Park the vehicle on a level surface approximately 7.6 m (25 ft) from the vertical wall or screen
directly in front of it.
5. 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 the measurement.
2. Make a 2.4 m (8 ft) horizontal mark (using masking tape) on the vertical wall or screen at
the same distance from the ground as previously recorded.
6. 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.
7. NOTE: The appearance of the VOR beam pattern may vary between vehicles.
For VOR-type headlamps, locate the top edge of this high intensity area a distinct horizontal
cutoff in the beam pattern on the wall or screen. Using the adjusting screw, adjust the headlamp
until the top edge of this cutoff is even with the horizontal reference line.
8. For VOL-type headlamps, locate the distinct cutoff in the left portion of the beam pattern. Using
the adjusting screw, adjust the headlamp until the edge of this cutoff is 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.
Headlamp Assembly
Part
1 W714040 Upper radiator grille reinforcement pin-type retainer
2 W702733 Headlamp assembly bolt (3 required)
3 13008 Headlamp assembly (RH / LH)
4 13N129 Headlamp assembly lower clip
5 — Headlamp assembly electrical connectors (part of
14K102)
1. Remove the headlamp assembly-to-upper radiator grille reinforcement pin-type retainer.

3. Gently lift up on the headlamp assembly to disconnect assembly from the lower clip.
4. Disconnect the headlamp assembly electrical connectors and disengage the wiring assembly clips from
the headlamp assembly.
5. NOTE: The headlamp assembly has a lip that must fit under the front bumper assembly to insure proper
fit.
Remove the headlamp assembly.

If necessary, adjust the headlamps. For additional information, refer to Headlamp Adjustment in
this section.
Headlamp Bulb
NOTE: The headlamp assembly is shown removed for clarity.

1 13N019 Headlamp bulb cover
2 13N021A Headlamp low beam bulb
3 13N021B Headlamp high beam bulb
WARNING: The bulb contains gas under pressure. The bulb may shatter if the 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 these instructions may result in personal injury.
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.
NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position.
Left Hand Side
1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly in this section.
Right Hand Side
2. Position aside the degas bottle.

Both Sides
3. Remove the headlamp bulb.

1. Remove the headlamp bulb cover.
2. Disconnect and remove the headlamp bulb.

Parking Lamp — Auxiliary
Part
1 13200 Supplemental parking lamp assembly (RH/LH)
2 — Supplemental parking lamp electrical connector (part of
14K012)
1. Remove the front fender splash shield. For additional information, refer to Section 501-02 .
2. Disconnect the supplemental parking lamp electrical connector.
3. Unclip and remove the supplemental parking lamp assembly.

Turn Signal Lamp — Outside Rear View Mirror

1 13466 Outside rear view mirror turn signal lamp bulb
2 13B374 Outside rear view mirror turn signal lamp assembly (RH/LH)
Removal
1. Remove the exterior mirror cover. For additional information, refer to Section 501-09 .
2. Remove the outside rear view mirror turn signal assembly.

1. Remove the turn signal bulb and socket from the turn signal assembly and position the wiring harness
aside.
2. Release the turn signal clip and remove the turn signal assembly.
Installation
1. NOTE: Bulb and socket will be fully seated in the turn signal assembly when the 2 slots align with the rubber
seal.
Install the turn signal bulb and socket into the turn signal assembly.
2. Install the 2 rear hooks of the turn signal assembly under the edge of the rear view mirror and snap the turn
signal clip in place.
3. Install the exterior mirror cover. For additional information, refer to Section 501-09 .
Reversing Lamp Switch
Part
1 15520 Reversing lamp switch - 14 Nm (124 lb-in)
2 — Reversing lamp switch electrical connector (part of
13A690)
Stoplamp Switch

1 — Stoplamp switch electrical connector (part of 14K012)
2 13480 Stoplamp lamp switch
NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch and
cruise control deactivation switch. Install these switches with the booster push rod attached to the
brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake
pedal in any other position results in incorrect adjustment and damages the switches.
1. NOTE: The stoplamp switch is located above the cruise control deactivation switch (if equipped).
Rotate the stoplamp switch clockwise approximately one-eighth turn to remove the stoplamp switch.

Perform the brake pedal switch adjustment. For additional information, refer to Section 206-09 .
Headlamp Switch

1 — Headlamp switch electrical connector (part of 14K024)
2 11654 Headlamp switch
1. Using a suitable non-marring tool, work around the outer edge of the switch to release the clips and pull
the switch out through the front of the finish panel.

High Mounted Stoplamp
4-Door Sedan

1 13466 High mounted stoplamp cover
2 N807389 High mounted stoplamp cover clip (4 required)
3 W502564 High mounted stoplamp screw (2 required)
4 13A624 High mounted stoplamp lower bracket
5 13A613 High mounted stoplamp
6 13A624 High mounted stoplamp upper bracket
7 13466 High mounted stoplamp bulb (5 required)
8 — High mounted stoplamp lens (part of 13A613)
5-Door Hatchback
1 46058 High mounted stoplamp screw (2 required)
2 13A613 High mounted stoplamp
3 — High mounted stoplamp connector
4-Door Sedan
1. Remove the high mounted stoplamp assembly cover.
2. Disconnect the 2 clips on the side of the high mounted stoplamp assembly and lower the high mounted
stoplamp assembly down.
3. Disconnect the high mounted stoplamp assembly electrical connector and remove.
5-Door Hatchback
4. Remove the high mounted stoplamp assembly.

1. Remove the 2 high mounted stoplamp assembly screws.
2. Disconnect the high mounted stoplamp assembly electrical connector and the rear window washer hose
and remove the high mounted stoplamp assembly.
All Vehicles

Rear Lamp Assembly
4-Door Sedan
Part
1 13404/ Rear outer lamp assembly (RH/LH)
13405
2 13K262 Rear outer lamp assembly grommet
3 13466 Park/ turn/ stop lamp bulb
4 13411 Park/ turn/ stop lamp bulb socket
5 W707612 Rear outer lamp assembly retaining nut
6 13411 Reverse bulb socket
7 13466 Reverse bulb
8 15500/ Rear inner lamp assembly (RH/LH)
15501
9 — Rear inner lamp assembly retaining nut (part of the rear
inner lamp assembly)
5-Door Hatchback
1 13404/ 13405 Rear lamp assembly (RH/LH)
2 W714309 Rear lamp assembly screws (2 required)
3 13466 Rear lamp assembly lower inner bulb
4 13466 Rear lamp assembly outer bulb
5 13466 Rear lamp assembly upper bulb
6 13410 Rear lamp socket and wire assembly
7 16K262 Rear lamp assembly grommets (2 required)
8 W707977 Rear lamp assembly retainer nut (2 required)
4-Door sedan rear outer lamp assembly
1. Remove the pin-type retainer and position the luggage compartment trim panel aside.
2. Remove the rear outer lamp assembly.

1. Remove the rear outer lamp assembly retaining nut.
2. Disconnect and remove the rear outer lamp assembly.
4-Door sedan rear inner lamp assembly

4. Remove the rear inner lamp assembly.
1. Loosen the rear inner lamp assembly retaining nut.
2. Disconnect and remove the rear inner lamp assembly.
5-Door hatchback
5. Remove the 2 rear lamp assembly screws.
6. Remove the rear lamp assembly.

1. Pull the rear lamp assembly out.
2. Remove the 3 rear lamp assembly bulbs and remove the lamp assembly.
All vehicles
7. To install, reverse removal procedure.

SECTION 417-02: Interior Lighting 2011 Fiesta Workshop Manual
Interior Lighting
The interior lighting system consists of the following components:
Interior/map lamps
Luggage compartment lamp
Door ajar switches (integrated into the door latches)
Luggage compartment lid/liftgate ajar switch (integrated into the luggage compartment lid/liftgate
latch)
Ambient lighting module (located under the center console)
Ambient lighting switch (integrated into the passenger heated seat switch)
The interior lighting system consists of up to 3 subsystems:
Courtesy lamps
Demand lamps
Ambient lighting
Battery Saver
NOTE: Time-out is 10 seconds if the vehicle is in Factory mode or 0 seconds if the vehicle is in
Transport mode.
The provides automatic shut-off of the courtesy and demand lamps after a time-out period when the
ignition is OFF. A timer in the BCM starts when any of the following occur:
the ignition is changed to OFF

any door or luggage compartment lid/liftgate becomes ajar
the UNLOCK button of the transmitter is pressed
a door is unlocked using a key
the door lock switch is pressed
When 10 minutes (30 minutes for demand lamps) have elapsed, the automatically shuts the voltage off
to the lamps. The timer restarts (voltage is restored if the BCM is in battery saver mode) if any of the
following occurs:
the ignition is changed out of OFF

any door, luggage compartment lid or liftgate becomes ajar
the UNLOCK button of the transmitter is pressed
a door is unlocked using a key
the door lock switch is pressed
Courtesy Lamps
The courtesy lamp subsystem consists of the interior/map lamps, the door ajar switches and the BCM .
The turns the courtesy lamps on when a door is opened or when an unlock signal is received from the
Remote Keyless Entry (RKE) transmitter.
Illuminated Entry/Exit
The illuminated entry and exit features provide temporary illumination of the parking lamps, the
dimmable backlighting, the ambient backlighting and the courtesy lamps. Refer to the following table for
additional information.
NOTE: An arbitrator (software programming) within the determines which actions take precedence over
others (for example, an open door keeps the courtesy lamps on even when a command to lock the
doors is received).
NOTE: For vehicles without Intelligent Access (IA), the timer for the backlighting and ambient lighting is
reset to 25 seconds when the key is inserted or removed from the ignition lock cylinder.
Courtesy Dimmable Ambient

Action Parking Lamps
Lamps Backlighting Lighting
RKE transmitter or On for 25 seconds On for 25 On for 25 On for 25
mechanical unlocking of the seconds seconds seconds
doors
RKE transmitter or Off Off Off Off
mechanical locking of the
doors
Open a closed door after Off (on for remianing time if On On On
previously unlocking (no unlocked from transmitter or
ignition state change since mechanical unlocking of the
unlock) doors)
Close all doors Off On for 25 On for 25 On for 25
seconds seconds seconds
Ignition changed to ON Off On for 25 Off On
seconds
Ignition changed out of ON Off On for 25 On for 25 On for 25
seconds seconds seconds
Open a door after the Off On Off Off
ignition is changed to OFF
Ignition is OFF and doors Off On for 25 Off Off
are unlocked from the door seconds
lock switch
Ignition is OFF and doors Off Off Off Off
are locked from the door
lock switch
Theater Lighting
The theater lighting option ramps-up the courtesy lamps over 0.7 second when courtesy lamp activation
is requested. The theater lighting feature ramps-down the courtesy lamps over 1.7 seconds when
interior lighting deactivation is requested by any feature other than the panic alarm or battery saver.
Demand Lamps
The demand lamps subsystem consists of the map/reading lamps and the luggage compartment lamp
(sedan) or cargo lamp (5-door) lamp. The energizes the battery saver relay to supply voltage to the
demand lamps when the battery saver feature is not active.
Ambient Lighting
The ambient lighting LEDs illuminate the cup holders (front and rear) and the front and rear footwell
areas. The ambient lighting subsystem consists of the ambient lighting switch, the ambient lighting
module, and the harness with hardwired LEDs located within the floor console and under the instrument
panel footwell areas. The ambient lighting is operational when the ignition is in any state other than OFF
(the exception is when it is used in conjunction with the illuminated entry/exit features). The ambient
lighting switch cycles the LEDs through 7 different color combinations or to turn the ambient lighting off.
Interior Lighting
Special Tool(s)

tool
Flex Probe Kit

The Body Control Module (BCM) supplies voltage (and ground for the courtesy lamps) to the interior
lighting system. The interior lighting system illuminates the courtesy lamps to enhance visibility of the
interior when a vehicle door is ajar. The BCM controls all interior lighting functions and timing by
monitoring inputs from the door ajar switches, luggage compartment lid/liftgate ajar switch, door lock
switch, input from the Remote Keyless Entry (RKE) system and the ignition state.
The voltage supply circuit to the BCM for the interior lamps is also used for the horn.
Ambient Lighting
The ambient lighting module provides voltage and ground to the LEDs. The ambient lighting switch is an
input to the ambient lighting module. With each press of the ambient lighting switch, the ambient lighting
module cycles through a different color variation or turns the ambient lighting feature off. There are 3
different color (red, blue and green) LEDs housed within each LED assembly. By illuminating various
color combinations, the LEDs are able to produce 7 different colors of ambient light. The module retains
the last color setting between ignition cycles.
A FET is a type of transistor that, when used with module software, monitors and controls current flow
on module outputs. The FET protection strategy prevents module damage in the event of excessive
current flow.
The FET protected circuits for the interior lighting system are the interior lamp voltage supply, courtesy
lamp ground and ambient lighting module voltage supply circuits.
Interior/map lamps Bulb(s)

Luggage compartment/cargo lamp Wiring, terminals or connectors
Interior/map lamps
Luggage compartment/cargo lamp
Ambient lighting switch

tool.


