2016 Mustang Shop Manual

100-00 General Information 2016 Mustang
Description and Operation Procedure revision date: 01/12/2016
About This Manual
Introduction
WARNING: Before beginning any service procedure in this manual, refer to health and safety
warnings in section 100-00 General Information. Failure to follow this instruction may result in serious
personal injury.
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
This manual describes and directs repair procedures specified by Ford Motor Company for the vehicle. Critical
health and safety precautions are included. Anyone who deviates from these instructions risks compromising
personal safety or vehicle integrity.
SECTION CONTENT
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This manual is divided into groups, each containing sections numbered based on the component part number.
Section contents may include:
Specifications
Fluid capacities, component specifications and torque values not covered in other procedures
Description and Operation
Overview of the system, component locations, and system operation
Diagnosis and Testing
Symptom charts, DTC charts and diagnostic tests
See the Diagnosis and Testing Information in this document
General Procedures
Service adjustments, electronic programming and other special procedures
Removal and Installation
Component removal and installation instructions
Removal
Component removal instructions
Installation
Component installation instructions
Disassembly and Assembly
Component disassembly and assembly instructions
Disassembly and Assembly of Subassemblies
Assembly disassembly and assembly instructions
IMPORTANT INFORMATION
Section number 100-00 General Information contains the following important information (including this document):
Critical Health and Safety Precautions - service safety precautions applicable to the entire manual.
For additional information, refer to: Health and Safety Precautions (100-00 General Information,
Description and Operation).
A Symbols Glossary - definitions of the action directed by each symbol.
For additional information, refer to: Symbols Glossary (100-00 General Information, Description and
Operation).
Diagnostic Methods - support information for diagnostics.
Warnings, Notices and Notes
WARNINGS
Warnings provide information to avoid personal injury and to make sure service actions on critical safety systems
are performed correctly. Warnings that apply to an entire system or workshop manual section are located in
section 100-00 Description and Operation, Health and Safety Precautions.
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
NOTICES (in some publications, CAUTIONS)
Notices provide information to avoid damage to the vehicle or a component.
NOTES
Notes provide information critical for a complete and effective repair.
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.
Specified Chemicals or Materials
Throughout this manual, chemicals or materials are specified that must be used to properly complete a service
procedure or diagnostic step. In the event a specific material is not readily available, a substitute material meeting
the same specification may be used. Ford has not reviewed third party products for compliance with
environmental, health or safety regulations and is not responsible for their use. Use of third party products is at
your own risk. Additionally, such products may cause degraded performance, premature failures, and/or vehicle
component damage. All chemicals or materials used for vehicle servicing should be checked for compliance with
local environmental and health and safety regulations.
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LH and RH Designations
All LH and RH designations are oriented from the driver's seat position looking forward.
Vehicle LH and RH definition

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Item Part Number Description
1 — LH (left-hand)
2 — RH (right-hand)
All LH and RH engine designations are oriented from the flywheel position looking toward the crankshaft pulley.
Powertrain LH and RH definition

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1 — Front
2 — RH (right-hand)
3 — Rear
4 — LH (left-hand)
Standard Practices
The following rules apply, unless specified differently in the procedure:
FASTENERS
Reuse standard fasteners.

Replace fasteners with self-locking features.
Examples of fastener self-locking coatings or mechanical locking (with the locking features
highlighted yellow) are shown in the illustration.
Replace fasteners with torque angle specifications (those tightened a specified number of degrees).
Examples of self-locking nuts and bolts

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1 — Completely coated self-locking bolt
2 — Partially coated self-locking bolt
3 — Self-locking bolt with a locking washer
4 — Self-locking nut with a plastic locking insert
5 — Self-locking nut with thread deformation (3 indentations)
6 — Self-locking nut with thread deformation (to oval shape)
7 — Self-locking nut with integrated locking ring
SEALS AND GASKETS
Replace seals and gaskets, unless specified differently in the procedure.
EXTERIOR TRIM PARTS
Replace exterior trim parts fastened with glue or adhesive tape, unless specified differently in the procedure.
Mechanical Procedures
Illustrations in this manual may be used instead of written step instructions. Color-coding (see color scheme
illustration) is used to communicate the required step action or actions. Service action icons may be used to add
information regarding the required action.
For additional information, refer to: Symbols Glossary (100-00 General Information, Description and Operation).
Illustration Color-coding
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Part
Item Number Description
1 — Blue - Target or primary component to be removed/installed
(or disassembled/assembled).
2 — Green - Components that need to be removed prior to or
installed after the target/primary.
3 — Brown - Components that need to be removed prior to or
installed after the target/primary.
4 — Yellow - Components to be set aside for access, but not
removed. Also highlighted areas to inspect or adjust.
5 — Magenta - Electrical connectors and fasteners such as nuts,
bolts, clamps, or clips to be: detached, attached, loosened,
moved, removed or installed.
6 — Pale Blue - Special tool(s), general equipment, or common
tools used in an uncommon way.
Other color coding
Alternating Blue and White

Chemical, adhesive or sealer apply areas
Red
Sectioned or cut-away areas
Grey
Background components shown for location information
ILLUSTRATION TASK SEQUENCE
Components that must be removed or installed in a specific sequence are identified with a numbered callout. Any
associated step text is numbered accordingly.
Simple procedure example showing color-coding and task sequence.

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Black arrows are used to draw attention to components (usually fasteners). Arrows with multiples specified (here,
x2) identify an identical number of fasteners or items. Callouts (numbers inside circles) show a required sequence
or tightening torque.
In the illustration, the callouts indicate the removal sequence, which is reversed for installation. The yellow
coloring of the hose indicates it is to be positioned aside (not removed). Two identical (magenta-colored)
fasteners are indicated by the x2 arrow. The fasteners in this illustration require different torques (same torque for
the x2 fasteners) so numbered callouts are used to identify them with torque values in the associated step text.
The (magenta-colored) hose clamp is another fastener to be removed.
Examples of fastener removal sequence and an identical service action for 12 fasteners. Other possible
symbols are shown on the right.
Example of fastener sequence information with two persons required for the service action
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HIDDEN DETAILS
Separate detail boxes or transparent components may be used to show hidden items in an illustration.
Example of hidden fastener information

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SERVICE ACTION ICONS
Service action icons may be used to add information regarding the required action.
Location symbols show the location of a component or system on the vehicle.

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Example of service action icons pointing to highlighted components.
Movement arrows and service action icons show three dimensional or rotational movements.
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Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a
component.
Measurement symbols provide the information required to perform a specific measurement. These
symbols may include specific values.
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SPECIAL TOOLS, EQUIPMENT, MATERIALS AND TORQUE VALUES
When Ford special tools are required for the procedure, the tool and tool number are shown in an illustration.
Special tool numbers, general equipment, materials or torque values for the procedure step are shown in the text
steps.
Example of special service tool and symbol used to hold the gear shift in the required gear position.
Other possible symbols are shown on the right.
Example of two illustrations used together with sequence steps, service action icons and special service
tools
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Tool symbols direct the use of standard tools. The tool size or dimension may be specified.
HEALTH AND SAFETY SYMBOLS
Some procedures may contain health and safety symbols that are associated with a specific service action.
Always read and understand all health and safety precautions found in Section 100-00 before beginning any
procedure. For additional information, refer to: Health and Safety Precautions (100-00 General Information,
ISO warning symbols may be used to indicate potential hazards.
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These symbols prohibit various hazardous actions
These symbols direct the use of personal protection equipment

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Diagnosis and Testing Information
ELEMENTS OF DIAGNOSIS AND TESTING
Diagnosis and Testing may include:
Preliminary Inspection
In older manuals, Inspection and Verification
Symptom Chart
DTC Chart
Pinpoint Tests
Component Tests
Some diagnostics may be contained in Symptom Based Diagnostics. Some engine performance and emission
diagnostics may be placed in a separately published PC/ED manual.
MODULE NAMES MATCH THE DIAGNOSTIC SCAN TOOL
Module names and PID names in this manual match the Ford diagnostic scan tool: IDS.
The same diagnostic scan tool module name is found in some DTC definitions (for example, U024B Lost
Communication with Seat Control Module "G").
MODULE DESCRIPTIVE NAMES
A descriptive name is sometimes added to the diagnostic scan tool name to clarify module function. The
descriptive name will be followed by the diagnostic scan tool acronym in brackets.
Example: “Driver Active Motion Seat Module [SCMG]”.

Driver Active Motion Seat Module is the descriptive name added to clarify the function of the SCMG.
The SCMG acronym is used by diagnostic scan tool, defined as “Seat Control Module G”.
Copyright © 2016 Ford Motor Company

Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information display.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component
movements can be rotational or 1-3 dimensional movements.
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1 — Minor component movement clockwise/counterclockwise
2 — Major component movement clockwise/counterclockwise
3 — Component movement to the left/right/up/down
4 — Component movement towards/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.
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Part
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.
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1 — Steering wheel in straight ahead position
2 — Steering column lock locked
3 — Steering column lock unlocked
4 — Turn the steering wheel to the 90° left position
5 — Turn the steering wheel to the 90° right position
6 — Turn the steering wheel to the left-hand end position
7 — Turn the steering wheel to the right-hand end position
Body Types
Body type symbols are used to identify different body configurations.
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1 — 3, 4, 5-door body style
2 — Wagon body style
3 — Sports utility vehicle 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 — Underview
10 — Right-hand drive (RHD) vehicle
11 — Left-hand drive (LHD) vehicle
Gearshift lever and selector lever position symbols
Gearshift lever and selector lever position symbols are used to show the lever position that is required to be
selected to carry out a procedure step.
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Part
1 — Replaced by symbol 9
9 — Set the selector lever to the park (P) position
10 — Set the selector lever to the reverse (R) position
11 — Set the selector lever to the neutral (N) position
12 — Set the selector lever to the drive (D) position
13 — Set the selector lever to the drive (S) position
14 — Set the selector lever to the drive (M) position
15 — Set the selector lever to the drive (-) position
16 — Set the selector lever to the drive (+) position
17 — Set the gearshift lever to the neutral (N) position
18 — Further gearshift lever positions that may appear in
illustrations
Screwdriver symbols
The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure step.
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1 — Screwdriver
2 — Cross bladed screwdriver / Cross bladed Bit Socket
3 — Flat bladed screwdriver / Flat bladed Bit Socket
4 — Hexagonal screwdriver / Hexagonal Bit Socket
5 — TORX screwdriver / TORX Bit Socket
6 — Polydrive screwdriver / Polydrive Bit Socket
7 — Ball drive hex bit
Pliers symbols
The pliers symbols are used to show which pliers is recommended to carry out a procedure step.
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1 — Combination pliers
2 — Side cutter pliers
3 — Securing ring - inner
4 — Securing ring - outer
5 — Hose clamp pliers
6 — Locking pliers
7 — Long nose pliers
Drill symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry out a procedure step.
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1 — Drill bit with a specified diameter
2 — Hole saw with a specified diameter
3 — Stepped drill bit with a specified diameter
4 — Tap with a specified diameter
5 — Die with a specified diameter
6 — Scraper for circular holes
7 — Scraper for straight edges
Cutting tool symbols
The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure
step.
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1 — Cutting knife
2 — Air body saw
3 — Scissors
4 — Grinder
5 — Jig saw
6 — Plasma cutter
7 — Sanding Paper
8 — Wire brush
9 — Belt Sander
10 — Tin Snipes
Apply Chemical or load symbols
The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry out
a procedure step.
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Part
1 — Apply the substance from the specified tube
2 — Apply the substance from the specified cartridge
3 — Apply the specified chemical with a brush
4 — Apply the specified load to the specified component
5 — Apply a bead with a specific diameter from the specified
tube
6 — Apply a bead with a specific diameter 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 from the fluid can
10 — Apply fluid from the fluid can
11 — Clean the specified component with the specified material
12 — Apply a broken bead from the specified tube
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13 — Apply the specified chemical from a spray can
14 — Apply the specified lubricant to the specified component
15 — Apply spot welds to the specified component
16 — Apply a continuous weld to the specified component
17 — Handle the fluid using a syringe
18 — Extract the specified amount of fluid using a syringe
Measurement symbols
The measurement symbols are used to show where to measure which type of measurement to carry out a
procedure step.
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Part
1 — Measure the current using a digital multimeter
2 — Measure the voltage using a digital multimeter
3 — Measure the resistance using a digital multimeter
4 — Measure the length/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 using a suitable stopwatch
8 — Wait for the specified period of time
9 — The specified task requires the specified minimum
temperature
10 — The specified task requires the specified maximum
temperature not to be exceeded
11 — The specified task requires the specified temperature
range
12 — The specified task requires the specified temperature
13 — Measure and check for the specified value using a dial
indicator gauge
14 — Measure and check for the specified MAX value using a
dial indicator gauge
15 — Measure and check for the specified MIN value using a dial
indicator gauge
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General equipment symbols
The general equipment symbols are used to show where to use which type of general equipment to carry out a
procedure step.
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1 — Hot air gun
2 — Soldering iron
3 — Scraper
4 — Scriber
5 — Securing strap
6 — File with a specified size
7 — Center punch
8 — Marker
9 — Mallet
10 — Hose clamp
11 — Interior trim remover
12 — Vacuum cleaner
13 — Strap wrench
14 — Wedge
15 — Pin Punch
16 — Air blow gun
17 — Relocate and support the component
18 — C-clamp
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1 — Plastic scraper
Welding symbols
These symbols indicate the type of welding to be used.

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Part
1 — Metal inert gas (MIG) / Metal active gas (MAG) welding
equipment
2 — Metal inert gas (MIG) welding equipment
3 — Metal inert gas (MIG) brazing equipment
4 — Apply a continuous weld to the specified component
5 — Apply spot welds to the specified component
6 — C-clamp
Drilling and grinding symbols
These symbols indicate the type of drilling or grinding to be used.

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Part
1 — Drill through first body layer with a suitable diameter
2 — Drill through first body layer with the specified diameter
3 — Drill through the indicated number of body layers with a
suitable diameter
4 — Drill through the indicated number of body layers with the
specified diameter
5 — Drill through the indicated number of body layers with a
suitable diameter
6 — Drill through the indicated number of body layers with the
specified diameter
7 — Drill through all body layers with a suitable diameter
8 — Drill through all body layers with the specified diameter
9 — Grind one layer
10 — Grind two layers
11 — Grind to last layer
12 — Grind all layers
13 — Material thickness > Xmm
Material symbols
The material symbols are used to show where to use which type of material to carry out a procedure step.

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1 — Remove/Install the specified blind rivet
2 — Apply tape to the specified component/area
3 — Remove/Install the specified cable tie
Miscellaneous symbols
These symbols provide further information that is required to carry out a procedure step.
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Part
1 — Set the ignition switch to the 0 position
2 — Set the ignition switch to the II position
3 — The procedure step requires the aid of the specified
number of supporting technicians
4 — Self contained breathing apparatus
5 — General prohibition used in combination with another
symbol
6 — Do not use power tools
7 — Visual check
8 — Noise check
9 — Dispose the specified component
10 — Replaced by item 9 (Dispose the specified component)
11 — Set the engine speed to the specified value
12 — Fully apply the parking brake lever
13 — Fully release the parking brake lever
14 — Do not dispose of batteries into the waste bin
15 — Visual check using a mirror
16 — Area/component must be dry
Mandatory Protective equipment - Health and safety symbols
The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce
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possible health and safety risks.
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1 — Wear protective gloves
2 — Wear face guard
3 — Wear safety goggles
4 — Wear ear protectors
5 — Wear safety goggles and ear protectors
6 — Wear a respirator
Prohibition - Health and safety symbols and component damage
The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible component
damage and health and safety risks.
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1 — General prohibition symbol
2 — No naked flames
3 — No smoking
4 — No water
5 — Do not touch
6 — Do not switch
7 — No grinding
Warning symbols - Health and safety and component damage
The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible component
damage and health and safety risks.
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Part
1 — Hazardous voltage/Electrical shock/Electrocution
2 — Fire Hazard/Highly flammable
3 — Burn hazard/Hot surface
4 — Automatic start-up
5 — Toxic
6 — Explosive material
7 — Battery hazard
8 — Corrosive material
9 — Lifting hazard
10 — Hand crush/Force from above
11 — Cutting of fingers or hand
12 — Pressure hazard
13 — Invisible laser radiation. Do not view directly with optical
instruments (magnifiers). Class 1M laser product
Control Diagram symbols - Description and Operation procedures
These symbols provide further information on the type of connectivity, direction of flow or type of data bus of a
system.
1
Item
—
Part Number Description
Mid-speed Controller Area Network (CAN)
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2 — High-speed Controller Area Network (CAN)
3 — Local Interconnect Network (LIN)
4 — Wires crossing not connected

Battery and Battery Charging Health and Safety Precautions
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: Battery posts, terminals and related accessories contain lead and lead components. Wash
hands after handling. Failure to follow these instructions may result in serious personal injury.
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Body Repair Health and Safety and General Precautions
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 serious personal injury.
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
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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.
WARNING: All safety belt components must be inspected and corrected as part of any collision
repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a
Collision found in Section 501-20A General Procedures of this manual. Failure to follow this instruction
may result in incorrect operation of the safety belt system and increase the risk of serious personal
injury or death in a crash.
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: Collision damage repair must conform to the instructions contained in this workshop
manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled,
salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint
components) are not authorized by Ford.
Departure from the instructions provided in this manual, including alternate repair methods or the use of
substitute components, risks compromising crash safety. Failure to follow these instructions may
adversely affect structural integrity and crash safety performance, which could result in serious personal
injury to vehicle occupants in a crash.

Brake and Clutch Systems Health and Safety Precautions
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 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.
NOTICE: If the brake fluid is spilled on the paintwork, the affected area must be immediately washed
down with cold water.
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Climate Control System Health and Safety Precautions
WARNING: Air conditioning R-134a liquid refrigerant is capable of harming eyes or freezing skin.
Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these instructions
WARNING: Air conditioning R-134a refrigerant gas is capable of displacing the air necessary for
breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not
release a large quantity of R-134a gas within a confined space or allow it to be exposed to a high
temperature flame (such as a torch). Consult the Material Safety Data Sheet for further information.
Failure to follow these instructions may result in serious personal injury or death.
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. Failure to follow
these instructions may result in serious personal injury.
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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: The electric booster heater may become hot during use and can burn unprotected skin.
Allow enough time for the heater to cool before servicing. Failure to follow this instruction may result in
serious personal injury.

Diagnostic Methods
Effective Diagnostic Techniques
NOTE: Do not use this document in place of Ford-prescribed Symptom Based Diagnostics or Workshop Manual
diagnostics. Diagnostic Methods is intended to provide Ford vehicle diagnostic information only for support of
Ford-prescribed diagnostics.
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. Recreate 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.
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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 Practices: Refer to section 418-00 Module Communications Network, Diagnosis and Testing, to
diagnose a network outage or no response from an individual module (or modules).
Diagnostic Trouble Code 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
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 a DTC is retained 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.
Clearing Continuous Memory Diagnostic Trouble Codes
Continuous Memory DTCs caused by the issue being repaired or created during the diagnosis and repair must be
cleared or they will confuse future diagnosis. NOTE: Do not clear DTCs from unresolved vehicle issues.
Ford On-Demand Diagnostic Trouble Codes
Ford Motor Company modules have a unique feature that performs a special diagnostic program at the request of
the technician (using a diagnostic 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, but 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 Diagnostic Trouble Codes
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 to make sure the vehicle voltage will be stable.
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
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called "fault byte") codes 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 Scan Tool Usage
If The Integrated Diagnostic System Scan Tool Does Not Communicate With The Vehicle Communication
Module
1. Check the Vehicle Communication Module connection and power from the DLC.
2. Check the communication between the scan tool and the Vehicle Communication Module.
3. Follow scan tool instructions to retry.
If The Integrated Diagnostic System 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 a PCM engineering part number, tear tag, or calibration number to identify the vehicle and
start a session. These identifying numbers may be found:
The PCM engineering part number and the 4-character tear tag are printed on the PCM
label.
(PTS website users only) The PCM engineering part number can be determined from OASIS
using the VIN. Choose “HVBoM” from the OASIS tab menu and search Powertrain engine
modules for the PCM engineering part number (If the first character is a "P" in the part
number, enter only the characters following the "P" into IDS).
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 section 418-00 Module Communications Network, Diagnosis and
Testing, 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 or Terminal Probe Kit
29-011A must be used to connect test equipment or jumper wires to pins (terminals).
Male to female pin (terminal) fit is critical for correct connection and durability.
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).
Checking Power-Providing Circuits
Measuring a power wire with the intended load disconnected using a Digital Multimeter (DMM) will only find
open circuits (open fuse or wire).
Recommended practice: Circuits carrying approximately 200-1000 mA* may be loaded with a 250-350
mA test light. Measure circuit voltage with a Digital Multimeter (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.
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*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 accuracy is limited to circuits carrying less than approximately 5 amperes (this is due to the fact
that very small resistances, undetectable by a Digital Multimeter (DMM), cause significant voltage loss in
higher current circuits).
Digital Multimeter (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 Digital Multimeter (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
Digital Multimeter (DMM), cause significant voltage loss in higher current circuits.
The Digital Multimeter (DMM) applies a small amount of voltage to the circuit or component to calculate
resistance. As a result, Digital Multimeter (DMM) ohmmeters are very sensitive to any level of voltage
present. Voltage present in the circuit will corrupt the Digital Multimeter (DMM) reading.
Checking For Unintended Continuity (Shorts) To Other Circuits
A Digital Multimeter (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 Digital Multimeter (DMM) indication (no detected resistance).
Shorts to voltage are checked with a 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 back probes specifically designed for the purpose 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 an 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
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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 (Refer to 418-01
Module Configuration for more information).
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 (for example, 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 could be damaged by a direct
connection to ground/power.

Diesel Fuel System Health and Safety Precautions
WARNING: Vehicles with scheduled remote start technology may start at any time. Make sure the
scheduled remote start system is disabled when servicing or working in close proximity to rotating
engine parts. Failure to follow this instruction may result in serious personal injury.
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.
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Engine Cooling System Health and Safety Precautions
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.
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Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
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
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: Do not carry personal electronic devices such as cell phones, pagers or audio equipment
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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: 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
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.
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 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.

Health and Safety Precautions
General Service Warnings
Review carefully the information below before beginning any repair. Following these warnings is a list of specific
system warnings that must be reviewed before beginning work on any listed system.
WARNING: Wear eye and ear protection when servicing a vehicle. Failure to follow this instruction
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.
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WARNING: Chemicals or materials specified in this manual, if used improperly, may present a
personal health hazard. Always consult the material safety information sheet before using any material
specified by this manual. Failure to follow this instruction may result in serious personal injury.
WARNING: Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate
during operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and
replace with a new fan as necessary. Failure to follow this instruction may result in serious personal
injury.
WARNING: Cooling fans may run with the ignition off. Disable the fans before working nearby. On
electric vehicles, disconnect the charging cable to prevent unexpected fan operation. Failure to follow
this instruction may result in personal injury.
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: Serious injury may occur if the engine is accidently started by another person during
service work. Remove the key from the vehicle to prevent unauthorized starts. Failure to follow this
instruction may result in serious personal injury.
WARNING: Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the
vehicle weight, including any vehicle cargo or modifications. Identify the correct jacking points in section
100-02 of this manual. Position the vehicle on a hard, level surface. After jacking, always support vehicle
with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake and block all
wheels remaining on the ground. Failure to follow these instructions may result in unintended vehicle
movement and serious personal injury or death.
WARNING: Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the
vehicle weight, including any vehicle cargo or modifications. Always position the hoist lift arms as shown
in section 100-02 of this manual. Do not use the engine to power the drive wheels unless all drive wheels
are elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with the ground
can cause unintended vehicle movement. Failure to follow these instructions may result in serious
personal injury or death.
WARNING: Removal of heavy components (such as engines, transmissions or axles) while the vehicle
is lifted on a hoist may create a dangerous weight imbalance. Restrain the vehicle on the hoist with
chains or straps to prevent vehicle movement. Failure to follow this instruction may result in serious
personal injury or death.
WARNING: Always secure transmission, transfer case, and axle assemblies to their service jack.
Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with
obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.
WARNING: Always secure engines, transmissions, or other heavy components to the support fixture
with straps and wooden support blocks. Improperly secured assemblies could fall off the fixture,
resulting in serious personal injury.
WARNING: Never support an engine by the intake or exhaust manifolds. The engine may drop
suddenly. 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. Failure to follow these instructions
WARNING: Keep solvents away from ignition sources. Solvents may be flammable and can ignite or
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explode if not handled correctly. Failure to follow this instruction 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.
Carefully review the safety warnings for each system using the links below before beginning any service or repair.
For additional information, refer to: Climate Control System Health and Safety Precautions (100-00 General
Information, Description and Operation).
For additional information, refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General
For additional information, refer to: Brake and Clutch Systems Health and Safety Precautions (100-00 General
For additional information, refer to: Body Repair Health and Safety and General Precautions (100-00 General
For additional information, refer to: Engine Cooling System Health and Safety Precautions (100-00 General
For additional information, refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00 General Information, Description and Operation).
For additional information, refer to: Liquefied Petroleum Gas (LPG) and Compressed Natural Gas (CNG) Fuel
Systems Health and Safety Precautions (100-00 General Information, Description and Operation).
For additional information, refer to: Pyrotechnic Device Health and Safety Precautions (100-00 General
For additional information, refer to: Wheel and Tire Health and Safety Precautions (100-00 General Information,
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Liquefied Petroleum Gas (LPG) and Compressed Natural Gas (CNG) Fuel Systems Health and Safety
Precautions
WARNING: Service of Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) vehicle
systems is restricted to qualified personnel and authorized workshops. The required qualifications vary
by region. Always observe local laws and legislative directives regarding CNG or LPG vehicle service.
Failure to follow this instruction may result in serious personal injury or death.
WARNING: Compressed Natural Gas (CNG) or Liquefied Petroleum Gas (LPG) is highly flammable
and toxic when contained in unventilated work areas. Work in a dedicated area with good ventilation and
no sources of ignition. Failure to follow these instructions may result in serious personal injury or death.
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WARNING: Liquefied Petroleum Gas (LPG) is capable of harming eyes or freezing skin. Always wear
personal protection gear, including safety goggles and gloves to avoid contact with liquid gas. Failure to
WARNING: Always observe local regulations regarding storage or indoor parking of Liquefied
Petroleum Gas (LPG) vehicles. Do not park vehicles near sources of heat, ignition or unventilated open
pits. Failure to follow these instructions may result in serious personal injury.
WARNING: Liquefied Petroleum Gas (LPG) is heavier than air and will collect in low points in a
building, such as drains or work pits. Never discharge a tank inside a building. If possible, tanks should
be discharged beforehand by running the vehicle. Any discharge of gas must be done outside in
well-ventilated flat areas. Failure to follow these instructions may result in the accumulation of
combustible gas, which could cause personal injury or death in a fire or explosion.
WARNING: Extreme heat such as paint drying ovens will cause an increase in Compressed Natural
Gas (CNG) or Liquefied Petroleum Gas (LPG) fuel tank pressure. The fuel tank must be removed before
using paint drying ovens with temperatures above 60° C. Failure to follow this instruction may result in a
release of combustible gas, which could cause personal injury or death in a fire or explosion.
WARNING: Liquefied Petroleum Gas (LPG) may present a personal health hazard if handled
improperly. Always consult the LPG material safety information sheet before servicing a LPG vehicle.
Failure to follow this instruction may result in serious personal injury or death.

Pyrotechnic Device Health and Safety Precautions
WARNING: Always carry a live airbag with the deployment door, trim cover or tear seam pointed away
from the body. Do not place a live airbag down with the deployment door, trim cover or tear seam facing
down. Failure to follow these instructions may result in serious personal injury in the event of an
accidental deployment.
WARNING: Always carry or transport a live safety belt inflator with the safety belt buckle bolt
installed in the inflator tube hand tight. Failure to follow this instruction may result in serious personal
injury in the event of an accidental deployment.
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load
limiters, etc.) outdoors with all personnel at least 9 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 serious personal injury.
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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.
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
airbags have deployed. Failure to follow these instructions may result in serious personal injury or death
in a crash.
WARNING: Anytime the Safety Canopy or side air curtain has deployed, a new headliner and new roof
pillar upper trim panels with attaching hardware must be installed. Make sure the headliner includes the
word AIRBAG where it meets each roof B-pillar trim panel. Remove any other damaged components or
hardware and replace with new. Always use new torque-prevailing type J-nuts when installing the Safety
Canopy. Failure to follow these instructions may result in the Safety Canopy or side air curtain deploying
incorrectly and increases the risk of serious personal injury or death in a crash.
WARNING: Do not repair or service restraint component connector terminals. If restraint connector
terminals need repair, replace with the service connector pigtails. Failure to follow this instruction may
result in incorrect operation of the vehicle safety restraint, which increases the risk of serious personal
WARNING: Never disassemble or tamper with seat belt deployable components, including
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
Tampering or back probing may cause an accidental deployment and result in personal injury or death.
WARNING: Never tamper with, repair, or modify a Restraints Control Module (RCM) or any other
Supplemental Restraint System (SRS) component. Failure to follow this instruction may result in
incorrect operation of the Supplemental Restraint System (SRS), which increases the risk of serious
personal injury or death in a crash.
WARNING: Never probe the electrical connectors on airbag, Safety Canopy or side air curtain
assemblies. Failure to follow this instruction may result in the accidental deployment of these
assemblies, which increases the risk of serious personal injury or death.
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 serious personal
injury or death.
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy or side air
curtain assembly. Never insert any type of fastener or tie strap around any portion of the Safety Canopy,
side air curtain assembly, or related interior trim panel. Failure to follow this instruction may result in the
Safety Canopy or side airbag curtain deploying incorrectly and increases the risk of serious personal
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 risk of serious personal injury
or death in a crash.
WARNING: Never allow oil, grease, water or foreign contaminants to get on/in the occupant
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classification system (OCS) components or electrical connectors. Failure to follow this instruction may
result in incorrect operation of the OCS and increases 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 a live Safety Canopy or side air curtain assembly with the 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: Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag to
deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury or
death in a crash.
WARNING: Always carry the live hood actuator by holding it around the cylinder with the mounting
bracket up and with the cap pointing away from the body. Always place the live hood actuator on its side
with the cap pointing away from people. Never place anything in front of the cap. Failure to follow these
instructions may result in serious personal injury in the event of an accidental deployment.
WARNING: If a vehicle has been in a pedestrian impact, inspect the impact sensor mounting areas for
damage. If damaged, a new bumper cover must be installed. New pedestrian impact sensors must be
installed. Failure to follow these instructions may result in serious personal injury or death in a
pedestrian impact.
WARNING: Do not repair or service pedestrian protection system component connector terminals. If
pedestrian protection system connector terminals need repair, replace with the service connector
pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle pedestrian
protection system, which increases the risk of serious personal injury or death in a pedestrian impact.
WARNING: Never tamper with, repair, or modify a pedestrian protection system component. Failure to
follow this instruction may result in incorrect operation of the pedestrian protection system, which
increases the risk of serious personal injury or death in a pedestrian impact.
WARNING: Never probe the electrical connectors on pedestrian protection system pyrotechnic
assemblies. Failure to follow this instruction may result in the accidental deployment of these
assemblies, which increases the risk of serious personal injury or death.
WARNING: Pyrotechnic components are very hot immediately after deployment and might be covered
with pyrotechnic residuals. Do not handle pyrotechnic components immediately after deployment. Always
wear protective gloves, safety glasses and breathing protection to prevent skin contact and inhaling of
pyrotechnic residuals. Failure to follow this instruction may result in serious personnel injury.
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Wheel and Tire Health and Safety Precautions
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 instruction may result
in serious personal injury.
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. 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 vehicle occupant(s).
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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: 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.

Diagnosis and Testing Procedure revision date: 08/7/2015
Diagnostic Trouble Code Charts
Master DTC Index
ABS Module
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock
Brake System (ABS) and Stability Control, Diagnosis and Testing).
APIM For AM/FM/CD/SYNC®,
REFER to: Information and Entertainment System (415-00A Information and
Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC,
Diagnosis and Testing).
For Touchscreen display,
REFER to: Information and Entertainment System (415-00 Information and
Entertainment System - General Information - Vehicles With: Touchscreen
Display) .
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ACM For AM/FM/CD/SYNC®,
Display) .
BCM
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules,
BCMB
REFER to: Body Control Module B (BCMB) (419-10 Multifunction Electronic Modules,
CCM
REFER to: Cruise Control (419-03B Cruise Control - Vehicles With: Adaptive Cruise
Control, Diagnosis and Testing).
DACMC For AM/FM/CD/SYNC®,
Display) .
DDM
REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and
Entry Systems, Diagnosis and Testing).
DSM
REFER to: Front Seats (501-10A Front Seats, Diagnosis and Testing).
DSP
Entertainment System - General Information - Vehicles With: Touchscreen Display) .
FCIM For AM/FM/CD/SYNC®,
Display) .
FCDIM
GWM
REFER to: Communications Network (418-00 Module Communications Network) .
GPSM For AM/FM/CD/SYNC®,
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Display) .
HUD
REFER to: Collision Warning and Collision Avoidance System (419-03C Collision
Warning and Collision Avoidance System, Diagnosis and Testing).
ICM
REFER to: Instrumentation, Message Center and Warning Chimes (413-01
Instrumentation, Message Center and Warning Chimes) .
IPC
Instrumentation, Message Center and Warning Chimes) .
Moveable Roof Control
Module A (MRCMA) REFER to: Convertible Top (501-18 Convertible Top, Diagnosis and Testing).
Moveable Roof Control
Module B (MRCMB) REFER to: Convertible Top (501-18 Convertible Top, Diagnosis and Testing).
OCSM
REFER to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental
Restraint System, Diagnosis and Testing).
PAM
REFER to: Parking Aid (413-13A Parking Aid - Vehicles With: Rear Parking Aid,
PSCM
REFER to: Power Steering (211-02 Power Steering) .
PCM
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls -
2.3L EcoBoost (231kW/314PS), Diagnosis and Testing).
(2.3L)
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls -

3.7L Duratec (227kW/301PS), Diagnosis and Testing).
(3.7L)
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls -

5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Diagnosis and Testing).
(5.0L)
REFER to: Electronic Engine Controls (303-14D Electronic Engine Controls -
5.2L 32V Ti-VCT, Diagnosis and Testing).
(5.2L)
PDM
RCM
RTM
SCME
SCCM
REFER to: Steering Wheel and Column Electrical Components (211-05 Steering Wheel
and Column Electrical Components, Diagnosis and Testing).
SODL
REFER to: Blind Spot Information System (419-04 Side and Rear Vision, Diagnosis and
Testing).
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SODR
REFER to: Blind Spot Information System (419-04 Side and Rear Vision, Diagnosis and
Testing).
VDM
REFER to: Vehicle Dynamic Suspension (204-05 Vehicle Dynamic Suspension,

100-01 Identification Codes 2016 Mustang
Identification Codes
VIN
VIN Locator
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The 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 VC label. If the VIN plate requires
replacement, authorized dealers must contact their respective regional office.
Item Description
1 WMI (World Manufacturer)
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
The first 3 VIN positions are the WMI (world manufacturer identifier.
1FA - Ford Motor Company, USA, passenger car
Restraint Type
The fourth VIN position is the vehicle restraint type code.
6 - Active safety belts (all positions), driver and front passenger air bags, driver and front passenger knee
inflatables, side inflatables 1st and 2nd row (Coupe)
T - Active safety belts (all positions), driver and front passenger air bags, driver and front passenger knee
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inflatables, side inflatables 1st and 2nd row (Convertible)
Vehicle Line, Series and Body Type
Positions 5 through 7 indicate vehicle line, series and body type.
P8A - 2-door coupe

P8C - 2-door coupe, GT
P8E - 2-door convertible
P8F - 2-door convertible, GT
P8T - 2-door coupe, I4
P8U - 2-door convertible, I4
Engine Type
The eighth VIN position identifies the engine type, displacement and number of cylinders.
F - 5.0L, DOHC, 4-valve, sequential fuel injection, V8

H - 2.3L Ti-VCT (twin independent variable cam timing), turbo-charged, in-line 4-cylinder
M - 3.7L, 4-valve, port fuel injection, 6-cylinder
Z - 5.2L, DOHC, Ti-VCT (twin independent variable cam timing), super-charged, V8
Check Digit
The ninth VIN position is a government-assigned, computer-generated check digit.
0-9
Model Year
The tenth VIN position is the model year code.
G - 2016
Assembly Plant
The eleventh digit identified the assembly plant code.
5 - Flat Rock Assembly, Flat Rock, Michigan (USA)
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.
100001-599999
VC Codes
VC Label Locator
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The VC label contains the manufacturer name, the month and year of manufacture, the certification statement and
the VIN. It also includes GVW 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.
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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 information
Paint Code
Paint codes are 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.
CY - Competition Orange
DR - Avalanche
G1 - Shadow Black
H3 - Triple Yellow (tri-coat)
HN - Guard
J4 - Deep Impact Blue
J7 - Magnetic
PQ - Race Red
RR - Ruby Red (tri-coat)
UX - Ingot Silver Metallic
YZ - Oxford White
Interior Trim Codes
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
1 - Chord II cloth seats

2 - Vinyl/cloth seats
3 - Recaro cloth/vinyl seats
4 - Trend mini-perforated/milled pebble leather seats
5 - Natural grain leather seats
A - Alcantra/Recaro cloth seats (SVT)
B - Hot/Cold leather seats (SVT)
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L - Tutone natural grain leather seats
Q - Dash perforated leather seats
S - Milled pebble leather seats
Interior Trim Color Codes
1 - Ebony
2 - Soft Ceramic
3 - Bronze Fire
4 - Red Line
5 - Ebony with Red accents
Y - Yellow Jacket
Tape/Paint Stripe Codes
Tape and paint stripe codes are:
Blank - Less stripe

1 - Black with White
2 - White with Black
3 - Blue with Black
4 - White with Red
5 - Blue with Red
6 - Black with Red
S - Silver
X - Black
Radio Codes
The following lists available radio codes:
1- AM/ FM stereo with CD player

2- AM/ FM stereo, CD player and SDARS (Satellite Digital Audio Receiver System)
3- AM/ FM stereo, CD player, SDARS (Satellite Digital Audio Receiver System) and HD (high-definition)
4- AM/ FM stereo, CD player and dual tuner
Axle Codes
The axle codes and related gear ratios are:
BB - 3.73 ratio with manual or automatic transmission

DD - 3.55 ratio with manual transmission
GG - 3.31 ratio with automatic transmission
YY - 3.15 ratio
Transmission Codes
Available transmissions are as follows:
3 - 6-speed automatic (6R80)

E - 6-speed manual (3160)
X - 6-speed manual (MT82)
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
AA - BR33-5310-A
BB - BR33-5310-B
CC - BR33-5310-C
FF - BR33-5310-F
GG - BR33-5310-G
Rear Springs
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AA - BR33-5560-A
BB - BR33-5560-B
CC - BR33-5560-C
DD - BR33-5560-D
EE - BR33-5560-E
FF - BR33-5560-F
GG - BR33-5560-G
JJ - BR3V-5560-J
LL - BR3V-5560-L
MM - AR3V-5560-M
NN - AR33-5560-N
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.
Item Description
1 Model year (year in which the calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
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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 - EVAP
6 Certification region (lead region where multiple regions are included in one calibration), example: A - U.S.
federal
7 Revision level (will advance as revisions occur), obtained through scan tool
Model Year
F - 2015
G - 2016
Vehicle Code
ZG - Mustang
Transmission Code
1 - Automatic transmission
2 - 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 (U.S. 4K, final sale in export markets)

1- Heavy duty gas engine/Dyno
2- Fast Automobile Manufacturers' Association, U.S.
3- Alternative durability protocol, U.S.
4- Not assigned
5- Not assigned
6- EVAP
7- Mileage accumulation aging endurance durability
8- OBD
9- Not assigned
Certification Region
5 - U.S. 50 states
A - U.S. federal, including altitude, may include Canada and/or Mexico
B - U.S. California standard, includes U.S. green states
C - Canada
D - China
E - European Community - Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland, Italy,
Luxembourg, Netherlands, Portugal, Spain, Sweden and UK (United Kingdom)
F - European Extended Community - E-plus Croatia, Czech Republic, Estonia, Hungary, Norway, Poland,
Romania, Russian Federation, Slovakia, Slovenia, Switzerland and Yugoslavia
G - GCC (Gulf Cooperative Council) - Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and UAE (United Arab
Emirates)
H - Hong Kong
J - Japan
K - Korea
L - Malaysia
M - Mexico
N - New Zealand
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P - Australia
Q - South America - Brazil
S - Singapore
T - Taiwan
U - South America - unleaded fuel regions
V - Vietnam
X - Rest Of World
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)

100-02 Jacking and Lifting 2016 Mustang
Jacking and Lifting - Overview
Jacking and Lifting Points
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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: 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
result in serious personal injury.
NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose.
NOTICE: Do not attempt to use jack pressure on either the front bumper or the rear bumper on any
vehicle. Damage to bumper covers will occur.
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.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference.
NOTICE: When raising a vehicle on a two-column hoist, use care when positioning the vehicle so that the
hoisting forks do not interfere with suspension components, mounting brackets or stabilizer mounting
brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle or
rear cover.

100-04 Noise, Vibration and Harshness 2016 Mustang
Noise, Vibration and Harshness (NVH)
Acceptable 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. 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
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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.
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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.
Hz (Hertz):
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, similar to 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.
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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 40.2 kmh (25 mph) - 104.6 kmh (65
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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.

100-04 Noise, Vibration and Harshness 2016 Mustang
Noise, Vibration and Harshness (NVH)
Special Tool(s)
MASTERTECH MTS-4000
ANALYZER
257-00018
EngineEAR
107-R2100
Chassis Ears
JSP97170
Squeak And Rattle Kit
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164-R4900
Ultrasonic Leak Detector
134-R0135
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 sytem 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
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" diagnostic technique.This diagnostic method divides the
problem into related areas to correct the customer concern.
Verify the "symptom".

Determine which "symptoms(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:
Test drive the vehicle with the vibration sensor inside the vehicle.
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.
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 Revolutions Per Minute
(RPM)/frequency and driveshaft frequency should be calculated.
Frequencies with an amplitude reading of 0.06 Gs or less are barely perceptible NVH levels. No
corrective action is necessary.
Place the vibration sensor on or near the suspect area outside the vehicle.
Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading.
Compare the readings.
A match in frequency indicates the problem component or area.
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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.
Noise, Vibration and Harshness (NVH) Analyzer (Vetronix)
The MTS 4000 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 MTS 4000 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 personal computer
Can be powered from a variety of power sources: cigarette lighter, AC power or the internal battery pack
The MTS 4000 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 (dB). All frequency bands used for noise measurements are the same as for the
vibration measurements, up to 1,000 Hertz (Hz).
The third 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 Electronic Vibration Analyzer (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 Electronic Vibration Analyzer (EVA) has a strobe balancing function that can be
used to detect imbalance on rotating components such as a driveshaft or engine accessories.
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Item Description
1 Electronic Vibration Analyzer (EVA) screen
2 Frequency mode displayed in Revolutions Per Minute (RPM) or Hertz (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 Revolutions Per Minute (RPM)/ Hertz (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 Hertz (Hz). A reading of 10 Hertz (Hz) can be displayed as an
8 Hertz (Hz) through 12 Hertz (Hz).
Vibrate Software
Vibrate Software 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 and
driveline 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
Revolutions Per Minute (RPM) and the engine Revolutions Per Minute (RPM) on the worksheet graph. The
point on the graph where the vibration frequency Revolutions Per Minute (RPM) reading and the engine
Revolutions Per Minute (RPM) reading intersect indicates the specific component group causing the
symptom.
A frequency measurement tool capable of measuring vibration frequency and Revolutions Per
Minute (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 Hertz
(Hz) or 600 to 4,800 Revolutions Per Minute (RPM). Though the Reed tachometer is able to measure multiple
frequencies, it does not measure amplitude.
Sirometer
The Sirometer measures frequency in Hertz (Hz) and Revolutions Per Minute (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,
constant velocity joints, brakes, springs or axle 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
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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 mechanics stethoscope is an inexpensive tool for locating noises in motors and other moving parts. It can be
used to help diagnose 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 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
Ultra High Molecular Weight (UHMW) (frosted) tape
Squeak and rattle oil tube
Squeak and rattle grease tube
Leak Detector
The 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 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.
Diagnostic Guide
To begin a successful diagnosis, record the reported findings, then proceed to each of the numbered process
steps to complete the diagnosis.
1: Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much information
as possible about the problem and take a test drive with the customer. There are many ways a customer will
describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is
important that the concern is correctly interpreted and the customer descriptions are recorded. During the
interview, ask the following questions:
When was it first noticed?

Did it appear suddenly or gradually?
Did any abnormal occurrence coincide with or proceed 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
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 provided by the customer. It is important to know the specific concern 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
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away.
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).
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 at which the
condition occurs.
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.
4: Verify the Customer Concern
Verify the customer concern by carrying out a road test.
A road test may be necessary if the symptom relates to the suspension system or is sensitive to
torque.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 concern. 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. 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 concern,
especially when a road test with the customer is not possible.
The Heavy Acceleration Test helps to determine if the concern is torque-related.
The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related.
The Steering Input Test helps to determine how the wheel bearings and other suspension components
contribute to a vehicle speed-related concern.
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.
To identify if the noise is coming from the electric motor and /or gearbox (such as for a whine issue), it can
be helpful sometimes to shift into neutral while driving while the condition is present.
The Vehicle Cold Soak Procedure helps to identify concerns 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 concern occurs. Note the vehicle speed, and if
possible, determine the vibration frequency.
Attempt to identify what part of the vehicle the concern is coming from.
Attempt to identify the source of the concern.
Proceed as necessary.
Heavy Acceleration Test
Accelerate hard from 0-64 km/h (0-40 mph).

Decelerate in a lower gear.
The concern 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 concern occurred when carrying out the Slow Acceleration
Test.
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Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine or
motor as a source.
Steering Input Test
Drive at the speed where the concern occurs, while making sweeping turns in both directions.
If the concern goes away or gets worse, the wheel bearings, hubs and tire tread wear are all possible
sources.
Brake Test
Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking
applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force.
Accelerate to 89-97 km/h (55-60 mph).
Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard
upon brake application and diminish when the brake is released.
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 bumpy 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.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
Test preparations include matching the customer conditions (if known). If not known, document the
conditions. 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 concern temperature (if
known) for 6-8 hours.
Before starting the vehicle, conduct a visual inspection under the hood.
Listen for pumps that circulate coolant for motor, electronics, heater and battery.
NOTICE: Never probe moving parts.
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.
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.
Symptom Charts
Noise, Vibration and Harshness (NVH) Symptoms
Classify Noise, Vibration and Harshness (NVH) Symptoms
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
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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 Hertz (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 Hertz (Hz). After doing the
necessary calculations it is determined the first order tire and wheel frequency is 7 Hertz (Hz) and the first order
driveshaft frequency is 22 Hertz (Hz). Based on this information it can be determined the vibration is most likely a
second order tire and wheel vibration: 7 Hertz (Hz) (first order tire and wheel frequency) multiplied by 2 (second
order) equals 14 Hertz (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 electric motor-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
In calculating and using frequency readings it is important to remember the direct relationship between Hertz (Hz)
and Revolutions Per Minute (RPM). One Hertz (Hz) is equal to 60 Revolutions Per Minute (RPM). This is easy to
remember. Think of Hertz (Hz) as cycles per second. There are 60 seconds in a minute, therefore multiply the
Hertz (Hz) reading by 60 to get Revolutions Per Minute (RPM). Conversely, divide Revolutions Per Minute (RPM)
by 60 to get Hertz (Hz).
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Use the Frequency and Revolutions Per Minute (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 Revolutions Per Minute
(RPM). Calculate the tire and wheel Revolutions Per Minute (RPM) and frequency by carrying out and following:
Measure the diameter of the tire.

Record the speed at which the vibration occurs.
Obtain the corresponding tire and wheel Revolutions Per Minute (RPM) and frequency from the Tire Speed
and Frequency Chart.
If the vehicle speed is not listed, 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 Revolutions Per Minute (RPM) listed for
that tire diameter in the chart. Then divide that number by 60. For example: a 40 MPH (Miles Per
Hour) vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 Revolutions
Per Minute (RPM). Divide 420 Revolutions Per Minute (RPM) by 60 seconds = 7 Hertz (Hz) at 40
MPH (Miles Per Hour).
Tire Speed and Frequency Chart
Tire Tire Revolutions Per Tire Revolutions Per Tire Revolutions Per Tire Revolutions Per
Diameter Minute (RPM)/Hertz Minute (Revolutions Per Minute (RPM)/Hertz Minute (RPM)/Hertz
(Hz) at value listed Minute (RPM)/Hertz (Hz) (Hz) at value listed (Hz) at value listed
below at value listed below below below
in (mm) 9.9 mph (16 km/h) 49.7 mph (80 km/h) 60.3 mph (97 km/h) 70.2 mph (113 km/h)
19.02 in 182 910/15 1092/18 1274/21
(483 mm)
20.00 in 173 865/14 1038/17 1211/20
(508 mm)
20.98 in 165 825/14 990/16 1155/19
(533 mm)
Tire Tire Revolutions Per Tire Revolutions Per Tire Revolutions Per Tire Revolutions Per
Diameter Minute (RPM)/Hertz Minute (Revolutions Per Minute (RPM)/Hertz Minute (RPM)/Hertz
(Hz) at value listed Minute (RPM)/Hertz (Hz) (Hz) at value listed (Hz) at value listed
below at value listed below below below
22.05 in 158 790/13 948/16 1106/18
(560 mm)
23.03 in 151 755/13 906/15 1057/18
(585 mm)
24.02 in 145 725/12 870/14 1015/17
(610 mm)
25.00 in 139 695/12 834/14 973/16
(635 mm)
25.98 in 134 670/11 804/13 938/16
(660 mm)
26.97 in 129 645/11 774/13 903/15
(685 mm)
27.95 in 124 620/10 744/12 868/14
(710 mm)
28.94 in 119 595/10 714/12 833/14
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(735 mm)
29.92 in 115 575/10 690/11 805/13
(760 mm)
30.91 in 111 555/9 666/11 777/13
(785 mm)
31.89 in 108 540/9 648/11 756/13
(810 mm)
32.87 in 105 525/9 630/10 735/12
(835 mm)
34.02 in 102 510/8 612/10 714/12
(864 mm)
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.
Noise, Vibration and Harshness (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.
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.
Symptom Chart: 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 axle shaft-speed related
vibration calculations should be carried out.
Symptom Chart-Tire-Speed Related Vibrations
Symptom Chart
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Condition Possible Actions
Sources
First order tire vibration Tire or wheel Symptom Chart: NVH
REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis
and Testing).
Wheel bearings Symptom Chart: NVH
REFER to: Front Suspension (204-01 Front Suspension, Diagnosis
and Testing).
Driveshaft Symptom Chart: NVH
REFER to: Driveshaft (205-01 Driveshaft, Diagnosis and Testing).
Brake disc Symptom Chart: NVH
REFER to: Front Disc Brake (206-03 Front Disc Brake, Diagnosis
and Testing).
or REFER to: Rear Disc Brake (206-04 Rear Disc Brake, Diagnosis
and Testing).
Second order tire Tire or wheel Symptom Chart: NVH
vibration REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis
and Testing).
Third order tire Tire or wheel Symptom Chart:NVH
vibration REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis
and Testing).
Driveshaft Symptom Chart: NVH
REFER to: Driveshaft (205-01 Driveshaft, Diagnosis and Testing).
Symptom Chart-Driveshaft-Speed Related Vibrations
Symptom Chart

Sources
Sources
First order driveshaft Driveshaft Symptom Chart: NVH
vibration REFER to: Driveshaft (205-01 Driveshaft, Diagnosis and Testing).
Second order driveshaft Axle shaft Symptom Chart: NVH
vibration REFER to: Rear Drive Axle and Differential (205-02 Rear Drive
Axle/Differential, Diagnosis and Testing).
Third order driveshaft Drive axle Symptom Chart: NVH
vibration REFER to: Rear Drive Axle and Differential (205-02 Rear Drive
Symptom Chart: Powertrain-Speed Related Vibrations
vibration.
NOTE: Some powertrain-speed related vibrations are normal though they should not be felt in the passenger
compartment.
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Symptom Chart
Condition Possible Sources Actions

First through sixth Transmission/transaxle Symptom Chart: NVH
order powertrain REFER to: Diagnosis By Symptom (307-01 Automatic
vibration Transmission - 6-Speed Automatic Transmission - 6R80,
orREFER to: Manual Transmission (308-03A Manual
Transmission - 6-Speed Manual Transmission - MT82, Diagnosis
and Testing).
Transmission/transaxle Symptom Chart: NVH
mounts REFER to: Diagnosis By Symptom (307-01 Automatic
Transmission - 6-Speed Automatic Transmission - 6R80,
Accessory speed Coolant pump(s) Symptom Chart: NVH
related vibration REFER to: Engine Cooling (303-03A Engine Cooling - 2.3L
EcoBoost (231kW/314PS), Diagnosis and Testing).
, REFER to: Engine Cooling (303-03B Engine Cooling - 3.7L
Duratec (227kW/301PS), Diagnosis and Testing).
or REFER to: Engine Cooling (303-03C Engine Cooling - 5.0L
32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Diagnosis and
Testing).
A/C compressor motor Symptom Chart: NVH
REFER to: Climate Control System - Vehicles With: Dual
Automatic Temperature Control (DATC) (412-00 Climate Control
System - General Information, Diagnosis and Testing).
or REFER to: Climate Control System - Vehicles With:
Electronic Manual Temperature Control (EMTC) (412-00 Climate
Control System - General Information, Diagnosis and Testing).
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.
vibration.
NOTE: Some powertrain-speed related vibrations are normal though they should not be felt in the passenger
compartment.
Symptom Chart

0.5 order engine Engine Symptom Chart: NVH
vibration REFER to: Engine (303-00 Engine System - General Information,
Engine Symptom Chart: NVH
REFER to: Engine (303-00 Engine System - General Information,
First through sixth Engine Symptom Chart: NVH
order engine REFER to: Engine (303-00 Engine System - General Information,
vibration Diagnosis and Testing).
Engine mounts
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REFER to: Engine (303-00 Engine System - General Information,
REFER to: Diagnosis By Symptom (307-01 Automatic Transmission
- 6-Speed Automatic Transmission - 6R80, Diagnosis and Testing).
Exhaust system Symptom Chart: NVH
REFER to: Exhaust System (309-00A Exhaust System - 2.3L
,REFER to: Exhaust System (309-00B Exhaust System - 3.7L
orREFER to: Exhaust System (309-00C Exhaust System - 5.0L
Testing).
Belt driven Engine pulley Symptom Chart: NVH
accessory drive REFER to: Engine (303-00 Engine System - General Information,
vibration Diagnosis and Testing).
Accessory drive belt Symptom Chart: NVH
REFER to: Accessory Drive (303-05A Accessory Drive - 2.3L
REFER to: Accessory Drive (303-05B Accessory Drive - 3.7L
or REFER to: Accessory Drive (303-05C Accessory Drive - 5.0L
Testing).
Coolant pump Symptom Chart: NVH
REFER to: Engine Cooling (303-03A Engine Cooling - 2.3L
, REFER to: Engine Cooling (303-03B Engine Cooling - 3.7L
or REFER to: Engine Cooling (303-03C Engine Cooling - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Diagnosis and Testing).
Generator bearing
REFER to: Generator - 2.3L EcoBoost (201kW/273PS) (414-02
Generator and Regulator, Removal and Installation).
,REFER to: Generator - 3.7L Duratec (227kW/301PS) (414-02
Generator and Regulator, Removal and Installation).
orREFER to: Generator - 5.0L 32V Ti-VCT (414-02 Generator and
Regulator, Removal and Installation).
A/C compressor Symptom Chart: NVH
REFER to: Climate Control System - Vehicles With: Dual Automatic
Temperature Control (DATC) (412-00 Climate Control System -
General Information, Diagnosis and Testing).
or REFER to: Climate Control System - Vehicles With: Electronic
Manual Temperature Control (EMTC) (412-00 Climate Control
Symptom Chart: Noise, Air Leaks or Water Leaks
Symptom Chart

Wind noise, air or Body Symptom Chart:NVH
water leaks REFER to: Body System (501-00 Body System - General
Information, Diagnosis and Testing).
Front end noise Front suspension Symptom Chart: NVH
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while driving REFER to: Front Suspension (204-01 Front Suspension, Diagnosis
vehicle and Testing).
Drive axle Symptom Chart: NVH
REFER to: Rear Drive Axle and Differential (205-02 Rear Drive
Brake system Symptom Chart: NVH
REFER to: Brake System (206-00 Brake System - General
Steering linkage or Symptom Chart: NVH
gear REFER to: Power Steering (211-02 Power Steering, Diagnosis and
Testing).
Body Symptom Chart:NVH
REFER to: Body System (501-00 Body System - General
Rear end noise Rear suspension Symptom Chart: NVH
while driving REFER to: Rear Suspension (204-02 Rear Suspension, Diagnosis
vehicle and Testing).
Drive axle Symptom Chart: NVH
REFER to: Rear Drive Axle and Differential (205-02 Rear Drive
Brake system Symptom Chart: NVH
REFER to: Brake System (206-00 Brake System - General
Noise with vehicle Transmission/transaxle Symptom Chart: NVH
stopped REFER to: Diagnosis By Symptom (307-01 Automatic Transmission
A/C compressor motor Symptom Chart: NVH
or REFER to: Climate Control System - Vehicles With: Electronic
Symptom Chart: Harshness
Symptom Chart

Sources
Harsh vehicle Front Symptom Chart: NVH
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ride suspension REFER to: Suspension System (204-00 Suspension System - General
Rear Symptom Chart: NVH
suspension REFER to: Rear Suspension (204-02 Rear Suspension, Diagnosis and
Testing).

METRICS
BOLT STRENGTH IDENTIFICATION

ENGLISH SYSTEM
Grade 1 or 2 Grade 5 Grade 8

English bolts: Identification marks on the bolt head represent Rockwell hardness. Generally, the bolt’s
grade is equal to the number of marks plus two. The higher the grade, the stronger the bolt.
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METRIC SYSTEM
4.6 4.8 5.8 8.8 9.8 10.9
Metric bolts: Identification class numbers on bolt heads represent tensile strength. Higher numbers indicate
stronger bolts. Common metric fastener bolt strength properties are 9.8 and 10.9.
HEX NUT STRENGTH IDENTIFICATION

ENGLISH SYSTEM METRIC SYSTEM
Grade 5 Grade 8
Identification dots represent Rockwell hardness. The Identification class numbers on nuts represent tensile
nut’s grade is equal to the number of dots plus two. strength. Higher numbers indicate stronger nuts. Nuts
The higher the grade, the stronger the nut. may also have blue finish or paint daub on hex flat.
OTHER TYPES OF PARTS

Metric identification schemes vary by type of part, most often a variation of that used for bolts and nuts. Note
that many types of English and Metric fasteners carry no special identification if they are otherwise unique.
9
–Stamped U-Nuts
2 MET CLASS CLASS CLASS

10.9 9.8 8.8
–Tapping, thread forming and certain –Studs, Large studs may carry the property class number.
other case hardened screws. Smaller studs use a geometric code on the end.
Revision 1, 8/10/2000
METRICS
ENGLISH/METRIC CONVERSION
DESCRIPTION MULTIPLY BY FOR METRIC EQUIVALENT

Acceleration ft/s2 0.3048 m/s2
in/s2 0.0254 m/s2
Torque lb-in 0.11298 N .m
lb-ft 1.3558 N .m
Power horsepower 0.746 kW
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Pressure or Stress inches of water 0.2491 kPa
psi 6.895 kPa
psi 0.069 bar
Energy or Work BTU 1055.0 Joules(J)
lb-ft 1.3558 Joules(J)
kiloWatt-hour 3,600,000 Joules(J)
or 3.6 x 106
Light foot candle 10.764 lumens/square meter (lm/m2)
Fuel Performance miles/gal 0.4251 kilometers/liter (km/L)
gal/mile 2.3527 liters/kilometer (L/km)
Velocity mph 1.6093 kilometers/hour (km/h)
Length inch 25.4 mm
foot 0.3048 m
yard 0.9144 m
mile 1.609 km
Area square inch (in2) 645.2 mm2
6.45 cm2
square ft (ft2) 0.0929 m2
square yard 0.8361 m2
Volume cubic inch (in3) 16387.0 mm3
16.387 cm3
0.0164 liters (L)
quart 0.9464 liters (L)
gallon 3.7854 liters(L)
cubic yard 0.7646 m3
Mass pound 0.4536 kg
ton 907.18 kg
ton 0.9078 tonne (t)
Force kilogram 9.807 N
ounce 0.2780 N
pound 4.448 N
Temperature degree Farenheit (˚F) (˚F-32) 0.556 degree Celsius (˚C)
Revision 1, 8/10/2000
Torque Wrench Adapter Formulas
Click wrench below for formulas
Half Moon Wrench Right Half Moon Wrench Left
Straight Torque Adapter 15 Degree Wobble Extension
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Straight Torque Adapter Reversed Straight Torque
at 90 Degrees Adapter with Extension
Torque Wrench Straight Torque Adapter

with Extension with Extension
Crow's Foot at 90 Degrees Crow's Foot Straight

303-00 Engine System - General Information 2016 Mustang
Specifications Procedure revision date: 07/16/2014
Specifications
Materials
Item Specification
Dye-Lite® Gasoline Engine Oil Leak Detection Dye 164-R3700 (Rotunda) -
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Engine - Overview
Base Part Number: 6L084
Engine Information
NOTE: 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 specifications.
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.
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This section covers general procedures and diagnosis and testing of the engine system, except for exhaust
emission control devices, which are covered in the 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
EVAP
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: Identification Codes (100-01 Identification Codes, Description and Operation).

Engine
Inspection and Verification - Engine Performance
NOTE: There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out
Inspection and Verification - Engine Performance or Inspection and Verification - NVH.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
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. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the DLC.
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5. NOTE: The 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.
check for No Power To The Scan Tool, to diagnose no power to the scan tool,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and
Testing).
6. If the scan tool does not communicate with the vehicle:

verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
to diagnose no response from the PCM,
Testing).
7. Carry out the network test.

If the scan tool responds with no communication for one or more modules,
Testing).
If the network test passes, retrieve and record continuous memory DTCs.
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, refer to the appropriate 303-14 section.
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine Performance.
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: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and
Testing).
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 elimination type of diagnostic approach to pinpoint the responsible system.
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.
4. Visually inspect for obvious signs of mechanical damage.
5. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
6. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the DLC.
7. NOTE: The 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.
check for No Power To The Scan Tool, to diagnose no power to the scan tool,
Testing).
8. If the scan tool does not communicate with the vehicle:
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verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
to diagnose no response from the PCM,
Testing).
9. Carry out the network test.

If the scan tool responds with no communication for one or more modules,
Testing).
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 appropriate 303-14 section.
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 areas.
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 injection pump Gasoline Turbocharged
Direct Injection (GTDI) engine or 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 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 FEAD components. To
isolate FEAD noise, carry out the Engine Accessory Test,
Testing).
Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine. Use the
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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.
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.
Turbocharger noise (Gasoline Turbocharged Direct Injection (GTDI) engine)
A common source of noise is the turbocharger. Some whine or air rush noise is an acceptable condition.
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

Symptom Possible Sources Action
Difficult starting Inoperative or damaged Refer to the appropriate section in Group
ignition system 303 for the procedure. Refer to Powertrain
Air or vacuum leak Control/Emissions Diagnosis (PC/ED)
Inoperative or damaged fuel manual.
system
Inoperative or damaged
starting system
Damaged charging system/
battery REFER to: Charging System - 2.3L
EcoBoost (201kW/273PS) (414-00 Charging
System - General Information, Diagnosis
and Testing).
or REFER to: Charging System - 3.7L
Duratec (227kW/301PS) (414-00 Charging
and Testing).
or REFER to: Charging System - 5.0L 32V
Ti-VCT (414-00 Charging System - General
or REFER to: Charging System - 5.2L 32V
Ti-VCT (414-00 Charging System - General
Burnt valve INSTALL a new cylinder head. TEST the
system for normal 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. TEST the
Damaged head gasket INSTALL a new cylinder head gasket. TEST
the system for normal operation after the
repair.
Inoperative or damaged Refer to the appropriate section in Group
cooling system 303 for the procedure.
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Fail-safe cooling invoked (if Refer to Powertrain Control/Emissions
equipped) Diagnosis (PC/ED) manual.
Poor idling Vacuum leaks Refer to the appropriate section in Group
Inoperative or damaged 303 for the procedure. Refer to Powertrain
EGR system Control/Emissions Diagnosis (PC/ED)
manual.
ignition system 303 for the procedure.
cooling system 303 for the procedure.
Inoperative or damaged fuel
system
Incorrect valve clearance ADJUST valve clearance. Refer to the
appropriate section in Group 303 for the
procedure. TEST the system for normal
operation after the repair.
Incorrect valve-to-valve seat INSTALL a new cylinder head. TEST the
contact system for normal operation after the repair.
Damaged head gasket INSTALL a new cylinder head gasket. TEST
repair.
Engine runs rough Inoperative or damaged fuel Refer to the appropriate section in Group
system 303 for the procedure.
Air or vacuum leaks
EGR system fault
cooling system
ignition system
Burnt or sticking valve INSTALL a new valve. TEST the system for
Weak or broken valve spring INSTALL a new valve spring. TEST the
Carbon accumulation in ELIMINATE carbon buildup. TEST the
combustion chamber system for normal operation after the repair.
Excessive oil Leaking oil REPAIR oil leakage. TEST the system for
consumption normal operation after the repair.
Blocked or restricted INSPECT the turbocharger drain pipe.
turbocharger oil drain pipe REPAIR as necessary. TEST the system for
Damaged or collapsed air Tighten hoses clamps. INSPECT for
intake hoses and tubes damage and REPAIR as necessary. TEST
repair.
Damaged exhaust or INSPECT for leaks. Leaks can be detected
exhaust leaks at audibility or visually, by a discoloration
turbocharger housing or caused by escaping hot exhaust gases.
exhaust manifold. REPAIR as necessary. TEST the system for
Turbocharger oil seals REFER to Turbocharger Internal Oil Leak
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leaking Test.
REFER to: Turbocharger (303-04E Fuel
Charging and Controls - Turbocharger - 2.3L
EcoBoost (231kW/314PS), Diagnosis and
Testing).
TEST the system for normal operation after
the repair.
Inoperative PCV system REPAIR or INSTALL new components as
necessary. TEST the system for normal
Incorrect oil CHANGE oil to correct specification. TEST
repair.
Worn valve stem seal INSTALL a new valve stem seal. TEST the
Worn valve stem or valve INSTALL a new cylinder head. TEST the
guide system for normal operation after the repair.
Sticking piston rings INSTALL new piston rings. TEST the system
Worn piston ring groove INSTALL a new piston and piston pin. TEST
repair.
Worn piston or cylinder INSTALL a new piston or cylinder block.
the repair.
Oil in coolant Leaking head gasket INSPECT the engine components. INSTALL
Damaged cylinder block new engine components as necessary.
Damaged cylinder head Refer to the appropriate section in Group
303 for the procedure. TEST the system for
Leaking oil cooler INSPECT the oil cooler and seal for
damage. INSTALL new components as
necessary. Refer to the appropriate section
in Group 303 for the procedure.
Coolant in oil Leaking head gasket INSPECT the engine components. INSTALL
Damaged cylinder block new engine components as necessary.
Damaged cylinder head Refer to the appropriate section in Group
303 for the procedure. TEST the system for
Insufficient power Inoperative or damaged Refer to the appropriate section in Group
ignition system 303 for the procedure. Refer to Powertrain
Air intake system blockage Control/Emissions Diagnosis (PC/ED)
Lubrication system blockage manual.
Inoperative or damaged fuel
system
Turbocharger turbine or INSPECT the turbocharger. REFER to the
compressor wheel damage Check for Free Rotation— Off Vehicle.
Testing).
the repair.
Damaged exhaust or INSPECT for leaks. Leaks can be detected
exhaust leaks at audibility or visually, by a discoloration
turbocharger housing or caused by escaping hot exhaust gases.
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exhaust manifold REPAIR as necessary. TEST the system for
Malfunctioning turbocharger Refer to Powertrain Control/Emissions
bypass valve Diagnosis (PC/ED) manual.
Oil level too high DRAIN oil to correct level.
Incorrect engine oil INSTALL correct specification engine oil.
the repair.
Excessive accessory drive Refer to the appropriate section in Group
belt loading 303 for the procedure.
cooling system
Damaged or plugged INSPECT exhaust system. TEST the system
exhaust system for normal operation after the repair.
Incorrect tire size
REFER to: Suspension System (204-00
Suspension System - General Information,
Dragging brakes
REFER to: Brake System (206-00 Brake
and Testing).
Slipping transmission Refer to the appropriate section in Group
307 for the procedure.
Slipping clutch Refer to the appropriate section in Group
308 for the procedure.
Incorrect valve clearance ADJUST valve clearance. Refer to the
Worn or damaged valve INSTALL a new valve tappet. TEST the
tappet system for normal operation after the repair.
Damaged valve guide INSTALL a new cylinder head assembly.
Compression leakage at TEST the system for normal operation after
valve seat the repair.
Seized valve stem
Weak or broken valve spring INSTALL a new valve spring. TEST the
Worn or damaged cam INSTALL a new camshaft. TEST the system
Damaged head gasket INSTALL a new head gasket. TEST the
Cracked or distorted INSTALL a new cylinder head assembly.
cylinder head TEST the system for normal operation after
the repair.
Damaged, worn or sticking INSTALL a new piston ring(s). TEST the
piston ring(s) system for normal operation after the repair.
Worn or damaged piston INSTALL a new piston and piston pin. TEST
repair.
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Engine emits Clogged Air Cleaner (ACL) INSTALL a new ACL element. TEST the
excessive black element system for normal operation after the repair.
smoke (black/blue
/white)
Incorrect type or grade of DRAIN and FILL with specified oil.
oil
Blocked or restricted INSPECT the turbocharger oil drain pipe.
turbocharger oil drain pipe REPAIR as necessary. TEST the system for
Damaged/restricted or REPAIR or INSTALL a new tube as
leaking turbocharger intake necessary. TEST the system for normal
tube assembly operation after the repair.
Engine wear (piston rings, REPAIR as necessary. TEST the system for
valve guides) normal operation after the repair.
Plugged crankcase Visually INSPECT the crankcase ventilation
ventilation system system.
Turbocharger oil seals REFER to Turbocharger Internal Oil Leak
leaking Test.
Testing).
the repair.
Symptom Chart - NVH
Symptom Chart - NVH