418-00 .
(BCM).
DTC Charts

B1091:12 Courtesy Lamp Sense: Circuit Short To Battery GO to Pinpoint Test B .
B1175:92 Drivers Door Ajar Switch: Performance Or GO to Pinpoint Test D .
Incorrect Operation
B1176:92 Passenger Door Ajar Switch: Performance Or GO to Pinpoint Test D .
Incorrect Operation
B1178:92 Boot/Trunk Ajar Switch: Performance Or GO to Pinpoint Test C .
Incorrect Operation
B11E9:92 Left Rear Door Ajar Switch: Performance Or GO to Pinpoint Test D .
Incorrect Operation
B11EA:92 Right Rear Door Ajar Switch: Performance Or GO to Pinpoint Test D .
Incorrect Operation
B12F1:11 Ambient Lighting Zone 1 Output: Circuit Short GO to Pinpoint Test H .
To Ground
B12F1:15 Ambient Lighting Zone 1 Output: Circuit Short If the ambient lighting is inoperative, GO to
To Battery Or Open Pinpoint Test H .
If the ambient lighting is always on, GO to

Pinpoint Test J .
B1D14:11 Interior Lights Circuit "B": Circuit Short To GO to Pinpoint Test B .
Ground
Symptom Chart
Symptom Chart
The courtesy lamps do not Wiring, terminals or GO to Pinpoint
illuminate with a door open connectors Test A .
Door latch
Body Control Module
(BCM)
One or more courtesy Wiring, terminals or VERIFY the bulbs
lamps are inoperative connectors are OK. If OK,
Interior lamp GO to Pinpoint
BCM Test B .
The luggage Wiring, terminals or VERIFY the bulb
compartment/cargo lamp is connectors is OK. If OK, GO
inoperative Luggage compartment to Pinpoint Test
lid/liftgate latch C.
Luggage
compartment/cargo
lamp
The courtesy lamps are Wiring, terminals or GO to Pinpoint
always on connectors Test D .
Door latch
BCM
The luggage Wiring, terminals or GO to Pinpoint
compartment/cargo lamp is connectors Test E .
always on Luggage compartment
lid/liftgate latch
One or more demand lamps Wiring, terminals or VERIFY the bulbs
are inoperative connectors are OK. If OK,
Interior/map lamps GO to Pinpoint
Test F .
The battery saver does not Wiring, terminals or GO to Pinpoint
deactivate after time-out connectors Test G .
BCM
The ambient lighting is Wiring, terminals or GO to Pinpoint
inoperative connectors Test H .
Ambient lighting
harness
Ambient lighting
module
BCM
The ambient lighting does Wiring, terminals or GO to Pinpoint
not cycle through all color connectors Test I .
variations Ambient lighting switch
Ambient lighting
harness
Ambient lighting
module
The ambient lighting is Wiring, terminals or GO to Pinpoint
always on connectors Test J .
BCM
Pinpoint Tests
Pinpoint Test A: The Courtesy Lamps Do Not Illuminate With A Door Open
Refer to Wiring Diagrams Cell 117 , Remote Keyless Entry and Alarm for schematic and connector
information.
Normal Operation
The Body Control Module (BCM) sends a voltage signal to each door ajar switch (integrated into the
door latch), which is routed to ground when the door is closed (the door ajar switch is closed when the
door is closed). When the door is opened, the signal to ground is interrupted, indicating an open door to
the BCM . When the BCM determines a door is open, the battery saver relay energizes (if not already
energized) to supply voltage to the interior lamps and the BCM provides ground to the courtesy lamps.
The demand lamp system (map lamps) uses the interior lamps ground circuit.

Door latch
BCM
PINPOINT TEST A: THE COURTESY LAMPS DO NOT ILLUMINATE WITH A DOOR OPEN

A1 CHECK THE OPERATION OF THE COURTESY LAMPS FROM
ALL THE DOORS
NOTE: Make sure the interior lamp switches are in the DOOR Yes
or COURTESY position before carrying out this step. CLOSE the doors. GO to
A2 .
Open all the doors and observe the interior lamps.
Do the interior lamps illuminate? No
CLOSE the doors. GO to
Pinpoint Test B .
A2 CHECK THE DOOR AJAR SWITCH OPERATION
Ignition OFF. Yes
Disconnect: Suspect Door Latch . INSTALL a new door latch
Do the courtesy lamps illuminate? in question. REFER to
operation.
No
GO to A3 .
A3 CHECK THE DOOR AJAR SWITCH CIRCUIT FOR A SHORT
TO GROUND
Disconnect: BCM C2280G. Yes
Measure the resistance between the suspect door latch, GO to A4 .
harness side and ground as follows:
No
Suspect Door Latch Connector-Pin Circuit REPAIR the circuit in
question for a short to
LH front C525-3 CPL26 (GN/VT) ground. TEST the system
RH front C609-6 CPL31 (WH)
LH rear C705-3 CPL36 (GN)
RH rear C805-6 CPL39 (YE)
correctly. No
corroded connector.
Pinpoint Test B: One Or More Courtesy Lamps Are Inoperative
Refer to Wiring Diagrams Cell 89 , Interior Lamps for schematic and connector information.
Normal Operation
The Body Control Module (BCM) supplies voltage and ground to the courtesy lamps when requested.
The voltage supply is also used for the demand lamp function (map lamps).
DTC B1091:12 (Courtesy Lamp Sense: Circuit Short To Battery) — a continuous and on-demand
DTC that sets when the BCM detects a short to voltage from the courtesy lamp ground controlled
circuit.
DTC B1D14:11 (Interior Lights Circuit "B": Circuit Short to Ground) — a continuous and on-
demand DTC that sets when the BCM detects a short to ground from the courtesy lamp voltage
supply circuit.

Interior lamp
BCM
PINPOINT TEST B: ONE OR MORE COURTESY LAMPS ARE INOPERATIVE

B1 CHECK THE OPERATION OF THE COURTESY LIGHTING
WITH THE LH FRONT DOOR OPEN
NOTE: For vehicles equipped with a moonroof, make sure Yes

the interior lamp switches are in the DOOR position before GO to B4 .
carrying out this step.
No
Open the LH front door and observe the interior lamps.
Are all the interior lamps inoperative?
B2 CHECK FOR VOLTAGE TO THE INOPERATIVE COURTESY
LAMP
Disconnect: Inoperative Lamp. Yes
With a door open, measure the voltage between the
inoperative interior lamp, harness side and ground as follows: No
Inoperative Lamp Connector-Pin Circuit the system for normal
operation.
Front (with moonroof) C926-3 CLN01 (GN/VT)
Front (without moonroof) C901-3 CLN01 (GN/VT)
Rear C932-3 CLN01 (GN/VT)

B3 CHECK THE INOPERATIVE COURTESY LAMP GROUND
Measure the voltage between the inoperative interior lamp Yes
pins, harness side as follows: INSTALL a new interior
lamp for the lamp in
Connector-Pin Connector-Pin question. TEST the system
Inoperative Lamp Circuit Circuit No

Front (with moonroof) C926-3 C926-2 (YE/GY) for an open. TEST
CLN01 (GN/VT) CLN03 (YE/GY) operation.
Front (without moonroof) C901-3 C901-1
CLN01 (GN/VT) CLN03 (YE/GY)

Rear C932-3 C932-1
CLN01 (GN/VT) CLN03 (YE/GY)

B4 CHECK THE OPERATION OF THE COURTESY LAMPS
FROM ALL THE DOORS
Open all the doors and observe the interior lamps. Yes
Do the interior lamps illuminate? GO to Pinpoint Test A .
No
CLOSE all the doors. GO to
B5 .
B5 CHECK THE OPERATION OF THE MAP LAMP
Ignition ON. Yes
Use the map lamp function on the front interior lamp and GO to B6 .
attempt to turn the lamp on.
Does the front interior lamp illuminate? No
GO to B8 .
B6 CHECK THE COURTESY LAMPS GROUND CONTROLLED
Ignition ON. REPAIR circuit CLN03
Measure the voltage between the BCM C2280C-5, circuit (YE/GY) for a short to
CLN03 (YE/GY), harness side and ground. voltage. CYCLE the ignition
ON and then OFF. CLEAR
No
GO to B7 .

B7 CHECK THE COURTESY LAMPS GROUND CONTROLLED
CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between the BCM C2280C-5, circuit GO to B13 .
CLN03 (YE/GY), harness side and the BCM C2280C-4,
circuit CLN01 (GN/VT), harness side. No
(YE/GY) for an open. TEST
operation.

B8 ISOLATE THE FRONT INTERIOR LAMP
Ignition OFF. Yes
Disconnect: Front Interior Lamp C926 (with moonroof) or INSTALL a new front interior
C901 (without moonroof). lamp. CLEAR the DTCs.
Cycle the ignition ON and then OFF. TEST the system for normal
Open the LH front door. operation.
Does the rear interior lamp illuminate?
No
CLOSE the LH front door.
GO to B9 .
B9 ISOLATE THE LUGGAGE COMPARTMENT/CARGO LAMP
Disconnect: Luggage Compartment/Cargo Lamp C489. Yes
Cycle the ignition ON and then OFF. INSTALL a new luggage
Open the LH front door. compartment/cargo lamp.
Does the rear interior lamp illuminate? CLEAR the DTCs. TEST the
system for normal
operation.
No
CLOSE the LH front door.
GO to B10 .
B10 ISOLATE THE REAR INTERIOR LAMP
Disconnect: Rear Interior Lamp C932. Yes
Cycle the ignition ON and then OFF. INSTALL a new rear interior
Open the LH front door. lamp. CLEAR the DTCs.
Measure the voltage between the rear interior lamp C932-3, TEST the system for normal
circuit CLN01 (GN/VT), harness side and ground. operation.
No
GO to B11 .
B11 CHECK THE INTERIOR LAMP VOLTAGE SUPPLY CIRCUIT

Measure the resistance between the rear interior lamp C932- REPAIR circuit CLN01
3, circuit CLN01 (GN/VT), harness side and ground. (GN/VT) for a short to
ground. CYCLE the ignition
ON and then OFF. CLEAR
No
GO to B12 .

B12 CHECK THE INTERIOR LAMP VOLTAGE SUPPLY CIRCUIT
FOR AN OPEN
Connect: Front, Rear and Luggage Compartment/Cargo Yes
Lamps . GO to B12 .
CLN03 (YE/GY), harness side and the BCM C2280C-4, No
circuit CLN01 (GN/VT), harness side. REPAIR circuit CLN01
operation.

correctly. No
corroded connector.
Pinpoint Test C: The Luggage Compartment/Cargo Lamp Is Inoperative

Normal Operation
The Body Control Module (BCM) sends a voltage signal to the luggage compartment lid/liftgate ajar
switch (integrated into the latch) to monitor the ajar switch status. The switch is normally closed when
the luggage compartment lid/liftgate is closed, and open when the luggage compartment lid/liftgate is
open. The ajar switch also controls the ground side of the luggage compartment lamp. The luggage
compartment ajar switch completes the path to ground for the luggage compartment/cargo lamp when
the luggage compartment lid/liftgate is open.
DTC B1178:92 (Boot/Trunk Ajar Switch: Performance Or Incorrect Operation) — an on-demand

DTC that sets when the BCM detects an open from the luggage compartment lid/liftgate ajar input
circuit.

Luggage compartment/cargo lamp
PINPOINT TEST C: THE LUGGAGE COMPARTMENT/CARGO LAMP IS INOPERATIVE
Result / Action to
Test Step
Take
C1 CHECK THE COURTESY LAMP OPERATION
Open the LH front door and observe the interior lamps. Yes
Do the courtesy lamps illuminate? GO to C2 .
No
GO to Pinpoint Test
A.
C2 CHECK THE LUGGAGE COMPARTMENT LID/LIFTGATE AJAR
PID
Ignition ON. Yes
Enter the following diagnostic mode on the scan tool: BCM GO to C3 .
DataLogger.
Monitor the BCM luggage compartment lid/liftgate ajar switch PID No
while opening and closing the luggage compartment lid/liftgate. If the PID always
Does the PID agree with the luggage compartment lid/liftgate indicates closed, GO
positions? to C6 . If the PID
always indicates open,
GO to C8 .
C3 CHECK FOR VOLTAGE TO THE LUGGAGE
COMPARTMENT/CARGO LAMP
Ignition OFF. Yes
Open the luggage compartment lid/liftgate. INSTALL a new
Disconnect: Luggage Compartment/Cargo Lamp C489. luggage compartment
Measure the voltage between the luggage compartment/cargo lamp. TEST the
lamp C489-1, circuit CLN01 (GN/VT), harness side and the system for normal
luggage compartment lamp C489-2, circuit CLN13 (WH/BU). operation.
No
GO to C4 .

C4 CHECK THE LUGGAGE COMPARTMENT/CARGO LAMP
VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Measure the voltage between the luggage compartment/cargo Yes
lamp C489-1, circuit CLN01 (GN/VT), harness side and ground. GO to C5 .
No
(GN/VT) for an open.
TEST the system for
normal operation.

C5 CHECK THE LUGGAGE COMPARTMENT/CARGO LAMP
Connect: Luggage Compartment/Cargo Lamp C489. Yes
Disconnect: Luggage Compartment Lid/Liftgate Latch C4223. INSTALL a new
Measure the voltage between the luggage compartment lid/liftgate luggage compartment
latch C4223-4, circuit CLN13 (WH/BU), harness side and ground. lid/liftgate latch.
REFER to Section
501-14 . TEST the
system for normal
operation.
No
TEST the system for
normal operation.

C6 RECHECK THE PID WITH THE LUGGAGE
COMPARTMENT/LIFTGATE LATCH DISCONNECTED
Disconnect: Luggage Compartment Lid/Liftgate Latch C4223. Yes
Enter the following diagnostic mode on the scan tool: BCM INSTALL a new
DataLogger. luggage compartment
Monitor the BCM luggage compartment lid/liftgate ajar switch PID. lid/liftgate latch.
Does the PID indicate the luggage compartment lid/liftgate is REFER to Section
open? 501-14 . TEST the
system for normal
operation.
No
GO to C7 .
C7 CHECK THE LUGGAGE COMPARTMENT/LIFTGATE AJAR INPUT
Ignition OFF. Yes
Measure the resistance between the luggage compartment
lid/liftgate latch C4223-3, circuit CPL44 (YE/OG), harness side and No
ground. REPAIR circuit CPL44
(YE/OG) for a short to
ground. TEST the
system for normal
operation.

C8 BYPASS THE LUGGAGE COMPARTMENT/LIFTGATE LATCH
Ignition OFF. Yes
Disconnect: Luggage Compartment Lid/Liftgate Latch C4223. REMOVE the jumper
Ignition ON. wire. INSTALL a new
Connect a fused jumper wire between the luggage compartment luggage compartment
lid/liftgate latch C4223-3, circuit CPL44 (YE/OG), harness side and lid latch. REFER to
the luggage compartment lid/liftgate latch C4223-2, circuit GD143 Section 501-14 . TEST
(BK/VT), harness side. the system for normal
operation.
No
REMOVE the jumper
wire. GO to C9 .

DataLogger.
Monitor the BCM luggage compartment lid/liftgate ajar switch PID.
Does the PID indicate the luggage compartment lid/liftgate is
closed?
C9 BYPASS THE LUGGAGE COMPARTMENT/LIFTGATE LATCH
GROUND CIRCUIT
Connect a fused jumper wire between the luggage compartment Yes
lid/liftgate latch C4223-3, circuit CPL44 (YE/OG), harness side and REMOVE the jumper
ground. wire. REPAIR circuit
GD143 (BK/VT) for an
open. TEST the
system for normal
operation.
No
REMOVE the jumper
wire. GO to C10 .

DataLogger.
Monitor the BCM luggage compartment lid/liftgate ajar switch PID.
Does the PID indicate the luggage compartment lid/liftgate is
closed?
C10 CHECK THE LUGGAGE COMPARTMENT/LIFTGATE AJAR
INPUT CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Measure the resistance between the BCM C2280G-7, circuit
CPL44 (YE/OG), harness side and the luggage compartment No
lid/liftgate latch C4223-3, circuit CPL44 (YE/OG), harness side. REPAIR circuit CPL44
(YE/OG) for an open.
TEST the system for
normal operation.

Disconnect all BCM the connectors. Yes
The system is
may have been
corroded connector.
Pinpoint Test D: The Courtesy Lamps Are Always On
Refer to Wiring Diagrams Cell 117 , Remote Keyless Entry and Alarm for schematic and connector
information.
Normal Operation
The Body Control Module (BCM) sends a voltage signal to each door ajar switch (integrated into the
door latch), which is routed to ground when the door is closed (the door ajar switch is closed when the
door is closed). When the door is opened, the signal to ground is interrupted, indicating an open door to
the BCM . When the BCM determines a door is open, the battery saver relay energizes (if not already
energized) to supply voltage to the interior lamps and then the BCM provides ground to the courtesy
lamps.

B1175:92 — Driver Door Ajar Switch: An on-demand DTC that sets when the BCM
Performance Or Incorrect Operation detects an open from the LH front door ajar circuit.
B1176:92 — Passenger Door Ajar Switch: An on-demand DTC that sets when the BCM
Performance Or Incorrect Operation detects an open from the RH front door ajar circuit.
B11E9:92 — Left Rear Door Ajar Switch: An on-demand DTC that sets when the BCM
Performance Or Incorrect Operation detects an open from the LH rear door ajar circuit.
B11EA:92 — Right Rear Door Ajar Switch: An on-demand DTC that sets when the BCM
Performance Or Incorrect Operation detects an open from the RH rear door ajar circuit.

Door latch
BCM
PINPOINT TEST D: THE COURTESY LAMPS ARE ALWAYS ON

D1 CHECK THE DOOR AJAR PIDs
Ignition ON. Yes
Close all the doors. GO to D5 .
DataLogger. No
Monitor the BCM door ajar switch PIDs while opening and GO to D2 .
closing all the doors.
Do all the door ajar switch PID values agree with the door
positions?
D2 BYPASS THE SUSPECT DOOR LATCH
Ignition OFF. Yes
Disconnect: Suspect Door Latch . REMOVE the jumper wire.
Ignition ON. INSTALL a new door latch
Connect a fused jumper wire between the suspect door latch for the one in question.
pins, harness side as follows: REFER to Section 501-14 .
TEST the system for
Connector-Pin Connector-Pin normal operation.
No
Suspect Door Latch Circuit Circuit REMOVE the jumper wire.
GO to D3 .
LH front C525-3 C525-5
CPL26 (GN/VT) GD143 (BK/VT)

RH front C609-6 C609-4
CPL31 (WH) GD145 (BK/BU)

LH rear C705-3 C705-5
CPL36 (GN) GD143 (BK/VT)

RH rear C805-6 C805-4
CPL39 (YE) GD145 (BK/BU)
Monitor the suspect BCM door ajar switch PID.

Does the PID indicate the suspect door is closed?
D3 BYPASS THE DOOR LATCH GROUND CIRCUIT
Connect a fused jumper wire between the suspect door latch, Yes
harness side and ground as follows: REMOVE the jumper wire.
REPAIR the door latch
Suspect Door Latch Connector-Pin Circuit ground circuit in question
LH front C525-3 CPL26 (GN/VT) system for normal
operation.
RH front C609-6 CPL31 (WH)
LH rear C705-3 CPL36 (GN) No
RH rear C805-6 CPL39 (YE) GO to D4 .
Monitor the suspect BCM door ajar switch PID.
Does the PID indicate the suspect door is closed?
D4 CHECK THE DOOR AJAR SWITCH INPUT CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: BCM C2280G. GO to D6 .
Measure the resistance between the suspect door ajar switch,
harness side and the BCM , harness side as follows: No
REPAIR the door ajar input
Suspect Door Ajar Latch BCM circuit in question for an
Connector-Pin Connector-Pin Circuit open. TEST the system for
normal operation.
LH front C2280G-10 CPL26
(GN/VT)
RH front C2280G-22 CPL31
(WH)
LH rear C2280G-4 CPL36 (GN)
RH rear C2280G-3 CPL39 (YE)

D5 CHECK THE COURTESY LAMP GROUND CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF. Yes
Disconnect: BCM C2280C. GO to D6 .
CLN03 (YE/GY), harness side and ground. No
(YE/GY) for an open. TEST
operation.
Connect all the BCM connectors and make sure they seat normal operation.
correctly.
Operate the system and determine if the concern is still No
present. The system is operating
corroded connector.
Pinpoint Test E: The Luggage Compartment/Cargo Lamp Is Always On
Normal Operation
The Body Control Module (BCM) sends a voltage signal to the luggage compartment lid/liftgate ajar
switch (integrated into the latch) to monitor the ajar switch status. The switch is normally closed when
the luggage compartment lid/liftgate is closed, and open when the luggage compartment lid/liftgate is
open. The ajar switch also controls the ground side of the luggage compartment lamp. The luggage
compartment ajar switch completes the path to ground for the luggage compartment/cargo lamp when
the luggage compartment lid/liftgate is open.

PINPOINT TEST E: THE LUGGAGE COMPARTMENT/CARGO LAMP IS ALWAYS ON

E1 CHECK THE LUGGAGE COMPARTMENT
LID/LIFTGATE AJAR PID
Ignition ON. Yes
Enter the following diagnostic mode on the scan GO to E2 .
tool: BCM DataLogger.
Monitor the BCM luggage compartment No
lid/liftgate ajar PID while opening and closing GO to Pinpoint Test C .
the luggage compartment lid/liftgate.
Does the PID agree with the luggage
compartment lid/liftgate positions?
E2 CHECK THE LUGGAGE COMPARTMENT
LID/LIFTGATE LATCH
Ignition OFF. Yes
Disconnect: Luggage Compartment Lid/Liftgate REPAIR circuit CLN13 (WH/BU) for a
Latch C4223. short to ground. TEST the system for
Ignition ON. normal operation.
Does the luggage compartment/cargo lamp
continue to illuminate? No
INSTALL a new luggage compartment
lid/liftgate latch. REFER to Section 501-
14 . TEST the system for normal
operation.
Pinpoint Test F: One Or More Demand Lamps Are Inoperative
Normal Operation
The Body Control Module (BCM) supplies voltage to the interior lamps when the battery saver feature is
not active. This voltage supply is shared with the courtesy lamps. The interior lamps have a dedicated
ground circuit that is used for the map lamps to function independently of the courtesy lamp operation.

Interior/map lamps
PINPOINT TEST F: ONE OR MORE DEMAND LAMPS ARE INOPERATIVE
Result / Action to
Test Step
Take
F1 CHECK THE COURTESY LAMP OPERATION
NOTE: For vehicles equipped with a moonroof, make sure the Yes
interior lamp switches are in the DOOR position before carrying out GO to F2 .
this step.
No
Check the operation of the courtesy lamps with any door open. GO to Pinpoint Test
Do the courtesy lamps operate correctly? B.
F2 DETERMINE IF THE FRONT AND REAR DEMAND LAMPS ARE
OPERATIVE
Operate the map lamp function from the front and rear interior Yes
lamps. REPAIR circuit
Is the map lamp function inoperative from both lamps? GD143 (BK/VT) for
an open. TEST the
system for normal
operation.
No
GO to F3 .
F3 CHECK INTERIOR LAMP GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Inoperative Interior Lamp. INSTALL a new
Ignition ON. interior lamp in
Measure the voltage between the inoperative interior lamp pins, question. TEST the
harness side as follows: system for normal
operation.
Connector-Pin Connector-Pin
No
REPAIR circuit
Inoperative Lamp Circuit Circuit GD143 (BK/VT) for
an open. TEST the
Front (with moonroof) C926-3 C926-4 system for normal
operation.
CLN01 (GN/VT) GD143 (BK/VT)
Front (without moonroof) C901-3 C901-2

Rear C932-3 C932-2
Pinpoint Test G: The Battery Saver Does Not Deactivate After Time-out
Normal Operation
The Body Control Module (BCM) provides a battery saver function that automatically shuts off of the
courtesy lamps after 10 minutes and the demand lamps (map lamps and luggage compartment/cargo
lamp) after 30 minutes have elapsed in order to save battery power.
If the courtesy lamps remain on after the battery saver feature activates (10 minutes), GO to Pinpoint
Test D .
Refer to Interior Lighting , Battery Saver for specific information regarding the conditions which the
battery saver activates.
Wiring, terminals, or connectors

BCM
PINPOINT TEST G: THE BATTERY SAVER DOES NOT DEACTIVATE AFTER TIME-OUT

G1 CHECK THE INTERIOR LAMP VOLTAGE
SUPPLY CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280C. REPAIR circuit CLN01 (GN/VT) for a short to
Ignition ON. voltage. TEST the system for normal operation.
Turn any map lamp on.
Does the map lamp turn on?
No
GO to G2 .
G2 CHECK FOR CORRECT BCM
OPERATION
damaged pins
pushed-out pins No
Connect all the BCM connectors and The system is operating correctly at this time.
make sure they seat correctly. The concern may have been caused by a loose
Operate the system and verify the concern or corroded connector.
is still present.
Pinpoint Test H: The Ambient Lighting Is Inoperative
Normal Operation
When the ignition is in any state other than OFF, the Body Control Module (BCM) supplies voltage to the
ambient lighting module and the ambient lighting switch. The ambient lighting module supplies voltage
and ground to the ambient lighting LEDs. The ambient lighting switch cycles through the 7 color
combinations or turns the ambient lighting feature off.
When the ambient lighting switch is pressed, voltage is routed to the ambient lighting module, indicating
a request for the module to cycle the ambient lighting to the next setting.
The ambient lighting switch is a momentary contact switch.
DTC B12F1:11 (Ambient Lighting Zone 1 Output: Circuit Short To Ground) — a continuous and
on-demand DTC that sets when the BCM detects a short to ground from the ambient lighting
module voltage supply circuit.
DTC B12F1:15 (Ambient Lighting Zone 1 Output: Circuit Short To Battery Or Open) — a
continuous and on-demand DTC that sets when the BCM detects an open from the ambient
lighting module voltage supply circuit.

Ambient lighting harness
Ambient lighting module
BCM
PINPOINT TEST H: THE AMBIENT LIGHTING IS INOPERATIVE
Result / Action to
Test Step
Take
H1 CHECK FOR VOLTAGE TO THE AMBIENT LIGHTING MODULE
Ignition OFF. Yes
Disconnect: Ambient Lighting Module C3347. GO to H4 .
Ignition ON.
Measure the voltage between the ambient lighting module C3347- No
1, circuit CBX07 (GN/RD), harness side and ground. GO to H2 .

H2 CHECK THE AMBIENT LIGHTING MODULE VOLTAGE SUPPLY
Ignition OFF. Yes
Disconnect: BCM C2280E. GO to H3 .
Measure the resistance between the ambient lighting module
C3347-1, circuit CBX07 (GN/RD), harness side and ground. No
(VT/BN) for a short to
ground. CYCLE the
ignition ON and then
OFF. CLEAR the
DTCs. TEST the
system for normal
operation.

H3 CHECK THE AMBIENT LIGHTING MODULE VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
Measure the resistance between the ambient lighting module Yes
C3347-1, circuit CBX07 (GN/RD), harness side and the BCM GO to H11 .
C2280E-24, circuit CLN02 (VT/BN), harness side.
No
REPAIR circuit CBX07
(GN/RD) or circuit
CLN02 (VT/BN) for an
open. TEST the
system for normal
operation.