Drone type noise Powertrain mount(s) CARRY OUT the Powertrain/Drivetrain
Mount Neutralizing procedure.
REFER to: Powertrain/Drivetrain Mount
Neutralizing (303-00 Engine System -
General Information, General
Procedures).
TEST the system for normal operation
after the repair.
Drumming noise - occurs Engine vibration excites CARRY OUT the Powertrain/Drivetrain
inside the vehicle during the body resonances Mount Neutralizing procedure.
idle or high idle, hot or inducing interior noise REFER to: Powertrain/Drivetrain Mount
cold. Very low-frequency Neutralizing (303-00 Engine System -
drumming is very rpm General Information, General
dependent Procedures).
after the repair.
Engine drumming noise - Powertrain mount(s) CARRY OUT the Powertrain/Drivetrain
accompanied by vibration Mount Neutralizing procedure.
REFER to: Powertrain/Drivetrain Mount
Neutralizing (303-00 Engine System -
General Information, General
Procedures).
after the repair.
Rattle - occurs at idle or Powertrain mount(s) CHECK the powertrain mounts for
at light acceleration from a damage. INSTALL new mounts as
stop necessary. For engine, Refer to the
procedure. For transaxle, Refer to the
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appropriate section in Group 307 or
Group 308 for the procedure. TEST the
system for normal operation after the
repair.
Whine/moan type noise - Powertrain mount(s) CHECK the powertrain mounts for
pitch increases or damage. INSTALL new mounts as
changes with vehicle necessary. For engine, Refer to the
speed appropriate section in Group 303 for the
repair.
Clunk - occurs when Powertrain mounts CHECK the powertrain mounts for
shifting from PARK or damage. INSTALL new mounts as
between REVERSE and necessary. For engine, Refer to the
DRIVE appropriate section in Group 303 for the
repair.
Idle speed is too high CHECK for the correct idle speed. TEST
repair.
Accessory drive bearing Accessory drive idler CARRY OUT the Engine Cold Soak
hoot - occurs at idle or or tensioner pulley procedure.
high idle in cold bearing is experiencing REFER to: Noise, Vibration and
temperatures of stick/slip between ball Harshness (NVH) (100-04 Noise,
approximately 4°C (40°F) bearings and the Vibration and Harshness, Diagnosis and
or colder at the first start bearing race Testing).
of the day PLACE the EngineEAR probe directly on
the idler/ tensioner center post or bolt to
verify which bearing is making the noise.
INSTALL new parts as necessary. Refer
to the appropriate section in Group 303
for the procedure. TEST the system for
Accessory drive belt Defective/worn or CARRY OUT the Engine Accessory Test.
noise, squeal or chirping incorrect accessory REFER to: Noise, Vibration and
drive belt Harshness (NVH) (100-04 Noise,
Misaligned pulley(s) Vibration and Harshness, Diagnosis and
Pulley runout Testing).
Damaged or worn INSPECT components and INSTALL new
accessory drive parts as necessary. Refer to the
component or idler appropriate section in Group 303 for the
Fluid contamination of procedure. TEST the system for normal
the accessory drive operation after the repair.
belt or pulleys
Damaged or worn
accessory drive belt
tensioner
Damaged pulley
grooves
Clunking noise Coolant pump has CHECK the coolant pump for excessive
excessive end play or end play. INSPECT the coolant pump for
imbalance imbalance with the drive belt off.
INSTALL a new coolant pump as
necessary. Refer to the appropriate
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section in Group 303 for the procedure.
after the repair.
Whine/hum - occurs when Fuel pump module Acceptable condition. Fuel pump module
unlocking the vehicle or turns on before engine starts to prime the
opening the door with the fuel system.
engine off Gasoline
Turbocharged Direct
Injection (GTDI) only
Whine or moaning noise Air intake system CHECK the air cleaner and ducts for
correct fit. INSPECT the air intake
system for leaks or damage. REPAIR as
Whistling noise - normally Air intake system CHECK the air intake ducts, air cleaner,
accompanied with poor throttle body and vacuum hoses for leaks
idle condition and correct fit. REPAIR or ADJUST as
Turbocharger intake REPAIR or INSTALL a new tube as
tube assembly leaking necessary. TEST the system for normal
Loose connections or TIGHTEN hose clamps. INSPECT for
damage to air intake damage and REPAIR as necessary.
hoses and tubes TEST the system for normal operation
after the repair.
Air leaks at turbine INSPECT for leaks. Leaks can usually be
housing, blown joints or detected audibility or visually, by a
damaged exhaust discoloration caused by escaping hot
exhaust gases. REPAIR as necessary.
after the repair.
Carbon build up in the INSPECT the turbocharger. REFER to
turbine housing the Check for Free Rotation - Off Vehicle.
Charging and Controls - Turbocharger -
2.3L EcoBoost (231kW/314PS),
after the repair.
Turbocharger REPAIR as necessary. TEST the system
imbalance due to for normal operation after the repair.
foreign object/damage
Turbine bearing failure INSPECT the turbocharger. REFER to
the Check for Free Rotation - Off Vehicle.
Charging and Controls - Turbocharger -
2.3L EcoBoost (231kW/314PS),
after the repair.
Inoperative Refer to Powertrain Control/Emissions
turbocharger bypass Diagnosis (PC/ED) manual.
valve
Whine or air rush type Turbocharger Acceptable condition. Some whine or air
noise noise is common.
Chrip or whoosh sound Turbocharger bypass CHECK the turbocharger bypass valve.
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valve REPAIR as necessary. TEST the system
Hissing noise - occurs Vacuum leak Use the Ultrasonic Leak
during idle or high idle that Detector/EngineEAR to locate the
is apparent with the hood source. Scan the air intake system from
open the inlet to each cylinder intake port.
DISCARD the leaking parts, and
INSTALL a new component. TEST the
repair.
Vehicles with a plastic Acceptable condition. Some plastic
intake manifold manifolds exhibit this noise, which is the
effect of the plastic manifold.
Grinding noise - occurs Incorrect starter motor INSPECT the starter motor for correct
during engine cranking mounting mounting. REPAIR as necessary. Refer
Starter motor CHECK the starter motor. INSTALL a
new starter motor as necessary. Refer to
the appropriate section in Group 303 for
the procedure. TEST the system for
Incorrect starter motor INSPECT the starter motor drive for
drive engagement wear or damage. INSTALL a new starter
motor as necessary. Refer to the
INSPECT the flywheel/flexplate for wear
or damage. INSTALL a new
flywheel/flexplate as necessary. Refer to
Engine noise, front of Damaged or separated CHECK for obvious signs of damage or
engine - knocking noise crankshaft wobble during operation. INSTALL new
from lower front of engine pulley/damper as necessary. Refer to the appropriate
after the repair.
Engine noise, front of Timing drive REMOVE the accessory drive belt. Refer
engine - ticking, tapping or components to the appropriate section in Group 303
rattling noise from the for the procedure.
front of the engine USE the EngineEAR to isolate the noise
to the engine front cover.
REMOVE the engine front cover and
INSPECT the timing drive components.
INSTALL new parts as necessary. Refer
Engine noise, upper end - Fuel rail clip CHECK for loose or damaged fuel rail
ticking noise near the fuel Fuel injector clip(s). REPAIR as necessary.
rail and intake manifold USE the EngineEAR to isolate the noisy
injector(s). INSTALL a new injector(s) as
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after the repair.
Fuel injection pump This is a normal engine noise that can be
(GTDI only) verified by listening to another vehicle. If
noise is excessive, REPAIR as
Engine noise, upper end - Valve train noise (bled CARRY OUT the Valve Train Analysis
ticking, knocking or rattle down lifter/lash Component Test in this section. INSTALL
noise that occurs during adjuster) new parts as necessary. Refer to the
idle or high idle during the appropriate section in Group 303 for the
first cold start of the day procedure. TEST the system for normal
and may disappear as the operation after the repair.
engine warms
Engine noise, upper end - Worn or damaged REMOVE the spark plugs. INSPECT and
occurs mostly with a spark plugs INSTALL new as necessary. Refer to the
warm engine at appropriate section in Group 303 for the
light/medium acceleration procedure. TEST the system for normal
Engine noise, upper end - Low oil level CHECK the oil level. FILL as 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
Low oil pressure CARRY OUT the Oil Pressure Test in this
section. If not within specifications,
REMOVE the engine oil pan. Refer to the
procedure. INSPECT for a blocked oil
pick up tube. TEST the system for normal
Worn valve train CARRY OUT the Valve Train Analysis
components Component Test in this section. INSTALL
new parts as necessary. Refer to the
Worn valve guides CARRY OUT the Valve Guide Inner
Diameter procedure.
REFER to: Valve Guide Inner Diameter
(303-00 Engine System - General
Information, General Procedures).
Excessive runout of the INSPECT for abnormalities on the valve
valve seats or the valve face and valve seat. INSTALL a new
face cylinder head assembly if abnormalities
are found.
Engine noise, upper end - Gasoline octane too VERIFY with customer the type of
pinging noise low gasoline used. CORRECT as necessary.
after the repair.
KS operation CHECK the KS operation. INSTALL a
new KS. Refer to the appropriate section
in Group 303 for the procedure. TEST
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repair.
Incorrect spark timing CHECK the spark timing. REPAIR as
High operating INSPECT the cooling system for leaks.
temperature 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 necessary. TEST the system
Spark plug CHECK the spark plugs. REPAIR or
INSTALL new spark plugs as necessary.
after the repair.
Catalytic converter Compare with a similar vehicle for what is
acceptable noise.
Engine noise, lower end - Oil pump USE the EngineEAR to verify the oil pump
ticking or knocking noise as the source of the noise at low rpm.
near the oil filter adapter REPAIR as necessary. Refer to the
Engine noise, lower end - Excessive clearance CARRY OUT the Piston Diameter
light knocking noise, also between the piston and procedure.
described as piston slap. the cylinder wall REFER to: Piston Diameter (303-00
Noise is most noticeable Engine System - General Information,
when the engine is cold General Procedures).
with light to medium Measure the cylinder bore diameter.
acceleration. The noise Subtract the piston diameter from the
disappears as the engine cylinder bore diameter to find the piston-
warms to-cylinder bore clearance. REFER to the
appropriate 303-01 Section for
specifications.
Engine noise, lower end - Excessive clearance MEASURE the piston pin bore and the
light double knock or between the piston and piston pin in 2 directions on each side.
sharp rap sound. Occurs the piston pin REFER to the appropriate 303-01
mostly with a warm engine Section for specifications.
at idle or low speeds in
drive. Increases in relation
to engine load. Associated
with a poor lubrication
history
Engine noise, lower end - Excessive clearance CARRY OUT the Connecting Rod
light knocking noise. The between the Bearing Journal Clearance procedure.
noise is most noticeable connecting rod REFER to: Connecting Rod Bearing
when the engine is warm. bearings and the Journal Clearance (303-00 Engine
The noise tends to crankshaft System - General Information, General
decrease when the vehicle Procedures).
is coasting or in neutral
Engine noise, lower end - Worn or damaged CARRY OUT the Crankshaft Main
deep knocking noise. The crankshaft main Bearing Journal Clearance procedure.
noise is most noticeable bearings REFER to: Crankshaft Main Bearing
when the engine is warm, Journal Clearance (303-00 Engine
at lower rpm and under a System - General Information, General
light load and then at float Procedures).
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Engine noise, rear of Damaged INSPECT the flywheel/flexplate for wear
engine - knocking noise at flywheel/flexplate or damage. INSTALL a new
rear of engine flywheel/flexplate as necessary. Refer to
Engine vibration - vibration Excessive engine pulley CARRY OUT the Engine Accessory Test.
felt at all times runout REFER to: Noise, Vibration and
Harshness (NVH) (100-04 Noise,
Vibration and Harshness, Diagnosis and
Testing).
INSTALL a new engine pulley as
after the repair.
Damaged or worn CARRY OUT the Engine Accessory Test.
accessory component REFER to: Noise, Vibration and
Harshness (NVH) (100-04 Noise,
Testing).
REPAIR or INSTALL a new component
as necessary. TEST the system for
Engine vibration - at idle, a Cylinder misfire Using the scan tool, CARRY OUT the
low-frequency vibration cylinder power balance and the relative
(5-20 Hz) or mild shake compression test. REPAIR as necessary.
that is felt through the Refer to the appropriate section in Group
seat/ floorpan 303 for the procedure. TEST the system
Engine or torque VERIFY the torque converter to
converter out of crankshaft pilot clearance is correct.
balance REPAIR as necessary. RE-INDEX the
torque converter on the flex plate by 120
degrees for a 3- bolt converter or 180
degrees for a 4-bolt converter. Refer to
Engine vibration - is felt Powertrain mount(s) CHECK the powertrain mounts for
with increases and damage. INSTALL new mounts as
decreases in engine rpm necessary. For engine, Refer to the
repair.
Engine or transmission INSPECT the powertrain/ drivetrain for
grounded to chassis correct clearances. REPAIR as
Engine vibration - Engine out-of-balance CARRY OUT the NERU Test.
increases intensity as the REFER to: Noise, Vibration and
engine rpm is increased Harshness (NVH) (100-04 Noise,
Testing).
ROTATE the torque converter, 120
degrees for 3- bolt or 180 degrees for 4-
bolt. INSPECT the torque converter pilot
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outer diameter-to-crankshaft pilot inner
diameter. REPAIR as necessary. Refer to
Engine vibration - mostly Combustion instability CHECK the ignition system. INSTALL
at coast/neutral coast. new components as necessary. Refer to
Condition improves with the appropriate section in Group 303 for
vehicle acceleration the procedure. TEST the system for
Engine vibration or Worn or damaged INSPECT the spark plugs for cracks, high
shudder - occurs with light spark plugs resistance or broken insulators. INSTALL
to medium acceleration a new spark plug(s) as necessary. Refer
above 56 km/h (35 mph) to the appropriate section in Group 303
Plugged fuel injector REPAIR or INSTALL a new injector as
after the repair.
Contaminated fuel INSPECT the fuel for contamination.
DRAIN the fuel system and refill. TEST
repair.
Component Tests
The following component tests are used to diagnose engine concerns.
Engine Oil Leaks
NOTE: If an overnight drive is done, the fan air or road air blast can cause erroneous readings.
NOTE: When diagnosing engine oil leaks, the source and location of the leak must be positively identified prior
to repair.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and
flywheel/flexplate 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 Dye-Lite® Gasoline Engine Oil Leak Detection 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 leak detection 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:
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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
Oil pressure switch or EOP sensor
Turbocharger oil tubes
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
Turbocharger oil tubes
Leakage Points - With Transmission and Flywheel/Flexplate 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
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
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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 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 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
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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 (Original Equipment Manufacturer) 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 10-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.
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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
1. NOTE: Once all of the previous conditions are met, carry out an oil consumption test.
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 10-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 10-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 10-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 4,800 km (3,000 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 detector. 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.
4. 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. A single or
adjoining, multiple cylinder leak can be traced by viewing the tips.
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.
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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 feet) 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.
The following are potential gauge readings. Some are normal; others should be investigated further.
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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 TB (Throttle Body) gasket
leak.
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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.
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 oil pressure switch (refer to the appropriate 303-01 engine section) or EOP
sensor (refer to the appropriate 303-14 section).
2. Connect a commercially available oil pressure gauge to the oil pressure sender 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 303-01
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
7. Remove the commercially available oil pressure gauge.
8. Install and connect the oil pressure switch (refer to the appropriate 303-01 engine section) or EOP sensor
(refer to the appropriate 303-14 section).
Valve Train Analysis 2.3L Ecoboost / 3.7L Duratec

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.
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Check for worn or damaged valve tips.
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 the appropriate 303-07 section.
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. NOTICE: Only rotate the crankshaft clockwise. If the engine is rotated counterclockwise the valve
train timing may slip resulting in the engine having to be retimed.
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 indicator reading should be zero. If zero reading is not obtained, repeat Steps 2
through 5.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller followers
or valve tappets.
7. Install the spark plugs. Refer to the appropriate 303-07 section.
Valve Train Analysis 5.0L 32V Ti-VCT / 5.2L 32V Ti-VCT
Valve Train Analysis - Engine Off, Valve Cover Removed
Check for damaged or severely worn parts and correct assembly.
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 the appropriate 303-07 section.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the dial indicator is on top of the
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camshaft lobe and on the same plane as the valve tappet.
3. NOTICE: Only rotate the crankshaft clockwise. If the engine is rotated counterclockwise the valve
train timing may slip resulting in the engine having to be retimed.
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 indicator reading should be zero. If zero reading is not obtained, repeat Steps 2
through 5.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller followers
or valve tappets.
7. Install the spark plugs. Refer to the appropriate 303-07 section.
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General Procedures Procedure revision date: 08/28/2012
Bearing Inspection
Inspection
1. Cratering - fatigue failure

Spot glazing - incorrect seating
Scratching - dirty engine oil
Base exposed - poor lubrication
Both edges worn - journal damaged
One edge worn - journal tapered or bearing not seated
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Connecting Rod Bearing Journal Clearance
Check
NOTE: Refer to the appropriate Section 303-01 for the specification.
1. NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod
bearing journal clearance.
Remove the connecting rod bearing cap and connecting rod bearing.
2. Position a piece of Plastigage across the bearing surface.
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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.
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Crankshaft Main Bearing Journal Clearance
Check
1. NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
Remove the crankshaft main bearing cap and crankshaft main bearing.
2. Position a piece of Plastigage across the crankshaft main bearing surface.
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3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and tighten to specifications, then remove the crankshaft main bearing cap.
4. Measure the Plastigage to get the crankshaft main bearing clearance. The Plastigage should be smooth
and flat. A changing width indicates a tapered or damaged crankshaft or crankshaft bearing.

Cylinder Block Core Plug Replacement
Special Tool(s) / General Equipment
100-001 (T50T-100-A)
Slide Hammer
Materials
Name Specification
Threadlock 262 WSK-M2G351-A6
TA-26
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Repair
All core plugs
1. NOTE: Cylinder block core plug shown, cylinder head core plug similar.
Using the Slide Hammer and a commercially available body dent puller attachment or commercially
available freeze plug puller remove the core plug.
Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer.
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. NOTE: 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. Remove the excess sealant after installation.
Material: Threadlock 262 / TA-26 (WSK-M2G351-A6)
Expansion-type
4. NOTE: Do not contact the crown when installing an expansion-type core plug. This could expand the plug
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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. Remove the excess sealant after installation.

Cylinder Block Distortion
Feeler Gauge
Check
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.
Use the General Equipment: Feeler Gauge
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Cylinder Bore Taper
Check
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.
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Cylinder Head Distortion
Feeler Gauge
Check
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)
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence
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shown.

Exhaust Manifold Cleaning and Inspection
Feeler Gauge
Cleaning
1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing
surfaces.
Inspection
1. 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)
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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.

Piston Diameter
Check
1. Measure the piston diameter 90 degrees from the piston pin and 41 mm (1.61 in) down from the top of the
piston at the point indicated.
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Piston Inspection
Inspection
1. NOTE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.
Clean and inspect the (1) ring lands, (2) pin bosses, (3) skirts and the (4) tops of the pistons. If wear
marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
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2. NOTE: Make sure the oil ring holes are clean.
Using a Piston Ring Groove Scraper, clean the piston ring grooves.

Piston Ring End Gap
Feeler Gauge
Check
1. NOTE: 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.
Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
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2. Using the Feeler Gauge Set measure the top piston ring end gap and the second piston ring end gap

Piston Selection
Check
NOTE: Refer to the appropriate Section 303-01 for the specifications.
1. NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a
piston.
Measure the cylinder bore in 2 directions.

Select a piston size based on the cylinder bore.
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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.

Powertrain/Drivetrain Mount Neutralizing
Adjustment
NOTE: Refer to the appropriate section and procedure for special instructions on loosening and tightening
mount fasteners.
1. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
2. NOTE: 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 m (1.97 ft) - 1.2 m (3.94 ft). Then move the vehicle in reverse
the same distance.
3. Tighten the powertrain/drivetrain mount fasteners.
4. Test the system for normal operation.
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RTV Sealing Surface Cleaning and Preparation
Plastic Scraper
Materials
Name Specification
Motorcraft® Silicone Gasket Remover -
ZC-30-A
Motorcraft® Metal Surface Prep -
ZC-31-B
Metal Brake Parts Cleaner (U.S.) -
PM-4-A, PM-4-B (U.S.)
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Cleaning
NOTICE: Place clean, lint-free towels over exposed cavities. Carefully remove the towels so foreign
material is not dropped into the cavities. Any foreign material (including any material created while
cleaning surfaces) that enters the fluid passages, may cause failure.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to
clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
1. Remove loose sealant by hand or with the aid of a plastic scraper.

Use the General Equipment: Plastic Scraper
2. Apply Motorcraft® Silicone Gasket Remover to surface. Allow to set for several minutes.
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
3. Use a lint-free towel and plastic scraper to remove any remaining sealant. A second application of Silicone
Gasket Remover may be required.
4. Clean the surface with Motorcraft® Metal Brake Parts Cleaner to remove all residual sealant and oil.
Material: Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)
5. NOTE: Motorcraft® Metal Surface Prep Wipes is a pre-saturated disposable wipe to be used as a final
step in surface preparation. It creates a conversion coating providing an improved base for RTV sealing.
The wipe is a dry-in-place application and does not require rinsing.
NOTE: Discard wipe after a single use.
Prep the surface with Motorcraft® Metal Surface Prep Wipes. All surfaces that are to be sealed with RTV
are to be wiped. Make sure the surface is moistened with the fluid.
Material: Motorcraft® Metal Surface Prep / ZC-31-B
6. NOTICE: Drying the surface with a towel will contaminate the surface and may cause oil leaks.
Allow the surface to air dry. (Approximately 2 minutes.)

Valve Stem Diameter
Check
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is
within specification.
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Valve Guide Inner Diameter
Check
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.
Measure the ball gauge with a micrometer.
If the valve guide is not within specifications, install a new cylinder head assembly.
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303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS) 2016 Mustang
Specifications
Engine
Item Specification
Displacement 4.957 L (302 CID)
No. of cylinders 8
Bore 92.2 mm (3.629 in)
Stroke 92.7 mm (3.649 in)
Firing order 1-5-4-8-6-3-7-2
Spark plug 12405
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Spark plug gap 1.25-1.35 mm (0.049-0.053 in)
Compression ratio 11.0:1
Engine weight (without accessory drive components) 431.0 lb (195.5 kg)
Lubricants
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); XO-5W20-QSP (US);
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) CXO-5W20-LSP12 (Canada)
Engine Oil Capacity
Item Specification
Service fill including oil filter 8.0 qt (7.6 L)
Oil Pressure
Item Specification
Oil pressure @ idle with engine at normal operating temperature 10–15 psi (69–103 kPa)
Oil pressure @ 2,000 rpm with engine at normal operating temperature 30–40 psi (207–276 kPa)
Cylinder Head and Valve Train
Item Specification
Combustion chamber 3.33–3.51 in³ (54.5–57.5 cm³)
volume
Valve stem diameter - 0.2368–0.2380 in (6.015–6.044 mm)
intake
Valve stem diameter - 0.2368–0.2380 in (6.015–6.044 mm)
exhaust
Valve stem-to-guide 0.0008–0.0027 in (.02–.069 mm)
clearance - intake
Valve stem-to-guide 0.0018–0.0037 in (.045–.094 mm)
clearance - exhaust
Valve head diameter - 1.46 in (37 mm)
intake
Valve head diameter - 1.22 in (31 mm)
exhaust
Valve face runout 0.0020 in (.05 mm)
Valve face angle 3 angle
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Valve seat width - intake 0.051–0.059 in (1.3–1.5 mm)
Valve seat width - exhaust 0.055–0.063 in (1.4–1.6 mm)
Valve seat runout 0.0016 in (.04 mm)
Valve seat angle 121/91/61 degrees
Valve spring free length - 2.020 in (51.32 mm)
intake
Valve spring free length - 2.020 in (51.32 mm)
exhaust
Valve spring 0.118 in (3 mm)
perpendicularity - intake
Valve spring 0.118 in (3 mm)
perpendicularity - exhaust
Valve spring compression 650 N
force - intake
Valve spring compression 650 N
force - exhaust
Valve spring installed height 1.5748 in (40 mm)
- intake
Valve spring installed height 1.5748 in (40 mm)
- exhaust
Valve spring installed force 265 N
- intake
Valve spring installed force 265 N
- exhaust
Roller follower ratio 2:1
Cylinder head gasket 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.050 mm (0.002 in)
surface flatness in any 150 mm (6 in) x 150 mm (6 in) area; 0.1 mm (0.004 in) overall
Hydraulic Lash Adjuster

Item Specification
Diameter — intake 0.472 in (12 mm)
Diameter — exhaust 0.472 in (12 mm)
Clearance-to-bore 0.0007–0.0020 in (.018–.05 mm)
Hydraulic leakdown rate — intake 0.45-3 secondsa
Hydraulic leakdown rate — exhaust 0.45-3 secondsa
Collapsed lash adjuster gap 0.0138–0.0335 in (.35–.85 mm)
Camshaft
Item Specification
Lobe lift - intake 0.2348 in (5.963 mm)
Lobe lift - exhaust 0.2161 in (5.488 mm)
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Journal diameter 1.1268 in (28.62 mm)
Journal bore inside diameter 1.1292–1.1282 in (28.682–28.657 mm)
Journal-to-bearing clearance 0.0010–0.0030 in (.025–.075 mm)
Runout 0.0016 in (.04 mm)
End play 0.0059 in (.15 mm)
Cylinder Block
Item Specification
Cylinder bore diameter 3.6299–3.6307 in (92.2–92.22 mm)
Cylinder bore maximum taper 0.0005 in (.013 mm)
Cylinder bore maximum out-of-round 0.0004 in (.01 mm)
Main bearing bore inside diameter 2.850–2.851 in (72.4–72.424 mm)
Head gasket surface flatness 0.0254 mm (0.001 in) across any 38.1 mm (1.5 in) square
Crankshaft
Item Specification
Main bearing journal diameter 2.657–2.658 in (67.481–67.505 mm)
Main bearing journal maximum taper 0.0002 in (.004 mm)
Main bearing journal maximum out-of-round 0.0002 in (.006 mm)
Main bearing journal-to-main bearing clearance 0.0010–0.0018 in (.025–.045 mm)
Connecting rod journal diameter 2.086–2.087 in (52.983–53.003 mm)
Connecting rod journal maximum taper 0.0002 in (.004 mm)
Item Specification
Connecting rod journal maximum out-of-round 0.0002 in (.006 mm)
Crankshaft maximum end play 0.0110 in (.28 mm)
Piston and Connecting Rod
Item Specification
Piston diameter - single grade 3.6284–3.6289 in
(92.161–92.175 mm)
Piston-to-cylinder bore clearance (at grade size)b 0.0010–0.0023 in (.025–.059 mm)
Piston ring end gap - top 0.0059–0.0098 in (.15–.25 mm)
Piston ring end gap - intermediate 0.0118–0.0217 in (.3–.55 mm)
Piston ring end gap — oil control 0.0059–0.0177 in (.15–.45 mm)
Piston ring groove width - top 0.0480–0.0492 in (1.22–1.25 mm)
Piston ring groove width - intermediate 0.0480–0.0488 in (1.22–1.24 mm)
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Piston ring groove width— oil control 0.0996–0.1004 in (2.53–2.55 mm)
Piston ring width - top 0.0461–0.0469 in (1.17–1.19 mm)
Piston ring width - intermediate 0.0461–0.0469 in (1.17–1.19 mm)
Piston ring-to-groove clearance - top 0.0012–0.0031 in (.03–.08 mm)
Piston ring-to-groove clearance - intermediate 0.0012–0.0028 in (.03–.07 mm)
Piston pin bore diameter 0.8663–0.8665 in (22.004–22.01 mm)
Piston pin diameter 0.8660–0.8661 in (21.997–22 mm)
Piston pin length 2.390–2.402 in (60.7–61 mm)
Piston pin-to-piston fit (clearance) 0.0002–0.0005 in (.004–.013 mm)
Connecting rod-to-pin clearance 0.0001–0.0007 in (.003–.018 mm)
Connecting rod pin bore diameter 0.8663–0.8667 in
(22.003–22.015 mm)
Connecting rod length (center-to-center) 5.93 in (150.7 mm)
Connecting rod maximum allowed bend 0.0015 in (.038 mm)
Connecting rod maximum allowed twist 0.0020 in (.05 mm)
Connecting rod bearing-to-crankshaft clearance 0.0011–0.0027 in (.028–.069 mm)
Connecting rod side clearance (as assembled to crank) — standard 0.0128 in (.325 mm)
play
Connecting rod side clearance (as assembled to crank) — max. play 0.0197 in (.5 mm)
a. Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leakdown fluid in the lash
adjuster
b. Before Grafal coating.

Engine - Overview
Overview
The 5.0L (302 CID) is a V-8 engine with the following features:
Dual overhead camshafts

Four valves per cylinder
SFI
Aluminum cylinder heads
Aluminum, 90-degree V-cylinder block
Twin independent VCT system
Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
Electronic ignition system with 8 ignition coils
Engine Identification
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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. The codes contain all the pertinent information relating to the dates, optional equipment and
revisions.
Engine Code Information Label
Item Description
1 Essex engine plant
2 Engine displacement
3 Transmission
4 Vehicle line
5 Sequential number
6 Engine build date (DDMMYY)
7 Essex engine plant
8 Bar code
9 Engine part number
Engine Cylinder Identification
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Engine Oil Flow Illustration
Item Description
1 Oil filter
2 Oil filter adapter
3 EOP switch
4 Cylinder head — LH
5 Timing chain tensioner — LH
6 Exhaust camshaft
7 Intake camshaft
8 Exhaust VCT unit
9 Intake VCT unit
10 Cylinder block
11 Cylinder head — RH
12 Timing chain tensioner — RH
13 Oil pump
14 Oil pump screen and pickup tube
15 Oil pan baffle and gasket
16 Oil pan
17 Oil Cooler
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the:
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crankshaft main bearings.
crankshaft thrust main bearing.
connecting rod bearings.
oil galleries.
All other parts are lubricated by splash of the oil.
The lubrication system of the 5.0L (4V) engine is designed to provide optimum oil flow to critical components of
the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil
pump using top seal rotors.
The heart of the system is a positive displacement internal gear oil pump.
Generically, this design is known as a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the cylinder block.
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back
to the inlet side of the oil pump.
Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure
both at hot idle and maximum speed.
The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature
and high-speed conditions.
Valve Train
The valves are actuated by a hydraulic lash adjuster and roller follower. The hydraulic lash adjusters and roller
followers:
provide hydraulic lash adjustment.

ride on the camshaft lobes.
Twin Independent VCT System
The twin independent VCT system allows variable control of the valves 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.
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Engine Component View
Engine — Upper Components
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Part
1 6051 RH cylinder head gasket
2 6049 RH cylinder head
3 6250 RH exhaust camshaft
4 6250 RH intake camshaft
5 6582 RH valve cover
6 12405 Spark plug (8 required)
7 12029 Ignition coil on plug (8 required)
8 9F991 Throttle body
9 6P013 RH fuel injector insulator shield
10 6P013 LH fuel injector insulator shield
11 9F792 Fuel rail
12 9F593 Fuel injector (8 required)
13 9424 Intake manifold
14 6582 LH valve cover
15 6049 LH cylinder head
16 6051 LH cylinder head gasket
17 6754 Oil indicator tube
18 6750 Oil indicator
19 — Camshaft bearing cap (part of 6049) (2 required)
20 6K254 Secondary tensioner (2 required)
21 — Camshaft bearing cap (part of 6049) (16 required)
22 6K297 Secondary tensioner shoe (2 required)
23 6250 LH intake camshaft
24 6268 Secondary timing chain (2 required)
25 6256 Intake camshaft Variable Camshaft Timing (VCT) (2
required)
26 6256 Exhaust camshaft Variable Camshaft Timing (VCT) (2
required)
27 6250 LH exhaust camshaft
Engine — Lower Components
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Part
1 6675 Oil pan
2 6C878 Oil pan baffle and gasket
3 — Crankshaft main bearing cap (part of 6010) (5 required)
4 6A338 Crankshaft lower main bearing (4 required)
5 6A339 Crankshaft lower thrust main bearing
6 6600 Oil pump
7 6303 Crankshaft
8 6333 Crankshaft upper main bearing (5 required)
9 6A341 Thrust washer
10 6010 Cylinder block
11 6A340 Crankshaft pulley bolt
12 N807033 Crankshaft pulley washer
13 6316 Crankshaft pulley
14 6700 Crankshaft front oil seal
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15 8509 Coolant pump pulley
16 8501 Coolant pump
17 6B297 Variable Camshaft Timing (VCT) variable force solenoid (4
required)
18 6019 Engine front cover
19 6L266 RH primary timing chain tensioner
20 6K255 RH timing chain tensioner arm
21 6268 RH primary timing chain
22 6M256 RH timing chain guide
23 6L266 LH primary timing chain tensioner
24 6K255 LH timing chain tensioner arm
25 6268 LH primary timing chain
26 6306 Crankshaft sprocket
27 6B274 LH timing chain guide
28 6K318 Crankshaft rear seal retainer plate
29 12A227 Crankshaft sensor ring
30 6375 Flywheel (manual transmission)
31 6375 Flexplate (automatic transmission)
32 6881 Oil filter adapter
33 6A642 Oil cooler
34 6731 Oil filter

Engine
1. For basic mechanical concerns.

REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
For driveability concerns. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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Removal and Installation Procedure revision date: 02/10/2015
Camshaft LH
Materials
Name Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) WSS-M2C945-A
XO-5W20-QSP (U.S.)
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.
NOTE: If the RH camshafts are being serviced at the same time as the LH camshafts, remove the RH
camshafts first. Refer to the procedure in this section.
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NOTE: If the components are to be reinstalled, they must be installed in their original locations.
1. Remove the LH VCT units.

Refer to: Variable Camshaft Timing (VCT) Unit (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
(308kW/418PS), Removal and Installation).
2. Remove and discard the VCT system oil filters.
3. NOTICE: The front camshaft bearing mega cap must be removed first and then the remaining
camshaft bearing caps. Failure to follow this direction may result in damage to the engine.
Remove the bolts and the front camshaft bearing mega cap.
4. Remove the bolts and the camshaft bearing caps.
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5. Remove the intake and exhaust camshafts.
6. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect
the camshaft lobes and valves for damage. Replace damaged components as necessary.
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Installation
1. NOTE: If the components are to be reinstalled, they must be installed in their original locations.
1. Assemble the hydraulic lash adjusters onto the spring clips on the camshaft roller followers.
2. Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil.
Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W20-QSP
(U.S.) (WSS-M2C945-A)
3. Install the camshaft roller follower and hydraulic lash adjuster assemblies.
2. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) / XO-5W20-QSP (U.S.)
(WSS-M2C945-A)
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3. NOTE: Do not tighten at this time.
Install the camshaft bearing caps and the bolts.
Install the front camshaft bearing mega cap and the bolts.
5. Tighten the bolts.
Torque:
Stage 1: 53 lb.in (6 Nm)
Stage 2: 45°
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6. Install new VCT system oil filters into the camshafts.
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7. Install the LH VCT units.

Camshaft RH
Materials
Name Specification
XO-5W20-QSP (U.S.)
Removal
NOTE: If the components are to be reinstalled, they must be installed in their original locations.
1. Remove the RH VCT units.
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2. Remove the VCT system oil filters from the camshafts.
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6. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect
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Installation
(U.S.) (WSS-M2C945-A)
Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
(WSS-M2C945-A)
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Torque:
Stage 2: 45°
6. Install the VCT system oil filters into the camshafts.
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7. Install the RH VCT units.

Crankshaft Front Seal
Base Part Number: 6700
303-1531
Installer, Front Crank Seal and Damper
303-335 (T88T-6701-A)
Installer, Front Cover Oil Seal
TKIT-1988-F
TKIT-1988-FLM
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303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FH/FMH/FLMH
TKIT-1993-LMH/MH
Strap Wrench
Three Leg Puller
Materials
Name Specification
XO-5W20-QSP (U.S.)
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Removal
1. Remove the following items:

1. Refer to: Cooling Fan Motor and Shroud (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT
V8 (308kW/418PS), Removal and Installation).
2. Refer to: Accessory Drive Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
3. Refer to: Air Conditioning (A/C) Compressor Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), Removal and Installation).
2. Remove the crankshaft pulley bolt and washer.

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3. Using the 3 Leg Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
Use the General Equipment: Three Leg Puller
Discard the crankshaft pulley bolt.
4. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Using the special tool, remove and discard the crankshaft front oil seal.
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
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Installation
1. Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.
(WSS-M2C945-A)
2. Using the special tools, install the new crankshaft front oil seal.
Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal. , 303-1531 Installer,
Front Crank Seal and Damper.
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3. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned.
Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
(WSS-M2C945-A)
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5. Using the special tools, install the crankshaft pulley.
6. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer.
Use the General Equipment: Strap Wrench
Torque:
Stage 1: 103 lb.ft (140 Nm)
Stage 2: Loosen: 360°
Stage 4: 90°
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7. Install the following items:
2. Refer to: Accessory Drive Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
8. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a
diagnostic scan tool.

Crankshaft Rear Seal
100-001 (T50T-100-A)
Slide Hammer
205-153 (T80T-4000-W)
Handle
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303-1250
Seal Installer, Rear Main
TKIT-2006UFFLM
303-519 (T95P-6701-EH)
Remover, Crankshaft Rear Oil Seal
TKIT-1995-FH/FLMH
TKIT-1995-LMH/MH
Materials
Name Specification
XO-5W20-QSP (U.S.)
Removal
1. Remove the flexplate or flywheel.

Refer to: Flexplate (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
Refer to: Flywheel (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
2. NOTE: Automatic transmission spacer plate shown, manual transmission similar.
Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.
Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or
has any visual damage, it must be discarded.
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3. Using the special tools, remove and discard the crankshaft rear seal.
Use Special Service Tool: 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Seal. , 100-001 (T50T-
100-A) Slide Hammer.
Installation
1. Lubricate the seal bore and the seal lips with clean engine oil.
(WSS-M2C945-A)
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2. Position the special tool onto the end of the crankshaft.
Use Special Service Tool: 303-1250 Seal Installer, Rear Main.
Slide the new crankshaft rear seal onto the tool.
3. Using the special tools, install the crankshaft rear seal.

Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 303-1250 Seal Installer, Rear Main.
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Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
5. Install the flexplate or flywheel.

Installation).
Installation).

Crankshaft Rear Seal with Retainer Plate
Base Part Number: 6K301
100-001 (T50T-100-A)
Slide Hammer
205-153 (T80T-4000-W)
Handle
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303-1250
TKIT-2006UFFLM
303-519 (T95P-6701-EH)
TKIT-1995-FH/FLMH
TKIT-1995-LMH/MH
Plastic Scraper
Materials
Name Specification
XO-5W20-QSP (U.S.)
ZC-30-A
ZC-31-B
TA-30
PM-4-A, PM-4-B (U.S.)
Removal
1. Remove the flexplate or flywheel.

Installation).
Installation).
Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or
has any visual damage, it must be discarded.
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Use Special Service Tool: 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Seal. , 100-001 (T50T-
100-A) Slide Hammer.
4. Disconnect the CKP sensor electrical connector.

Remove the bolt and the CKP sensor.
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5. Remove the oil pan.
Refer to: Oil Pan (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
6. Remove the bolts and the crankshaft rear seal retainer plate.
7. 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 all traces of old sealant.
Clean and inspect the mating surface.

Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information,
General Procedures).
Installation
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1. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. Failure to follow this procedure may cause future oil leaks.
Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating
surface on the engine block.
2. Install the crankshaft rear seal retainer plate and the bolts.
Torque:
Stage 2: 45°
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3. Lubricate the crankshaft rear seal bore and the seal lips with clean engine oil.
(WSS-M2C945-A)

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6. Install the CKP sensor and the bolt.

Torque: 89 lb.in (10 Nm)
Connect the CKP sensor electrical connector.
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7. Install the oil pan.
Installation).
Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
9. Install the flexplate or flywheel.

Installation).
Installation).
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Cylinder Head LH
303-050 (T70P-6000)
Lifting Bracket, Engine
303-F072
Support Bar, Engine
Oil Drain Equipment
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Materials
Name Specification
XO-5W20-QSP (U.S.)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.

Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. Release the fuel system pressure.

Refer to: Fuel System Pressure Release (310-00C Fuel System - General Information - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), General Procedures).
3. Drain the engine cooling system.

Refer to: Cooling System Draining and Vacuum Filling (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), General Procedures).
4. Disconnect the LH HO2S electrical connector and detach the harness retainer.
5. NOTE: Automatic transmission shown, manual transmission similar.
Disconnect the LH catalyst monitor sensor electrical connector and detach the harness retainers.
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1. Refer to: Intake Manifold (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
Removal and Installation).
2. Refer to: Camshaft LH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
3. Refer to: Catalytic Converter LH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
7. Install the LH engine mount bracket, bolts and stud bolt.

Torque: 41 lb.ft (55 Nm)
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8. Using the special tools, lower the engine onto the LH engine mount.
Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine. , 303-F072 Support
Bar, Engine.
9. Disconnect the Camshaft Position (CMP) sensors and the ignition interference capacitor electrical
connectors.
Remove the bolt and position the ground wire aside.
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10. Detach the wiring harness retainer from the cylinder head.
11. Remove and discard the bolts.

Remove the cylinder head.
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12. Discard the cylinder head gasket.
NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all
coolant, oil or other foreign material is removed.
Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and
the cylinder block
Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General
Procedures).
Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General
Procedures).
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Installation
1. Install the cylinder head gasket.
2. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must
be installed.
Install the cylinder head and the new bolts.

Torque:
Stage 6: 90°
Stage 7: 90°
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3. Attach the wiring harness retainer to the cylinder head.
4. Install the ground wire and bolt.

Connect the Camshaft Position (CMP) sensors and the ignition interference capacitor electrical
connectors.
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5. NOTICE: Do not position the legs of the Engine Support Bar on the fenders. Instead, the legs
should be positioned on the body structure. Failure to follow these instructions may result in body
damage.
Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine. , 303-F072 Support Bar,
Engine.
Using the special tools raise the LH side of the engine 25 mm (1 inch).
6. Remove the bolts, stud bolt and the LH engine mount bracket.
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1. Refer to: Catalytic Converter LH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Refer to: Camshaft LH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
Connect the LH catalyst monitor sensor electrical connector and attach the harness retainers.
9. Connect the LH HO2S electrical connector and attach the harness retainer.
10. Remove the oil pan drain plug and drain the engine oil.
Use the General Equipment: Oil Drain Equipment
Install the oil pan drain plug.
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11. Remove and discard the engine oil filter.
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12. NOTE: Do not lubricate the O-ring seal.
Install a new oil filter.

Torque:
Stage 2: 180°
13. Fill the engine with clean engine oil.

Refer to: Specifications (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
Specifications).
(WSS-M2C945-A)
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14. Fill and bleed the engine cooling system.

Cylinder Head RH
303-050 (T70P-6000)
303-F072
Support Bar, Engine
Oil Drain Equipment
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Materials
Name Specification
XO-5W20-QSP (U.S.)
Removal




2. Refer to: Camshaft RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
3. Refer to: Exhaust Manifold RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
5. Install the RH engine mount bracket, bolts and stud bolts.

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6. Using the special tools, lower the engine onto the RH engine mount.
Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine. , 303-F072 Support
Bar, Engine.
7. Disconnect the heater hose.

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8. Disconnect the camshaft position sensor electrical connector.
9. Disconnect the CHT electrical connector.

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11. Remove and discard the cylinder head gasket.

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the cylinder block
Procedures).
Procedures).
Installation
1. Install the new cylinder head gasket.

be installed.
Install the cylinder head and the new bolts.

Torque:
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Stage 6: 90°
Stage 7: 90°
3. Connect the heater hose.

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4. Connect the camshaft position sensor electrical connector.
5. Connect the CHT electrical connector.

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6. Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine. , 303-F072 Support Bar,
Engine.
Using the special tools raise the RH side of the engine 25 mm (1 inch).
7. Remove the bolts, stud bolts and the RH engine mount bracket.
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1. Refer to: Exhaust Manifold RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Refer to: Camshaft RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
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Torque:
Stage 2: 180°

Specifications).
(WSS-M2C945-A)
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Engine Front Cover
Base Part Number: 6C086
Plastic Scraper
Oil Drain Equipment
Materials
Name Specification
XO-5W20-QSP (U.S.)
ZC-30-A
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ZC-31-B
TA-30
Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) WSS-M97B44-D
VC-3-B (U.S.)
PM-4-A, PM-4-B (U.S.)
Removal


3. Disconnect the battery ground and positive cables.

Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).


1. Refer to: Degas Bottle (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and Installation).
3. Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering - 5.0L 32V Ti-VCT/5.0L Ti-VCT
6. Loosen the coolant pump pulley bolts.

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1. Refer to: Crankshaft Front Seal (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Refer to: Valve Cover RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
3. Refer to: Valve Cover LH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
8. Disconnect the lower radiator hose from the thermostat housing assembly.
9. Remove the thermostat housing bolts.

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10. Release the clamp and remove the upper radiator hose T-connector/thermostat housing assembly.
Release the clamp and remove the degas bottle coolant hose.
11. Remove and discard the thermostat housing O-ring seal.

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12. Disconnect the heater hose.
13. Remove the bolts and the coolant pump pulley.

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14. Remove the bolts and the coolant pump.
15. Remove and discard the coolant pump O-ring seal.

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16. Disconnect the throttle body and EVAP purge valve electrical connectors.
17. Detach the wiring harness retainers from the engine front cover and stud bolt.
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18. Remove the wiring harness retainers.
Remove the nut and ground wire.
19. Remove the bolt and the accessory drive belt tensioner.
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20. Remove the nut, the bolt and position the generator aside.
21. NOTE: Vehicles are equipped with either an underbody shield or a subframe bracket and underbody
shield assembly.
1. Remove the bolts and the underbody shield.

2. Remove the bolts and the subframe bracket and underbody shield assembly.
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22. Remove the nut and the wiring harness retainer.
23. Remove the bolts and stud bolts.

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25. NOTE: Timing drive components removed from view for clarity.
Remove the engine front cover from the front cover to cylinder block dowels.
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26. Remove and discard the gaskets.

Installation
1. Install new gaskets on the engine front cover.
2. NOTICE: The VCT variable force solenoid pins must be fully depressed to avoid interference with
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the VCT valve tips when installing the engine front cover. Failure to follow these instructions can
result in damage to the engine.
NOTE: RH shown, LH similar.
Fully depress the VCT variable force solenoid pins.

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3. NOTICE: The engine front cover must be installed and all fasteners final tightened within 5 minutes
of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten
fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the
fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is
exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this
procedure can cause future oil leakage.
Apply a 15 mm (0.59 in) diameter drop of silicone gasket and sealant to the cylinder head-to-cylinder block
joints and the oil pan-to-cylinder block joints.
4. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before
installation.
NOTE: Timing drive components removed from view for clarity.
Position the engine front cover onto the dowels.
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Install the bolts and stud bolts.

Torque:
Stage 1: Fasteners 1-15 : 18 lb.ft (25 Nm)
Stage 2: Fasteners 16-19 : 89 lb.in (10 Nm)
Stage 3: Fasteners 1-15 : 60°
6. Install the wiring harness retainer and the nut.

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7. Install the generator, the bolt and the nut.
8. Install the accessory drive belt tensioner and bolt.

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9. Install the ground wire and nut.
Install the wiring harness retainers.
10. Attach the wiring harness retainers to the engine front cover and stud bolt.
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11. Connect the throttle body and EVAP purge valve electrical connectors.
12. Install a new coolant pump O-ring seal and lubricate with clean engine coolant.
Material: Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) / VC-3-B (U.S.) (WSS-M97B44-D)
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13. Install the coolant pump and bolts.
Torque:
Stage 2: 60°
14. Install the coolant pump pulley and the bolts.

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15. Connect the heater hose.
16. Install a new thermostat housing O-ring seal and lubricate with clean engine coolant.
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17. Install the upper radiator hose T-connector/thermostat housing assembly and clamp.
Install the degas bottle coolant hose and clamp.
18. Install the thermostat housing bolts.

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19. Connect the lower radiator hose to the thermostat housing assembly.

1. Refer to: Valve Cover LH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
2. Refer to: Valve Cover RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
3. Refer to: Crankshaft Front Seal (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
21. Tighten.
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Torque:
Stage 2: 180°
shield assembly.
1. Install the underbody shield and the bolts.

Torque:
A: 97 lb.in (11 Nm)
B: 18 lb.in (2 Nm)
2. Install the subframe bracket and underbody shield assembly and the bolts.
Torque:
C: 46 lb.ft (63 Nm)
D: 18 lb.in (2 Nm)
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Specifications).
(WSS-M2C945-A)
28. Connect the battery positive and ground cables.


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Engine Mount LH
303-050 (T70P-6000)
303-F072
Support Bar, Engine
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Removal


3. If equipped with a strut tower cross brace, detach the wiring harness retainer.
Remove the nuts and the strut tower cross brace.
4. NOTE: The engine appearance cover rubber grommets may remain on the cover. If so, remove the
grommets from the cover and install them on the intake manifold before installing the cover.
Remove the engine appearance cover.

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5. Remove the retainers and the radiator top shield.

7. Remove the LH engine mount nut.

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8. Remove the RH engine mount nut.
damage.
Install the special tools and raise the engine 50 mm (2 inch).

Use Special Service Tool: 303-F072 Support Bar, Engine. , 303-050 (T70P-6000) Lifting Bracket, Engine.
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10. Remove the bolts and the engine mount.
Installation
1. Install the engine mount and the bolts.

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2. Lower the engine onto the engine mounts and remove the special tools
3. Install the RH engine mount nut.

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4. Install the LH engine mount nut.

6. Install the radiator top shield and the retainers.

Install the engine appearance cover.
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8. If equipped, install the strut tower cross brace and nuts.
Attach the wiring harness retainer.
9. Connect the battery ground and positive cables.
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Engine Mount RH
303-050 (T70P-6000)
303-F072
Support Bar, Engine
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Removal



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2. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
3. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
7. Remove the fasteners and the cowl extension.

8. Remove the fasteners and the battery heat shield.
9. Disconnect the CMP sensor electrical connector, the wiring harness retainers and position the
harness aside.
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Remove the bolt and the CMP sensor.
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damage.

13. Remove the bolts and the engine mount.

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Installation
1. Install the engine mount and bolts.


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5. Install the CMP sensor and the bolt.
Connect the CMP sensor electrical connector and the wiring harness retainers.
6. Install the battery heat shield and fasteners.

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7. Install the cowl extension and fasteners.


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Exhaust Manifold RH
303-050 (T70P-6000)
303-F072
Support Bar, Engine
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Removal
6-Speed Automatic Transmission - 6R80/6-Speed Manual Transmission - MT82

2. Recover the refrigerant.

Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control
System - General Information, General Procedures).


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7. NOTE: Discard the O-ring seal and gasket.
Remove the nut and disconnect the A/C compressor fitting.

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6-Speed Manual Transmission - MT82
11. Disconnect the HO2S electrical connector and wiring harness retainer.
harness aside.
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damage.


1. Refer to: Catalytic Converter RH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Refer to: Starter Motor (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
6-Speed Automatic Transmission - 6R80
17. Disconnect the HO2S electrical connector.

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18. Remove the transmission cooling tube nut and bracket from the flexplate inspection cover stud bolt.
19. Remove the transmission cooling tube bracket nut and position the bracket and tubes aside.
20. Detach the wiring harness retainers from the oil pan.
21. Remove the nut and ground strap from the RH engine mount bracket stud bolt.
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22. Remove the bolts, the stud bolts and the RH engine mount bracket.
23.
Remove and discard the nuts.
Remove the exhaust manifold.
Clean and inspect the exhaust manifold.
Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information,
24. Remove and discard the gasket and studs.
Installation

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1. Install new studs and new gasket.
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2.
Install the exhaust manifold.
Install the new nuts.
Torque:

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4. Install the ground strap and nut onto the RH engine mount bracket stud bolt.
5. Attach the wiring harness retainers to the oil pan.

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6. Install the transmission cooling tube bracket and nut.


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8. Connect the HO2S electrical connector.


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14. Connect the HO2S electrical connector and wiring harness retainer.
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18. NOTE: Install a new O-ring seal and gasket.
Connect the A/C compressor fitting and install the nut.


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23. Recharge the A/C system.

Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control
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Flexplate
Removal
1. Remove the transmission.

Refer to: Transmission - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed Automatic
Transmission - 6R80, Removal and Installation).
2. NOTE: The flexplate bolts are torque-to-yield design and are not reusable.
Remove and discard the bolts.

Remove the flexplate.
Installation
1. Install the flexplate and the bolts.

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Torque:
Stage 2: 60°
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2. Install the transmission.
Refer to: Transmission - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed Automatic
Transmission - 6R80, Removal and Installation).

Flywheel
Removal
1. Remove the clutch disc.

Refer to: Clutch Disc and Pressure Plate - 5.0L 32V Ti-VCT (308-01 Clutch, Removal and Installation).
2. NOTE: The flywheel bolts are torque-to-yield design and are not reusable.

Remove the flywheel.
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Installation
1. Install the flywheel and the bolts.

Torque:
Stage 3: 60°
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2. Install the clutch disc.

Intake Manifold
Removal


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7. 1. Remove the nuts.

2. Position the heater hose aside.
3. Remove the heater hose support.
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8. Detach the vacuum tube retainer.
Disconnect the vacuum tube.
Refer to: Quick Release Coupling (310-00C Fuel System - General Information - 5.0L 32V
Release the clamps and position the vacuum tube aside.
9. Disconnect the throttle body electrical connector.

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10. 1. Disconnect the couplings and remove the crankcase vent tube.
2. Disconnect the EVAP purge valve electrical connector.
3. Disconnect the EVAP tube and position aside.
11. 1. Remove the nuts.

2. Position the heater hose aside.
3. Remove the heater hose support.
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12. Remove the fuel rail insulators.
13. Disconnect the RH fuel injector electrical connectors.

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14. Disconnect the LH fuel injector electrical connectors.
15. Disconnect the fuel supply tube.

Refer to: Quick Release Coupling (310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L
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16. NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly.
Remove the fuel rail bolts.
17. 1. Loosen the intake manifold bolts.

2. Position the manifold up and towards the front of the engine to access the rear of the manifold.
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18. Disconnect the wiring harness electrical connectors.
Detach the wiring harness retainers.
Remove the intake manifold.
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Clean and inspect all sealing surfaces.
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 if found, install a new intake
manifold. Failure to follow these instructions can result in engine damage.
1. Install new gaskets.

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2.
Position the intake manifold onto the engine.
Attach the wiring harness retainers.
Connect the wiring harness electrical connectors.
3. 1. Position the manifold to the installed position.

2. Tighten the intake manifold bolts.
Torque:
Stage 2: 35°
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4. Install the fuel rail bolts.
Torque:
Stage 2: 90°
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5. Connect the fuel supply tube.
6. Connect the LH fuel injector electrical connectors.

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7. Connect the RH fuel injector electrical connectors.
8. Install the fuel rail insulators.

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9. 1. Install the heater hose support.
2. Position the heater hose.
3. Install the nuts.
10. 1. Install the crankcase vent tube and connect the couplings.
2. Connect the EVAP purge valve electrical connector.
3. Connect the EVAP tube.
11. Connect the throttle body electrical connector.
12. Install the vacuum tube and clamps.

Connect the vacuum tube.
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Attach the vacuum tube retainer.
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13. 1. Install the heater hose support.
2. Position the heater hose.
3. Install the nuts.

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Oil Cooler
Locking Pliers
Materials
Name Specification
XO-5W20-QSP (U.S.)
VC-3-B (U.S.)
Removal
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shield assembly.
1. Loosen the 2 front bolts, remove the remaining bolts and the underbody shield.
2. Loosen the 2 front bolts, remove the remaining bolts and the subframe bracket and underbody
shield assembly.

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4. Using hose locking pliers, clamp the oil cooler coolant hoses.
Use the General Equipment: Locking Pliers
Disconnect the coolant hoses.
5. Remove the retainer and the oil cooler.

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6. 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 and discard the gasket.

Inspect the oil cooler.
Installation
1. Install a new gasket.

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2. Install the oil cooler and the retainer.
3. Connect the coolant hoses.

Remove the hose locking pliers.
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Torque:
Stage 2: 180°
shield assembly.

Torque:
A: 97 lb.in (11 Nm)
B: 18 lb.in (2 Nm)
Torque:
C: 46 lb.ft (63 Nm)
D: 18 lb.in (2 Nm)
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6. Inspect and adjust the coolant level in the degas bottle
7. Inspect and adjust the engine oil level.

(WSS-M2C945-A)

Oil Pan
303-050 (T70P-6000)
303-F072
Support Bar, Engine
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Plastic Scraper
Oil Drain Equipment
Vehicle/Axle Stands
Materials
Name Specification
ZC-30-A
Engine Oil - 5W20 WSS-M2C948-B

ZC-31-B
TA-30
PM-4-A, PM-4-B (U.S.)
Removal


3. NOTICE: Make sure to minimize damage to sealer foam and avoid pulling apart dash seal brackets
from retainer pins. Excessive damage may allow engine noise, fumes, air or water to enter the
passenger compartment.
1. Remove the steering column dash seal nuts.

2. Loosen the dash seal.
3. Hand start the dash seal nuts.
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4. Using a holding device, hold the steering wheel in the straight-ahead position.
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7. Remove the oil level indicator.

9. Install clips to support the cooling module.

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harness aside.
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damage.

17. Remove the front wheels and tires.

Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
shield assembly.

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19. Remove the pin-type retainers, bolts and the underbody shield.
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22. 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).
WARNING: DO NOT hammer, pry or force steering column and column shafts during
installation or removal. Failure to follow this instruction may cause damage to steering
components that could lead to loss of steering control during vehicle operation and could result in
serious personal injury or death.
WARNING: DO NOT attempt to remove or install the steering column lower u-joint at the
steering gear without first loosening the steering column dash seal and fasteners. Failure to follow
this instruction may cause damage to steering components that could lead to loss of steering
control during vehicle operation and could result in serious personal injury or death.
Detach the steering column lower shaft from the lower coupling.
1. Remove and discard the steering column shaft bolt.
2. Pull apart the steering column shaft from the coupling.
3. Secure the lower shaft to the frame rail to avoid damage to the shaft.
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Detach the wiring harness retainer from the oil pan stud bolt.
25. Disconnect the oil level sensor electrical connector and wiring harness retainer.
26. Detach the wiring harness pin-type retainers.

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27. Detach the brake tube retainers from the subframe.
28. Using an adjustable stand, support the subframe.

Use the General Equipment: Vehicle/Axle Stands
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29. Mark the position of the front subframe for reference during installation.
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30. Mark the position of the rear subframe for reference during installation.
31. Remove and discard the rear subframe bolts.

32. Remove and discard the front subframe nuts.
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35. Remove the stud bolts and the flexplate inspection cover.
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36. Using an adjustable stand, lower the subframe 102 mm (4.0 in).
37. Remove the bolts, stud bolts and the oil pan.
38.
Remove the bolts and the oil pump screen and pickup tube.
Remove and discard the O-ring seal.
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39. Remove and discard the oil pan baffle and gasket.
to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths.
Make sure that the mating faces are clean and free of foreign material.
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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.
Make sure that the oil pan mating faces of the cylinder block, engine front cover and real seal retaining
plate are clean and free of foreign material.
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Installation
1. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be
removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage. If
this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying
the sealer and final torque all of the fasteners within 1 hour of applying the sealer.
NOTE: If the engine front cover has been removed, it is only necessary to apply sealant to the crankshaft
rear seal retainer plate-to-cylinder block sealing surfaces.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-
to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.
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2. Install the new oil pan baffle and gasket.
3. Using a new O-ring seal, install the oil pump screen and pickup tube and the bolts.
Torque:
Oil pump screen and pickup tube-to-oil pump bolts :
Stage 2: 45°
Oil pump screen and pickup tube-to-spacer bolt : 18 lb.ft (25 Nm)
4. NOTE: Fastener locations 7, 13 and 16 are stud bolts.
Install the oil pan and the bolts.

Torque:
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Stage 3: 45°
5. Using an adjustable stand, raise the subframe.

6. Install the flexplate inspection cover and the stud bolts.

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9. Install the new front subframe nuts loosely.
10. Use a suitable alignment tool with a 15 mm (0.59 in) OD shaft that is long enough to go through the
subframe and body.
Align the subframe to the alignment marks made during removal.
Install the new rear subframe bolts loosely.
11. Tighten the rear subframe bolts in a cross pattern.
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12. Tighten the front subframe nuts in a cross pattern.
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13. Remove the adjustable stand.
14. Attach the brake line retainers to the subframe.

15. Attach the EPAS wiring harness pin-type retainers.
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16. Connect the oil level sensor electrical connector and wiring harness retainer.
17. Attach the wiring harness retainer to the oil pan stud bolt.
Install the wiring harness retainer and the nut.
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19. WARNING: DO NOT hammer, pry or force steering column and column shafts during
1. Connect the steering column shaft to the steering gear universal joint.
2. Install the new steering column shaft bolt.
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20. Inspect the steering column lower shaft.
Refer to: Steering Column Collapsed Check (211-04 Steering Column, General Procedures).

Torque:
Stage 2: 180°
22. Install the underbody shield, bolts and the pin-type retainers.
shield assembly.

Torque:
A: 97 lb.in (11 Nm)
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B: 18 lb.in (2 Nm)
Torque:
C: 46 lb.ft (63 Nm)
D: 18 lb.in (2 Nm)
24. Install the front wheels and tires.

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30. Install the cowl extension and the fasteners.

32. Remove the clips.

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34. Install the oil level indicator.

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37. Remove the holding device.
38. 1. Position the steering column dash seal.

2. Tighten the steering column dash seal nuts.
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Specifications).
Material: Engine Oil - 5W20 (WSS-M2C948-B)


Oil Pressure Switch
Materials
Name Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24-B
Removal
NOTE: Removal steps in this procedure may contain installation details.

2. Disconnect the EOP switch electrical connector.
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NOTE: If the oil pressure switch is to be reused, apply thread sealant.
Remove the EOP switch.

Material: Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque:
Stage 2: 180°
Installation
1. To install, reverse the removal procedure.

Oil Pump
Removal

2. Remove the timing chains.

Refer to: Timing Chain (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
3. Remove the crankshaft sprocket.
4. Remove the oil pan.

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Installation).
5. Remove the bolts, stud bolts and the oil pump.

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Installation
1. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil
pump over the crankshaft until seated against the block.
Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners hand tight.
Torque:
Stage 1: A: 89 lb.in (10 Nm)
Stage 2: B: 18 lb.ft (25 Nm)
Stage 3: C: 89 lb.in (10 Nm)
Stage 4: D: 177 lb.in (20 Nm)
Stage 5: A: 45°
Stage 6: B: 75°
Stage 7: C: 45°
Stage 8: D: 60°
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2. Install the oil pan.
Installation).
3. Install the crankshaft sprocket.
4. Install the timing chains.

Installation).

Timing Chain
303-448 (T93P-6303-A)
Holding Tool, Crankshaft
TKIT-1993-FLM
TKIT-1993-LM
Removal
NOTICE: The timing chain procedure has changed from prior model year engines and must be followed
exactly or damage to the engine will result.
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NOTE: In order to remove the LH timing chain, the RH timing chain must be removed first.
RH and LH timing chains
1. Remove the engine front cover.

Refer to: Engine Front Cover (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
2. Using the special tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.
Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
3. Verify the timing mark on the RH VCT unit is on top, if not, rotate the crankshaft clockwise one complete
revolution so the keyway is at the 12 o'clock position.
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4. Remove the bolts and the RH primary timing chain tensioner.
5. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to
remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after
removing the RH timing chain tensioner arm.
Remove the RH timing chain tensioner arm.

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remove the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after removing
the RH timing chain guide.
Remove the bolt and the RH timing chain guide.
7. Remove the RH timing chain.

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LH timing chain
9. Remove the bolts and the LH primary timing chain tensioner.

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remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 5 o'clock position after
removing the LH timing chain tensioner arm.
Remove the LH timing chain tensioner arm.
remove the LH timing chain guide. Return the crankshaft keyway to the 5 o'clock position after removing
the LH timing chain guide.
Remove the bolt and the LH timing chain guide.

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12. Remove the LH timing chain.
Installation
LH timing chain
1. Install the LH timing chain.

Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
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2. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install
the LH timing chain guide. Return the crankshaft keyway to the 5 o'clock position after installing the LH
timing chain guide.
Install the LH timing chain guide and bolt.

the LH timing chain arm. Return the crankshaft keyway to the 5 o'clock position after installing the LH
timing chain arm.
Install the LH timing chain tensioner arm.

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4. 1. Compress the primary timing chain tensioner plunger, using an edge of a vise.
2. Install a suitable pin into the hole of the tensioner housing to hold the plunger in place during
installation.
5. 1. Install the LH primary timing chain tensioner and bolts.

2. Remove the holding pin from the tensioner.
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6. Using the special tool, rotate the crankshaft clockwise one complete revolution.
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RH and LH timing chains
8. Install the RH timing chain.

Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH
timing chain guide.
Install the RH timing chain guide and bolt.

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the RH timing chain arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH
timing chain arm.
Install the RH timing chain tensioner arm.
installation.
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12. 1. Install the RH primary timing chain tensioner and bolts.
13. Install the engine front cover.

Refer to: Engine Front Cover (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),

Valve Cover LH
205-142 (T80T-4000-J)
Installer, Differential Bearing Cone
205-153 (T80T-4000-W)
Handle
303-1247
VCT Spark Plug Tube Seal Remover and Installer
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TKIT-2006UF-FLM
TKIT-2006UF-ROW
Plastic Scraper
Materials
Name Specification
ZC-30-A
ZC-31-B
TA-30
PM-4-A, PM-4-B (U.S.)
Removal


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7. 1. Remove the pin-type retainer.
2. Depress the retainer.
3. Position the sound enhancement pipe aside.
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8. 1. Disconnect the EVAP tube quick release coupling.

2. Detach the EVAP tube from the retainers.
9. 1. Position the safety clip aside.
2. Disconnect the quick release couplings and remove the fuel tube.
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10. Remove the LH ignition coils.
Refer to: Ignition Coil-On-Plug (303-07C Engine Ignition - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
11. Disconnect the VCT variable force solenoid electrical connectors.

12. 1. Remove the oil level indicator.
2. Depress the tab.
3. Rotate the oil level indicator tube counterclockwise.
4. Pull the oil level indicator tube from the engine.
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13. Loosen the bolts and remove the valve cover.
14. NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.
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15. Inspect the VCT variable force solenoid seals. Remove and discard any damaged seals using the special
tools.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 205-142 (T80T-4000-J) Installer, Differential
Bearing Cone.
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16. Inspect the spark plug seals. Remove and discard any damaged seals using the special tools.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 303-1247 VCT Spark Plug Tube Seal
Remover and Installer.
Clean the valve cover mating surface of the cylinder head and engine front cover.
Installation
1. NOTE: Installation of new seals is only required if damaged seals were removed.
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Using the special tools, install new spark plug tube seals.
Using the special tools, install new VCT variable force solenoid seals.
Bearing Cone.
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4. NOTICE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant
must be removed and the sealing area cleaned.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-cylinder head
joints.
5. Install the valve cover and tighten the bolts.
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6. 1. Push the oil level indicator tube into the engine.
2. Rotate the oil level indicator tube clockwise.
3. Verify the tab is locked in place.
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7. Attach the wiring harness retainers.
Connect the VCT variable force solenoid electrical connectors.
8. Install the LH ignition coils.

9. 1. Position the fuel tube and connect the quick release couplings.
2. Install the safety clip.
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10. 1. Connect the EVAP tube coupling.
2. Attach the EVAP tube to the retainers.
11. 1. Position the sound enhancement pipe onto the retainer.

2. Install the pin-type retainer.
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Valve Cover RH
205-142 (T80T-4000-J)
205-153 (T80T-4000-W)
Handle
303-1247
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TKIT-2006UF-FLM
TKIT-2006UF-ROW
Plastic Scraper
Materials
Name Specification
ZC-30-A
ZC-31-B
TA-30
PM-4-A, PM-4-B (U.S.)
Removal


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7. Remove the RH ignition coils.

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8. Disconnect the VCT variable force solenoid electrical connectors.
9. Loosen the bolts and remove the valve cover.
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11. Inspect the VCT variable force solenoid seals. Remove any damaged seals using the special tools.
Bearing Cone.
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12. Inspect the spark plug seals. Remove any damaged seals using the special tools.
Clean the valve cover mating surface of the cylinder head and engine front cover.
Installation
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Using the special tools, install new spark plug tube seals.
Using the special tools, install new VCT variable force solenoid seals.
Bearing Cone.
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Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-cylinder head
joints.
5. Install the valve cover and tighten the bolts.
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6. Attach the wiring harness retainers.
Connect the VCT variable force solenoid electrical connectors.
7. Install the RH ignition coils.

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Variable Camshaft Timing (VCT) Unit
Removal
NOTE: If the RH VCT units are being serviced at the same time as the LH VCT units, remove the RH VCT units
first.
Right hand units

Installation).
2. Remove the intake and exhaust VCT assembly bolts.
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3. Slide the VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
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4. 1. Depress the secondary timing chain tensioner.
2. Turn the tensioner counterclockwise 90 degrees.
5. Remove the VCT assemblies and the secondary timing chain.

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Left hand units

Installation).
8. Slide the Variable Camshaft Timing VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
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Installation
Left hand units
1. Position the secondary timing chain onto the VCT assemblies. Align the colored links on the secondary
timing chain with the timing marks on the VCT assemblies as shown in the illustration.
The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
The timing mark on the exhaust VCT assembly should align with the single colored link.
2. Install the VCT assemblies and the secondary timing chain onto the camshafts. The timing mark on the
exhaust VCT assembly should be approximately in the 2 o'clock position.
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3. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the
camshaft) to seat the VCT assemblies onto the camshafts.
Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully
seat the VCT assemblies onto the camshafts.
If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until
they are fully seated on the camshafts.
4. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT
assembly bolts.
Install the intake and the exhaust VCT assembly bolts.

Torque:
Stage 2: 90°
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Installation).
Right hand units
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assembly bolts.

Torque:
Stage 2: 90°
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Installation).

Removal Procedure revision date: 07/16/2015
Engine
303-F047
303-F072
Support Bar, Engine
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Magnetic Socket
Floor Crane
Oil Drain Equipment
Trolley Jack
Wooden Block





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7. Remove the pin-type retainers and the hood insulation.

8. 1. Detach the windshield washer hose retainers.
2. Disconnect the windshield washer hose C-Lock Couplers.
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9. NOTE: Index-mark the hood hinge location to aid in hood installation.
Remove the nuts and the hood.

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12. Remove the nut and the engine ground wire from the cowl.
13. NOTE: It is not necessary to separate the air cleaner outlet pipe and the air cleaner, the 2 components
can be removed as an assembly.
Remove the following items:


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18. Disconnect the top PCM electrical connector, the 16 pin electrical connector and detach the wiring harness
retainers from the PCM bracket.

2. Depress the retainer.
3. Position the sound enhancement pipe aside.
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20. 1. Release the clamp and remove the degas bottle hose.
2. Slide the spring clip until it hits the stop on the hose fitting.
3. Release the clamp and remove the coolant bypass T assembly from the engine.
21. Disconnect the lower radiator hose from the thermostat housing assembly.
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22. Disconnect the heater hose quick connect couplings.
23. Remove the intake manifold.

Refer to: Intake Manifold (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal
and Installation).
24. Detach the EVAP tube from the LH valve cover and the LH inner fender.
25. Position the cover aside.
Remove the nut and disconnect the B+ cable.
Disconnect the wiring harness electrical connector.
Detach the harness retainer.
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Disconnect the LH catalyst monitor sensor electrical connector and detach the harness retainers.
shield assembly.

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31. Disconnect the oil cooler hoses.

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Detach the wiring harness retainer from the oil pan stud bolt.
34. Disconnect the LH HO2S electrical connector and wiring harness retainer.
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WARNING: DO NOT hammer, pry or force steering column and column shafts during
Detach the steering column lower shaft from the lower coupling.
2. Pull apart the steering column shaft from the coupling.
3. Secure the lower shaft to the frame rail to avoid damage to the shaft.
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36. Rotate the transmission electrical connector.

Pull the transmission electrical connector out to disconnect.
Detach the retainers and position the wiring harness aside.
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39. Remove the stud bolts and the flexplate inspection cover.
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40. Remove the rubber access plug.
41. NOTE: Only rotate the crankshaft in a clockwise direction.
Remove and discard the torque converter nuts.

Use the General Equipment: Magnetic Socket
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42. Remove the engine rear cover plate stud bolts.
43. Remove the top transmission-to-engine bolt and stud bolt.

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damage.

Use Special Service Tool: 303-F072 Support Bar, Engine. , 303-F047 Lifting Bracket, Engine.
47. Remove the nut and ground strap from the RH engine mount bracket stud bolt.
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48. Remove the bolts, the stud bolts and the RH engine mount bracket.
49. Detach the wiring harness retainers from the A/C compressor stud bolts.
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50. Remove the stud bolts and position the A/C compressor aside.
51. Remove the bolts, the stud bolt and the LH engine mount bracket.
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52.
Remove the LH catalytic converter.

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54. Remove RH transmission-to-engine bolts.
55. Remove LH transmission-to-engine bolts.

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56. 1. Attach the Floor Crane to the Engine Lifting Bracket
Use the General Equipment: Floor Crane
2. Once the engine is supported by the Floor Crane, remove the special tools.
Use Special Service Tool: 303-F072 Support Bar, Engine.
57. NOTICE: Do not support the transmission by the fluid pan, failure to follow this instruction may
result in serious damage to the transmission.
Install a jack and wooden block under the transmission bell housing to support the transmission.
Use the General Equipment: Wooden Block
Use the General Equipment: Trolley Jack
58. 1. Remove the remaining transmission-to-engine bolt.
2. Separate the engine from the transmission.
59. Using the Floor Crane lift the engine from the vehicle.
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Disassembly Procedure revision date: 08/17/2015
Engine
100-001 (T50T-100-A)
Slide Hammer
205-142 (T80T-4000-J)
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205-153 (T80T-4000-W)
Handle
303-1247
TKIT-2006UF-FLM
TKIT-2006UF-ROW
303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FH/FMH/FLMH
TKIT-1993-LMH/MH
303-448 (T93P-6303-A)
TKIT-1993-FLM
TKIT-1993-LM
303-519 (T95P-6701-EH)
TKIT-1995-FH/FLMH
TKIT-1995-LMH/MH
303-F047
Floor Crane
Three Leg Puller
Mounting Stand
Plastic Scraper
Materials
Name Specification
ZC-30-A
ZC-31-B
PM-4-A, PM-4-B (U.S.)
NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in
engine damage.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the
components for installation into their original location.
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NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
1. NOTE: The flexplate bolts are torque-to-yield design and are not reusable
Remove and discard the flexplate bolts.

Remove the flexplate.
2. 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.
NOTICE: Loosen the bolts evenly to prevent clutch pressure plate damage.
NOTE: If the parts are to be reused, index-mark the pressure plate to the flywheel.
Remove and discard the pressure plate bolts.

Remove the pressure plate and the clutch disc.
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3. NOTE: The flywheel bolts are torque-to-yield design and are not reusable
Remove and discard the flywheel bolts.

Remove the flywheel.
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4. NOTE: Engine equipped with manual transmission shown, automatic transmission engine similar.
5. Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any
visual damage, it must be replaced.
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Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer. , 303-519 (T95P-6701-EH) Remover,
Crankshaft Rear Oil Seal.
7. Using a floor crane, install the engine on a mounting stand and remove the special tool.
Remove Special Service Tool: 303-F047 Lifting Bracket, Engine.
Use the General Equipment: Mounting Stand
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8. NOTE: Manual transmission engine shown, automatic transmission engine similar.
Disconnect the RH HO2S electrical connector and wiring harness retainer.

9. Disconnect the engine oil level sensor electrical connector and the wiring harness retainer.
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10. Disconnect the EOP ) switch electrical connector and the wiring harness retainers.
11.
Disconnect the LH camshaft position sensor electrical connectors.
Remove the bolt and the ground wire.
Remove the bolts and the LH camshaft position sensors.
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12. Disconnect the KS electrical connectors.
13.
Disconnect the RH camshaft position sensor electrical connectors.
Remove the bolts and the RH camshaft position sensors.
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14. Disconnect the CHT sensor and the CKP sensor electrical connectors.
15. Remove the RH spark plug cover.

16. NOTE: Engine equipped with automatic transmission shown, manual transmission engine similar.
Disconnect the wiring harness electrical connectors and retainers.
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17. Remove the crankcase ventilation tube.
Remove the LH spark plug cover.
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18. Disconnect the wiring harness electrical connectors and retainers.
19. Detach the wiring harness retainer from the engine front cover stud bolt.
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20. 1. Detach the wiring harness retainer from the engine front cover stud bolt.
2. Remove the nut and the ground wire.
3. Remove the wiring harness from the engine.
21. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal.
Remove the bolts and the ignition coils.

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22. Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug
assemblies.
23. Loosen the bolts and remove the RH valve cover.

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Bearing Cone.
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Clean the valve cover mating surface of the RH cylinder head and engine front cover.
28. 1. Remove the oil level indicator.

2. Depress the tab.
3. Rotate the oil level indicator tube counterclockwise.
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4. Pull the oil level indicator tube from the engine.
29. Loosen the bolts and remove the LH valve cover.

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Bearing Cone.
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Clean the valve cover mating surface of the LH cylinder head and engine front cover.
34.
Remove the exhaust manifold.
Clean and inspect the exhaust manifold.
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Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information,

36. Remove the crankshaft pulley bolt and washer.
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37. Using the 3 Leg Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
Discard the crankshaft pulley bolt.
38. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Using the special tool, remove and discard the crankshaft front oil seal.
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
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41. Remove and discard the coolant pump O-ring seal.
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43. Remove the nut, the bolt and the generator.

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46. Remove the engine front cover from the front cover to cylinder block dowels.
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50. Verify the timing mark on the RH VCT unit is on top, if not, rotate the crankshaft clockwise one complete
revolution so the keyway is at the 12 o'clock position.
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51. Remove the bolts and the RH primary timing chain tensioner.
remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after
removing the RH timing chain tensioner arm.
Remove the RH timing chain tensioner arm.

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remove the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after removing
the RH timing chain guide.
Remove the bolt and the RH timing chain guide.

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56. Slide the VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
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63. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect
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65. Remove the bolts and the LH primary timing chain tensioner.
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remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 5 o'clock position after
removing the LH timing chain tensioner arm.
Remove the LH timing chain tensioner arm.
remove the LH timing chain guide. Return the crankshaft keyway to the 5 o'clock position after removing
the LH timing chain guide.
Remove the bolt and the LH timing chain guide.

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69. Remove the crankshaft sprocket.

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71. Slide the Variable Camshaft Timing VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
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78. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect
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79. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage can result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head
gasket surface, unprotected, on a bench surface.
NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are a
tighten-to-yield design and cannot be reused.

80. Remove and discard the cylinder head gasket.
81. Remove the dowels.
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the cylinder block.
Procedures).
Procedures).
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83. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage can result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head
gasket surface, unprotected, on a bench surface.
NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are a
tighten-to-yield design and cannot be reused.

84. Discard the cylinder head gasket.
85. Remove the dowels.
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the cylinder block.
Procedures).
Procedures).
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87. Remove the bolts and the KSs.
88. Remove the bolt and the CKP sensor.