H4 CHECK THE AMBIENT LIGHTING SWITCH OUTPUT CIRCUIT
While pressing and releasing the ambient lighting switch, measure Yes
the voltage between the ambient lighting module C3347-2, circuit GO to H5 .
CLN54 (BN/YE), harness side and ground.
No
If voltage is always
present, GO to H7 .
If no voltage is
present, GO to H8 .
Is the voltage greater than 10 volts with the switch pressed

and 0 volts with the switch released?
H5 CHECK THE AMBIENT LIGHTING MODULE GROUND CIRCUIT
FOR AN OPEN
Measure the voltage between the ambient lighting module C3347- Yes
1, circuit CBX07 (GN/RD), harness side and the ambient lighting GO to H6 .
module C3347-8, circuit GD908 (BK), harness side.
No
(BK) or circuit GD115
TEST the system for
normal operation.

H6 CHECK THE AMBIENT LIGHTING HARNESS
Ignition OFF. Yes
Check any of the diode circuits between the ambient lighting GO to H10 .
module, harness side as follows:
No
Connector-Pin Connector-Pin REPAIR or INSTALL a
new ambient lighting
harness. TEST the
Circuit Circuit system for normal
operation.
C3347-5 C3347-4
CLN45 (GN) RLN44 (BN)

C3347-6 C3347-4
CLN46 (BU) RLN44 (BN)

C3347-7 C3347-4
CLN44 (OG) RLN44 (BN)
Does the meter indicate the circuit is good?

H7 CHECK THE AMBIENT LIGHTING SWITCH OUTPUT CIRCUIT
Ignition OFF. Yes
Disconnect: Ambient Lighting Switch C2401. REPAIR circuit CLN54
Ignition ON. (BN/YE) or circuit
Measure the voltage between the ambient lighting module C3347- CLN60 (WH/BN) for a
2, circuit CLN54 (BN/YE), harness side and ground. short to voltage. TEST
operation.
No
INSTALL a new
ambient lighting
switch. REFER to
Ambient Lighting
TEST the system for
normal operation.

H8 CHECK FOR VOLTAGE TO THE AMBIENT LIGHTING SWITCH
Ignition OFF. Yes
Connect: Ambient Lighting Module C3347. GO to H9 .
Disconnect: Ambient Lighting Switch C2401.
Ignition ON. No
Measure the voltage between the ambient lighting switch C2401-2, REPAIR circuit CLN02
circuit CLN02 (VT/BN), harness side and ground. (VT/BN) for an open.
TEST the system for
normal operation.

H9 BYPASS THE AMBIENT LIGHTING SWITCH
Connect and remove a fused jumper wire between the ambient Yes
lighting switch C2401-2, circuit CLN02 (VT/BN), harness side and REMOVE the jumper
the ambient lighting switch C2401-1, circuit CLN60 (WH/BN), wire. INSTALL a new
harness side. ambient lighting
switch. REFER to
Ambient Lighting
TEST the system for
normal operation.
No
REMOVE the jumper
CLN54 (BN/YE) or
circuit CLN60
TEST the system for
normal operation.
Do the ambient LEDs illuminate and cycle through a color
change each time the jumper wire is connected and removed?
H10 CHECK FOR CORRECT AMBIENT LIGHTING MODULE
OPERATION
Disconnect the ambient lighting module connector. Yes
corrosion ambient lighting
damaged pins module. REFER to
pushed-out pins Ambient Lighting
Connect the ambient lighting module connector and make sure it Module in this section.
seats correctly. TEST the system for
No
The system is
may have been
corroded connector.
H11 CHECK FOR CORRECT BCM OPERATION
The system is
may have been
corroded connector.
Pinpoint Test I: The Ambient Lighting Does Not Cycle Through All Color Variations
Normal Operation
ambient lighting module and the ambient lighting switch. The ambient lighting module supplies voltage
and ground to the ambient lighting LEDs. The ambient lighting switch cycles through the 7 color
combinations or turns the ambient lighting feature off.
When the ambient lighting switch is pressed, voltage is routed to the ambient lighting module, indicating
a request for the module to cycle the ambient lighting to the next setting.
The ambient lighting switch is a momentary contact switch.

Ambient lighting harness
Ambient lighting module
PINPOINT TEST I: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR
VARIATIONS
Result / Action to
Test Step
Take
I1 CHECK THE AMBIENT LIGHTING SWITCH OUTPUT CIRCUIT
Ignition OFF. Yes
Disconnect: Ambient Lighting Module C3347. GO to I2 .
Ignition ON.
While pressing and releasing the ambient lighting switch, measure No
the voltage between the ambient lighting module C3347-2, circuit If voltage is always
CLN54 (BN/YE), harness side and ground. present, GO to I3 . If
no voltage is present,
GO to I4 .
Is the voltage greater than 10 volts with the switch pressed

and 0 volts with the switch released?
I2 CHECK THE AMBIENT LIGHTING HARNESS
Ignition OFF. Yes
Check the diode circuits between the ambient lighting module, GO to I6 .
No
Connector-Pin Connector-Pin REPAIR or INSTALL a
new ambient lighting
harness. TEST the
Circuit Circuit system for normal
operation.
C3347-5 C3347-4
CLN45 (GN) RLN44 (BN)

C3347-6 C3347-4
CLN46 (BU) RLN44 (BN)

C3347-7 C3347-4
CLN44 (OG) RLN44 (BN)

Does the meter indicate good for each circuit check?
I3 CHECK THE AMBIENT LIGHTING SWITCH OUTPUT CIRCUIT FOR
A SHORT TO VOLTAGE
Ignition OFF. Yes
Disconnect: Ambient Lighting Switch C2401. REPAIR circuit CLN54
Ignition ON. (BN/YE) or circuit
Measure the voltage between the ambient lighting module C3347- CLN60 (WH/BN) for a
2, circuit CLN60 (WH/BN), harness side and ground. short to voltage. TEST
operation.
No
INSTALL a new
ambient lighting
switch. REFER to
Ambient Lighting
TEST the system for
normal operation.

I4 CHECK FOR VOLTAGE TO AMBIENT LIGHTING SWITCH
Ignition OFF. Yes
Connect: Ambient Lighting Module C3347. GO to I5 .
Disconnect: Ambient Lighting Switch C2401.
Ignition ON. No
Measure the voltage between the ambient lighting switch C2401-2, REPAIR circuit CLN02
circuit CLN02 (VT/BN), harness side and ground. (VT/BN) for an open.
TEST the system for
normal operation.

I5 BYPASS THE AMBIENT LIGHTING SWITCH
Connect and remove a fused jumper wire between the ambient Yes
lighting switch C2401-2, circuit CLN02 (VT/BN), harness side and REMOVE the jumper
the ambient lighting switch C2401-1, circuit CLN60 (WH/BN), wire. INSTALL a new
harness side. ambient lighting
switch. REFER to
Ambient Lighting
TEST the system for
normal operation.
No
REMOVE the jumper
CLN54 (BN/YE) or
circuit CLN60
TEST the system for
normal operation.
Do the ambient LEDs illuminate and cycle through a color

change each time the jumper wire is connected and removed?
I6 CHECK FOR CORRECT AMBIENT LIGHTING MODULE
OPERATION
Disconnect the ambient lighting module connector. Yes
corrosion ambient lighting
damaged pins module. REFER to
pushed-out pins Ambient Lighting
Connect the ambient lighting module connector and make sure it Module in this section.
seats correctly. TEST the system for
No
The system is
may have been
corroded connector.
Pinpoint Test J: The Ambient Lighting Is Always On
Normal Operation
ambient lighting module and the ambient lighting switch.
The ambient lighting also has its own illuminated entry/exit strategy. For additional information regarding
this strategy, refer to Interior Lighting , Illuminated Entry/Exit.
DTC B12F1:15 (Ambient Lighting Zone 1 Output: Circuit Short To Battery Or Open) — a
continuous and on-demand DTC that sets when the BCM detects a short to voltage from the
ambient lighting module voltage supply circuit.

BCM
PINPOINT TEST J: THE AMBIENT LIGHTING IS ALWAYS ON
NOTE: Under some conditions, the ambient lighting system is active for up to 10 minutes after the
ignition is changed to OFF or a door is opened. Make sure the battery saver feature operates correctly
before continuing diagnostics.

J1 CHECK THE BCM AMBIENT LIGHTING
SYSTEM OUTPUT CIRCUIT FOR A SHORT
TO VOLTAGE
Ignition OFF. Yes
Disconnect: BCM C2280E. REPAIR circuit CLN54 (BN/YE) or circuit CLN60
Ignition ON. (WH/BN) for a short to voltage. CLEAR the
Does the ambient lighting continue to DTCs. TEST the system for normal operation.
illuminate?
No
GO to J2 .
J2 CHECK FOR CORRECT BCM
OPERATION
damaged pins
pushed-out pins No
Connect all the BCM connectors and The system is operating correctly at this time.
make sure they seat correctly. The concern may have been caused by a loose
Operate the system and verify the or corroded connector.
Ambient Lighting Module
Part
1 — Lower instrument panel finish panel
2 83B01 Floor console finish panel
3 — Ambient lighting module electrical connector (part of
14K006)
4 W790200 Ambient lighting module screws (2 required)
5 13C788 Ambient lighting module
2. Remove the floor console finish panel for access to the ambient lighting module. For additional
information, refer to the floor console exploded view in Section 501-12 .
Lift upward on the rear of the floor console finish panel to release the floor console finish panel
clips.
If equipped, disconnect the electrical connector.
Slide the park brake lever boot and the floor console finish panel over the park brake lever.
3. Remove the ambient lighting module.

Remove the 2 screws.

Ambient Lighting Switch
Part
1 W714972-S1 Retaining clip (4 required)
2 15K12A Media bezel
3 13D806A Ambient lighting switch
4 — Ambient lighting switch electrical connector (part of
14E078)
removal.
SECTION 418-00: Module Communications Network 2011 Fiesta Workshop Manual
Communications Network
Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit. Multiplexing allows 2
or more electronic modules (nodes) to communicate simultaneously over a twisted-wire pair [data (+) and data
(-)] network. 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.
The vehicle has 2 module communication networks connected to the Data Link Connector (DLC) and
communicate with the scan tool. The communication networks are:
High Speed Controller Area Network (HS-CAN)

Medium Speed Controller Area Network (MS-CAN)
The Infotainment Controller Area Network (I-CAN) is connected to the DLC , but the I-CAN modules
communicate with the scan tool over the MS-CAN . The Front Control/Display Interface Module (FCDIM) is
used as a gateway module for the messages to transfer between the scan tool and the modules on the I-CAN .
Network Topology
Termination
Module Name Network Type Module
ABS module HS-CAN No
Accessory Protocol Interface Module (APIM) (if equipped) HS-CAN / I-CAN No/No
Audio Control Module (ACM) I-CAN Yes
Body Control Module (BCM) MS-CAN Yes
Front Control/Display Interface Module (FCDIM) ( MS-CAN / I-CAN MS-CAN / I-CAN No/Yes
gateway module)
Global Positioning System Module (GPSM) (if equipped) I-CAN No
Instrument Panel Cluster (IPC) ( HS-CAN / MS-CAN gateway module) HS-CAN / MS- Yes/Yes
CAN
Occupant Classification System Module (OCSM) HS-CAN No
PCM HS-CAN Yes
Power Steering Control Module (PSCM) HS-CAN No
Remote Function Actuator (RFA) module (if equipped) HS-CAN / MS- No/No
CAN
Restraints Control Module (RCM) HS-CAN No
Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) MS-CAN No
Transmission Control Module (TCM) (if equipped) HS-CAN No
Network Termination
The CAN uses a network termination circuit to improve communication reliability. The network termination of
the CAN bus occurs inside the termination modules by termination resistors. Termination modules are located
at either end of the bus network. As network messages are broadcast in the form of voltage signals, the
network voltage signals are stabilized by the termination resistors. Each termination module has a 120 ohm
resistor across the positive and negative bus connection in the termination module. With 2 termination modules
on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network
impedance, or total resistance is 60 ohms.
Network termination improves bus message reliability by stabilizing bus voltage, and eliminating electrical
interference.
Gateway Module
The IPC is the gateway module, translating HS-CAN to MS-CAN and vice versa. The FCDIM is the gateway
module, translating MS-CAN to I-CAN and vice versa, allowing a message to be distributed throughout the
three networks. The IPC and the FCDIM are the only modules on this vehicle that have this ability.
SECTION 418-00: Module Communications Network 2011 Fiesta Workshop Manual
Communications Network
Special Tool(s)

scan tool
Flex Probe Kit

The High Speed Controller Area Network (HS-CAN) operates at a maximum data transfer speed of 500 Kbps
and is designed for real time powertrain information transfer and control. Modules on the HS-CAN communicate
using bussed messages. The HS-CAN uses an unshielded twisted pair cable, data bus (+) and data bus (-)
circuits. In addition to scan tool communication, the HS-CAN allows sharing of information between all modules
on the network.
The Medium Speed Controller Area Network (MS-CAN) operates at a maximum data transfer speed of 125
Kbps for bus messages and is designed for general information transfer. Modules on the MS-CAN
communicate using bussed messages. The MS-CAN uses an unshielded twisted pair cable, data bus (+) and
data bus (-) circuits. In addition to scan tool communication, the MS-CAN allows sharing of information between
all modules on the network.
The Infotainment Controller Area Network (I-CAN) operates at a maximum data transfer speed of 500 Kbps and
is designed for real time audio and multimedia information transfer and control. Modules on the I-CAN
communicate using bussed messages. The I-CAN uses an unshielded twisted pair cable, data bus (+) and data
bus (-) circuits. The I-CAN allows sharing of information between all modules on the network. The I-CAN is
connected to the Data Link Connector (DLC), but the I-CAN modules communicate with the scan tool over the
MS-CAN . The Front Control/Display Interface Module (FCDIM) is used as a gateway module for the messages
to transfer between the scan tool and the modules on the I-CAN .
Controller Area Network (CAN) Fault Tolerance
NOTE: The oscilloscope traces below are from the Integrated Diagnostic System (IDS) oscilloscope taken
using the IDS pre-configured CAN settings. The traces are for both data (+) and data (-) taken simultaneously
(2-channel) at a sample rate of 1 mega-sample per second (1MS/s) or greater.
Traces below are viewed at 500mV per division (vertical axis) and 20 microseconds (20µs) per division
(horizontal axis). Readings taken with a different oscilloscope vary from those shown. Compare any suspect
readings to a known good vehicle.
Normal CAN Operation

The data (+) and data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network
traffic. As 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 message is sent.
Successful communication of a message can usually be identified by the slight spike at the end of a message
transmission. Any signals that are significantly different than the normal CAN waveform may cause network
DTCs (U-codes) to set or may cause a complete network outage.
CAN Circuits Shorted Together

In the event the data (+) and data (-) circuits become shorted together, the signal stays at base voltage (2.5V)
continuously and all communication capabilities are lost.
CAN (+) Circuit Shorted To Ground
In the event the data (+) circuit becomes shorted to ground, both the data (+) and data (-) circuits are pulled low
(0V) and all communication capabilities are lost.
CAN (-) Circuit Shorted To Ground
In the event the data (-) circuit becomes shorted to ground, the data (-) circuit is pulled low (0V) and the data (+)
circuit reaches near-normal peak voltage (3.0V) during communication but falls to 0V instead of normal base
voltage (2.5V). Communication may continue but at a degraded level.
CAN (+) Circuit Shorted To Battery Voltage

In the event the data (+) circuit becomes shorted to battery voltage, the data (+) circuit is pulled high (12V) and
the data (-) circuit falls to abnormally high voltage (above 5V) during communication and reaches battery
voltage (12V) for peak voltage. Communication may continue but at a degraded level.
CAN (-) Circuit Shorted To Battery Voltage
In the event the data (-) circuit becomes shorted to battery voltage, both the data (+) and data (-) circuits are
pulled high (12V) and all communication capabilities are lost.
CAN Circuit Signal Corruption

Rhythmic oscillations, inductive spikes or random interference can disrupt the network communications. The
corruption signal source may be outside electrical interference such as motors or solenoids or internal
interference generated from a module on the network. In some cases, an open in either the data (+) or data (-)
circuit to a network module may cause the module to emit interference on the one circuit which is still
connected. The trace shown is an example of a "sawtooth" pattern transmitted from a module with one open
network circuit.
Other corruptions may be present when a module is intermittently powered up and down. The module on power
up may initiate communication out of sync with other modules on the network causing momentary
communication outages.
Controller Area Network (CAN) Multiplex Messages
Modules on the CAN utilize simultaneous communication of 2 or more messages on the same network circuits.
The following chart summarizes the messages sent and received on the network.
CAN Module Communication Message Chart
NOTE: This chart describes the specific HS-CAN and MS-CAN messages broadcast by each module, and the
module(s) that receive the message.
NOTE: For the I-CAN , message mapping is not essential to diagnostics as the symptoms arising from a
message error are all related to the audio system. For audio system concerns, refer to Section 415-00 .
Broadcast Message Originating Module Network Type Receiving Module(s)

ABS flag data ABS module HS-CAN IPC
PCM
TCM
ABS info ABS module HS-CAN IPC
TCM
ABS info2 ABS module HS-CAN RFA
PCM
TCM
ABS_Request ABS module HS-CAN IPC
PCM
RCM
TCM
ABS vehicle reference speed (gateway) IPC MS-CAN BCM
Accelerometer data ABS module HS-CAN TCM
Accelerometer data (gateway) IPC MS-CAN FCDIM
Air/fuel freeze frame data PCM HS-CAN TCM
Body information 4 IPC HS-CAN ABS module
PCM
Body system data (gateway) BCM MS-CAN FCDIM
IPC
RFA module
Charging system current data PCM HS-CAN IPC
Charging system data PCM HS-CAN IPC
Chime request data FCDIM MS-CAN IPC
Date/time adjust request FCDIM MS-CAN IPC
Date/time data IPC MS-CAN FCDIM
Display data IPC MS-CAN FCDIM
Display parameters FCDIM MS-CAN IPC
BCM
Driver information data (gateway) IPC MS-CAN BCM
FCDIM
TPMS
Engine idle speed data PCM HS-CAN ABS module
IPC
Engine torque data 1 (gateway) IPC MS-CAN BCM
RFA module
TPMS
Engine torque data 3 PCM HS-CAN TCM
Engine torque data flags PCM HS-CAN ABS module
TCM
Engine torque status PCM HS-CAN ABS module
IPC
TCM
IPC information 1 IPC HS-CAN PCM
TCM
IPC information 3 IPC HS-CAN ABS module
PCM
IPC PATS status IPC HS-CAN PCM
IPC status data IPC MS-CAN BCM
FCDIM
RFA module
Illumination data BCM MS-CAN FCDIM
IPC
Light and chime request BCM MS-CAN FCDIM
IPC
TPMS
OCS data OCSM HS-CAN RCM
OCS serial data OCSM HS-CAN RCM
PCM PATS status PCM HS-CAN IPC
Pedal data IPC HS-CAN ABS module
PCM
PEPS data RFA module MS-CAN IPC
BCM
PEPS status RFA module MS-CAN IPC
Power mode data IPC HS-CAN ABS module
PCM
PSCM
Power mode status IPC MS-CAN BCM
FCDIM
RFA module
Powertrain data 1 PCM HS-CAN ABS module
IPC
RCM
TCM
RCM event RCM HS-CAN IPC
PCM
RCM event (gateway) IPC MS-CAN BCM
RCM serial number RCM HS-CAN ABS module
OCSM
RCM status RCM HS-CAN APIM
IPC
OCSM
Restraints data IPC HS-CAN RCM
Speed control status PCM HS-CAN IPC
TCM
Speed control switch data (gateway) IPC HS-CAN PCM
Steering wheel angle sensor data PSCM HS-CAN ABS module
PCM
Torque data 1 PCM HS-CAN ABS module
IPC
RCM
TCM
TPMS status TPMS MS-CAN IPC
Transmission configuration PCM HS-CAN ABS module
TCM
Transmission data TCM HS-CAN IPC
PCM
Transmission data 3 TCM HS-CAN ABS module
IPC
OCSM
PCM
Transmission data 4 TCM HS-CAN IPC
PCM
Transmission gear data 2 PCM HS-CAN ABS module
Transmission input data 1 TCM HS-CAN PCM
Transmission input data 2 TCM HS-CAN ABS module
IPC
PCM
Vehicle age IPC MS-CAN BCM
FCDIM
Vehicle age IPC HS-CAN PCM
TCM
Vehicle configuration data IPC MS-CAN BCM
FCDIM
RFA module
Vehicle configuration data (gateway) IPC HS-CAN ABS module
PCM
PSCM
RCM
Vehicle speed data PCM HS-CAN ABS module
IPC
PSCM
RCM
TCM
Vehicle speed data (gateway) IPC MS-CAN BCM
FCDIM
HVAC module
RFA module
TPMS
Wheel speed data ABS module HS-CAN PCM
TCM
Wheel speed data (gateway) IPC MS-CAN FCDIM
2. Visually inspect for obvious signs of electrical damage.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible)

Electrical
Battery Junction Box (BJB) fuse(s):
1 (40A) (ABS module)
2 (50A) (Transmission Control Module (TCM))
9 (20A) (ABS module)
16 (15A) (PCM)
27 (7.5A) (PCM, TCM )
Central Junction Box (CJB) fuse(s):
1 (15A) (Remote Function Actuator (RFA) module)
3 (7.5A) (Instrument Panel Cluster (IPC))
4 (7.5A) (Occupant Classification System Module (OCSM))
5 (15A) (no power to scan tool)
7 (7.5A) (Front Control/Display Interface Module (FCDIM))
9 (20A) ( RFA module)
10 (15A) (Audio Control Module (ACM), Accessory Protocol Interface Module (APIM), Global
Positioning System Module (GPSM) vehicles built after 1/14/2011)
12 (20A) (Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM))
14 (20A) ( RFA module)
16 (15A) (Global Positioning System Module (GPSM) vehicles built up to 1/14/2011)
19 (7.5A) ( ACM , IPC )
20 (10A) ( Restraints Control Module (RCM))
21 (10A) (Body Control Module (BCM), IPC , Power Steering Control Module (PSCM))
22 (7.5A) (ABS module, PCM)
23 (10A) ( TCM , TPM / VSM )
26 (7.5A) ( TPM / VSM )
Data Link Connector (DLC)
3. Connect the scan tool to the DLC .
NOTE: Make sure to use the latest scan tool software release.
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
If the Integrated Diagnostic System (IDS) does not communicate with the VCM :
GO to Pinpoint Test R , to diagnose No Power To The Scan Tool.
4. Establish a scan tool session.

NOTE: The scan tool first attempts to communicate with the PCM, after establishing
communication with the PCM, the scan tool then attempts to communicate with all other modules
on the vehicle.
If an IDS session cannot be established with the vehicle, ( IDS may state "No communication can
be established with the PCM"):
Choose "NO" when the scan tool prompts whether or not to retry communication.
Enter either a PCM part number, tear tag or calibration number to identify the vehicle and
start a session (the PCM part number and 4-character tear tag are printed on the PCM
label).
GO to Pinpoint Test A , to diagnose The PCM Does Not Respond To The Scan Tool.

If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step
6.
If the network test fails, GO to Symptom Chart to diagnose the failed communication network.
If a module fails to communicate during the network test, GO to Symptom Chart .
6. Retrieve and review the DTCs.

If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network DTC
diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics (U-codes).
If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, repair procedures such as module reprogramming often set network
DTCs. Replacing a module to resolve a network DTC is unlikely to correct the concern. To prevent repeat
network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery, refer to
Section 414-01 .
Communication Network DTC Chart