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89. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the threaded fitting and the oil cooler.

Discard the oil cooler.
90.
Remove the bolts and the oil filter adapter.
Discard the gasket.
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91. Remove the bolts and the oil pan.
92.
Remove the bolts and the oil pump screen and pickup tube.
Discard the O-ring seal.
93. Remove and discard the oil pan baffle and gasket.
94. Remove the oil pump screen and pickup tube spacer.
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Clean the mating surface of the cylinder block.

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97. Remove the bolts and the crankshaft rear seal retainer plate.
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99. Remove the bolts, the stud bolts and the oil pump.
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100. 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.
101. NOTICE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If
not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in
engine damage.
Remove the bolts and the connecting rod cap.

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102. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or
engine damage may occur.
Remove the piston through the top of the cylinder block.
103. Repeat the previous 2 steps for each of the remaining pistons.
104. Disassemble the 8 pistons.

Refer to: Piston (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Disassembly and
Assembly of Subassemblies).
105. 1. Remove and discard the cross-mounted main cap bolts.

2. Remove and discard the main bearing cap bolts and stud bolt.
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106. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing
(3).
107. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from
the cylinder block.
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108. Remove the bolts and the piston cooling jets from the cylinder block.

Disassembly and Assembly of Subassemblies Procedure revision date: 07/7/2015
Cylinder Head
303-1249
Valve Spring Compressor
TKIT-2006UF-FLM
TKIT-2006UF-ROW
303-1418
Compressor, Valve Spring
TKIT-2008ET-FLM
TKIT-2008ET-ROW
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303-300 (T87C-6565-A)
Set, Valve Spring Compressor
T88C-1000-ST
TKIT-1988-FESTIVA
TKIT-1988-TRACER
TKIT-2009TC-F
303-350 (T89P-6565-A)
Compressor, Valve Spring
TKIT-1989-F
TKIT-1989-FLM
TKIT-1989-FM
TKIT-1990-LMH
Materials
Name Specification
XO-5W20-QSP (U.S.)
VC-3-B (U.S.)
DISASSEMBLY
NOTE: If the components are to be reinstalled, they must be installed in their original locations. Mark the
components for installation into their original locations.
LH cylinder heads
1.
Remove the bolts and the coolant outlet.
Discard the gasket.
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2. Remove the bolts, the CMP sensors and the radio interference capacitor.
RH cylinder heads
3. Remove the bolt and the CMP sensor.

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4. Remove and discard the CHT sensor.
5.
Remove the bolt and the coolant outlet.
Discard the O-ring seal.
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All cylinder heads
6. Remove the spark plugs.
7. Using the special tools, remove the keys, retainer and spring.
Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor. , 303-350 (T89P-
6565-A) Compressor, Valve Spring. , 303-1249 Valve Spring Compressor. , 303-1418 Compressor, Valve
Spring.
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8. Remove and discard the valve stem seal.
9. Remove the valve from the cylinder head.

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10. Repeat the previous steps for each of the remaining valves.
ASSEMBLY
All cylinder heads
1. NOTE: Lubricate the new valve stem seal and valve guide bore with clean engine oil.
Install the new valve stem seal.

(WSS-M2C945-A)
2. Install the valve into the cylinder head.

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3. Using the special tools, install the spring, retainer and keys.
Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor. , 303-350 (T89P-
6565-A) Compressor, Valve Spring. , 303-1249 Valve Spring Compressor. , 303-1418 Compressor, Valve
Spring.
4. Repeat the previous steps for each of the remaining valves.
5. Install the spark plugs.

RH cylinder heads
6. Install a new CHT sensor.

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7. Install the CMP sensor and bolt.
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8. NOTE: Lubricate the O-ring seal with clean engine coolant prior to installing.
Using a new O-ring seal, install the coolant outlet pipe.

LH cylinder heads
9. Using a new gasket, install the coolant outlet and the bolts.
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10. Install the CMP sensors, the radio interference capacitor and the bolts.

Disassembly and Assembly of Subassemblies Procedure revision date: 04/20/2015
Piston
Materials
Name Specification
XO-5W20-QSP (U.S.)
DISASSEMBLY
1. Remove and discard the piston rings.
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2.
Remove and discard the piston pin retainers.
Remove the piston pin.
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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.
Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod.

Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
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ASSEMBLY
1. If the piston and/or connecting rod are being installed new, the connecting rod orientation marks and the
arrow on the top of the dome of the piston should be facing toward the front of the engine block.
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2. Position the piston on the connecting rod.
3. Lubricate and install the piston pin.

(WSS-M2C945-A)
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4. NOTE: The piston pin retainer gap orientation must be toward the top of the piston.
Install the piston pin retainers.
5. Lubricate and install the oil control rings.

1. Upper oil control ring.
2. Oil control expander ring.
3. Lower oil control ring.
(U.S.) (WSS-M2C945-A)
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6. Install the lower compression ring.
1. The "O" mark on the ring pointing up toward the top of the piston.
2. Hook feature will point down toward the bottom of piston.
(U.S.) (WSS-M2C945-A)
7. Install the upper compression ring.

1. The "O" mark on the ring pointing up toward the top of the piston.
(U.S.) (WSS-M2C945-A)
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8. Position the piston ring gaps.
1. Center line of the piston parallel to the wrist pin bore.
2. Upper compression ring gap.
3. Upper oil control ring gap.
4. Lower oil control ring gap.
5. Oil control expander ring and lower compression ring gap.

Assembly Procedure revision date: 02/10/2015
Engine
205-142 (T80T-4000-J)
205-153 (T80T-4000-W)
Handle
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303-1247
TKIT-2006UF-FLM
TKIT-2006UF-ROW
303-1250
TKIT-2006UFFLM
303-1531
Installer, Front Crank Seal and Damper
303-335 (T88T-6701-A)
Installer, Front Cover Oil Seal
TKIT-1988-F
TKIT-1988-FLM
303-448 (T93P-6303-A)
TKIT-1993-FLM
TKIT-1993-LM
303-F047
Strap Wrench
Floor Crane
Mounting Stand
Clutch Alignment Tool
Piston Ring Compressor
Materials
Name Specification
XO-5W20-QSP (U.S.)
TA-30
VC-3-B (U.S.)
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
NOTICE: The timing chain alignment procedure has changed from prior model year engines and must be
followed exactly or damage to the engine will result.
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NOTE: During engine assembly it may become necessary to check bearing clearances and end play. Refer to
Section 303-00.
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the rear of the crankshaft.
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3. NOTE: This chart is for selecting main bearings 1 and 5 only, the remaining bearings will be selected
using a different chart in the next step.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for main bearings 1 and 5.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft main
bearing code.
Read down the column below the engine block main bearing code letter and across the row next to
the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s)
for the No. 1 crankshaft main bearing.
As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the
correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower
bearing.
Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5
bearing.
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4. NOTE: This chart is for selecting main bearings 2, 3 and 4 only.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for main bearings 2, 3 and 4.
Read the second letter of the engine block main bearing code and the second letter of the
crankshaft main bearing code.
Read down the column below the engine block main bearing code letter and across the row next to
the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s)
for the No. 2 crankshaft main bearing
As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the
correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower
bearing
Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select
the No. 3 and No. 4 bearings.
5. Install the piston cooling jets and bolts.
Torque:
Stage 2: 45°
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6. Install the crankshaft main bearings.
Install the crankshaft upper main bearings into the cylinder block.
Install the crankshaft lower main bearings and thrust bearing into the bearing caps.
Make sure all oil passages are aligned.
Lubricate all main bearings with clean engine oil.
(U.S.) (WSS-M2C945-A)
7. NOTE: Lubricate the crankshaft bearing journals with clean engine oil.
Install the crankshaft into the cylinder block.

(WSS-M2C945-A)
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8. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft thrust surface).
NOTE: Lubricate the thrust washer with clean engine oil.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5
main boss.
(WSS-M2C945-A)
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9. NOTE: Lubricate the fastener threads with clean engine oil.
Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as
possible, alternately draw the caps down evenly using the cap fasteners.
(WSS-M2C945-A)
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10. Push the crankshaft forward to seat the crankshaft thrust washer.
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11. Tighten the vertical main bearing cap fasteners.
Torque:
Stage 1: 1 through 20: 177 lb.in (20 Nm)
Stage 2: 1 through 10: 30 lb.ft (40 Nm)
Stage 3: 11 through 20 : 48 lb.ft (65 Nm)
Stage 4: 1 through 20: 90°
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12. Install the cross-mounted main bearing cap fasteners.
Torque:
Stage 3: 60°
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13. Check the crankshaft end play.
Specifications).
Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
Check the piston-to-cylinder block and piston ring clearances.
Specifications).
Assemble the pistons and position the piston ring gaps.
Refer to: Piston (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Disassembly
and Assembly of Subassemblies).
14. Lubricate with clean engine oil and install the connecting rod bearings.
(WSS-M2C945-A)
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15. NOTICE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or
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.
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 piston with clean engine oil.
Using a piston ring compressor, install the piston.

Use the General Equipment: Piston Ring Compressor
(U.S.) (WSS-M2C945-A)
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16. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod
ends. Excessive bearing clearance will result if not mated correctly.
Install the connecting rod cap and bearing.

Install the new bolts hand tight.
17. Repeat the previous 2 steps for each of the remaining pistons.
18. Tighten the connecting rod bolts.

Torque:
Stage 3: 105°
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19. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil
pump over the crankshaft until seated against the block.
Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners hand tight.
Torque:
Stage 1: A: 89 lb.in (10 Nm)
Stage 2: B: 18 lb.ft (25 Nm)
Stage 3: C: 89 lb.in (10 Nm)
Stage 4: D: 177 lb.in (20 Nm)
Stage 5: A: 45°
Stage 6: B: 75°
Stage 7: C: 45°
Stage 8: D: 60°
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20. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. Failure to follow this procedure may cause future oil leaks.
Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating
surface on the engine block.
21. Install the crankshaft rear seal retainer plate and the bolts.
Torque:
Stage 2: 45°
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22. Install the oil pump screen and pickup tube spacer.
23. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal
surface prep. Failure to follow this procedure can cause future oil leakage. If this timing cannot be met,
tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque
all of the fasteners within 1 hour of applying the sealer.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-
to-cylinder block sealing surfaces.
24. Install the oil pan baffle and gasket.
25. Using a new O-ring seal, install the oil pump screen and pickup tube and the bolts.
Torque:
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Oil pump screen and pickup tube-to-oil pump bolts :
Stage 2: 45°
Oil pump screen and pickup tube-to-spacer bolt : 18 lb.ft (25 Nm)
26. Install the oil pan and the fasteners.
Torque:
Stage 3: 45°
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27. Using a new gasket, install the oil filter adapter and the bolts.
Torque:
Stage 2: 60°
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28. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Install a new oil cooler and the threaded fitting.

29. NOTICE: The CKP sensor must be positioned into the fitting on the crankshaft rear seal retainer
plate and be flush against the boss on the engine block before the bolt is installed. If the CKP
sensor is installed incorrectly, the CKP sensor can be damaged.
Install the CKP sensor must be positioned into the fitting on the crankshaft rear seal retainer plate.
Make sure the CKP sensor is flush with the engine block boss.
Install the bolt.
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30. Install the KSs and the bolts.
31. Install the dowels on theRH bank of the cylinder block.

32. Install a new RH cylinder head gasket.
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be installed.
Install the RH cylinder head and the new bolts.

Torque:
Stage 6: 90°
Stage 7: 90°
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34. Install the dowels on the LH bank of the cylinder block.
35. Install a new LH cylinder head gasket.

be installed.
Install the LH cylinder head and the new bolts.

Torque:
Stage 6: 90°
Stage 7: 90°
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37. Install the crankshaft sprocket.
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NOTICE: The LH camshafts, VCT units and timing chains must be installed first. Only turn the crankshaft
as instructed. Failure to do so may result in the camshafts installed out of phase and serious damage to
the engine will result.
(U.S.) (WSS-M2C945-A)
Install theLH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the
illustration.
(WSS-M2C945-A)
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Torque:
Stage 2: 45°
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44. Install new VCT system oil filters into the camshafts.
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assembly bolts.

Torque:
Stage 2: 90°
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Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
the LH timing chain guide. Return the crankshaft keyway to the 5 o'clock position after installing the LH
timing chain guide.
Install the LH timing chain guide and bolt.

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the LH timing chain arm. Return the crankshaft keyway to the 5 o'clock position after installing the LH
timing chain arm.
Install the LH timing chain tensioner arm.
installation.
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53. 1. Install the LH primary timing chain tensioner and bolts.
54. Using the special tool, rotate the crankshaft clockwise one complete revolution.
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(U.S.) (WSS-M2C945-A)
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Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the
illustration.
(WSS-M2C945-A)

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Torque:
Stage 2: 45°
61. Install the VCT system oil filters into the camshafts.
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assembly bolts.

Torque:
Stage 2: 90°
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Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH
timing chain guide.
Install the RH timing chain guide and bolt.

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the RH timing chain arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH
timing chain arm.
Install the RH timing chain tensioner arm.
installation.
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70. 1. Install the RH primary timing chain tensioner and bolts.
71. Install new gaskets on the engine front cover.

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72. NOTICE: The VCT variable force solenoid pins must be fully depressed to avoid interference with
the VCT valve tips when installing the engine front cover. Failure to follow these instructions can
result in damage to the engine.
Fully depress the VCT variable force solenoid pins.

Apply a 15 mm (0.59 in) diameter drop of silicone gasket and sealant to the cylinder head-to-cylinder block
joints and the oil pan-to-cylinder block joints.
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74. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before
installation.
Position the engine front cover onto the dowels.

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Install the bolts and stud bolts.

Torque:
Stage 1: Fasteners 1-15 : 18 lb.ft (25 Nm)
Stage 2: Fasteners 16-19 : 89 lb.in (10 Nm)
76. Install the generator, the bolt and the nut.

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77. Install the accessory drive belt tensioner and bolt.
78. Install a new coolant pump O-ring seal and lubricate with clean engine coolant.
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79. Install the coolant pump and bolts.
Torque:
Stage 2: 60°
80. Install the coolant pump pulley and the bolts.

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81. Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.
(WSS-M2C945-A)
82. Using the special tools, install the new crankshaft front oil seal.
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83. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned.
Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
84. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
(WSS-M2C945-A)
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85. Using the special tools, install the crankshaft pulley.
86. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer.
Use the General Equipment: Strap Wrench
Torque:
Stage 4: 90°
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88.
Install the exhaust manifold.
Torque:
Using the special tools, install new spark plug tube seals into the LH valve cover.
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Using the special tools, install new VCT variable force solenoid seals into the LH valve cover.
Bearing Cone.
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91. Install a new gasket onto the LH valve cover.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder head
joints.
93. Install the LH valve cover and tighten the bolts.
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94. 1. Push the oil level indicator tube into the engine.
2. Rotate the oil level indicator tube clockwise.
3. Verify the tab is locked in place.
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Using the special tools, install new spark plug tube seals into the RH valve cover.
Using the special tools, install new VCT variable force solenoid seals into the RH valve cover.
Bearing Cone.
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97. Install a new gasket onto the RH valve cover.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder head
joints.
99. Install the RH valve cover and tighten the bolts.
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100. NOTE: When installing ignition coils, apply a small amount of silicone brake caliper grease and dielectric
compound to the inside of the ignition coil boots before installation.
Install the ignition coils and the bolts.

Install the ignition coils and the bolts.
Material: Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
Torque:
Stage 2: 50°
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101. Position the wiring harness on the engine.
Install the ground wire and the nut.
Attach the wiring harness retainer to the engine front cover stud bolt.
102. Attach the wiring harness retainer to the engine front cover stud bolt.
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103. Connect the wiring harness electrical connectors and retainers.
104. Install the LH spark plug cover.

Install the crankcase ventilation tube.
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105. NOTE: Engine equipped with automatic transmission shown, manual transmission engine similar.
Connect the wiring harness electrical connectors and retainers.
106. Install the spark plug cover.

107. Connect the CHT sensor and the CKP sensor electrical connectors.
108. Install the RH camshaft position sensors and the bolts.

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Connect the RH camshaft position sensor electrical connectors.
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109. Connect the KS electrical connectors.
110. Install the LH camshaft position sensors and the bolts.

Position the ground wire and install the bolt.
Connect the LH camshaft position sensor electrical connectors.
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111. Connect the EOP ) switch electrical connector and the wiring harness retainers.
112. Connect the engine oil level sensor electrical connector and the wiring harness retainer.
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113. NOTE: Manual transmission engine shown, automatic transmission engine similar.
Connect theRH HO2S electrical connector and wiring harness retainer.
114. Install the special tool and remove the engine from the engine stand using a floor crane.
Install Special Service Tool: 303-F047 Lifting Bracket, Engine.
Use the General Equipment: Mounting Stand
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115. Lubricate the seal bore and the seal lips with clean engine oil.
(WSS-M2C945-A)
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118. NOTE: Engine equipped with manual transmission shown, automatic transmission engine similar.
Install the engine-to-transmission spacer plate and the crankshaft sensor ring.
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119. Install the flywheel and the bolts.

Torque:
Stage 3: 60°
120. NOTICE: If installing a new pressure plate and/or flywheel, align the paint dot on the pressure plate
as close as possible to the paint dot on the flywheel or a clutch system vibration can occur.
NOTICE: If installing the original pressure plate, align it using the index-marks made during
removal or a clutch system vibration can occur.
Using a clutch aligner, position the clutch disc on the flywheel. If installing the original pressure plate, align
the pressure plate to the flywheel using the index-marks made during removal. If installing a new pressure
plate, align the pressure plate to the flywheel using the paint dots. Install new pressure plate bolts by
turning the bolts 1 turn at a time in a star pattern until the clutch is fully secured.
Use the General Equipment: Clutch Alignment Tool
Torque:
Stage 2: 60°
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121. Install the flexplate and the bolts.

Torque:
Stage 2: 60°
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Installation Procedure revision date: 07/23/2015
Engine
303-F047
303-F072
Support Bar, Engine
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Magnetic Socket
Floor Crane
Trolley Jack
Wooden Block
Materials
Name Specification
Motorcraft® Multi-Purpose Grease Spray ESB-M1C93-B
XL-5-A
XO-5W20-QSP (U.S.)
1. NOTE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with multi-
purpose grease or damage to the torque converter or the engine crankshaft can occur.
Lubricate the torque converter pilot hub with multi-purpose grease.

Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
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2. Inspect the torque converter stud and flexplate for paint marks.
Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.
3. Lubricate the input shaft with multi-purpose grease.

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4. With the aid of an assitant, use the Floor Crane to install the engine into the vehicle.
5. 1. Align the engine to the transmission.

2. Draw the engine and transmission together using the bolts.
damage.
1. Install the special tools.

Use Special Service Tool: 303-F072 Support Bar, Engine.
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2. Once the engine is supported by the Engine Support Bar, remove the Floor Crane.
7. Remove the jack and wooden block.

Use the General Equipment: Trolley Jack
8. Install LH transmission-to-engine bolts.
9. Install the RH transmission-to-engine bolt. cardiagn.com

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11.
Install the LH catalytic converter.
Torque:
12. Install the LH engine mount bracket, bolts and stud bolt.
13. Install the A/C compressor and the stud bolts.

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14. Attach the wiring harness retainers to the A/C compressor stud bolts.
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16. Install the ground strap and nut onto the RH engine mount bracket stud bolt.
Use Special Service Tool: 303-F072 Support Bar, Engine. , 303-F047 Lifting Bracket, Engine.
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20. Install the top transmission-to-engine bolt and stud bolt.
21. Install the engine rear cover plate stud bolts.

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22. NOTE: Only rotate the crankshaft in a clockwise direction.
Install the new torque converter nuts.

Use the General Equipment: Magnetic Socket
23. Install the rubber access plug.

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24. Install the flexplate inspection cover and the stud bolts.

27. Push the transmission electrical connector in to connect.

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Rotate the transmission electrical connector.
Position the wiring harness and attach the retainers.
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30. Connect the LH HO2S electrical connector and wiring harness retainer.
31. Attach the wiring harness retainer to the oil pan stud bolt.
Install the wiring harness retainer and the nut.
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33. Connect the oil cooler hoses.

Torque:
Stage 2: 180°
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shield assembly.

Torque:
A: 97 lb.in (11 Nm)
B: 18 lb.in (2 Nm)
Torque:
C: 46 lb.ft (63 Nm)
D: 18 lb.in (2 Nm)

Connect the LH catalyst monitor sensor electrical connector and attach the wiring harness retainers.

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38. Attach the wiring harness retainer.

Connect the wiring harness electrical connector.
Connect the B+ cable and install the nut.
Position the cover.
39. Attach the EVAP tube to the LH valve cover and the LH inner fender.
40. Install the intake manifold.
and Installation).
41. Connect the heater hose quick connect couplings.
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42. Connect the lower radiator hose to the thermostat housing assembly.
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43. 1. Install the coolant bypass T assembly and clamp onto the engine.
2. Slide the spring clip until it hits the stop on the hose fitting.
3. Install the degas bottle hose and clamp.
44. 1. Position the sound enhancement pipe onto the retainer.

2. Install the pin-type retainer.
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45. Connect the top PCM electrical connector, the 16 pin electrical connector and attach the wiring harness
retainers to the PCM bracket.
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51. Install the engine ground wire and nut.

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54. NOTE: Use the index-mark for location to aid in hood installation.
Install the hood and the nuts.

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55. 1. Connect the windshield washer hose C-Lock Couplers.
2. Attach the windshield washer hose retainers.
56. Install the hood insulation and the pin-type retainers.

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Specifications).
(WSS-M2C945-A)
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303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Procedure revision date:
Specifications 05/27/2015
Specifications
Materials
Description Specification
Motorcraft® Orange Antifreeze/Coolant Concentrated VC-3-B WSS-M97B44-D
Motorcraft® Orange Antifreeze/Coolant Prediluted VC-3DIL-B WSS-M97B44-D2
Cooling System Capacities
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Description Specification
Base engine with oil cooler 13.6 qt (12.88L)
Performance Package engine with oil cooler 14.0 qt (13.28L)
Cooling System Pressure
Complete cooling system maximim pressure 145 kPa (21 psi)

Pressure relief cap 145 kPa (21 psi)
Radiator pressure test (removed from the vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures
Starts to open 82.2°C (180°F)

Fully open 94.5°C (202°F)

(308kW/418PS)
Description and Operation 08/6/2014
Engine Cooling - Component Location
NOTE: Coolant temperature will vary with ambient temperature and load. Temperatures shown are for ambient
temperature of 38° C (100° F). Red arrows indicate a temperature over 82.2° C (180° F), Orange arrows
indicate a temperature of approximately 82.2° C (180° F), Blue arrows indicate a temperature below 82.2° C
(180° F).
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Item Description
1 Degas bottle
2 Pressure relief cap
3 Upper radiator hose
4 Radiator-to-degas bottle hose
5 Radiator
6 Oil cooler outlet hose
7 Oil cooler inlet hose
8 Lower radiator hose
9 Thermostat housing
10 Degas bottle-to-engine hose
11 Coolant bypass T assembly
12 Heater inlet hose
13 Heater outlet hose
14 Heater outlet tube
15 Coolant pump
16 Oil cooler
17 Oil filter
18 Oil filter adapter
19 Cylinder block
20 Cylinder head LH
21 Cylinder head RH
22 Heater inlet tube
23 Coolant outlet connector
24 Coolant outlet connector-to-degas bottle hose
25 Heater core
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(308kW/418PS)
Engine Cooling - System Operation and Component Description
System Operation
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, operated by engine rotation through 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.
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
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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.
The degas bottle holds surplus coolant and removes air from the cooling system. It also allows for coolant
expansion and system pressurization, replenishes coolant to the cooling system and serves as the location for
service fill.
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 sets, and the MIL illuminates.
Fail Safe Cooling
A strategy called Fail Safe Cooling is built into the PCM that will control the engine if it starts to overheat.
Stage 1 of the strategy commences if the engine starts to overheat. The CHT sensor transmits a signal to the
PCM, which moves the temperature gauge pointer into the red zone.
If the engine is not switched off and the temperature continues to rise, the Powertrain Check Lamp is illuminated.
This indicates to the driver that the engine is approaching critical limits and should be stopped. At this point DTC
P1285 is set in the PCM which can be retrieved using a scan tool.
Stage 2 of the strategy commences if the lamp and temperature gauge are ignored by the driver. The PCM will
start to control the engine by cutting out 4 cylinders and restricting engine speed below 3,000 RPM.
Simultaneously the MIL illuminates. This indicates that long term engine damage can occur and vehicle emissions
will be affected. At this point DTC P1299 is set in the PCM which can be retrieved using a scan tool.
Air is drawn into the deactivated cylinders. This helps to control the temperature of the engine internal
components. The deactivated cylinders are alternated to allow even cooling of all the cylinders.
NOTE: If the driver is using a high percentage of throttle travel (for example, an overtaking maneuver) when the
PCM starts engine deactivation (Stage 2), the deactivation will be delayed for 10 seconds.
NOTE: After 4-cylinder operation has begun, the engine will not revert to 8-cylinder operation, even if the
temperature should fall, until the ignition is switched off and then on again.
NOTE: The MIL can only be extinguished by using a scan tool after the fault has been rectified and the DTC
cleared.
Stage 3 of the strategy will commence if the engine temperature continues to rise. This results in the engine being
totally disabled before major engine damage or seizure occurs. The Powertrain Check Lamp will begin to flash,
indicating to the driver that the engine will be switched off after 30 seconds. This allows the driver time to choose
a suitable parking place.
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(308kW/418PS)
Diagnosis and Testing 01/13/2015
Engine Cooling
Materials
Name Specification
Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) WSS-M97B44-D2
VC-3DIL-B (U.S.)
VC-3-B (U.S.)
Special Tool(s)
3-Way HD Antifreeze Coolant Test
Kit
328-2050-62291 or equivalent
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Coolant/Battery Refractometer
300-ROB75240 or equivalent
Radiator Tester
014-R1072 or equivalent
UView® Combustion Leak Tester

UVU560000-R

Material: Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.) (WSS-M97B44-D2)
DTC Chart
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
section 100-00 General Information. Failure to follow this instruction may result in serious personal
injury.
REFER to: Engine Cooling System Health and Safety Precautions (100-00 General Information, Description and
Operation).
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
PCM DTC Chart
DTC Description Action

P0125 Insufficient Coolant Temp For GO to Pinpoint Test C
Closed Loop Fuel Control
P0128 Coolant Thermostat (Coolant GO to Pinpoint Test C
Temp Below Thermostat
Regulating Temperature)
P0217 Engine Coolant Overtemperature GO to Pinpoint Test B
Condition
P0480 Fan 1 Control Circuit Refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
P0481 Fan 2 Control Circuit Refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
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P1285 Cylinder Head Overtemperature Refer to Powertrain Control/Emissions Diagnosis
Condition (PC/ED) manual.
P1299 Cylinder Head Overtemperature GO to Pinpoint Test B
Protection Active
All Other PCM —
Diagnostic Trouble REFER to: Electronic Engine Controls (303-14C
Codes (DTCs) Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), Diagnosis and Testing).
Inspection and Verification
NOTICE: The engine cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Always fill the
cooling system with the manufacturer's specified coolant. Chemically flush the cooling system if a
non-specified coolant has been used. Failure to follow these instructions may damage the engine or
cooling system.
NOTE: During normal vehicle operation, Motorcraft Orange Antifreeze/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.
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 Diagnostic Trouble Codes (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 Diagnostic Trouble Codes (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.

Visual Inspection Chart
Mechanical Electrical
Leaks or weeps at: Inoperative or damaged:
Hoses Electric cooling fan
Tubes Wiring, connectors, relays or
Clamp joints modules
Gaskets CHT sensor
O-rings
Thermostat housing
Oil Cooler
Radiator
Pressure relief cap
Coolant pump
Heater core (wet floor or coolant odor in vehicle)
Lower intake manifold
Degas bottle
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)
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Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat housing
Lower intkake manifold
Oil cooler
Radiator
Pressure relief cap
Cooling fan
Coolant pump
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.
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®
Orange Antifreeze/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®
Gold Antifreeze/Coolant, however, may not change the color or appearance of the orange-
colored coolant. Detection of contamination with Motorcraft® Gold Antifreeze/Coolant is
determined by the presence of nitrite. If contamination with Motorcraft® Gold
Antifreeze/Coolant is suspected, test the coolant with the 3-Way HD Antifreeze Coolant Test
Kit. Follow the nitrite testing directions in the kit to determine if nitrite is present in the
system. If nitrite is present, flush the system and refill with the correct mixture of distilled
water and Motorcraft® Orange Antifreeze/Coolant Concentrated.
REFER to: Cooling System Draining and Vacuum Filling (303-03C Engine Cooling - 5.0L 32V
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 mixture of distilled water and
Motorcraft® Orange Antifreeze/Coolant Concentrated.
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® Orange
Antifreeze/Coolant Concentrated.
An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system.
For engine diagnosis,
Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange
Antifreeze/Coolant Concentrated. REFER to: Cooling System Draining and Vacuum Filling
(303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), General
Procedures).
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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,
Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange
Antifreeze/Coolant Concentrated. REFER to: Cooling System Draining and Vacuum Filling
(303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), General
Procedures).
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the
Coolant/Battery Refractometer. Maintain the coolant concentration within 48% to 50%, which
equates to a freeze point between -34˚C and -37˚C (-30˚F and -34˚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 48/52 to 50/50 (freeze
protection -34°C to -37°C [-30°F to -34°F]) engine coolant 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
Motorcraft® Orange Antifreeze/Coolant Concentrated 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.
Symptom Chart

Loss of coolant Refer to the Diagnostic GO to Pinpoint Test A
Routine
The engine overheats Refer to the Diagnostic GO to Pinpoint Test B
Routine
The engine does not reach Refer to the Diagnostic GO to Pinpoint Test C
normal operating temperature Routine
The block heater does not Block heater CHECK continuity in all 3 power cable circuits.
operate correctly power cable If any circuit measures more than 5 ohms,
Block heater INSTALL a new power cable.
CHECK the resistance of the block heater. If
the resistance does not measure between 30
and 40 ohms, INSTALL a new block heater.
REFER to: Block Heater (303-03C Engine
Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
The electric cooling fan is Wiring Refer to Powertrain Control/Emissions Diagnosis

inoperative in one or more Relays (PC/ED) manual.
speeds or does not operate Fuses
correctly Cooling fan motor
Cooling fan
resistor
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The electric cooling fan stays Wiring Refer to Powertrain Control/Emissions Diagnosis
on all the time Relays (PC/ED) manual.
Noisy electric cooling fan Foreign material REMOVE the foreign material from the cooling
operation contamination fan and shroud. TEST the system for normal
Fan motor operation. If still noisy, INSTALL a new cooling
fan assembly.
REFER to: Cooling Fan Motor and Shroud
(303-03C Engine Cooling - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
Fan blade INSTALL a new cooling fan assembly.

detached from fan REFER to: Cooling Fan Motor and Shroud
motor (303-03C Engine Cooling - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
Pinpoint Tests
Loss of Coolant
Normal operation and Fault Conditions
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.
Possible Sources
Coolant hoses or tubes

Hose clamps
Thermostat O-ring seal or gasket
Coolant pump O-ring seal or gasket
Thermostat housing
Oil cooler (may leak internally or externally)
Radiator
Pressure relief cap
Coolant pump leaking from weep hole
Heater core
Lower intake manifold
Engine gaskets (may leak internally or externally)
Degas bottle
PINPOINT TEST A : PINPOINT TEST
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.
A1 CARRY OUT INSPECTION AND VERIFICATION
Carry out Inspection and Verification.
Are any concerns present?
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Yes REPAIR as needed.
No GO to A2
A2 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE ENGINE COOLING SYSTEM
NOTE: Allow the engine to cool before checking the engine coolant level.
Ignition OFF
Visually inspect the engine coolant level at the degas bottle and adjust as necessary. Pressure test the
engine cooling system. Refer to Component Tests, Cooling System Pressure Test in this section.
Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.

No GO to A3
A3 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK

Inspect the engine coolant in the degas bottle for signs of engine oil or transmission fluid.
Is engine oil evident in the coolant?
Yes
No GO to A4
A4 CHECK THE ENGINE OIL FOR COOLANT

Remove the oil level indicator from the engine.
Is coolant evident in the oil?

Yes
No GO to A5
A5 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES
NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.
Using a cooling system combustion gas leak tester, following the instructions supplied with the tester,
check the coolant for combustion gases.
Are combustion gases present?
Yes
No The cooling system is operational.
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The Engine Overheats
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 coolant pump through the engine block and cylinder head. A separate circuit from the engine also feeds
the heater core with coolant. The coolant pump 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.
Possible Sources
Low coolant level

External engine coolant leak
Airlock in system
Pressure relief cap installation
Restricted airflow through A/C condenser/radiator
Internal engine coolant leak
Coolant condition/concentration
Non-OEM engine enhancement components
Electric cooling fan
CHT sensor
Radiator
Thermostat
Coolant pump
Coolant flow restriction
Diagnostic Trouble Code (DTC) Fault Trigger Conditions

DTC Description Fault Trigger Conditions
P0217 Engine Coolant Overtemperature Sets in the PCM when an engine overheat condition was
Condition sensed by the CHT sensor.
P1299 Cylinder Head Overtemperature Sets in the PCM when an engine overheat condition was
Protection Active sensed by the CHT sensor.
PINPOINT TEST B : PINPOINT TEST

B1 CARRY OUT INSPECTION AND VERIFICATION
Carry out the Inspection and Verification procedure in this section.
Are any concerns present?

No GO to B2
B2 CHECK FOR PCM (POWERTRAIN CONTROL MODULE) DTCS
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Ignition ON.
Using a scan tool, perform PCM self-test.
Is DTC P0217 and/or P1299 present?
Yes GO to B4
No Actual engine overheating has not been verified. CHECK the engine coolant temperature
gauge operation.
Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
If any other PCM DTCs are retrieved,
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 5.0L 32V
B3 CHECK FOR ACTIVE GRILL SHUDDER DTCS

Review the PCM DTCs.
Are any active grill shudder DTCs present?
Yes
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Diagnosis and Testing).
No GO to B4
B4 CHECK FOR AN AIRFLOW OBSTRUCTION AND MISSING AIR DEFLECTORS
NOTE: Verify no vehicle front end damage is present.

Check the radiator or A/C condenser for an external obstruction such as leaves or cardboard and verify
all air deflectors are present.
Is an airflow obstruction present or air deflectors missing?
Yes REPAIR as necessary.

No GO to B5
B5 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE COOLING SYSTEM
Ignition OFF.
Visually check the engine coolant level in the coolant expansion tank and adjust as necessary. Pressure
test the cooling system.
Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.

No GO to B6
B6 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK

Inspect the engine coolant in the coolant expansion tank for signs of engine oil.
Is engine oil evident in the coolant?
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Yes
No GO to B7
B7 CHECK THE ENGINE OIL FOR COOLANT

Remove the oil level indicator from the engine.
Is coolant evident in the oil?
Yes
No GO to B8
B8 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES
NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.
Using a cooling system combustion gas leak tester, following the instructions supplied with the tester,
check the coolant for combustion gases.
Are combustion gases present?
Yes
No GO to B9
B9 CHECK COOLANT CONDITION

Check the coolant for dirt, rust or contamination and check the coolant concentration.
Is the coolant condition OK?

Yes GO to B10
No FLUSH the engine cooling system.
REFER to: Cooling System Flushing (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L
B10 CHECK THE ELECTRIC COOLING FAN OPERATION

Start the engine.
Place the climate control function selector in the MAX A/C position and the blower motor switch in the HI
position.
Did the electric cooling fan operate?
Yes GO to B11
No DIAGNOSE the electric cooling fan operation. Refer to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. Section 3 Symptom Charts.
B11 CHECK THE COOLANT PUMP OPERATION
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Start the engine.
Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT
position. Feel the heater outlet hose.
Is the heater outlet hose hot?
Yes GO to B12
No INSTALL a new coolant pump.
REFER to: Coolant Pump (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
B12 CHECK THE THERMOSTAT OPERATION
NOTE: This cooling system uses a cold side thermostat. The coolant in the radiator must reach full
operating temperature for the thermostat to remain in an open state.
Start the engine.
Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT
position. Feel the lower radiator hose.
Is the lower radiator hose hot?
Yes CHECK the temperature gauge operation.

No GO to B13
B13 VISUALLY INSPECT THE THERMOSTAT

Carry out the Thermostat Visual Inspection in the Component Tests portion of this section.
Is the thermostat damaged?
Yes INSTALL a new thermostat.

REFER to: Thermostat (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
No INSTALL a new thermostat.
If the engine still overheats, INSTALL a new radiator. REFER to: Radiator (303-03C
Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
The Engine Does Not Reach Normal Operating Temperature
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 coolant pump through the engine block and cylinder head. A separate circuit from the engine also feeds
the heater core with coolant. The coolant pump 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
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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. 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.
Possible Sources
Low coolant level

Thermostat
Temperature gauge
CHT
Diagnostic Trouble Code (DTC) Fault Trigger Conditions

P0125 Insufficient Coolant Temp for Sets in the PCM when the CHT sensor has not achieved the
Closed Loop Fuel Control required temperature level to enter closed loop operating conditions
within a specified amount of time after starting the engine.
P0128 Coolant Thermostat (Coolant Sets in the PCM when the thermostat monitor has not achieved the
Temp Below Thermostat required engine operating temperature within a specified amount of
Regulating Temperature) time after starting the engine.
PINPOINT TEST C : PINPOINT TEST
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew
C1 CARRY OUT INSPECTION AND VERIFICATION
Carry out the Inspection and Verification procedure in this section.
Were any concerns found?

No GO to C2
C2 CHECK FOR DTC P0125 OR P0128

Using a scan tool, perform the PCM self-test.
Is DTC P0125 or P0128 present?
Yes GO to C3
No The cooling system is operational. If an inoperative temperature gauge is suspected,
CHECK the temperature gauge operation.
If an inoperative climate control system is suspected, CHECK the climate control system
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operation. For Dual Automatic Temperature Control (DATC), REFER to: Climate Control
System - Vehicles With: Dual Automatic Temperature Control (DATC) (412-00 Climate
Control System - General Information, Diagnosis and Testing).
For Electronic Manual Temperature contro (EMTC), REFER to: Climate Control System -
Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control
If any other Diagnostic Trouble Codes (DTCs) are retrieved, REFER to: Electronic Engine
Controls (303-14B Electronic Engine Controls - 3.7L Duratec (227kW/301PS), Diagnosis
and Testing).
C3 CHECK THE COOLANT LEVEL
NOTE: Allow the engine to cool before checking the coolant expansion tank.
Visually check the engine coolant level in the coolant expansion tank
Is the engine coolant level within specification?
Yes INSTALL a new thermostat.

CLEAR Diagnostic Trouble Codes (DTCs). If the DTC returns check for correct CHT
sensor operation.
No GO to Pinpoint Test A
Component Tests
Cooling System Pressure Test
NOTE: Vehicles have a pressure relief cap on the degas bottle and no radiator cap.
1. Turn the engine OFF.
2. Check the engine coolant level and adjust as necessary.
3. Remove the degas bottle cap. Inspect the degas bottle cap and degas bottle for any issues that would
cause improper sealing, such as for cross-threading, burrs, damaged o-ring, etc. If any issues are found,
INSTALL a new cap and/or degas bottle.
4. Attach the Pressure Tester and adaptor (Snap-On TA53 or equivalent), to the degas bottle cap. The cap
must hold pressure of 145 kPa +/- 21 kPa (21 PSI +/- 3 PSI). If any issues are found, INSTALL a new cap.
5. Attach the Pressure Tester and adaptor (Snap-On TA52, AST ASSFZ-47, Redline RDL95-0750 or
equivalent) to the degas bottle.
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NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the specifications
table in this section, or cooling system components can be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will result.
6. To pressurize the engine cooling system, slowly press the plunger of the pressure test pump and increase
the pressure to between 124 - 138 kPa (18 - 20 PSI). Observe the gauge reading for approximately 2
minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks
and repair as necessary.
7. If no leaks are found and the pressure drops, the leak may be internal to the engine. Inspect the coolant
for engine oil and the engine oil for coolant.
8. If the pressure does not drop remove the cooling system Pressure Tester and adaptor from degas bottle.
9. Install the degas bottle cap until it contacts the hard stop.
Thermostat
Install a new thermostat only after at least one of the following tests and checks have been carried out:
Pinpoint Test 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
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
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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.
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.
1. Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the
Specifications table.

(308kW/418PS)
General Procedures 01/19/2016
Cooling System Draining and Vacuum Filling
ROB75240
Coolant/Battery Refractometer (Fahrenheit)
Fluid Container
Cooling System Vacuum Tester and Refiller
Materials
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Name Specification
VC-3DIL-B (U.S.)
VC-3-B (U.S.)
Draining
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 result in
damage to the engine or cooling system components.
NOTICE: The vehicle cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix
coolant types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to follow
these instructions may damage the engine or cooling system.
NOTICE: 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. Failure to
follow these instructions may damage the engine or cooling system.
NOTE: During normal vehicle operation, Motorcraft® Orange Antifreeze/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.
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or
contaminated coolant requires replacement.
1.
WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap
with a thick cloth.
Remove the pressure relief cap.

3. NOTE: If equipped.
Remove the underbody shield.
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5.
WARNING: Be prepared to collect escaping fluid.
Use a hose to drain the coolant.

Open the radiator drain valve and drain the engine coolant in a suitable, clean container.
Use the General Equipment: Fluid Container
Filling
Filling and Bleeding with a Vacuum Cooling System Filler

1. NOTICE: The cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not
mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant.
Failure to follow these instructions may damage the engine or cooling system.
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze 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.
NOTE: Add Motorcraft® Orange Antifreeze/Coolant or equivalent.
NOTE: Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the
coolant's corrosion protection.
NOTE: 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.
NOTE: Ford Motor Company does NOT recommend the use of recycled engine coolant in
vehicles originally equipped with Motorcraft® Orange Antifreeze/Coolant since a Ford-approved
recycling process is not yet available.
When adding or topping off the engine coolant:
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Measure the coolant concentration in the vehicle.
Use Special Service Tool: ROB75240 Coolant/Battery Refractometer (Fahrenheit).
Determine the concentration desired based on the vehicle duty cycle of extreme hot or cold
operating conditions.
Add, top-off or adjust the coolant as follows:
For concentrations measured 48/52 to 50/50 (freeze protection -34˚C to -37˚C [-30˚F to -34˚F]) use
Motorcraft® Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same
range.
Material: Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.)
(WSS-M97B44-D2)
For all other concentrations, use Motorcraft® Orange Antifreeze/Coolant Concentrated and/or
distilled water to get to the desired concentration.
Material: Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) / VC-3-B (U.S.)
(WSS-M97B44-D)
When refilling the engine coolant after a flush procedure, use a mixture of Motorcraft® Orange
Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.
2. Close the radiator drain valve.

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Install the underbody shield.

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5. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed the
system.
Use the General Equipment: Cooling System Vacuum Tester and Refiller
6. Recommended coolant concentration is 48/52 to 50/50 engine coolant to distilled water (freeze protection
-34˚C to -37˚C [-30˚F to -34˚F]).
7. 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% provides freeze protection down to -50˚C (-58˚F)
Engine coolant concentrations above 60% will decrease the overheat protection characteristics of
the engine coolant and may damage the engine.
8. For extremely hot climates:

It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
Engine coolant concentrations below 40% will decrease the freeze and corrosion protection
characteristics of the engine coolant and may damage the engine.
9. Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34˚C to
-37˚C [-30˚F to -34˚F]) mixture of engine coolant and distilled water for optimum cooling system and engine
protection.
Filling and Bleeding without a Vacuum Cooling System Filler
10. NOTICE: The cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not
mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant.
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Failure to follow these instructions may damage the engine or cooling system.
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze 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.
NOTE: Add Motorcraft® Orange Antifreeze/Coolant or equivalent.
NOTE: Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the
coolant's corrosion protection.
NOTE: 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.
NOTE: Ford Motor Company does NOT recommend the use of recycled engine coolant in
vehicles originally equipped with Motorcraft® Orange Antifreeze/Coolant since a Ford-approved
recycling process is not yet available.
When adding or topping off the engine coolant:

Measure the coolant concentration in the vehicle.
Use Special Service Tool: ROB75240 Coolant/Battery Refractometer (Fahrenheit).
Determine the concentration desired based on the vehicle duty cycle of extreme hot or cold
operating conditions.
Add, top-off or adjust the coolant as follows:
For concentrations measured 48/52 to 50/50 (freeze protection -34˚C to -37˚C [-30˚F to -34˚F]) use
Motorcraft® Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same
range.
Material: Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.)
(WSS-M97B44-D2)
For all other concentrations, use Motorcraft® Orange Antifreeze/Coolant Concentrated and/or
distilled water to get to the desired concentration.
(WSS-M97B44-D)
When refilling the engine coolant after a flush procedure, use a mixture of Motorcraft® Orange
Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.
11. Close the radiator drain valve.

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14. Fill the degas bottle to the MAX FILL line.
15. Recommended coolant concentration is 48/52 to 50/50 engine coolant to distilled water (freeze protection
-34˚C to -37˚C [-30˚F to -34˚F]).
16. 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% provides freeze protection down to -50˚C (-58˚F)
Engine coolant concentrations above 60% will decrease the overheat protection characteristics of
the engine coolant and may damage the engine.
17. For extremely hot climates:

It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
Engine coolant concentrations below 40% will decrease the freeze and corrosion protection
characteristics of the engine coolant and may damage the engine.
18. Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34˚C to
-37˚C [-30˚F to -34˚F]) mixture of engine coolant and distilled water for optimum cooling system and engine
protection.
19. Install the degas bottle cap until it contacts the hard stop.
20. Turn the climate control system off.
21. Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds.
22. Turn the engine off for and wait for 1 minute to purge any large air pockets from the cooling system.
23. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew
Check the engine coolant level in degas bottle and if necessary fill to the top of the MAX FILL line on the
degas bottle if the engine is warm or to the top of the MIN FILL LEVEL if the engine is cold.
24. Start the engine and let it idle until the engine reaches normal operating temperature and the thermostat is
fully open. A fully open thermostat is verified by the cooling fan cycling on at least once.
25. Increase the engine speed to 3,500 rpm and hold for 30 seconds.
26. Allow the engine to idle for 30 seconds.
27. Turn the engine off for 1 minute.
28. Repeat steps 25 through 27 a total of 5 times to remove any remaining air trapped in the system.
29. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew
Check the engine coolant level in degas bottle and if necessary fill to the top of the MAX FILL line on the
degas bottle.
30. Install the pressure relief cap.
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(308kW/418PS)
Cooling System Flushing
Materials
Name Specification
Motorcraft® Premium Cooling System Flush ESR-M14P7-A
VC-1
Flushing
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NOTE: To remove rust, sludge and other foreign material from the cooling system, use cooling system flush
that is safe for use with aluminum radiators. This cleaning restores cooling system efficiency and helps prevent
overheating. A pulsating or reversed direction of flushing water will loosen sediment more quickly than a steady
flow in the normal coolant flow direction. In severe cases where cleaning solvents will not clean the cooling
system efficiently, it will be necessary to use the pressure flushing method using cooling system flusher.
Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance
with local, state or federal laws.
1. Add Motorcraft® Premium Cooling System Flush to the cooling system and follow the directions on the
package.
Material: Motorcraft® Premium Cooling System Flush / VC-1 (ESR-M14P7-A)
2. Drain the cooling system.

3. Remove the radiator.

Refer to: Radiator (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal
and Installation).
4. NOTICE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator can
result.
Position the radiator upside down and with a high pressure hose in the lower radiator hose opening,
backflush the the radiator.
5. Remove the thermostat.

Refer to: Thermostat (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
6. Install the coolant inlet connection without the thermostat.

7. Backflush the engine. Position the high-pressure water hose into the engine through the upper radiator
hose and backflush the engine.
8. Install the thermostat.

Refer to: Thermostat (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
9. Install the radiator.

Refer to: Radiator (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal
and Installation).
10. Fill and bleed the cooling system.

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(308kW/418PS)
Heater Core Backflushing
Materials
Name Specification
Motorcraft® Premium Cooling System Flush ESR-M14P7-A
VC-1
Flushing
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1. Partially drain the cooling system.
2. Add Premium Cooling System Flush to backflush the heater core and follow the directions on the package.
Flush with water thoroughly after using Premium Cooling System Flush prior to refilling the cooling system.
Material: Motorcraft® Premium Cooling System Flush / VC-1 (ESR-M14P7-A)


(308kW/418PS)
Removal and Installation 01/15/2015
Block Heater
Removal

2. NOTE: Make sure the block heater wiring is routed and secured away from rotating or hot components.
Disconnect the block heater electrical connector.
3. Remove the block heater.

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Installation


(308kW/418PS)
Coolant Pump
Hose Clamp Remover/Installer
Materials
Name Specification
ZC-31-B
VC-3-B (U.S.)
Removal
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2. Remove the air cleaner outlet pipe.

Refer to: Air Cleaner Outlet Pipe (303-12C Intake Air Distribution and Filtering - 5.0L 32V Ti-VCT/5.0L
3. Loosen the coolant pump pulley bolts.
4. Remove the accessory drive belt.

Refer to: Accessory Drive Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
5. NOTICE: Cover the A/C compressor belt to prevent coolant contamination of the belt.
Completely cover the A/C compressor belt with waterproof plastic.
6. Remove the thermostat housing.

Refer to: Thermostat Housing (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8

8. Disconnect the heater outlet hose from the heater outlet tube.
Release the clamp and disconnect the lower degas bottle hose from the heater outlet tube.
Use the General Equipment: Hose Clamp Remover/Installer
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10. NOTE: This step is only necessary when installing a new component.
Remove the bolt and the heater outlet tube.

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Installation
Install a new O-ring seal on the heater outlet tube and lubricate it with clean engine coolant.
(WSS-M97B44-D)
Install the heater outlet tube and the bolt.
2. Inspect the sealing surfaces and clean with metal surface prep wipes.
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3. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert the
pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed into the
coolant pump cavity or the O-ring seal can be damaged, causing the coolant pump to leak.
Install a new O-ring seal and lubricate it with clean engine coolant.
(WSS-M97B44-D)
Install the coolant pump and tighten the bolts in 2 stages.
Torque:
Stage 2: 60°
4. Connect the lower degas bottle hose to the heater outlet tube and position the clamp.
Connect the heater outlet hose to the heater outlet tube.
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5. NOTE: Only tighten the bolts finger tight at this stage.
Position the coolant pump pulley and install the bolts finger tight.
6. Install the thermostat housing.
Refer to: Thermostat Housing (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
7. Remove the plastic from the A/C compressor belt.
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8. Install the acceccory drive belt.
9. Tighten the coolant pump pulley bolts.

10. Install the air cleaner outlet pipe.



(308kW/418PS)
Cooling Fan Motor and Shroud
Removal
1. Remove the air cleaner.

Refer to: Air Cleaner (303-12C Intake Air Distribution and Filtering - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8

3. Remove the bolts and position the degas bottle aside.
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4. Disconnect the cooling fan electrical connectors and detach the wiring harness retainers.
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5. Remove the bolts.
6. Remove the cooling fan motor and shroud.

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Installation

(308kW/418PS)
Degas Bottle
Base Part Number: 8A080
Fluid Suction Gun

Locking Pliers
Materials
Name Specification
VC-3DIL-B (U.S.)
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VC-3-B (U.S.)
Removal
1.
WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap
with a thick cloth.
Remove the pressure relief cap.

2. Using general tools clamp the lower degas bottle hose and syphon the coolant from the degas bottle.
Use the General Equipment: Fluid Suction Gun
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3. Release the clamps, disconnect the upper degas bottle coolant hoses.

5. Position the degas bottle and disconnect the lower coolant hose.
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Installation
2. Fill the degas bottle with the recommended coolant mixture and fill level.
Material: Motorcraft® Orange Antifreeze/Coolant Prediluted (U.S.) / VC-3DIL-B (U.S.) (WSS-M97B44-D2)

(308kW/418PS)
Radiator
Removal

2. Release the clamp and disconnect the lower radiator hose.
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3. Remove the cooling fan motor and shroud.

Refer to: Cooling Fan Motor and Shroud (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
4. Remove the retainers and the radiator sight shield.

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5. Release the clamp and disconnect the upper radiator hose.
6. Release the clamp and disconnect the upper coolant hose.

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7. Remove the bolts and the upper radiator support brackets.
8. NOTE: Front bumper removed for clarity.
1. Position the radiator towards the engine.

2. Release the upper tabs and position the A/C condenser aside.
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NOTE: Front bumper removed for clarity.
Remove the bolts and position aside the transmission fluid cooler.
10. NOTE: Front bumper removed for clarity.
Remove the radiator.

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Installation


(308kW/418PS)
Thermostat
Materials
Name Specification
VC-3-B (U.S.)
Removal

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3. NOTICE: Cover the accessory drive belts to prevent coolant contamination of the belts.
Completely cover the accessory drive belts with waterproof plastic.
4. NOTE: During installation, make sure the coolant outlet connection is fully seated on the thermostat
housing before tightening the bolts.
Remove the bolts and detach the coolant inlet connector.

5. Remove the thermostat and discard the O-ring seal.

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Installation
1. 1. Install a new O-ring seal and lubricate it with clean engine coolant.
(WSS-M97B44-D)


(308kW/418PS)
Thermostat Housing
Removal


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3. NOTICE: Cover the accessory drive belts to prevent coolant contamination of the belts.
Completely cover the accessory drive belts with waterproof plastic.
4. Release the clamp and disconnect the lower radiator hose from the coolant inlet connection.
5. Remove the thermostat housing bolts.

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6. Pull the upper radiator hose T-connector spring clip up until the end of the clip is in the detent on the quick
connect coupling and remove the thermostat housing from the upper radiator hose T-connector.
7. Remove and discard the thermostat housing gasket.

Installation
1. Install a new thermostat housing gasket.

To install, reverse the removal procedure.
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303-04C Fuel Charging and Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Fuel Charging and Controls - Component Location
5.0L 32V Ti-VCT
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Item Description
1 Throttle Body (TB)
2 Fuel injector
3 Fuel rail
FPDM
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Item Description
1 FPDM. (The FPDM is located beneath the rear seat cushion on the LH
side).

(308kW/418PS)
Fuel Charging and Controls - System Operation and Component Description
System Operation
For System Operation, Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. See Section 1
Description and Operation.
Component Description
For Component Description, Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. See Section 1
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(308kW/418PS)
Fuel Charging and Controls
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. For
information about these,
For PCM DTC,

REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
(308kW/418PS), Diagnosis and Testing).
For driveability symptoms without DTC, Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. See
Section 3, Symptom Charts.
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(308kW/418PS)
Fuel Injectors
1. The fuel injectors are serviced with the fuel rail.

Refer to: Fuel Rail (303-04C Fuel Charging and Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
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(308kW/418PS)
Fuel Pump Driver Module (FPDM)
Removal
NOTE: The FPDM is located beneath the rear seat cushion on the LH side.
1. Remove the rear seat cushion.

Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
2. 1. Disconnect the FPDM electrical connector.

2. Remove the FPDM retaining nuts and then remove the FPDM.
Installation
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1. 1. Install the FPDM, then install and tighten the FPDM retaining nuts.
2. Connect the FPDM electrical connector.
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2. Install the rear seat cushion.

(308kW/418PS)
Fuel Rail
Removal


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5. Disconnect the fuel supply tube quick release coupling.
6. Position the heater hoses aside.

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7. Remove the nuts and then remove the heater hose supports.
8. Position the vacuum tube assembly aside.

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9. Remove the LH and RH fuel rail insulators.
10. Disconnect the fuel injector electrical connectors.

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11. Remove the fuel rail retaining bolts and remove the fuel rail.
12. Remove the fuel injectors from the fuel rail.

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13. Remove and discard all of the fuel injector O-ring seals. Remove the fuel injector retaining clips.
Installation
1. 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.
NOTICE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not
interchangeable.
NOTE: Make sure that new fuel injector O-ring seals are installed.
NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is reused, the 2
sides of the clip should be squeezed back into shape by placing it between index finger and thumb.
Install the new fuel injector O-ring seals and the new fuel injector retaining clips onto the fuel injectors.
Lubricate the new fuel injector O-ring seals with clean engine oil.
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2. NOTE: Orient the fuel injector assemblies so the flat sides of the fuel rail injector cup is aligned with the
flat side of the fuel injector retainer.
Install the fuel injectors into the fuel rail.
3. Install the fuel rail, then install and tighten the fuel rail retaining bolts.
Torque:
Stage 2: 90°
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4. Connect the fuel injector electrical connectors.
5. Install the LH and RH fuel rail insulators.

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6. Install the vacuum tube assembly aside.
7. Install the heater hose supports, then install and tighten the heater hose support nuts.
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8. Install the heater hoses.
9. Connect the fuel supply tube quick release coupling.

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13. Pressurize the fuel system.

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(308kW/418PS)
Throttle Body
Base Part Number: 9F991
Removal
1. Remove the engine appearance cover.
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3. Disconnect the Throttle Body (TB) electrical connector. Remove the Throttle Body (TB) retaining bolts and
then remove the Throttle Body (TB).
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4. Remove and discard the Throttle Body (TB) gasket.
Installation
NOTICE: Make sure that the mating faces are clean and free of foreign material.
1. Install a new Throttle Body (TB) gasket.

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2. Install the Throttle Body (TB), then install and tighten the Throttle Body (TB) retaining bolts. Connect the
Throttle Body (TB) electrical connector.
Torque:
Stage 2: 60°

4. The engine appearance cover rubber grommets may remain on the cover. If so, remove the grommets
from the cover and install them on the intake manifold before installing the cover.
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303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Accessory Drive - Component Location
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Item Description
1 Accessory drive belt
2 Drive belt idler pulley assembly
3 Coolant pump pulley
4 Crankshaft belt pulley
5 Belt - A/C compressor
6 Pulley - A/C compressor
7 Accessory drive belt tensioner
8 Generator pulley

(308kW/418PS)
Accessory Drive
2. Visually inspect for obvious signs of mechanical damage.
Visual Inspection Chart
Mechanical
Damaged or contaminated accessory drive belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt
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Incorrect fitment of the accessory drive belt
Generator
Air conditioning (A/C) compressor
Pulley(s)
Loose hardware
Accessory Drive Belt Concerns
NOTICE: Do not lubricate the accessory drive belt as potential damage to the accessory drive belt
material construction may occur.
Cracking
Accessory drive belts are made from rubber which hardens with time and can develop cracks. As the accessory
drive belt runs on the back of some of the pulleys, the cracks are opened up. Small cracks are not considered to
be a failure of the accessory drive belt. Only if the crack is deep enough to reach the bottom of the groove to
expose the cord or any chunks are found to be missing from the accessory drive belt, is the accessory drive belt
condition considered to be unacceptable.
1. Check the accessory drive belt for cracks. If the damage exceeds the acceptable limit, install a new
accessory drive belt.
REFER to: Accessory Drive Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
Chunking
Chunking describes the condition where long lengths of rubber become detached from the ribs of the accessory
drive belt. This is considered to be a failure of the accessory drive belt.
2. Check the accessory drive belt for damage. If any chunks are found to be missing, install a new accessory
drive belt.
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Pilling
Pilling is dust that forms in between the ribs of the accessory drive belt from rubber that is worn off the accessory
drive belt when it is new. There may also be loose particles left on the accessory drive belt during the
manufacturing process. These are worn off and form into small balls of rubber that then get trapped in the
grooves of the accessory drive belt. This condition will usually clear itself within 4800 km - 8000 km (3000 miles -
5000 miles) of normal driving.
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3. Check the accessory drive belt for pilling. The condition of the accessory drive belt should be compared
against the illustration.
1. Small scattered pills. Not considered a concern. No action required.
2. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new accessory drive
belt if noise is apparent.
4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new accessory drive
belt if noise is apparent.
5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new accessory
drive belt.
6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL a new accessory
drive belt.
Incorrect fitment
Accessory drive belt noise can be generated by the accessory drive belt being incorrectly fitted on the pulley as
shown in the following illustration. Make sure that all the V grooves on the accessory drive belt contact correctly
with the pulley.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
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Accessory drive belt Accessory drive Use a stethoscope or other listening device to
noise system determine the source of the noise. INSTALL new
components as necessary. TEST the system for
normal operation.
Accessory drive belt CHECK the accessory drive belt is correctly
incorrectly installed. installed in the pulley grooves. INSTALL a new
accessory drive belt as necessary.
REFER to: Accessory Drive Belt (303-05C
Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT
TEST the system for normal operation.
Pulley(s). CHECK the pulley(s) for damage, freedom of
rotation, stone entrapment and alignment.
INSTALL new components as necessary. TEST
the system for normal operation.
Lubricant or other CHECK the accessory drive belt for
contamination. contamination or damage. RECTIFY the source
of the leak and INSTALL a new accessory drive
belt.
REFER to: Accessory Drive Belt (303-05C
Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT
NOTE: Chirp is Pulley misalignment CHECK that the accessory drive belt is running
defined as a (usually evident at centrally on the flat pulleys. TEST the system for
twittering noise, often idle). normal operation.
intermittent CHECK the pulleys for excessive end float and
Accessory drive belt bent flanges.
chirp With the engine running at idle, use a
stethoscope to identify the source of the noise.
INSTALL new components as necessary. TEST
the system for normal operation.
NOTE: Rattle is Loose components CHECK the components or hardware for correct
defined as a metallic or hardware. installation and tighten as necessary. TEST the
knocking noise system for normal operation.
Accessory drive belt
rattle
Component Tests
Accessory Drive Belt Tensioner - Static Check
The accessory drive belt tensioner may be checked statically as follows:
1. Inspect the area surrounding the accessory drive belt tensioner for lubricant or other contamination. Rectify
any leaks before installing a new accessory drive belt tensioner. If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the damping mechanism inside may be damaged. INSTALL a
new accessory drive belt tensioner as necessary.
REFER to: Accessory Drive Belt Tensioner (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
3. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a friction device,
therefore some friction within the system is normal.
Using the correct tool, move the accessory drive belt tensioner from its relaxed position through its full
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stroke and back to the relaxed position to make sure there is no excessive stick, grab or bind, and to make
sure there is tension on the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of rotation and alignment.
INSTALL a new accessory drive belt tensioner as necessary.
5. If the accessory drive belt tensioner meets the above criteria, proceed to test the accessory drive belt
tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, INSTALL a
new accessory drive belt tensioner.
Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be checked dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive belt
tensioner should move (respond) when the engine is accelerated rapidly or when the A/C clutch cycles ON
and OFF (the degree of movement can be up to 4 mm). If the accessory drive belt tensioner movement is
not constant without engine acceleration or A/C clutch cycling, a pulley or shaft is possibly bent, out of
round, or the damping mechanism inside the accessory drive belt tensioner may be damaged. INSTALL a
new accessory drive belt tensioner as necessary.
2. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory drive belt) may cause
excessive accessory drive belt tensioner movement. Check the condition by installing a new accessory
drive belt.
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(308kW/418PS)
Accessory Drive Belt
Removal

2. Rotate the accessory drive belt tensioner counter clockwise and remove the accessory drive belt.
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Installation
2. After installation, make sure the accessory drive belt is correctly seated on all pulleys.
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(308kW/418PS)
Accessory Drive Belt Tensioner
Base Part Number: 6B209
Removal

2. Rotate the accessory drive belt tensioner counter clockwise and position aside the accessory drive belt.

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Installation

(308kW/418PS)
Air Conditioning (A/C) Compressor Belt
Cable Ties
Removal
NOTICE: Under no circumstances should the A/C compressor belt, 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 A/C compressor belt, accessory drive belt or
pulleys.

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3. Cut the A/C compressor belt and discard the belt.
Installation
1. NOTE: Make sure the A/C compressor belt is correctly seated on the A/C compressor pulley.
Position the A/C compressor belt in 3 stages.

Stage 1: Slide the A/C compressor belt between the crankshaft pulley and the accessory drive belt
tensioned.
Stage 2: Position the A/C compressor belt behind the crankshaft pulley with the accessory drive belt
ribs facing towards the front of the vehicle.
Stage 3: Position the A/C compressor belt onto the A/C compressor pulley with the lower portion of
the accessory drive belt ribs facing towards the front of the vehicle and above the oil pan as shown.
2. NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and
A/C compressor pulleys.
Position the A/C compressor belt onto the top of the crankshaft pulley and feed a cable tie with a minimum
width of 3 mm (0.12 in) through the crankshaft pulley spokes, up and over the A/C compressor belt and
tighten the cable tie.
Use the General Equipment: Cable Ties
3. NOTICE: The A/C compressor belt must be above the oil pan flange or damage to the A/C
compressor belt and engine can occur.
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With the A/C compressor belt positioned above the oil pan flange, rotate the crankshaft by hand clockwise
180°.
4. Remove the cable tie and rotate the crankshaft clockwise by hand 360° to verify the A/C compressor belt
has correctly seated onto the crankshaft and A/C compressor pulleys.
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6. Install the accessory drive belt.



303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Specifications
General Specifications
Item Specification
Normal engine cranking speed (Average) 200-250 RPM
Starting circuit maximum voltage drop (Engine at normal operating temperature) (Average) 0.5 volt
Starter motor maximum load current draw 800 amps
Starter motor no-load current draw (Average) 60-80 amps
Starter motor normal load current draw (Average) 130-190 amps
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(308kW/418PS)
Starting System - Overview
Starting System
The starting system controls the cranking of the engine. When the PCM receives inputs from the ignition switch -
push button start, transmission (with automatic transmission) or clutch pedal position switch (with manual
transmission), run/start relay and the BCM it then energizes the BJB starter relay. When the starter relay is
energized it applies power to the starter motor which cranks the engine.
Remote Start
Vehicles with automatic transmission are equipped with a remote start system. The remote start system allows
the vehicle to be started from up to 30 meters (98 feet) away. For more information on the remote start system,
refer to the owners literature and
Refer to: Handles, Locks, Latches and Entry Systems - System Operation and Component Description (501-14
Handles, Locks, Latches and Entry Systems, Description and Operation).
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(308kW/418PS)
Starting System - System Operation and Component Description
System Operation
System Diagram - with Push Button Start
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Network Message Chart
Module Network Input Messages Powertrain Control Module (PCM)
Broadcast Originating Message Purpose

Message Module
Crank request BCM Provides the PCM with indication that the driver has commanded the
engine to crank.
Power mode BCM Provides the PCM with ignition mode.
Ignition status BCM Provides the PCM with ignition mode.
Module Network Input Messages Body Control Module (BCM)
Broadcast Message Originating Message Purpose

Module
Intelligent access RFA module The response from the BCM request for the RFA module ID. If the RFA
Module
system status module ID response is incorrect, then the PATS is disabled.
Push Button Start System
This vehicle is equipped with a PATS that disables the engine from cranking if an unprogrammed PATS key is used
or an invalid PCM ID is received. The PATS is controlled by the BCM. If there is a PATS concern that causes the
engine to be disabled, the IPC displays the corresponding message in the message center. For additional
information,
Refer to: Passive Anti-Theft System (PATS) - System Operation and Component Description (419-01B Passive
Anti-Theft System (PATS), Description and Operation).
Ignition modes are controlled by the RFA module and the BCM. For additional information on the ignition switch -
push button start modes,
Refer to: Steering Wheel and Column Electrical Components - System Operation and Component Description
(211-05 Steering Wheel and Column Electrical Components, Description and Operation).
The ignition switch - push button start is connected to the RFA module and the BCM as a backup in case of a
failure. If there is a circuit failure to either module from the ignition switch - push button start, the modules
communicate the ignition switch - push button start request to each other over the Medium Speed Controller Area
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Network (MS-CAN).
During a start event the ignition switch - push button start is pressed in combination with either the brake pedal
(automatic transmission) or the clutch pedal (manual transmission) input. The RFA module, the BCM and the PCM
receive a request to start the engine. The PCM recognizes the correct inputs and provides voltage and ground to
energize the starter relay coil and close the starter relay contacts. The starter relay contacts close, providing
voltage to the starter solenoid, allowing the starter motor to crank the engine. The PCM disengages the starter
motor once an engine Revolutions Per Minute (RPM) threshold is reached, a set crank time is exceeded or the
ignition switch - push button start is pressed indicating an engine shutdown.
Remote Start
Vehicles with automatic transmission are equipped with a remote start system. The remote start feature allows
the operator to remotely start the engine from up to 30 meters (98 feet) away and is activated using the Passive
Key. Once started, the engine runs for 10 minutes. The run time can be extended by the operator. Refer to the
Owners Guide for more information. For more information on enabling the Remote start system refer to
Refer to: Handles, Locks, Latches and Entry Systems - System Operation and Component Description (501-14
Handles, Locks, Latches and Entry Systems, Description and Operation).
and the Owners Literature.
Ignition Switch - Push Button Start
The ignition switch - push button start (Engine Start/Stop button) is a momentary contact switch that is hardwired
to the BCM and the PCM. The ignition switch - push button start is used to obtain the OFF, ON or START ignition
modes. The ignition switch - push button start is part of the FCIM and cannot be serviced separately. For more
information,
Refer to: Steering Wheel and Column Electrical Components - System Operation and Component Description
(211-05 Steering Wheel and Column Electrical Components, Description and Operation).
BCM
Refer to: Module Controlled Functions - System Operation and Component Description (419-10 Multifunction
Electronic Modules, Description and Operation).
PCM
The PCM provides power and ground to the starter relay to initiate cranking of the engine.
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303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS) 2016 Mustang
Starting System
2. Check the battery for loose, damaged or corroded connections.
3. Check the generator for loose, damaged or corroded connections.
4. Check the battery condition and state of charge.

REFER to: Battery (414-01) .

REFER to: Accessory Drive Belt (303-05C Accessory Drive - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and Installation).
Verify the crankshaft and each of the components driven by the accessory drive belt rotate and are not seized or damaged.
6. If any aftermarket accessories have been added to the vehicle, make sure they are properly wired.
7. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding.
DTC Charts
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PCM DTC Chart

P06E9 Engine Starter Performance If the engine cranks, Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Section 3 Symptom Charts. If the engine does not crank, GO to Pinpoint Test A
P0830 Clutch Pedal Switch "A" Circuit GO to Pinpoint Test A
P1594 Forced Engine Shutdown - Remote Start System
Fault, No Unattended Vehicle Timeout REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 5.0L 32V
P1595 Forced Engine Shutdown - Remote Start System
Fault, Transmission Range Not In Park Position REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls - 5.0L 32V
P162F Starter Motor Disabled - Engine Crank Time Too Long Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. Section 3 Symptom
Charts.
P2535 Ignition Switch Run/Start Position Circuit High GO to Pinpoint Test D
All Other — Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. Section 3 Symptom
DTCs Charts.
BCM DTC Chart

C113A:11 Wakeup Control: Circuit Short To Ground GO to Pinpoint Test C
C113A:15 Wakeup Control: Circuit Short To Battery or GO to Pinpoint Test C
Open
P0830:11 Clutch Pedal Switch "A" Circuit: Circuit Short To GO to Pinpoint Test A
Ground
All Other —
DTCs REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis
and Testing).
Symptom Chart(s)
Symptom Chart: Starting System
Symptom Chart
The engine does not crank Refer to the Pinpoint Test GO to Pinpoint Test A
The engine cranks slowly Refer to the Pinpoint Test PERFORM the starter system component test. REFER to Starter Motor - Positive Circuit Test
in this section.
The engine cranks but will not Fuses Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual. Section 3 Symptom
start PCM Charts.
Fuel pump
Fuel pump relay
Starter
Wiring, terminals or
connectors
Unusual starter noise Refer to the Pinpoint Test GO to Pinpoint Test B
The starter spins but the engine Starter motor INSPECT the starter motor mounting and engagement. REPAIR as necessary.
does not crank Damaged flexplate INSPECT the flexplate for damaged, missing or worn teeth. REPAIR as necessary.
The starter does not disengage Starter relay REMOVE the starter relay. If the engine stops cranking, INSTALL a new relay. If the engine
from the flexplate Wiring, terminals or continues to crank, REPAIR circuit CDC25 (BN/GN) for a short to voltage.
connectors
The remote start is inoperative Remote start feature

not enabled REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
Passive Key or battery Systems, Diagnosis and Testing).
PCM
connectors
The remote start has poor Passive key or battery

range performance After market systems REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
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High power devices Systems, Diagnosis and Testing).
TV/radio transmission
towers
Pinpoint Test(s)
Engine Does Not Crank
Refer to Wiring Diagrams Cell 20 for schematic and connector information.
Normal Operation and Fault Conditions
REFER to: Starting System - System Operation and Component Description (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
DTC Fault Trigger Conditions

P06E9 Engine Starter Performance The PCM sets this DTC when no engine rotation is detected during a crank event.
P0830:11 Clutch Pedal Switch "A" Circuit: Circuit Short The BCM sets this DTC when a short to ground is detected on the clutch bottom of travel circuit
To Ground during an on-demand self test.
Possible Sources
Battery
Battery cables
IPC
Starter motor
BJB starter relay
Visual Inspection and Diagnostic Pre-checks
Inspect the run/start relay.

Inspect the high current BJB connections.
Verify the BJB fuse 60 (5A).
Verify the BJB fuse 30 (30A).
Inspect the passive key.
Inspect the CPP switch (manual transmission only).
PINPOINT TEST A : ENGINE DOES NOT CRANK

A1 PERFORM INSPECTION AND VERIFICATION
NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.
NOTE: If it is necessary to leave the battery charger connected during testing, do not leave it on its highest or boost setting. The highest settings can
exceed 16 volts, resulting in false test results and setting of DTCs.
Perform Inspection and Verification procedure in this section.
Was an obvious cause for an observed or reported concern found?
Yes CORRECT the cause as necessary.

No GO to A2
A2 CHECK FOR NO KEY DETECTED MESSAGE IN THE MESSAGE CENTER

NOTE: There are certain areas inside the vehicle where the passive key may not be detected and the message center displays NO KEY DETECTED. If the
passive key is in the far outside edges of the interior (like in a door map pocket or above a sun visor) it might not be detected. Move the passive key to a
different location and try to start the vehicle again.
Check the message displayed in the message center while pressing the engine start/stop switch.
Is NO KEY DETECTED displayed?
Yes DIAGNOSE the NO KEY DETECTED concern.

REFER to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System (PATS), Diagnosis and Testing).
No GO to A3
A3 VERIFY THE BCM (BODY CONTROL MODULE) , IPC (INSTRUMENT PANEL CLUSTER) AND PCM (POWERTRAIN CONTROL MODULE) PASS THE
NETWORK TEST
Ignition ON.
Using a diagnostic scan tool, perform the Network Test.
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Did the BCM, IPC and PCM pass the Network Test?
Yes GO to A4
No
REFER to: Communications Network (418-00) .
A4 RETRIEVE BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, perform BCM self-test.
Are any BCM Diagnostic Trouble Codes (DTCs) present?
Yes For DTC P0830:11 GO to A26

For all BCM Diagnostic Trouble Codes (DTCs), REFER to the BCM DTC Chart in this section.
No GO to A5
A5 RETRIEVE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, perform PCM self-test.
Are any PCM Diagnostic Trouble Codes (DTCs) other than P06E9 present?
Yes REFER to the PCM DTC Chart in this section.

No With automatic transmission, GO to A6
With manual transmission, GO to A11
A6 CHECK THE OPERATION OF THE STOPLAMPS

While observing the stoplamps, apply the brake pedal.
Do the stoplamps illuminate?
Yes GO to A7
No DIAGNOSE All the Stoplamps are inoperative.
REFER to: Stoplamps (417-01 Exterior Lighting, Diagnosis and Testing).
A7 CHECK THE BRAKE PEDAL POSITION (BOO1) PID (PARAMETER IDENTIFICATION)

Using a diagnostic scan tool, view PCM Parameter Identifications (PIDs).
Monitor the PCM B001 PID while applying the brake pedal.
Does the PID read On?
Yes GO to A9
No GO to A8
A8 CHECK THE BPP (BRAKE PEDAL POSITION) SWITCH CIRCUIT FOR VOLTAGE AT THE PCM (POWERTRAIN CONTROL MODULE)
Ignition OFF.
Disconnect PCM C175B.
While applying the brake pedal, measure:
Click to display connectors

Positive Lead Measurement / Action Negative Lead
C175B-67 Ground
Is the voltage greater than 11 volts?
Yes GO to A28
No REPAIR the circuit.
A9 CHECK BCM (BODY CONTROL MODULE) IGN_SW_STATE PID (PARAMETER IDENTIFICATION)

Using a diagnostic scan tool, view the BCM Parameter Identifications (PIDs).
Make sure the transmission is in PARK or NEUTRAL.
Monitor the BCM PID IGN_SW_STATE while pressing the engine start/stop switch and the brake pedal.
Does the PID change from Off to Start when the ignition switch - push button start and brake pedal are pressed?
Yes GO to A10
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No DIAGNOSE No power in ON.
REFER to: Steering Wheel and Column Electrical Components (211-05 Steering Wheel and Column Electrical Components, Diagnosis
and Testing).
A10 CHECK THE PCM (POWERTRAIN CONTROL MODULE) IN GEAR-TRANSMISSION IS APPLYING A LOAD TO ENGINE (IN_GEAR) PID
(PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the PCM Parameter Identifications (PIDs).
Monitor the PCM PID IN_GEAR, while placing the gear selector in PARK and then NEUTRAL.
Does the PID read No in both positions?
Yes GO to A12
No
REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
Automatic Transmission - 6R80, Diagnosis and Testing).
A11 CHECK THE PCM (POWERTRAIN CONTROL MODULE) CLUTCH PEDAL AT OR NEAR BOTTOM OF TRAVEL (CPP_BOT) PID (PARAMETER
IDENTIFICATION)
Using a diagnostic scan tool, while viewing the PCM PID CPP_BOT, fully apply the clutch pedal and release.
Does the PID change from NO to YES when the clutch pedal is fully applied?
Yes GO to A12
No GO to A23
A12 CHECK THE PCM (POWERTRAIN CONTROL MODULE) ENGINE CRANKING (ENG_CRANK) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the PCM Parameter Identifications (PIDs).
Monitor the PCM PID ENG_CRANK while pressing the engine start/stop switch and the brake pedal (with automatic transmission) or fully apply the clutch
pedal (with manual transmission).
Does the PID change from Inactive to Active?
Yes GO to A13
No GO to A28
A13 CHECK THE STARTER RELAY CONTROL OPERATION
NOTICE: The following step uses a test light to simulate normal circuit loads. To avoid connector terminal damage, use the Flex Probe Kit for the
test light probe connection to the vehicle. Do not use the test light probe directly on any connector.
Remove the BJB starter relay.
Measure:
Positive Lead Measurement / Negative Lead
Action
BJB starter relay pin 1 BJB starter relay pin 2

While pressing the engine start/stop switch and the brake pedal, observe the test light.
Does the test light illuminate when the engine start/stop switch is pressed?
Yes GO to A14
No GO to A21
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A14 CHECK THE VOLTAGE TO THE STARTER RELAY
Measure:
Ground
BJB starter relay pin 3
Yes GO to A15
No VERIFY BJB fuse 30 (30A) is OK. If OK, REPAIR the circuit for an open. If not OK, REFER to the Wiring Diagrams manual to identify
the possible causes of the circuit short.
A15 CHECK THE STARTER MOTOR OPERATION AT THE STARTER RELAY

Ignition OFF.
With the transmission in PARK or NEUTRAL, momentarily connect a fused jumper wire:

Action
Action
BJB starter relay pin 3 BJB starter relay pin 5
Did the starter engage and the engine crank?
Yes INSTALL a new starter relay.

No GO to A16
A16 CHECK THE BATTERY GROUND CABLES
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Measure:
Ground G106
Ground G108
Are the voltages greater than 11 volts?
Yes GO to A17
No CLEAN or INSTALL new negative battery cables as necessary.
REFER to: Battery Cables - 5.0L 32V Ti-VCT (414-01 Battery, Mounting and Cables, Removal and Installation).
A17 CHECK THE STARTER MOTOR GROUND

Measure:
Action
Starter motor case
Yes GO to A18
No CLEAN the starter motor mounting flange and MAKE SURE the starter motor is correctly mounted.
REFER to: Starter Motor (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and Installation).
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A18 CHECK THE VOLTAGE TO THE STARTER MOTOR
Measure:

C197A-1 ("B" terminal) Ground
Yes GO to A19
No INSTALL a new positive battery cable.
A19 CHECK THE STARTER MOTOR FOR CORRECT OPERATION

Perform Starter Motor - Positive Circuit Test in this section.
Was an obvious cause found?
Yes Correct the cause as necessary.

No GO to A20
A20 CHECK FOR START INPUT AT THE STARTER

Connect BJB starter relay.
Disconnect Starter solenoid C197A.
While holding the key in the START position, measure:

C197C-1 ("S" terminal) Ground
Yes CLEAN the starter solenoid "S" terminal and starter solenoid connector. CHECK the wiring and the starter motor for a loose or
intermittent connection.
No REPAIR the circuit for an open.
A21 CHECK THE PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BJB starter relay.
Measure:

C175B-1 Ground
C175B-58 Ground
Are the resistances greater than 10,000 ohms?
Yes GO to A22
No REPAIR the affected circuit.
A22 CHECK THE PCM (POWERTRAIN CONTROL MODULE) STARTER RELAY CIRCUITS FOR AN OPEN
Measure:

C175B-1 BJB starter relay pin 1

C175B-58 BJB starter relay pin 2
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Are the resistances less than 3 ohms?
Yes GO to A28
A23 CHECK THE CPP (CLUTCH PEDAL POSITION) SWITCH OPERATION

Ignition OFF.
While fully applying the clutch pedal, measure:

C175B-9 Ground
Is the resistance less than 3 ohms?
Yes GO to A28
No GO to A24
A24 CHECK THE CPP (CLUTCH PEDAL POSITION) GROUND CIRCUIT FOR AN OPEN
Disconnect CPP switch C2353.
Measure:

C2353-2 Ground
Yes GO to A25
A25 CHECK THE CPP (CLUTCH PEDAL POSITION) SWITCH CIRCUIT FOR AN OPEN
Measure:

C175B-9 C2353-1
Yes INSTALL a new CPP switch.

REFER to: Clutch Pedal Position (CPP) Switch (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
A26 CHECK FOR DTC WITH CPP (CLUTCH PEDAL POSITION) SWITCH DISCONNECTED
Ignition OFF.
Disconnect CPP switch C2353.
Ignition ON.
Was DTC P0830:11 retrieved during on-demand self-test with the CPP switch disconnected?
Yes GO to A27
No INSTALL a new CPP switch.
REFER to: Clutch Pedal Position (CPP) Switch (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
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A27 CHECK THE CLUTCH BOTTOM OF TRAVEL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BCM C2280A.
Measure:

C175B-9 Ground
Is the resistance greater than 10,000 ohms?
Yes GO to A29
A28 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all PCM connectors.
Repair:
corrosion (install new connectors or terminals - clean module pins)
damaged or bent pins - install new terminals/pins
pushed-out pins - install new pins as necessary
Reconnect the PCM connectors. Make sure they seat and latch correctly.
Operate the system and determine if the concern is still present.
Is the concern still present?
Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and
FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause
of any connector or pin issues.
A29 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all BCM connectors.
Repair:
Reconnect the BCM connectors. Make sure they seat and latch correctly.

FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, Click here to access
Guided Routine (BCM).
Unusual Starter Noise
Correct starter operation relies on correct mounting of the starter to the engine, alignment of the starter ring gear to the flexplate and correct functioning of the
starter assembly (internal gears, bearings).
Possible Sources
Engine
Starter motor
Starter motor mounting
Inspect the starter motor.

Inspect the starter motor mounting.
PINPOINT TEST B : UNUSUAL STARTER NOISE

B1 CHECK THE STARTER MOUNTING
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Inspect the starter mounting bolts for looseness.
Is the starter motor mounted correctly?
Yes GO to B2
No INSTALL the starter motor correctly.
REFER to: Starter Motor (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
B2 CHECK FOR STARTER NOISE

Ignition OFF.
Connect a remote starter switch between the starter solenoid C197A-1 ("B" terminal) and C197C-1 ("S" terminal).
Engage the starter and verify the noise is due to starter operation.
Is the noise due to the starter engagement?
Yes
REFER to: Starter Motor (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and
Installation).
No
REFER to: Engine (303-00) .
to continue diagnosis.
C113A:11 or C113A:15
The wake-up control circuit wakes up the PCM prior to the engine cranking. The PCM needs to wake up prior to a crank request so it has time to go through its
initialization. The wake-up control circuit is controlled by the BCM. The BCM activates the wake-up control circuit when the driver door is opened or when the
ignition is in the ON or START position.

C113A:11 PCM Wakeup Control: Circuit Short to Ground This DTC is set by the BCM when a short to ground is detected on the wake-up control circuit.
C113A:15 PCM Wakeup Control: Circuit Short to Battery or This DTC is set by the BCM when a short to voltage or an open is detected on the wake-up
Open control circuit.
Possible Sources
BCM
PCM
Wiring, terminals or connectors
PINPOINT TEST C : C113A:11 OR C113A:15

C1 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform the BCM self-test.
Is DTC C113A:11 present?
Yes GO to C2
No If DTC C113A:15 is present, GO to C4
For all other BCM Diagnostic Trouble Codes (DTCs),
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
C2 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR A SHORT TO GROUND

Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, clear the BCM Diagnostic Trouble Codes (DTCs).
Is BCM DTC C113A:11 present?
Yes GO to C3
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No GO to C8
C3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BCM C2280F.
Measure:

C175B-65 Ground
Yes GO to C7
C4 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR INTERNAL SHORT OR OPEN
Ignition OFF.
Ignition ON.
Is BCM DTC C113A:15 present?
Yes GO to C5
No GO to C8
C5 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C175B-65 Ground
Is any voltage present?

Yes REPAIR the circuit.
No GO to C6
C6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) WAKE-UP SIGNAL CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C175B-65 C2280F-18
Yes GO to C7
C7 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
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Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test
and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, Click here to
access Guided Routine (BCM).
No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root
cause of any connector or pin issues.
C8 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
P2535
When the ignition switch - push button start has been pressed, the PCM receives a voltage signal on the crank detect circuit. When the required inputs have
been received, the PCM supplies voltage and ground to the starter relay coil. The ignition switch - push button start is part of the FCIM and cannot be serviced
separately. For more information,
REFER to: Starting System - System Operation and Component Description (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),

P2535 Ignition Switch Run/Start Position Circuit The PCM sets this DTC when the PCM detects voltage on the crank detect circuit while engine is
High running.
Possible Sources
Ignition switch - push button start

BCM
PCM
PINPOINT TEST D : P2535

D1 CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH THE PCM (POWERTRAIN CONTROL MODULE)
DISCONNECTED
Ignition OFF.
Ignition ON.
Measure:

C175B-42 Ground
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Yes GO to D2
No GO to D4
D2 CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH THE IGNITION SWITCH - PUSH BUTTON START
DISCONNECTED
Ignition OFF.
Disconnect FCIM C2402A.
Ignition ON.
Measure:

C175B-42 Ground
Yes GO to D3
No Install a new ignition switch - push button start.
REFER to: Front Controls Interface Module (FCIM) (415-00A Information and Entertainment System - General Information -
Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
(without touchscreen), or REFER to: Front Controls Interface Module (FCIM) (415-00B Information and Entertainment System -
General Information - Vehicles With: Touchscreen Display, Removal and Installation).
(with touchscreen)
D3 CHECK THE CRANK DETECT CIRCUIT FOR A SHORT TO VOLTAGE WITH THE BCM (BODY CONTROL MODULE) DISCONNECTED
Ignition OFF.
Disconnect BCM C2280B.
Ignition ON.
Measure:

C175B-42 Ground

No
Click here to access Guided Routine (BCM).
D4 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
and FOLLOW the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
Component Test(s)
Starter Motor - Positive Circuit Test
NOTE: Always make the multimeter connection at the component terminal rather than at the wiring end of the connector. Making a connection at the wiring
end of the connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and component.
1. Make sure the battery is fully charged.

REFER to: Battery (414-01) .
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2. Perform a battery drain test.
REFER to: Battery Drain Check (414-01 Battery, Mounting and Cables, General Procedures).
3. Connect a remote starter switch between starter solenoid “S” terminal and the battery positive terminal.
4. Connect the multimeter positive lead to the battery positive post. Connect the negative lead to the starter solenoid "M" terminal.
5. Place gear selector lever in Park or Neutral.
6. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volt or less.
7. If the voltage reading is 0.5 volt or less, perform Starter Motor - Ground Circuit Test in this section.
8. A voltage reading greater than 0.5 volt is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid.
Remove the cables from the solenoid "B", "S" and "M" terminals. Clean the cables and connections and reinstall the cables to the correct terminals.
Repeat Steps 3 through 6.
9. If the voltage reading is still greater than 0.5 volt when checked at the "M" terminal, move the multimeter negative lead to the starter solenoid “B”
terminal.
10. With the gear selector lever in Park or Neutral, engage the remote starter switch. Read and record the voltage.
11. If the voltage reading at the "B" terminal is lower than 0.5 volt, the concern is in the connections at the starter solenoid or in the solenoid contacts. Install
a new starter motor.
12. If the voltage reading taken at the solenoid "B" terminal is greater than 0.5 volt after cleaning the cables and connections at the solenoid, the concern is in
the positive battery cable connection or in the positive battery cable itself. Clean the positive battery cable connection. If this does not resolve the
concern, install a new positive battery cable.
Starter Motor - Ground Circuit Test
A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. This procedure checks the voltage drop in the
ground circuit.
1. Connect a remote starter switch between starter solenoid "S" terminal and the battery positive terminal.
2. Connect the multimeter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to
the negative battery terminal.
3. Place gear selector lever in Park or Neutral.
4. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.5 volt or less.
5. If the voltage reading is greater than 0.5 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground
connection. Retest.
6. If the voltage reading is greater than 0.5 volt, install a new negative battery cable.
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7. If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor.

(308kW/418PS)
Starter Motor Drive Gear and Flywheel Ring Gear Inspection
Inspection
1. Remove the starter motor.

Refer to: Starter Motor (303-06C Starting System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
2. Check the wear patterns on the starter drive gear and the flywheel or flexplate ring gear. If the wear
pattern is normal, then install the starter motor.
3. If the starter motor drive gear and the flywheel or flexplate ring gear are not fully engaging and the starter
motor drive gear is scored or damaged, then install a new starter motor.
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4. If the teeth on the flywheel or flexplate ring gear are scored or damaged, then install a new flywheel or
flexplate.
Installation).
Installation).

(308kW/418PS)
Starter Motor
Removal
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.

2. Disconnect the battery.
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3. Open the starter motor solenoid battery cable cover.
4. 1. Remove the starter motor solenoid battery cable nut and then disconnect the starter motor solenoid
battery cable.
2. Remove the starter motor solenoid wire nut and then disconnect the starter motor solenoid wire.
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5. Remove the starter motor mounting bolts and then remove the starter motor.
6. Inspect the starter motor drive gear and flywheel ring gear.
Refer to: Starter Motor Drive Gear and Flywheel Ring Gear Inspection (303-06C Starting System - 5.0L
32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), General Procedures).
Installation
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303-07C Engine Ignition - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Specifications
Item Specification
Spark plug 12405
Spark plug gap 0.049–0.053 in (1.25–1.35 mm)
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(308kW/418PS)
Engine Ignition - Component Location
5.0L 32V Ti-VCT
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Item Description
1 Ignition coil-on-plug(s)
2 Spark plug(s)

(308kW/418PS)
Engine Ignition - System Operation and Component Description
System Operation
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(308kW/418PS)
Engine Ignition
For PCM DTC,

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(308kW/418PS)
Ignition Coil-On-Plug
Removal
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2. 1. Disconnect the PCV valve quick release coupling and position aside.
2. Disconnect the crankcase ventilation tube quick release coupling and position aside.
3. Remove the ignition coil-on-plug covers.
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3. Disconnect the ignition coil-on-plug electrical connectors.
4. NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and
surrounding area before removing the ignition coil-on-plugs.
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease
removal.
1. Remove the ignition coil-on-plug bolts.
2. Remove the ignition coil-on-plugs.
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Installation
1. Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug
assemblies.
2. 1. Install the ignition coil-on-plugs.
2. Install the ignition coil-on-plug bolts.
Torque:
Stage 2: 45°
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3. Connect the ignition coil-on-plug electrical connectors.
4. 1. Install the ignition coil-on-plug covers.

2. Connect the PCV valve quick release coupling.
3. Connect the crankcase ventilation tube quick release coupling.
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5. NOTE: The engine appearance cover rubber grommets may remain on the engine appearance cover. If
so, remove the grommets from the engine appearance cover and install them on the intake manifold
before installing the engine appearance cover.

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(308kW/418PS)
Spark Plugs
Removal
1. Remove the ignition coil-on-plugs.

2. NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread
or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down)
prior to spark plug removal.
NOTICE: If a spark plug is dropped, internal damage may result and the spark plug must be
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discarded. The use of a damaged spark plug may cause cylinder misfire resulting in engine
damage.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
Remove the spark plugs.

Installation

303-08C Engine Emission Control - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Engine Emission Control - Component Location
5.0L 32V Ti-VCT
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Item Description
1 PCV valve

(308kW/418PS)
Engine Emission Control - System Operation and Component Description
System Operation
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(308kW/418PS)
Engine Emission Control
For PCM DTC,

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(308kW/418PS)
Positive Crankcase Ventilation (PCV) Valve
Removal
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2. Disconnect the crankcase ventilation tube-to-PCV valve quick connect coupling.
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3. Remove the RH spark plug cover.
4. Rotate the PCV valve counterclockwise and remove the PCV valve. Discard the PCV valve.
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Installation
NOTICE: A new PCV valve must be installed if removed. Damage will occur to the locking mechanism on
the PCV valve.
1. Lubricate the new PCV valve O-ring seal with clean engine oil.

303-12C Intake Air Distribution and Filtering - 5.0L 32V Ti-VCT/5.0L 2016 Mustang
Ti-VCT V8 (308kW/418PS)
Intake Air Distribution and Filtering - Overview
Overview
The air intake system cleans intake air with a replaceable, dry-type engine Air Cleaner (ACL) element made of
treated, pleated paper. A new Air Cleaner (ACL) element must be installed periodically as scheduled. Engine
performance and fuel economy are adversely affected when maximum restriction of the Air Cleaner (ACL)
element is reached.
The air intake system measures airflow with the MAF sensor.
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Intake Air Distribution and Filtering
For PCM DTC,

REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.3L EcoBoost (231kW/314PS),
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 3.7L Duratec (227kW/301PS),
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Air Cleaner
Removal
1. 1. Loosen the clamp and position the air cleaner outlet pipe from the air cleaner.
2. Disconnect the MAF sensor electrical connector.
3. Detach and position the wire harness from the air cleaner.
2. 1. Detach and position the sound symposer from the air cleaner.
2. Remove the bolt and the air cleaner.
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Installation

Air Cleaner Outlet Pipe
Removal
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2. 1. Disconnect and position aside the 2 brake booster tubes, crankcase ventilation tube and resonator
air inlet tube.
2. Loosen the 2 clamps and remove the air cleaner outlet pipe.
Torque: 48 lb.in (5.4 Nm)
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Installation

303-13C Evaporative Emissions - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Evaporative Emissions - Overview
Overview
The EVAP system prevents hydrocarbon emissions from entering the atmosphere by storing fuel vapors and
routing the vapors to the engine to be consumed during normal engine operation.
The EVAP system consists of:
EVAP canister
EVAP canister purge valve
EVAP canister vent solenoid
Fuel Tank Pressure (FTP) sensor and tube
Easy Fuel (capless) fuel tank filler pipe
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(308kW/418PS)
Evaporative Emissions - System Operation and Component Description
System Operation
Refer to the PC/ED manual section 1 Description and Operation.
System Diagram
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Item Description
1 Air Cleaner (ACL) outlet pipe
2 Intake manifold
3 RH valve cover
4 LH valve cover
5 PCV valve (part of LH valve cover)
6 EVAP canister purge valve
7 Fuel tank
8 Fuel Tank Pressure (FTP) sensor and tube
9 Fuel tank filler pipe
10 EVAP canister

(308kW/418PS)
Evaporative Emissions
Engine Diagnostic Information
For PCM DTC,

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(308kW/418PS)
Evaporative Emission System Leak Test
Activation
Phase 1 - Leak Verification
1. Run the EVAP Test with the scan tool.
2. NOTE: Some small leaks may not be detected using the EVAP Test. If the system has passed the test but
a leak is still suspected, then proceed to Phase 2.
If the EVAP system failed the EVAP Test, then proceed to Phase 2.
Phase 2 - System Leak Check
3. Disconnect the fuel vapor tube-to-EVAP canister purge valve quick connect coupling.
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4. Connect the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester to the fuel vapor tube quick
connect coupling. Refer to the manufacturer's instructions.
5. NOTE: The battery ground cable was previously disconnected in the fuel vapor tube quick connect
coupling procedure.
Connect the battery ground cable.

6. Close the canister vent solenoid with the scan tool.
7. NOTE: The supplemental refueling adapter is located in the jack storage compartment.
Install the supplemental refueling adapter into the Easy FuelTM (capless) fuel tank filler pipe assembly.
8. NOTE: If smoke does not exit the fuel tank filler pipe neck area after the system is pressurized, open the
canister vent solenoid with the scan tool to allow the air to purge. Once smoke is seen at the canister
vent solenoid, close the canister vent solenoid with the scan tool.
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.
9. Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe neck
area.
10. Continue to enter smoke into the system for 60 seconds to obtain pressure.
11. Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while
checking for exiting smoke.
12. 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).
13. Repair any leaks as necessary.
14. Repeat the leak test until the system passes.

(308kW/418PS)
Evaporative Emission Canister
Base Part Number: 9E857
Removal
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1. Position the vehicle on a hoist.

2. Disconnect the negative battery cable.

3. Disconnect the EVAP canister electrical connector.
4. Remove the bolts, pin type retainers and bracket.

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6. Remove the nuts and lower the EVAP canister.

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7. 1. Disconnect the EVAP canister quick connect couplings.
2. Disconnect the vent hose and remove the EVAP canister.
Installation

(308kW/418PS)
Evaporative Emission Canister Purge Valve
Base Part Number: 9D289
Removal
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1. Disconnect the negative battery cable.

3. 1. Disconnect the EVAP canister purge valve electrical connector.

2. Disconnect the EVAP canister purge valve quick connect coupling.
3. Remove the bolts and the EVAP canister purge valve.
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Installation

(308kW/418PS)
Evaporative Emission Canister Ventilation Filter
Removal
1. Remove the EVAP canister.

Refer to: Evaporative Emission Canister (303-13C Evaporative Emissions - 5.0L 32V Ti-VCT/5.0L Ti-VCT
2. Disconnect the EVAP canister solenoid electrical connector.
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3. Remove the bolts and EVAP canister shield.
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4. If necessary, remove the EVAP canister solenoid.
5. Release the tabs and remove EVAP canister ventilation filter.

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Installation

(308kW/418PS)
Evaporative Emission Canister Vent Solenoid
Removal
1. Remove the EVAP canister.

Refer to: Evaporative Emission Canister (303-13C Evaporative Emissions - 5.0L 32V Ti-VCT/5.0L Ti-VCT
2. Disconnect the EVAP canister solenoid electrical connector.
3. Remove the bolts and EVAP canister shield.

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4. Remove the EVAP canister solenoid.
Installation

(308kW/418PS)
Fuel Tank Pressure Sensor and Tube
Base Part Number: 9J279
Removal
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2. Disconnect the battery ground cable.

3. Remove the rear subframe.

Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
4. Disconnect the quick release coupling, routing clips and the fuel tank pressure sensor electrical connector.
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5. Disconnect the routing clips.
6. Disconnect the quick release coupling and routing clips.

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7. Disconnect the quick release coupling and routing clips. Remove the fuel tank pressure sensor and tube.
Installation

303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Electronic Engine Controls - Component Location
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Electronic Engine Controls- Front
Item Description
1 RH exhaust VCT oil control solenoid
2 RH intake VCT oil control solenoid
3 LH intake VCT oil control solenoid
4 LH exhaust VCT oil control solenoid
5 Mass Air Flow (MAF) Intake Air Temperature (IAT) sensor
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Electronic Engine Controls - Rear
Item Description
1 LH exhaust CMP sensor
2 LH intake CMP sensor
3 Left hand IMRC position sensor
4 Left hand IMRC actuator
5 Left hand IMRC solenoid
6 Right hand IMRC solenoid
7 Right hand IMRC actuator
8 Right hand IMRC position sensor
9 RH intake CMP sensor
10 RH exhaust CMP sensor
11 KS
12 CHT sensor
13 CKP sensor
14 HO2S
15 Catalyst monitor sensor
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Powertrain Control Module (PCM)
Item Description
1 PCM

(308kW/418PS)
Electronic Engine Controls - Overview
Overview
The EEC system provides optimum control of the engine through the enhanced capability of the PCM. The EEC
system also has an OBD monitoring system with features and functions to meet federal regulations on exhaust
emissions.
The EEC system has two major divisions: hardware and software. The hardware includes the PCM, sensors,
switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the strategy
control for outputs (engine hardware) based on the values of the inputs to the PCM.
The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and calibration
stored within the PCM, the PCM generates the appropriate output. The system is designed to minimize emissions
and optimize fuel economy and driveability. The software strategy controls the basic operation of the engine,
provides the OBD strategy, controls the MIL, communicates to the scan tool over the DLC, allows for flash
EEPROM, provides idle air and fuel trim, and controls failure mode effects management (FMEM).
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(308kW/418PS)
Electronic Engine Controls - System Operation and Component Description
System Operation
System Operation
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) Manual Section 1 Description and Operation.
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(308kW/418PS)
Electronic Engine Controls
DTC Chart: Powertrain Control Module (PCM)
Powertrain Control Module (PCM) DTC Chart

P0128 Coolant Thermostat (Coolant
Temp Below Thermostat REFER to: Engine Cooling (303-03C Engine Cooling - 5.0L 32V
Regulating Temperature) Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Diagnosis and Testing).
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P0461 Fuel Level Sensor A Circuit First, Refer to Powertrain Control/Emissions Diagnosis (PC/ED)
Range/Performance manual. If sent here from the PC/ED manual,
REFER to: Instrumentation, Message Center and Warning Chimes
(413-01 Instrumentation, Message Center and Warning Chimes,
P0462 Fuel Level Sensor A Circuit Low First, Refer to Powertrain Control/Emissions Diagnosis (PC/ED)
manual. If sent here from the PC/ED manual,
P0463 Fuel Level Sensor A Circuit High First, Refer to Powertrain Control/Emissions Diagnosis (PC/ED)
manual. If sent here from the PC/ED manual,
P0504 Brake Switch A / B Correlation Without adaptive cruise control,
REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and
Testing).
With adaptive cruise control, REFER to: Cruise Control (419-03B
Cruise Control - Vehicles With: Adaptive Cruise Control, Diagnosis
and Testing).
P0521 Engine Oil Pressure
Sensor/Switch "A" Circuit REFER to: Instrumentation, Message Center and Warning Chimes
Range/Performance (413-01 Instrumentation, Message Center and Warning Chimes,
Sensor/Switch "A" Circuit Low REFER to: Instrumentation, Message Center and Warning Chimes
Sensor/Switch "A" Circuit High REFER to: Instrumentation, Message Center and Warning Chimes
P0524 Engine Oil Pressure Too Low
P0532 A/C Refrigerant Pressure With DATC,
Sensor “A” Circuit Low REFER to: Climate Control System - Vehicles With: Dual Automatic
, With EMTC
REFER to: Climate Control System - Vehicles With: Electronic
P0533 A/C Refrigerant Pressure With DATC,
Sensor “A” Circuit High REFER to: Climate Control System - Vehicles With: Dual Automatic
, With EMTC
P0562 System Voltage Low
REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P0563 System Voltage High
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P0572 Brake Switch A Circuit Low Without adaptive cruise control,
Testing).
and Testing).
P0573 Brake Switch A Circuit High Without adaptive cruise control,
Testing).
and Testing).
P0620 Generator Control Circuit
P0625 Generator Field Terminal Circuit
Low REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P0626 Generator Field Terminal Circuit
High REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
With DATC,
P0645 A/C Clutch Relay Control Circuit
, With EMTC
P0657 Actuator Supply Voltage "A"
Circuit/Open REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
P065B Generator Control Circuit
Range/Performance REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P06E9 No engine rotation detected
during crank event REFER to: Starting System (303-06C Starting System - 5.0L 32V
P0701 Transmission Control System
Range/Performance REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0702 Transmission Control System
Electrical REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0705 Transmission Range Sensor "A"
Circuit (PRNDL Input) REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Circuit Range/Performance REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
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Circuit Low REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Circuit High REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Circuit Intermittent REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0710 Transmission Fluid Temperature
Sensor "A" Circuit REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Range/Performance Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
Sensor "A" Circuit Low REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Sensor "A" Circuit High REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0715 Turbine/Input Shaft Speed
Sensor "A" Circuit No Signal REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Sensor "A" Circuit Intermittent REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0720 Output Shaft Speed Sensor
Circuit REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Circuit Range/Performance REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Circuit No Signal REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
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P0729 Gear 6 Incorrect Ratio
REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0740 Torque Converter Clutch
Solenoid Circuit/Open REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Solenoid Circuit REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Performance/Stuck Off Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
Solenoid Circuit Stuck On REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Solenoid Circuit Electrical REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Solenoid Circuit Intermittent REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0748 Pressure Control Solenoid "A"
Electrical REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0750 Shift Solenoid "A"
P0751 Shift Solenoid "A"
Performance/Stuck Off REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
cardiagn.com
P0752 Shift Solenoid "A" Stuck On
P0753 Shift Solenoid "A" Electrical
P0754 Shift Solenoid "A" Intermittent
P0755 Shift Solenoid "B"
P0756 Shift Solenoid "B"
P0757 Shift Solenoid "B" Stuck On
P0758 Shift Solenoid "B" Electrical
P0759 Shift Solenoid "B" Intermittent
P0760 Shift Solenoid "C"
P0761 Shift Solenoid "C"
P0762 Shift Solenoid "C" Stuck On
P0763 Shift Solenoid "C" Electrical
P0764 Shift Solenoid "C" Intermittent
P0765 Shift Solenoid "D"
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P0766 Shift Solenoid "D"
P0767 Shift Solenoid "D" Stuck On
P0768 Shift Solenoid "D" Electrical
P0769 Shift Solenoid "D" Intermittent
P0770 Shift Solenoid "E"
P0772 Shift Solenoid "E" Stuck On
P0773 Shift Solenoid "E" Electrical
P0774 Shift Solenoid "E" Intermittent
P07A8 Transmission Friction Element
"D" Stuck Off REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P07A9 Transmission Friction Element
"D" Stuck On REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P07AA Transmission Friction Element
"E" Stuck Off REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0812 Reverse Input Circuit
REFER to: Reversing Lamps (417-01 Exterior Lighting, Diagnosis
and Testing).
P0830 Clutch Pedal Switch "A" Circuit
REFER to: Starting System (303-06C Starting System - 5.0L 32V
P0833 Clutch Pedal Switch "B" Circuit Without adaptive cruise control,
cardiagn.com
Testing).
and Testing).
P0882 TCM Power Input Signal Low
P0883 TCM Power Input Signal High
P0960 Line Pressure Control (LPC) A
Control Circuit/Open REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Control Circuit/Open REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Control Circuit Low REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Control Circuit High REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0973 Shift Solenoid "A" Control Circuit
Low REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0974 Shift Solenoid "A" Control Circuit
High REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0976 Shift Solenoid "B" Control Circuit
P0977 Shift Solenoid "B" Control Circuit
P0979 Shift Solenoid "C" Control Circuit
P0980 Shift Solenoid "C" Control Circuit
P0982 Shift Solenoid "D" Control Circuit
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P0983 Shift Solenoid "D" Control Circuit
Range/Performance REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P0A5A Generator Current Sensor
Circuit Range/Performance REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P0A5B Generator Current Sensor
Circuit Low REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P0A5C Generator Current Sensor
Circuit High REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
P1001 KOEO Not Able to Complete, RETRIEVE and RECORD all Diagnostic Trouble Codes (DTCs).
KOER Aborted REPAIR any self-test or Continuous Memory Diagnostic Trouble
Codes (CMDTCs) first. CLEAR the DTC. RERUN the
KOERself-test. If the DTC returns, REPROGRAM the PCM with the
latest software.
REFER to: Module Configuration - System Operation and
Component Description (418-01 Module Configuration, Description
and Operation).
RERUN the KOER self-test. If the DTC returns, INSTALL a new
PCM.
REFER to: Powertrain Control Module (PCM) (303-14C Electronic
Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
. After installing the new PCM PROGRAM it with the latest
software.
P1299 Cylinder Head Overtemperature
Protection Active REFER to: Engine Cooling (303-03C Engine Cooling - 5.0L 32V
P1397 System Voltage Out Of Self Test
Range REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging
With DATC,
A/C Demand Out Of Self Test General Information, Diagnosis and Testing).
P1464
Range , With EMTC
Vehicle Speed Sensor Out Of REFER to: Anti-Lock Brake System (ABS) and Stability Control
P1501
Self Test Range (206-09 Anti-Lock Brake System (ABS) and Stability Control,
P1594 Forced engine shutdown –
remote start system fault, No REFER to: Locks, Latches and Entry Systems (501-14 Handles,
unattended vehicle timeout Locks, Latches and Entry Systems, Diagnosis and Testing).
P1595 Forced engine shutdown –
remote start system fault, REFER to: Locks, Latches and Entry Systems (501-14 Handles,
cardiagn.com
transmission range not in park Locks, Latches and Entry Systems, Diagnosis and Testing).
P161A Incorrect Response from
Immobilizer Control Module REFER to: Passive Anti-Theft System (PATS) (419-01B Passive
Anti-Theft System (PATS), Diagnosis and Testing).
P1636 Inductive Signature Chip
Communication Error REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P163E Transmission Control Module
Programming Error REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P163F Transmission ID Block
Corrupted, Not Programmed REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P1700 Transmission Indeterminate
Failure (Failed to Neutral) REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P1702 Transmission Range Sensor
Circuit Intermittent REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P1703 Brake Switch Out Of Self-Test Without adaptive cruise control,
Range REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and
Testing).
and Testing).
P1705 Transmission Range Circuit Not
Indicating Park/Neutral During REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Self Test Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
P170A Clutch Switch Out Of Self Test Without adaptive cruise control,
Range REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and
Testing).
and Testing).
Sensor Out Of Self Test Range REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Solenoid Circuit REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
P177F Unable to Fully Engage Neutral
P1783 Transmission Overtemperature
Condition REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
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P1921 Transmission Range Signal
P193E A/C Clutch Request Signal With DATC,
, With EMTC
P2066 Fuel Level Sensor "B" Circuit
Range/Performance REFER to: Instrumentation, Message Center and Warning Chimes
Low REFER to: Instrumentation, Message Center and Warning Chimes
High REFER to: Instrumentation, Message Center and Warning Chimes
P2535 Ignition Switch Run/Start
Position Circuit High REFER to: Starting System (303-06C Starting System - 5.0L 32V
P25B0 Fuel Level Sensor "A" Stuck
P25B1 Fuel Level Sensor "B" Stuck
P25B2 Fuel Level Sensor "A" or "B"
Stuck REFER to: Instrumentation, Message Center and Warning Chimes
P2700 Transmission Friction Element
"A" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
"B" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
"C" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
"D" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
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"E" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
"F" Apply Time REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Pressure Control Solenoid Stuck REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
On Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
Pressure Control Solenoid REFER to: Diagnostic Trouble Code (DTC) Charts and Pinpoint
Intermittent Tests - 5.0L 32V Ti-VCT (307-01 Automatic Transmission - 6-Speed
U0104 Lost Communication With Cruise Without adaptive cruise control,
Control Module REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and
Testing).
and Testing).
U0121 Lost Communication With GO to Pinpoint Test A
Anti-Lock Brake System (ABS)
Control Module
U0164 Lost Communication With HVAC Without touchscreen,
Control Module REFER to: Information and Entertainment System (415-00A
Information and Entertainment System - General Information -
Vehicles With: AM/FM/CD/SYNC, Diagnosis and Testing).
With touchscreen, REFER to: Information and Entertainment
System (415-00B Information and Entertainment System - General
Information - Vehicles With: Touchscreen Display, Diagnosis and
Testing).
U0212 Lost Communication With GO to Pinpoint Test B
Steering Column Control Module
All — Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Other Section 3 Symptom Charts.
DTCs
Pinpoint Tests
U0121
DTC Fault Trigger Condition-PCM

U0121 Lost Communication With Anti-Lock The PCM sets this DTC if data messages received from the
Brake System (ABS) Control Module ABS module over the High Speed Controller Area Network
(HS-CAN) are missing.
cardiagn.com
REFER to: Communications Network - System Operation and Component Description (418-00 Module
Communications Network, Description and Operation).
Possible Sources
ABS module
BCM
PCM
PINPOINT TEST A : U0121

A1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Verify there is an observable symptom present.
Is an observable symptom present?
Yes GO to A2
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.
A2 CHECK THE COMMUNICATION NETWORK

Using a diagnostic scan tool, perform a network test.
Does the ABS module pass the network test?
Yes GO to A3
No
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis
and Testing).
A3 PERFORM ABS (ANTI-LOCK BRAKE SYSTEM) MODULE SELF-TEST
Using a diagnostic scan tool, perform a ABS module self-test.
Are any Diagnostic Trouble Codes (DTCs) recorded?
Yes
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake
System (ABS) and Stability Control, Diagnosis and Testing).
No GO to A4
A4 CHECK THE BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, retrieve the BCM Diagnostic Trouble Codes (DTCs).
Yes
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No GO to A5
A5 PERFORM THE PCM (POWERTRAIN CONTROL MODULE) SELF-TEST

Using a diagnostic scan tool, perform the PCM self-test.
Is DTC P0562 or DTC P0563 recorded?
Yes REFER to PCM DTC Chart in this section.

No GO to A6
A6 RECHECK THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES

(DTCS)
NOTE: If new modules were installed prior to the DTC being set, the module configuration may be
incorrectly set during the PMI, or the PMI may not have been carried out.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs).
Wait 10 seconds.
Repeat the PCM self-test.
Is DTC U0121 still present?
Yes GO to A7
No The system is operating correctly at this time. The DTC may have been set due to high
A7 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0121 SET IN OTHER MODULES
Using a diagnostic scan tool, clear all Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Using a diagnostic scan tool, retrieve all Continuous Memory Diagnostic Trouble Codes (CMDTCs).
Is DTC U0121 set in any other module?
Yes GO to A8
No GO to A9
A8 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION

Ignition OFF.
Disconnect and inspect all ABS MODULE connectors.
Repair:
corrosion (install new connector or terminals – clean module pins)
damaged or bent pins – install new terminals/pins
pushed-out pins – install new pins as necessary
Reconnect all the ABS MODULE connectors. Make sure they seat and latch correctly.
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Yes CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for
this concern, DISCONTINUE this test and FOLLOW TSB instructions. If no Technical
Service Bulletins (TSBs) address this concern, INSTALL a new ABS MODULE.
REFER to: Anti-Lock Brake System (ABS) Module (206-09 Anti-Lock Brake System
(ABS) and Stability Control, Removal and Installation).
No The system is operating correctly at this time. The concern may have been caused by
module connections. ADDRESS the root cause of any connector or pin issues.

Ignition OFF.
Disconnect and inspect PCM connector.
Repair:
Reconnect the PCM connector. Make sure it seats and latches correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new PCM.
REFER to: Powertrain Control Module (PCM) (303-14C Electronic Engine Controls - 5.0L
32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and Installation).
U0212

U0212 Lost Communication With Steering The PCM sets this DTC if data messages received from the SCCM
Column Control Module over the High Speed Controller Area Network (HS-CAN) are
missing.
Possible Sources
SCCM
BCM
PCM
PINPOINT TEST B : U0212

B1 VERIFY THE CUSTOMER CONCERN
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Ignition ON.
Yes GO to B2
B2 CHECK THE COMMUNICATION NETWORK

Does the SCCM module pass the network test?
Yes GO to B3
No
and Testing).
B3 PERFORM SCCM (STEERING COLUMN CONTROL MODULE) MODULE SELF-TEST

Using a diagnostic scan tool, perform a SCCM module self-test.
Yes
No GO to B4
B4 CHECK THE BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Yes
No GO to B5
B5 PERFORM THE PCM (POWERTRAIN CONTROL MODULE) SELF-TEST


No GO to B6
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B6 RECHECK THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Wait 10 seconds.
Yes GO to B7
B7 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0212 SET IN OTHER MODULES
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Yes GO to B8
No GO to B9
B8 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all SCCM connectors.
Repair:
Reconnect all the SCCM connectors. Make sure they seat and latch correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new SCCM MODULE.
REFER to: Steering Column Control Module (SCCM) (211-05 Steering Wheel and Column
Electrical Components, Removal and Installation).
B9 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
cardiagn.com
U0164

U0164 Lost Communication With HVAC The PCM sets this DTC if data messages received from the FCIM
Control Module through the GWM are missing.
The HVAC control module is housed in the FCIM.

Possible Sources
FCIM module
BCM
PCM
PINPOINT TEST C :
C1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Yes GO to C2
C2 CHECK THE COMMUNICATION NETWORK

Does the FCIM module pass the network test?
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Yes GO to C3
No
and Testing).
C3 PERFORM FCIM (FRONT CONTROLS INTERFACE MODULE) MODULE SELF-TEST

Using a diagnostic scan tool, perform a FCIM module self-test.
Yes Without touchscreen,

Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC, Diagnosis
and Testing).
With touchscreen,
REFER to: Information and Entertainment System (415-00B Information and
Entertainment System - General Information - Vehicles With: Touchscreen Display,
No GO to C4
C4 CHECK THE BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Yes
No GO to C5
C5 PERFORM THE PCM (POWERTRAIN CONTROL MODULE) SELF-TEST

No GO to C6
C6 RECHECK THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES

(DTCS)
Wait 10 seconds.
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Yes GO to C7
C7 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0164 SET IN OTHER MODULES
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Yes GO to C8
No GO to C9
C8 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) MODULE

OPERATION
Ignition OFF.
Disconnect and inspect all FCIM MODULE connectors.
Repair:
Reconnect all the FCIM MODULE connectors. Make sure they seat and latch correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new FCIM MODULE.
Without touchscreen,
REFER to: Front Controls Interface Module (FCIM) (415-00A Information and
Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC, Removal
and Installation).
With touchscreen,
REFER to: Front Controls Interface Module (FCIM) (415-00B Information and
Entertainment System - General Information - Vehicles With: Touchscreen Display,

Ignition OFF.
Repair:
cardiagn.com

(308kW/418PS)
Camshaft Position (CMP) Sensor
Materials
Name Specification
Motorcraft® SAE 5W-20 Full Synthetic Motor Oil (U.S.) WSS-M2C945-A
XO-5W20-QFS (U.S.)
Removal
All sensors
cardiagn.com
and Installation).
RH (right-hand) Camshaft Position (CMP) Sensors
2. 1. Disconnect the intake CMP sensor electrical connector and remove the retainer and the CMP
sensor.
Material: Motorcraft® SAE 5W-20 Full Synthetic Motor Oil (U.S.) / XO-5W20-QFS (U.S.)
(WSS-M2C945-A)
2. Disconnect the exhaust CMP sensor electrical connector and remove the retainer and the CMP
sensor.
(WSS-M2C945-A)
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LH (left-hand) Camshaft Position (CMP) Sensors
3. 1. Disconnect the intake CMP sensor electrical connector and remove the retainer and the CMP
sensor.
(WSS-M2C945-A)
2. Position aside the radio ignition interference capacitor.
3. Disconnect the exhaust CMP sensor electrical connector and remove the retainer and the CMP
sensor.
(WSS-M2C945-A)
Installation
NOTE: Before installation, lubricate the CMP sensor O-ring seal with clean engine oil.
cardiagn.com
(308kW/418PS)
Catalyst Monitor Sensor
Base Part Number: 9G444
303-476 (T94P-9472-A)
Socket, Exhaust Gas Oxygen Sensor
TKIT-1994-F
TKIT-1994-FLM/FM
TKIT-1994-LM/M
Materials
Name Specification
cardiagn.com
High Temperature Nickel Anti-Seize Lubricant -
XL-2
Penetrating and Lock Lubricant -
XL-1
Removal
All sensors

Right hand (RH) Catalyst monitor sensor
2. 1. Disconnect the catalyst monitor sensor electrical connector.

2. Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.
Material: Penetrating and Lock Lubricant / XL-1
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Left hand (LH) Catalyst monitor sensor

Installation
Left hand (LH) Catalyst monitor sensor
1. 1. Calculate the correct torque wrench setting for the following torque. Refer to Torque Wrench
Adapter Formula in the Apex.
Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.
Material: High Temperature Nickel Anti-Seize Lubricant / XL-2
2. Connect the catalyst monitor sensor electrical connector.
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Right hand (RH) Catalyst monitor sensor
2. Connect the catalyst monitor sensor electrical connector.
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(308kW/418PS)
Clutch Pedal Position (CPP) Switch
Removal
1. Disconnect the electrical connector and remove CPP switch from the bracket.
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Installation

(308kW/418PS)
Crankshaft Position (CKP) Sensor
Removal

and Installation).
2. Disconnect the CKP sensor electrical connector, remove the bolt and the sensor.
Installation

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2. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.

(308kW/418PS)
Cylinder Head Temperature (CHT) Sensor
Removal

and Installation).
2. NOTE: Do not reuse the CHT sensor, install a new sensor.
1. Disconnect the CHT sensor electrical connector.

2. Remove and discard the CHT sensor.
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Installation

(308kW/418PS)
Engine Oil Pressure (EOP) Sensor
Materials
Name Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24-B
Removal
NOTE: Vehicles equipped with performance package only.

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2. Disconnect the EOP switch electrical connector.
NOTE: If the oil pressure switch is to be reused, apply thread sealant.
Remove the EOP switch.

Material: Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque:
Stage 2: 180°
Installation

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(308kW/418PS)
Heated Oxygen Sensor (HO2S)
303-476 (T94P-9472-A)
Socket, Exhaust Gas Oxygen Sensor
TKIT-1994-F
TKIT-1994-FLM/FM
TKIT-1994-LM/M
Materials
Name Specification
cardiagn.com
XL-2
Penetrating and Lock Lubricant -
XL-1
Removal
All sensors

RH (right-hand) Heated Oxygen Sensor (HO2S)
2. 1. Disconnect the HO2S electrical connector.

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LH (left-hand) Heated Oxygen Sensor (HO2S)

Installation
LH (left-hand) Heated Oxygen Sensor (HO2S)
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RH (right-hand) Heated Oxygen Sensor (HO2S)
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(308kW/418PS)
Intake Manifold Runner Control (IMRC) Actuator
Base Part Number: 9J559
Removal

and Installation).
2. Remove the IMRC sensors.

Refer to: Intake Manifold Runner Control (IMRC) Position Sensor (303-14C Electronic Engine Controls -
5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal and Installation).
3. Remove the hoses, retainers and the IMRC actuators.
cardiagn.com
Installation

(308kW/418PS)
Intake Manifold Runner Control (IMRC) Position Sensor
Removal

and Installation).
2. Remove the retainers and the LH IMRC position sensor.

Remove the retainers and the RH IMRC position sensor.
cardiagn.com
Installation

(308kW/418PS)
Intake Manifold Runner Control (IMRC) Solenoid
Removal

and Installation).
2. Disconnect the 6 vacuum hoses from the IMRC solenoids, remove the 3 retainers and the solenoid
mounting plate.
Remove the 2 retainers and remove the IMRC solenoids.
cardiagn.com
Installation

(308kW/418PS)
Knock Sensor (KS)
Removal

and Installation).
2. NOTE: Note the position of the components before removal.
1. Disconnect the KS electrical connectors.

2. Remove the bolts and the KS.
cardiagn.com
Installation
1. NOTE: Make sure that the components are installed to the position noted before removal.

(308kW/418PS)
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor
Removal
1. 1. Disconnect the mass air flow (MAF) intake air temperature (IAT) sensor electrical connector.
2. Remove the retainers and the mass air flow (MAF) intake air temperature (IAT) sensor.
cardiagn.com
Installation

(308kW/418PS)
Powertrain Control Module (PCM)
Removal
1. NOTE: PCM installation DOES NOT require new keys or programming of keys, only a Parameter Reset
of the PATS.
NOTE: This step is only necessary when installing a new component.
Download the module information to the diagnostic tool using the PMI routine.
Refer to: Module Configuration - System Operation and Component Description (418-01 Module
Configuration, Description and Operation).
2. Unclip and position aside the BJB.
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3. 1. Disconnect the PCM electrical connectors.
2. Remove the retainers and the PCM.
cardiagn.com
Installation
1. 1. Connect the PCM electrical connectors.

2. Install the PCM and the retainers.
2. Position back the BJB.

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Upload the module information from the diagnostic tool using the Programmable Modules Installation
routine.
4. Carry out the Parameter Reset procedure.

Refer to: Anti-Theft Security Access (419-01B Passive Anti-Theft System (PATS), General Procedures).
5. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the

(308kW/418PS)
Variable Camshaft Timing (VCT) Oil Control Solenoid
Base Part Number: 6B297/6M280
Removal
RH (right-hand) Variable Camshaft Timing (VCT) Oil Control Solenoids
1. Remove the RH valve cover.

Refer to: Valve Cover RH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal
and Installation).
2. Remove the bolts and the RH VCT oil control solenoids.

Torque:
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Stage 2: 20°
LH (left-hand) Variable Camshaft Timing (VCT) Oil Control Solenoids
3. Remove the LH valve cover.

Refer to: Valve Cover LH (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal
and Installation).
4. Remove the bolts and the LH VCT oil control solenoids.

Torque:
Stage 2: 20°
cardiagn.com
Installation

501-00 Body System - General Information 2016 Mustang
Specifications
Materials
Name Specification
Seam Sealer -
TA-2-B
Silicone Spray Lubricant ESR-M13P4-A
XL-6
Permatex® Trim and Weatherstrip Adhesive -
81850
TA-30
cardiagn.com
Body - Overview
Insulation
Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the
vehicle. Mastic insulators are also used as insulation. Insulation is installed:
under the roof.

above and below the instrument panel.
at the cowl side panels.
over the front and rear floorpans.
inside the B-, C- and D-pillar sections.
on the wheelhouse/quarter panel.
behind the rear quarter trim panel.
Other forms of insulation include:
front tunnel stiffening pad.
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dash panel stiffener.
rear wheelhouse mastic pads.
It has heat-bonded mastic deadeners for improved NVH characteristics.
It also has sound dampeners located inside the D-pillar and plug holes in the inner rear quarter.
Body Sealer Types and Applications
Seam Sealer
heavy-bodied, non-sag adhesive/sealer used on standing cosmetic seams, truck bed seams, tooled door
skin seams and floorpans.
can be used on water leaks and noise concerns.
Silicone Gasket and Sealant
form-in-place gasket and multi-purpose adhesive/sealant.

room temperature curing silicone rubber.
Silicone Spray Lubricant
keeps the door and 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.
Trim and Weatherstrip Adhesive
quick drying, strong adhesive designed to hold weatherstripping onto all body panels and surrounding
metal.

Body System
Symptom Chart(s)
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 HI.
Turn the air recirculation OFF.
Close the windows and doors.
Open the hood and spray soapy water along body seams and grommets. Make sure to test the
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areas around the A-pillar at the fender and the 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. The vehicle should be driven in 4 different
directions, with all 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. The source of the noise can be detected by stopping movement of the suspect
part by hand or by using dampening or low friction materials.
Symptom Chart: Body System - General Information

Draft/wind noise and Loose fit seal PINCH seal carrier to improve retention on seal flange.
water leak around door
Seal installed incorrectly REINSTALL the seal.
perimeter
Door misaligned REALIGN the door. CHECK door gaps and fit in door
opening and ADJUST as necessary. For door alignment,
REFER to: Front Door Alignment (501-03 Body Closures,
Scuff plate installed REINSTALL the scuff plate.
incorrectly
Seal or seal pushpins INSTALL a new seal/pushpins.
damaged
Sheet metal joints in door SEAL leaks with seam sealer.
or door opening
Draft/wind noise and Door glass misaligned ADJUST door glass.
water leak around glass
Glass run installed REINSTALL glass run. To reinstall the glass run,
run
incorrectly or not fully REFER to: Front Door Glass Run and Bracket (501-11
seated Glass, Frames and Mechanisms, Removal and
Installation).
Leak path behind glass run INSTALL foam rope behind glass run.
Glass run channel spread PINCH glass run channel to reduce size of opening.
wide
Glass run damaged INSTALL a new glass run. To install the glass run,
REFER to: Front Door Glass Run and Bracket (501-11
Glass, Frames and Mechanisms, Removal and
Installation).
Glass run overstuffed in REINSTALL glass run. INSTALL new part as necessary.
corners creating pucker To reinstall the glass run,
Installation).
Inner glass run reveal lip REINSTALL glass run. INSTALL new part as necessary.
not contacting sheet metal To reinstall the glass run,
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Installation).
Inner belt overstuffed REINSTALL inner belt and INSTALL foam rope behind
creating gap between inner lip of glass run at belt. INSTALL new glass run as
glass and glass run necessary.
Draft/wind noise and Belt line seal installed ADJUST seal (do not bend the flange).
water leak at inner belt incorrectly on flange
line
No contact with side glass ADJUST door glass.
No contact with glass runs ADJUST belt line seal or ADD foam at seal ends.
at both ends of belt line
seal
Belt line seal damaged INSTALL a new seal.
Draft/wind noise and Belt line seal installed ADJUST seal.
water leak at outer belt incorrectly on flange (no
line glass contact)
Belt line seal does not ADJUST door glass.
contact the glass
No contact with glass runs ADJUST belt line seal or ADD foam at seal ends.
at both ends of belt line
seal
Belt line seal damaged INSTALL a new seal.
Draft/wind noise at inner Hole in weathershield SEAL hole with suitable tape.
door handle/speaker
Weathershield misaligned REALIGN weathershield. INSTALL a new weathershield if
opening
pressure sensitive adhesive fails.
Exterior door handle seal REALIGN or INSTALL a new seal as necessary.
misaligned/damaged
Speaker or speaker seal REPAIR speaker seal or INSTALL a new door speaker.
missing or damaged
Draft/wind noise and Missing or damaged CHECK plugs/grommets for correct installation or
water leaks at floor pan plugs/grommets damage. INSTALL new plugs/grommets if necessary.
and grommets
Road noise Missing mastic insulators CHECK for missing mastic insulators.
Missing body insulators CHECK for missing body insulators.
Rattles in body/doors Loose wires/cables CHECK that all wires/cables are correctly routed and
and instrument panel inserted in correct retainers.
Loose objects/components CHECK doors by carefully striking underside of doors
in door wells, pillars with a rubber mallet while listening for rattles in doors and
quarter trim panels pillars. REMOVE or TIGHTEN loose objects/components.
Buzz from instrument panel IDENTIFY which components of the instrument panel are
components buzzing. SECURE/FASTEN components as necessary,
ADD foam or felt as needed if rattle persists.
Door drain holes Holes clogged with mud or CLEAN drain holes of foreign material with a punch or
collecting water road tar screwdriver. CHECK drain holes regularly.
Wind noise from exterior Exterior mirror housing REALIGN with edges shingled to airflow, with no gaps.
rear view mirror misaligned
Mirror sail gasket REINSTALL with gasket unfolded and aligned correctly.
folded/misaligned
Mirror housing trim cap REINSTALL with edges shingled to airflow.
installed incorrectly
Inner sail trim installed REINSTALL sail trim. ADJUST door trim.
incorrectly
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Inner sail gasket/barrier REINSTALL trim cover with gasket/barrier aligned
installed incorrectly correctly.
Air path through wiring BLOCK air path(s) with foam/tape.
bundle/fastener access
holes
Exposed fastener access INSTALL a new cap if missing.
hole on mirror housing/sail
Mirror housing trim cap INSTALL a new exterior mirror. To install new mirror,
under-flush to housing REFER to: Exterior Mirror (501-09 Rear View Mirrors,
causing whistle Removal and Installation).
Rattle/vibration from Mirror mounting nuts loose TIGHTEN mirror mounting nuts.
exterior rear view mirror REFER to: Exterior Mirror (501-09 Rear View Mirrors,
Aftermarket air If possible, REMOVE aftermarket air deflector/stone
deflector/stone shields shield, then ROAD TEST vehicle. If concern is no longer
present, ADVISE the customer the aftermarket
component was causing concern.
Draft/wind noise and Air traveling up windshield INSTALL foam rope full length of the A-pillar.
water leak around molding along A-pillar
perimeter of all fixed
Gaps in sealant bead of Install new windshield/rear glass. To install new
glass
windshield/rear glass windshield/rear glass,
REFER to: Fixed Glass (501-11 Glass, Frames and
Mechanisms, General Procedures).
Windshield/rear glass Install new windshield/rear glass. To install new
misaligned or not installed windshield/rear glass,
correctly REFER to: Fixed Glass (501-11 Glass, Frames and
Mechanisms, General Procedures).
Rear hood seal at base of REALIGN or INSTALL a new seal as necessary.
windshield
misaligned/damaged
High mounted stoplamp CHECK high mounted stoplamp seal. REPAIR or
INSTALL as necessary.
A-pillar applique along INSPECT attachment clips for damage and REINSTALL
windshield lifting part. INSTALL new part as necessary.
Draft/wind noise and Loose fit seal PINCH seal carrier to improve retention on seal flange or
water leak around INSERT foam in carrier.
liftgate/luggage
Seal misaligned or installed REINSTALL seal.
compartment perimeter
incorrectly
Liftgate/luggage REALIGN luggage compartment lid. CHECK luggage
compartment misaligned compartment lid fit in body opening and ADJUST as
necessary. To realign luggage compartment lid,
REFER to: Luggage Compartment Lid Alignment (501-03
Body Closures, General Procedures).
Scuff plate misaligned REINSTALL scuff plate.
Seal or seal pushpins INSTALL a new seal or pushpins.
damaged
Wind noise created by Fender splash shield REALIGN fender splash shield.
airflow over or behind misaligned
body panels
Body panel misaligned REALIGN appropriate body panel.
(exposed edge)
Hood misaligned (front CHECK hood gaps and fit. ADJUST hood as necessary.
margin) To align hood,
REFER to: Hood Alignment (501-03 Body Closures,
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Front grille edge noise APPLY foam in hollow areas behind louvers.
Wind noise created by Grille fit to leading edge on If possible, ADJUST grille opening panel forward to
grille opening panel hood eliminate wind noise.
Sharp edges due to REMOVE sharp edges (no visible surface damage).
material imperfections
Wind noise from air Air extractor housing REINSTALL air extractor housing.
extractor (body vent) seated incorrectly
Air extractor housing or INSTALL a new air extractor.
flaps damaged
Wind noise from bug Turbulence created by DETERMINE if the component is an Original Equipment
shield/exterior location and shape Manufacturer (OEM) part or aftermarket. If aftermarket,
windshield sun visor ADVISE customer accordingly. If Original Equipment
Manufacturer (OEM), VERIFY correctly installed. If noise
is abnormal REPAIR or INSTALL new as required.
Wind noise from cowl Leaf screen rubber lip not REINSTALL part. If part still does not fit, CHECK for
panel (leaf screen) touching windshield damaged attachment clips. INSTALL new part as
necessary.

501-02 Front End Body Panels 2016 Mustang
Active Grille Shutter - Overview
Overview
The active grille shutter system (when equipped) is comprised of the grille shutter assembly and the grille shutter
actuator. The active grille shutter system is primarily used to maximize fuel economy by reducing aerodynamic
drag on the vehicle. The active grille shutter system is also used to shorten engine warm-up time, increasing
engine efficiency and providing heat to the vehicle occupants in a timely manner. The grille shutter actuator
receives position commands from the PCM. The active grille shutter system carries out a calibration sequence
whenever the engine is started, fully opening and closing the shutters before being positioned in the programmed
position as requested by the PCM.
PCM inputs/outputs that may be used for controlling of grille shutters are the:
ECT sensor
IAT sensor
A/C pressure transducer
APP sensor
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ABS module (through the HS-CAN)
AAT (ambient air temperature) sensor
TCT (turbo charge temperature) sensor
MCT (manifold charge temperature) sensor
TOT (transmission oil temperature) sensor
Engine cooling fan motor
Engine oil temperature

Active Grille Shutter - System Operation and Component Description
System Operation
System Diagram
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PCM Network Input Messages
Broadcast Message Originating Module Message Purpose

Vehicle speed ABS module Vehicle speed is used to determine positioning of the grille shutters.
Active Grille Shutter
The grille shutter actuator positions the grille shutters based on commands from the PCM. The grille shutter
moves 90 degrees from fully closed to fully open and, based on the position commanded by the PCM, is set in 1
of 16 positions (approximately 6 degrees between positions).
During normal operation, the grille shutter may be partially to fully open when the engine is off, depending on the
ambient temperature. After an engine starting event, a calibration of the grille shutter system occurs, which
typically takes 15-20 seconds. The grille shutter system performs the calibration sequence by detecting the end
positions, open and closed. The calibration sequence can begin in either direction, open or closed, and continues
until it is successful or a fault is sensed. A long pause may occur between the 2 portions (open/close) of the
calibration sequence. If certain faults are present (shutter blocked or actuator error), a recalibration is initiated in
an attempt to resolve the problem. If the problem is not resolved after a calibrated number of attempts (usually 3
or 4), a timer starts and sets a DTC when the timer reaches a predetermined limit. Other faults also trigger a
recalibration request, but not until a grille shutter DTC is set in the PCM.
The PCM communicates the desired position (open or closed) of the grille shutter based on various PCM inputs
(vehicle speed, coolant temperature, ambient temperature, A/C system pressure, etc.). The PCM communicates
to the grille shutter actuator via a LIN. The LIN supports bi-directional communication between the grille shutter
actuator and PCM, allowing the grille shutter actuator to communicate position and fault information to the PCM.
The PCM sets grille shutter Diagnostic Trouble Codes (DTCs) when the fault information is communicated by the
grille shutter actuator for a predetermined amount of time. Any failures of the LIN for over 10 seconds
continuously results in the grille shutter actuator positioning the grille shutter fully open. There is no indication to
the driver of the vehicle when a fault with the grille shutter system is present or a grille shutter DTC is set in the
PCM.
Grille Shutter Actuator
The grille shutter actuator is a smart motor which receives position requests from the PCM via the LIN. One of the
grille shutter blinds connects to the grille shutter actuator using a retainer. The grille shutter actuator can be
serviced individually or as an entire assembly, which includes the grille shutter, grille shutter actuator, retainer,
housing and jumper harness.
Grille Shutter
The grille shutter is comprised of shutter blinds which are linked to each other. One of the individual shutter blinds
is fixed to the grille shutter actuator. When the grille shutter actuator moves, it moves the attached shutter which
causes the other linked shutters to move. The grille shutter is serviced as an assembly (individual shutter blinds
are not serviceable) or as an entire assembly, which includes the grille shutter, grille shutter actuator, retainer,
housing and jumper harness.
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P059F Active Grille Air Shutter "A" Performance GO to Pinpoint Test A
/ Stuck Off
P05A1 Active Grille Air Shutter "A" Position GO to Pinpoint Test A
Sensor Minimum / Maximum Stop
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Performance
P05A2 Active Grille Air Shutter "A" Control INSTALL a new grille shutter actuator.
Circuit / Open REFER to: Active Grille Shutter Actuator
(501-02 Front End Body Panels, Removal
and Installation).
P05A7 Active Grille Air Shutter Control Module GO to Pinpoint Test A
"A" Supply Voltage Circuit Low
P05C0 Active Grille Air Shutter Module “A” Over INSTALL a new grille shutter actuator.
Temperature REFER to: Active Grille Shutter Actuator
(501-02 Front End Body Panels, Removal
and Installation).
U0046 Vehicle Communication Bus C GO to Pinpoint Test A
U0284 Lost Communication With Active Grille GO to Pinpoint Test A
Air Shutter Module "A"
All other Diagnostic - Refer to the appropriate section in Group
Trouble Codes (DTCs) 303 for the procedure.
Symptom Chart(s)
Symptom Chart: Active Grille Shutter
Symptom Chart

The active grille shutter is inoperative or does not operate Refer to the Pinpoint GO to Pinpoint Test
correctly Test A
Pinpoint Test(s)
The Active Grille Shutter is Inoperative or Does Not Operate Correctly
REFER to: Active Grille Shutter - System Operation and Component Description (501-02 Front End Body Panels,

P059F Active Grille Air Shutter "A" When the grille shutter actuator senses it is unable to move the grille
Performance / Stuck Off shutter, it sends a message to the PCM via the LIN. The PCM sets this
DTC when the fault is communicated for a predetermined amount of
time.
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P05A1 Active Grille Air Shutter "A" When the grille shutter actuator senses it is unable to obtain a fully
Position Sensor Minimum / open or closed position of the grille shutter, it sends a message to the
Maximum Stop Performance PCM via the LIN. The PCM then sets the DTC when the fault is
communicated for a predetermined amount of time.
P05A7 Active Grille Air Shutter Control When the grille shutter actuator senses low voltage, it sends a
Module "A" Supply Voltage message to the PCM via the LIN. The PCM sets this DTC when the
Circuit Low fault is communicated for a predetermined amount of time.
U0046 Vehicle Communication Bus C This DTC sets when the PCM detects a short to voltage, ground or
open in the LIN.
U0284 Lost Communication With When the PCM does not receive communication from the grille shutter
Active Grille Air Shutter Module actuator for a predetermined amount of time, the PCM sets this DTC.
"A"
Possible Causes
Fuse
Grille shutter actuator
Active grille shutter
PCM
Verify BJB fuse 85 (15A) is OK.

Make sure the grille opening does not have any debris or other obstructions that inhibit operation of the
grille shutter.
Make sure the grille shutter actuator electrical connector is not disconnected.
PINPOINT TEST A : THE ACTIVE GRILLE SHUTTER IS INOPERATIVE OR DOES NOT OPERATE
CORRECTLY
A1 RETRIEVE THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Is DTC DTC P05A7, U0046 or U0284 present?
Yes GO to A2
No For DTC P059F or P05A1, GO to A7
For all other PCM Diagnostic Trouble Codes (DTCs), Refer to the appropriate section in
Group 303 for the procedure.
A2 CHECK THE VOLTAGE SUPPLY TO THE GRILLE SHUTTER ACTUATOR

Ignition OFF.
Disconnect: Grille Shutter Actuator C1651.
Ignition ON.
Measure:

C1651-3 Ground
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Yes GO to A3
No VERIFY BJB fuse 85 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
Wiring Diagrams manual to identify the cause of the circuit short.
A3 CHECK THE GRILLE SHUTTER ACTUATOR GROUND CIRCUIT FOR AN OPEN

Ignition OFF.
Measure:

C1651-1 Ground
Yes For DTC U0046 or U0284, GO to A4

For DTC P05A7, GO to A9
A4 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect: PCM C1551B.
Measure:

C1651-2 C1551B-50
Yes GO to A5
A5 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C1651-2 Ground
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No GO to A6
A6 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C1651-2 Ground
Yes For DTC U0046 or U0248, GO to A10

For all other Diagnostic Trouble Codes (DTCs), GO to A9
A7 VERIFY THE GRILLE SHUTTER OPERATION USING THE GRILLE SHUTTER A POSITION -
COMMANDED (GRILL_A_CMD) PARAMETER IDENTIFICATION (PID)
Start the engine and allow it to idle for at least 30 seconds to allow for the grille shutter calibration to
complete.
Using a diagnostic scan tool, select the PCM GRILL_A_CMD Parameter Identification (PID) and active
command the grille shutter from 100% (open) to 0% (closed) while observing the grille shutter operation
from the front of the vehicle.
Does the grille shutter fully open and close when commanded by the diagnostic scan tool?
Yes The grille shutter system is operating correctly at this time. The concern may have been
caused by debris/obstruction or the grille shutter actuator electrical connector. INSPECT
the electrical connector and REPAIR or REPLACE as necessary.
No GO to A8
A8 CHECK THE GRILLE SHUTTER FOR OBSTRUCTIONS AND/OR MECHANICAL BINDING

CONCERNS
Ignition OFF.
Remove the grille shutter actuator.
Manually open and close the grille shutter, removing any obstructions which can inhibit operation of the
grille shutter or linkage. The grille shutter should open and close easily with no binding.
Does the grille shutter operate freely with no binding or obstruction?
Yes GO to A9
No REPAIR the binding/obstruction, or if necessary, INSTALL a new grille shutter assembly.
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Removal and
Installation).
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A9 CHECK FOR CORRECT GRILLE SHUTTER ACTUATOR OPERATION
Ignition OFF.
Disconnect: Grille Shutter Actuator C1651 (if not previously disconnected).
Inspect the grille shutter actuator electrical connector and jumper harness.
Repair:
corrosion (install new connector or terminals - clean module pins)
damaged or bent pins - install new terminals/pins as necessary
Reconnect the grille shutter actuator connector, jumper harness and all previously disconnected system
connectors. Make sure they seat and latch correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new grille shutter actuator.
REFER to: Active Grille Shutter Actuator (501-02 Front End Body Panels, Removal and
Installation).
A10 CHECK FOR THE CORRECT GRILLE SHUTTER ACTUATOR OPERATION

Inspect the grille shutter actuator and PCM electrical connectors.
Repair:
Reconnect the grille shutter actuator connector, jumper harness and all previously disconnected system
connectors. Make sure they seat and latch correctly.

Service Bulletins (TSBs) address this concern, INSTALL a new grille shutter actuator.
REFER to: Active Grille Shutter Actuator (501-02 Front End Body Panels, Removal and
Installation).
CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test. If the concern is still
present, INSTALL a new PCM. Refer to the appropriate section in Group 303 for the
procedure.
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Removal
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2. Detach the ambient air temperature sensor.
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3. Remove the retainers and bolts and position the active grille shutter forward.
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4. NOTE: Radiator and condenser removed for clarity.
1. Disconnect the active grille shutter actuator electrical connector.

2. Remove the retainers and the bridge link.
5. Remove the active grille shutter.

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Installation

Active Grille Shutter Actuator
Removal
1. Remove the active grille shutter assembly.

Refer to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).
2. Remove the upper linkage.
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3. Remove the retainer. Using a screwdriver, push up on the clip and remove the active grille shutter actuator.
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Installation

Cowl Panel Grille
Removal
NOTE: LHD shown, RHD similar.
1. Remove the wiper pivot arms.

Refer to: Windshield Wiper Pivot Arm - LHD (501-16 Wipers and Washers, Removal and Installation).
2. Remove the retainers and the battery cover.
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3.
Remove the retainers and the clips.
1. Remove the retainers.
2. Depress and remove the clips.
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4. 1. Lift the cowl panel grille up.
2. Pull the cowl panel grille out and remove.
Installation

Fender Splash Shield
Removal
NOTE: LH side shown, RH side similar.
1. Remove the wheel and tire.

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4. Remove the fender splash shield.
Installation

Fender
Removal
1. Remove the fender splash shield.

Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
2. Remove the rocker panel moulding.

Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).

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4. Remove the bolt and separate the front bumper cover from the fender bracket.
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5. 1. Remove the headlamp assembly bolt.
2. Remove the fender bolt.
6. Remove the cowl panel grille to fender clip.

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7. Remove the bolt.
8. 1. Position aside the door weatherstrip.

2. Remove the bolt.
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9. Remove the retainers and sound insulation.
10. Remove the bolt and nut.

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11. Remove the sound insulation.
12. Remove the bolts and the fender.

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Installation

Hood
Removal
All vehicles
1. Remove the retainers and hood insulation.
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2. Detach the windshield washer hose retainers and couplings.
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Vehicles equipped with hood scoop
Remove the nuts and the brackets.

Remove the scoop assembly.

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All vehicles
Remove the striker latch to hood bolts and the striker latch.
Remove the retainers and the hood pad assembly.

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7. NOTE: RH side shown, LH side similar.
Index-mark the hood hinge location to aid in hood installation.
8. NOTE: An assistant is necessary for the removal of the hood.
Remove the nuts and the hood.

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Installation
2. Check the hood alignment. Align the hood as necessary.

Refer to: Hood Alignment (501-03 Body Closures, General Procedures).

501-03 Body Closures 2016 Mustang
Front Door Alignment
Inspection
NOTE: Coupe shown, convertible similar.
1. Check front door to body dimensions.

Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks,
Adjustment
All alignments
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1. Remove the bolts and the striker assembly.
Front door in and out, up and down alignment
2. Open the door.

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3. Loosen the nuts to permit movement of the door.
Loosen:
: 2 turn(s)
4. Adjust the door to specification.
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5. Tighten the nuts.
Front door fore, aft and tilt alignment
6. Open the door.

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7. Loosen the bolts to permit movement of the door.
Loosen:
: 2 turn(s)
8. Carefully close the door.

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9. Adjust the door to specification.
10. Carefully open the door.

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Torque:
1.: 22 lb.ft (30 Nm)
2.: 89 lb.in (10 Nm)
All alignments
12. Loosen the bolts to permit movement of the striker assembly.

Loosen:
: 2 turn(s)
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13. Check body to front door dimensions.
14. Check the front door glass alignment.

Refer to: Door Window Glass Adjustment - Convertible (501-11 Glass, Frames and Mechanisms, General
Procedures).
Refer to: Door Window Glass Adjustment - Coupe (501-11 Glass, Frames and Mechanisms, General
Procedures).
15. Install the removed components.

Hood Alignment
Inspection
1. Check hood to body dimensions.

All alignments
2. Remove the hood latch.

Refer to: Hood Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
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Hood fore and aft, left and right alignments
3. Loosen the bolts to permit movement of the hood and adjust to specification.
Loosen:
: 2 turn(s)

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Hood front up and down alignments
5. Adjust the bump stop rubbers.
6. Adjust the hood to specification.