DTC Description Source Action
U0001:00 High Speed Controller RFA The module could not communicate on the network at a
Area Network (HS- point in time. The fault is not currently present (the
CAN) Communication module had to communicate with the scan tool to report
Bus: no subtype this DTC). CLEAR the DTC. REPEAT the network test
information with the scan tool. VERIFY the integrity of the
connectors and wiring Refer to Wiring Diagrams Cell 14 ,
Module Communications Network for schematic and
U0001:88 High Speed Controller ABS The module could not communicate on the network at a
Area Network (HS- module point in time. The fault is not currently present (the
CAN) Communication PSCM module had to communicate with the scan tool to report
Bus PCM this DTC). CLEAR the DTC. REPEAT the network test
with the scan tool. VERIFY the integrity of the
U0002:81 High Speed Controller PCM The module could not communicate on the network at a
Area Network (HS- point in time. The fault is not currently present (the
CAN) Communication module had to communicate with the scan tool to report
Bus Performance this DTC). CLEAR the DTC. REPEAT the network test
U0010:00 Medium Speed RFA The module could not communicate on the network at a
Controller Area Network point in time. The fault is not currently present (the
(MS-CAN) module had to communicate with the scan tool to report
Communication Bus: no this DTC). CLEAR the DTC. REPEAT the network test
subtype information with the scan tool. VERIFY the integrity of the
U0010:88 Medium Speed BCM The module could not communicate on the network at a
Controller Area Network FCDIM point in time. The fault is not currently present (the
(MS-CAN) module had to communicate with the scan tool to report
Communication Bus this DTC). CLEAR the DTC. REPEAT the network test
U0028:00 Vehicle Communication TCM The module could not communicate on the network at a
Bus A point in time. The fault is not currently present (the
module had to communicate with the scan tool to report
this DTC). CLEAR the DTC. REPEAT the network test
U0028:08 Vehicle Communication RCM The module could not communicate on the network at a
Bus A: Bus point in time. The fault is not currently present (the
Signal/Message module had to communicate with the scan tool to report
Failures this DTC). CLEAR the DTC. REPEAT the network test
U0028:88 Vehicle Communication RCM The module could not communicate on the network at a
Bus A: Bus Off point in time. The fault is not currently present (the
module had to communicate with the scan tool to report
U0073:00 Control Module TCM The module could not communicate on the network at a
Communication Bus "A" point in time. The fault is not currently present (the
Off module had to communicate with the scan tool to report
U0074:88 Infotainment Controller FCDIM The module could not communicate on the network at a
Area Network (I-CAN) point in time. The fault is not currently present (the
Communication Bus module had to communicate with the scan tool to report
U3000:88 Control Module: Bus Off APIM The module could not communicate on the network at a
point in time. The fault is currently not present since the
module is currently communicating with the scan tool
reporting this DTC. CLEAR the DTC. REPEAT the
network test with the scan tool. VERIFY the integrity of
the connectors and wiring Refer to Wiring Diagrams Cell
14 , Module Communications Network for schematic and
Symptom Chart
Symptom Chart
The vehicle does not start Wiring, GO to Pinpoint Test R .
with the scan tool connected terminals or
to the Data Link Connector connectors
(DLC) and/or multiple Scan tool
malfunction indicators are
only on when the scan tool is
connected to the DLC .
The PCM does not respond Wiring, REFER to the Powertrain
to the scan tool terminals or Control/Emissions Diagnosis
connectors (PC/ED) manual, Section 5,
PCM pinpoint test QA before
proceeding to Pinpoint Test A . If
pinpoint test QA has been
completed, GO to Pinpoint Test
A.
The ABS module does not Fuse GO to Pinpoint Test B .
respond to the scan tool Wiring,
terminals or
connectors
ABS module
The Instrument Panel Cluster Fuse(s) GO to Pinpoint Test C .
(IPC) does not respond to the Wiring,
scan tool terminals or
connectors
IPC
The Occupant Classification Fuse GO to Pinpoint Test D .
System Module (OCSM) Wiring,
does not respond to the scan terminals or
tool connectors
OCSM
The Restraints Control Fuse GO to Pinpoint Test E .
Module (RCM) does not Wiring,
respond to the scan tool terminals or
connectors
RCM
The Accessory Protocol Fuse GO to Pinpoint Test F .
Interface Module (APIM) Wiring,
tool connectors
APIM
The Remote Function Fuse GO to Pinpoint Test G .
Actuator (RFA) module does Wiring,
not respond to the scan tool terminals or
connectors
RFA module
The Front Control/Display Fuse GO to Pinpoint Test H .
Interface Module (FCDIM) Wiring,
tool connectors
FCDIM
The Power Steering Control Fuse GO to Pinpoint Test I .
Module (PSCM) does not Wiring,
connectors
PSCM
The Body Control Module Fuse GO to Pinpoint Test J .
(BCM) does not respond to Wiring,
the scan tool terminals or
connectors
BCM
The Audio Control Module Fuse GO to Pinpoint Test K .
(ACM) does not respond to Wiring,
the scan tool terminals or
connectors
ACM
The Global Positioning Fuse GO to Pinpoint Test L .
System Module (GPSM) Wiring,
tool connectors
GPSM
The Transmission Control Fuse GO to Pinpoint Test M .
Module (TCM) does not Wiring,
connectors
TCM
The Tire Pressure Monitor Fuse GO to Pinpoint Test N .
(TPM)/Vehicle Security Wiring,
Module (VSM) does not terminals or
respond to the scan tool connectors
TPM / VSM
No Medium Speed Controller Wiring, GO to Pinpoint Test O .
Area Network (MS-CAN) terminals or
communication, all modules connectors
are not responding BCM
FCDIM
IPC
RFA module
(if equipped)
TPM / VSM
(if equipped)
No High Speed Controller Wiring, GO to Pinpoint Test P .
Area Network (HS-CAN) terminals or
communication, all modules connectors
are not responding ABS module
APIM (if
equipped)
IPC
OCSM
PCM
PSCM
RCM
RFA module
(if equipped)
TCM (if
equipped)
No Infotainment Controller Wiring, If the FCDIM does not pass a
Area Network (I-CAN) terminals or network test, DIAGNOSE the
communication, all modules connectors FCDIM first. GO to Pinpoint Test
are not responding ACM H.
APIM If the FCDIM passes a network
FCDIM test, GO to Pinpoint Test Q .
GPSM
No power to the scan tool Fuse GO to Pinpoint Test R .
Wiring,
terminals or
connectors
Scan tool
Data Link
Connector
(DLC)
Pinpoint Tests
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 14 , Module Communications Network for schematic and connector information.
Refer to Wiring Diagrams Cell 23 , Electronic Engine Controls for schematic and connector information.
Normal Operation
The PCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN).

PCM
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS THE
NETWORK TEST
Enter the following diagnostic mode on the scan tool: Network Test. Yes
In the left hand pane of the IDS network test display screen, verify If "pass" or a DTC was
whether any HS-CAN modules passed the network test. listed next to the PCM, a
Is the text "pass" or a DTC listed next to any of the following network fault is not
modules (if equipped): ABS module, Accessory Protocol Interface currently present. GO to
Module (APIM), Instrument Panel Cluster (IPC), Occupant Pinpoint Test r to
Classification System Module (OCSM), Power Steering Control diagnose an intermittent
Module (PSCM), PCM, Remote Function Actuator (RFA), HS-CAN fault condition.
Restraints Control Module (RCM) orTransmission Control Module
(TCM)? If "pass" or a DTC was
listed next to one or more
modules other than the
PCM, GO to A2 .
No
No modules are currently
communicating on the
HS-CAN . GO to Pinpoint
Test q to diagnose no
HS-CAN communication.
A2 PC/ED MANUAL PINPOINT TEST QA VERIFICATION CHECK
Verify that pinpoint test QA has been carried out. Yes
Has pinpoint test QA been carried out? GO to A3 .
No
REFER to the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual, Section 5,
pinpoint test QA to
diagnose no
communication with the
PCM.
A3 CHECK THE HS-CAN TERMINATION RESISTANCE
Ignition OFF. Yes
Disconnect: Negative Battery Cable. CONNECT the negative
Measure the resistance between the Data Link Connector (DLC) C251- battery cable. GO to A5 .
6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit
VDB05 (WH), harness side. No
GO to A4 .

A4 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC
FOR AN OPEN
Measure the resistance between the PCM C175B-20, circuit VDB04 CONNECT the negative
(WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), battery cable. GO to A5 .
harness side.
No
question. CLEAR the
DTCs. REPEAT the
network test with the
scan tool.
Measure the resistance between the PCM C175B-19, circuit VDB05
(WH), harness side and the DLC C251-14, circuit VDB05 (WH),
harness side.

A5 CHECK FOR CORRECT PCM OPERATION
Check for: INSTALL a new PCM.
damaged pins 14 . CLEAR the DTCs.
pushed-out pins REPEAT the network test
Connect all the PCM connectors and make sure they seat correctly. with the scan tool.
corroded connector.
CLEAR the DTCs.
REPEAT the network test
with the scan tool.
Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool
Normal Operation
The ABS module communicates with the scan tool through the High Speed Controller Area Network (HS-CAN).

Fuse
ABS module
PINPOINT TEST B: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

B1 CHECK THE ABS MODULE VOLTAGE SUPPLY CIRCUITS
FOR AN OPEN
Ignition OFF. Yes
Disconnect: ABS Module C135. GO to B2 .
Ignition ON.
Measure the voltage between the ABS module C135-1, circuit No
SBB01 (RD), C135-8, circuit CBP22 (GN/WH) and C135-32, VERIFY the Battery Junction Box
circuit SBB28 (GN/RD), harness side and ground. (BJB) fuses 1 (40A), 9 (20A) and
22 (7.5A) are OK. If OK, REPAIR
the circuit in question. If not OK,
REFER to the Wiring Diagrams
manual to identify the possible
network test with the scan tool.

B2 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to B3 .
Measure the resistance between the ABS module C135-47,
circuit GD123 (BK/GY), harness side and ground. No
REPAIR the circuit. CLEAR the
DTCs. REPEAT the network test
with the scan tool.

B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS
MODULE AND THE DLC FOR AN OPEN
Measure the resistance between the ABS module C135-12, Yes
circuit VDB04 (WH/BU), harness side and the DLC C251-6, CONNECT the negative battery
circuit VDB04 (WH/BU), harness side. cable. GO to B4 .
No
REPAIR the circuit in question.
Measure the resistance between the ABS module C135-13,

circuit VDB05 (WH), harness side and the DLC C251-14, circuit
VDB05 (WH), harness side.

B4 CHECK FOR CORRECT ABS MODULE OPERATION
Disconnect the ABS module connector. Yes
Check for: INSTALL a new ABS module.
damaged pins CLEAR the DTCs. REPEAT the
pushed-out pins network test with the scan tool.
Connect the ABS module connector and make sure it seats
correctly. No
with the scan tool.
Pinpoint Test C: The Instrument Panel Cluster (IPC) Does Not Respond To The Scan Tool
Normal Operation
The Instrument Panel Cluster (IPC) communicates with the scan tool and other network modules on the High
Speed Controller Area Network (HS-CAN). The IPC does not communicate with the scan tool on the Medium
Speed Controller Area Network (MS-CAN).
Fuse(s)
IPC
PINPOINT TEST C: THE IPC DOES NOT RESPOND TO THE SCAN TOOL
Section 413-01 .

C1 CHECK THE HS-CAN TERMINATION RESISTANCE
Ignition OFF. Yes
Disconnect: Negative Battery Cable. CONNECT the negative battery
Disconnect the scan tool cable from the Data Link Connector cable. GO to C2 .
(DLC).
Measure the resistance between the DLC C251-6, circuit No
VDB04 (WH/BU), harness side and the DLC C251-14, circuit GO to C4 .

C2 CHECK THE IPC VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: IPC C220. GO to C3 .
Ignition ON.
Measure the voltage between the IPC , harness side and No
ground as follows: VERIFY the Central Junction
Box (CJB) fuse 3 (7.5A), 19
Connector-Pin Circuit (7.5A) and 21 (10A) is OK. If
OK, REPAIR the circuit in
C220-4 CBP21 (BU/GY) question. If not OK, REFER to
C220-15 CBP19 (BN/WH)
C220-32 SBP03 (BU/RD) the circuit short. CLEAR the
with the scan tool.
C3 CHECK THE IPC GROUND CIRCUIT FOR AN OPEN
Disconnect: Negative Battery Cable. Yes
Measure the resistance between IPC C220-6, circuit GD115 GO to C4 .
(BK/GY) harness side and ground.
No

C4 CHECK THE HS-CAN CIRCUITS BETWEEN THE IPC AND THE
DLC FOR AN OPEN
Measure the resistance between the IPC C220-18, circuit Yes
VDB04 (WH/BU), harness side and the Data Link Connector GO to C5 .
(DLC) C251-6, circuit VDB04 (WH/BU), harness side.
No

VDB05 (WH), harness side and the DLC C251-14, circuit
C5 CHECK THE MS-CAN CIRCUITS BETWEEN THE IPC AND THE
DLC FOR AN OPEN
Measure the resistance between the IPC C220-23, circuit Yes
VDB06 (GY/OG), harness side and the Data Link Connector CONNECT the negative battery
(DLC) C251-3, circuit VDB06 (GY/OG), harness side. cable. GO to C6 .
No

VDB07 (VT/OG), harness side and the DLC C251-11, circuit
VDB07 (VT/OG), harness side.

C6 CHECK FOR CORRECT IPC OPERATION
Check for: INSTALL a new IPC . REFER to
corrosion Section 413-01 . CLEAR the
damaged pins DTCs. REPEAT the network test
pushed-out pins with the scan tool.
Connect all the IPC connectors and make sure they seat
correctly. No
connector.
Pinpoint Test D: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan
Tool
Normal Operation
The Occupant Classification System Module (OCSM) communicates with the scan tool through the High Speed
Controller Area Network (HS-CAN).
Fuse
OCSM
PINPOINT TEST D: THE OCSM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

D1 CHECK THE OCSM VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Depower the SRS . Refer to Section 501-20B . GO to D2 .
Disconnect: OCSM C3159.
Deactivate the SRS . Refer to Section 501-20B . No
Repower the SRS . Refer to Section 501-20B . VERIFY the Central Junction Box
Ignition ON. (CJB) fuse 4 (7.5A) is OK. If OK,
Measure the voltage between the OCSM C3159-1, circuit REPAIR the circuit. If not OK,
CBP04 (VT), harness side and ground. REFER to the Wiring Diagrams
REACTIVATE the SRS . REFER
to Section 501-20B . CLEAR the
with the scan tool.
D2 CHECK THE OCSM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to D3 .
Measure the resistance between the OCSM C3159-14, circuit
GD145 (BK/BU), harness side and ground. No
REPAIR the circuit. REACTIVATE
the SRS . REFER to Section 501-
20B . CLEAR the DTCs. REPEAT
the network test with the scan tool.

D3 CHECK THE HS-CAN CIRCUITS BETWEEN THE OCSM AND
THE DATA LINK CONNECTOR (DLC) FOR AN OPEN
Measure the resistance between the OCSM C3159-18, circuit Yes
VDB04 (WH/BU), harness side and the DLC C251-6, circuit CONNECT the negative battery
VDB04 (WH/BU), harness side. cable. GO to D4 .
No
Measure the resistance between the OCSM C3159-9, circuit

D4 CHECK FOR CORRECT OCSM OPERATION
Disconnect the OCSM connector. Yes
Check for: INSTALL a new OCSM .
corrosion REACTIVATE the SRS . REFER
damaged pins to Section 501-20B . CLEAR the
pushed-out pins DTCs. REPEAT the network test
Connect the OCSM connector and make sure it seats with the scan tool.
correctly.
Verify the concern is still present. No
corroded connector. REACTIVATE
Pinpoint Test E: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
Normal Operation
The Restraints Control Module (RCM) communicates with the scan tool through the High Speed Controller Area
Network (HS-CAN).
Fuse
RCM
PINPOINT TEST E: THE RCM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

E1 CHECK THE RCM CONNECTION
Ignition OFF. Yes
Depower the SRS . Refer to Section 501-20B . GO to E2 .
Disconnect: RCM C310A.
Disconnect: RCM C310B. No
Are RCM C310A pins 13 and 14 and RCM C310B pins 9 REPAIR the RCM connector pins
and 10 OK? as necessary. REPOWER the
SRS . REFER to Section 501-
E2 CHECK THE RCM VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Deactivate the SRS . Refer to Section 501-20B . Yes
Repower the SRS . Refer to Section 501-20B . GO to E3 .
Ignition ON.
Measure the voltage between the RCM C310A-13, circuit No
CBP20 (YE/VT), harness side and ground. VERIFY the Central Junction Box
(CJB) fuse 20 (10A) is OK. If OK,
REPAIR the circuit. If not OK,
with the scan tool.