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All alignments
7. Check the body to hood dimensions.


Luggage Compartment Lid Alignment
Inspection
1. Check luggage compartment lid to body dimensions.

All alignments
2. Remove the luggage compartment lid latch.

Refer to: Luggage Compartment Lid Latch - Coupe (501-14 Handles, Locks, Latches and Entry Systems,
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Luggage compartment lid fore and aft, left and right alignments
3. Loosen the bolts to permit movement of the luggage compartment lid.

Loosen:
: 2 turn(s)
4. Adjust the luggage compartment lid to specifications.

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5. Carefully open luggage compartment lid.

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Luggage compartment lid up and down alignments
7. Adjust the adjusting screws.

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9. Open the luggage compartment lid.
10. Adjust the luggage compartment lid bump stop rubbers.

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All alignments
12. Check the body to luggage compartment lid dimensions.

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Front Door
Removal
1. Disconnect the front door electrical connector.
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2. Remove the check arm bolt.
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3. NOTE: This step requires the aid of another technician.
Remove the door hinge pivot bolts.

Remove the door.

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Installation
Check the door to body alignment. Align the door as necessary.

Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).

Front Door Check Arm
Removal
1. Remove the check arm bolt.

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2. Remove the front door trim panel.
Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
3. Remove the nuts.

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4. Remove the front watershield.
5. Remove the check arm assembly.

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Installation

Fuel Filler Door
Removal
1. Open the fuel filler door.
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2. Using a screwdriver, pry the retaining tab back and slide the fuel filler door from the fuel filler door hinge.
Installation
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Fuel Filler Door Assembly
Removal
NOTE: The fuel filler door assembly is damaged during the removal process and requires a new fuel filler door
assembly installed.
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2. Remove the fuel tank filler pipe.
Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS), Removal
and Installation).
Refer to: Fuel Tank Filler Pipe (310-01B Fuel Tank and Lines - 3.7L Duratec (227kW/301PS), Removal and
Installation).
Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and Installation).
3. Unseat the fuel filler door assembly boot from inside the wheel opening.
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4. NOTE: Clearance is limited. When all four clips release you can rotate the housing out of the vehicle.
Using a screwdriver, punch 4 holes at the indicated areas. Insert the screwdriver and release the clips
while pulling the housing away from the vehicle.
Installation

Fuel Filler Door Spring
Removal
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2. Using a screwdriver, press the tab to release the fuel filler door spring from the fuel filler door assembly.
Installation
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Luggage Compartment Lid
Removal
All vehicles
1. Remove the bump stops.
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2. Remove the retainers and the luggage compartment lid trim panel.
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Remove the luggage compartment lid moulding.

Refer to: Luggage Compartment Lid Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
If equipped, remove the rear spoiler.

Refer to: Rear Spoiler (501-08 Exterior Trim and Ornamentation, Removal and Installation).
5. Detach the wiring harness retainers and disconnect the luggage compartment lid electrical connectors.
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Convertible
6. 1. Detach the latch lock cable retainers.

2. Remove the bolts and position aside the latch lock cable.
All vehicles
7. On both sides, remove the strut.

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Remove the nuts and the luggage compartment lid.

Installation
2. Check the luggage compartment lid alignment. Align the luggage compartment lid as necessary.
Refer to: Luggage Compartment Lid Alignment (501-03 Body Closures, General Procedures).

501-05 Interior Trim and Ornamentation 2016 Mustang
A-Pillar Trim Panel - Convertible
Removal
NOTE: RH side shown, LH side similar.
1.
Remove the sun visor.
1. Remove the sun visor cap.
2. Release the clip.
3. Remove the sun visor.
4. If equipped.
Disconnect the electrical connector.
2.
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Remove the A-pillar trim panel.
1. Release the retainers.
2. If equipped.
Disconnect the speaker electrical connector.
3. Release the clips and remove the A-pillar trim panel.
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Installation

A-Pillar Trim Panel - Coupe
Removal
1. Remove the pin-type retainer and position aside the door weatherstrip.
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2.
Remove the A-pillar trim panel.
1. Release the clips and disconnect the tether anchor.
2. If equipped
Disconnect the speaker electrical connector
3. Release the clips and remove the A-pillar trim panel.
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Installation

Front Door Trim Panel
Removal
1. Remove the cover and the upper trim panel bolt.

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2. Remove the front door window control switch.
Refer to: Front Door Window Control Switch (501-11 Glass, Frames and Mechanisms, Removal and Installation).
3. Remove the front door trim panel center bolt.

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4. Remove the front door trim panel lower retainers.
5.
Position the rear upper portion of the front door trim panel away from the door.
2. Release the pin-type retainers.
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6.
Position the rear and lower portion of the front door trim panel away from the door.
1. Release the pin-type retainer.
7.
Position the front door trim panel away from the door.
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8.
Remove the front door trim panel.
1. Lift up and out and release the door trim panel from the door.
2. If equipped.
Disconnect the electrical connectors.
3. Release the latch cable.
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Installation
1. NOTE: Transfer parts as necessary.

Headliner
Materials
Name Specification
3M™ Super-Fast Repair Adhesive -
04747
Removal
On both sides.
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Remove the sun visors.
1. Remove the retainer cap.
2. Release the retainer.
4. If equipped.
2. On both sides, remove the A-pillar trim panels.

Refer to: A-Pillar Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and Installation).
3. Detach the wire harness and electrical connector retainers and disconnect the electrical connector.
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On both sides.
Remove the retainer and the sun visor clip.
5. If equipped.
Disconnect the rear view mirror electrical connector.
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On both sides.
Release the clips, disconnect the tether clip and remove the D-pillar trim panel.
7. On both sides, remove the rear quarter trim panels.

Refer to: Rear Quarter Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
8. On both sides.
Remove the head restraints.
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9. Position both front seats in the full forward and full reclined position.
10. Remove the headliner.

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Installation
1. NOTE: These steps are only necessary when installing a new component.
NOTE: Obtain the specified adhesive commercially. Depending on the headliner and optional wire
harness(es), the purchase of multiple tubes is suggested.
1. Using tape, mark the wire at the exit points for proper length from headliner-to-body/ roof
connectors.
2. Carefully remove the wire harness from the original headliner.
3. Using a marking tool, mark the new headliner with the routing and exit points of the wire harness
from the original headliner.
4. NOTICE: Make sure not to damage the wire harness when cutting the excess adhesive from
the wire harness.
Cut and remove any excess adhesive from the wire harness.
5. Position the wire harness onto the new headliner, making sure the harness has enough length to be
connected to the body/roof connectors at the tape location(s) applied earlier. Apply tape to
temporarily hold the wire harness in position on the headliner.
6. Apply the adhesive in the same location as the factory installed adhesive along the full length of the
wire harness-to-headliner to avoid any NVH concern(s).
Material: 3M™ Super-Fast Repair Adhesive / 04747
2. NOTE: Transfer parts as necessary.

Headliner - Lowering
On both sides.
1. Remove the retainer cap.
2. Release the retainer.
4. If equipped.

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3. Detach the wire harness and electrical connector retainers and disconnect the electrical connector.
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On both sides.
Remove the retainer and the sun visor clip.
5. If equipped.
Disconnect the rear view mirror electrical connector.
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On both sides.
7. On both sides, remove the rear quarter trim panels.

Refer to: Rear Quarter Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
8. Position both front seats in the full forward and full reclined position.
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9. Lower the headliner.

Loadspace Trim Panel - Convertible
Removal
1. Remove the rear seat backrest.

Refer to: Rear Seat Backrest - Convertible (501-10B Rear Seats, Removal and Installation).
2. Position the safety belt guide aside, release the clips and remove the upper loadspace trim panel.
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3.
Remove the middle loadspace trim panel.
1. Release the clips.
2. Pull forward and outward to release the rear tab, position the front and rear safety belts aside and
remove the middle loadspace trim panel.
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4. Release the clips and remove the scuff plate trim panel.
5. Release the clips and remove the lower loadspace trim panel.
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Installation
NOTE: During installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are
accessible to the occupants.

Loadspace Trim Panel - Coupe
Removal
1. Position aside the door weatherstrip.
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2. Release the clips and remove the scuff plate trim panel.

4. Release the latch and position the seat backrest down.
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5. Position aside the safety belt guide, release the clips and remove the loadspace trim panel.
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Installation
NOTE: During installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are

Parcel Shelf - Convertible
Removal
1. On both sides, remove the loadspace trim panels.

Refer to: Loadspace Trim Panel - Convertible (501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. NOTE: LH side shown, RH side similar.
On both sides.
Disconnect the tonneau cover sensor electrical connectors.
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On both sides.
Remove the D-tower covers.
1. Remove the pin-type retainers.
2. Release the clip and remove the cover.
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4. Remove the pin-type retainers and the parcel shelf.
Installation

Parcel Shelf - Coupe
Removal
1. Release the second row seat base floor backrest latch and position the seat backrest in the full flat
position.
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2. On both sides, remove the loadspace trim panels.
Refer to: Loadspace Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and
Installation).
On both sides.
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4. Remove the pin-type retainers and the parcel shelf.
Installation

Rear Quarter Trim Panel
Removal
1. Remove the load space trim panel.

Refer to: Loadspace Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and Installation).
2. Release the clips, disconnect the tether clip and remove the C-pillar trim panel.
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3. Release the tabs and remove the D-ring retainer cover.
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4. Remove the D-ring bolt and position aside the seatbelt.
5.
Remove the rear quarter trim panel.
1. Open the garment hook retainer cover.
2. Remove the retainer and the garment hook.
3. Release the clips and remove the rear quarter trim panel.
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Installation
1. NOTE: During installation, make sure the seatbelt webbing is not twisted and the seatbelts and buckles are

Steering Column Shrouds
Flat-Bladed Screwdriver
Interior Trim Remover
Removal
1. Fully extend and lower the steering column.
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2. Release the tabs and disconnect the upper gap hider from the upper steering column shroud and position aside.
Use the General Equipment: Interior Trim Remover
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3.
Release the upper steering column shroud tabs.
Rotate the steering wheel 90 degrees and release the steering column shroud tab.
Use the General Equipment: Flat-Bladed Screwdriver
Rotate the steering wheel 180 degrees and release the steering column shroud tab.
4. Release the outer clips on each side and remove the upper steering column shroud.
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5. Remove the lower steering column shroud screws and the lower steering column shroud.
Installation
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501-08 Exterior Trim and Ornamentation 2016 Mustang
Luggage Compartment Lid Moulding
Removal
1. Remove the luggage compartment lid trim panel.
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2. Disconnect the rear parking aid camera electrical connector.
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3. Remove the screw covers.
4. Remove the screws.

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5. Disengage the W-clips from the luggage compartment lid moulding using a non-marring trim removal
tool.
Depress molded clips to disengage.
6. Remove the luggage compartment lid moulding.

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7. NOTE: If required, remove the attachment bracket.
Remove the screws.

8. Remove the luggage compartment lid moulding bracket.

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Installation
1. NOTE: Ensure the moulding engages luggage compartment lid bracket before the w-clips engage.
2. If installing a new moulding, configure the rear video camera following the instructions on the scan tool
located using the following path: Electrical> Service Functions>LIN New Module Initialization.

Rear Spoiler
Removal
1. Remove the luggage compartment lid trim panel.
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2. Remover the rubber grommets.
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3. Remove the nuts.
4. NOTE: The rear spoiler uses two-side adhesive tape to fasten the spoiler to the luggage compartment lid.
Lift the rear spoiler to detach from the luggage compartment lid.
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5. Clean any residual adhesive and dirt from the luggage compartment lid surface.
Installation
1. NOTE: When installing the spoiler, apply approximately 15 lbs. of pressure along the length of the spoiler
to ensure adhesion of the two-side tape.

Rocker Panel Moulding
Removal
1. Remove the 3 pushpin type retainers and partially position aside the splash shield.
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2. Remove the pushpin type retainers from the underside of the rocker panel moulding.
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3. 1. Starting at the rear of the rocker panel moulding, detach the retainers from the rocker panel.
2. Disengage the four tab retainers at the fender.
4. Remove the rocker panel moulding.

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Installation

Front Door Upper Moulding
Removal
LH side shown, RH side similar.

Door glass must be in down position.
1. Remove the door sail panel.
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2. NOTE: Rear weatherstrip shown, front is similar.
Position aside the weatherstrip at the front and rear of door to access the fasteners.
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3. Remove the screw at the rear of the upper door moulding.
4. Remove the pin type retainer from the upper door moulding.
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5. NOTICE: Use care when disengaging the retainer tabs on the upper door moulding to avoid
damage to the moulding.
1. Disengage the tabs on the upper door moulding from the door, along the length of the moulding.
2. Slide the upper door moulding rearward past the door sail panel and remove the moulding.
Installation

501-09 Rear View Mirrors 2016 Mustang
Rear View Mirrors - Overview
Overview - Exterior, Power
The power mirror system allows the LH and RH exterior mirror glass to be positioned electronically. The
movement of the exterior mirror glass is controlled by the exterior mirror control switch and the LH or RH mirror
selection buttons determine which exterior mirror glass is controlled. The exterior mirror control switch and the
mirror selection buttons are integral to the LH front window control switch.
Overview - Exterior, Memory
The memory mirror feature allows the driver to recall or save the preferred positioning of the LH and RH exterior
mirror glass. The preferred positioning of the driver seat and exterior mirrors can be associated with a numbered
memory preset button or passive key.
Overview - Exterior, Heated
The exterior mirrors are available with heated mirror glass, which heats the mirror glass to remove frost, snow,
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ice and condensation. The rear window defrost switch controls operation of the heated exterior mirror glass. The
heated exterior mirror glass only operates when the rear window defrost system is active.
Overview - Exterior, Power Folding
The power folding mirror feature allows the exterior mirrors to be electronically folded and unfolded by pressing
the exterior mirror fold switch (integral to the LH front window control switch).
Overview - Exterior, Turn Signal Lamps
The LH and RH exterior mirrors may be equipped with a mirror-mounted turn signal lamps. For repair procedures
and information on the mirror-mounted turn signal lamps,
Refer to: Turn Signal and Hazard Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
Overview - Exterior, Pony Projection Lamps
The LH and RH exterior mirrors may be equipped with pony projection lamps. For repair procedures and
information on the mirror-mounted pony projection lamps,
Refer to: Interior Lighting (417-02 Interior Lighting, Diagnosis and Testing).
Overview - Exterior, BLIS® Light Emitting Diodes (LEDs)
The LH and RH exterior mirrors may be equipped with BLIS® LED. For repair procedures and information on the
mirror-mounted BLIS® Light Emitting Diodes (LEDs),
Refer to: Blind Spot Information System (419-04 Side and Rear Vision, Diagnosis and Testing).
Overview - Interior
This vehicle may be equipped with a manual or auto-dimming interior rear view mirror. The manual dimming interior
mirror has a lever at the bottom of the mirror assembly that must be pushed forward or pulled rearward to change
the reflectance of the interior mirror glass. During nighttime conditions, the auto-dimming interior mirror
automatically darkens the mirror glass when headlamps are detected from behind the vehicle to reduce unwanted
glare. The auto-dimming feature is active any time the ignition is ON.

Rear View Mirrors - System Operation and Component Description
System Operation
System Diagram - Exterior, Power, Without Memory
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System Operation - Exterior, Power, Without Memory
The LH, RH, up or down exterior mirror glass movement is controlled by the exterior mirror control switch, which
supplies voltage and ground to the LH and RH exterior mirror motors. The exterior mirror control switch receives
voltage from the BCM fuse 23 (10A) any time the ignition is on. When the exterior mirror selection switch is in the
LH or RH position and the exterior mirror control switch is pressed left, right, up or down, the switch supplies
voltage and ground to the appropriate exterior mirror motor.
Each exterior mirror shares a common ground circuit for left, right, up and down movement.
System Diagram - Exterior, Power, With Memory

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Module Network Input Messages — PDM

Message Module
Mirror DDM Commands the PDM to initiate the RH exterior mirror glass movments,
command memory save or recall and also used to abort a memory recall that is in
progress.
System Operation - Exterior, Power, With Memory
When a memory recall or save is initiated, the DDM sends the memory command message to the PDM through
the MS-CAN. Based on this message, the DDM and PDM recall the requested memory preset mirror position
from internal memory or save the current mirror position to correspond with the requested preset. During a
memory recall, the DDM and PDM supply voltage and ground to the appropriate exterior mirror motors to achieve
the desired memory positions that are stored in memory based on feedback from the mirror motor sensors. If the
exterior mirror control switch is activated in any direction during a memory recall, the DDM sends the manual
mirror override message to the PDM. After this message is received, the DDM and PDM abort the memory recall.
After the recall is aborted, the DDM or PDM respond to the exterior mirror control switch inputs. A memory recall
is also aborted if the driver seat control switch is activated in any direction during a memory recall.
The LH exterior mirror glass position memory presets are stored in the DDM and the RH exterior mirror glass
position memory presets are stored in the PDM.
A memory recall or memory save can be initiated by the memory set switch, RKE transmitter or Intelligent Access
(IA) key (if equipped) or the keyless entry keypad. For additional information on memory recall or memory save,
refer to the Owner's Literature.
For additional information on the memory feature,

Refer to: Front Seats - System Operation and Component Description (501-10A Front Seats, Description and
Operation).
System Diagram - Exterior, Heated, Without Memory

System Operation - Exterior, Heated, Without Memory
The rear window defrost system controls operation of the heated exterior mirror glass. The heated exterior mirror
glass only operates when the rear window defrost system is active. The heated exterior rear view mirror glass
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deactivates when the rear window defrost deactivates.
The heated mirror glass receives voltage from the rear window defrost relay located inside the BJB. The LH and
RH heated mirror glass does not share the same ground.
System Diagram - Exterior, Heated, With Memory
Module Network Input Messages — DDM and PDM

Mirror heat request FCIM Used to command the heated exterior mirror glass on and off
System Operation - Exterior, Heated, With Memory
The rear window defrost system controls operation of the heated exterior mirror glass. The heated exterior mirror
glass only operates when the rear window defrost system is active. The heated exterior rear view mirror glass
deactivates when the rear window defrost deactivates.
Based on the mirror heat request message received from the FCIM through the MS-CAN, the DDM controls the
operation of the LH heated exterior mirror glass and the PDM controls the operation of the RH heated exterior
mirror glass.
System Diagram - Exterior, Power Fold
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System Operation - Exterior, Power Fold
The power folding exterior mirror feature allows both power exterior rear view mirrors to be folded or unfolded by
pressing the exterior mirror fold switch (integral to the LH front window control switch). The power folding exterior
mirrors are controlled by the power folding mirror relay. When the ignition is on and a mirror fold is initiated by
pressing the exterior mirror fold switch, the exterior mirror control switch sends a ground signal to the power
folding mirror relay. The power folding mirror relay activate the power folding mirrors in the opposite direction of
the last activation. The power folding mirror relay controls movement by reversing the polarity of the voltage and
ground it supplies to the power folding mirror motors. The RH and LH power folding mirrors fold or unfold at the
same time and cannot be controlled independently. The power folding mirrors contain a drive motor that is not
replaceable. If a power folding mirror drive motor is found to be inoperative, a new power folding exterior rear
view mirror assembly must be installed.
NOTE: If the power folding mirrors are folded or unfolded several times continuously, the power lockout feature
disables the system for approximately 3-10 minutes to prevent damage to the power fold motors. After 3-10
minutes have elapsed, normal operation resumes.
NOTE: The power folding mirrors may need to be synchronized when the LH, RH or both power folding mirrors
are partially folded in toward the door manually, and then folded inward using the power folding mirror control
switch. Refer to Power Folding Mirrors Synchronization in this section.
System Operation- Interior Manual-Dimming
The manual interior rear view mirror can be adjusted from a day position to a night position to reduce unwanted
glare caused by headlamps from behind the vehicle. Adjusting the interior mirror is accomplished by using the
day/night tab, located on the bottom of the interior mirror. Pulling the tab rearward, towards the driver, adjusts the
mirror to the night position. Pushing the tap forward, away from the driver, adjusts the mirror to the day position.
System Operation- Interior Auto-Dimming
The interior auto-dimming mirror uses 2 integral photoelectric sensors to detect exterior lighting conditions. When
the forward facing sensor detects daytime conditions, the rearward facing sensor is inactive and the mirror glass
stays in a high reflectance mode. When the forward facing sensor detects nighttime conditions, the rearward
facing sensor is active. When bright lights (glare) are detected by the rearward facing sensor, the mirror glass is
electronically darkened. To provide increased visibility when backing up, the interior rear view mirror automatically
returns to a high reflectance mode any time reverse gear is selected, regardless of exterior lighting conditions.
Exterior Mirror Control Switch
The exterior mirror control switch is a momentary contact switch, integral to the LH front window control switch,
that provides the driver with the controls to move the LH and RH exterior rear view mirrors left, right, up or down.
The LED on each exterior mirror selection button illuminates to indicate which exterior mirror is selected for
adjustment.
On vehicles equipped with the memory mirror feature, the exterior mirror control switch is connected to the DDM
through a LIN circuit.
On vehicles without the memory mirror feature, the exterior mirror control switch provides voltage and ground to
the selected exterior mirror motor to move the exterior mirror glass to the desired position.
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Exterior Mirror Fold Switch
The exterior mirror fold switch is a momentary contact switch, integral to the LH front window control switch, that
sends a ground signal to the power folding mirror relay to fold or unfold the exterior rear view mirrors to the
desired position.
Memory Set Switch
The memory set switch contains 3 momentary contact switches. It is hard-wired to the DDM and is used to recall
1 of 3 memory positions stored in the DSM. For more information on the memory set switch,
Refer to: Front Seats - System Operation and Component Description (501-10A Front Seats, Description and
Operation).
Exterior Mirror
Each exterior mirror has 2 bi-directional motors that are used to control the position of the exterior mirror glass.
The sensors used to monitor the mirror glass position are integral to the motors.
If equipped with heated mirrors, the heated exterior mirrors use heating elements that are integral to the exterior
mirror glass.
If equipped with power folding mirrors, each exterior mirror has an integral, bi-directional folding motor that is
used to fold and unfold the exterior mirror.
If equipped with exterior mirrors that include turn signal indicators and/or puddle lamps,
Refer to: Exterior Lighting - System Operation and Component Description (417-01 Exterior Lighting, Description
and Operation).
If equipped with exterior mirrors that include blind spot monitoring (BLIS),
Refer to: Blind Spot Information System - System Operation and Component Description (419-04 Side and Rear
Vision, Description and Operation).
The exterior mirrors use a jumper harness between the vehicle wiring harness, the exterior mirror motors and the
heated mirror glass. The exterior mirror jumper harness is integral to the exterior mirror. Before replacing an
exterior mirror or motor, inspect the jumper harness for opens, shorted circuits or damaged and pushed-out pins.
If a concern with the exterior mirror jumper harness exists, attempt to repair the jumper harness.
DDM
On vehicles equipped with the memory mirrors feature, the DDM monitors the exterior mirror control switch
through a LIN circuit. The DDM is responsible for supplying voltage and ground to the LH exterior mirror motors,
LH exterior mirror motor sensors and LH exterior mirror glass heating element.
The DDM sends the RH exterior mirror movement request to the PDM through the MS-CAN.
PDM
On vehicles equipped with the memory mirrors feature, the PDM is responsible for supplying voltage and ground
to the RH exterior mirror motors, RH exterior mirror motor sensors and RH exterior mirror glass heating element.
Interior Rear View Mirror - Manual-Dimming
The manual dimming interior rear view mirror has a lever at the back of the mirror that must be pulled forward or
pushed rearward by the driver to activate the manual dimming function. Manual dimming is completely controlled
by the driver.
Interior Rear View Mirror - Auto-Dimming
The auto-dimming rear view mirror has 2 photoelectric sensors, one on the front of the mirror (facing the
windshield) and one on the rear of the mirror (at the top of the mirror glass). Based on inputs from these sensors,
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.
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Rear View Mirrors
DTC Chart: DDM

B1163:11 Left Mirror Heater Output: Circuit GO to Pinpoint Test E
Short To Ground
B1163:15 Left Mirror Heater Output: Circuit GO to Pinpoint Test E
Short To Battery Or Open
B1C09:11 Driver Left/Right Mirror Motor: GO to Pinpoint Test C
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Circuit Short To Ground
B1C09:15 Driver Left/Right Mirror Motor: GO to Pinpoint Test C
Circuit Short To Battery Or Open
B1C10:11 Driver Up/Down Mirror Motor: GO to Pinpoint Test C
B1C10:15 Driver Up/Down Mirror Motor: GO to Pinpoint Test C
B1C13:11 Driver Up/Down Mirror Motor GO to Pinpoint Test C
Feedback: Circuit Short To
Ground
B1C13:15 Driver Up/Down Mirror Motor GO to Pinpoint Test C
Battery Or Open
B1C14:11 Driver Left/Right Mirror Motor GO to Pinpoint Test C
Ground
B1C14:15 Driver Left/Right Mirror Motor GO to Pinpoint Test C
Battery Or Open
C1B15:11 Sensor Supply Voltage B: Circuit GO to Pinpoint Test C
Short To Ground
C1B15:15 Sensor Supply Voltage B: Circuit GO to Pinpoint Test C
Short To Battery or Open
All other DDM -
Diagnostic Trouble REFER to: Locks, Latches and Entry Systems
Codes (DTCs) (501-14 Handles, Locks, Latches and Entry
Systems, Diagnosis and Testing).
DTC Chart: PDM
B1164:11 Right Mirror Heater Output: Circuit GO to Pinpoint Test E
Short To Ground
B1164:15 Right Mirror Heater Output: Circuit GO to Pinpoint Test E
Short To Battery Or Open
B1C11:11 Passenger Left/Right Mirror Motor: GO to Pinpoint Test D
B1C11:15 Passenger Left/Right Mirror Motor: GO to Pinpoint Test D
B1C12:11 Passenger Up/Down Mirror Motor: GO to Pinpoint Test D
B1C12:15 Passenger Up/Down Mirror Motor: GO to Pinpoint Test D
B1C15:11 Passenger Up/Down Mirror Motor GO to Pinpoint Test D
Feedback: Circuit Short To Ground
B1C15:15 Passenger Up/Down Mirror Motor GO to Pinpoint Test D
Feedback: Circuit Short To Battery
Or Open
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B1C16:11 Passenger Left/Right Mirror Motor GO to Pinpoint Test D
Feedback: Circuit Short To Ground
B1C16:15 Passenger Left/Right Mirror Motor GO to Pinpoint Test D
Feedback: Circuit Short To Battery
Or Open
C1B15:11 Sensor Supply Voltage B: Circuit GO to Pinpoint Test D
Short To Ground
C1B15:15 Sensor Supply Voltage B: Circuit GO to Pinpoint Test D
All other PDM -
Diagnostic Trouble REFER to: Locks, Latches and Entry Systems
Codes (DTCs) (501-14 Handles, Locks, Latches and Entry
Symptom Chart(s)
Symptom Chart: Rear View Mirrors - Exterior
NOTE: Clean the entire mirror assembly and glass to assist in verification of the customer concern and/or
impact damage. Do not clean any mirror glass or housing with an ice scraper, razor blade, abrasive pad, harsh
chemicals or petroleum based cleaning products, as these may damage the mirror glass and/or housing.
Condition Possible Causes Action

The exterior mirror(s) fold Power folding mirrors For vehicles equipped with power folding
inward due to wind pressure are not synchronized mirror, SYNCHRONIZE the power folding
(vehicles equipped with mirrors.
folding mirrors only) If the concern is still present after
Mirror structural bracket the power folding mirrors
is damaged synchronization procedure was
performed, INSPECT the mirror for
structural damage. If necessary,
INSTALL a new mirror.
REFER to: Exterior Mirror (501-09
Rear View Mirrors, Removal and
Installation).
For vehicles not equipped with power
folding mirror, INSPECT the mirror for
structural damage. If necessary, INSTALL
a new mirror.
REFER to: Exterior Mirror (501-09 Rear
View Mirrors, Removal and Installation).
The LH or RH exterior mirror Exterior mirror selection switch INSTALL a new front door window control switch.
selection switch LED is REFER to: Front Door Window Control Switch
inoperative (exterior mirror (501-11 Glass, Frames and Mechanisms,
selection switch functions Removal and Installation).
normally)
A single mirror is inoperative Refer to the Pinpoint Test GO to Pinpoint Test A
(without memory mirrors)
A single mirror does not Refer to the Pinpoint Test GO to Pinpoint Test B
function correctly in all
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directions (without memory
mirrors)
Both exterior mirrors are Wiring, terminals or VERIFY that all power windows can be
inoperative (without memory connectors operated normally from the LH front door
mirrors) Power window concern window control switch.
Exterior mirror control If all power windows operate
switch (integral to the normally from the LH front door
front door window window control switch, INSTALL a
control switch) new LH front door window control
switch.
REFER to: Front Door Window
Control Switch (501-11 Glass,
Frames and Mechanisms, Removal
and Installation).
If all power window do not operate
normally from the LH front door
window control switch, DIAGNOSE
the power windows before
continuing diagnostics of the
exterior mirrors.
REFER to: Glass, Frames and
Mechanisms (501-11 Glass,
Frames and Mechanisms, Diagnosis
and Testing).
Both exterior mirrors are Wiring, terminals or VERIFY that all power windows can be
inoperative (with memory connectors operated normally from the LH front door
mirrors) Power window concern window control switch.
Exterior mirror control If all power windows operate
switch (integral to the normally from the LH front door
front door window window control switch, INSTALL a
control switch) new LH front door window control
DDM switch.
REFER to: Front Door Window
Control Switch (501-11 Glass,
Frames and Mechanisms, Removal
and Installation).
If the concern is the same after
installing a new LH front door
window control switch, INSTALL a
new DDM.
REFER to: Driver Door Module
(DDM) (419-10 Multifunction
Electronic Modules, Removal and
Installation).
If all power window do not operate
normally from the LH front door
window control switch, DIAGNOSE
the power windows before
continuing diagnostics of the
exterior mirrors.
REFER to: Glass, Frames and
Mechanisms (501-11 Glass,
Frames and Mechanisms, Diagnosis
and Testing).
The LH exterior mirror is Refer to the Pinpoint Test GO to Pinpoint Test C

inoperative (with memory
mirrors)
The LH exterior mirror does Refer to the Pinpoint Test GO to Pinpoint Test C
not operate correctly in all
directions (with memory
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mirrors)
The RH exterior mirror is Refer to the Pinpoint Test GO to Pinpoint Test D
inoperative (with memory
mirrors)
The RH exterior mirror does Refer to the Pinpoint Test GO to Pinpoint Test D
not operate correctly in all
directions (with memory
mirrors)
The LH or RH heated Refer to the Pinpoint Test GO to Pinpoint Test E
exterior mirror is inoperative
or always on (with memory
mirrors)
One or both heated exterior Refer to the Pinpoint Test GO to Pinpoint Test F
mirrors are inoperative
(without memory mirrors)
Both heated exterior mirrors Refer to the Pinpoint Test DIAGNOSE the rear window defrost system.
are always on (without REFER to: Glass, Frames and Mechanisms
memory mirrors) (501-11 Glass, Frames and Mechanisms,
The LH and RH heated Normal operation of the heated No action required, the system is operating
exterior mirrors do not exterior mirror correctly at this time.
defrost at the same rate
The LH and/or RH power Refer to the Pinpoint Test GO to Pinpoint Test G
folding mirror is
inoperative/does not operate
correctly (if equipped)
The RH and LH power Normal operation of the power No action required, the system is operating
folding mirror do not fold folding mirror correctly at this time.
and/or unfold at the same
rate of speed (if equipped)
The projector lamp is Wiring, terminals or
inoperative or always on connectors REFER to: Interior Lighting (417-02 Interior
Projector lamp Lighting, Diagnosis and Testing).
BCM
The exterior mirror turn Wiring, terminals or
indicator is inoperative or connectors REFER to: Turn Signal and Hazard Lamps
always on Communication concern (417-01 Exterior Lighting, Diagnosis and Testing).
(vehicles with memory
mirrors)
Turn indicator
Door module (vehicles
with memory mirrors)
BCM
The Blind Spot Information Wiring, terminals or

System (BLIS®) indicator is connectors REFER to: Blind Spot Information System
inoperative or always on Exterior mirror glass (419-04 Side and Rear Vision, Diagnosis and
Side obstacle detection Testing).
control module
Symptom Chart: Rear View Mirrors - Interior
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The interior mirror is Interior mirror CLEAN the affected interior mirror surface.
blemished glass/housing is
dirty
The interior mirror Interior mirror If the mirror is still on the windshield, do not remove. ATTEMPT
vibrates or is loose mounting loose to fully seat the mirror first. If the mirror is still loose or vibrates,
REMOVE and REINSTALL the mirror. If the condition still exists,
INSTALL a new interior mirror.
REFER to: Interior Rear View Mirror (501-09 Rear View Mirrors,
The interior Refer to the GO to Pinpoint Test H
auto-dimming mirror Pinpoint Test
does not operate
correctly
Symptom Chart: Rear View Mirrors - Exterior NVH

Exterior Power folding mirrors SYNCHRONIZE the power folding mirrors.
mirror are not synchronized
housing (if equipped)
vibrates or is
loose Exterior mirror TIGHTEN the exterior mirror mounting nuts.
mounting nuts loose REFER to: Exterior Mirror (501-09 Rear View Mirrors, Removal
and Installation).
Aftermarket air If possible, REMOVE the aftermarket parts and ROAD TEST the
deflector/stone vehicle. If the concern is no longer present, ADVISE the customer
shields that the aftermarket components were causing the undesired
vibration.
Exterior Exterior mirror motor PRESS the center of the exterior mirror glass up, down, left and
mirror glass mounting screws right to make sure the exterior mirror glass is seated correctly. If
vibrates or is loose the exterior mirror glass is still loose, REMOVE the exterior mirror
loose Exterior mirror glass glass. INSPECT the exterior mirror backing plate for damage.
loose INSPECT the exterior mirror motor mounting screws and TIGHTEN
if necessary. If the exterior mirror backing plate is damaged,
INSTALL a new exterior mirror glass.
REFER to: Exterior Mirror (501-09 Rear View Mirrors, Removal
and Installation).
Wind noise Foam gasket between VERIFY the gasket is in good condition. If necessary,
exterior mirror housing and REPOSITION the gasket between the exterior mirror housing and
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door is misaligned or the door. The foam gasket is not serviceable and if it cannot be
damaged repaired, INSTALL a new exterior mirror.
and Installation).
Exterior mirror is not VERIFY there are no gaps between the exterior mirror and the
correctly fitted to the door door. If necessary, LOOSEN the exterior mirror nuts and
REPOSITION the exterior mirror as necessary.
and Installation).
Exterior mirror impact INSPECT the exterior mirror to ensure that there is no damage to
damage the housing or glass.
Pinpoint Tests
A Single Mirror Is Inoperative (Without Memory Mirrors)
The exterior mirror control switch supplies voltage and ground to the exterior mirror motors based on switch
inputs. Each exterior mirror shares a common circuit for both up/down and left/right movement.
Possible Causes

Exterior mirror control switch (integral to the front door window control switch)
Exterior mirror
Visual Inspection and Diagnostic Pre-Checks
Inspect the suspect exterior mirror for damage or obstructions.
PINPOINT TEST A : A SINGLE MIRROR IS INOPERATIVE (WITHOUT MEMORY MIRRORS)
NOTICE: The following step uses a test lamp to simulate normal circuit loads. To avoid connector
terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle.
Do not use the test lamp probe directly on any connector.
A1 CHECK THE EXTERIOR MIRROR
Ignition OFF.
Disconnect: inoperative exterior mirror C520 (LH exterior mirror) or C626 (RH exterior mirror).
Ignition ON.
Select the inoperative exterior mirror by pressing the appropriate exterior mirror selection switch.
Connect:

LH exterior mirror
Lead 1 Measurement / Action Lead 2

C520-1 C520-2
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RH exterior mirror

C626-1 C626-2
Observe the test light while holding the exterior mirror control switch in the up position.
Did the test light illuminate?
Yes CHECK the inoperative exterior mirror jumper harness between the vehicle harness and
the exterior mirror motor for open circuits and damaged or pushed-out pins. If the jumper
harness is not OK, REPAIR the jumper harness. If the jumper harness cannot be repaired,
INSTALL a new exterior mirror.
REFER to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
No GO to A2
A2 CHECK THE EXTERIOR MIRROR MOTOR COMMON CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect: Front Door Window Control Switch C504.
Measure:

LH exterior mirror

C520-2 C504-12
RH exterior mirror

C626-2 C504-12
Yes INSTALL a new exterior mirror control switch (integral to the front door window control
switch).
REFER to: Front Door Window Control Switch (501-11 Glass, Frames and Mechanisms,
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A Single Mirror Does Not Function Correctly In All Directions (Without Memory Mirrors)
The exterior mirror control switch supplies voltage and ground to the appropriate exterior mirror motors based on
switch inputs. Each exterior mirror shares a common circuit for both up/down and left/right movement.
Possible Causes

Exterior mirror motor
Exterior mirror
Inspect the exterior mirror control switch.

Inspect the suspect exterior mirror for damage or obstructions.
PINPOINT TEST B : A SINGLE MIRROR DOES NOT FUNCTION CORRECTLY IN ALL DIRECTIONS
(WITHOUT MEMORY MIRRORS)
B1 CHECK THE EXTERIOR MIRROR LEFT AND RIGHT MOVEMENT
Ignition ON.
Operate the LH and RH exterior mirrors in the left and right direction using the exterior mirror control
switch.
Do both exterior mirrors move left and right?

Yes GO to B2
No GO to B6
B2 CHECK THE EXTERIOR MIRROR UP/DOWN MOTOR

Ignition OFF.
Disconnect: incorrectly operating C520 (LH exterior mirror) or C626 (RH exterior mirror).
Ignition ON.
Select the incorrectly operating mirror on the exterior mirror control switch.
Connect:

LH exterior mirror

C520-1 C520-2
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RH exterior mirror

C626-1 C626-2
Observe the test light while using the exterior mirror control switch in the up, down and released
positions.
Did the test light illuminate in the up and down position and not illuminate in the released position?
Yes GO to B10
No GO to B3
B3 CHECK THE EXTERIOR MIRROR UP/DOWN CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Ignition ON.
Measure:

LH exterior mirror

C520-1 Ground

RH exterior mirror

C626-1 Ground

No GO to B4
B4 CHECK THE EXTERIOR MIRROR UP/DOWN CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

LH exterior mirror
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C520-1 Ground

RH exterior mirror

C626-1 Ground
Yes GO to B5
B5 CHECK THE EXTERIOR MIRROR UP/DOWN CIRCUIT FOR AN OPEN

Measure:

LH exterior mirror

C520-1 C504-9
RH exterior mirror

C626-1 C504-7
switch).
B6 CHECK THE EXTERIOR MIRROR LEFT/RIGHT MOTOR

Ignition OFF.
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Disconnect: incorrectly operating C520 (LH exterior mirror) or C626 (RH exterior mirror).
Ignition ON.
Select the incorrectly operating mirror on the exterior mirror control switch.
Connect:

LH exterior mirror

C520-4 C520-2

RH exterior mirror

C626-4 C626-2
Observe the test light while using the exterior mirror control switch in the left, right and released positions.
Did the test light illuminate in the right and left position and not illuminate in the released position?
Yes GO to B10
No GO to B7
B7 CHECK THE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Ignition ON.
Measure:

LH exterior mirror

C520-4 Ground

RH exterior mirror

C626-4 Ground
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No GO to B8
B8 CHECK THE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

LH exterior mirror

C520-4 Ground

RH exterior mirror

C626-4 Ground
Yes GO to B9
B9 CHECK THE EXTERIOR MIRROR LEFT/RIGHT CIRCUIT FOR AN OPEN
Measure:

LH exterior mirror

C520-4 C504-8

RH exterior mirror

C626-4 C504-6
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switch).
B10 CHECK THE EXTERIOR MIRROR JUMPER HARNESS

Inspect the exterior mirror jumper harness between the vehicle harness and the exterior mirror motor for:
Open or short circuits
Damaged or pushed out pins
Corrosion
Is the harness OK?
Yes INSTALL a new exterior mirror motor.
No REPAIR the harness as necessary. If the harness cannot be repaired, INSTALL a new
exterior mirror.
The LH Exterior Mirror Is Inoperative Or Does Not Operate Correctly In One Or More Direction(s) (With
Memory Mirrors)

The DDM supplies voltage and ground to the LH exterior mirror motors based on input provided by the exterior
mirror control switch. To support the memory function, the DDM supplies a 5 volt reference and ground to the
mirror motor sensors. The DDM monitors the feedback voltage from the horizontal and vertical sensors to
determine the position of the LH mirror glass. The DDM is capable of storing Diagnostic Trouble Codes (DTCs)
for the LH exterior mirror motor drive and mirror position feedback circuits when a concern exists.

B1C09:11 Driver Left/Right Mirror Motor: This continuous and on-demand DTC sets if the DDM detects a
Circuit Short To Ground higher than expected current draw when voltage is applied to the
horizontal mirror motor circuit.
B1C09:15 Driver Left/Right Mirror Motor: This continuous and on-demand DTC sets if the DDM detects a
Circuit Short To Battery Or Open lower than expected current draw when voltage is applied to the
B1C10:11 Driver Up/Down Mirror Motor: This continuous and on-demand DTC sets if the DDM detects a
Circuit Short To Ground higher than expected current draw when voltage is applied to the
vertical mirror motor circuit.
B1C10:15 Driver Up/Down Mirror Motor: This continuous and on-demand DTC sets if the DDM detects a
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B1C13:11 Driver Up/Down Mirror Motor This continuous and on-demand DTC sets if the DDM detects a
Feedback: Circuit Short To short to ground on the vertical position feedback circuit.
Ground
B1C13:15 Driver Up/Down Mirror Motor This continuous and on-demand DTC sets if the DDM detects a
Feedback: Circuit Short To short to voltage or open on the vertical position feedback circuit.
Battery Or Open
B1C14:11 Driver Left/Right Mirror Motor This continuous and on-demand DTC sets if the DDM detects a
Feedback: Circuit Short To short to ground on the horizontal position feedback circuit.
Ground
B1C14:15 Driver Left/Right Mirror Motor This continuous and on-demand DTC sets if the DDM detects a
Feedback: Circuit Short To short to voltage or open on the horizontal position feedback
Battery Or Open circuit.
C1B15:11 Sensor Supply Voltage B: Circuit This continuous and on-demand DTC sets if the DDM detects a
Short To Ground short to ground on the LH exterior mirror position sensor voltage
supply circuit.
C1B15:15 Sensor Supply Voltage B: Circuit This continuous and on-demand DTC sets if the DDM detects a
Short To Battery or Open short to voltage or open on the LH exterior mirror position sensor
voltage supply circuit.
Possible Causes

Exterior mirror
DDM
Inspect BJB fuse 11 (30A).
PINPOINT TEST C : THE LH (LEFT-HAND) EXTERIOR MIRROR IS INOPERATIVE OR DOES NOT

OPERATE CORRECTLY IN ONE OR MORE DIRECTION(S) (WITH MEMORY MIRRORS)
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may cause damage to the connector. Use only Rotunda Flex Probes (NUD105-
R025D)
C1 CHECK THE DDM (DRIVER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform the DDM self-test.
Are any Diagnostic Trouble Codes (DTCs) present?
Yes For Diagnostic Trouble Codes (DTCs) B1C09:11 or B1C09:15, GO to C15

For Diagnostic Trouble Codes (DTCs) B1C10:11 or B1C10:15, GO to C19
For Diagnostic Trouble Codes (DTCs) B1C13:11, B1C13:15, B1C14:11, B1C14:15,
C1B15:11, or C1B15:15, GO to C8
For all other DDM Diagnostic Trouble Codes (DTCs),
REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
No GO to C2
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C2 CHECK THE EXTERIOR MIRROR SELECTION SWITCH
Using a diagnostic scan tool, monitor the MIR_SEL DDM Parameter Identification (PID).
Operate the exterior mirror selection buttons to select the LH and then RH exterior mirrors.
Does the MIR_SEL DDM Parameter Identification (PID) match the selector switch in both positions?
Yes GO to C3
No INSTALL a new front door window control switch.
C3 CHECK THE EXTERIOR MIRROR CONTROL SWITCH

Using a diagnostic scan tool, monitor the MIR_SW_DN, MIR_SW_UP, MIR_SW_L, and MIR_SW_R DDM
Parameter Identifications (PIDs).
Press the exterior mirror control switch in the left, right, up and down directions.
Do the DDM Parameter Identifications (PIDs) match the control switch in all directions?
Yes GO to C4
C4 CHECK THE LH (LEFT-HAND) MIRROR COMMON CIRCUIT FOR VOLTAGE AT THE LH

(LEFT-HAND) EXTERIOR MIRROR
Ignition OFF.
Disconnect: LH Exterior Mirror C520.
Connect:

C520-2 Ground
Ignition ON.
Select the LH mirror with the exterior mirror selection switch.
Monitor the test light while pressing the exterior mirror control switch in the left and down directions.
Does the test light illuminate only when the exterior mirror control switch is pressed in the left and
down directions?
Yes GO to C24
No If the test light is illuminated when the exterior mirror control switch is not pressed in any
direction, GO to C5
If the test light does not illuminate when the exterior mirror control switch is pressed in the
left and down directions, GO to C6
C5 CHECK THE COMMON CIRCUIT FOR A SHORT TO VOLTAGE AT THE LH (LEFT-HAND)

EXTERIOR MIRROR
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Ignition OFF.
Disconnect: DDM C501B.
Ignition ON.
Measure:

C520-2 Ground

No GO to C23
C6 CHECK THE COMMON CIRCUIT FOR AN OPEN BETWEEN THE LH (LEFT-HAND) EXTERIOR
MIRROR AND THE DDM (DRIVER DOOR MODULE)
Ignition OFF.
Measure:

C520-2 C501B-17
Yes GO to C7
C7 CHECK THE COMMON CIRCUIT FOR A SHORT TO GROUND AT THE LH (LEFT-HAND)
EXTERIOR MIRROR
Measure:

C520-2 Ground
Yes GO to C23
C8 CHECK THE POSITION SENSOR CIRCUITS FOR A SHORT TO VOLTAGE AT THE LH
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Ignition OFF.
Ignition ON.
Measure:

C520-12 Ground
C520-10 Ground
C520-9 Ground
C520-8 Ground
Yes REPAIR the affected circuit.

No GO to C9
C9 CHECK THE POSITION SENSOR CIRCUITS FOR A SHORT TO GROUND AT THE LH

Ignition OFF.
Measure:

C520-10 Ground
C520-9 Ground
C520-8 Ground
Yes GO to C10
C10 CHECK THE POSITION SENSOR CIRCUITS FOR AN OPEN BETWEEN THE LH (LEFT-HAND)
EXTERIOR MIRROR AND THE DDM (DRIVER DOOR MODULE)
Measure:

C520-12 C501B-15
C520-10 C501B-6
C520-9 C501B-5
C520-8 C501B-16
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Yes GO to C11
C11 CHECK THE MIRROR POSITION SENSOR REFERENCE VOLTAGE AT THE LH (LEFT-HAND)
EXTERIOR MIRROR
Connect: DDM C501B.
Ignition ON.
Measure:

C520-9 C520-12
Is the voltage approximately 5 volts?
Yes GO to C12
No GO to C23
C12 CHECK THE DDM (DRIVER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS) WITH
THE LH (LEFT-HAND) EXTERIOR MIRROR DISCONNECTED
Using a diagnostic scan tool, clear the DDM Diagnostic Trouble Codes (DTCs).
Perform the DDM self-test.
Is DTC B1C13:15 or B1C14:15 present?

Yes GO to C13
No GO to C23
THE HORIZONTAL POSITION SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND
Ignition OFF.
Connect:

C520-10 C520-12
Ignition ON.
Is DTC B1C14:11 present?
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Yes REMOVE the jumper wire. GO to C14
No REMOVE the jumper wire. GO to C23
THE VERTICAL POSITION SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND
Ignition OFF.
Connect:

C520-8 C520-12
Ignition ON.
Yes REMOVE the jumper wire. GO to C24

No REMOVE the jumper wire. GO to C23
C15 CHECK FOR VOLTAGE TO THE HORIZONTAL MOTOR CIRCUIT AT THE LH (LEFT-HAND)
EXTERIOR MIRROR
Ignition OFF.
Connect:

C520-4 Ground
Ignition ON.
Select the LH mirror on the exterior mirror selection switch.
Monitor the test light while pressing the exterior mirror control switch in the right direction.
Does the test light illuminate only when the exterior mirror control switch is pressed in the right
direction?
Yes GO to C24
direction, GO to C16
right direction, GO to C17
C16 CHECK THE HORIZONTAL MIRROR CIRCUIT FOR A SHORT TO VOLTAGE AT THE LH
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Ignition OFF.
Ignition ON.
Measure:

C520-4 Ground

No GO to C23
C17 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR A SHORT TO GROUND AT THE LH
Ignition OFF.
Measure:

C520-4 Ground
Yes GO to C18
C18 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN OPEN BETWEEN THE LH (LEFT-HAND)
Measure:

C520-4 C501B-8
Yes GO to C23
C19 CHECK FOR VOLTAGE TO THE VERTICAL MOTOR CIRCUIT AT THE LH (LEFT-HAND)
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EXTERIOR MIRROR
Ignition OFF.
Connect:

C520-1 Ground
Ignition ON.
Select the LH mirror on the exterior mirror selection switch.
Monitor the test light while pressing the exterior mirror control switch in the up direction.
Does the test light illuminate only when the exterior mirror control switch is pressed in the up
direction?
Yes GO to C24
direction, GO to C20
up direction, GO to C21
C20 CHECK THE VERTICAL MIRROR CIRCUIT FOR A SHORT TO VOLTAGE AT THE LH
Ignition OFF.
Ignition ON.
Measure:

C520-1 Ground

No GO to C23
C21 CHECK THE VERTICAL MOTOR CIRCUIT FOR A SHORT TO GROUND AT THE LH
Ignition OFF.
Measure:

C520-1 Ground
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Yes GO to C22
C22 CHECK THE VERTICAL MOTOR CIRCUIT FOR AN OPEN BETWEEN THE LH (LEFT-HAND)
Measure:

C520-1 C501B-7
Yes GO to C23
C23 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Disconnect and inspect all DDM connectors.
Repair:
Reconnect the DDM connectors and all previously disconnected exterior mirror system connectors. Make
sure they seat and latch correctly.
Operate the system to determine if the concern is still present.

this concern, DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical
Service Bulletins (TSBs) address this concern, INSTALL a new DDM.
REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal
and Installation).
C24 CHECK THE EXTERIOR MIRROR JUMPER HARNESS

Inspect the exterior mirror jumper harness between the vehicle harness and the mirror motors for:
Corrosion
Is the harness OK?
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exterior mirror.
The RH Exterior Mirror Is Inoperative Or Does Not Operate Correctly In One Or More Direction(s) (With
Memory Mirrors)
The PDM supplies voltage and ground to the RH exterior mirror motors based on input provided by the exterior
mirror control switch. To support the memory function, the PDM supplies a 5 volt reference and ground to the
mirror motor sensors. The PDM monitors the feedback voltage from the horizontal and vertical sensors to
determine the position of the RH mirror glass. The PDM is capable of storing Diagnostic Trouble Codes (DTCs)
for the RH exterior mirror motor drive and mirror position feedback circuits when a problem exists.

B1C11:11 Passenger Left/Right Mirror Motor: This continuous and on-demand DTC sets if the PDM detects a
Circuit Short To Ground higher than expected current draw when voltage is applied to
the horizontal mirror motor circuit.
B1C11:15 Passenger Left/Right Mirror Motor: This continuous memory DTC sets if the PDM detects a lower
Circuit Short To Battery Or Open than expected current draw when voltage is applied to the
B1C12:11 Passenger Up/Down Mirror Motor: This continuous memory DTC sets if the PDM detects a higher
Circuit Short To Ground than expected current draw when voltage is applied to the
B1C12:15 Passenger Up/Down Mirror Motor: This continuous and on-demand DTC sets if the PDM detects a
B1C15:11 Passenger Up/Down Mirror Motor This continuous and on-demand DTC sets if the PDM detects a
Feedback: Circuit Short To Ground short to ground on the vertical position feedback circuit.
B1C15:15 Passenger Up/Down Mirror Motor This continuous and on-demand DTC sets if the PDM detects a
Feedback: Circuit Short To Battery short to voltage or open on the vertical position feedback circuit.
Or Open
B1C16:11 Passenger Left/Right Mirror Motor This continuous and on-demand DTC sets if the PDM detects a
Feedback: Circuit Short To Ground short to ground on the horizontal position feedback circuit.
B1C16:15 Passenger Left/Right Mirror Motor This continuous and on-demand DTC sets if the PDM detects a
Feedback: Circuit Short To Battery short to voltage or open on the horizontal position feedback
Or Open circuit.
C1B15:11 Sensor Supply Voltage B: Circuit This continuous and on-demand DTC sets if the PDM detects a
Short To Ground short to ground on the RH exterior mirror position sensor
voltage supply circuit.
C1B15:15 Sensor Supply Voltage B: Circuit This continuous and on-demand DTC sets if the PDM detects a
Short To Battery or Open short to voltage or open on the RH exterior mirror position
sensor voltage supply circuit.
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Possible Causes

Exterior mirror
PDM
Inspect BCM fuse 26 (30A).
PINPOINT TEST D : THE RH (RIGHT-HAND) EXTERIOR MIRROR IS INOPERATIVE OR DOES NOT

OPERATE IN ONE OR MORE DIRECTION(S) (WITH MEMORY MIRRORS)
R025D)
D1 PERFORM A NETWORK TEST
Ignition ON.
Do the DDM and PDM pass the network test?
Yes GO to D2
No
D2 CHECK THE PDM (PASSENGER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, perform the PDM self-test.
Yes For Diagnostic Trouble Codes (DTCs) B1C11:11 or B1C11:15, GO to D16

For Diagnostic Trouble Codes (DTCs) B1C12:11 or B1C12:15, GO to D20
For Diagnostic Trouble Codes (DTCs) B1C15:11, B1C15:15, B1C16:11, B1C16:15,
C1B15:11, or C1B15:15, GO to D9
For all other PDM Diagnostic Trouble Codes (DTCs),
No GO to D3
D3 CHECK THE EXTERIOR MIRROR SELECTION SWITCH

Using a diagnostic scan tool, monitor the MIR_SEL DDM Parameter Identification (PID).
Operate the exterior mirror selection buttons to select the LH and then RH exterior mirrors.
Does the MIR_SEL DDM Parameter Identification (PID) match the selector switch in both positions?
Yes GO to D4
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D4 CHECK THE EXTERIOR MIRROR CONTROL SWITCH

Select the RH mirror with the exterior mirror selection switch.
Using a diagnostic scan tool, monitor the MIR_SW_DN, MIR_SW_UP, MIR_SW_L, and MIR_SW_R DDM
Parameter Identifications (PIDs).
Press the exterior mirror control switch in the left, right, up and down directions.
Do the MIR_SW_DN, MIR_SW_UP, MIR_SW_L, and MIR_SW_R DDM Parameter Identifications (PIDs)
match the control switch in all directions?
Yes GO to D5
D5 CHECK THE RH (RIGHT-HAND) MIRROR COMMON CIRCUIT FOR VOLTAGE AT THE RH

(RIGHT-HAND) EXTERIOR MIRROR
Ignition OFF.
Disconnect: RH Exterior Mirror C626.
Connect:

C626-2 Ground
Ignition ON.
While pressing the exterior mirror control switch in the left and down directions, monitor the test light.
Does the test light illuminate only when the exterior mirror control switch is pressed in the left and
down directions?
Yes GO to D25
direction, GO to D6
left and down directions, GO to D7
D6 CHECK THE COMMON CIRCUIT FOR A SHORT TO VOLTAGE AT THE RH (RIGHT-HAND)

EXTERIOR MIRROR
Ignition OFF.
Disconnect: PDM C652B.
Ignition ON.
Measure:
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C626-2 Ground

No GO to D24
D7 CHECK THE COMMON CIRCUIT FOR AN OPEN BETWEEN THE RH (RIGHT-HAND) EXTERIOR
MIRROR AND THE PDM (PASSENGER DOOR MODULE)
Ignition OFF.
Measure:

C626-2 C652B-17
Yes GO to D8
D8 CHECK THE COMMON CIRCUIT FOR A SHORT TO GROUND AT THE RH (RIGHT-HAND)

EXTERIOR MIRROR
Measure:

C626-2 Ground
Yes GO to D24
D9 CHECK THE MIRROR MOTOR FEEDBACK CIRCUITS FOR A SHORT TO VOLTAGE AT THE RH
Ignition OFF.
Ignition ON.
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Measure:

C626-8 Ground
C626-9 Ground
C626-10 Ground
C626-12 Ground

No GO to D10
D10 CHECK THE MIRROR MOTOR FEEDBACK CIRCUITS FOR A SHORT TO GROUND AT THE RH
Ignition OFF.
Measure:

C626-8 Ground
C626-9 Ground
C626-10 Ground

Yes GO to D11
D11 CHECK THE MIRROR MOTOR FEEDBACK CIRCUITS FOR AN OPEN BETWEEN THE RH
(RIGHT-HAND) EXTERIOR MIRROR AND THE PDM (PASSENGER DOOR MODULE)
Measure:

C626-8 C652B-16
C626-9 C652B-5
C626-10 C652B-6
C626-12 C652B-15
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Yes GO to D12
D12 CHECK THE MIRROR MOTOR FEEDBACK REFERENCE VOLTAGE AT THE RH (RIGHT-HAND)
EXTERIOR MIRROR
Connect: PDM C652B.
Ignition ON.
Measure:

C626-9 C626-12
Yes GO to D13
No GO to D24
WITH THE RH (RIGHT-HAND) EXTERIOR MIRROR DISCONNECTED
Using a diagnostic scan tool, clear the PDM Diagnostic Trouble Codes (DTCs).
Perform the PDM self-test.
Is DTC B1C15:15 or B1C16:15 present?
Yes GO to D14
No GO to D24
WITH THE HORIZONTAL POSITION SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND
Ignition OFF.
Connect:

C626-10 C626-12
Ignition ON.
Yes REMOVE the jumper wire. GO to D15

No REMOVE the jumper wire. GO to D24
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WITH THE VERTICAL POSITION SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND
Ignition OFF.
Connect:

C626-8 C626-12
Ignition ON.
Yes REMOVE the jumper wire. GO to D25

No REMOVE the jumper wire. GO to D24
D16 CHECK FOR VOLTAGE TO THE HORIZONTAL MOTOR CIRCUIT AT THE RH (RIGHT-HAND)
EXTERIOR MIRROR
Ignition OFF.
Connect:

C626-10 Ground
Ignition ON.
While pressing the exterior mirror control switch in the right direction, monitor the test light.
Does the test light illuminate only when the exterior mirror control switch is pressed in the right
direction?
Yes GO to D25
direction, GO to D17
right direction, GO to D18
D17 CHECK THE HORIZONTAL MIRROR CIRCUIT FOR A SHORT TO VOLTAGE AT THE RH
Ignition OFF.
Ignition ON.
Measure:
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C626-10 Ground

No GO to D24
D18 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR A SHORT TO GROUND AT THE RH
Ignition OFF.
Measure:

C626-10 Ground
Yes GO to D19
D19 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN OPEN BETWEEN THE RH (RIGHT-HAND)
EXTERIOR MIRROR AND THE PDM (PASSENGER DOOR MODULE)
Measure:

C626-10 C652B-6
Yes GO to D24
D20 CHECK FOR VOLTAGE TO THE VERTICAL MOTOR CIRCUIT AT THE RH (RIGHT-HAND)
EXTERIOR MIRROR
Ignition OFF.
Connect:
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C626-8 Ground
Ignition ON.
While pressing the exterior mirror control switch in the up direction, monitor the test light.
Does the test light illuminate only when the exterior mirror control switch is pressed in the up
direction?
Yes GO to D25
direction, GO to D21
up direction, GO to D22
D21 CHECK THE VERTICAL MIRROR CIRCUIT FOR A SHORT TO VOLTAGE AT THE RH
Ignition OFF.
Ignition ON.
Measure:

C626-8 Ground

No GO to D24
D22 CHECK THE VERTICAL MOTOR CIRCUIT FOR A SHORT TO GROUND AT THE RH
Ignition OFF.
Measure:

C626-8 Ground
Yes GO to D23
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D23 CHECK THE VERTICAL MOTOR CIRCUIT FOR AN OPEN BETWEEN THE RH (RIGHT-HAND)
EXTERIOR MIRROR AND THE PDM (PASSENGER DOOR MODULE)
Measure:

C626-8 C652B-16
Yes GO to D24
D24 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Disconnect and inspect all PDM connectors.
Repair:
Reconnect the PDM connectors and all previously disconnected exterior mirror system connectors. Make
Service Bulletins (TSBs) address this concern, INSTALL a new PDM.
REFER to: Passenger Door Module (PDM) (419-10 Multifunction Electronic Modules,
D25 CHECK THE EXTERIOR MIRROR JUMPER HARNESS

Corrosion
Is the harness OK?
exterior mirror.
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One Or Both Heated Exterior Mirrors Is Inoperative Or Always On (With Memory Mirrors)

B1163:11 Left Mirror Heater Output: This continuous and on-demand DTC sets if the DDM detects a
Circuit Short To Ground higher than expected current draw when voltage is applied to the LH
exterior mirror heater circuit.
B1163:15 Left Mirror Heater Output: This continuous and on-demand DTC sets if the DDM detects a lower
Circuit Short To Battery Or than expected current draw when voltage is applied to the LH exterior
Open mirror heater circuit.
B1164:11 Right Mirror Heater Output: This continuous and on-demand DTC sets if the PDM detects a higher
Circuit Short To Ground than expected current draw when voltage is applied to the RH exterior
mirror heater circuit.
B1164:15 Right Mirror Heater Output: This continuous and on-demand DTC sets if the PDM detects a lower
Circuit Short To Battery Or than expected current draw when voltage is applied to the RH exterior
Open mirror heater circuit.
Possible Causes

Exterior mirror
Door module
PINPOINT TEST E : ONE OR BOTH HEATED EXTERIOR MIRRORS IS INOPERATIVE OR ALWAYS ON
(WITH MEMORY MIRRORS)
R025D)
E1 CHECK THE DDM (DRIVER DOOR MODULE) OR PDM (PASSENGER DOOR MODULE)
DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform the DDM ( LH heated exterior mirror inoperative or always on) or
PDM ( RH heated exterior mirror is inoperative or always on) self-test.
Yes For DDM DTC B1163:11 or PDM DTC B1164:11, GO to E7

For DDM DTC B1163:15 or PDM DTC B1164:15, GO to E3
For all other DDM or PDM Diagnostic Trouble Codes (DTCs),
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No GO to E2
E2 VERIFY THE OPERATION OF THE REAR WINDOW DEFROST SYSTEM

Start the engine.
With the engine running, activate the rear window defrost.
Using an infrared temperature gun or equivalent, measure the temperature of the rear window for
approximately 30 seconds, noting changes in temperature.
Did the temperature of the rear window glass rise?
Yes GO to E3
No DIAGNOSE the rear window defrost system prior to continuing diagnostics for the heated
exterior mirrors.
REFER to: Glass, Frames and Mechanisms (501-11 Glass, Frames and Mechanisms,
E3 CHECK THE EXTERIOR MIRROR HEATER OUTPUT VOLTAGE AT THE INOPERATIVE EXTERIOR
MIRROR
Ignition OFF.
Disconnect: Inoperative Exterior Mirror C520 or C626.
Start the engine.
Connect:

LH Exterior Mirror

C520-6 C520-7
RH Exterior Mirror

C626-6 C626-7
Does the test light illuminate only when the rear window defrost is activated?
Yes GO to E11
No If the test light is illuminated at all times, GO to E4
If the test light does not illuminate, GO to E5
E4 CHECK THE HEATER CIRCUIT FOR A SHORT TO VOLTAGE AT THE EXTERIOR MIRROR
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Ignition OFF.
Disconnect: DDM C501B or PDM C652B.
Ignition ON.
Measure:

LH Exterior Mirror

C520-6 Ground

RH Exterior Mirror

C626-6 Ground

No For the LH mirror, GO to E10
For the RH mirror, GO to E9
E5 CHECK FOR VOLTAGE TO THE HEATER CIRCUIT AT THE EXTERIOR MIRROR

Turn the rear window defrost off.
Connect:

LH Exterior Mirror

C520-6 Ground

RH Exterior Mirror

C626-6 Ground
Does the test light illuminate?
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Yes REPAIR the ground circuit.
No GO to E6
E6 CHECK FOR AN OPEN IN THE HEATER CIRCUIT BETWEEN THE MIRROR AND THE DOOR
MODULE
Ignition OFF.
Measure:

LH Exterior Mirror

C520-6 C501B-20

RH Exterior Mirror

C626-6 C652B-20
Yes For the LH mirror, GO to E10

For the RH mirror, GO to E9
E7 CHECK THE HEATER CIRCUIT FOR A SHORT TO GROUND AT THE EXTERIOR MIRROR
Ignition OFF.
Disconnect: Inoperative Exterior Mirror C520 or C626.
Measure:

LH Exterior Mirror

C520-6 Ground

RH Exterior Mirror
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C626-6 Ground
Yes GO to E8
E8 CHECK THE DOOR MODULE DIAGNOSTIC TROUBLE CODES (DTCS) WITH THE EXTERIOR
MIRROR DISCONNECTED
Connect: DDM C501B or PDM C652B.
Ignition ON.
Using a diagnostic scan tool, clear the DDM or PDM Diagnostic Trouble Codes (DTCs).
Is DDM DTC B1163:15 or PDM DTC B1164:15 present?
Yes GO to E11
No For the LH exterior mirror, GO to E10
For the RH exterior mirror, GO to E9
E9 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Disconnect and inspect all PDM connectors.
Repair:
Reconnect the PDM connectors and all previously disconnected exterior mirror system connectors. Make
Service Bulletins (TSBs) address this concern, INSTALL a new PDM.
REFER to: Passenger Door Module (PDM) (419-10 Multifunction Electronic Modules,
E10 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Disconnect and inspect all DDM connectors.
Repair:
Reconnect the DDM connectors and all previously disconnected exterior mirror system connectors. Make
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Service Bulletins (TSBs) address this concern, INSTALL a new DDM.
REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal
and Installation).
E11 CHECK THE EXTERIOR MIRROR JUMPER HARNESS

Inspect the exterior mirror jumper harness between the vehicle harness and the mirror glass for:
Corrosion
Is the harness OK?
Yes INSTALL a new exterior mirror glass.
exterior mirror.
One Or Both Heated Exterior Mirrors Are Inoperative (Without Memory Mirrors)

The heated exterior mirrors receive voltage from the rear window defrost system. The heated exterior mirrors
only operate when the rear window defrost is on.
REFER to: Glass, Frames and Mechanisms - System Operation and Component Description (501-11 Glass,
Frames and Mechanisms, Description and Operation).
Possible Causes
Fuse
Rear window defrost system concern
Exterior mirror
Inspect the suspect exterior mirror housing and glass for damage.
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PINPOINT TEST F : ONE OR BOTH HEATED EXTERIOR MIRRORS ARE INOPERATIVE (WITHOUT
MEMORY MIRRORS)
F1 CHECK THE OPERATION OF THE REAR WINDOW DEFROST SYSTEM
Start the engine.
Using an infrared temperature gun or equivalent, measure the temperature of the rear window glass for
approximately 30 seconds, noting changes in temperature.
Does the temperature of the rear window glass rise?
Yes GO to F2
No DIAGNOSE the rear window defrost system.
F2 CHECK THE OPERATION OF THE HEATED EXTERIOR MIRRORS

With the rear window defrost ON, using an infrared temperature gun or equivalent, measure the
temperature of the LH and RH exterior mirror glass for approximately 30 seconds, noting changes in
temperature.
Does the temperature of at least one exterior mirror glass rise?
Yes For inoperative LH heated mirror glass, GO to F3

For inoperative RH heated mirror glass, GO to F5
No VERIFY that BJB fuse 11 (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.
F3 CHECK THE VOLTAGE TO THE LH (LEFT-HAND) HEATED EXTERIOR MIRROR GLASS

Ignition OFF.
Start the engine.
Measure:

C520-6 Ground
Yes GO to F4
F4 CHECK THE LH (LEFT-HAND) EXTERIOR MIRROR GROUND CIRCUIT FOR AN OPEN

Ignition OFF.
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Measure:

C520-7 Ground
Yes GO to F7
No REPAIR the circuit
F5 CHECK THE VOLTAGE TO THE RH (RIGHT-HAND) HEATED EXTERIOR MIRROR GLASS

Ignition OFF.
Start the engine.
Measure:

C626-6 Ground
Yes GO to F6
F6 CHECK THE RH (RIGHT-HAND) EXTERIOR MIRROR GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C626-7 Ground
Yes GO to F7
F7 CHECK THE EXTERIOR MIRROR JUMPER HARNESS

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Corrosion
Is the harness OK?
Yes INSTALL a new exterior mirror glass.
exterior mirror.
The LH and/or RH Power Folding Mirror Is Inoperative/Do Not Operate Correctly (if equipped)
REFER to: Rear View Mirrors - System Operation and Component Description (501-09 Rear View Mirrors,
Possible Causes
Binding or obstructed power folding mirror

Power folding mirrors are not synchronized
Power folding mirror motor lockout feature is active
Power folding mirror
Power folding mirror relay
Exterior mirror fold switch (integral to the front door window control switch)
If the power folding mirrors are folded or unfolded several times continuously, the power lockout feature
disables the system for approximately 3-10 minutes to prevent damage to the power fold motors. After
3-10 minutes have elapsed, normal operation resumes.
The power folding mirrors may need to be synchronized when the LH, RH or both power folding mirrors are
partially folded in toward the door manually, and then folded inward using the power folding mirror control
switch.
Verify that the power folding mirrors are not binding or obstructed.
PINPOINT TEST G : THE LH (LEFT-HAND) AND/OR RH (RIGHT-HAND) POWER FOLDING MIRROR IS

INOPERATIVE/ DO NOT OPERATE CORRECTLY (IF EQUIPPED)
R025D)
G1 CHECK POWER FOLDING MIRROR OPERATION
Ignition ON.
Press the exterior mirror folding switch to activate the power folding mirrors.
Are both power folding mirrors inoperative or do not operate correctly?
Yes GO to G2
No GO to G10
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G2 CHECK THE EXTERIOR FOLDING MIRROR CONTROL SWITCH
Ignition OFF.
Perform the appropriate component test.
Did the exterior folding mirror control switch pass the component test?
Yes GO to G3
No INSTALL a new exterior folding mirror control switch (integral to the front door window
control switch).
G3 CHECK THE FOLDING MIRROR CONTROL CIRCUIT FOR A SHORT TO GROUND

Disconnect: Power Folding Mirror Relay C3276.
Measure:

C504-2 Ground
Yes GO to G4
No REPAIR the circuit. SYNCHRONIZE the power folding mirrors.
G4 CHECK THE FOLDING MIRROR CONTROL CIRCUIT FOR AN OPEN
Measure:

C504-2 C3276-4
Yes GO to G5
G5 CHECK FOR VOLTAGE TO THE POWER MIRROR FOLD RELAY

Ignition ON.
Measure:
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C3276-3 Ground
Yes GO to G6
No VERIFY that BCM fuse 2 (7.5A) is OK. If OK, REPAIR the circuit for an open. If not OK,
REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.
G6 CHECK FOR GROUND TO THE POWER MIRROR FOLD RELAY

Ignition OFF.
Measure:

C3276-1 Ground
Yes GO to G7
G7 CHECK THE POWER FOLDING MIRROR RELAY FOR A SHORT TO VOLTAGE

Ignition OFF.
Ignition ON.
Measure:

LH exterior mirror

C520-10 Ground
C520-12 Ground

RH exterior mirror

C626-10 Ground
C626-12 Ground
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No GO to G8
G8 CHECK THE POWER FOLDING MIRROR RELAY OUTPUT CIRCUITS FOR AN OPEN
Ignition OFF.
Measure:

LH concern

C3276-2 C520-10
C3276-5 C520-12
Yes GO to G9
No REPAIR the circuit(s).
G9 CHECK THE POWER FOLDING MIRROR RELAY FOR A SHORT TO GROUND

Measure:

LH exterior mirror

C520-10 Ground
C520-12 Ground

RH exterior mirror

C626-10 Ground
C626-12 Ground
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Yes INSTALL a new power folding mirror relay. SYNCHRONIZE the power folding mirrors.
No REPAIR the circuit(s). SYNCHRONIZE the power folding mirrors.
G10 CHECK THE POWER FOLDING MIRROR RELAY OUTPUT CIRCUITS FOR AN OPEN
Disconnect: Power Folding Mirror Relay C3276.
Measure:

LH exterior mirror

C3276-2 C520-10
C3276-5 C520-12

RH exterior mirror

C3276-2 C626-10
C3276-5 C626-12
Yes INSTALL a new power folding mirror relay. SYNCHRONIZE the power folding mirrors.
No REPAIR the circuit(s). SYNCHRONIZE the power folding mirrors.
G11 CHECK THE EXTERIOR MIRROR JUMPER HARNESS
Corrosion
Is the harness OK?
Yes INSTALL a new exterior mirror.

SYNCHRONIZE the power folding mirrors.
exterior mirror.
SYNCHRONIZE the power folding mirrors.
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The Interior Auto-Dimming Mirror Does Not Operate Correctly
REFER to: Rear View Mirrors - System Operation and Component Description (501-09 Rear View Mirrors,
Possible Causes
Fuse
Obstructed forward or rearward sensors
Gear input concern
Reverse lamp concern
Interior auto-dimming mirror
Inspect the interior mirror forward and rearward facing sensors for damage, debris or obstructions
PINPOINT TEST H : THE INTERIOR AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY
R025D)
H1 VERIFY THE OPERATION OF THE REVERSE LAMPS
Ignition ON.
Apply the parking brake.
While observing the reversing lamps, select each gear in the entire range.
Do the reverse lamps illuminate ONLY in REVERSE?
Yes Select PARK. GO to H2

No Select PARK. DIAGNOSE the reverse lamps.
REFER to: Reversing Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
H2 INSPECT THE MIRROR FOR PROPER INSTALLATION

Inspect the interior auto-dimming mirror to make sure the rearward facing sensor is at the top of the
mirror glass.
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Is the rearward facing sensor at the top of the interior auto-dimming mirror glass?
Yes GO to H3
No INSTALL the interior auto-dimming mirror as per the removal and installation procedure.
REFER to: Interior Rear View Mirror (501-09 Rear View Mirrors, Removal and
Installation).
H3 VERIFY THE FORWARD AND REARWARD FACING SENSORS ARE NOT BLOCKED
Visually verify the forward and rearward facing sensors are not blocked or obstructed. Sources of
obstruction can include:
Stickers, window decals or tags.
Fold-down screens for TVs or DVD players.
Non-OEM window tinting.
Dirt and debris
Are either of the sensors blocked?
Yes If possible, REMOVE the obstruction. If it is not possible to remove the obstruction,
ADVISE the customer the blockage will affect the operation of the auto-dimming mirror.
No GO to H4
H4 VERIFY THE OPERATION OF THE INTERIOR AUTO-DIMMING MIRROR - DAYLIGHT
CONDITIONS
Simulate daylight conditions by using a bright lamp to illuminate the forward and rearward facing sensors.
The mirror should adjust to a high reflectance state (mirror will be clear).
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Did the mirror adjust to a high reflectance (clear) state?
Yes GO to H5
No INSTALL a new interior auto-dimming mirror.
Installation).
H5 VERIFY THE OPERATION OF THE INTERIOR AUTO-DIMMING MIRROR - NIGHTTIME

CONDITIONS WITHOUT GLARE
NOTE: Covering the sensor(s) with a finger or hand is not adequate for this step.
Simulate nighttime conditions without glare by using black electrical tape or other dark material to cover
the forward and rearward facing sensors. The mirror should adjust to a high reflectance state (mirror will
be clear).
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Did the mirror adjust to a high reflectance (clear) state?
Yes GO to H6
No INSTALL a new interior auto-dimming mirror.
Installation).
H6 VERIFY THE OPERATION OF THE INTERIOR AUTO-DIMMING MIRROR - NIGHTTIME

CONDITIONS WITH GLARE
Remove the black electrical tape or other dark material from the rearward facing sensor.
Simulate nighttime conditions with glare by using black electrical tape or other dark material to cover the
forward facing sensor while illuminating the rearward facing sensor using a bright light. The mirror should
adjust to a low reflectance state (mirror will be darkened).
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Did the mirror adjust to a low reflectance (darkened) state?
Yes GO to H7
No GO to H8
H7 VERIFY THE OPERATION OF THE INTERIOR AUTO-DIMMING MIRROR - VEHICLE IN REVERSE

AND NIGHTTIME CONDITIONS WITH GLARE
Continue to illuminate the rearward facing sensor with the forward facing sensor covered.
Select REVERSE.
Did the mirror adjust to a high reflectance (clear) state after reverse was selected?
Yes Select PARK. The system is operating correctly at this time. REVIEW the operation of the
interior auto-dimming mirror feature with the customer.
No GO to H10
H8 CHECK FOR VOLTAGE TO THE INTERIOR AUTO-DIMMING MIRROR

Ignition OFF.
Disconnect: Interior Auto-Dimming Mirror C911.
Ignition ON.
Measure:

C911-1 Ground
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Yes GO to H9
No Verify BCM fuse 23 (10A) is OK. If the fuse is OK, REPAIR the circuit. If the fuse is not
OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit
short.
H9 CHECK FOR GROUND AT THE INTERIOR AUTO-DIMMING MIRROR

Ignition OFF.
Measure:

C911-4 Ground
Yes GO to H10
H10 CHECK FOR VOLTAGE TO THE INTERIOR AUTO-DIMMING MIRROR REVERSE INHIBIT
CIRCUIT
Ignition OFF.
Disconnect: Interior Auto-Dimming Mirror C911 if not previously disconnected.
Ignition ON.
Measure:

C911-9 Ground
Select REVERSE.
Select PARK.
Is the voltage greater than 11 volts when reverse gear is selected and no voltage present when
reverse gear is not selected?
Yes INSTALL a new interior auto-dimming mirror.

Installation).
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Exterior Mirror
Removal
NOTE: The power folding mirrors may need to be synchronized anytime the mirrors are folded or unfolded
without using the exterior mirror control switch, or if a new power folding mirror is installed.
Exterior mirror assembly
1. Operate window to full up position.

3. Remove the front door speaker.
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Refer to: Front Door Speaker LH (415-00B Information and Entertainment System - General Information -
Vehicles With: Touchscreen Display, Removal and Installation).
Refer to: Front Door Speaker RH (415-00B Information and Entertainment System - General Information -
4. For vehicles equipped with door mounted tweeters, remove the tweeter.
5. Remove the rectangular tape cover.

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6. For vehicles not equipped with door mounted tweeters, remove the tape cover.
7. NOTE: The mirror wiring is accessed through the lower speaker port.
Disconnect the mirror electrical and separate the wiring harness guide.
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8. NOTE: Reconnect the window switch.
Operate door glass to the full down position.
9. NOTICE: Support the exterior mirror during fastener removal to prevent damage to the mirror or
door surface.
Remove the exterior mirror mounting nut and bolts.
10. Remove the exterior mirror.

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Mirror glass
11.
Position aside the mirror glass.
1. Position the mirror glass fully in and up.
2. Using a flat blade screwdriver, insert the blade between the mirror glass and motor. Twist and
release the mirror glass.
3. Position aside the mirror glass.
12. NOTE: The number and location of the electrical connectors will vary due to option content.
Disconnect the mirror glass electrical connectors.

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Mirror Motor
13. Remove the mirror glass.
14.
Remove the mirror bezel.
2. Release the tabs.
15. Remove the screws and position the motor aside.

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16. Disconnect the electrical connectors and remove the mirror motor.
Mirror cover
17. Remove the mirror motor.
18. If equipped, disconnect the mirror mounted side turn signal.

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19.
Remove the mirror cover.
1. Remove the screw.
3. Remove the mirror cover.
Mirror mounted turn signal
20. Remove the mirror cover.
21. Remove the mirror mounted turn signal.

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Puddle lamp
22. Remove the mirror glass.
23. Press the tab, lower the puddle lamp and disconnect the electrical connectors.
Installation
2. If equipped, synchronize the power folding mirrors.

Interior Rear View Mirror
501-025
Installer, Rear View Mirror
501-D118A (501-D118)
Mirror Remover
Removal
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1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section
100-00 General Information. Failure to follow this instruction may result in serious personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
2. Mirror Types
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Mirror type 1
3. If equipped, disconnect the interior mirror electrical connector.

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4. Adjust the jaws on the interior mirror remover.
5. NOTICE: Make sure the interior mirror remover is fully inserted into the rear view mirror mount access hole.
Otherwise, damage to the windshield glass may occur.
Using the interior mirror remover, release the locking tab.

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6. Using a closed hand, bump the adjustment handle of the interior mirror remover to slide the mirror upward on the
mirror mount.
7. Slide the interior mirror off the interior mirror mount.

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Mirror type 2
8.
Remove the interior mirror.
1. Insert the interior mirror remover into the release tab.
Use Special Service Tool: 501-D118A (501-D118) Mirror Remover.
2. Pull the lower edge of the interior mirror remover away from the windshield.
3. Slide the interior mirror off the mirror mount.
Mirror type 3
9. Remove the rain sensor covers.

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10. Disconnect the interior mirror electrical connector.
11.
1. Position the interior mirror assembly to release the indexing tab.
2. Inspect the indexing tab and turn the interior mirror slightly counter clock-wise.
3. Turn the interior mirror 45 degrees counter clock-wise.
4. Pull the interior mirror off the mirror mount.
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Mirror type 4
12. If a new mirror is being installed, use a diagnostic scan tool, begin the PMI process for the IPMAfollowing the
13. Remove the rain sensor covers.

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14. Disconnect the interior mirror electrical connector.
15.
1. Turn the interior mirror assembly counter clock-wise.
2. Remove the interior mirror off the mirror mount.
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Mirror type 5
16.
1. Release the locking tab.
2. Slide the interior mirror off the mirror mount.
Mirror type 6
17. Disconnect the electrical connector and unclip the wiring harness.
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18.
1. Loosen the set screw.
2. Slide the interior mirror upward.
Installation
Mirror type 1
1. Slide the interior rear view mirror over the windshield bracket from the top.
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2. NOTE: An audible click will be heard as the mirror fully seats.
Using the interior mirror installer, fully seat the interior mirror.
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3. If equipped, connect the electrical connector.
4. If equipped with a compass module which requires calibration, check the compass zone and calibration.
Mirror type 2
5. Using the interior mirror installer, fully seat the interior mirror.
Use Special Service Tool: 501-025 Installer, Rear View Mirror.
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6. If equipped with a compass module which requires calibration, check the compass zone and calibration.
Mirror type 3
Mirror type 4
9. If a new mirror has been installed, use a diagnostic scan tool, complete the PMI process for the IPMA
following the on-screen instructions.
If a new mirror has been installed, carry out the camera alignment using a scan tool.
Mirror type 5
10. Slide the interior mirror onto the mirror mount until the locking tab is engaged.
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Mirror type 6

501-10A Front Seats 2016 Mustang
Front Seats - Overview
Overview
Driver Power Seat - Without Memory
The seat control switch contains normally closed contacts which are grounded. An individual circuit is switched to
voltage when a specific adjustment position is selected. The seat control switch is hard-wired directly to the
applicable seat motors. The motor direction is determined by the polarity of voltage supplied from the seat control
switch.
The driver power seat is equipped with the following motors:
Front height motor (serviced with seat track assembly)

Rear height motor (serviced with seat track assembly)
Horizontal motor (serviced separately from the seat track assembly)
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Lumbar motor (serviced with power lumbar assembly)
Driver Power Seat - With Memory
The seat control switch provides a voltage signal to the DSM when a specific adjustment position is selected. The
power driver seat is controlled by the DSM. The DSM is located on the driver seat track. PMI is required when a
new DSM is installed. The DSM hard stop/soft stops must be set/reset any time a new DSM, driver seat track or
horizontal motor is installed. This system allows automatic positioning of the driver seat to 1 of 3 programmable
positions. For information on programming memory positions or recalling a stored memory position, refer to the
Owner's Literature.
The driver power seat is equipped with the following motors:

Passenger Power Seat
The seat control switch contains normally closed contacts which are grounded. An individual circuit is switched to
voltage when a specific adjustment position is selected. The seat control switch is hard-wired directly to the
applicable seat motors. The motor direction is determined by the polarity of voltage supplied from the seat control
switch.
The passenger power seat is equipped with the following motors:

Climate Controlled Seats
This system allows on-demand, independent, electrical heating/cooling of each front seat.
The climate controlled seat system consists of the following components:
Blower motor, located within each front seat cushion and backrest
Air filter integrated to each blower motor assembly (not serviceable)
Climate controlled seat buttons, located on the FDIM (touchscreen)
Climate controlled seat buttons, located on the FCIM
SCME, mounted to the bottom of the front passenger seat
Cushion and backrest manifolds
Cushion and backrest foam pads
Cushion and backrest trim covers
Remote Start Climate Operation
Different climate control modes/preferences can be selected when the vehicle is started using the remote start
feature. This can be accessed through the message center. For additional information on how to set the remote
start preferences, refer to the Owner's Literature. When the driver seat and/or passenger seat is set to AUTO
mode, the driver/passenger heated/climate controlled seat activates in full heat mode when the outside
temperature is less than 0° C (32° F) and full cool mode (climate controlled seats only) when outside temperature
is greater than 27° C (80° F) any time the vehicle is started using the remote start feature. No heated/climate
controlled seat adjustments are recognized during remote start operation. Once the ignition is cycled ON, the
heated/climate controlled seat returns to the previous settings (last ignition ON cycle) and adjustments can be
made normally. If the previous setting was off, the heated/climate controlled seat turns off.
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Front Seats - System Operation and Component Description
System Operation
System Diagram - Memory Seat
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Network Message Chart - Memory Seat
DSM Network Input Messages

Message Module
Ignition status BCM Provides the ignition status. This input is used for the easy entry/exit feature.
Gear lever PCM Provides the gear selector lever status. This input is used for the easy entry/exit
position and memory recall feature.
Personality BCM When the personality recall command is received from the BCM, the DSM
recall stores or recalls the associated memory seat position (1, 2 or 3). If a RKE
transmitter has been programmed to a memory position, this input is used to
recall the associated memory seat position.
Memory seat DDM When the memory set switch (1, 2 or 3) is activated, the DDM sends this
switch status message to the DSM, which then stores or recalls the associated memory seat
position.
System Diagram - Climate Controlled Seats

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Network Message Chart - Climate Controlled Seats
SCME Network Input Messages

Module
Climate control seat FDIM The climate control seat settings request message contains the
settings request climate controlled seat request information.
Climate control seat FCIM The climate control seat settings request message contains the
settings request climate controlled seat request information.
FDIM Network Input Messages

Message Module
Climate control seat SCME The SCME provides this message to the FDIM for the purpose of
settings status updating the displayed status of the climate controlled seat buttons on the
FDIM (touchscreen).
FCIM Network Input Messages

Module
Climate control seat SCME The SCME provides this message to the FCIM for the purpose of
settings status updating the displayed status of the climate controlled seat buttons on
the FCIM.
Memory Seat Operation
The driver seat control switch provides a voltage signal to the DSM only when activated. This voltage signal
causes the DSM to power the appropriate motor until the input is removed. The motor circuits are normally
grounded through the DSM. The DSM internally switches the appropriate circuit from ground to voltage to operate
the motors.
As the seat is adjusted, the DSM monitors the motor position sensors to record the current seat position. The
DSM removes voltage from the motor upon termination of the seat control switch input or if the DSM does not
detect movement from the motor while monitoring the position sensor during a memory recall operation.
If the DSM loses the signal from any of motor position sensors, the affected seat motor operates in jog mode.
Jog mode allows limited operation of the affected seat motor using only the seat control switch. When the seat
control switch is operated in jog mode, the seat moves in the desired direction for one second, then stops. The
seat control switch must be released, then pressed again in order to move the seat for an additional second. Jog
mode is an indication that there is a seat motor sensor fault. If the memory seat is operating in jog mode, a DTC
sets in the DSM.
DSM Hard Stop/Soft Stop
The DSM has the ability for soft stops both at the upper and lower limits on all axes of the driver seat. When an
axis reaches the hard stop and the switch is held for approximately one second, it then reverses direction 180 ms
and establishes the soft stop for that axis in that direction. The DSM uses this back up strategy to check sensor
integrity any time movement has stopped prematurely due to a sensor failure or obstruction.
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A hard stop occurs when one of the memory seat track axes or backrest recline physically reach the end of travel
and can go no further. A soft stop occurs when the seat stops before physically reaching the end of travel. The
hard stop is set by seat design and cannot be changed or adjusted. The soft stop is set by the DSM. To prevent
unnecessary stress on the seat and motors, the DSM sets soft stop positions, 2 for each moving axis. The DSM
uses a preset distance from the hard stop to determine where the soft stop occurs. When an axis reaches the
hard stop and the switch is held for approximately one second, the DSM establishes the soft stop for that axis in
that direction.
Easy Entry/Exit
The easy entry/exit feature is a function of the DSM that moves the driver seat back approximately 50.8 mm (2 in)
(unless seat is already positioned at or near the end of travel) when the ignition is turned off. The DSM receives
ignition status over the MS-CAN and operates the driver seat rearward. The DSM cancels this operation if a valid
input command is received from the driver seat control switch, memory set switch, exterior mirror control switch
or if the function has been disabled.
The DSM records the current seat positions before operating the seat for an easy exit operation. During easy
entry operation (when the ignition is turned on), the seat is returned to the recorded seat position previous to the
easy exit operation. Easy entry operation is cancelled if a valid input command is received by the DSM. A memory
position recall using the memory set switch also overrides the easy exit operation.
The easy entry/exit feature can be enabled/disabled on the message center. For information on programming
vehicle settings in the message center, refer to the Owner's Literature.
Climate Controlled Seat Operation
The driver and passenger climate controlled seat buttons are selected from the FCIM or FDIM (touchscreen). The
FDIM is mounted directly to the APIM. The climate controlled seat system functions independently of the vehicle's
climate control system. When the climate controlled seat buttons are pressed on the touchscreen, the APIM
sends the request to the GWM using the HS-CAN3. The GWM sends the message to the SCME over the
MS-CAN.
When the climate controlled seat buttons are pressed on FCIM, the FCIM sends the request to the SCME using
the MS-CAN.
The seat cushion and backrest are each equipped with a blower motor assembly. As cabin air is drawn through
each blower motor, the blower motors heat or cool the air, which is then directed into the foam pad where it is
distributed along the surface of the cushion and backrest of the seat. Once the system is activated, the SCME
uses a set of flexible algorithms to control the heating/cooling modes and the blower speed dependant on the
commanded climate controlled seat settings.
The SCME monitors seat cushion temperature while it supplies voltage and ground to both blower motors. The
SCME also supplies a variable voltage signal to control the blower speed. Cabin air enters the blower through a
filter attached to the blower motor housing. Heated or cooled air exits the blower motor and flows through the
foam pad.
Climate Controlled Seat Heating Characteristics
In heat mode, the blower motor can add up to 40–60° C (72–108° F) to the ambient inlet air temperature.
The system control settings are indicated next to each climate controlled seat heat button on the
touchscreen. The first setting is HIGH (3 indicators), the second setting is MED (2 indicators) and the third
is LOW (1 indicator), then OFF (no indicators).
When heating, the SCME varies the speed of the blower motors and the duty cycle of the integral Thermo-
Electric Device (TED) in order to reach and maintain the desired temperature determined by the system
control settings.
Climate Controlled Seat Cooling Characteristics
In cool mode, the blower motors can remove up to 8° C (14° F) from the ambient air temperature entering
the system.
The system control settings are based on the 3 indicators next to each climate controlled seat cool button
on the touchscreen. The first setting is HIGH (3 indicators), the second setting is MED (2 indicators) and
the third is LOW (1 indicator), then OFF (no indicators).
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The SCME maintains a constant blower motor speed and a constant Thermo-Electric Device (TED) supply
voltage (duty cycle is determined by the switch setting) in COOL mode.
Climate Controlled Seat Recovery Mode
NOTE: The presence of overtemperature faults (Diagnostic Trouble Codes (DTCs) B2729, B2730, B272A and
B272B) can be induced by incorrectly operating the climate controlled seat system after an initial heat setting
has been attained. If a heat setting is repeatedly turned off and on in an attempt to increase the seat
temperature or repeatedly toggled between heat and cool modes, an overtemperature condition can result and
the Diagnostic Trouble Codes (DTCs) may be set.
If the temperature of one of the blower motors rises above 110° C (229.8° F) in the heat mode or 65° C (148.9°
F) in the cool mode for more than 4 seconds, the SCME records an overtemperature DTC, removes voltage from
the Thermo-Electric Devices (TEDs) (part of the blower motor assembly) and goes into recovery mode (blower
only) for 30 seconds to cool down the blower motor. The same occurs if a temperature difference of 60° C (108°
F) or greater is detected between the backrest and cushion blower motors on either front seat. The SCME
continues to monitor the blower motors while in recovery mode. If the temperature of the Thermo-Electric Devices
(TEDs) do not drop to 105° C (220.8° F) in the heat mode or 60° C (139.9° F) in the cool mode after 30 seconds,
the system continues to cool the blower motors in recovery mode for up to 5 minutes. If the Thermo-Electric
Devices (TEDs) cool down after 30 seconds, but before 5 minutes (checked at 4 second intervals), the system is
operating normally. An overtemperature DTC is still recorded even if the system recovers and is operating
normally. This is more likely to occur during extreme cabin temperatures with significant seat back sun load. If the
system does not recover within 30 seconds in heat mode or within 5 minutes in cool mode, the SCME disables
that seat (fault mode) and remains off until the ignition is cycled. Also, if the SCME detects a temperature
differential fault twice during the same ignition cycle, the SCME disables the seat. When a fault causes a
shutdown, the climate controlled seat indicators turn off and that seat is not operational until the next ignition cycle.
Driver Seat Control Switch - With Memory
The seat control switch is hard-wired to the DSM, which controls seat operation. When a specific seat adjustment
position is selected, an individual circuit is switched to voltage.
Seat Control Switch - Without Memory
The seat control switch contains normally closed contacts (which are grounded). When a specific adjustment
position is selected, an individual circuit is switched to voltage.
DSM
The driver seat control switch and power memory seat motors are hard-wired to the DSM. The DSM controls the
operation of the power memory seat. The DSM communicates on the Medium Speed Controller Area Network
(MS-CAN). PMI is required when a new DSM is installed. The DSM hard stop/soft stops must be set/reset any
time a new DSM, driver seat track or horizontal motor is installed.
Memory Set Switch
The memory set switch contains 3 momentary contact switches. It is hard-wired to the DDM and is used to recall
each memory position stored in the DSM.
Driver Seat Track - With Memory
There are 3 front seat track bi-directional motors present on power seat tracks. The horizontal (fore/aft) front
seat track motor is the only seat track motor which can be serviced separately from the seat track assembly. All
other seat track motors (front height, rear height) are serviced as part of the seat track assembly. Each seat
track motor contains a Hall-effect sensor which provides seat track position information to the DSM for
setting/obtaining desired preset seat memory positions. The seat track motors move the power seat
forward/backward and up/down depending on the polarity of voltage supplied from the DSM.
Seat Track - Without Memory
There are 3 front seat track bi-directional motors present on power seat tracks. The horizontal (fore/aft) front
seat track motor is the only seat track motor which can be serviced separately from the seat track assembly. All
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other seat track motors (front height, rear height) are serviced as part of the seat track assembly. The seat track
motors move the power seat forward/backward and up/down depending on the polarity of voltage supplied from
the seat control switch.
FDIM
If equipped with climate controlled seats, the FDIM (touchscreen) contains climate controlled seat control buttons.
FCIM
If equipped with climate controlled seats, the FCIM contains climate controlled seat buttons. PMI is required when
a new FCIM is installed.
SCME
If equipped with climate controlled seats, The SCME controls the operation of the climate controlled seat system.
PMI is required when a new SCME is installed.
Blower Motor
If equipped with climate controlled seats, the seat cushion and backrest are each equipped with a blower motor
assembly that includes a seat blower (Thermo-Electric Device (TED) and fan motor, serviced as an assembly).
There is also a temperature sensor (thermistor) in each blower motor which provides feedback to the SCME. The
blower motor assembly is controlled by the SCME.
Front Seat Power Lumbar Assembly
The front seat power lumbar assembly is mounted to the backrest (serviced as an assembly).

Front Seats
DTC Chart: DDM
DDM DTC Chart

B1C03:23 Memory #1 Switch: Signal GO to Pinpoint Test D
Stuck Low
Stuck Low
Stuck Low
All other Diagnostic Trouble -
Codes (DTCs) REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
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DTC Chart: SCME
SCME DTC Chart

B103B Thermoelectric Driver Overcurrent Low GO to Pinpoint Test L
B103C Thermoelectric Driver Open Load GO to Pinpoint Test M
B103D Blower Driver Overtemperature GO to Pinpoint Test N
B1111 Driver Thermal Electric Device Control GO to Pinpoint Test L
Overtemperature Fault
B1113 Passenger Thermal Electric Device Control GO to Pinpoint Test O
Overtemperature Fault
B111B Passenger Thermoelectric Driver Overcurrent Low GO to Pinpoint Test O
B111C Passenger Thermoelectric Driver Open Load GO to Pinpoint Test P
B111D Passenger Blower Driver Overtemperature GO to Pinpoint Test Q
B1342 ECU is Faulted INSTALL a new SCME.
REFER to: Front Seat Climate Control Module [SCME] (501-10A Front Seats, Removal and
Installation).
B19A1 Passenger Seat Cushion Blower Speed Short to GO to Pinpoint Test R
Battery
B19A2 Passenger Seat Back Blower Speed Short to GO to Pinpoint Test S
Battery
B19A3 Driver Seat Cushion Blower Speed Short to Battery GO to Pinpoint Test T
B19A4 Driver Seat Back Blower Speed Short to Battery GO to Pinpoint Test U
B19A5 Passenger Seat Cushion Blower Speed Short to GO to Pinpoint Test V
Ground
B19A6 Passenger Seat Back Blower Speed Short to GO to Pinpoint Test W
Ground
B19A7 Driver Seat Cushion Blower Speed Short to Ground GO to Pinpoint Test X
B19A8 Driver Seat Back Blower Speed Short to Ground GO to Pinpoint Test Y
B2477 Module Configuration Failure NOTE: This DTC indicates PMI has not been done to a newly installed module or configuration
data has been lost.
Using a diagnostic scan tool, CARRY OUT PMI on the SCME. REPEAT the self-test. If PMI is
successful, the DTC will not be present.
B2486 Climate Control Seat Module Voltage Out of Range GO to Pinpoint Test K
B2729 Cushion Over-Temp Detected GO to Pinpoint Test AF
B272A Passenger Cushion Over-Temp Detected GO to Pinpoint Test Z
B272B Passenger Back Over-Temp Detected GO to Pinpoint Test AA
B272C Driver Differential Temperature Fault GO to Pinpoint Test AB
B272D Passenger Differential Temperature Fault GO to Pinpoint Test AC
B272E Driver Ignition Run/Blower Circuit Short to Ground GO to Pinpoint Test AD
B272F Passenger Ignition Run/Blower Circuit Short to GO to Pinpoint Test AE
Ground
B2730 Back Over-Temp Detected GO to Pinpoint Test AG
U2050 No Application Present INSTALL a new SCME.
REFER to: Front Seat Climate Control Module [SCME] (501-10A Front Seats, Removal and
Installation).
DTC Chart: DSM
DSM DTC Chart

B1317 Battery Voltage High GO to Pinpoint Test G
B1318 Battery Voltage Low GO to Pinpoint Test H
B1663 Seat Driver Front Up/Down Motor Stalled If the motor does not operate, GO to Pinpoint Test C If the motor operates in one second intervals, GO
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to Pinpoint Test D
B1664 Seat Driver Rear Up/Down Motor Stalled If the motor does not operate, GO to Pinpoint Test C If the motor operates in one second intervals, GO
to Pinpoint Test D
B1665 Seat Driver Forward/Backward Motor If the motor does not operate, GO to Pinpoint Test C If the motor operates in one second intervals, GO
Stalled to Pinpoint Test D
B1711 Seat Driver Front Up Switch Circuit Short To GO to Pinpoint Test C
Battery
B1715 Seat Driver Front Down Switch Circuit Short GO to Pinpoint Test C
To Battery
B1719 Seat Driver Forward Switch Circuit Short To GO to Pinpoint Test C
Battery
B1723 Seat Driver Rearward Switch Circuit Short To GO to Pinpoint Test C
Battery
B1727 Seat Driver Rear Up Switch Circuit Short To GO to Pinpoint Test C
Battery
B1731 Seat Driver Rear Down Switch Circuit Short GO to Pinpoint Test C
To Battery
B1952 Seat Rear Up/Down Position Feedback GO to Pinpoint Test D
Circuit Short To Battery
B1953 Seat Rear Up/Down Position Feedback GO to Pinpoint Test D
B1956 Seat Front Up/Down Position Feedback GO to Pinpoint Test D
B1957 Seat Front Up/Down Position Feedback GO to Pinpoint Test D
B1964 Seat Horizontal Forward/Rearward Position GO to Pinpoint Test D
Feedback Circuit Short To Battery
B1965 Seat Horizontal Forward/Rearward Position GO to Pinpoint Test D
Feedback Circuit Short To Ground
B2477 Module Configuration Failure NOTE: This DTC indicates PMI has not been carried out on a newly installed module or configuration
data has been lost. Presence of this DTC alone does not prevent basic seat operation from the seat
control switch.
Using a diagnostic scan tool, CARRY OUT PMI on the DSM. REPEAT the self-test and VERIFY
successful PMI. CLEAR the Diagnostic Trouble Codes (DTCs).
U0140 Lost Communication With Body Control GO to Pinpoint Test I
Module (GEM)
U2050 No Application Present INSTALL a new DSM.
REFER to: Driver Front Seat Module (DSM) (501-10A Front Seats, Removal and Installation).
Symptom Chart(s)
Symptom Chart: Front Seats
Symptom Chart

No communication with the DSM Refer to the Pinpoint
Test REFER to: Communications Network (418-00 Module Communications Network,
No communication with the DDM Refer to the Pinpoint

No communication with the FCIM Refer to the Pinpoint

No communication with the SCME Refer to the Pinpoint

The power seat is inoperative or Refer to the Pinpoint GO to Pinpoint Test F

does not operate correctly — Test
driver, without memory
The power seat is inoperative or Refer to the Pinpoint GO to Pinpoint Test A
does not operate correctly — Test
passenger
The power lumbar is inoperative Refer to the Pinpoint GO to Pinpoint Test B
— driver Test
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The memory seat does not Refer to the Pinpoint GO to Pinpoint Test C
operate horizontally/vertically Test
using the seat control switch
The memory seat does not Refer to the Pinpoint GO to Pinpoint Test D
operate using the memory SET Test
switch
The memory seat moves in Refer to the Pinpoint CARRY OUT the DSM self-test and RETRIEVE the Diagnostic Trouble Codes (DTCs).
one-second intervals Test REFER to the DSM DTC Chart.
The memory seat does not move Refer to the Pinpoint CARRY OUT the DSM self-test and RETRIEVE the Diagnostic Trouble Codes (DTCs).
to the correct memory position Test REFER to the DSM DTC Chart.
The memory seat does not Refer to the Pinpoint VERIFY the RKE transmitter is operating correctly and is associated to a memory
operate when using the RKE Test position. REFER to the Owner's Literature for information on associating a RKE
transmitter transmitter. CARRY OUT the DSM self-test and REFER to the DSM DTC Chart to
diagnose any Diagnostic Trouble Codes (DTCs) retrieved.
Easy entry/easy exit is Refer to the Pinpoint GO to Pinpoint Test E

inoperative/does not operate Test
correctly
One or both climate controlled Refer to the Pinpoint GO to Pinpoint Test J
seats are inoperative Test
A single climate controlled seat Excessive sunload CARRY OUT the SCME self-test and retrieve any Diagnostic Trouble Codes (DTCs).
does not operate correctly — or extreme cabin If any Diagnostic Trouble Codes (DTCs) are present, REFER to the SCME DTC
exhibits poor airflow or temperatures Chart.
performance Incorrectly installed If no Diagnostic Trouble Codes (DTCs) are present, CHECK the affected seat
backrest or cushion cushion or backrest for correct installation of the climate controlled seat
blower motor components (backrest or cushion blower motor, air duct and foam pad) and
Airflow blockage CHECK for airflow restrictions (backrest or cushion blower motor inlets and
Disconnected air outlets, filters and ducts) and REPAIR as needed. RETEST the system for
duct normal operation.
Pinpoint Test(s)
The Power Seat is Inoperative or Does Not Operate Correctly — Passenger
REFER to: Front Seats - System Operation and Component Description (501-10A Front Seats, Description and Operation).
Possible Causes
Fuse
Seat control switch
Horizontal motor
Seat track
PINPOINT TEST A : THE POWER SEAT IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY — PASSENGER
WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental Restraint System (SRS) deployment. Never
compromise or depart from these instructions. Failure to precisely follow all instructions could result in serious personal injury from an
A1 CHECK THE SEAT OPERATION
REFER to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
Disconnect: Passenger Side Airbag In-line C219.
Attempt to operate the seat in all directions.
Is the seat inoperative in all directions?
Yes GO to A2
No If only the horizontal motor is inoperative, GO to A4
If only the front height motor is inoperative, GO to A6
If only the rear height motor is inoperative, GO to A8
A2 CHECK FOR VOLTAGE TO THE SEAT CONTROL SWITCH

Disconnect: Passenger Seat Control Switch C3190.
Measure:
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C3190-8 Ground
Yes GO to A3
No VERIFY BJB fuse 13 (30A) 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. GO to A10
A3 CHECK THE SEAT CONTROL SWITCH GROUND CIRCUIT

Measure:

C3190-10 Ground
Yes INSTALL a new passenger seat control switch.

REFER to: Front Seat Control Switch (501-10A Front Seats, Removal and Installation).
GO to A10
No REPAIR the circuit. GO to A10
A4 CHECK FOR VOLTAGE TO THE SEAT HORIZONTAL MOTOR

Disconnect: Passenger Seat Horizontal Motor C332.
NOTE: The voltage being measured changes polarity depending upon which direction the seat control switch is activated.
While pushing the horizontal switch forward and rearward, measure:

C332-1 C332-3
Is the voltage greater than 11 volts when the seat control switch is operated in both directions?
Yes INSTALL a new horizontal motor.

REFER to: Front Seat Track Motor (501-10A Front Seats, Removal and Installation).
GO to A10
No GO to A5
A5 CHECK THE SEAT HORIZONTAL MOTOR CIRCUIT FOR AN OPEN

Measure:

C3190-1 C332-3
C3190-2 C332-1

GO to A10
No REPAIR the circuit in question. GO to A10
A6 CHECK FOR VOLTAGE TO THE SEAT FRONT HEIGHT MOTOR

Disconnect: Passenger Seat Front Height Motor C3074.
While pushing the front height switch upward and downward, measure:
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C3074-1 C3074-3
Yes INSTALL a new passenger seat track.

REFER to: Front Seat Track (501-10A Front Seats, Removal and Installation).
GO to A10
No GO to A7
A7 CHECK THE SEAT FRONT HEIGHT MOTOR CIRCUIT FOR AN OPEN

Measure:

C3190-6 C3074-3
C3190-5 C3074-1

GO to A10
A8 CHECK FOR VOLTAGE TO THE SEAT REAR HEIGHT MOTOR

Disconnect: Passenger Seat Rear Height Motor C3075.
While pushing the rear height switch upward and downward, measure:

C3075-1 C3075-3
Yes INSTALL a new passenger seat track.
GO to A10
No GO to A9
A9 CHECK THE SEAT REAR HEIGHT MOTOR CIRCUIT FOR AN OPEN

Measure:

C3190-9 C3075-3
C3190-7 C3075-1

GO to A10
A10 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY
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Connect: Passenger Side Airbag In-line C219.
Connect all previously disconnected connectors.
REFER to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).
Did the SRS prove out successfully?
Yes Repair is complete. RETURN the vehicle to the customer.

No
REFER to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing).
The Power Lumbar is Inoperative — Driver
Possible Causes

Seat control switch
Front seat power lumbar assembly
PINPOINT TEST B : THE POWER LUMBAR IS INOPERATIVE — DRIVER
B1 CHECK FOR VOLTAGE TO THE SEAT LUMBAR MOTOR
Disconnect: Driver Side Airbag In-line C345.
Disconnect: Driver Seat Lumbar Motor C3215.
While pushing the lumbar switch in both directions, measure:

C3215-A C3215-B
Yes INSTALL a new driver seat power lumbar assembly.
REFER to: Front Seat Power Lumbar Assembly (501-10A Front Seats, Removal and Installation).
GO to B3
No GO to B2
B2 CHECK THE SEAT LUMBAR MOTOR CIRCUITS FOR AN OPEN

Disconnect: Driver Seat Control Switch C352.
Measure:

C352-4 C3215-B
C352-3 C3215-A
Yes INSTALL a new driver seat control switch.

GO to B3
No REPAIR the circuit in question. GO to B3
B3 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY
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Connect: Driver Side Airbag In-line C345.

No
The Memory Seat Does Not Operate Horizontally/Vertically Using the Seat Control Switch

B1663 Seat Driver Front Up/Down During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position sensor to
Motor Stalled monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor operation on the next
activation of the seat control switch. If no movement continues to be monitored after 250 milliseconds, the DSM
disables the output.
B1664 Seat Driver Rear Up/Down During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position sensor to
Motor Stalled monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor operation on the next
activation of the seat control switch. If no movement continues to be monitored after 250 milliseconds, the DSM
B1665 Seat Driver During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position sensor to
Forward/Backward Motor monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor operation on the next
Stalled activation of the seat control switch. If no movement continues to be monitored after 250 milliseconds, the DSM
B1711 Seat Driver Front Up Switch If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
Circuit Short to Battery circuit for greater than 2 minutes, the DTC is set as continuous. With the DTC set, any input signal on the circuit is
ignored.
B1715 Seat Driver Front Down If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
Switch Circuit Short to circuit for greater than 2 minutes, the DTC is set as continuous. With the DTC set, any input signal on the circuit is
Battery ignored.
B1719 Seat Driver Forward Switch If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
ignored.
B1723 Seat Driver Rearward Switch If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
ignored.
B1727 Seat Driver Rear Up Switch If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
ignored.
B1731 Seat Driver Rear Down If voltage is sensed on the switch input circuit during the DSM self-test, the DTC is set. If voltage is sensed on the input
Switch Circuit Short to circuit for greater than 2 minutes, the DTC is set as continuous. With the DTC set, any input signal on the circuit is
Battery ignored.
Possible Causes
Fuse
Seat control switch
Horizontal motor
Seat track
DSM
Verify BCM fuse 2 (7.5A) is OK.

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PINPOINT TEST C : THE MEMORY SEAT DOES NOT OPERATE HORIZONTALLY/VERTICALLY USING THE SEAT CONTROL SWITCH
C1 RETRIEVE THE DSM (DRIVER FRONT SEAT MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Activate the seat control switch in all directions.
Using a diagnostic scan tool, perform DSM self-test. If the diagnostic scan tool does not communicate with the DSM,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).
Are any DSM Diagnostic Trouble Codes (DTCs) present?
Yes If Diagnostic Trouble Codes (DTCs) B1663, B1664, and B1665 are all retrieved, GO to C10
For DTC B1711, B1715, B1719, B1723, B1727 or B1731, GO to C3
For DTC B1663, GO to C18
For all other Diagnostic Trouble Codes (DTCs), REFER to the DSM DTC Chart. GO to C28
No GO to C2
C2 CHECK THE DSM (DRIVER FRONT SEAT MODULE) SEAT CONTROL SWITCH PARAMETER IDENTIFICATIONS (PIDS)
While operating the seat control switch in all positions, monitor the following DSM seat control switch Parameter Identifications (PIDs) using a
diagnostic scan tool:
Driver Power Seat Front Up/Down Switch (SFNT_SW)
Driver Power Seat Forward/Backward Switch (SFWD_SW)
Driver Power Seat Rear Up/Down Switch (SREARSW)
Do the PID states agree with the switch positions?
Yes GO to C9
No VERIFY BJB fuse 12 (30A) is OK.
If OK, GO to C3
If not OK or fails while operating the seat control switch, DISCONNECT the seat control switch C3387 and GO to C7
C3 CHECK THE SEAT CONTROL SWITCH

Ignition OFF.
Remove the driver seat control switch.
Carry out the seat control switch component test.
Is the seat control switch OK?

Yes GO to C4
No INSTALL a new driver seat control switch.
GO to C28
C4 CHECK FOR VOLTAGE TO THE SEAT CONTROL SWITCH

Measure:

C352-9 Ground
Yes GO to C5
No REPAIR the circuit. GO to C28
C5 CHECK THE SEAT CONTROL SWITCH GROUND CIRCUIT FOR AN OPEN

Measure:

cardiagn.com
C352-7 Ground
Yes GO to C6
No REPAIR the circuit. GO to C28
C6 CHECK THE CIRCUITS BETWEEN THE SEAT CONTROL SWITCH AND DSM (DRIVER FRONT SEAT MODULE) FOR A SHORT TO
VOLTAGE
Disconnect: DSM C341B.
Ignition ON.
Measure:

C352-8 Ground
C352-1 Ground
C352-5 Ground
C352-2 Ground
C352-6 Ground
C352-10 Ground
Yes REPAIR the circuit in question. GO to C28

No GO to C7
C7 CHECK THE CIRCUITS BETWEEN THE SEAT CONTROL SWITCH AND DSM (DRIVER FRONT SEAT MODULE) FOR A SHORT TO
GROUND
Ignition OFF.
Measure:

C352-8 Ground
C352-1 Ground
C352-5 Ground
C352-2 Ground
C352-6 Ground
C352-10 Ground
Yes GO to C8
No REPAIR the circuit in question. GO to C28
C8 CHECK THE CIRCUITS BETWEEN THE SEAT CONTROL SWITCH AND DSM (DRIVER FRONT SEAT MODULE) FOR AN OPEN
Measure:

C352-8 C341B-17
C352-1 C341B-18
C352-5 C341B-16
C352-2 C341B-6
C352-6 C341B-15
C352-10 C341B-5
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Yes GO to C27
C9 CHECK THE SEAT TRACK OPERATION USING DSM (DRIVER FRONT SEAT MODULE) ACTIVE COMMANDS AND PARAMETER
IDENTIFICATIONS (PIDS)
Toggle the following DSM active commands ON and OFF using a diagnostic scan tool while monitoring the seat movement:
Front Motor Up (FRONT_UP)
Front Motor Down (FRONT_DWN)
Rear Motor Up (REAR_UP)
Rear motor down (REAR_DWN)
Horizontal Motor Forward (HORZ_FWD)
Horizontal Motor Backward (HORZ_BWD)
Does the driver seat operate correctly?
Yes The condition may be intermittent. CHECK for causes of an intermittent concern, particularly the pins and terminals of electrical
connectors that were disconnected. Do not install any new components at this time. Components should only be installed
when directed to do so in the pinpoint test. REPAIR any intermittent wiring, terminal or connector concerns found. GO to C28
No If no seat movement, GO to C10
If no front vertical seat movement, GO to C18
If no rear vertical seat movement, GO to C21
If no horizontal seat movement, GO to C24
C10 CHECK FOR VOLTAGE TO THE DSM (DRIVER FRONT SEAT MODULE)
Ignition OFF.
Disconnect: DSM C341A and C341B.
Measure:

C341A-1 Ground
Measure:

C341B-1 Ground

Yes GO to C11
No VERIFY BJB fuse 12 (30A) and BCM fuse 2 (7.5A) are OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of the circuit short. GO to C28
C11 CHECK THE DSM (DRIVER FRONT SEAT MODULE) GROUND CIRCUITS FOR AN OPEN
Measure:

C341A-2 Ground
Measure:

C341B-24 Ground
Yes GO to C12
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C12 CHECK THE FRONT HEIGHT MOTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C341B-23 Ground
C341B-11 Ground
Yes GO to C14
No GO to C13
C13 CHECK THE FRONT HEIGHT MOTOR CIRCUITS FOR A SHORT TO GROUND WITH THE MOTOR DISCONNECTED
Disconnect: Driver Seat Front Height Motor C382.
Measure:

C341B-23 Ground
C341B-11 Ground
Yes INSTALL a new driver seat track.

GO to C28
C14 CHECK THE REAR HEIGHT MOTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C341B-22 Ground
C341B-10 Ground
Yes GO to C16
No GO to C15
C15 CHECK THE REAR HEIGHT MOTOR CIRCUITS FOR A SHORT TO GROUND WITH THE MOTOR DISCONNECTED
Disconnect: Driver Seat Rear Height Motor C363.
Measure:

C341B-22 Ground
C341B-10 Ground

GO to C28
C16 CHECK THE HORIZONTAL MOTOR CIRCUITS FOR A SHORT TO GROUND
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Measure:

C341B-9 Ground
C341B-12 Ground
Yes GO to C27
No GO to C17
C17 CHECK THE HORIZONTAL MOTOR CIRCUITS FOR A SHORT TO GROUND WITH THE MOTOR DISCONNECTED
Disconnect: Driver Seat Horizontal Motor C362.
Measure:

C341B-9 Ground
C341B-12 Ground

GO to C28
C18 CHECK THE FRONT HEIGHT MOTOR FOR CORRECT OPERATION USING ACTIVE COMMANDS
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, view the following DSM active command Parameter Identifications (PIDs):
Front Motor Up (FRONT_UP)
Front Motor Down (FRONT_DWN)
NOTE: During the following step, the voltage being measured changes polarity dependent upon which direction the seat control is activated.
Using a diagnostic scan tool, toggle the active commands FRONT_UP and FRONT_DOWN on and off and measure:

C382-1 C382-3
Is the voltage greater than 11 volts when commanded ON in both directions and 0 volt when commanded OFF?

GO to C28
No GO to C19
C19 CHECK THE FRONT HEIGHT MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C341B-23 Ground
C341B-11 Ground
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No GO to C20
C20 CHECK THE FRONT HEIGHT MOTOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C341B-23 C382-3
C341B-11 C382-1
Yes GO to C27
C21 CHECK THE REAR HEIGHT MOTOR FOR CORRECT OPERATION USING ACTIVE COMMANDS
Ignition OFF.
Ignition ON.
Rear Motor Up (REAR_UP)
Rear motor down (REAR_DWN)
Using a diagnostic scan tool, toggle the active commands REAR_UP and REAR_DOWN on and off and measure:

C363-1 C363-3

GO to C28
No GO to C22
C22 CHECK THE REAR HEIGHT MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C341B-22 Ground
C341B-10 Ground

No GO to C23
C23 CHECK THE REAR HEIGHT MOTOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C341B-22 C363-3
C341B-10 C363-1
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Yes GO to C27
C24 CHECK THE HORIZONTAL MOTOR FOR CORRECT OPERATION USING ACTIVE COMMANDS
Ignition OFF.
Ignition ON.
Horizontal Motor Forward (HORZ_FWD)
Horizontal Motor Backward (HORZ_BWD)
Using a diagnostic scan tool, toggle the active commands HORZ_FWD and HORZ_BWD on and off and measure:

C362-1 C362-3

GO to C28
No GO to C25
C25 CHECK THE HORIZONTAL MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF.
Ignition ON.
Measure:

C341B-9 Ground
C341B-12 Ground

No GO to C26
C26 CHECK THE HORIZONTAL MOTOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C341B-9 C362-3
C341B-12 C362-1
Yes GO to C27
C27 CHECK THE DSM (DRIVER FRONT SEAT MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all of the DSM connectors.
Repair:
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Reconnect the DSM connectors. Make sure they seat and latch correctly.
NOTE: Do not reconnect Driver Side Airbag In-line C345 at this time.
Reconnect all previously disconnected connectors.
Ignition ON.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new DSM.
GO to C28
cause of any connector or pin issues. GO to C28
C28 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
The Memory Seat Does Not Operate Using the Memory SET Switch
DSM DTC Fault Trigger Conditions

B1663 Seat Driver Front Up/Down Motor During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position
Stalled sensor to monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor
operation on the next activation of the seat control switch. If no movement continues to be monitored after 250
milliseconds, the DSM disables the output.
B1664 Seat Driver Rear Up/Down Motor During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position
Stalled sensor to monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor
B1665 Seat Driver Forward/Backward During self-test, the DSM attempts to operate the appropriate seat track motor and uses the motor's position
Motor Stalled sensor to monitor movement. If no motor movement is sensed, the DTC is set. The DSM will retry motor
B1952 Seat Rear Up/Down Position If a short to voltage or an open condition is present on the affected motor's position sensor (Hall-effect) feedback
Feedback Circuit Short to Battery circuit, the DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate
the associated motor in one-second increments.
B1953 Seat Rear Up/Down Position If a short to ground condition is present on the affected motor's position sensor (Hall-effect) feedback circuit, the
Feedback Circuit Short to Ground DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate the
associated motor in one-second increments.
B1956 Seat Front Up/Down Position If a short to voltage or an open condition is present on the affected motor's position sensor (Hall-effect) feedback
Feedback Circuit Short to Battery circuit, the DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate
the associated motor in one-second increments.
B1957 Seat Front Up/Down Position If a short to ground condition is present on the affected motor's position sensor (Hall-effect) feedback circuit, the
Feedback Circuit Short to Ground DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate the
associated motor in one-second increments.
B1964 Seat Horizontal Forward/Rearward If a short to voltage or an open condition is present on the affected motor's position sensor (Hall-effect) feedback
Position Feedback Circuit Short to circuit, the DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate
Battery the associated motor in one-second increments.
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B1965 Seat Horizontal Forward/Rearward If a short to ground condition is present on the affected motor's position sensor (Hall-effect) feedback circuit, the
Position Feedback Circuit Short to DTC is set. After a DTC is set, a memory recall is not possible but the seat control switch can operate the
Ground associated motor in one-second increments.
DDM DTC Fault Trigger Conditions

B1C03:23 Memory #1 Switch: If a short to ground is sensed on the switch input circuit during the DDM self-test, the DTC is set. If activity is sensed on
Signal Stuck Low the input circuit for greater than 2 minutes, the DTC is set as continuous. With the DTC set, any input signal on the circuit
is ignored.
is ignored.
is ignored.
Possible Causes

Memory SET switch
Missing ignition status information
Horizontal motor
Seat track
DSM
PINPOINT TEST D : THE MEMORY SEAT DOES NOT OPERATE USING THE MEMORY SET SWITCH
WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental Restraint System (SRS) deployment. Never compromise
or depart from these instructions. Failure to precisely follow all instructions could result in serious personal injury from an accidental deployment.
D1 CHECK THE DSM (DRIVER FRONT SEAT MODULE) IGNITION SWITCH STATUS PID (PARAMETER IDENTIFICATION) STATES
Ignition ON.
Using a diagnostic scan tool, monitor the DSM IGN_SW PID while operating the ignition.
Do the PID states agree?
Yes GO to D2
No To diagnose no power in run,
REFER to: Steering Wheel and Column Electrical Components (211-05 Steering Wheel and Column Electrical Components, Diagnosis
and Testing).
D2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)

Operate the memory seat in all directions through the full range of travel.
Place the memory seat in the middle of each range of travel.
Using a diagnostic scan tool, perform self-test on the DSM and DDM. If the diagnostic scan tool does not communicate to the DSM and/or DDM,
Yes For DTC B1C03:23, B1C04:23 or B1C05:23, GO to D4

If Diagnostic Trouble Codes (DTCs) B1952, B1956 and B1964 are all retrieved, GO to D9
If Diagnostic Trouble Codes (DTCs) B1953, B1957 and B1965 are all retrieved, GO to D9
For DTC B1663 or B1956, GO to D10
For DTC B1957, GO to D11
For all other Diagnostic Trouble Codes (DTCs), REFER to the DSM or DDM DTC Chart(s).
No GO to D3
D3 MONITOR DSM (DRIVER FRONT SEAT MODULE) PARAMETER IDENTIFICATIONS (PIDS) AND CHECK FOR CORRECT MEMORY SET SWITCH
INPUTS
While activating the memory recall 1, 2 and 3 buttons, monitor the following DSM memory recall switch status Parameter Identifications (PIDs) using a
diagnostic scan tool:
Memory 1 recall switch status (MEM_1).
Do the PID values agree with the switch button positions?
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Yes GO to D9
No GO to D4
D4 CHECK THE MEMORY SET SWITCH

Ignition OFF.
Disconnect: Driver Door Lock Control Switch C541.
While pressing and releasing the indicated memory recall button 1, measure the component side resistance of the driver door lock control switch using the
following table:

Action
C541, pin 5, Component Side C541, pin 3, Component Side
following table:

Action
Action
following table:
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Action
Are the resistances less than 20 ohms with the switch buttons pressed and greater than 10,000 ohms with the switch buttons released?
Yes GO to D5
No INSTALL a new door lock control switch.
REFER to: Door Lock Control Switch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
D5 CHECK THE MEMORY SET SWITCH GROUND CIRCUIT FOR AN OPEN

Ignition OFF.
Measure:

C541-3 Ground
Yes GO to D6
D6 CHECK THE MEMORY SET CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C541-5 Ground
C541-6 Ground
C541-7 Ground
Yes REPAIR the circuit in question.

No GO to D7
D7 CHECK THE MEMORY SET SWITCH CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C541-5 Ground
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C541-6 Ground
C541-7 Ground
Yes GO to D8
No REPAIR the circuit in question.
D8 CHECK THE MEMORY SET SWITCH CIRCUITS FOR AN OPEN

Measure:

C541-5 C501B-1
C541-6 C501B-3
C541-7 C501B-2
Yes GO to D20
D9 CHECK THE DSM (DRIVER FRONT SEAT MODULE) SENSOR PARAMETER IDENTIFICATIONS (PIDS)
While operating the seat control switch in all positions, monitor the following DSM seat control switch Parameter Identifications (PIDs) using a diagnostic scan
tool:
Driver Power Seat Front Up/Down Switch (SFNT_MT)
Driver Power Seat Forward/Backward Switch (SFWD_MT)
Driver Power Seat Rear Up/Down Switch (SREARMT)
Does each PID indicate the sensor is operational throughout each motor's full range of travel?
Yes GO to D19
No If the PID indicates driver seat front vertical position sensor is not present, GO to D10
If the PID indicates driver seat rear vertical position sensor is not present, GO to D13
If the PID indicates driver seat horizontal position sensor is not present, GO to D16
D10 CHECK THE FRONT HEIGHT SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
Measure:

C382-2 Ground
C382-4 Ground
Yes REPAIR the circuit in question. GO to D21

No GO to D11
D11 CHECK THE FRONT HEIGHT SENSOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C382-2 Ground
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C382-4 Ground
Yes GO to D12
No REPAIR the circuit in question. GO to D21
D12 CHECK THE FRONT HEIGHT SENSOR CIRCUITS FOR AN OPEN

Measure:

C382-2 C341B-8
C382-4 C341B-4

GO to D21
D13 CHECK THE REAR HEIGHT SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C363-2 Ground
C363-4 Ground
Is any voltage present on any circuits?

No GO to D14
D14 CHECK THE REAR HEIGHT SENSOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C363-2 Ground
C363-4 Ground
Yes GO to D15
D15 CHECK THE REAR HEIGHT SENSOR CIRCUITS FOR AN OPEN

Measure:

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C363-2 C341B-3
C363-4 C341B-8

GO to D21
D16 CHECK THE HORIZONTAL SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C362-2 Ground
C362-4 Ground
Is any voltage present on any circuits?

No GO to D17
D17 CHECK THE HORIZONTAL SENSOR CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C362-2 Ground
C362-4 Ground
Yes GO to D18
D18 CHECK THE HORIZONTAL SENSOR CIRCUITS FOR AN OPEN

Measure:

C362-2 C341B-8
C362-4 C341B-14

GO to D21
D19 CHECK THE DSM (DRIVER FRONT SEAT MODULE) OPERATION

Ignition OFF.
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Repair:
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new DSM.
GO to D21
of any connector or pin issues. GO to D21
D20 CHECK THE DDM (DRIVER DOOR MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all of the DDM connectors.
Repair:
Reconnect the DDM connectors. Make sure they seat and latch correctly.
Connect: Driver Door Lock Control Switch C541.
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new DDM.
REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
D21 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
Easy Entry/Easy Exit is Inoperative/Does Not Operate Correctly
Possible Causes
Easy entry/exit feature is not enabled

Missing ignition status information - communication bus message
DSM
PINPOINT TEST E : EASY ENTRY/EASY EXIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

E1 CHECK THE DRIVER POWER SEAT OPERATION
Ignition ON.
Check the message center to verify the easy entry/exit feature is turned on.
Using the seat control switch, verify the driver power seat operates fully forward and backward.
Using a diagnostic scan tool, perform the DSM self-test.
Are any Diagnostic Trouble Codes (DTCs) received?
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Yes REFER to the DSM DTC Chart.
No If disabled, ENABLE the easy entry/exit feature through the message center. REFER to the Owner's Literature. TEST the
system for normal operation. If OK, INSTRUCT the customer on correct system operation. Otherwise, GO to E2
E2 CHECK THE DSM (DRIVER FRONT SEAT MODULE) IGNITION SWITCH STATUS PID (PARAMETER IDENTIFICATION) STATES
Ignition ON.
Using a diagnostic scan tool, monitor the DSM IGN_SW PID while operating the ignition.
Do the PID states agree with ignition mode?
Yes INSTALL a new DSM.

No DIAGNOSE the ignition status concern.
REFER to: Steering Wheel and Column Electrical Components (211-05 Steering Wheel and Column Electrical Components,
The Power Seat is Inoperative or Does Not Operate Correctly — Driver, Without Memory
Possible Causes
Fuse
Seat control switch
Horizontal motor
Seat track
PINPOINT TEST F : THE POWER SEAT IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY — DRIVER, WITHOUT MEMORY
F1 CHECK THE SEAT OPERATION
Attempt to operate the seat in all directions.
Is the seat inoperative in all directions?
Yes GO to F2
No If only the horizontal motor is inoperative, GO to F4
If only the front height motor is inoperative, GO to F6
If only the rear height motor is inoperative, GO to F8
F2 CHECK FOR VOLTAGE TO THE SEAT CONTROL SWITCH

Measure:

C352-9 Ground
Yes GO to F3
possible causes of the circuit short. GO to F10
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F3 CHECK THE SEAT CONTROL SWITCH GROUND CIRCUIT
Measure:

C352-7 Ground

GO to F10
No REPAIR the circuit. GO to F10
F4 CHECK FOR VOLTAGE TO THE SEAT HORIZONTAL MOTOR

While pushing the horizontal switch forward and rearward, measure:

C362-1 C362-3

GO to F10
No GO to F5
F5 CHECK THE SEAT HORIZONTAL MOTOR CIRCUIT FOR AN OPEN

Measure:

C352-6 C362-3
C352-5 C362-1

GO to F10
No REPAIR the circuit in question. GO to F10
F6 CHECK FOR VOLTAGE TO THE SEAT FRONT HEIGHT MOTOR

While pushing the front height switch upward and downward, measure:

C382-1 C382-3

GO to F10
No GO to F7
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F7 CHECK THE SEAT FRONT HEIGHT MOTOR CIRCUIT FOR AN OPEN
Measure:

C352-1 C382-3
C352-2 C382-1

GO to F10
F8 CHECK FOR VOLTAGE TO THE SEAT REAR HEIGHT MOTOR

While pushing the rear height switch upward and downward, measure:

C363-1 C363-3

GO to F10
No GO to F9
F9 CHECK THE SEAT REAR HEIGHT MOTOR CIRCUIT FOR AN OPEN

Measure:

C352-8 C363-3
C352-10 C363-1

GO to F10
F10 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
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DTC: B1317

B1317 Battery Voltage NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events.
High
The DSM continuously monitors the input voltage for correct operation. If the DSM detects input voltage above 15 volts, it stores DTC
B1317 in memory. If DTC B1317 is set, the DSM disables the memory system outputs for the driver seat memory operation.
Possible Causes

DSM
PINPOINT TEST G : DTC: B1317

G1 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B1317, B1676 OR P0563 SET IN OTHER MODULES
Ignition ON.
Using a diagnostic scan tool, retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Is DTC B1317, B1676 or P0563 set in more than one module?
Yes DIAGNOSE the charging system concern. Refer to the appropriate section in Group 414 for the procedure.
No GO to G2
G2 CHECK THE BATTERY VOLTAGE

Turn off all interior/exterior lights and accessories.
Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery voltage
Does the battery voltage rise to 15 volts or higher?
No GO to G3
G3 RECHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B1317
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, clear the Continuous Memory Diagnostic Trouble Codes (CMDTCs).
Is DTC B1317 present?

No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump
starting the vehicle.
DTC: B1318
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B1318 Battery Voltage The DSM continuously monitors the input voltage for correct operation. If the DSM detects input voltage below 10 volts, it stores DTC
Low B1318 in memory. If DTC B1318 is set, the DSM disables the memory system outputs for the driver seat memory operation.
Possible Causes

DSM
PINPOINT TEST H : DTC: B1318
H1 RECHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B1318
Ignition ON.
Using a diagnostic scan tool, repeat the DSM self-test.
Is DTC B1318 still present?
Yes GO to H2
No The system is operating normally at this time. The DTC may have been set previously due to a discharged battery condition.
H2 CHECK FOR CHARGING SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) IN THE PCM (POWERTRAIN CONTROL MODULE)
Using a diagnostic scan tool, retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from the PCM.
Are any charging system Diagnostic Trouble Codes (DTCs) present?
No GO to H3
H3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE

Ignition OFF.
Check the battery condition and verify the battery is fully charged.
REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
Is the battery OK and fully charged?
Yes GO to H4
No DIAGNOSE the charging system concern. Refer to the appropriate section in Group 414 for the procedure.
H4 CHECK THE DSM (DRIVER FRONT SEAT MODULE) VOLTAGE SUPPLY
Measure and record the voltage at the battery.
Disconnect: DSM C341A and C341B.
Ignition ON.
Measure:

C341A-1 Ground

C341B-1 Ground
Yes GO to H5
No REPAIR the circuit. CLEAR the DTC. GO to H7
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H5 CHECK THE DSM (DRIVER FRONT SEAT MODULE) GROUND CIRCUIT
Ignition OFF.
Disconnect: Negative Battery Cable.
Measure:

C341A-2 Ground

C341B-24 Ground
Yes CONNECT the negative battery cable. GO to H6

No REPAIR the circuit. CONNECT the negative battery cable. GO to H7
H6 CHECK THE DSM (DRIVER FRONT SEAT MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new DSM.
GO to H7
cause of any connector or pin issues. GO to H7
H7 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC: U0140
The DSM and the BCM communicate using the MS-CAN.
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U0140 Lost Communication With Body Control Set by the DSM whenever it has lost communication to the BCM for 15 seconds or longer while DSM
Module (GEM ) input is between 10 and 15 volts.
Possible Causes
Module communication
DSM
BCM
PINPOINT TEST I : DTC: U0140

I1 VERIFY CUSTOMER CONCERN
Ignition ON.
Yes GO to I2
No The system is operating normally at this time. The DTC may have been set due to high network traffic or intermittent fault
condition.
I2 CHECK THE COMMUNICATION NETWORK

Ignition ON.
Using a diagnostic scan tool, perform the network test.
Does the DSM pass the network test?
Yes GO to I3
No
I3 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE SELF-TEST
Check for recorded DSM Diagnostic Trouble Codes (DTCs) from the self-test.
Is DTC B1317 or B1318 recorded?
Yes For DTC B1317, GO to Pinpoint Test G

For DTC B1318, GO to Pinpoint Test H
No GO to I4
I4 RECHECK THE DSM (DRIVER FRONT SEAT MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
NOTE: If new modules were installed prior to the DTC being set, the module configuration may be incorrectly set during PMI or the PMI may not have
been carried out.
Using a diagnostic scan tool, repeat the DSM self-test.
Yes GO to I5
No The system is operating correctly at this time. The DTC may have been set due to high network traffic or intermittent fault
condition.
I5 CHECK FOR DTC U0140/U0140:00 IN OTHER MODULES
been carried out.
Ignition OFF.
Ignition ON.
Wait 10 seconds.
Is DTC U0140/U0140:00 set in other modules?
Yes
No INSTALL a new DSM.
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One or Both Single Climate Controlled Seats are Inoperative
The SCME is supplied voltage at all times, but the climate controlled seat system only operates with the engine running. The system can be operated with the
ignition ON engine OFF by using a diagnostic scan tool to bypass the climate controlled seat buttons on the touchscreen and FCIM. When commanding a heat
or cool mode operation in this manner, it only operates in 15 second intervals.
Both voltage supply circuits are spliced together internal to the SCME, so if one circuit becomes open, both seats can still be operated. However, if a fault
occurs setting a DTC specific to either climate controlled seat, only the affected seat is disabled by the SCME.
Possible Causes

FDIM
FCIM
SCME
PINPOINT TEST J : ONE OR BOTH CLIMATE CONTROLLED SEATS ARE INOPERATIVE

J1 CHECK FOR SCME (FRONT SEAT CLIMATE CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, perform the SCME self-test.
Were any Diagnostic Trouble Codes (DTCs) retrieved?
Yes GO to the SCME DTC Chart.

No If the diagnostic scan tool did not communicate to the SCME,
Otherwise, GO to J2
J2 CHECK OPERATION OF THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) USING PARAMETER IDENTIFICATIONS (PIDS)
NOTE: This step verifies the SCME is able to receive and process inbound command messages from the network and demonstrates if the SCME is
operational. If the SCME is functioning correctly, this indicates the FDIM or FCIM may not be sending the commands correctly.
Using a diagnostic scan tool, view the SCME Parameter Identifications (PIDs):
Driver Seat
Seat cushion thermal electric device temperature (CSHTEMP)
Seat back thermal electric device temperature (BKTMP)
Climate-controlled seat heat command (TED_HEAT_D)
Front Passenger Seat

Passenger Cushion Thermal Electric Device (TED) Temperature (PCSHTMP)
Passenger Back (TED) Temperature (PBKTMP)
Passenger (TED) Heat Mode (TED_HEAT_P)
NOTE: The SCME active commands TED_HEAT_D (driver seat) and TED_HEAT_P (passenger seat) are limited to 15 seconds in the ON state.
Operate the affected climate controlled seat using the active command while monitoring the appropriate Parameter Identifications (PIDs) for that seat.
When the command is in process, the blower motor temperature Parameter Identifications (PIDs) on the affected seat should momentarily
increase. If no temperature increase is noted, remove the cushion blower filter and repeat the active command while physically monitoring the
cushion blower for fan movement.
Do the PID states or cushion blower movement indicate climate controlled seat operation when using the active command?
Yes GO to J3
No INSTALL a new SCME.
REFER to: Front Seat Climate Control Module [SCME] (501-10A Front Seats, Removal and Installation).
J3 USE THE FCIM (FRONT CONTROLS INTERFACE MODULE) BUTTONS AND MONITOR THE SCME (FRONT SEAT CLIMATE CONTROL
MODULE) PID (PARAMETER IDENTIFICATION) FOR A RESPONSE
Using a diagnostic scan tool, view the SCME Parameter Identifications (PIDs):
Driver State Seat Mode (DCCSMOD) (driver seat)
Passenger State Seat Mode (PCCSMOD) (passenger seat)
Start the engine.
NOTE: Operation of the climate controlled seats repeatedly on and off or repeatedly switching between heat and cool modes may cause SCME
Diagnostic Trouble Codes (DTCs) to set, disabling one or both seat system and may require Diagnostic Trouble Codes (DTCs) to be cleared before
seat operation may continue. It is recommended to allow time between modes for seat temperatures to return toward ambient temperatures before
continuing.
Attempt to operate the affected climate controlled seat in all modes using the appropriate buttons on the FCIM while monitoring the SCME PID
DCCSMOD (driver seat) or PCCSMOD (passenger seat).
Do all the PID states match the climate controlled seat settings selected on the FCIM?
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Yes To diagnose the inoperative touchscreen button(s),
REFER to: Information and Entertainment System (415-00B Information and Entertainment System - General Information -
Vehicles With: Touchscreen Display, Diagnosis and Testing).
No If only the climate seat functionality is inoperative, INSTALL a new FCIM.
REFER to: Front Controls Interface Module (FCIM) (415-00B Information and Entertainment System - General Information -
If other features of the FCIM are also inoperative, DIAGNOSE the FCIM concern.
REFER to: Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) (412-00 Climate Control
DTC B2486
The SCME monitors the input voltage for correct operation. If the SCME detects input voltage below 10 volts or above 15 volts, it stores DTC B2486 in memory.
If DTC B2486 is set, the SCME enters a standby mode and suspends operation of both seats until system voltage between 10 and 15 volts is restored and a
climate controlled seat switch button is selected on.

B2486 Climate Control Seat NOTE: DTC B2486 can be set if the vehicle has been recently jump started, the battery has been recently charged or the
Module Voltage Out of battery has been discharged. The battery may become discharged due to excessive load(s) on the charging system from
Range aftermarket accessories or if the battery has been left unattended with the accessories on.
If the SCME detects voltage below 10 volts or greater than 15 volts, the DTC is set.
Possible Causes

SCME
PINPOINT TEST K : DTC B2486
K1 RETRIEVE ALL CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES (CMDTCS) IN ALL MODULES
Ignition ON.
Using a diagnostic scan tool, retrieve all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Are any charging system related Diagnostic Trouble Codes (DTCs) retrieved from the PCM?
No GO to K2
K2 CHECK BATTERY CONDITION

Ignition OFF.
Carry out the Battery Condition Test.
Did the battery pass the condition test?
Yes If the battery passed the condition test but required a recharge, DIAGNOSE the charging system concern. Refer to the
appropriate section in Group 414 for the procedure. CLEAR all Diagnostic Trouble Codes (DTCs). TEST the system for normal
operation.
If the battery passed the condition test and did not require a recharge, GO to K3
No INSTALL a new battery.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
K3 CHECK CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine speed to increase above 2,000 rpm while performing this step or the generator may self-excite and result in default
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charging system output voltage. If engine speed goes above 2,000 rpm, shut the vehicle OFF and restart the engine before performing this step.
Start the engine.
Measure the voltage of the battery with and without a load on the charging system as follows:
Turn off all accessories and run the engine at 1,500 rpm for a minimum of 2 minutes while measuring battery voltage.
Turn on headlights and HVAC fan on high and run engine at 1,500 rpm for a minimum of 2 minutes while measuring battery voltage.
Was the battery voltage between 13 and 15.2 volts?
Yes GO to K4
No DIAGNOSE the charging system concern. Refer to the appropriate section in Group 414 for the procedure.
K4 CHECK VOLTAGE AT THE SCME (FRONT SEAT CLIMATE CONTROL MODULE)
Disconnect: SCME C3265A.
Ignition ON.
Measure:

C3265A-E Ground
C3265A-F Ground
Yes GO to K5
No REPAIR the circuit in question. GO to K7
K5 CHECK SCME (FRONT SEAT CLIMATE CONTROL MODULE) GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C3265A-M Ground
Repeat this measurement while wiggling the harness.
Yes GO to K6
No REPAIR the circuit. GO to K7
K6 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all of the SCME connectors.
Repair:
Reconnect the SCME connectors. Make sure they seat and latch correctly.
NOTE: Do not reconnect Passenger Side Airbag In-line C219 at this time.
Ignition ON.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new SCME.
GO to K7
cause of any connector or pin issues. GO to K7
K7 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY
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No
DTCs B103B and B1111
The SCME monitors the backrest and cushion blower motor circuits. If a short to ground or voltage on any of these circuits is detected, the Diagnostic Trouble
Codes (DTCs) will be set.

B103B Thermoelectric Driver If SCME outputs to the driver seat backrest or cushion blower motor (circuit pins G, H, J or K at the SCME
Overcurrent Low connector) or any components within these circuit loops are shorted to ground or a blower motor resistance of less
than 0.9 ohm is sensed, the SCME shuts down the driver seat system and sets this DTC.
B1111 Driver Thermal Electric Device If the SCME blower motor driver integrated circuit temperature exceeds 175° C (347° F), the SCME shuts down the
Control Overtemperature Fault driver seat system and sets this DTC.
Possible Causes

Backrest blower motor
Cushion blower motor
SCME
PINPOINT TEST L : DTCS B103B AND B1111
L1 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C3265A-G Ground
C3265A-H Ground
C3265A-J Ground
C3265A-K Ground
Yes GO to L2
No If the resistance of C3265A-G and C3265A-H to ground is not greater than 10,000 ohms to ground, GO to L6
If the resistance of C3265A-J and C3265A-K to ground is not greater than 10,000 ohms to ground, GO to L7
L2 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:
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C3265A-G Ground
C3265A-H Ground
C3265A-J Ground
C3265A-K Ground
Yes If voltage is present at C3265A-G and/or C3265A-H, GO to L8

If voltage is present at C3265A-J and/or C3265A-K, GO to L9
No GO to L3
L3 CHECK THE RESISTANCE OF THE BLOWER MOTOR AND WIRING

Ignition OFF.
Measure:

C3265A-G C3265A-H
C3265A-J C3265A-K
Are the resistances between 0.9 and 10 ohms?
Yes GO to L10
No If the resistance between C3265A-G and C3265A-H is not between 0.9 and 10 ohms, GO to L5
If the resistance between C3265A-J and C3265A-K is not between 0.9 and 10 ohms, GO to L4
L4 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE RESISTANCE

Disconnect: Driver Seat Backrest Blower Motor C3034.
Measure the component side resistance between:

Action
Action
C3034-1, Component Side C3034-2, Component Side
Is the resistance between 0.9 and 10 ohms?
Yes REPAIR the circuit(s) in question. GO to L11

No INSTALL a new backrest blower motor.
REFER to: Front Seat Backrest Blower Motor (501-10 Front Seats) .
GO to L11
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L5 CHECK CUSHION BLOWER MOTOR RESISTANCE
Disconnect: Driver Seat Cushion Blower Motor C3035.

Action
Yes REPAIR the circuit(s) in question. GO to L11

No INSTALL a new cushion blower motor.
REFER to: Front Seat Cushion Blower Motor (501-10A Front Seats, Removal and Installation).
GO to L11
L6 CHECK THE CUSHION BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND

Measure:

C3265A-G Ground
C3265A-H Ground

Yes INSTALL a new cushion blower motor.
GO to L11
No REPAIR the circuit in question. GO to L11
L7 CHECK THE BACKREST BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND

Measure:

C3265A-J Ground
C3265A-K Ground
Yes INSTALL a new backrest blower motor.

GO to L11
No REPAIR the circuit in question. GO to L11
L8 CHECK THE CUSHION BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
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Ignition ON.
Measure:

C3265A-G Ground
C3265A-H Ground
Yes REPAIR the circuit in question. GO to L11

GO to L11
L9 CHECK THE BACKREST BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:

C3265A-J Ground
C3265A-K Ground
Yes REPAIR the circuit in question. GO to L11

GO to L11
L10 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
NOTE: Do not reconnect Driver Side Airbag In-line C345 or Passenger Side Airbag In-line C219 at this time.
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new SCME.
GO to L11
of any connector or pin issues. GO to L11
L11 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
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DTC B103C
The SCME monitors the backrest and cushion blower motor circuits. If an open on any of these circuits is detected, the DTC will be set.

B103C Thermoelectric Driver If SCME outputs to the driver seat backrest or cushion blower motor (circuit pins G, H, J or K at the SCME connector) or any
Open Load components within these circuit loops are open, disconnected or a blower motor resistance greater than 90,000 ohms is
sensed, the SCME continues normal operation and sets this DTC.
Possible Causes

SCME
PINPOINT TEST M : DTC B103C
M1 CHECK BLOWER MOTOR CIRCUITS FOR AN OPEN
Measure:

C3265A-G C3035-1
C3265A-H C3035-2
Measure:

C3265A-J C3034-1
C3265A-K C3034-2
Yes GO to M2
No REPAIR the circuit(s) in question. GO to M5
M2 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:

C3265A-G Ground
C3265A-H Ground
C3265A-J Ground
C3265A-K Ground
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Yes REPAIR the circuit(s) in question. GO to M5

No GO to M3
M3 CHECK BACKREST AND CUSHION BLOWER MOTOR RESISTANCES


Action

Action
Action
Yes GO to M4
No If the backrest blower motor resistance measurement failed, INSTALL a new backrest blower motor.
GO to M5
If the cushion blower motor resistance measurement failed, INSTALL a new cushion blower motor.
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GO to M5
M4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to M5
of any connector or pin issues. GO to M5
M5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B103D

ignition ON engine OFF by using a diagnostic scan tool to bypass the climate controlled seat switches on the touchscreen and FCIM. When commanding a heat
or cool mode operation in this manner, the climate controlled seat system only operates in 15 second intervals.
Cabin air is drawn through and distributed to each of the blower motors located in the seat cushion and backrest. The blower motors then heat or cool the air.
The air is then directed into the foam pad where it is distributed along the surface of the cushion and backrest of the seat. Once the system is activated, the
SCME uses a set of flexible algorithms to control the heating/cooling modes and the blower speed dependant on the commanded climate controlled seat
settings.