E3 CHECK THE RCM CASE GROUND
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to E4 .
Measure the resistance between the RCM C310A-14, circuit
GD174 (BK/WH), harness side and ground. No
REPAIR the circuit. REACTIVATE
E4 CHECK THE HS-CAN CIRCUITS BETWEEN THE RCM AND
THE DLC FOR AN OPEN
Measure the resistance between the RCM C310B-10, circuit Yes
VDB04 (WH/BU), harness side. cable. GO to E5 .
No
with the scan tool.
Measure the resistance between the RCM C310B-9, circuit


E5 CHECK FOR CORRECT RCM OPERATION
Disconnect all the RCM connectors. Yes
Check for: INSTALL a new RCM .
corrosion REACTIVATE the SRS . REFER
damaged pins to Section 501-20B . CLEAR the
pushed-out pins DTCs. REPEAT the network test
Connect all the RCM connectors and make sure they seat with the scan tool.
correctly.
at this time. The concern may have
been caused by a loose or
corroded connector. REACTIVATE
Pinpoint Test F: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool
Normal Operation
TheAccessory Protocol Interface Module (APIM) communicates with the scan tool and other network modules
on the High Speed Controller Area Network (HS-CAN). The APIM does not communicate with the scan tool on
the Infotainment Controller Area Network (I-CAN).
Fuse
APIM
PINPOINT TEST F: THE APIM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

F1 CHECK THE APIM VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: APIM C2383. GO to F2 .
Ignition ON.
Measure the voltage between the APIM C2383-1, circuit SBP10 No
(YE/RD), harness side and ground. VERIFY the Central Junction
Box (CJB) fuse 10 (15A) is OK.
If OK, REPAIR the circuit. If not
short. CLEAR the DTCs.
REPEAT the network test with
the scan tool.

F2 CHECK THE APIM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to F3 .
Measure the voltage between the APIM , harness side and
Connector-Pin Circuit CLEAR the DTCs. REPEAT the
C2383-6 GD111 (BK/BU)
C2383-37 GD111 (BK/BU)
C2383-38 GD111 (BK/BU)
F3 CHECK THE HS-CAN CIRCUITS BETWEEN THE APIM AND
THE DLC FOR AN OPEN
Measure the resistance between the APIM C2383-53, circuit Yes
VDB04 (WH/BU), harness side and the DLC C251-6, circuit GO to F4 .
VDB04 (WH/BU), harness side.
No
Measure the resistance between the APIM C2383-54, circuit


F4 CHECK FOR CORRECT APIM OPERATION
Check for: INSTALL a new APIM . REFER
corrosion to Section 415-00 . CLEAR the
Connect the APIM connector and make sure it seats correctly.
the scan tool.
Pinpoint Test G: The Remote Function Actuator (RFA) Module Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 110 , Power Door Locks for schematic and connector information.
Normal Operation
The Remote Function Actuator (RFA) module communicates with the scan tool and some network modules on
the Medium Speed Controller Area Network (MS-CAN), and communicates with other network modules only on
the High Speed Controller Area Network (HS-CAN).
Fuse
RFA module
PINPOINT TEST G: THE RFA MODULE DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

G1 CHECK THE RFA MODULE VOLTAGE SUPPLY CIRCUITS FOR
AN OPEN
Ignition OFF. Yes
Disconnect: RFA module (Gray Hardshell) and C3503B (Green GO to G2 .
Hardshell).
Ignition ON. No
Measure the voltage between the RFA module C3503A-1, circuit VERIFY the Central Junction
SBP09 (RD), harness side and ground; and C3503A-2, circuit Box (CJB) fuses 1 (15A), 9
SBP14 (BN/RD), harness side and ground. (20A) and 14 (20A) are OK. If
question. If not OK, REFER to
the circuit short. CLEAR the
DTCs. REPEAT the network
test with the scan tool.
Measure the voltage between the RFA module C3503A-1, circuit

G2 CHECK THE RFA MODULE GROUND CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to G3 .
Measure the resistance between the RFA module C3503A-1,
circuit GD145 (BK/BU), harness side and ground. No
Disconnect: RFA module C3503D (Natural Hardshell).

Measure the resistance between the RFA module C3503D-3,
circuit GD145 (BK/BU), harness side and ground; and RFA
module C3503D-4, circuit GD145 (BK/BU) harness side and
ground.

G3 CHECK THE HS-CAN CIRCUITS BETWEEN THE RFA MODULE
AND THE DLC FOR AN OPEN
Measure the resistance between the RFA module C3503B-1, Yes
circuit VDB04 (WH/BU), harness side and the DLC C251-6, GO to G4 .
circuit VDB04 (WH/BU), harness side.
No
Measure the resistance between the RFA module C3503B-2,
circuit VDB05 (WH), harness side and the DLC C251-14, circuit

G4 CHECK THE MS-CAN CIRCUITS BETWEEN THE RFA MODULE
Measure the resistance between the RFA module C3503B-15, Yes
circuit VDB06 (GY/OG), harness side and the DLC C251-3, CONNECT the negative battery
circuit VDB06 (GY/OG), harness side. cable. GO to G5 .
No
Measure the resistance between the RFA module C3503B-14,

circuit VDB07 (VT/OG), harness side and the DLC C251-11,
circuit VDB07 (VT/OG), harness side.
Disconnect the RFA module connector. Yes
Connect the RFA module connector and make sure it seats
correctly. No
the scan tool.
Pinpoint Test H: The Front Control/Display Interface Module (FCDIM) Does Not Respond To The Scan
Tool
Normal Operation
The Front Control/Display Interface Module (FCDIM) communicates with the scan tool through the Medium
Speed Controller Area Network (MS-CAN) and with other modules through the Infotainment Controller Area
Network (I-CAN).
Fuse
FCDIM
PINPOINT TEST H: THE FCDIM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

H1 CHECK THE FCDIM VOLTAGE SUPPLY CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: FCDIM C2123. GO to H2 .
Ignition ON.
Measure the voltage between the FCDIM C2123-1, circuit No
SBP07 (WH/RD), harness side and ground. VERIFY the Central Junction
Box (CJB) fuse 7 (7.5A) is OK. If
OK, REPAIR the circuit. If not
the scan tool.

H2 CHECK THE FCDIM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to H3 .
For vehicles built up to 1/14/2011, measure the resistance
between the FCDIM C2123-7, circuit GD115 (BK/GY), harness No
side and ground. REPAIR the circuit. CLEAR the
with the scan tool.
For vehicles built after 1/14/2011, Measure the resistance

between the FCDIM C2123-9, circuit GD115 (BK/GY), harness
side and ground.

H3 CHECK THE MS-CAN CIRCUITS BETWEEN THE FCDIM AND
THE DLC FOR AN OPEN
Measure the resistance between the FCDIM C2123-2, circuit Yes
VDB06 (GY/OG), harness side and the DLC C251-3, circuit GO to H4 .
VDB06 (GY/OG), harness side.
No


H4 CHECK THE I-CAN CIRCUITS BETWEEN THE FCDIM AND
THE DLC FOR AN OPEN
Measure the resistance between the FCDIM C2123-4, circuit Yes
VDB06 (GY/OG), harness side and the DLC C251-1, circuit CONNECT the negative battery
VDB06 (GY/OG), harness side. cable. GO to H5 .
No

H5 CHECK FOR CORRECT FCDIM OPERATION
Disconnect the FCDIM connector. Yes
Check for: INSTALL a new FCDIM . REFER
Connect the FCDIM connector and make sure it seats correctly.
with the scan tool.
Pinpoint Test I: The Power Steering Control Module (PSCM) Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 43 , Power Steering Controls for schematic and connector information.
Normal Operation
The PSCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN).
Fuse
PSCM
PINPOINT TEST I: THE PSCM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

I1 CHECK THE PSCM VOLTAGE SUPPLY CIRCUITS FOR AN
OPEN
Ignition OFF. Yes
Disconnect: PSCM C2368A and C2368B. GO to I2 .
Ignition ON.
Measure the voltage between the PSCM C2368A-1, circuit No
SBF02 (YE/RD) harness side and ground. VERIFY theBattery Junction Box
(BJB) fuse mega 2 (60A) and
21 (10A) is OK. If OK, REPAIR
the circuit in question. If not OK,
causes of the circuit short. CLEAR
the DTCs. REPEAT the network
Measure the voltage between the PSCM C2368B-5, circuit

CBP21 (BU/GY) harness side and ground.

I2 CHECK THE PSCM GROUND CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to I3 .
Disconnect: PSCM C2368C.
Measure the resistance between the PSCM 2368C-1, circuit No
GD120 (BK/GN), harness side and ground. REPAIR the circuit. CLEAR the
with the scan tool.

I3 CHECK THE HS-CAN CIRCUITS BETWEEN THE PSCM AND
THE DLC FOR AN OPEN
Measure the resistance between the PSCM C2368B-2, circuit Yes
VDB04 (WH/BU), harness side. cable. GO to I4 .
No
Measure the resistance between the PSCM C2368B-6, circuit


I4 CHECK FOR CORRECT PSCM OPERATION
Disconnect the PSCM connector. Yes
Check for: INSTALL a new PSCM . REFER
Connect the PSCM connector and make sure it seats
correctly. No
with the scan tool.
Pinpoint Test J: The Body Control Module (BCM) Does Not Respond To The Scan Tool
Normal Operation
The Body Control Module (BCM) communicates with the scan tool through the Medium Speed Controller Area
Network (MS-CAN).
Fuse
BCM
PINPOINT TEST J: THE BCM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

J1 CHECK THE BCM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: BCM C2280B. GO to J2 .
Ignition ON.
Measure the voltage between the BCM C2280B-4, circuit CBP21 No
(BU/GY) harness side and ground. VERIFY the Central Junction
Box (CJB) fuse 21 (10A) is OK.
If OK, REPAIR the circuit. If not
the scan tool.

J2 CHECK THE BCM GROUND CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to J3 .
Measure the resistance between the BCM C2280B-7, circuit
GD115 (BK/GY), harness side and ground; and C2280B-16, No
circuit GD115 (BK/GY), harness side and ground. REPAIR the circuit in question.

Measure the resistance between the BCM C2280A-12, circuit
GD133 (BK), harness side and ground; and C2280A-16, circuit
GD115 (BK/BU), harness side and ground.
J3 CHECK THE MS-CAN CIRCUITS BETWEEN THE BCM AND
THE DLC FOR AN OPEN
Measure the resistance between the BCM C2280F-24, circuit CONNECT the negative battery
VDB06 (GY/OG), harness side and the DLC C251-3, circuit cable. GO to J4 .
VDB06 (GY/OG), harness side.
No
Measure the resistance between the BCM C2280F-23, circuit


J4 CHECK FOR CORRECT BCM OPERATION
Disconnect the BCM connector. Yes
Check for: INSTALL a new BCM . REFER
damaged pins DTCs. REPEAT the network
pushed-out pins test with the scan tool.
Connect the BCM connector and make sure it seats correctly.
the scan tool.
Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
Normal Operation
The Audio Control Module (ACM) communicates with the scan tool through the MS-CAN . The FCDIM is used
as a gateway module.
Fuse
ACM
PINPOINT TEST K: THE ACM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

K1 CHECK THE ACM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN
Ignition OFF. Yes
Disconnect: ACM C240A. GO to K2 .
Ignition ON.
Measure the voltage between the ACM C240A-1, circuit SBP10 No
(YE/RD), harness side and ground; and for vehicles built up to For vehicles built up to
1/14/2011 measure the voltage between the ACM C240A-7, circuit 1/14/2011 VERIFY the
CBP19 (BN/WH), harness side and ground. Central Junction Box
(CJB) fuses 10 (15A) and
19 (7.5A) are OK.
For vehicles built after

1/14/2011 VERIFY the
Central Junction Box
(CJB) fuses 10 (15A) is
OK.
If OK, REPAIR the circuit

in question. If not OK,
REFER to the Wiring
Diagrams manual to
Is the voltage greater than 10 volts? CLEAR the DTCs.
with the scan tool.
K2 CHECK THE ACM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to K3 .
Measure the resistance between the ACM C240A-13, circuit GD111
REPAIR the circuit.
CLEAR the DTCs.
with the scan tool.

K3 CHECK THE I-CAN CIRCUITS BETWEEN THE ACM AND THE
FCDIM FOR AN OPEN
Measure the resistance between the ACM C240A-14, circuit VDB06 CONNECT the negative
(GY/OG), harness side and the FCDIM C2123-4, circuit VDB06 battery cable. GO to K4 .
(GY/OG), harness side.
No
question. CLEAR the
DTCs. REPEAT the
network test with the scan
tool.
Measure the resistance between the ACM C240A-15, circuit VDB07

(VT/OG), harness side and the FCDIM C2123-5, circuit VDB07
(VT/OG), harness side.