B103D Blower Driver If the SCME outputs to the driver seat blower or any components within these circuit loops are shorted to ground or cause
Overtemperature an excessive current draw, the SCME overheats, shuts down the driver seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST N : DTC B103D
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N1 CHECK THE BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND
Disconnect: SCME C3265C.
Measure:

C3265C-16 Ground
Yes GO to N2
No REPAIR the circuit. GO to N5
N2 CHECK THE BLOWER MOTOR FEED CIRCUITS FOR A SHORT TOGETHER

Ignition ON.
Measure:

C3265C-16 C3265C-15
Yes GO to N3
No REPAIR the circuits. GO to N5
N3 CHECK THE BACKREST BLOWER AND CUSHION BLOWER RESISTANCES

NOTE: The ohmmeter must be connected with the positive lead to pin 3 and the negative lead to pin 4 when measuring. Ohmmeter leads incorrectly
connected will result in false readings and lead to incorrect identification of components that are not faulty.
Action

Action
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Are the resistances between 4000 and 10,000 ohms?
Yes GO to N4
GO to N5
GO to N5
N4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to N5
of any connector or pin issues. GO to N5
N5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B1113 and B111B
The SCME monitors the backrest and cushion blower motor circuits. If a short to ground or voltage on any of these circuits is detected, the Diagnostic Trouble
Codes (DTCs) will be set.
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B1113 Passenger Thermal Electric If the SCME blower motor driver integrated circuit temperature exceeds 175° C (347° F), the SCME shuts down
Device Control Overtemperature the driver seat system and sets this DTC.
Fault
B111B Passenger Thermo-Electric Driver If SCME outputs to the driver seat backrest or cushion blower motor (circuit pins A, B, C or D at the SCME
Overcurrent Low connector) or any components within these circuit loops are shorted to ground or a blower motor resistance of less
than 0.9 ohm is sensed, the SCME shuts down the driver seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST O : DTC B1113 AND B111B
O1 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C3265A-A Ground
C3265A-B Ground
C3265A-C Ground
C3265A-D Ground
Yes GO to O2
No If the resistance of C3265A-A and C3265A-B to ground is not greater than 10,000 ohms to ground, GO to O6
If the resistance of C3265A-C and C3265A-D to ground is not greater than 10,000 ohms to ground, GO to O7
O2 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265A-A Ground
C3265A-B Ground
C3265A-C Ground
C3265A-D Ground
Yes If voltage is present at C3265A-A and/or C3265A-B, GO to O8

If voltage is present at C3265A-C and/or C3265A-D, GO to O9
No GO to O3
O3 CHECK THE RESISTANCE OF THE BLOWER MOTOR AND WIRING

Ignition OFF.
Measure:

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C3265A-A C3265A-B
C3265A-C C3265A-D
Yes GO to O10
No If the resistance between C3265A-A and C3265A-B is not between 0.9 and 10 ohms, GO to O5
If the resistance between C3265A-C and C3265A-D is not between 0.9 and 10 ohms, GO to O4
O4 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE RESISTANCE

Disconnect: Passenger Seat Backrest Blower Motor C3039.

Action
Yes REPAIR the circuit(s) in question. GO to O11

GO to O11
O5 CHECK CUSHION BLOWER MOTOR RESISTANCE

Disconnect: Passenger Seat Cushion Blower Motor C3040.

Action
Yes REPAIR the circuit(s) in question. GO to O11

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GO to O11
O6 CHECK THE CUSHION BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND

Measure:

C3265A-A Ground
C3265A-B Ground
Yes INSTALL a new cushion blower motor.

GO to O11
No REPAIR the circuit in question. GO to O11
O7 CHECK THE BACKREST BLOWER MOTOR CIRCUITS FOR A SHORT TO GROUND

Measure:

C3265A-C Ground
C3265A-D Ground
Yes INSTALL a new backrest blower motor.

GO to O11
No REPAIR the circuit in question. GO to O11
O8 CHECK THE CUSHION BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:
C3265A-A Ground
C3265A-B Ground
Yes REPAIR the circuit in question. GO to O11

GO to O11
O9 CHECK THE BACKREST BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:

C3265A-C Ground
C3265A-D Ground
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Yes REPAIR the circuit in question. GO to O11

GO to O11
O10 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to O11
of any connector or pin issues. GO to O11
O11 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B111C
The SCME monitors the backrest and cushion blower motor circuits. If an open on any of these circuits is detected, the DTC will be set.

B111C Passenger If SCME outputs to the passenger seat backrest or cushion blower motor (circuit pins A, B, C or D at the SCME connector)
Thermoelectric Driver or any components within these circuit loops are open, disconnected or a blower motor resistance greater than 90,000
Open Load ohms is sensed, the SCME continues normal operation and sets this DTC.
Possible Causes

SCME
PINPOINT TEST P : DTC B111C
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P1 CHECK BLOWER MOTOR CIRCUITS FOR AN OPEN
Disconnect: Passenger Side Backrest Blower Motor C3039.
Measure:

C3265A-A C3040-1
C3265A-B C3040-2
Measure:

C3265A-C C3039-1
C3265A-D C3039-2
Yes GO to P2
No REPAIR the circuit(s) in question. GO to P5
P2 CHECK BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:

C3265A-A Ground
C3265A-B Ground
C3265A-C Ground
C3265A-D Ground

Yes REPAIR the circuit(s) in question. GO to P5
No GO to P3
P3 CHECK BACKREST AND CUSHION BLOWER MOTOR RESISTANCES


Action
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Action
Yes GO to P4
GO to P5
GO to P5
P4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, SCME.
GO to P5
of any connector or pin issues. GO to P5
P5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B111D
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ignition ON engine OFF by using a diagnostic scan tool to bypass the climate controlled seat switches on the touchscreen and FCIM. When commanding a heat
or cool mode operation in this manner, the climate controlled seat system only operates in 15 second intervals. Both voltage supply circuits are spliced together
internal to the SCME, so if one circuit becomes open, both seats can still be operated. However, if a fault occurs setting a DTC specific to either climate
controlled seat, only the affected seat is disabled by the SCME.
settings.

B111D Passenger Blower Driver If the SCME outputs to the passenger seat blower or any components within these circuit loops are shorted to ground
Overtemperature or cause an excessive current draw, the SCME overheats, shuts down the passenger seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST Q : DTC B111D
Q1 CHECK THE BLOWER MOTOR FEED CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265C-8 Ground
Yes GO to Q2
No REPAIR the circuit. GO to Q5
Q2 CHECK THE BLOWER MOTOR FEED CIRCUITS FOR A SHORT TOGETHER

Ignition ON.
Measure:

C3265C-7 C3265C-8
Yes GO to Q3
No REPAIR the circuits. GO to Q5
Q3 CHECK THE BACKREST BLOWER AND CUSHION BLOWER RESISTANCES

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Action

Action
Are the resistances between 4000 and 10,000 ohms?

Yes GO to Q4
GO to Q5
GO to Q5
Q4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to Q5
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of any connector or pin issues. GO to Q5
Q5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A1
The SCME supplies voltage and ground to the passenger seat cushion backrest and cushion blower motors. The SCME also sends a speed control voltage
signal to the blower motor to control blower speed.

B19A1 Passenger Seat Cushion Blower Speed If the passenger seat cushion blower speed circuit is shorted to voltage, the SCME shuts down the
Short to Battery passenger seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST R : DTC B19A1
R1 CHECK CUSHION BLOWER MOTOR BLOWER SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-3 Ground
Yes GO to R2
No GO to R3
R2 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE WITH THE CIRCUIT ISOLATED
Ignition OFF.
Ignition ON.
Measure:

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C3265C-3 Ground
Yes REPAIR the circuit. GO to R6

No GO to R3
R3 CHECK CUSHION BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR A SHORT TOGETHER
Ignition OFF.
Measure:

C3265C-3 C3265C-8
Yes GO to R4
No REPAIR the circuits. GO to R6
R4 CHECK CUSHION BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR AN INTERNAL SHORT TOGETHER
Ignition OFF.

Action
Action
Is the resistance greater than 2M ohms?
Yes GO to R5
GO to R6
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R5 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to R6
of any connector or pin issues. GO to R6
R6 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A2
The SCME supplies voltage and ground to the passenger seat backrest blower motor. The SCME also sends a speed control voltage signal to the blower motor
to control blower speed.

B19A2 Passenger Seat Back Blower Speed If the passenger seat backrest blower speed circuit is shorted to voltage, the SCME shuts down the
Short to Battery passenger seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST S : DTC B19A2
S1 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:
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C3265C-4 Ground
Yes GO to S2
No GO to S3
S2 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE WITH THE CIRCUIT ISOLATED
Ignition OFF.
Ignition ON.
Measure:

C3265C-4 Ground
Yes REPAIR the circuit. GO to S6

No GO to S3
S3 CHECK BACKREST BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR A SHORT TOGETHER
Ignition OFF.
Measure:

C3265C-4 C3265C-8
Yes GO to S4
No REPAIR the circuits. GO to S6
S4 CHECK BACKREST BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR AN INTERNAL SHORT TOGETHER
Ignition OFF.

Action
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Yes GO to S5
GO to S6
S5 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to S6
of any connector or pin issues. GO to S6
S6 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A3
The SCME supplies voltage and ground to the driver seat cushion blower motor. The SCME also sends a speed control voltage signal to the blower motor to
control blower speed.

B19A3 Driver Seat Cushion Blower Speed Short If the driver seat cushion blower speed circuit is shorted to voltage, the SCME shuts down the driver seat
to Battery system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST T : DTC B19A3
T1 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
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Ignition ON.
Measure:

C3265C-11 Ground
Yes GO to T2
No GO to T3
T2 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE WITH THE CIRCUIT ISOLATED
Ignition OFF.
Ignition ON.
Measure:

C3265C-11 Ground
Yes REPAIR the circuit. GO to T6

No GO to T3
T3 CHECK CUSHION BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR A SHORT TOGETHER
Ignition OFF.
Measure:

C3265C-11 C3265C-16
Yes GO to T4
No REPAIR the circuits. GO to T6
T4 CHECK CUSHION BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR AN INTERNAL SHORT TOGETHER
Ignition OFF.

Action
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C3035-3, Component Side C3035-7, Component side
Yes GO to T5
GO to T6
T5 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to T6
of any connector or pin issues. GO to T6
T6 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A4
The SCME supplies voltage and ground to the driver seat backrest blower motor. The SCME also sends a speed control voltage signal to the blower motor to

B19A4 Driver Seat Back Blower Speed Short to If the driver seat backrest blower speed circuit is shorted to voltage, the SCME shuts down the driver seat
Battery system and sets this DTC.
Possible Causes

SCME
cardiagn.com
PINPOINT TEST U : DTC B19A4
U1 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-12 Ground
Yes GO to U2
No GO to U3
U2 CHECK BACKREST BLOWER MOTOR BLOWER SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE WITH THE CIRCUIT ISOLATED
Ignition OFF.
Ignition ON.
Measure:

C3265C-12 Ground
Yes REPAIR the circuit. GO to U6

No GO to U3
U3 CHECK BACKREST BLOWER MOTOR BLOWER SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR A SHORT TOGETHER
Ignition OFF.
Measure:

C3265C-12 C3265C-16
Yes GO to U4
No REPAIR the circuits. GO to U6
U4 CHECK BACKREST BLOWER MOTOR SPEED CONTROL AND BLOWER OUTPUT CIRCUITS FOR AN INTERNAL SHORT TOGETHER
Ignition OFF.

Action
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Yes GO to U5
GO to U6
U5 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to U6
of any connector or pin issues. GO to U6
U6 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY


No
DTC B19A5
The SCME supplies voltage and ground to the passenger seat cushion blower motor. The SCME also sends a speed control voltage signal to the blower motor
cardiagn.com
B19A5 Passenger Seat Cushion Blower Speed If the passenger seat cushion blower speed circuit is shorted to ground, the SCME shuts down the
Short to Ground passenger seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST V : DTC B19A5
V1 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265C-3 Ground
Yes GO to V2
No REPAIR the circuit. GO to V5
V2 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT AND BLOWER GROUND CIRCUIT FOR A SHORT TOGETHER
Measure:

C3265C-3 C3265C-7

Yes GO to V3
No REPAIR the circuits. GO to V5
V3 DETERMINE CUSHION BLOWER MOTOR OR SCME (FRONT SEAT CLIMATE CONTROL MODULE) FAILURE
Remove the cushion blower motor from the passenger seat.
Remove the cushion blower motor from the driver seat and install it on the passenger seat.
Connect: Passenger Seat Cushion Blower Motor C3040.
Connect: SCME C3265C.
Start the engine and check operation of the passenger seat climate controlled seat system.
Does the seat operate with the cushion blower motor from the other seat installed?
Yes INSTALL a new seat cushion blower motor.

GO to V5
No GO to V4
V4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
cardiagn.com
Ignition ON.
GO to V5
cause of any connector or pin issues. GO to V5
V5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A6
The SCME supplies voltage and ground to the passenger seat backrest blower motor. The SCME also sends a speed control voltage signal to the blower motor

B19A6 Passenger Seat Back Blower Speed If the passenger seat backrest blower speed circuit is shorted to ground, the SCME shuts down the
Short to Ground passenger seat system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST W : DTC B19A6
W1 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265C-4 Ground
cardiagn.com
Yes GO to W2
No REPAIR the circuit. GO to W5
W2 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT AND BLOWER GROUND CIRCUIT FOR A SHORT TOGETHER
Measure:

C3265C-4 C3265C-7
Yes GO to W3
No REPAIR the circuits. GO to W5
W3 DETERMINE BACKREST BLOWER MOTOR OR SCME (FRONT SEAT CLIMATE CONTROL MODULE) FAILURE
Remove the backrest blower motor from the passenger seat.
Remove the backrest blower motor from the driver seat and install it on the passenger seat.
Connect: Passenger Seat Backrest Blower Motor C3039.
Start the engine and check operation of the passenger seat climate controlled seat system.
Does the seat operate with the backrest blower motor from the other seat installed?
Yes INSTALL a new seat backrest blower motor.

GO to W5
No GO to W4
W4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to W5
cause of any connector or pin issues. GO to W5
W5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A7
cardiagn.com
The SCME supplies voltage and ground to the driver seat cushion blower motor. The SCME also sends a speed control voltage signal to the blower motor to

B19A7 Driver Seat Cushion Blower Speed Short If the driver seat cushion blower speed circuit is shorted to ground, the SCME shuts down the driver seat
to Ground system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST X : DTC B19A7
X1 CHECK CUSHION BLOWER MOTOR BLOWER SPEED CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265C-11 Ground
Yes GO to X2
No REPAIR the circuit. GO to X5
X2 CHECK CUSHION BLOWER MOTOR SPEED CONTROL CIRCUIT AND BLOWER GROUND CIRCUIT FOR A SHORT TOGETHER
Measure:

C3265C-11 C3265C-15
Yes GO to X3
No REPAIR the circuits. GO to X5
X3 DETERMINE CUSHION BLOWER MOTOR OR SCME (FRONT SEAT CLIMATE CONTROL MODULE) FAILURE
Remove the cushion blower motor from the passenger seat.
Remove the cushion blower motor from the passenger seat and install it on the driver seat.
Connect: Driver Seat Cushion Blower Motor C3035.
Start the engine and check operation of the driver seat climate controlled seat system.
Does the seat operate with the cushion blower motor from the other seat installed?
Yes INSTALL a new seat cushion blower motor.
cardiagn.com
GO to X5
No GO to X4
X4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
Ignition ON.
GO to X5
cause of any connector or pin issues. GO to X5
X5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B19A8
The SCME supplies voltage and ground to the driver seat backrest blower motor. The SCME also sends a speed control voltage signal to the blower motor to

B19A8 Driver Seat Back Blower Speed Short to If the driver seat backrest blower speed circuit is shorted to ground, the SCME shuts down the driver seat
Ground system and sets this DTC.
Possible Causes

SCME
PINPOINT TEST Y : DTC B19A8
Y1 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT FOR A SHORT TO GROUND
cardiagn.com
Measure:

C3265C-12 Ground
Yes GO to Y2
No REPAIR the circuit. GO to Y5
Y2 CHECK BACKREST BLOWER MOTOR SPEED CONTROL CIRCUIT AND BLOWER GROUND CIRCUIT FOR A SHORT TOGETHER
Measure:

C3265C-12 C3265C-15
Yes GO to Y3
No REPAIR the circuits. GO to Y5
Y3 DETERMINE BACKREST BLOWER MOTOR OR SCME (FRONT SEAT CLIMATE CONTROL MODULE) FAILURE
Remove the backrest blower motor from the driver seat.
Remove the backrest blower motor from the passenger seat and install it on the driver seat.
Connect: Driver Seat Backrest Blower Motor C3034.
Start the engine and check operation of the driver seat climate controlled seat system.
Does the seat operate with the backrest blower motor from the other seat installed?
Yes INSTALL a new seat backrest blower motor.

GO to Y5
No GO to Y4
Y4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to Y5
cause of any connector or pin issues. GO to Y5
Y5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY
cardiagn.com

No
DTC B272A
The SCME monitors seat cushion temperature while it supplies voltage and ground to both blower motors. The SCME also supplies a variable voltage signal to
control the blower speed. Cabin air enters the blower through a filter attached to the blower motor housing. Heated or cooled air exits the blower motor and
flows through a duct to the foam pad.

B272A Passenger Cushion If the passenger seat cushion blower motor temperature exceeds 70° C (158° F) in cool mode or 85° C (185° F) in heat
Over-Temp Detected mode for more than 4 seconds, the SCME shuts down the passenger seat system and sets this DTC.
Possible Causes

Restricted blower motor filter
Crushed or restricted cushion foam pad
SCME
PINPOINT TEST Z : DTC B272A
Z1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Start the vehicle and set the passenger seat to HIGH heat.
Was DTC B272A retrieved on-demand during the self-test?
Yes GO to Z2
No GO to Z5
Z2 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR THERMISTOR CIRCUITS FOR A SHORT TO GROUND
Disconnect: SCME C3265B.
Measure:

C3265B-2 Ground
C3265B-3 Ground
Yes GO to Z3
No REPAIR the circuit in question. GO to Z22
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Z3 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR THERMISTOR AND WIRING
Connect: Passenger Seat Cushion Blower Motor C3040.
Measure:

C3265B-2 C3265B-3
Compare the measured resistance value with the following table:
Ambient Temperature Resistance

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Is the resistance within the limits indicated?
Yes GO to Z18
No GO to Z4
Z4 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR THERMISTOR


Action
Action

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
cardiagn.com
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS27 (WH/OG) or RHS10 (BU/OG) for an open or high resistance. GO to Z22
No INSTALL a new passenger seat cushion blower motor.
GO to Z22
Z5 CONFIRM THE FAULT WHILE MONITORING THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) SEAT BACK THERMO-ELECTRIC DEVICE
TEMPERATURE (PBKTEMP) AND SEAT CUSHION THERMO-ELECTRIC DEVICE TEMPERATURE (PCSHTEMP) PARAMETER IDENTIFICATIONS (PIDS)
Set the passenger seat to OFF.
Using a diagnostic scan tool, clear the SCME Diagnostic Trouble Codes (DTCs).
Using a diagnostic scan tool, monitor the SCME PBKTEMP and PCSHTEMP Parameter Identifications (PIDs).
NOTE: A crushed seat cushion foam pad may be the cause of the fault, making it necessary to occupy the seat to recreate and identify the fault.
Attempt to recreate the fault. Start the vehicle and set the passenger seat to HIGH heat for at least 15 minutes while occupying the seat.
Do the Parameter Identifications (PIDs) increase incrementally (gradually) and stay within 15° C (27° F) of each other?
Yes Fault not present at this time. Fault may have been set due to a past failure, incorrect use of the climate controlled seat system by
repeated switching between heat and cool modes or due to excessive passenger compartment temperature.
No If the PCSHTEMP PID increases incrementally and is greater than 15° C (27° F) of the PBKTEMP PID, GO to Z6
If the PCSHTEMP PID increases quickly (temperature "jumps" and does not increase incrementally) and is greater than 15° C (27° F)
of the PBKTEMP PID, GO to Z16
Z6 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS

With the engine running, set both front seats to HIGH cool.
Note the airflow exhausting from the passenger seat cushion blower motor and compare it to the airflow exhausting from the driver seat cushion blower motor.
Carry out a wiggle test of the wire harnesses between the SCME and the passenger seat cushion blower motor while monitoring blower operation. The
blower should operate consistently and not change speeds.
Is the airflow exhausting from the passenger seat cushion blower motor comparable to the airflow exhausting from the driver seat cushion blower
motor with no change in operation when carrying out the wiggle test?
Yes GO to Z7
No If the airflow exhausting from the passenger seat cushion blower motor is not comparable to the airflow exhausting from the driver seat
cushion blower motor, GO to Z8
If the passenger seat cushion blower motor operation changed while carrying out the wiggle test, IDENTIFY and REPAIR the wiring
fault.
Z7 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS WHILE OCCUPIED

Note the airflow exhausting from the passenger seat cushion blower motor with the passenger seat occupied and compare it to the airflow exhausting from
the driver seat cushion blower motor with the driver seat occupied.
Is the airflow exhausting from the passenger seat cushion blower motor comparable to the airflow exhausting from the driver seat cushion blower
motor?
Yes GO to Z16
No INSTALL a new passenger seat cushion foam pad.
Z8 CHECK THE PASSENGER SEAT CUSHION BLOWER FOR AN OBSTRUCTION OR RESTRICTED FILTER
Ignition OFF.
Inspect the blower of the passenger seat cushion blower motor assembly for an obstruction or for a restricted filter.
Is the blower obstructed or the filter restricted?
Yes REMOVE the obstruction or INSTALL a passenger seat cushion blower motor.
No GO to Z9
Z9 CHECK THE PASSENGER SEAT CUSHION BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN
cardiagn.com
Measure:

C3265C-3 C3040-7
Yes GO to Z10
No REPAIR the circuit. GO to Z22
Z10 CHECK THE PASSENGER SEAT CUSHION BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-7 Ground
Yes REPAIR the circuit. GO to Z22

No GO to Z11
Z11 CHECK THE PASSENGER SEAT CUSHION BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-8 Ground
Yes GO to Z12
No REPAIR the circuit. GO to Z22
Z12 CHECK THE PASSENGER SEAT CUSHION BLOWER CIRCUITS FOR AN OPEN
Measure:

C3265C-8 C3040-3
C3265C-7 C3040-4
Yes GO to Z13
No REPAIR the circuit in question. GO to Z22
Z13 CHECK THE PASSENGER SEAT CUSHION BLOWER RESISTANCE

connected results in false readings and leads to incorrect identification of components that are not damaged.

Action
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Is the resistance between 4,000 and 10,000 ohms?
Yes GO to Z14
GO to Z22
Z14 CHECK THE PASSENGER SEAT CUSHION BLOWER SPEED CONTROL RESISTANCE

Action

Is the resistance between 240K and 400K ohms?
Yes GO to Z15
GO to Z22
Z15 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR INSTALLATION AND FOR CRUSHED SEAT CUSHION
Ignition OFF.
Remove the passenger seat.
REFER to: Front Seat (501-10A Front Seats, Removal and Installation).
Remove the passenger seat cushion cover.
REFER to: Front Seat Cushion Cover (501-10A Front Seats, Removal and Installation).
Inspect the passenger seat cushion for the following:
Blower motor correctly installed
Cushion foam pad crushed or restricted
Is the passenger seat cushion blower motor correctly installed and are there no signs of damage to the foam pad?
Yes INSTALL the passenger seat cushion cover and seat. GO to Z18
No CORRECTLY install the passenger seat cushion blower motor or INSTALL a new passenger seat cushion foam pad. GO to Z22
Z16 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR THERMISTOR AND WIRING
cardiagn.com
Measure:

C3265B-2 C3265B-3

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to Z18
No GO to Z17
Z17 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR THERMISTOR


Action
Action

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
cardiagn.com
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS27 (WH/OG) or RHS10 (BU/OG) for an open or high resistance. GO to Z22
GO to Z22
Z18 CHECK THE PASSENGER SEAT CUSHION BLOWER MOTOR HEATING/COOLING CIRCUITRY CURRENT DRAW
Connect all SCME, blower motor and Body Harness-to-Seat Harness Connectors.
NOTICE: It may be necessary to open the seat wire harness conduit to allow placing the inductive current probe around the circuit as described in
the following step. Care must be taken when opening up the wire harness so as not to damage any wiring or connectors. Do not damage any
wiring or induce stress on any wiring or connectors. Close up the wire harness once repairs to the seat are complete.
NOTE: Use a commercially available inductive current probe (such as Electronic Specialties Current Probe/Multimeter 685 or a Fluke I410 [used with a
digital multimeter]) or the low current probe from the VMM available for use with IDS. If these are unavailable, the inductive current probe feature from a
battery tester may be substituted.
Place an inductive current probe around circuit CHS07 (GY/BU) near SCME C3265A-A and monitor the current draw.
Start the engine and set the passenger seat to HIGH heat.
Is the current draw less than 11 amps?
Yes GO to Z19
GO to Z22
Z19 CHECK RESISTANCE OF THE PASSENGER SEAT CUSHION BLOWER MOTOR AND WIRING
Ignition OFF.
Measure:

C3265A-A Ground
C3265A-B Ground
Yes GO to Z21
No GO to Z20
Z20 CHECK THE RESISTANCE OF THE PASSENGER SEAT CUSHION BLOWER MOTOR

Action
cardiagn.com
Yes REPAIR circuit CHS07 (GY/BU) or RHS07 (BU) for an open or high resistance. GO to Z22
GO to Z22
Z21 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to Z22
of any connector or pin issues. GO to Z22
Z22 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B272B
The SCME monitors seat backrest temperature while it supplies voltage and ground to both blower motors. The SCME also supplies a variable voltage signal to
flows through the foam pad.

B272B Passenger Back If the passenger seat backrest blower motor temperature exceeds 70° C (158° F) in cool mode or 85° C (185° F) in heat
Over-Temp Detected mode for more than 4 seconds, the SCME shuts down the passenger seat system and sets this DTC.
Possible Causes

Crushed or restricted backrest foam pad
SCME
PINPOINT TEST AA : DTC B272B
cardiagn.com
AA1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Start the vehicle and set the passenger seat to HIGH heat.
Was DTC B272B retrieved on-demand during the self-test?
Yes GO to AA2
No GO to AA5
AA2 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C3265B-4 Ground
C3265B-5 Ground
Yes GO to AA3
No REPAIR the circuit in question. GO to AA22
AA3 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR AND WIRING
Connect: Passenger Seat Backrest Blower Motor C3039.
Measure:

C3265B-4 C3265B-5

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AA18
No GO to AA4
AA4 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR


Action
cardiagn.com

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS36 (YE/BU) or RHS20 (GN/BU) for an open or high resistance. GO to AA22
No INSTALL a new passenger seat backrest blower motor.
GO to AA22
AA5 CONFIRM THE FAULT WHILE MONITORING THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) SEAT BACK THERMO-ELECTRIC DEVICE
TEMPERATURE (PBKTEMP) AND SEAT CUSHION THERMO-ELECTRIC DEVICE TEMPERATURE (PCSHTEMP) PARAMETER IDENTIFICATIONS (PIDS)
Using a diagnostic scan tool, monitor the SCME PBKTEMP and PCSHTEMP Parameter Identifications (PIDs).
NOTE: A crushed seat backrest foam pad may be the cause of the fault, making it necessary to occupy the seat to recreate and identify the fault.
Attempt to recreate the fault. Start the vehicle and set the passenger seat to HIGH heat for at least 15 minutes while occupying the seat.
No If the PBKTEMP PID increases incrementally and is greater than 15° C (27° F) of the PCSHTEMP PID, GO to AA6
If the PBKTEMP PID increases quickly (temperature "jumps" and does not increase incrementally) and is greater than 15° C (27° F) of
the PCSHTEMP PID, GO to AA16
AA6 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS

Note the airflow exhausting from the passenger seat backrest blower motor and compare it to the airflow exhausting from the driver seat backrest blower
motor.
Carry out a wiggle test of the wire harnesses between the SCME and the passenger seat backrest blower motor while monitoring blower operation. The
blower should operate consistently and not change speeds.
Is the airflow exhausting from the passenger seat backrest blower motor comparable to the airflow exhausting from the driver seat backrest blower
Yes GO to AA7
No If the airflow exhausting from the passenger seat backrest blower motor is not comparable to the airflow exhausting from the driver
seat backrest blower motor, GO to AA8
If the passenger seat backrest blower motor blower operation changed while carrying out the wiggle test, IDENTIFY and REPAIR the
wiring fault.
AA7 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS WHILE OCCUPIED
Note the airflow exhausting from the passenger seat backrest blower motor with the passenger seat occupied and compare it to the airflow exhausting from
the driver seat backrest blower motor with the driver seat occupied.
Is the airflow exhausting from the passenger seat backrest blower motor comparable to the airflow exhausting from the driver seat backrest blower
motor?
cardiagn.com
Yes GO to AA16
No INSTALL a new passenger seat backrest foam pad.
AA8 CHECK THE PASSENGER SEAT BACKREST BLOWER FOR AN OBSTRUCTION OR RESTRICTED FILTER
Ignition OFF.
Inspect the blower of the passenger seat backrest blower motor assembly for an obstruction or for a restricted filter.
Yes REMOVE the obstruction or INSTALL a new passenger seat backrest blower motor.
No GO to AA9
AA9 CHECK THE PASSENGER SEAT BACKREST BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN
Measure:

C3265C-4 C3039-7
Yes GO to AA10
No REPAIR the circuit. GO to AA22
AA10 CHECK THE PASSENGER SEAT BACKREST BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-7 Ground

Yes REPAIR the circuit. GO to AA22
No GO to AA11
AA11 CHECK THE PASSENGER SEAT BACKREST BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-8 Ground
Yes GO to AA12
No REPAIR the circuit. GO to AA22
AA12 CHECK THE PASSENGER SEAT BACKREST BLOWER CIRCUITS FOR AN OPEN
Measure:

cardiagn.com
C3265C-8 C3039-3
C3265C-7 C3039-4
Yes GO to AA13
No REPAIR the circuit in question. GO to AA22
AA13 CHECK THE PASSENGER SEAT BACKREST BLOWER RESISTANCE


Action
Yes GO to AA14
GO to AA22
AA14 CHECK THE PASSENGER SEAT BACKREST BLOWER SPEED CONTROL RESISTANCE

Action
Yes GO to AA15
cardiagn.com
GO to AA22
AA15 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR INSTALLATION AND FOR CRUSHED SEAT BACKREST
Ignition OFF.
Remove the passenger seat backrest cover.
REFER to: Front Seat Backrest Cover (501-10A Front Seats, Removal and Installation).
Inspect the passenger seat backrest for the following:
Backrest foam pad crushed or restricted
Is the passenger seat backrest blower motor correctly installed and are there no signs of damage to the foam pad?
Yes INSTALL the passenger seat backrest cover and seat. GO to AA18
No CORRECTLY install the passenger seat backrest blower motor or INSTALL a new passenger seat backrest foam pad. GO to AA22
AA16 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR AND WIRING
Measure:

C3265B-4 C3265B-5

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms

Yes GO to AA18
No GO to AA17
AA17 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR


Action
cardiagn.com

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS35 (VT/OG) or RHS15 (GY/BN) for an open or high resistance. GO to AA22
GO to AA22
AA18 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR HEATING/COOLING CIRCUITRY CURRENT DRAW
Place an inductive current probe around circuit CHS06 (BU/BN) near SCME C3265A-C and monitor the current draw.
Start the engine and set the passenger seat to HIGH heat.
Yes GO to AA19
GO to AA22
AA19 CHECK RESISTANCE OF THE PASSENGER SEAT BACKREST BLOWER MOTOR AND WIRING
Ignition OFF.
Measure:

C3265A-C Ground
C3265A-D Ground
Yes GO to AA21
No GO to AA20
AA20 CHECK THE RESISTANCE OF THE PASSENGER SEAT BACKREST BLOWER MOTOR

Action
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Yes REPAIR circuit CHS01 (GY/VT) or RHS01 (WH/VT) for an open or high resistance. GO to AA22
GO to AA22
AA21 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AA22
of any connector or pin issues. GO to AA22
AA22 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B272C
settings.
A differential fault occurs when the cushion and backrest blower motors on an affected seat are reporting very different temperatures to the SCME. This may
result from an airflow restriction or a circuit fault of either blower motor area. If a blower motor is clear of obstruction and is operational, check the other blower
motor and circuitry on the seat. It is important to note that a blower motor with a higher temperature may be operating correctly and not the area of concern.
cardiagn.com
The other blower motor may be indicating a much lower temperature, causing the DTC to set.

B272C Driver Differential If there is a temperature differential between the driver backrest and cushion blower motor of 60° C (108° F) or more for more than
Temperature 4 seconds, or if the blower motor is disconnected or the duct is blocked, this DTC sets. When this happens for the first time in a
Fault key cycle, the SCME puts the driver seat system into recovery mode (see principles of operation). If the system is able to recover,
it returns to normal function. If the system is able to recover and it occurs a second time in the same key cycle, the SCME shuts
down the driver seat system.
Possible Causes

Cushion or backrest blower motor
SCME
PINPOINT TEST AB : DTC B272C
AB1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Was DTC B2729 or B2730, retrieved on-demand during the self-test?
Yes For DTC B2729, GO to Pinpoint Test AF

For DTC B2730, GO to Pinpoint Test AG
No GO to AB2
AB2 MONITOR SCME (FRONT SEAT CLIMATE CONTROL MODULE) BLOWER MOTOR TEMPERATURE PARAMETER IDENTIFICATIONS (PIDS)
Using a diagnostic scan tool, monitor the following SCME Parameter Identifications (PIDs):
NOTE: Make sure the temperature of the climate controlled seats has stabilized before monitoring the Parameter Identifications (PIDs). Not allowing
stabilization can cause incorrect readings and lead to incorrect identification of components that are not faulty.
Monitor blower motor temperature Parameter Identifications (PIDs) with the climate controlled seats OFF. Compare the PID values of the driver seat to those
of the front passenger seat, this can help identify if there is a concern with the driver seat cushion or backrest PID value readings.
Are both driver seat blower motor temperature Parameter Identifications (PIDs) within 10° C (18° F) of the ambient temperature?
Yes GO to AB3
No If the driver seat cushion PID varies 10° C (18° F) or more from ambient temperature, GO to AB16
If the driver seat backrest PID varies 10° C (18° F) or more from ambient temperature, GO to AB32
AB3 CONFIRM THE FAULT IS IN THE SEAT CUSHION OR THE BACKREST

Ignition OFF.
Start the engine.
NOTE: A crushed seat cushion foam pad may be the cause of the fault. It may be necessary to sit on the seat or place something of reasonable size and
weight on the seat to recreate the fault.
After cycling the ignition and with the engine running, set the driver seat to high heat. Allow the seat to heat for at least 15 minutes while monitoring the blower
motor temperature Parameter Identifications (PIDs) of the driver seat.
Do the driver seat cushion blower motor and backrest blower motor Parameter Identifications (PIDs) vary more than 60° C (108° F) from each other?
Yes If the driver seat cushion PID is 60° C (108° F) hotter than the backrest PID, GO to AB5
If the driver seat backrest PID is 60° C (108° F) hotter than the cushion PID, GO to AB20
No GO to AB4
AB4 CHECK THE BLOWER MOTOR COOLING PERFORMANCE

Check the blower motors cooling performance on the affected seat. Refer to Component Test — Blower Motor Cooling Performance in this section.
Did the blower motors pass the component test?
Yes The DTC may have been set by extreme cabin temperatures or excessive sunload on the seat causing the system to enter recovery
mode. Occupant size and weight characteristics can also be a factor. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the
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self-test. TEST the system for normal operation. If a concern cannot be found or duplicated, RETURN the vehicle to the customer.
No CHECK the affected seat cushion or backrest for correct installation of the climate controlled seat components (blower motor, air ducts
and foam pad). CHECK for airflow restrictions (blower motor inlets and outlets, filters and ducts) and REPAIR as needed. CHECK for
an intermittent wiring fault. REPAIR as needed. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test.
AB5 CHECK FOR CORRECT BLOWER MOTOR INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the seat.
Remove the seat cushion trim cover.
Inspect the driver seat cushion for the following:
Cushion blower obstructed
Blower filter restricted or plugged
Seat cushion foam pad crushed or restricted
Is the blower motor correctly installed and the foam pad OK?
Yes GO to AB6
No Correctly INSTALL the cushion blower motor or INSTALL a new seat cushion foam pad.
AB6 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE CIRCUIT FOR A SHORT TO VOLTAGE
Position the driver seat in the vehicle and connect the seat-to-floor connectors.
Ignition ON.
Measure:

C3265A-K Ground
Yes REPAIR the circuit. GO to AB36

No GO to AB7
AB7 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265A-J Ground
Yes GO to AB8
No REPAIR the circuit. GO to AB36
AB8 CHECK THE RESISTANCE OF THE BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE AND WIRING
Measure:

C3265A-J Ground
C3265A-K Ground
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Yes GO to AB10
No GO to AB9
AB9 CHECK THE RESISTANCE OF THE BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE

Action
Yes REPAIR circuit CHS01 (GY/VT) or RHS01 (WH/VT) for an open or high resistance. GO to AB36
GO to AB36
AB10 CHECK BLOWER CIRCUIT AND SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-16 Ground
C3265C-11 Ground
Yes REPAIR the circuit in question. GO to AB36

No GO to AB11
AB11 CHECK BLOWER AND SPEED CONTROL CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-16 Ground
C3265C-11 Ground
Yes GO to AB12
No REPAIR the circuit in question. GO to AB36
AB12 CHECK THE BLOWER AND WIRING
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Measure:

C3265C-16 C3265C-15
Yes GO to AB14
No GO to AB13
AB13 CHECK THE BLOWER RESISTANCE


Action

No INSTALL a new driver seat cushion blower motor.
GO to AB36
AB14 CHECK THE BLOWER SPEED CONTROL AND CIRCUIT RESISTANCE

Measure:

C3265C-11 C3265C-15
Yes GO to AB16
No GO to AB15
AB15 CHECK THE BLOWER SPEED CONTROL RESISTANCE

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Action

GO to AB36
AB16 CHECK THERMISTOR CIRCUIT FOR A SHORT TO VOLTAGE
Measure:

C3265B-7 Ground

No GO to AB17
AB17 CHECK THERMISTOR CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C3265B-7 Ground
Yes GO to AB18
AB18 CHECK THE BLOWER MOTOR THERMISTOR AND WIRING RESISTANCE AT THE SCME (FRONT SEAT CLIMATE CONTROL MODULE)
Measure:

C3265B-7 C3265B-8
cardiagn.com

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AB35
No GO to AB19
AB19 CHECK THE BLOWER MOTOR THERMISTOR RESISTANCE


Action

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR the circuit(s) in question. GO to AB36

GO to AB36
AB20 CHECK FOR CORRECT BLOWER MOTOR INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the driver seat.
Remove the driver seat backrest cover.
Inspect the driver seat backrest for the following:
Backrest blower obstructed
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Seat backrest foam pad crushed or restricted
Yes GO to AB21
No Correctly INSTALL the backrest blower motor or INSTALL a new seat backrest foam pad. INSTALL the seat. GO to AB36
AB21 CHECK CUSHION BLOWER MOTOR CIRCUIT FOR A SHORT TO VOLTAGE
Position the driver seat in the vehicle and connect the seat-to-floor connectors.
Ignition ON.
Measure:

C3265A-H Ground

No GO to AB22
AB22 CHECK CUSHION BLOWER MOTOR + CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265A-G Ground
Yes GO to AB23
AB23 CHECK THE RESISTANCE OF THE CUSHION BLOWER MOTOR AND WIRING
Measure:

C3265A-G C3265A-H
Yes GO to AB25
No GO to AB24
AB24 CHECK THE CUSHION BLOWER MOTOR RESISTANCE


Action
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GO to AB36
AB25 CHECK BLOWER CIRCUIT AND SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-16 Ground
C3265C-12 Ground

No GO to AB26
AB26 CHECK BLOWER AND SPEED CONTROL CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-16 Ground
C3265C-12 Ground
Yes GO to AB27
No REPAIR the circuit in question. GO to AB36
AB27 CHECK THE BLOWER AND WIRING RESISTANCE

Measure:

C3265C-16 C3265C-15
Yes GO to AB29
No GO to AB28
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AB28 CHECK THE BLOWER RESISTANCE

Action

GO to AB36
AB29 CHECK THE BLOWER SPEED CONTROL AND CIRCUIT RESISTANCE

Measure:

C3265C-12 C3265C-15
Yes GO to AB31
No GO to AB30
AB30 CHECK THE BLOWER SPEED CONTROL RESISTANCE


Action
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GO to AB36
AB31 CHECK THERMISTOR CIRCUIT FOR A SHORT TO VOLTAGE

Ignition ON.
Measure:

C3265B-9 Ground

No GO to AB32
AB32 CHECK THERMISTOR CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265B-9 Ground

Yes GO to AB33
AB33 CHECK THE BLOWER MOTOR THERMISTOR AND WIRING RESISTANCE

Measure:

C3265B-9 C3265B-10

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
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Yes GO to AB35
No GO to AB34
AB34 CHECK THE BLOWER MOTOR THERMISTOR RESISTANCE


Action

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms

GO to AB36
AB35 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AB36
of any connector or pin issues. GO to AB36
AB36 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY
cardiagn.com

No
DTC B272D
settings.
A differential fault occurs when the cushion and backrest blower motors on an affected seat are reporting very different temperatures to the SCME. This may
result from an airflow restriction or a circuit fault of either blower motor area. If a blower motor is clear of obstruction and is operational, check the other blower
motor and circuitry on the seat. It is important to note that a blower motor with a higher temperature may be operating correctly and not the area of concern.
The other blower motor may be indicating a much lower temperature, causing the DTC to set.

B272D Passenger If there is a temperature differential between the passenger backrest and cushion blower motor of 60° C (108° F) or more for
Differential more than 4 seconds, or if the blower motor is disconnected or the duct is blocked, this DTC sets. When this happens for the first
Temperature Fault time in a key cycle, the SCME puts the passenger seat system into recovery mode (see principles of operation). If the system is
able to recover, it returns to normal function. If the system is able to recover and it occurs a second time in the same key cycle,
the SCME shuts down the passenger seat system.
Possible Causes

SCME
PINPOINT TEST AC : DTC B272D
AC1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Was DTC B272A or B272B, retrieved on-demand during the self-test?
Yes For DTC B272A, GO to Pinpoint Test Z

For DTC B272B, GO to Pinpoint Test AA
No GO to AC2
AC2 MONITOR SCME (FRONT SEAT CLIMATE CONTROL MODULE) BLOWER MOTOR TEMPERATURE PARAMETER IDENTIFICATIONS (PIDS)
Using a diagnostic scan tool, monitor the following SCME Parameter Identifications (PIDs):
NOTE: Make sure the temperature of the climate controlled seats has stabilized before monitoring the Parameter Identifications (PIDs). Not allowing
cardiagn.com
stabilization can cause incorrect readings and lead to incorrect identification of components that are not faulty.
Monitor blower motor temperature Parameter Identifications (PIDs) with the limate controlled seats OFF. Compare the PID values of the driver seat to those
of the front passenger seat, this can help identify if there is a concern with the passenger seat cushion or backrest PID value readings.
Are both passenger seat blower motor temperature Parameter Identifications (PIDs) within 10° C (18° F) of the ambient temperature?
Yes GO to AC3
No If the passenger seat cushion PID varies 10° C (18° F) or more from ambient temperature, GO to AC16
If the passenger seat backrest PID varies 10° C (18° F) or more from ambient temperature, GO to AC32
AC3 CONFIRM THE FAULT IS IN THE SEAT CUSHION OR THE BACKREST

Ignition OFF.
Start the engine.
NOTE: A crushed seat cushion foam pad may be the cause of the fault. It may be necessary to sit on the seat or place something of reasonable size and
weight on the seat to recreate the fault.
After cycling the ignition and with the engine running, set the passenger seat to high heat. Allow the seat to heat for at least 15 minutes while monitoring the
blower motor temperature Parameter Identifications (PIDs) of the passenger seat.
Do the passenger seat cushion blower motor and backrest blower motor Parameter Identifications (PIDs) vary more than 60° C (108° F) from each
other?
Yes If the passenger seat cushion PID is 60° C (108° F) hotter than the backrest PID, GO to AC5
If the passenger seat backrest PID is 60° C (108° F) hotter than the cushion PID, GO to AC20
No GO to AC4
AC4 CHECK THE BLOWER MOTOR COOLING PERFORMANCE

Check the blower motor cooling performance on the affected seat. Refer to Component Test — Blower Motor Cooling Performance in this section.
Did the blower motors pass the component test?
Yes The DTC may have been set by extreme cabin temperatures or excessive sunload on the seat causing the system to enter recovery
mode. Occupant size and weight characteristics can also be a factor. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the
self-test. TEST the system for normal operation. If a concern cannot be found or duplicated, RETURN the vehicle to the customer.
No CHECK the affected seat cushion or backrest for correct installation of the climate controlled seat components (blower motor, air ducts
and foam pad). CHECK for airflow restrictions (blower motor inlets and outlets, filters and ducts) and REPAIR as needed. CHECK for
an intermittent wiring fault. REPAIR as needed. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the self-test.
AC5 CHECK FOR CORRECT BLOWER MOTOR INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the seat.
Remove the seat cushion trim cover.
Inspect the seat cushion for the following:
Cushion blower obstructed
Yes GO to AC6
No Correctly INSTALL the cushion blower motor or INSTALL a new seat cushion foam pad.
AC6 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE CIRCUIT FOR A SHORT TO VOLTAGE
Position the passenger seat in the vehicle and connect the seat-to-floor connectors.
Ignition ON.
Measure:

C3265A-D Ground
cardiagn.com
Yes REPAIR the circuit. GO to AC36
No GO to AC7
AC7 CHECK BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265A-C Ground
Yes GO to AC8
No REPAIR the circuit. GO to AC36
AC8 CHECK THE RESISTANCE OF THE BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE AND WIRING
Measure:

C3265A-C Ground
C3265A-D Ground
Yes GO to AC10
No GO to AC9
AC9 CHECK THE RESISTANCE OF THE BACKREST BLOWER MOTOR THERMO ELECTRIC DEVICE

Action
Action
Yes REPAIR circuit CHS06 (BU/BN) or RHS06 (WH) for an open or high resistance. GO to AC36
GO to AC36
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AC10 CHECK BLOWER CIRCUIT AND SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-8 Ground
C3265C-3 Ground
Yes REPAIR the circuit in question. GO to AC36

No GO to AC11
AC11 CHECK BLOWER AND SPEED CONTROL CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-8 Ground
C3265C-3 Ground
Yes GO to AC12
No REPAIR the circuit in question. GO to AC36
AC12 CHECK THE BLOWER AND WIRING

Measure:

C3265C-8 C3265C-7
Yes GO to AC14
No GO to AC13
AC13 CHECK THE BLOWER RESISTANCE


Action
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GO to AC36
AC14 CHECK THE BLOWER SPEED CONTROL AND CIRCUIT RESISTANCE

Measure:

C3265C-3 C3265C-7
Yes GO to AC16
No GO to AC15
AC15 CHECK THE BLOWER SPEED CONTROL RESISTANCE


Action
Action

GO to AC36
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AC16 CHECK THERMISTOR CIRCUIT FOR A SHORT TO VOLTAGE
Measure:

C3265B-2 Ground

No GO to AC17
AC17 CHECK THERMISTOR CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C3265B-2 Ground
Yes GO to AC18
AC18 CHECK THE BLOWER MOTOR THERMISTOR AND WIRING RESISTANCE AT THE SCME (FRONT SEAT CLIMATE CONTROL MODULE)
Measure:

C3265B-2 C3265B-3

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AC35
No GO to AC19
AC19 CHECK THE BLOWER MOTOR THERMISTOR RESISTANCE


Action
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0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR the circuit(s) in question. GO to AC36

GO to AC36
AC20 CHECK FOR CORRECT BLOWER MOTOR INSTALLATION AND FOR CRUSHED FOAM
Ignition OFF.
Remove the passenger seat backrest cover.
Inspect the passenger seat backrest for the following:
Backrest blower obstructed
Seat backrest foam pad crushed or restricted
Yes GO to AC21
No Correctly INSTALL the backrest blower motor or INSTALL a new seat backrest foam pad. INSTALL the seat. GO to AC36
AC21 CHECK CUSHION BLOWER MOTOR CIRCUIT FOR A SHORT TO VOLTAGE
Position the passenger seat in the vehicle and connect the seat-to-floor connectors.
Ignition ON.
Measure:

C3265A-B Ground

No GO to AC22
AC22 CHECK CUSHION BLOWER MOTOR + CIRCUIT FOR A SHORT TO GROUND
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Measure:

C3265A-A Ground
Yes GO to AC23
AC23 CHECK THE RESISTANCE OF THE CUSHION BLOWER MOTOR AND WIRING
Measure:

C3265A-A C3265A-B
Yes GO to AC25
No GO to AC24
AC24 CHECK THE CUSHION BLOWER MOTOR RESISTANCE


Action
Action

GO to AC36
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AC25 CHECK BLOWER CIRCUIT AND SPEED CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-8 Ground
C3265C-4 Ground

No GO to AC26
AC26 CHECK BLOWER AND SPEED CONTROL CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-8 Ground
C3265C-4 Ground
Yes GO to AC27
No REPAIR the circuit in question. GO to AC36
AC27 CHECK THE BLOWER AND WIRING RESISTANCE

Measure:

C3265C-8 C3265C-7
Yes GO to AC29
No GO to AC28
AC28 CHECK THE BLOWER RESISTANCE


Action
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GO to AC36
AC29 CHECK THE BLOWER SPEED CONTROL AND CIRCUIT RESISTANCE

Measure:

C3265C-4 C3265C-7
Yes GO to AC31
No GO to AC30
AC30 CHECK THE BLOWER SPEED CONTROL RESISTANCE


Action
Action

GO to AC36
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AC31 CHECK THERMISTOR CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265B-4 Ground

No GO to AC32
AC32 CHECK THERMISTOR CIRCUIT FOR A SHORT TO GROUND
Measure:

C3265B-4 Ground
Yes GO to AC33
AC33 CHECK THE BLOWER MOTOR THERMISTOR AND WIRING RESISTANCE

Measure:

C3265B-4 C3265B-5

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AC35
No GO to AC34
AC34 CHECK THE BLOWER MOTOR THERMISTOR RESISTANCE


Action
cardiagn.com

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms

GO to AC36
AC35 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AC36
of any connector or pin issues. GO to AC36
AC36 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B272E
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The SCME supplies voltage and ground to the backrest and cushion blower motors. The blower motors are independently controlled by separate speed control
circuits from the SCME.

B272E Driver Ignition If either the blower voltage supply or return circuits are open (to both cushion or backrest blowers) or shorted to voltage, the
Run/Blower Circuit Short DTC is set and after 4-6 seconds the SCME disables outputs to the driver seat. The DTC also sets if the blower voltage
to Ground supply or return circuit is open to only one blower when SCME supply voltage is less than 12 volts.
Possible Causes

SCME
PINPOINT TEST AD : DTC B272E
AD1 CHECK THE BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-16 Ground
C3265C-15 Ground
Yes REPAIR the circuit in question. GO to AD5

No GO to AD2
AD2 CHECK THE BLOWER MOTOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C3265C-16 C3035-3
C3265C-15 C3035-4
Yes GO to AD3
No REPAIR the circuit in question. GO to AD5
AD3 CHECK THE RESISTANCE OF THE CUSHION AND BACKREST BLOWER MOTORS
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Action

Action
Are the resistances between 4,000 and 10,000 ohms?
Yes GO to AD4
GO to AD5
GO to AD5
AD4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AD5
of any connector or pin issues. GO to AD5
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AD5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B272F
The SCME supplies voltage and ground to the backrest and cushion blower motors. The blower motors are independently controlled by separate speed control
circuits from the SCME.

B272F Passenger Ignition If either the blower voltage supply or return circuits are open (to both cushion or backrest blowers) or shorted to voltage,
Run/Blower Circuit Short the DTC is set and after 4-6 seconds the SCME disables outputs to the passenger seat. The DTC also sets if the blower
to Ground voltage supply or return circuit is open to only one blower when SCME supply voltage is less than 12 volts.
Possible Causes

SCME
PINPOINT TEST AE : DTC B272F
AE1 CHECK THE BLOWER MOTOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-8 Ground
C3265C-7 Ground
Yes REPAIR the circuit in question. GO to AE5

No GO to AE2
AE2 CHECK THE BLOWER MOTOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:
cardiagn.com
C3265C-8 C3040-3
C3265C-7 C3040-4
Yes GO to AE3
No REPAIR the circuit in question. GO to AE5
AE3 CHECK THE RESISTANCE OF THE CUSHION AND BACKREST BLOWER MOTORS

Action

Action
Action
Are the resistances between 4,000 and 10,000 ohms?
Yes GO to AE4
GO to AE5
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GO to AE5
AE4 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AE5
of any connector or pin issues. GO to AE5
AE5 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B2729

The SCME monitors seat cushion temperature while it supplies voltage and ground to both blower motors. The SCME also supplies a variable voltage signal to
flows through a duct to the foam pad.

B2729 Cushion Over-Temp If the driver seat cushion blower motor temperature exceeds 70° C (158° F) in cool mode or 85° C (185° F) in heat mode for
Detected more than 4 seconds, the SCME shuts down the driver seat system and sets this DTC.
Possible Causes

Crushed or restricted cushion foam pad
SCME
PINPOINT TEST AF : DTC B2729
AF1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Start the vehicle and set the driver seat to HIGH heat.
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Was DTC B2729 retrieved on-demand during the self-test?
Yes GO to AF2
No GO to AF5
AF2 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR THERMISTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C3265B-7 Ground
C3265B-8 Ground
Yes GO to AF3
No REPAIR the circuit in question. GO to AF22
AF3 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR THERMISTOR AND WIRING
Connect: Driver Seat Cushion Blower Motor C3035.
Measure:

C3265B-7 C3265B-8

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AF18
No GO to AF4
AF4 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR THERMISTOR


Action
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0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS26 (VT) or RHS05 (YE/VT) for an open or high resistance. GO to AF22
GO to AF22
AF5 CONFIRM THE FAULT WHILE MONITORING THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) SEAT BACK THERMAL ELECTRIC
DEVICE TEMPERATURE (BKTMP) AND SEAT CUSHION THERMAL ELECTRIC DEVICE TEMPERATURE (CSHTEMP) PARAMETER IDENTIFICATIONS
(PIDS)
Set the driver seat to OFF.
Using a diagnostic scan tool, monitor the SCME BKTMP and CSHTEMP Parameter Identifications (PIDs).
NOTE: A crushed seat cushion foam pad may be the cause of the fault, making it necessary to occupy the seat to recreate and identify the fault.
Attempt to recreate the fault. Start the vehicle and set the driver seat to HIGH heat for at least 15 minutes while occupying the seat.
No If the CSHTEMP PID increases incrementally and is greater than 15° C (27° F) of the BKTMP PID, GO to AF6
If the CSHTEMP PID increases quickly (temperature "jumps" and does not increase incrementally) and is greater than 15° C (27° F) of
the BKTMP PID, GO to AF16
AF6 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS
Note the airflow exhausting from the driver seat cushion blower motor and compare it to the airflow exhausting from the driver seat cushion blower motor.
Carry out a wiggle test of the wire harnesses between the SCME and the driver seat cushion blower motor while monitoring blower operation. The blower
should operate consistently and not change speeds.
Is the airflow exhausting from the driver seat cushion blower motor comparable to the airflow exhausting from the driver seat cushion blower motor
with no change in operation when carrying out the wiggle test?
Yes GO to AF7
No If the airflow exhausting from the driver seat cushion blower motor is not comparable to the airflow exhausting from the passenger seat
cushion blower motor, GO to AF8
If the driver seat cushion blower motor blower operation changed while carrying out the wiggle test, IDENTIFY and REPAIR the wiring
fault.
AF7 COMPARE OPERATION OF THE DRIVER AND DRIVER SEATS WHILE OCCUPIED
Note the airflow exhausting from the driver seat cushion blower motor with the driver seat occupied and compare it to the airflow exhausting from the
passenger seat cushion blower motor with the passenger seat occupied.
Is the airflow exhausting from the driver seat cushion blower motor comparable to the airflow exhausting from the passenger seat cushion blower
motor?
Yes GO to AF16
No INSTALL a new driver seat cushion foam pad.
AF8 CHECK THE DRIVER SEAT CUSHION BLOWER FOR AN OBSTRUCTION OR RESTRICTED FILTER
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Ignition OFF.
Inspect the driver seat cushion blower motor assembly for an obstruction or for a restricted filter.
Is the blower motor obstructed or the filter restricted?
Yes REMOVE the obstruction or INSTALL a new driver seat cushion blower motor.
No GO to AF9
AF9 CHECK THE DRIVER SEAT CUSHION BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN
Measure:

C3265C-11 C3035-7
Yes GO to AF10
No REPAIR the circuit. GO to AF22
AF10 CHECK THE DRIVER SEAT CUSHION BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C3265C-15 Ground
Yes REPAIR the circuit. GO to AF22

No GO to AF11
AF11 CHECK THE DRIVER SEAT CUSHION BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-16 Ground
Yes GO to AF12
No REPAIR the circuit. GO to AF22
AF12 CHECK THE DRIVER SEAT CUSHION BLOWER CIRCUITS FOR AN OPEN
Measure:

C3265C-16 C3035-3
C3265C-15 C3035-4
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Yes GO to AF13
No REPAIR the circuit in question. GO to AF22
AF13 CHECK THE DRIVER SEAT CUSHION BLOWER RESISTANCE


Action
Yes GO to AF14
GO to AF22
AF14 CHECK THE DRIVER SEAT CUSHION BLOWER SPEED CONTROL RESISTANCE
Action
Yes GO to AF15
GO to AF22
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AF15 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR INSTALLATION AND FOR CRUSHED SEAT CUSHION
Ignition OFF.
Remove the driver seat cushion cover.
Inspect the driver seat cushion for the following:
Is the driver seat cushion blower motor correctly installed and are there no signs of damage to the foam pad?
Yes INSTALL the driver seat cushion cover and seat. GO to AF18
No CORRECTLY install the driver seat cushion blower motor or INSTALL a new driver seat cushion foam pad. GO to AF22
AF16 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR THERMISTOR AND WIRING
Measure:

C3265B-7 C3265B-8

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AF18
No GO to AF17
AF17 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR THERMISTOR

Action
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0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS26 (VT) or RHS05 (YE/VT) for an open or high resistance. GO to AF22
GO to AF22
AF18 CHECK THE DRIVER SEAT CUSHION BLOWER MOTOR HEATING/COOLING CIRCUITRY CURRENT DRAW
Place an inductive current probe around circuit CHS02 (YE/BU) near SCME C3265A-G and monitor the current draw.
Start the engine and set the driver seat to HIGH heat.
Yes GO to AF19
GO to AF22
AF19 CHECK RESISTANCE OF THE DRIVER SEAT CUSHION BLOWER MOTOR AND WIRING
Ignition OFF.
Measure:

C3265A-G Ground
C3265A-H Ground
Yes GO to AF21
No GO to AF20
AF20 CHECK THE RESISTANCE OF THE DRIVER SEAT CUSHION BLOWER MOTOR

Action
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Yes REPAIR circuit CHS02 (YE/BU) or RHS02 (BU/OG) for an open or high resistance. GO to AF22
GO to AF22
AF21 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AF22
of any connector or pin issues. GO to AF22
AF22 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
DTC B2730
The SCME monitors seat backrest temperature while it supplies voltage and ground to both blower motors. The SCME also supplies a variable voltage signal to
flows through the foam pad.

B2730 Back Over-Temp If the driver seat backrest blower motor temperature exceeds 70° C (158° F) in cool mode or 85° C (185° F) in heat mode for
Detected more than 4 seconds the SCME shuts down the driver seat system and sets this DTC.
Possible Causes
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SCME
PINPOINT TEST AG : DTC B2730
AG1 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) FOR ON-DEMAND DIAGNOSTIC TROUBLE CODES (DTCS)
Start the vehicle and set the driver seat to HIGH heat.
Was DTC B2730 retrieved on-demand during the self-test?
Yes GO to AG2
No GO to AG5
AG2 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR THERMISTOR CIRCUITS FOR A SHORT TO GROUND
Measure:

C3265B-9 Ground
C3265B-10 Ground
Yes GO to AG3
No REPAIR the circuit in question. GO to AG22
AG3 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR THERMISTOR AND WIRING
Connect: Driver Seat Backrest Blower Motor C3034.
Measure:

C3265B-9 C3265B-10

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AG18
No GO to AG4
AG4 CHECK THE PASSENGER SEAT BACKREST BLOWER MOTOR THERMISTOR

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Action

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS35 (VT/OG) or RHS15 (GY/BN) for an open or high resistance. GO to AG22
No INSTALL a new driver seat backrest blower motor.
GO to AG22
AG5 CONFIRM THE FAULT WHILE MONITORING THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) SEAT BACK THERMAL ELECTRIC
DEVICE TEMPERATURE (BKTMP) AND SEAT CUSHION THERMAL ELECTRIC DEVICE TEMPERATURE (CSHTEMP) PARAMETER IDENTIFICATIONS
(PIDS)
Using a diagnostic scan tool, monitor the SCME BKTMP and CSHTEMP Parameter Identifications (PIDs).
NOTE: A crushed seat backrest foam pad may be the cause of the fault, making it necessary to occupy the seat to recreate and identify the fault.
Attempt to recreate the fault. Start the vehicle and set the driver seat to HIGH heat for at least 15 minutes while occupying the seat.
No If the BKTMP PID increases incrementally and is greater than 15° C (27° F) of the CSHTEMP PID, GO to AG6
If the BKTMP PID increases quickly (temperature "jumps" and does not increase incrementally) and is greater than 15° C (27° F) of the
CSHTEMP PID, GO to AG16
AG6 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS

Note the airflow exhausting from the driver seat backrest blower motor and compare it to the airflow exhausting from the passenger seat backrest blower
motor.
Carry out a wiggle test of the wire harnesses between the SCME and the driver seat backrest blower motor while monitoring blower operation. The blower
should operate consistently and not change speeds.
Is the airflow exhausting from the driver seat backrest blower motor comparable to the airflow exhausting from the passenger seat backrest blower
Yes GO to AG7
No If the airflow exhausting from the driver seat backrest blower motor is not comparable to the airflow exhausting from the passenger
seat backrest blower motor, GO to AG8
If the driver seat backrest blower motor operation changed while carrying out the wiggle test, IDENTIFY and REPAIR the wiring fault.
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AG7 COMPARE OPERATION OF THE DRIVER AND PASSENGER SEATS WHILE OCCUPIED
Note the airflow exhausting from the driver seat backrest blower motor with the driver seat occupied and compare it to the airflow exhausting from the
passenger seat backrest blower motor with the passenger seat occupied.
Is the airflow exhausting from the driver seat backrest blower motor comparable to the airflow exhausting from the passenger seat backrest blower
motor?
Yes GO to AG16
No INSTALL a new driver seat backrest foam pad.
AG8 CHECK THE DRIVER SEAT BACKREST BLOWER FOR AN OBSTRUCTION OR RESTRICTED FILTER
Ignition OFF.
Inspect the blower of the driver seat backrest blower motor assembly for an obstruction or for a restricted filter.
Yes REMOVE the obstruction or INSTALL a new driver seat cushion blower motor.
No GO to AG9
AG9 CHECK THE DRIVER SEAT BACKREST BLOWER SPEED CONTROL CIRCUIT FOR AN OPEN
Measure:

C3265C-12 C3034-7
Yes GO to AG10
No REPAIR the circuit. GO to AG22
AG10 CHECK THE DRIVER SEAT BACKREST BLOWER CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:
C3265C-15 Ground
Yes REPAIR the circuit. GO to AG22

No GO to AG11
AG11 CHECK THE DRIVER SEAT BACKREST BLOWER CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3265C-16 Ground
Yes GO to AG12
No REPAIR the circuit. GO to AG22
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AG12 CHECK THE DRIVER SEAT BACKREST BLOWER CIRCUITS FOR AN OPEN
Measure:

C3265C-16 C3034-3
C3265C-15 C3034-4
Yes GO to AG13
No REPAIR the circuit in question. GO to AG22
AG13 CHECK THE DRIVER SEAT BACKREST BLOWER RESISTANCE


Action
Yes GO to AG14
GO to AG22
AG14 CHECK THE DRIVER SEAT BACKREST BLOWER SPEED CONTROL RESISTANCE

Action
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Yes GO to AG15
GO to AG22
AG15 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR INSTALLATION AND FOR CRUSHED SEAT BACKREST
Ignition OFF.
Remove the driver seat backrest cover.
Inspect the driver seat backrest for the following:
Backrest foam pad crushed or restricted
Is the driver seat backrest blower motor correctly installed and are there no signs of damage to the foam pad?
Yes INSTALL the driver seat backrest cover and seat. GO to AG18
No CORRECTLY install the driver seat backrest blower motor or INSTALL a new driver seat backrest foam pad. GO to AG22
AG16 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR THERMISTOR AND WIRING
Measure:

C3265B-9 C3265B-10

0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes GO to AG18
No GO to AG17
AG17 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR THERMISTOR


Action
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0-10° C (32-50° F) 2,782-1,663 ohms
10-20° C (50-68° F) 1,837-1,140 ohms
20-30° C (68-86° F) 1,260-806 ohms
30-40° C (86-104° F) 893-570 ohms
40-50° C (104-122° F) 630-428 ohms
Yes REPAIR circuit VHS35 (VT/OG) or RHS15 (GY/BN) for an open or high resistance. GO to AG22
GO to AG22
AG18 CHECK THE DRIVER SEAT BACKREST BLOWER MOTOR HEATING/COOLING CIRCUITRY CURRENT DRAW
Place an inductive current probe around circuit CHS01 (GY/VT) near SCME C3265A-J and monitor the current draw.
Start the engine and set the driver seat to HIGH heat.
Yes GO to AG19
GO to AG22
AG19 CHECK RESISTANCE OF THE DRIVER SEAT BACKREST BLOWER MOTOR AND WIRING
Ignition OFF.
Measure:

C3265A-J Ground
C3265A-K Ground
Yes GO to AG21
No GO to AG20
AG20 CHECK THE RESISTANCE OF THE DRIVER SEAT BACKREST BLOWER MOTOR
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Action
Yes REPAIR circuit CHS01 (GY/VT) or RHS01 (WH/VT) for an open or high resistance. GO to AG22
GO to AG22
AG21 CHECK THE SCME (FRONT SEAT CLIMATE CONTROL MODULE) OPERATION
Ignition OFF.
Repair:
Ignition ON.
GO to AG22
of any connector or pin issues. GO to AG22
AG22 VERIFY THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PROVES OUT SUCCESSFULLY

No
Component Test(s)
Blower Motor Cooling Performance
NOTE: This test is intended to check the cooling mode performance of an operational climate controlled seat backrest or cushion blower motor and verify it is
cooling inlet air at the blower motor (ambient cabin air) between 6-8° C (10-14° F).
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NOTE: Make sure the vehicle is out of direct sunlight and is in an area with a stable air temperature when testing the climate controlled seat system.
NOTE: For correct temperature measurements, the seat being tested should be occupied.
1. Using a diagnostic scan tool, monitor the following SCME Parameter Identifications (PIDs):
Driver State Seat Mode (DCCSMOD)
Passenger State Seat Mode (PCCSMOD)
2. Any initial PID value of greater than 205° C (401° F) or less than 2° C (36° F) indicates a system hardware failure. Do not proceed with this test. GO to
Symptom Chart or SCME DTC Chart for diagnostic direction.
3. Gain access to the seat cushion and backrest blower motors and use a suitable thermocouple temperature measuring device to monitor the air inlet
temperature.
Place the temperature probe near each blower motor air filter.
4. NOTE: The engine must be running to operate the climate controlled seat system and carry out this test.
Operate system in high cool mode and measure the temperature at the cushion blower motor filter using the thermocouple device.
Secure the temperature probe at the cushion blower motor and record the air inlet temperature.
5. Use a diagnostic scan tool to measure the cushion blower motor PID temperature and record the value.
Monitor the MODE PID and verify the system is operating. If during testing, the PID value changes to Blower Only state, the system has entered
into recovery mode and voltage to the blower motors are disabled. If this occurs, the seat has failed the test. Do not continue. Return to the
diagnostic routine.
6. Subtract the cushion blower motor PID temperature from the cushion air inlet temperature and record the temperature difference value.
7. Continue to operate the system in high cool mode and use the thermocouple device to measure the temperature at the backrest blower motor filter.
Secure the temperature probe at the backrest blower motor and close the backrest trim cover before measuring and recording the air inlet
temperature.
8. Use a diagnostic scan tool to measure the backrest blower motor PID temperature and record the value.
Monitor the MODE PID and verify the system is operating. If during testing, the PID value changes to Blower Only state, the system has entered
into recovery mode and voltage to the blower motors is disabled. If this occurs, the seat has failed the test. Do not continue. Return to the
diagnostic routine.
9. Subtract the backrest blower motor PID temperature from the backrest air inlet temperature and record the value.
10. Compare the cushion and backrest calculated temperature values. The temperature difference should be between 6-8° C (10-14° F).
11. If the calculated temperature values are not within these specifications, check the climate controlled seat components for air duct or filter restrictions,
blockages, duct or electrical disconnections and for incorrect assembly. Repair as needed. If OK, carry out the SCME self-test and if any Diagnostic
Trouble Codes (DTCs) are retrieved, go to SCME DTC Chart for diagnostic direction. Return to the diagnostic routine.

Driver Front Seat Module (DSM)
Removal
NOTE: LHD driver seat shown, RHD driver seat similar.
NOTE: The PMI process must begin with the current DSM installed. If the current DSM does not respond
to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
Using a diagnostic scan tool, begin the PMI process for the DSM following the on-screen instructions.
2. Position the driver front seat to the full rearward and full upward position.
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3. Disconnect the DSM electrical connectors.
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4. Remove the screws and the DSM.
Installation
Using a diagnostic scan tool, complete the PMI process for the DSM following the on-screen instructions.
Operate the seat in all directions through the full range of travel to set soft stops and avoid a premature
stopping point occurrence after the vehicle is returned to the customer.
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Front Head Restraint Guide Sleeve
Flat Headed Screw Driver
Removal
NOTE: Typical head restraint guide sleeve shown, others similar.
1. Depress the locking tabs and remove the head restraint.
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2. NOTE: Seat backrest cushion removed for clarity.
Remove the headrest restraint guide sleeves.

Use the General Equipment: Flat Headed Screw Driver
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3. Discard the head restraint guide sleeves.
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. Install the new head restraint guide sleeves.

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2. Depress the locking tabs and install the head restraint.

Front Seat
Removal
NOTE: LHD driver seat shown, all others similar.
1. Position the seat to access the front seat bolts.

If a power seat cannot be positioned horizontally to access the front seat bolts, diagnose the
inoperative horizontal seat track motor.
Refer to: Front Seats (501-10A Front Seats, Diagnosis and Testing).
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2. Depower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System,
3. Remove the front seat shield bolt caps.

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4. Disconnect the front seat electrical connector(s) and position the wire harness aside.
5. NOTE: Follow the unique instructions or graphic for this step in the installation.
Remove the bolts and the front seat.

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Installation
2.
Install the front seat bolts in the following sequence.
1. Install the front inboard bolt.
2. Install the front outboard bolt.
3. Install the rear inboard bolt.
4. Install the rear outboard bolt.
3. Repower the SRS.
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System,
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Front Seat Backrest
Removal
All seats
1. Remove the front seat.

Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
2. Remove the screws and the recline cover.
3. Release the retaining clip and remove the front seat recline handle. cardiagn.com
Manual driver seat
4.
If equipped, remove the height adjusting handle.
1. Raise the height adjusting handle.
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3. Slide the height adjusting handle forward.
Power seats and manual driver seat
5. Remove the side shield screws.

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6.
Remove the side shield.
1. Lift up on the rear of the side shield and pull outward.
2. Push the side shield forward.
3. If equipped, disconnect the electrical connector.
Passenger manual seat

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8.
1. Pull the rear of the side shield out.
2. Firmly grasp the side shield, lift up and out, separating the side shield from the recliner bracket.
3. From underneath, squeeze the retainers together and pull out on the side shield.
4. Slide the side shield forward.
All seats
9.
Position the front seat backrest cover.
1. Release the wire harness electrical connector retainer(s).
2. Detach the front seat backrest cover straps from the seat cushion frame.
3. Position the front seat backrest cover aside.
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10. Remove the bolts and backrest.
Installation

Front Seat Backrest Blower Motor
Removal

2.
1. Release the wire harness electrical connector retainers.
2. Detach the front seat backrest cover straps.
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3.
Remove the backrest cover insert.
2. Position the backrest cover upward.
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4.
1. Release the J-clip.
2. Position the backrest cover from between the seat cushion and backrest cushion.
5. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strips or
the hook-and-loop strips may be torn from the seat backrest foam pad.
Release the hook-and-loop strips and position the backrest cover upward.
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6. Release the wire harness retainer and disconnect the blower motor electrical connector.
7. Disconnect the blower motor manifold from the backrest cushion.

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8. NOTE: The backrest foam has been removed for clarity.
Remove the blower motor.

1. Release the blower motor horizontal retainer.
2. Release the blower motor vertical retainers.
Installation

Front Seat Backrest Cover
Hog Ring Plier
Removal
WARNING: Front seat backrest trim covers installed on seats equipped with seat side airbags cannot
be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side airbag deploying incorrectly and increase the risk of serious
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NOTE: LHD drive seat shown, all others similar.

2. Remove the front head restraint guide sleeves.

Refer to: Front Head Restraint Guide Sleeve (501-10A Front Seats, Removal and Installation).
3. If equipped, remove the inner safety belt guide.
4.
If equipped, remove the outer safety belt guide.
1. Remove the cover.
2. Remove the front bolt.
3. Remove the rear bolt.
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5. Remove the seat release handle bezel.
6.
1. Releases the wire harness electrical connector retainer(s).
2. Detach the front seat backrest cover straps.
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7.
2. Position the backrest cover upwards.
8.
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10. Detach the side airbag deployment chute retainers and position aside.
11. Pull the side airbag deployment chute through the backrest foam.
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12. Release the backrest cover J-clips and position the backrest cover upward.
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13. Release the J-clip from the backrest frame.
14. Remove the hog rings.

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15. If equipped, position the safety belt strap as needed.
Release the hook-and-loop and remove the backrest cover.

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Installation
WARNING: Inspect the seat side airbag, airbag cavity, mounting surface and deployment chute for
damage or the presence of foreign material. Remove all foreign material. Install a new side airbag if it is
damaged. Install a new deployment chute if the deployment chute is damaged. Failure to follow these
1. To install, reverse the procedure.
2. Use the General Equipment: Hog Ring Plier

Front Seat Backrest Cover - Vehicles With: Recaro Seats
Removal
NOTE: Recaro seat shown, GT 350 Recaro seat similar.
All
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2. If equipped.
Remove the safety belt guide.
1. Remove the cover.
2. Remove the bolt.
3. NOTE: Inspect the pass-thru bezels for damage, replace as necessary.
Remove the front pass-thru bezels.

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4. NOTE: Inspect the pass-thru bezels for damage, replace as necessary.
Remove the rear pass-thru bezels.
5. Remove the backrest release handle bezel.

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6. Remove the side airbag.
Refer to: Side Airbag - Vehicles With: Recaro Seats (501-20B Supplemental Restraint System, Removal
and Installation).
7. Detach the J-clip from the backrest frame.
8. Release the backrest cover from the backrest carrier hooks.