K4 CHECK FOR CORRECT ACM OPERATION
damaged pins 00 . CLEAR the DTCs.
pushed-out pins REPEAT the network test
Connect all the ACM connectors and make sure they seat correctly. with the scan tool. TEST
Operate the system and verify the concern is still present. the system for normal
No
corroded connector.
CLEAR the DTCs.
with the scan tool.
Pinpoint Test L: The Global Positioning System Module (GPSM) Does Not Respond To The Scan Tool
Normal Operation
The Global Positioning System Module (GPSM) communicates with the scan tool through the MS-CAN . The
FCDIM is used as a gateway module.
Fuse
GPSM
PINPOINT TEST L: THE GPSM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

L1 CHECK THE GPSM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: GPSM C2398. GO to L2 .
Ignition ON.
Measure the voltage between the GPSM C2398-1, circuit SBP16 No
(VT/RD) (vehicles built up to 1/14/2011) circuit SBP10 (YE-RD) For vehicles built up to
(vehicles built after 1/14/2011), harness side and ground. 1/14/2011 VERIFY the
Central Junction Box (CJB)
fuse 16 (15A) is OK.
For vehicles built after

1/14/2011 VERIFY the
Central Junction Box (CJB)
fuse 10 (15A) is OK.
If OK, REPAIR the circuit. If

of the circuit short. CLEAR
tool.

L2 CHECK THE GPSM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to L3 .
Measure the resistance between the GPSM C2398-6, circuit GD111
REPAIR the circuit. CLEAR
tool.

L3 CHECK THE I-CAN CIRCUITS BETWEEN THE GPSM AND THE
DLC FOR AN OPEN
Measure the resistance between the GPSM C2398-2, circuit VDB06 CONNECT the negative
(GY/OG), harness side and the FCDIM C2123-4, circuit VDB06 battery cable. GO to L4 .
No
question. CLEAR the DTCs.
with the scan tool.
Measure the resistance between the GPSM C2398-3, circuit VDB07

(VT/OG), harness side and the FCDIM C2123-5, circuit VDB07
L4 CHECK FOR CORRECT GPSM OPERATION
Disconnect the GPSM connector. Yes
Check for: INSTALL a new GPSM .
damaged pins CLEAR the DTCs. REPEAT
pushed-out pins the network test with the
Connect the GPSM connector and make sure it seats correctly. scan tool.
tool.
Pinpoint Test M: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 29 , Transmission Controls for schematic and connector information.
Normal Operation
TheTransmission Control Module (TCM) communicates with the scan tool through the High Speed Controller
Area Network (HS-CAN).
Fuse
TCM
PINPOINT TEST M: THE TCM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

M1 CHECK THE TCM VOLTAGE SUPPLY CIRCUITS FOR AN
OPEN
Disconnect: TCM C1750A. Yes
Ignition ON. GO to M2 .
Measure the voltage between the TCM , harness side and
VERIFY the Battery Junction Box
Connector-Pin Circuit (BJB) fuses 2 (50A), 27 (7.5A)
and Central Junction Box (CJB)
C1750A-1 SBB02 (YE/RD) fuse 23 (10A) are OK. If OK,
REPAIR the circuit in question. If
C1750A-2 SBB02 (YE/RD)
not OK, REFER to the Wiring
C1750A-18 SBB27 (BU/RD) Diagrams manual to identify the
C1750A-31 CBP23 (BN/YE)
the scan tool.

M2 CHECK THE TCM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to M3 .
Measure the resistance between the TCM , harness side and
Connector-Pin Circuit CLEAR the DTCs. REPEAT the
C1750A-3 GD187 (BK/GN)
C1750A-4 GD187 (BK/GN)
C1750A-5 GD187 (BK/GN)
C1750A-6 GD187 (BK/GN)

M3 CHECK THE HS-CAN CIRCUITS BETWEEN THE TCM AND
THE DLC FOR AN OPEN
Measure the resistance between the TCM C1750A-34, circuit Yes
VDB04 (WH/BU), harness side and the Data Link Connector CONNECT the negative battery
(DLC) C251-6, circuit VDB04 (WH/BU), harness side. cable. GO to M4 .
No
Measure the resistance between the TCM C1750A-35, circuit


M4 CHECK FOR CORRECT TCM OPERATION
Disconnect both the TCM connectors. Yes
Check for: INSTALL a new TCM . REFER to
corrosion Section 307-11 . CLEAR the
Connect the TCM connector and make sure it seats correctly.
corroded connector.
Pinpoint Test N: The Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) Does Not Respond To
The Scan Tool
Refer to Wiring Diagrams Cell 118 , Tire Pressure Monitor System for schematic and connector information.
Normal Operation
The Tire Pressure Monitor (TPM)/Vehicle Security Module (VSM) communicates with the scan tool through the
Medium Speed Controller Area Network (MS-CAN).
Fuse
TPM / VSM
PINPOINT TEST N: THE TPM / VSM DOES NOT RESPOND TO THE SCAN TOOL
Section 414-01 .

N1 CHECK THE TPM / VSM VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Ignition OFF. Yes
Disconnect: TPM / VSM C4321A. GO to N2 .
Ignition ON.
Measure the voltage between the TPM / VSM , harness side and No
ground as follows: VERIFY the Central Junction
Box (CJB) fuses 12 (20A), 23
Connector-Pin Circuit (10A) and 26 (7.5A) are OK. If
C4321A-20 CBP26 (BU/WH) question. If not OK, REFER to
C4321A-23 CBP23 (BN/YE)
C4321A-24 SBP12 (GN/RD) the circuit short. CLEAR the

N2 CHECK THE TPM / VSM GROUND CIRCUIT FOR AN OPEN
Ignition OFF. Yes
Disconnect: Negative Battery Cable. GO to N3 .
Measure the resistance between the TPM / VSM C4321A-13,
circuit GD143 (BK/VT), harness side and ground; and TPM / No
VSM C4321A-14, circuit GD143 (BK/VT), harness side and REPAIR the circuit in question.
ground. CLEAR the DTCs. REPEAT the
N3 CHECK THE MS-CAN CIRCUITS BETWEEN THE TPM / VSM
Measure the resistance between the TPM / VSM C4321B-1, Yes
circuit VDB06 (GY/OG), harness side and the Data Link CONNECT the negative battery
Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. cable. GO to N4 .
No
Measure the resistance between the TPM / VSM C4321B-2,

circuit VDB07 (VT/OG), harness side and the DLC C251-11,

N4 CHECK FOR CORRECT TPM / VSM OPERATION
Disconnect the TPM / VSM connector. Yes
Check for: INSTALL a new TPM / VSM .
Connect the TPM / VSM connector and make sure it seats
correctly. No
connector.
Pinpoint Test O: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are
Not Responding
Normal Operation
The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted-pair cable.

Remote Function Actuator (RFA) module (if equipped)
PINPOINT TEST O: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
Section 414-01 .

O1 CHECK THE DLC PINS FOR DAMAGE
Ignition OFF. Yes
Disconnect the scan tool cable from the Data Link Connector (DLC). GO to O2 .
Inspect DLC pins 3 and 11 for damage.
No
REPAIR the DLC as
necessary. CLEAR the
Are DLC pins 3 and 11 OK?

O2 CHECK THE MS-CAN TERMINATION RESISTANCE
Disconnect: Negative Battery Cable. Yes
Measure the resistance between the DLC C251-3, circuit VDB06 GO to O3 .
(GY/OG), harness side and the DLC C251-11, circuit VDB07
No
(VT/OG), harness side. GO to O5 .

O3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A
SHORT TO GROUND
Measure the resistance between the DLC C251-3, circuit VDB06 Yes
(GY/OG), harness side and ground; and between DLC C251-11, GO to O4 .
circuit VDB07 (VT/OG), harness side and ground.
No
GO to O12 .

O4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A
SHORT TO VOLTAGE
Connect the negative battery cable. Yes
Ignition ON. REPAIR the circuit in
Measure the voltage between the DLC C251-3, circuit VDB06 question. CLEAR the DTCs.
(GY/OG), harness side and ground; and between the DLC C251-11, REPEAT the network test
circuit VDB07 (VT/OG), harness side and ground. with the scan tool.
No
GO to O13 .

O5 CHECK THE MS-CAN TERMINATION RESISTOR
Measure the resistance between the DLC C251-3, circuit VDB06 Yes
(GY/OG), harness side and ground; and between the DLC C251-11, GO to O6 .
No
GO to O9 .

O6 CHECK THE MS-CAN TERMINATION RESISTOR WITH THE BCM
DISCONNECTED
Disconnect: BCM C2280F (Black Hardshell). Yes
Measure the resistance between the DLC C251-3, circuit VDB06 GO to O7 .
(GY/OG), harness side and ground; and between the DLC C251-11,
circuit VDB07 (VT/OG), harness side. No
GO to O8 .

O7 CHECK THE MS-CAN CIRCUITS BETWEEN THE BCM AND THE
DLC FOR AN OPEN
Measure the resistance between the BCM C2280F-24, circuit Yes
VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 CONNECT the negative
(GY/OG), harness side. battery cable. GO to O13 .
No
with the scan tool.
Measure the resistance between the BCM C2280F-23, circuit

VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07
O8 CHECK THE MS-CAN CIRCUITS BETWEEN THE IPC AND THE
DLC FOR AN OPEN
Disconnect: Instrument Panel Cluster (IPC) C220. Yes
Measure the resistance between the IPC C220-23, circuit VDB06 CONNECT the negative
(GY/OG), harness side and the DLC C251-3, circuit VDB06 battery cable. GO to O15 .
No
with the scan tool.
Measure the resistance between the IPC C220-22, circuit VDB07

(VT/OG), harness side and the DLC C251-11, circuit VDB07

SHORT TOGETHER
Measure the resistance between DLC C251-3, circuit VDB06 Yes
(GY/OG), harness side and the DLC C251-11, circuit VDB07 GO to O11 .
(VT/OG) the harness side.
No
GO to O10 .
O10 CHECK THE MS-CAN CIRCUITS BETWEEN THE BCM AND THE
DLC FOR AN OPEN
Measure the resistance between DLC C251-3, circuit VDB06 Yes
(GY/OG), harness side and the DLC C251-11, circuit VDB07 REPAIR the DLC or
(VT/OG) the harness side. REPAIR the circuit in
with the scan tool.
No
A capacitor internal to a
module may still be
draining, causing irregular
resistance readings. WAIT 5
minutes. REPEAT the
pinpoint test.

SHORT TOGETHER
NOTE: Skip to the end of this test step once the suspect module has Yes
been identified. CONNECT the negative
battery cable. For the BCM ,
While measuring the resistance between the DLC C251-3, circuit GO to O18 . For the
VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 FCDIM , GO to O19 . For
(VT/OG), harness side; disconnect the following modules one at a the IPC , GO to O20 . For
time until the resistance is greater than 5 ohms. the RFA module, GO to
BCM 2280F O21 . For the TPM / VSM ,
FCDIM C2123 GO to O22 .
IPC C220
RFA module C3503B (if equipped) No
TPM / VSM C4321B REPAIR circuits VDB06
(GY/OG) and VDB07
(VT/OG) for a short
with the scan tool.
Did the resistance change to greater than 5 ohms with one of
the modules disconnected?
SHORT TO GROUND WITH THE MODULES DISCONNECTED
NOTE: Skip to the end of this test step once the suspect module has Yes
been identified

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Ford Fiesta 2011

Workshop Manual & Wiring Diagrams

2004,2005,2006,2007,2008,2009,2010,2011,2012 Free Software Foundation,Inc.

Steering Wheel Symbols

Body type symbols are used to identify different body configurations.

Gearshift Lever Position Symbols

Drilling and Threading Tool Symbols

Cutting Tool Symbols

Apply Chemicals, Lubricants, or Clamping Load Symbols

General Equipment Symbols

These symbols provide miscellaneous information required for the procedure.

Mandatory Protective Equipment

Prohibition Symbols — Health, Safety, and Component Care

Warning Symbols — Health and Safety Warnings or Component Care

System Diagram Symbols

The symbols provide Information about networks or wiring.

Using This Manual

Warnings, Notices, and Notes in This Manual

Notices provide information to avoid damage to the vehicle or a component.

Notes provide information critical for a complete and effective repair.

Vehicle and Engine Orientation Identifiers

How to Use Diagnostic Information

DTC and Symptom Charts

Using Module DTC Charts

Mechanical Procedures Such As Removal and Installation

Reuse Of Fasteners, Seals, Or Gaskets

Seals and gaskets must be replaced unless otherwise specified.

Illustration 1 - self-locking coatings or locking feature are highlighted yellow

1. Remove the engine oil pipe fastener at the engine connection.

Heating, Ventilation and Air Conditioning Safety Warnings

Always wear safety goggles.

Failure to follow these instructions may result in serious personal injury.

Battery System Service Warnings

WARNING: Do not get underneath the frame-mounted battery when disconnecting or

Brake System Service Warnings

Body and Frame Service Warnings

Never use non-Ford parts or accessories for completing repairs.

Salvaged or used parts

Engine Cooling System Service Warnings

Fuel System Service Warnings

General Service Warnings

WARNING: Carefully read cautionary information on product label. For EMERGENCY

Failure to follow these instructions may result in serious personal injury.

Safety Restraints Service Warnings

Fire suppression system components

WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners,

Tire and Wheel Service Warnings

load carrying capacity.

Effective Diagnostic Techniques

Understand and verify the symptom .

Diagnostic Scan Tool Testing

Continuous Memory Diagnostic Trouble Codes (CMDTCs)

Ford On-Demand DTCs

Network Communication DTCs

DTC Nomenclature (SAE J2012 and ISO 14229)

Integrated Diagnostic System (IDS) Scan Tool Usage

1. Check the VCM power; examine the connection to the vehicle.

2. Check the scan tool connection to the VCM .

3. Follow scan tool instructions to retry.

1. Verify the scan tool operation with a known good vehicle.

2. Verify the ignition is ON.

Measuring Automotive Circuits

Checking Power-Providing Circuits