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9. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the backrest foam pad.
NOTICE: Use care when separating the backrest cover from the hook-and-arrows, or the hooks
can be torn from the backrest foam pad.
Release the hook-and-loop strips, the hook-and-arrows and position the backrest cover up.
Recaro seat
Release the hook-and-loop strips and remove the backrest cover.

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GT 350 Recaro seat
Release the hook-and-loop strips and remove the backrest cover.
All
12. If required.
Remove the backrest carrier.
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Installation
WARNING: Inspect the seat side airbag, airbag cavity, mounting surface and deployment chute for
damage or the presence of foreign material. Remove all foreign material. Install a new side airbag if it is
damaged. Install a new deployment chute if the deployment chute is damaged. Failure to follow these
1. To install, reverse the procedure.

Front Seat Backrest Release Handle
Removal
NOTE: Power seat shown, all others similar.
1. Remove the front seat backrest cover.

Refer to: Front Seat Backrest Cover (501-10A Front Seats, Removal and Installation).
Refer to: Front Seat Backrest Cover - Vehicles With: Recaro Seats (501-10A Front Seats, Removal and
Installation).
2. If equipped.
Disconnect the backrest blower motor manifold from the backrest cushion.
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3. If equipped with a Recaro seat.
Remove the upper backrest foam.
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4. If equipped with a GT 350 Recaro seat.
Remove the upper backrest foam.
1. Pull the upper backrest foam away from the release handle.
2. Remove the upper backrest foam.
5. NOTE: If equipped, make sure that the safety belt guide strap is in the same position during installation.
Remove the seat backrest foam.

1. Pull the backrest foam from the backrest.
2. Lift the backrest foam from the backrest.
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6.
Position the release handle cable.
1. Detach the cable conduit.
2. Disconnect the cable from the recline mechanism.
7. Remove the release handle front bolts.

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8.
Remove the backrest release handle.
1. Remove the cable mount tie strap.
2. Remove the release handle side bolts.
Installation
1. To install, reverse removal procedure.

Front Seat Climate Control Module [SCME]
Removal
NOTE: LHD passenger seat shown, RHD passenger seat similar.
NOTE: The PMI process must begin with the current SCME installed. If the current SCME does not
respond to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
Using a diagnostic scan tool, begin the PMI process for the SCME following the on-screen instructions.
2. Position the front passenger seat to the full upward and full rearward positions.
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3. Remove the screws and position the SCME aside.
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4.
Remove the SCME.
1. Release the locking wedges.
2. Disconnect the electrical connectors.
Installation
Using a diagnostic scan tool, complete the PMI process for the SCME following the on-screen instructions.
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Front Seat Control Switch
Removal
1. Release the retaining clip and remove the front seat recline handle.
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3.
3. Disconnect the electrical connector.
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4. Remove the seat control switch knob.
5. Remove the screws and the seat control switch.

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Installation

Front Seat Cushion Blower Motor
Removal
All seats

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4.
5. NOTE: For passenger seats equipped with an OCS service kit, the OCS will be adhered to the bottom of
the seat cushion foam.
Release the J-clips and position the front of the seat cushion cover and foam assembly upwards.
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Passenger seat
6. NOTE: Original equipment (OE) OCS shown, service kit similar.
NOTE: If equipped with an OCS service kit, the OCS will be adhered to the bottom of the front seat
cushion.
Remove the OCS pin-type retainers.
7. NOTE: If equipped with an OCS service kit, the OCS is adhered to the bottom of the front seat cushion
foam. This requires the cushion cover, foam and OCS to be positioned aside as an assembly.
Position the front of the seat cushion cover, foam and OCS assembly upward.
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All seats
8. Remove the seat cushion blower motor screws.
9.
Remove the seat cushion blower motor.
1. Disconnect the seat cushion blower motor electrical connector.
2. Release the locking tabs.
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Installation
All Seats
2. Install the seat. If the passenger seat has been serviced, do not prove out theSRS at this time.
Passenger seat
3. 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
risk of serious personal injury or death in a crash.
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 using System Reset to rezero the seat weight. 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, take the following precautions before carrying out the OCS
reset.
Make sure the voltage to the OCSM is greater than 8 volts and less than 18 volts.
Make sure the OCS is not below 6º C (42.8º F) or above 36º C (96.7º F) when initiating the
OCS 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 6º C (42.8º F) to 36º C (96.7º
F) for a minimum of 30 minutes.
Make sure nothing is present on the passenger seat before and during the OCS reset
process.
Prior to carrying out the OCS reset, make sure a minimum of 8 seconds has elapsed after
cycling the ignition switch on.
Using a diagnostic scan tool, carry out the OCS reset. Cycle the ignition switch after the OCS reset.
4. If the first system reset attempt was successful, proceed to prove out the SRS.
5. If the first system reset attempt was not successful, carry out a thorough visual inspection of the OCS
connector and wiring for damage, pressure sensor hose for kinks and or damage, and seat-related wiring
harness and body wiring harness terminals and connectors for damage. Repair any concerns found and
proceed to the next step.
6. Carry out a second OCS reset. Cycle the ignition switch after the OCS reset. If the second attempt is
unsuccessful, install a new OCS service kit.
Refer to: Occupant Classification System (OCS) Sensor (501-20B Supplemental Restraint System,
7. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF. Wait 10 seconds
then turn the ignition ON and monitor the airbag warning indicator. The airbag warning indicator illuminates
continuously for approximately 6 seconds and turns off. Continue to monitor the airbag warning indicator for
approximately 30 seconds, as this is the time required for the RCM to complete testing of the SRS.
If a SRS fault is present, the airbag warning indicator either fails to light, remains lit continuously or
flashes. The flashing may not occur until approximately 30 seconds after the ignition has been turned
from OFF to ON. If this occurs, diagnose and repair any SRS faults before proceeding with other
repairs.
If, after the ignition has been turned on for 30 seconds, the airbag warning indicator remains unlit
with no chime or SRS message displayed in the message center, no SRS fault is present.
If the airbag warning indicator is inoperative and a SRS fault exists, a chime sounds in a pattern of 5
sets of 5 beeps or a message displays in the message center. If this occurs, diagnose and repair
the airbag warning indicator and any SRS faults before proceeding with other repairs.
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8. Using a scan tool, clear all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.

Front Seat Cushion Cover
Removal
All seats

2. Release the retaining clip and remove the seat recline handle.
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Manual driver seat
3.
Remove the height adjusting handle.
1. Raise the height adjusting handle.
3. Slide the height adjusting handle forward.
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Power seats and manual driver seat
5.
3. If equipped, disconnect the electrical connector.
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Passenger manual seat
7.
1. Pull the rear of the side shield out.
2. Firmly grasp the side shield, lift up and out, separating the side shield from the recliner bracket.
3. From underneath, squeeze the retainers together and pull out on the side shield.
4. Slide the side shield forward.
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All seats
8.
If equipped, position the front seat backrest cover.
1. Release the wire harness electrical connector retainer(s).
9. Detach the J-clips and position the cushion cover aside.

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10. NOTE: For passenger seats equipped with an OCS service kit, the OCS will be adhered to the bottom of
the seat cushion foam.
Release the J-clips and position the front of the seat cushion cover and foam assembly upwards.
Driver seat and passenger seat with OEM (Original Equipment Manufacturer)
11. Remove the front seat cushion cover and foam as an assembly.
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Passenger seat with service kit
12. NOTE: When equipped with an OCS service kit, the OCS is adhered to the bottom of the front seat
cushion foam. This requires the cushion cover, foam and OCS to be positioned aside as an assembly.
With the seat cushion cover, foam and OCS assembly positioned upward, remove the pin-type retainers.
13. NOTICE: Using excessive force when bending the bracket tab can damage the OCS sensor
housing.
NOTE: Follow the unique instructions or graphic for this step in the installation.
Disconnect the electrical connector, bend the bracket tab away and slide the OCS sensor off the bracket.
14. NOTE: Note the location of the OCS hose as it passes through the seat springs for proper installation.
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Route out the OCS hose and sensor from between the seat cushion support wires and remove the seat
cushion cover, foam and OCS sensor as an assembly.
All seats
Position the rear portion of the seat cushion cover from the foam.
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16. NOTICE: Use care when separating the seat cushion from the hook-and-arrow or the hook may be
torn from the seat cushion foam pad.
NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or
the hook-and-loop strips may be torn from the seat cushion foam pad.
Remove the seat cushion cover.

1. Position the seat cushion cover.
2. Release hook-and-loop strips.
3. Release the hook-and-arrows.
Installation
All Seats
2. Install the seat. If the passenger seat has been serviced, do not prove out theSRS at this time.
Passenger seat
3. NOTE: This step is only necessary when an OCS service kit is installed
Bend the OCS sensor bracket tab back.
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reset.
process.
repairs.
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Front Seat Power Lumbar Assembly
Removal

2.
1. Release the wire harness electrical connector retainers.
2. Detach the front seat backrest cove straps.
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3.
2. Position the backrest cover upwards.
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4.
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8. Release the backrest cover J-clips and position the backrest cover upward.
9. If equipped, remove the backrest blower motor.

Refer to: Front Seat Backrest Blower Motor (501-10 Front Seats) .
10. Disconnect the electrical connector, release the J-hooks and remove the lumbar assembly.
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Installation
1. WARNING: Inspect the seat side airbag, airbag cavity, mounting surface and deployment chute
for damage or the presence of foreign material. Remove all foreign material. Install a new side
airbag if it is damaged. Install a new deployment chute if the deployment chute is damaged. Failure
to follow these instructions may result in the seat side airbag deploying incorrectly and increase
the risk of serious personal injury or death in a crash.

Front Seat Track
Removal
1. Remove the front seat backrest.

Refer to: Front Seat Backrest (501-10A Front Seats, Removal and Installation).
2. Remove the front seat cushion cover and foam as an assembly.

Refer to: Front Seat Cushion Cover (501-10A Front Seats, Removal and Installation).
3. NOTE: This step is only necessary when the passenger seat is equipped with an original equipment (OE)
OCS.
Remove the OCS.

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Installation
1. NOTE: Transfer components to the new seat track as necessary.
2. NOTE: This step is only necessary when installing a new driver memory seat track.
Operate the seat in all directions through the full range of travel to set soft stops and avoid a premature
stopping point occurrence after the vehicle is returned to the customer.

Front Seat Track Motor
Electric Drill
Removal
1. NOTE: Positioning the seat fully upward provides access to service the seat track motor with the seat in
the vehicle.
Position the front seat to the full upward position.
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2. Depower the SRS.
5.
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6. NOTE: Seat track components are removed for clarity.
Disconnect the seat track motor electrical connector, release the wire harness retainers and position the
wire harness aside.
7. NOTE: Seat track components and wiring harness are removed for clarity.
Remove the bolts and the seat track motor.

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Installation
1. NOTE: Use the bolts from the old seat track motor.
Install the seat track motor bolts.

2. NOTICE: When using a drill to move the seat track, do not move the seat track to its forward or
rearward end of travel stops, otherwise a new seat track must be installed.
NOTE: Be sure to drive the seat track evenly or the track will bind during movement.
NOTE: Rotate the cables using 2 drills operating at similar speeds to most efficiently position the seat
track.
Insert the original seat track motor drive cables and drive the gearbox and seat track uniformly until the
front edge of the upper and lower seat tracks are flush.
Use the General Equipment: Electric Drill
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3. The front edges of the upper and lower seat track rails must align with each other on both sides of the
seat.
4. On both sides, remove the seat track motor bolts.
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5. NOTE: Install a new seat track if the block is not in place.
Verify the block is in place at the rear of the inboard seat track rail.
6. To aid installation.
Pull the long drive cable on the new motor assembly out of the sheathing.
7. Insert the long drive cable into the seat track gearbox.
8. Rotate the long drive cable to verify engagement to seat track gearbox.
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9. NOTICE: Do not severely bend the short drive cable during installation or damage to the cable will
occur.
Insert the short drive cable into the seat track gearbox.
1. Position the seat track motor while inserting the short cable into the seat track gearbox.
2. Rotate the short drive cable to verify engagement to seat track gearbox.
10. NOTICE: Do not cross-thread the bolts as they are load bearing. If the bolts are cross-threaded, a
new seat track must be installed.
NOTE: Seat track components and wiring harness are removed for clarity.
Install the seat track motor and install the new bolts in the sequence shown.
1. Install the rear inboard bolt.
2. Install the front inboard bolt.
3. Install the rear outboard bolt.
4. Install the front outboard bolt.
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11. NOTE: Seat track components are removed for clarity.
Connect the seat track motor electrical connector and engage the wire harness retainers.
12.
Install the side shield.
1. Connect the electrical connector.
2. Position the side shield and push it rearward.
3. Push the rear of the side shield inward.
4. Push the rear of the side shield downward.
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13. Install the side shield screws.
14. Install the retaining clip and the front seat recline handle.
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15. Repower the SRS.
16. On a driver seat with memory, operate the seat track horizontal motor in all directions through the full range
of travel to set the soft stops and avoid a premature stopping point occurrence after the vehicle is returned
to the customer.

501-10B Rear Seats 2016 Mustang
Rear Seat Backrest - Convertible
Removal

2. Release the fasteners attaching the seat backrest to the floor.

Torque: 35 lb.ft (47.5 Nm)
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3. Release the backrest locking clips. Remove the backrest.
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Installation
1. NOTE: During installation make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupant.

Rear Seat Backrest - Coupe
Removal

NOTE: LH seat shown, RH seat similar.
2. Release the fastener attaching the seat backrest to the floor.

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3.
Remove the backrest.
1. Release the backrest hinge from the pivot hinge.
2. Move the safety belt aside. Rotate the backrest toward the outboard side of the vehicle.
3. Lift the backrest to release it from the floor stud. Remove the backrest.
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Installation
1. NOTE: During installation make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupant.

Rear Seat Backrest Cover - Convertible
Removal
1. Remove the backrest.

2. Release the backrest cover J-clips from the backrest frame.
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3. Release the backrest cover carpet pin-type retainers from the backrest frame. Fold the carpet forward.
4. Release the backrest cover pin-type retainers from the top of the backrest frame.
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5. NOTICE: Use care when separating the seat backrest cover from the hook-and-loop strips, or the
hook-and-loop strips may be torn from the seat backrest foam pad.
Separate the backrest cover hook-and-loop strips from the backrest foam. Remove the backrest cover.
Installation

Rear Seat Backrest Cover - Coupe
Removal

Refer to: Rear Seat Backrest - Coupe (501-10B Rear Seats, Removal and Installation).
2. Release the backrest lower J-clip.
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3. NOTICE: Use care when separating the seat backrest cover from the hook-and-loop strips, or the
hook-and-loop strips may be torn from the seat backrest foam pad.
Separate the backrest cover hook-and-loop strips from the backrest foam. Position the backrest latch
strap through the backrest cover. Remove the backrest cover.
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Installation

Rear Seat Backrest Latch
Electric Drill
Removal
1. Remove the rear seat backrest cover.

Refer to: Rear Seat Backrest Cover - Coupe (501-10B Rear Seats, Removal and Installation).
2. Release the latch fasteners from the rear of the backrest frame.
3. Using an electric drill, remove the rivet. Remove the seat latch assembly.
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Installation
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Rear Seat Cushion
Removal
1. On both sides.
Move the front seat to the full forward position.
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2. NOTICE: The seat cushion tabs must be pressed in to release them from the floor. If the locking
tabs are not pressed in, it may result in damage to the tabs.
Located at the front of the seat cushion, press in on the locking tabs to release the seat cushion from the
floor.
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3. Lift and release the seat cushion. Remove the seat cushion.
Installation
1. NOTE: During installation make sure the seatbelt webbing is not twisted and the seatbelts and buckles
are accessible to the occupant.

Rear Seat Cushion Cover
Removal

2. Release the cushion cover J-clips and pin-type retainers from bottom of the seat cushion frame. Position
the J-clip attaching straps through the openings in the seat cushion foam.
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3. NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strips, or the
hook-and-loop strips may be torn from the seat cushion foam pad.
Separate the seat cushion cover from the hook-and-loop strips. Remove the cushion cover.
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Installation

501-11 Glass, Frames and Mechanisms 2016 Mustang
Glass, Frames and Mechanisms - Overview
Overview
Power Windows
Standard power window features include one-touch up/down operation (door windows only) when the master
window control switch (or passenger door window control switch) is momentarily pressed to the second detent
and released.
The master window control switch may be used to raise or lower the driver or passenger door windows. The
passenger door window can also be operated from the passenger door window control switch.
For convertible, the rear quarter windows can be raised or lowered from the master window control switch.
Rear Window Defrost
When the rear window defrost is activated, the rear window defrost grid is energized, warming/heating the glass
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to improve rearward visibility.

Glass, Frames and Mechanisms - System Operation and Component Description
System Operation
System Diagram - Power Windows (With Memory Driver Seat)
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Network Message Chart - Power Windows (With Memory Driver Seat)
Passenger Door Module (PDM) Network Input Messages

Message Module
Passenger window DDM When activating the front passenger window from the master window
command control switch, the passenger window command is sent from the DDM to
the PDM.
Body Control Module B (BCM-B) Network Input Messages

Message Module
Convertible top Movable Roof When the convertible top switch is activated, the Movable Roof Control
window drop Control Module A Module A (MRCMA) sends a message to the Body Control Module B
command (MRCMA) (BCM-B), which then sends a global open signal/command to fully open
all windows.
Global open BCM When the RKE transmitter is used to initiate a global open command,
command the BCM sends the message to the Body Control Module B (BCM-B)
which then sends a global open signal/command to fully open all
windows.
System Diagram - Power Windows (Without Memory Driver Seat)
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Network Message Chart - Power Windows (Without Memory Driver Seat)
Body Control Module B (BCM-B) Network Input Messages
Broadcast
Message Originating Module Message Purpose
Convertible top Movable Roof When the convertible top switch is activated, the Movable Roof Control
window drop Control Module A Module A (MRCMA) sends a message to the Body Control Module B
command (MRCMA) (BCM-B), which then sends a global open signal/command to fully open
all windows.
Global open BCM When the RKE transmitter is used to initiate a global open command,
command the BCM sends the message to the Body Control Module B (BCM-B)
which then sends a global open signal/command to fully open all
windows.
System Diagram - Rear Window Defrost
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Network Message Chart - Rear Window Defrost
Front Controls Interface Module (FCIM) Network Input Messages

Message Module
Climate APIM (if equipped The climate control requests message contains the rear window defrost
control with touchscreen) request information. When the rear window defrost function is requested
requests using voice command or the button is selected on the touchscreen, this input
activates the rear window defrost system.
Power Window Operation
NOTE: If the vehicle battery is disconnected while the door window is moving, the one-touch up feature (and
obstacle detection) is disabled. The convertible rear window motors do NOT need to be initialized as they do not
have one-touch up or one-touch down functions.
Refer to: Power Door Window Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
The power windows operate when the delayed accessory relay is active. The delayed accessory relay
(non-serviceable) is located in the BCM. Both door windows are equipped with obstacle detection and one-touch
up and one-touch down functionality. If an obstacle is detected as the window glass is moving upward, the window
motor automatically reverses direction and moves the glass downward.
The window one-touch up/down feature is activated by pulling/pressing the window control switch to the up/down
position (second detent). This allows the front door window glass to move upward/downward until it is fully
closed/open. A momentary activation of the window control switch, while the window glass is moving upward or
downward, stops the front door window glass.
If equipped with a memory driver seat, the master window control switch communicates to the DDM through a
LIN. To operate the driver door window, the DDM supplies the applicable voltage signals to the driver door
window regulator motor to operate the window in the desired direction. To operate the passenger door window
from the master window control switch, the DDM communicates to the PDM through the Medium Speed
Controller Area Network (MS-CAN), which then supplies the applicable voltage signals to the passenger door
window regulator motor to operate the window in the desired direction. The passenger door window control
switch provides ground input signals to the PDM, which then supplies the applicable voltage signals to the
passenger door window regulator motor to operate the window in the desired direction.
Global Open
NOTE: The global open feature may be enabled/disabled by the customer following a procedure listed in the
Owner's Literature. For a complete list of available programmable parameters, refer to Module Configuration in
Section 418-01.
The global open feature can automatically open both door windows and rear quarter windows (convertible) using
the RKE transmitter. The global open feature only activates when the ignition is off and the delayed accessory
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relay is not active. After unlocking the vehicle, pressing and holding the unlock button on the RKE transmitter
causes the Body Control Module B (BCM-B) to send a global open signal to each power window regulator motor.
When this signal is sent the windows begin to open. If the lock or unlock button on the RKE is pressed while the
windows are moving, the window operations will stop.
Short Drop Windows
When the window motor senses a door has been opened (by monitoring its door ajar switch), the window motor
opens the window slightly to clear the grooved channel weatherstrip. After the door is closed, the window motor
senses the closed door, and the window motor fully closes and seats the window glass into the grooved channel
weatherstrip. This function is on both the coupe and the convertible.
Rear Quarter Window Operation - Convertible
NOTE: The convertible rear window motors do NOT need to be initialized as they do not have one-touch up or
one-touch down functions.
Both rear quarter windows operate at the same time when activated by the master window control switch.
Convertible Top Drop Window Function
When the convertible top switch is operated (to raise or lower the convertible top), the Body Control Module B
(BCM-B) sends a signal on the global open circuit to the 4 window motors to activate a full down operation of all 4
windows. When the rear quarter windows reach the full DOWN position, the full down sensor in each rear quarter
window motor sends a signal to the BCM-B that the windows are in the full DOWN position. At this time, the
BCM-B allows the convertible top to operate (up or down). If the BCM-B does not see the full down signal from
both rear quarter window motors, the convertible top does not operate. The BCM-B also disables/inhibits the rear
quarter window control switch from operating the rear quarter windows when the convertible top is not in the full
UP or full DOWN position by sending a message (pulses) on the global open circuit (the front door window motors
ignore this message). This function is to prevent an accidental opening of the convertible top with the windows in
the UP position causing contact between the windows and convertible top which may result in damage to the
convertible top or windows.
Rear Window Defrost
When the rear window defrost switch (integral to the FCIM) is activated, the FCIM activates the rear window
defrost relay located in the BJB. When activated, the rear window defrost relay supplies voltage to the rear
window defrost grid.
If equipped, the rear window defrost can also be commanded on and off using voice commands or by touching the
rear window defrost button located on the touchscreen (FDIM). For additional information on voice or touchscreen
commanded features, refer to the Owner's Literature.
The FCIM deactivates the rear window defrost relay when one of these conditions is met:
The rear window defrost switch is pressed when the feature is active.
If equipped, the rear window defrost is commanded off using voice command or the touchscreen interface
when the feature is active.
Ignition state is changed from ON to OFF.
A predetermined timer completes.
Battery voltage has dropped below a specified threshold (load management strategy).
Remote Start - Rear Window Defrost Operation
The customer can select different climate control modes/preferences when the vehicle is started using the remote
start feature. This can be accessed through the message center. For additional information on setting the remote
start preferences, refer to the Owner's Literature. When the rear defrost is set to AUTO mode, the rear window
defrost activates when the outside temperature is less than 0°C (32°F) and the vehicle is started using the remote
start feature. No climate control adjustments are recognized during remote start operation. Once the ignition is
cycled to the ON mode, the climate control system returns to the previous settings (last ignition ON cycle) and
adjustments can be made normally. If the previous setting was off, the climate control system turns off.
Window Control Switches - Without Memory Driver Seat
The master window control switch (and passenger window control switch) sends 2 separate signals to the
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window motor: up and down. When the window control switch is pressed to the first detent position, a 12-volt
signal is sent to the window motor to request an up or down operation. When auto up or auto down is requested
(switch activated to the second detent position), the window control switch provides a 12-volt signal on both the
up and down line simultaneously. During an auto up or auto down request, the window motor determines intended
window direction by the signal first received. If the window control switch is activated too quickly to the second
detent position (less than 5 milliseconds of time between first detent signal and second detent signal), the window
motor is not able to determine the intended direction request and does not operate until the window control switch
is released and activated again. The up and down contacts are floating within the window control switch when the
switch is in the neutral position. The up and down feeds to the window motor are all low current.
For convertible, the master window control switch also operates the rear quarter windows. When the switch is
activated, a 12-volt signal is sent to both rear quarter window motors to request an up or down operation.
Master Window Control Switch - With Memory Driver Seat
The master window control switch receives voltage whenever the delayed accessory relay is active. The master
window control switch is grounded through the DDM. The master window control switch communicates to the
DDM through a LIN.
Passenger Window Control Switch - With Memory Driver Seat
The PDM provides a return (ground) for the passenger door window control switch. The passenger window
control switch sends 2 separate signals to the PDM: up and down. When the window control switch is pressed to
the first detent position, a ground signal is sent to the PDM to request an up or down operation. When auto up or
auto down is requested (switch activated to the second detent position), the window control switch provides a
ground signal on both the up and down line simultaneously. During an auto up or auto down request, the PDM
determines intended window direction by the signal first received
Door Window Regulator Motor
The door window regulator motor(s) are bi-directional. Window direction is determined by the low current voltage
signal(s) being supplied to the motor from the window control switch or associated door module (if equipped with
memory driver seat). The door window regulator motor contains integral electronics which control the one-touch
up/down movements as well as the short drop window feature.
Rear Quarter Window Regulator Motor
The rear quarter window regulator motor(s) are bi-directional. Window direction is determined by the low current
voltage signal(s) being supplied to the motor from the master window control switch or a command over the
global open circuit.
Front Controls Interface Module (FCIM)
The FCIM contains the rear window defrost button and also controls the rear window defrost relay. PMI is
required if installing a new module.
Front Display Interface Module (FDIM)
The FDIM contains a redundant rear window defrost button on the touchscreen display. The FDIM plugs directly
into the APIM, and does not communicate directly on any network.
Driver Door Module (DDM)
For vehicles equipped with memory driver seat, the DDM receives power window commands from the master
window control switch through a LIN. The DDM supplies the applicable voltage signals to the driver door window
regulator motor to operate the window in the desired direction.
The DDM also communicates master window control switch requests to the PDM through the Medium Speed
Controller Area Network (MS-CAN) to operate the passenger door window from the master window control
switch. PMI is required if installing a new module.
Passenger Door Module (PDM)
The PDM receives power window commands from the passenger door window control switch or from the DDM
through the Medium Speed Controller Area Network (MS-CAN). The PDM supplies the applicable voltage signals
to the passenger door window regulator motor to operate the window in the desired direction. PMI is required if
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installing a new module.
Body Control Module B (BCM-B)
During a global open command or whenever the convertible top switch is operated (to raise or lower the
convertible top if equipped), the Body Control Module B (BCM-B) sends a signal on a shared circuit to the window
motors to activate a full down operation of all windows. PMI is required if installing a new module.

Glass, Frames and Mechanisms
DTC Chart: Body Control Module B (BCM-B)
PDM DTC Chart

B127A:12 Global Window Control: Circuit Short To GO to Pinpoint Test I
Battery
B127A:14 Global Window Control: Circuit Short To GO to Pinpoint Test I
Ground or Open
Codes (DTCs) REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic
Modules, Diagnosis and Testing).
DTC Chart: Driver Door Module (DDM)
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DDM DTC Chart

B1088:83 LIN Bus "B": Value of Signal GO to Pinpoint Test B
Protection Calculation
Incorrect
B1088:87 LIN Bus "B": Missing Message GO to Pinpoint Test B
U2013:24 Switch Pack: Signal Stuck CLEAR the DTC. TEST the system for normal operation from the master window control switch. If any
High individual switches within the master window control switch are inoperative or the DTC returns,
INSTALL a new master window control switch.
REFER to: Front Door Window Control Switch (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
All other Diagnostic -
Trouble Codes (DTCs) REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry Systems,
DTC Chart: Front Controls Interface Module (FCIM)
FCIM DTC Chart

B1C83:12 Rear Defog Relay: Circuit Short GO to Pinpoint Test K
to Battery
B1C83:14 Rear Defog Relay: Circuit Short If the defrost is inoperative, GO to Pinpoint Test K If the defrost does not shut off, GO to
To Ground or Open Pinpoint Test L
Trouble Codes (DTCs) REFER to: Climate Control System - Vehicles With: Electronic Manual Temperature Control
(EMTC) (412-00 Climate Control System - General Information, Diagnosis and Testing).
REFER to: Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC)
(412-00 Climate Control System - General Information, Diagnosis and Testing).
DTC Chart: Passenger Door Module (PDM)
PDM DTC Chart

U2002:24 Switch: Signal Stuck GO to Pinpoint Test D
High
All other Diagnostic Trouble Codes -
(DTCs) REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
Symptom Chart(s)
Symptom Chart: Glass, Frames and Mechanisms
Symptom Chart

Both front door power windows are Wiring, DIAGNOSE any related DDM Diagnostic Trouble Codes (DTCs) first. REFER to
inoperative from the master window control terminals or the DDM DTC Chart in this section.
switch only - with memory driver seat connectors If there are no related Diagnostic Trouble Codes (DTCs) present, INSTALL a new
Master window master window control switch.
control switch REFER to: Front Door Window Control Switch (501-11 Glass, Frames and
DDM Mechanisms, Removal and Installation).
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Both front door power windows are Fuse VERIFY the BCM fuse 23 (10A) is OK. If OK, REPAIR circuit CBP23 (BN/YE) for
inoperative - without memory driver seat Wiring, an open. If not OK, REFER to the Wiring Diagrams manual to identify the possible
terminals or causes of the circuit short.
connectors
The LH front power window is Refer to the GO to Pinpoint Test A

inoperative/does not operate correctly - Pinpoint Test
without memory driver seat
The LH front power window is Refer to the GO to Pinpoint Test B
with memory driver seat
The RH front power window is Refer to the GO to Pinpoint Test C
without memory driver seat
The RH front power window is Refer to the GO to Pinpoint Test D
with memory driver seat
Both rear quarter windows are inoperative Refer to the GO to Pinpoint Test E
from the window control switch Pinpoint Test
The LH rear quarter window is Refer to the GO to Pinpoint Test F

inoperative/does not operate correctly Pinpoint Test
The RH rear quarter window is Refer to the GO to Pinpoint Test G

inoperative/does not operate correctly Pinpoint Test
The one-touch up/down feature is Refer to the GO to Pinpoint Test H

inoperative Pinpoint Test
The global open function is inoperative Refer to the GO to Pinpoint Test I

Pinpoint Test
The short drop window feature does not Refer to the GO to Pinpoint Test J
operate correctly Pinpoint Test
The defrost system is inoperative Refer to the GO to Pinpoint Test K

Pinpoint Test
The defrost system does not shut off Refer to the GO to Pinpoint Test L
automatically Pinpoint Test
The defrost system does not respond to Refer to the VERIFY the rear window defrost operation using the instrument panel rear
voice command only Pinpoint Test window defrost switch. If the rear window defrost is still inoperative, GO to
Pinpoint Test K If the rear window defrost operates, Refer to the appropriate
The defrost system does not respond to Refer to the VERIFY the rear window defrost operation using the instrument panel rear
touchscreen command only Pinpoint Test window defrost switch. If the rear window defrost is still inoperative, GO to
Pinpoint Test K If the rear window defrost operates, Refer to the appropriate
Pinpoint Test(s)
The LH Front Power Window is Inoperative/Does Not Operate Correctly - Without Memory Driver Seat
REFER to: Glass, Frames and Mechanisms - System Operation and Component Description (501-11 Glass, Frames and Mechanisms, Description and
Operation).
Possible Causes
Fuse
Master window control switch
Window regulator motor
PINPOINT TEST A : THE LH (LEFT-HAND) FRONT POWER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - WITHOUT
MEMORY DRIVER SEAT
A1 CHECK THE POWER TO THE WINDOW MOTOR
Ignition OFF.
Disconnect: Driver Door Window Regulator Motor C518.
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Measure:

C518-1 Ground
Yes GO to A2
possible causes of the circuit short. DE-INITIALIZE then INITIALIZE the window regulator motor.
REFER to: Power Door Window Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
A2 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C518-3 Ground
Yes GO to A3
No REPAIR the circuit. DE-INITIALIZE then INITIALIZE the window regulator motor.
A3 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C518-2 Ground
Yes GO to A4
A4 CHECK FOR A SHORT TO VOLTAGE IN THE WINDOW UP/DOWN CIRCUITS

Disconnect: Master Window Control Switch C504.
Ignition ON.
Measure:

C518-5 Ground
C518-4 Ground
Yes REPAIR the circuit in question. DE-INITIALIZE then INITIALIZE the window regulator motor.
No GO to A5
A5 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:
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C518-5 C504-20
C518-4 C504-19
Yes GO to A6
No REPAIR the circuit in question. DE-INITIALIZE then INITIALIZE the window regulator motor.
A6 CHECK THE MASTER WINDOW CONTROL SWITCH

Carry out the master window control switch component test.
Did the master window control switch pass the component test?
Yes INSTALL a new window regulator motor.

REFER to: Front Door Window Regulator Motor (501-11 Glass, Frames and Mechanisms, Removal and Installation).
No INSTALL a new master window control switch.
REFER to: Front Door Window Control Switch (501-11 Glass, Frames and Mechanisms, Removal and Installation).
DE-INITIALIZE then INITIALIZE the window regulator motor. REFER to: Power Door Window Initialization (501-11 Glass,
Frames and Mechanisms, General Procedures).
The LH Front Power Window is Inoperative/Does Not Operate Correctly - With Memory Driver Seat
Operation).

B1088:83 LIN Bus "B": Value of Signal Protection Calculation This DTC sets when the DDM has received invalid data from the master window control
Incorrect switch.
B1088:87 LIN Bus "B": Missing Message This DTC sets when the DDM has lost communication from the master window control
switch.
Possible Causes

Driver door window regulator motor
DDM
PINPOINT TEST B : THE LH (LEFT-HAND) FRONT POWER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - WITH MEMORY
DRIVER SEAT
B1 CHECK FOR DDM (DRIVER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform DDM self-test.
Are any DDM Diagnostic Trouble Codes (DTCs) present?
Yes For DTC B1088:83 and B1088:87, GO to B2

For all other Diagnostic Trouble Codes (DTCs), REFER to the DDM DTC Chart in this section.
No GO to B8
B2 CHECK FOR VOLTAGE TO THE MASTER WINDOW CONTROL SWITCH

Ignition OFF.
Disconnect: Master Window Control Switch C535 (coupe) or C504 (convertible).
Ignition ON.
For coupe, measure:
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C535-1 Ground
For convertible, measure:

C504-10 Ground
Yes GO to B3
B3 CHECK THE MASTER WINDOW CONTROL SWITCH GROUND CIRCUIT

Ignition OFF.
For coupe, measure:

C535-4 Ground

C504-11 Ground
Yes GO to B5
No GO to B4
B4 CHECK THE MASTER WINDOW CONTROL SWITCH GROUND CIRCUIT FOR AN OPEN
Disconnect: DDM C501A.
For coupe, measure:
C535-4 C501A-17

C504-11 C501A-17
Yes GO to B16
B5 CHECK THE MASTER WINDOW CONTROL SWITCH LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Disconnect: DDM C501A.
Ignition ON.
For coupe, measure:

C535-3 Ground
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C504-1 Ground

No GO to B6
B6 CHECK THE MASTER WINDOW CONTROL SWITCH LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
For coupe, measure:

C535-3 Ground

C504-1 Ground
Yes GO to B7
B7 CHECK THE MASTER WINDOW CONTROL SWITCH LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN
For coupe, measure:

C535-3 C501A-5

C504-1 C501A-5
Yes INSTALL a new master window control switch.

RETEST the system. If the concern is still present, GO to B16
B8 CHECK THE DRIVER'S FRONT WINDOW SWITCH - DRIVER'S DOOR (DF_WINDSW_DD) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view DDM Parameter Identifications (PIDs).
Monitor the DDM PID DF_WINDSW_DD while pressing and releasing the master window control switch in the up and down positions.
Does the PID status agree with the master window control switch as it is pressed and released?
Yes GO to B9
No INSTALL a new master window control switch.
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B9 CHECK THE BATTERY VOLTAGE TO THE WINDOW MOTOR
Ignition OFF.
Measure:

C518-1 Ground
Yes GO to B10
B10 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C518-3 Ground
Yes GO to B11
B11 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C518-2 Ground

Yes GO to B12
B12 CHECK FOR A SHORT TO VOLTAGE IN THE WINDOW UP/DOWN CIRCUITS

Ignition ON.
Measure:

C518-5 Ground
C518-4 Ground
No GO to B13
B13 CHECK FOR A SHORT TO GROUND IN THE WINDOW UP/DOWN CIRCUITS
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Ignition OFF.
Measure:

C518-5 Ground
C518-4 Ground
Yes GO to B14
B14 CHECK FOR AN OPEN IN THE WINDOW UP/DOWN CIRCUITS

Measure:

C518-5 C501B-10
C518-4 C501B-19
Yes GO to B15
B15 CHECK THE DDM (DRIVER DOOR MODULE) OUTPUT

Connect: DDM C501B.
Ignition ON.
While pressing and holding the master window control switch in the UP position, measure:

C518-4 Ground
While pressing and holding the master window control switch in the DOWN position, measure:

C518-5 Ground
Are the voltages greater than 11 volts when the master window control switch is activated in both up and down positions?
Yes INSTALL a new driver door window regulator motor.

No GO to B16
B16 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all the DDM connectors.
Repair:
Reconnect the DDM connectors. Make sure they seat and latch correctly.
Ignition ON.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new DDM.
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The RH Front Power Window is Inoperative/Does Not Operate Correctly - Without Memory Driver Seat
Operation).
Possible Causes
Fuse
Window control switch
Window regulator motor
Verify BCM fuse 26 (30A) is OK.
PINPOINT TEST C : THE RH (RIGHT-HAND) FRONT POWER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - WITHOUT
MEMORY DRIVER SEAT
C1 CHECK THE WINDOW OPERATION FROM BOTH WINDOW CONTROL SWITCHES
Ignition ON.
Attempt to operate the RH door window from the master window control switch and also the passenger door window control switch.
Does the RH door window operate from at least one window control switch?
Yes If the RH door window operates only from the passenger door window control switch, GO to C2
If the RH door window operates only from the master window control switch, GO to C3
No GO to C5
C2 CHECK THE WINDOW CONTROL SWITCH UP/DOWN CIRCUITS FOR AN OPEN

Ignition OFF.
Disconnect: Master Window Control Switch C504 and Passenger Door Window Control Switch C624.
Measure:

C624-3 C504-15
C624-2 C504-16

C3 CHECK FOR VOLTAGE TO THE PASSENGER WINDOW CONTROL SWITCH

Ignition OFF.
Disconnect: Passenger Door Window Control Switch C624.
Ignition ON.
Measure:

C624-1 Ground
Yes GO to C4
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C4 CHECK THE WINDOW CONTROL SWITCH CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C624-3 C504-15
C624-2 C504-16
Yes INSTALL a new passenger door window control switch.

C5 CHECK FOR BATTERY VOLTAGE TO THE WINDOW MOTOR

Ignition OFF.
Disconnect: Passenger Door Window Regulator Motor C608.
Measure:

C608-1 Ground
Yes GO to C6
No VERIFY BCM fuse 26 (30A) 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. DE-INITIALIZE then INITIALIZE the window regulator motor.
C6 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C608-3 Ground
Yes GO to C7
C7 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C608-2 Ground
Yes GO to C8
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C8 CHECK FOR A SHORT TO VOLTAGE IN THE WINDOW UP/DOWN CIRCUITS
Disconnect: Master Window Control Switch C504 and Passenger Door Window Control Switch C624.
Ignition ON.
Measure:

C608-5 Ground
C608-4 Ground
No GO to C9
C9 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C608-5 C624-3
C608-4 C624-2

The RH Front Power Window is Inoperative/Does Not Operate Correctly - With Memory Driver Seat

Operation).
Possible Causes

Passenger door window control switch
Passenger door window regulator motor
PDM

U2002:24 Switch: Signal Stuck This DTC sets when the PDM detects the window control switch is stuck in the UP or DOWN position or a short to ground is
High present on the input circuit for greater than 10 seconds.
PINPOINT TEST D : THE RH (RIGHT-HAND) FRONT POWER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - WITH MEMORY
DRIVER SEAT
D1 CHECK FOR PDM (PASSENGER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform PDM self-test.
Are any PDM Diagnostic Trouble Codes (DTCs) present?
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Yes For DTC U2002:24, GO to D2
For all other Diagnostic Trouble Codes (DTCs),
REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry Systems, Diagnosis and Testing).
No GO to D4
D2 CHECK THE WINDOW CONTROL SWITCH CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Disconnect: PDM C652A.
Measure:

C652A-8 Ground
C652A-9 Ground
Yes GO to D16
No GO to D3
D3 CHECK THE WINDOW CONTROL SWITCH CIRCUITS FOR A SHORT TO GROUND WITH THE WINDOW CONTROL SWITCH
DISCONNECTED
Measure:

C652A-8 Ground
C652A-9 Ground
Yes INSTALL a new passenger door window control switch.

D4 CHECK THE WINDOW OPERATION FROM BOTH WINDOW CONTROL SWITCHES

Ignition ON.
Attempt to operate the RH door window from the master window control switch and also the passenger door window control switch.
Does the RH door window operate from at least one window control switch?
Yes If the RH door window operates only from the passenger door window control switch, INSTALL a new master window control
switch.
If the RH door window operates only from the master window control switch, GO to D5
No GO to D9
D5 CHECK THE PASSENGER DOOR WINDOW CONTROL SWITCH RETURN CIRCUIT

Ignition OFF.
Measure:

C624-1 Ground
Yes GO to D7
No GO to D6
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D6 CHECK THE PASSENGER DOOR WINDOW CONTROL SWITCH RETURN CIRCUIT FOR AN OPEN
Measure:

C624-1 C652A-17
Yes GO to D16
D7 CHECK THE WINDOW CONTROL SWITCH UP/DOWN CIRCUITS

Measure:

C624-3 C652A-9
C624-2 C652A-8
Yes GO to D8
D8 CHECK THE PASSENGER DOOR WINDOW CONTROL SWITCH

Carry out the passenger door window control switch component test.
Did the passenger door window control switch pass the component test?
Yes GO to D16
No INSTALL a new passenger door window control switch.
D9 CHECK FOR BATTERY VOLTAGE TO THE WINDOW MOTOR
Ignition OFF.
Measure:

C608-1 Ground
Yes GO to D10
D10 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C608-3 Ground
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Yes GO to D11
D11 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C608-2 Ground
Yes GO to D12
D12 CHECK FOR A SHORT TO VOLTAGE IN THE WINDOW UP/DOWN CIRCUITS

Ignition ON.
Measure:

C608-5 Ground
C608-4 Ground
No GO to D13
D13 CHECK FOR A SHORT TO GROUND IN THE WINDOW UP/DOWN CIRCUITS

Ignition OFF.
Measure:

C608-5 Ground
C608-4 Ground
Yes GO to D14
D14 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN

Measure:

C608-5 C652B-10
C608-4 C652B-19
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Yes GO to D15
D15 CHECK THE PDM (PASSENGER DOOR MODULE) OUTPUT

Connect: PDM C652B.
Ignition ON.
While pressing and holding the window control switch in the UP position, measure:

C608-4 Ground
While pressing and holding the window control switch in the DOWN position, measure:

C608-5 Ground
Are the voltages greater than 11 volts when the door window control switch is activated in both up and down positions?
Yes INSTALL a new passenger door window regulator motor.

No GO to D16
D16 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all the PDM connectors.
Repair:
Reconnect the PDM connectors. Make sure they seat and latch correctly.
Ignition ON.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new PDM.
REFER to: Passenger Door Module (PDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
Both Rear Quarter Windows Are Inoperative From The Window Control Switch
Operation).
Possible Causes
Convertible top not in fully closed/latched or open position

The rear window operation from the switch is disabled when the convertible top is not fully open or fully closed. Verify the convertible top is in the fully
open, or fully closed and latched position before carrying out this pinpoint test.
PINPOINT TEST E : BOTH REAR QUARTER WINDOWS ARE INOPERATIVE FROM THE WINDOW CONTROL SWITCH
E1 CHECK FOR MRCMA (MOVABLE ROOF CONTROL MODULE A) DIAGNOSTIC TROUBLE CODES (DTCS)
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Ignition ON.
Using a diagnostic scan tool, perform MRCMA (Movable Roof Control Module A) self-test.
Are any MRCMA (Movable Roof Control Module A) Diagnostic Trouble Codes (DTCs) present?
Yes DIAGNOSE any convertible top related Diagnostic Trouble Codes (DTCs) first. Refer to the appropriate section in Group 501 for
the procedure.
No GO to E2
E2 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN

Ignition OFF.
Disconnect: Left Rear Power Window Motor C3118.
If equipped with memory driver seat, measure:

C504-13 C3118-4
C504-14 C3118-5
If not equipped with memory driver seat, measure:

C504-17 C3118-4
C504-18 C3118-5

The LH Rear Quarter Window is Inoperative/Does Not Operate Correctly
Operation).
Possible Causes
Fuse
Rear window regulator motor
PINPOINT TEST F : THE LH (LEFT-HAND) REAR QUARTER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
F1 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN
Ignition OFF.
Measure:

C504-17 C3118-4
C504-18 C3118-5
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Yes GO to F2
F2 CHECK THE POWER TO THE WINDOW MOTOR

Measure:

C3118-1 Ground
Yes GO to F3
possible causes of the circuit short.
F3 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C3118-3 Ground
Yes GO to F4
F4 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C3118-2 Ground

REFER to: Rear Quarter Window Regulator Motor - Convertible (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
The RH Rear Quarter Window is Inoperative/Does Not Operate Correctly
Operation).
Possible Causes
Fuse
Rear window regulator motor
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PINPOINT TEST G : THE RH (RIGHT-HAND) REAR QUARTER WINDOW IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
G1 CHECK THE WINDOW UP/DOWN CIRCUITS FOR AN OPEN
Ignition OFF.
Measure:

C504-17 C3119-4
C504-18 C3119-5
Yes GO to G2
G2 CHECK THE POWER TO THE WINDOW MOTOR

Measure:

C3119-1 Ground
Yes GO to G3
possible causes of the circuit short.
G3 CHECK THE WINDOW MOTOR DELAYED ACCESSORY FEED

Ignition ON.
Measure:

C3119-3 Ground
Yes GO to G4
G4 CHECK THE WINDOW MOTOR GROUND

Ignition OFF.
Measure:

C3119-2 Ground

Installation).
The One-Touch Up/Down Feature is Inoperative
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Operation).
Possible Causes
Window regulator motor not initialized

Window control switch
PINPOINT TEST H : THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE

H1 INITIALIZE THE SUSPECT POWER WINDOW
Carry out the initialization procedure on the suspect power window.
Is the one-touch up feature operating correctly?
Yes The system is operating normally at this time. The window lost initialization.
No If the LH front window one-touch up/down feature is inoperative, INSTALL a new master window control switch.
If the concern is still present, INSTALL a new window regulator motor. REFER to: Front Door Window Regulator Motor (501-11
Glass, Frames and Mechanisms, Removal and Installation).
If the RH front window one-touch up/down feature is inoperative from the passenger window control switch, INSTALL a new
passenger window control switch.
If the RH front window one-touch up/down feature is inoperative from the master window control switch, INSTALL a new master
window control switch.
The Global Open Function is Inoperative
Operation).

B127A:12 Global Window Control: Circuit Short To Battery This DTC sets when the Body Control Module B (BCM-B) detects a short to voltage on the global
open circuit.
B127A:14 Global Window Control: Circuit Short To Ground This DTC sets when the Body Control Module B (BCM-B) detects an open or short to ground on
or Open the global open circuit.
Possible Causes
Global open not enabled in the message center

RKE transmitter
Door window regulator motor not initialized
PINPOINT TEST I : THE GLOBAL OPEN FUNCTION IS INOPERATIVE

I1 CHECK FOR BODY CONTROL MODULE B (BCM-B) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform Body Control Module B (BCM-B) self-test.
Is Body Control Module B (BCM-B) DTC B127A:12 or B127A:14 present?
Yes For B127A:12, GO to I2

For B127A:14, GO to I7
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No GO to I13
I2 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect: Body Control Module B (BCM-B) C4368A.
Ignition ON.
NOTE: The LH and RH side window(s) each have their own global open circuits, however both of these circuits are tied together within the Body
Control Module B (BCM-B).
Measure:

C4368A-10 (LH window(s)) Ground
C4368A-22 (RH window(s)) Ground
Yes If voltage was present on the LH window circuit, GO to I3

If voltage was present on the RH window circuit, GO to I4
No GO to I17
I3 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO VOLTAGE WITH THE LH (LEFT-HAND) FRONT WINDOW MOTOR
DISCONNECTED
Ignition OFF.
Ignition ON.
Measure:

C4368A-10 Ground
Yes For coupe, REPAIR the circuit.

For convertible, GO to I5
No INSTALL a new driver door window regulator motor.
I4 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO VOLTAGE WITH THE RH (RIGHT-HAND) FRONT WINDOW MOTOR
DISCONNECTED
Ignition OFF.
Ignition ON.
Measure:

C4368A-22 Ground
Yes For coupe, REPAIR the circuit.

No INSTALL a new passenger door window regulator motor.
I5 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO VOLTAGE WITH THE LH (LEFT-HAND) REAR WINDOW MOTOR DISCONNECTED
Ignition OFF.
Ignition ON.
Measure:
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C4368A-10 Ground

No INSTALL a new left rear quarter window regulator motor.
Installation).
I6 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO VOLTAGE WITH THE RH (RIGHT-HAND) REAR WINDOW MOTOR
DISCONNECTED
Ignition OFF.
Disconnect: Right Rear Power Window Motor C3119.
Ignition ON.
Measure:

C4368A-22 Ground

No INSTALL a new right rear quarter window regulator motor.
Installation).
I7 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
NOTE: The LH and RH side window(s) each have their own global open circuits, however both of these circuits are tied together within the Body
Control Module B (BCM-B).
Measure:

C4368A-10 (LH window(s)) Ground
C4368A-22 (RH window(s)) Ground
Yes GO to I12
No If the LH window circuit resistance measurement was less than 10,000 ohms, GO to I8
If the RH window circuit resistance measurement was less than 10,000 ohms, GO to I9
I8 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO GROUND WITH THE LH (LEFT-HAND) FRONT WINDOW MOTOR
DISCONNECTED
Measure:

C4368A-10 Ground
Yes INSTALL a new driver door window regulator motor.

No For coupe, REPAIR the circuit.
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I9 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO GROUND WITH THE RH (RIGHT-HAND) FRONT WINDOW MOTOR
DISCONNECTED
Measure:

C4368A-22 Ground
Yes INSTALL a new passenger door window regulator motor.

No For coupe, REPAIR the circuit.
I10 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO GROUND WITH THE LH (LEFT-HAND) REAR WINDOW MOTOR DISCONNECTED
Measure:

C4368A-10 Ground
Yes INSTALL a new left rear quarter window regulator motor.

Installation).
I11 CHECK THE GLOBAL OPEN CIRCUIT FOR A SHORT TO GROUND WITH THE RH (RIGHT-HAND) REAR WINDOW MOTOR
DISCONNECTED
Disconnect: Right Rear Power Window Motor C3119.
Measure:

C4368A-22 Ground
Yes INSTALL a new right rear quarter window regulator motor.

Installation).
I12 CHECK THE GLOBAL OPEN CIRCUIT FOR AN OPEN

Ignition OFF.
Measure:

C4368A-10 C518-6
C4368A-22 C608-6
Yes GO to I17
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I13 CHECK THE GLOBAL OPEN OPERATION
Ignition OFF.
Open and close the driver door.
Attempt to carry out a global open operation using the RKE transmitter.
Does the global open function operate correctly with at least one window?
Yes GO to I14
No GO to I15
I14 CHECK FOR AN OPEN IN THE GLOBAL OPEN CIRCUIT TO THE SUSPECT WINDOW MOTOR
Disconnect the suspect window motor: Driver Door Window Regulator Motor C518, Passenger Door Window Regulator Motor C608, Left Rear
Power Window Motor C3118 or Right Rear Power Window Motor C3119.
For an inoperative LH door window, measure:

C4368A-10 C518-6
For an inoperative RH door window, measure:

C4368A-22 C608-6
For an inoperative left rear window, measure:

C4368A-10 C3118-6
For an inoperative right rear window, measure:

C4368A-22 C3119-6

Yes For an inoperative LH or RH door window, INSTALL a new window regulator motor.
For an inoperative left or right rear window, INSTALL a new window regulator motor.
Installation).
I15 VERIFY GLOBAL OPEN FEATURE IS ENABLED IN MESSAGE CENTER

Ignition ON.
Verify the global open feature (Remote Open) is enabled in the message center. REFER to the Owner's Literature.
Is the global open feature enabled in the message center?
Yes GO to I16
No The system is operating correctly at this time. INFORM the customer how to enable/disable the global open feature in the
message center. REFER to the Owner's Literature.
I16 CHECK THE RKE (REMOTE KEYLESS ENTRY) TRANSMITTER OPERATION

Operate the RKE lock/unlock function using all of the RKE transmitters.
Does the RKE lock/unlock function operate correctly with at least one of the RKE transmitters?
Yes GO to I17
No To diagnose the RKE system,
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REFER to: Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry Systems, Diagnosis and Testing).
I17 CHECK FOR CORRECT BODY CONTROL MODULE B (BCM-B) OPERATION

Ignition OFF.
Disconnect and inspect all the Body Control Module B (BCM-B) connectors.
Repair:
Reconnect the Body Control Module B (BCM-B) connectors and all previously disconnected window system connectors. Make sure they seat and
latch correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new Body Control
Module B (BCM-B).
REFER to: Body Control Module B (BCMB) (419-10 Multifunction Electronic Modules, Removal and Installation).
The Short Drop Window Feature Does Not Operate Correctly
Operation).
Possible Causes
Door window regulator motor not initialized

Door ajar switch
Door window regulator motor
PINPOINT TEST J : THE SHORT DROP WINDOW FEATURE DOES NOT OPERATE CORRECTLY
J1 VERIFY THE DOOR AJAR SWITCH OPERATION
Open and close the driver door and view the interior lamps operation.
Open and close the passenger door and view the interior lamps operation.
Do the interior lamps operate correctly?

Yes GO to J2
No DIAGNOSE the interior lamps,
REFER to: Interior Lighting (417-02 Interior Lighting, Diagnosis and Testing).
J2 CARRY OUT THE WINDOW MOTOR INITIALIZATION

Ignition ON.
Carry out the initialization procedure on the suspect power window.
Open and close the suspect door to verify the short drop function operates.
Does the short drop window feature operate correctly?
Yes The system is operating correctly at this time. The window lost initialization.
No GO to J3
J3 CHECK THE DRIVER WINDOW MOTOR AJAR SWITCH INPUT CIRCUIT

Ignition OFF.
Disconnect: Inoperative Driver Door Window Regulator Motor C518 or Passenger Door Window Regulator Motor C608.
Disconnect: Inoperative LH Front Door Latch C525 or RH Front Door Latch C609.
For driver door, measure:

C518-7 C525-3
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For passenger door, measure:

C608-7 C609-6

The Defrost System is Inoperative
Operation).

B1C83:12 Rear Defog Relay: Circuit Short to Battery This DTC sets when the FCIM detects a short to voltage on the rear window defrost relay control
circuit.
B1C83:14 Rear Defog Relay: Circuit Short To Ground or This DTC sets when the FCIM detects an open or short to ground on the rear window defrost relay
Possible Causes
Fuse
Rear window defrost relay
Rear window defrost grid
FCIM
Verify BJB fuses 9 (40A) and 66 (5A) are OK.

Inspect the rear window defrost grid and electrical connectors for damage.
PINPOINT TEST K : THE DEFROST SYSTEM IS INOPERATIVE

K1 CHECK THE REAR WINDOW DEFROST GRID VOLTAGE
Ignition OFF.
Disconnect: Heated Rear Window Element C402A (coupe) or C402 (convertible).
Ignition ON.
Activate the rear window defrost switch.
For coupe, measure:

C402A-1 Ground

C402-1 Ground
Yes GO to K2
No GO to K3
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K2 CHECK THE REAR WINDOW DEFROST GRID GROUND
Ignition OFF.
Disconnect: For coupe, heated Rear Window Element C402B.
For coupe, measure:

C402B-1 Ground

C402-2 Ground
Yes CARRY OUT the Grid Wire Test. REFER to Grid Wire Test. REPAIR the rear window defrost grid or INSTALL a new rear window
glass.
REFER to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
K3 CHECK THE REAR WINDOW DEFROST RELAY CONTROL CIRCUIT FOR VOLTAGE
Ignition OFF.
Disconnect: Rear Window Defrost Relay.
Ignition ON.
Measure:

Ground
Rear Window Defrost Relay, socket pin 1

Ground
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Yes GO to K4
No VERIFY the BJB fuses 9 (40A) and 66 (5A) are OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of the circuit short.
K4 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) OUTPUT
NOTICE: The following step uses a test lamp to simulate normal circuit loads. Use only a Rotunda Test Lamp (SGT27000) or 250- 300mA
incandescent bulb test lamp. To avoid connector terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle.
Connect:

Action
Rear Window Defrost Relay, socket pin 1 Rear Window Defrost Relay, socket pin 2
Activate the rear window defrost switch.
Yes GO to K5
No GO to K6
K5 CHECK THE REAR WINDOW DEFROST RELAY
Ignition OFF.
Carry out the rear window defrost relay component test.
Did the rear window defrost relay pass the component test?
Yes REPAIR the open in the rear window defrost relay output circuit.
No INSTALL a new rear window defrost relay.
K6 CHECK THE REAR WINDOW DEFROST RELAY CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Disconnect: FCIM C2402A.
Ignition ON.
Measure:

Ground
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No GO to K7
K7 CHECK THE REAR WINDOW DEFROST RELAY CONTROL CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C2402A-7
Yes GO to K8
K8 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Ignition OFF.
Disconnect and inspect all the FCIM connectors.
Repair:
Reconnect the FCIM connectors and all previously disconnected rear window defrost system connectors. Make sure they seat and latch correctly.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new FCIM. Refer to the
appropriate section in Group 415 for the procedure.
The Defrost System Does Not Shut Off Automatically
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Operation).

B1C83:14 Rear Defog Relay: Circuit Short To Ground or This DTC sets when the FCIM detects an open or short to ground on the rear window defrost relay
Possible Causes

Rear window defrost relay
FCIM
PINPOINT TEST L : THE DEFROST SYSTEM DOES NOT SHUT OFF AUTOMATICALLY
L1 CHECK THE REAR WINDOW DEFROST GRID VOLTAGE
Ignition OFF.
Disconnect: Rear Window Defrost Relay.
Disconnect: Heated Rear Window Element C402A (coupe) or C402 (convertible).
Ignition ON.
For coupe, measure:

C402A-1 Ground

C402-1 Ground

No GO to L2
L2 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) OUTPUT

NOTICE: The following step uses a test lamp to simulate normal circuit loads. Use only a Rotunda Test Lamp (SGT27000) or 250- 300mA
incandescent bulb test lamp. To avoid connector terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle.
Connect:

Action
Rear Window Defrost Relay, socket pin 1 Rear Window Defrost Relay, socket pin 2
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Yes GO to L3
No INSTALL a new rear window defrost relay.
L3 CHECK THE REAR WINDOW DEFROST RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect: FCIM C2402A.
Measure:

Rear Window Defrost Relay, socket pin 2 Ground
Yes GO to L4
L4 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Disconnect and inspect all the FCIM connectors.
Repair:
Reconnect the FCIM connectors and all previously disconnected rear window defrost system connectors. Make sure they seat and latch correctly.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new FCIM. Refer to the
Component Test- Grid Wire Test
1. Using a bright lamp in the vehicle, inspect the grid wire from the exterior. A broken grid wire will appear as a brown spot.
2. Run the engine at idle. Activate the rear window defrost switch. The indicator light should come on.
3. Working in the vehicle with a voltmeter, contact the broad red-brown stripes of the rear glass window (positive lead to B+ side and the negative lead to
ground side). The meter should read 10-13 volts. A lower voltage reading indicates a loose ground connection.
4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change.
5. With the negative lead of the meter grounded, touch each grid line of the heated rear window 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.
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Heated Window Grid Wire Repair
Materials
Name Specification
Motorcraft® Ultra-Clear Spray Glass Cleaner (U.S.) ESR-M14P5-A
ZC-23 (U.S.)
Rear Window Defroster Repair -
PM-11
Motorcraft® Lacquer Touch-Up Paint ESR-M2P100-C
PMPC-19500-XXXXX, PMPM-19500-XXXXX, PMPP-19500-XXXXX
Repair
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1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
injury.
NOTE: The antenna and heated window 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 has small ridges that
project above the surface of the glass and can easily be felt when running a fingernail across them.
Antenna and heated window grid lines that have been razor bladed will feel smooth when a fingernail is
dragged across the affected area. Inoperative heated window grid lines may appear to the eye to be
undamaged due to residue remaining on the glass and require diagnosis with a voltmeter or 12V test
lamp.
2. Bring the vehicle up to a room temperature of at least 16°C (60.8°F) or above.
3. 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 antenna and heated window
grid lines.
Clean the entire antenna and heated window grid line repair area with glass cleaner and 0000 steel wool to
remove all dirt, wax, grease, oil or other foreign material.
Material: Motorcraft® Ultra-Clear Spray Glass Cleaner (U.S.) / ZC-23 (U.S.) (ESR-M14P5-A)
4. Mark the location of the antenna or heated window grid break on the exterior of the rear window glass.
5. Using a polypropylene film fine line tape, mask the area directly above and below the antenna or heated
window grid break extending the tape 26 mm (1.0236 in) beyond the concern area in both directions. The
break area should be at the center of the mask. Polypropylene Film Fine Line Tape (commercially
available).
6. 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 antenna or heated window 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.
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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 produces
repaired resistance that is greater than Original Equipment Manufacturer (OEM) resistance, resulting in
poor defrost performance and excessive localized heating.
Apply the repair coating to the antenna or heated window 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. Polypropylene Film Fine Line Tape (commercially
available)
Material: Rear Window Defroster Repair / PM-11
Material: Motorcraft® Lacquer Touch-Up Paint / PMPC-19500-XXXXX, PMPM-19500-XXXXX,
PMPP-19500-XXXXX (ESR-M2P100-C)
7. 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.
8. NOTICE: Be careful not to damage the antenna or heated window grid line with the razor blade. If
this occurs, additional repair may be necessary.
Remove any excess repair compound above or below the antenna or heated window grid line with a razor
blade.
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9. NOTE: The interior side of the antenna or heated grid lines are not painted, but due to the silver
tarnishing tend to change the grid to a gold or brown color. The repair area will be bright silver and also
tarnish over time to match the rest of the antenna or heated window grid.
Test the system for normal operation.

Lead Terminal Repair
Materials
Name Specification
ZC-23 (U.S.)
Repair
1. Bring the vehicle up to at least the specified room temperature or above.

Temperature: 60.8°F (16°C)
2. NOTE: The new terminal covers the original terminal location, but it must be placed so the terminal
conductive areas will be placed on a good conductive base.
Terminal Kit — Back Glass 4F1Z-14421-AA
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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,
determines where to locate the new terminal. Some grid line bus bars may only allow the placement of
the terminal above or below the original tab location due to space limitations. For most vehicle
applications, the replacement tab location covers the original tab location, but still allows the replacement
tab to attach to the bus bar on good conductive material.
Place the replacement terminal type A over the original tab location, making sure the conductive areas of
the terminal 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 liquefies and changes 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. Allow the terminal to cool for another 2 minutes
before attaching the wiring lead to the terminal.
7. Attach the electrical lead connection to this terminal, turn on the heated rear window and verify the
operation.
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Power Door Window Initialization
Initialization
1. WARNING: Before beginning any service procedure in this manual, refer to health and safety
warnings in section 100-00 General Information. Failure to follow this instruction may result in
NOTE: This step is only necessary for an existing window regulator motor. If installing a new window
regulator motor, proceed to Step 2.
To initialize an existing window regulator motor, the motor must first be de-initialized. This can be
accomplished by disconnecting the battery cable or window motor fuse while the window is operating.
After the motor has been de-initialized, reconnect the battery cable or fuse before proceeding to the
following step.
2. WARNING: Keep objects and body parts clear of the glass panel when carrying out the
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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: The door MUST be closed during this procedure (for convertibles, the top and quarter glass must
be in the CLOSED and UP position) in order for the door window motor to initialize.
With the door window in the fully OPEN position, press and hold the window control switch in the UP
position at the second detent until the window glass stalls into the glass top run for at least 2 seconds.
Release the switch.
3. Press and hold the window control switch in the DOWN position at the second detent until the window
glass stalls at the bottom of its travel for at least 2 seconds.
4. Cycle the window glass up and down once more to set the window soft stop for the DOWN position.
5. Test for correct window operation by carrying out the one-touch up and one-touch down features.

Fixed Glass
Glass Cut-Out Wire

Power Caulk Gun
Power Fixed Glass Removal Tool
Cold Knife
Knife
Vacuum Cleaner
Materials
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Name Specification
Betaseal™ Express Dow Urethane Adhesive -
Sika Tack ASAP Urethane Adhesive -
Dow Urethane One Step Glass Primer -

Betaprime™ 5500/5500A/5500SA
Sika Urethane Metal and Glass Primer -
Sika 206 G+P
ZC-23 (U.S.)
Bare Metal Etch Primer -
BETAPRIME 5201
Body Primer -
BETASEAL™ 43538
Repair
1. NOTE: Some interior trim, exterior trim and/or components may require removal based on the tools and
removal method used.
NOTE: In some instances repair methods may be combined to achieve the best results.
Choose the best repair method for the type of glass being replaced.
1. Cold knife method – uses the cold knife to cut the urethane from the outside of a vehicle provided
the blade can reach the bead.
Use the General Equipment: Cold Knife
2. Power tool method – uses various power tools from inside the vehicle using a cutting or paddle type
blade.
Use the General Equipment: Power Fixed Glass Removal Tool
3. Piano wire method – uses the piano wire to cut the urethane from inside and outside of a vehicle
using an assistant.
Use the General Equipment: Glass Cut-Out Wire
2. When using the cold knife method, apply tape to protect the perimeter of the window opening from paint
damage. Multiple layers of tape may be required.
3.
NOTICE: New fixed glass must be installed within 2 hours of cutting the urethane adhesive. Cut or
scraped urethane becomes oxidized and inactive beyond 2 hours, reducing the effectiveness of
the repair bond.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or damage
the pinch weld during glass removal.
NOTICE: Take precautions to prevent damage to other components when cutting urethane.
NOTE: Fixed glass must be discarded once removed. A new fixed glass is required.
NOTE: Fixed glass may have locating pins that vary in location. It may be necessary to cut these pins
with a utility knife.
Remove the fixed glass and discard.

Use the General Equipment: Power Fixed Glass Removal Tool
Use the General Equipment: Cold Knife
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Use the General Equipment: Knife
4.
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 for the product being used. Use the same brand pinch weld primer,
glass primer and urethane adhesive.
NOTE: Touching the adhesive surface impairs the rebonding.
NOTE: Make sure the mating surfaces are clean and free of foreign material.
Prep the pinch weld area to install the new fixed glass.
1. Trim the original urethane adhesive using a utility knife, leaving a 1 mm to 2 mm (0.04 in to 0.08 in)
base on the pinch weld.
2. Remove any foreign material or dirt from the pinch weld using a soft brush or vacuum.
Use the General Equipment: Vacuum Cleaner
5. NOTE: Minimize applying bare metal primer over areas with remaining urethane adhesive and observe a
minimum flash time of 30 minutes.
If the paint layer was damaged on the pinch weld extending into bare metal, apply bare metal primer to
those areas only.
Material: Bare Metal Etch Primer / BETAPRIME 5201
6. NOTE: Minimize applying body primer over areas with remaining urethane adhesive and observe a
minimum flash time of 30 minutes.
Apply body primer as necessary.

1. Apply body primer to those areas only previously primed with bare metal primer.
Material: Bare Metal Etch Primer / BETAPRIME 5201
2. If the clearcoat layer was damaged on the pinch weld but not extending into bare metal, apply body
primer to those areas only.
Material: Body Primer / BETASEAL™ 43538
7. Clean the inside of the new fixed glass with glass cleaner.
8.
Apply glass primer according to the manufacturer's instructions to the new fixed glass. Allow at least 6
minutes to dry.
Material: Dow Urethane One Step Glass Primer / Betaprime™ 5500/5500A/5500SA
Material: Sika Urethane Metal and Glass Primer / Sika 206 G+P
9.
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Cut the urethane adhesive applicator tip to specification.
Material: Betaseal™ Express Dow Urethane Adhesive
Material: Sika Tack ASAP Urethane Adhesive
10.
NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.
NOTE: The fixed glass must be installed within 10 minutes of applying the urethane adhesive.
NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.
Apply a urethane adhesive bead.

1. Start and end at the original overlap points to prevent air and water leaks.
2. NOTE: Take care in applying urethane on vehicles without peripheral moldings as urethane
expulsion could become an appearance issue.
Apply a urethane adhesive bead 14 mm (0.551 in) high and 8 mm (0.314 in) wide on top of the
existing trimmed urethane adhesive bead on the pinch weld.
Use the General Equipment: Power Caulk Gun
Material: Betaseal™ Express Dow Urethane Adhesive
Material: Sika Tack ASAP Urethane Adhesive
3. Make sure there are no gaps in the bead.
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11. NOTICE: The door windows must be left open during the adhesive curing time.
Open the vehicle windows to prevent the air pressure of closing doors from compromising the urethane
adhesive bond.
12.
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 in
serious injury to vehicle occupant(s).
NOTE: If equipped, the adhesive strip backings must be removed from the A-pillar mouldings before
installing the fixed glass.
Install the fixed glass to the vehicle.

1. Install the fixed glass, pressing firmly by hand to ensure a good bond.
2. Secure the fixed glass in the correct position with tape until the urethane adhesive has cured.
13. If necessary, remove excess uncured urethane adhesive from the interior and exterior surface of the fixed
glass.
14. Install any removed components as needed.
15. If equipped, carry out the IPMA camera alignment.

Door Window Glass Adjustment - Coupe
Adjustment
All adjustments
1. NOTE: The front door must be aligned correctly before adjusting the front door window glass.
Check the front door alignment.

2. Open the door.
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Refer to: Front Door Speaker RH (415-00B Information and Entertainment System - General Information - Vehicles
With: Touchscreen Display, Removal and Installation).
Refer to: Front Door Speaker LH (415-00A Information and Entertainment System - General Information - Vehicles
With: AM/FM/CD/SYNC, Removal and Installation).
4. Remove the front door lower watershield.

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5. Remove the grommets and the adhesive tapes.
6. Raise the front door window glass to the full up position.

1. Install the front door window control switch.
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7. On coupe vehicles, remove the pin-type retainer and the door weatherstrip.
8. Close the door.

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Up/Down, Fore/Aft adjustment
9. Measure the gap between the top of the front door glass and the body at the specified locations.
1. Measurement at A-pillar 9mm.
2. Measurement at B-pillar 10mm
10. Open the door.

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11. Loosen both glass clamps, adjust the front door window glass as necessary and tighten the glass clamps.
12. Close the door.

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13. Check the door glass up/down, fore/aft to body dimensions.
In/Out adjustment
14. Close the door.

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16. Open the door.

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17. Loosen the nuts on the fore and aft front door glass runs.
18. Adjust the regulator rails equally in and out to avoid binding.
1. Loosen the lower window regulator nuts.
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19. Close the door.
20. Check the door glass in/out to body dimensions and adjust the door glass runs and regulator rails relative to the door
as necessary.
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21. Lower the front door window glass.
22. Tighten the front door glass regulator rail nuts.

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23. NOTE: Take care not to influence the position of the front door glass runs when tightening the nuts.
Tighten the nuts on the fore and aft front door glass runs.
1. Tighten the lower bolt and nuts on the fore and aft front door glass runs.
2. Tighten the upper nuts on the fore and aft front door glass runs.
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25. Close the door.

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All adjustments
26. Recheck the front door glass up/down, fore/aft to body dimensions at the specified locations.
27. Recheck the front door glass in/out to body dimensions at the specified locations.
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29. Carry out the power door window initialization.


Door Window Glass Adjustment - Convertible
Adjustment
NOTE: The rear quarter window glass must be aligned correctly before adjusting the front door window glass.
All adjustments
1. Check the rear quarter window glass adjustment.

Refer to: Rear Quarter Window Glass Adjustment - Convertible (501-11 Glass, Frames and Mechanisms,
2. NOTE: The front door must be aligned correctly before adjusting the front door window glass.
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Check the front door alignment.
3. Open the door.

Refer to: Front Door Speaker LH (415-00A Information and Entertainment System - General Information -

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6. Remove the grommets and the adhesive tapes.

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8. Close the door.
1. Measurement at A-pillar 9mm.
2. Measurement at B-pillar 8mm.
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10. Open the door.
11. Loosen both glass clamps, adjust the front door window glass as necessary and tighten the glass clamps.
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12. Close the door.
13. Check the door glass up/down, fore/aft to body dimensions.

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In/Out adjustment
14. Close the door.

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16. Open the door.
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17. Loosen the nuts on the fore and aft front door glass runs.
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1. Loosen the lower window regulator nuts.
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19. Close the door.
20. Check the door glass in/out to body dimensions and adjust the door glass runs and regulator rails relative
to the door as necessary.
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22. Tighten the front door glass regulator rail nuts.
23. NOTE: Take care not to influence the position of the front door glass runs when tightening the nuts.
Tighten the nuts on the fore and aft front door glass runs.
1. Tighten the lower bolt and nuts on the fore and aft front door glass runs.
2. Tighten the upper nuts on the fore and aft front door glass runs.
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25. Close the door.
All adjustments
26. Recheck the front door glass up/down, fore/aft to body dimensions at the specified locations.
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27. Recheck the front door glass in/out to body dimensions at the specified locations.
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29. Carry out the power door window initialization.


Rear Quarter Window Glass Adjustment - Convertible
Adjustment
All adjustments
1. Open the door and lower the convertible top.

1. Open the door.
2. Lower the convertible top.
2. If equipped, remove the RTM.

Refer to: Radio Transceiver Module (RTM) (419-10 Multifunction Electronic Modules, Removal and
Installation).
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3. Remove the rear quarter panel speaker.
Refer to: Rear Quarter Panel Speaker (415-00A Information and Entertainment System - General
Information - Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
4. Remove the rear quarter panel speaker bracket.

1. Remove the nuts.
2. Remove the stud bolt.
3. Detach the retainers and position aside the wiring harness.
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5. Remove the watershield.
1. Disconnect the rear quarter window regulator motor electrical connector and position aside the
wiring harness.
2. Detach the retainer and position aside the watershield.
3. Detach the wiring harness retainer and remove the watershield.
6. Close the door.

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7. Check the relative position of the rear quarter window glass to the body seals.
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8. Check the relative position of the rear quarter window glass to the door window glass.
9. Open the door.
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10. Adjust the rear quarter window glass as necessary.
1. Loosen the rear quarter window glass bolts.
2. Adjust the rear quarter window glass as necessary.
11. Close the door.

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12. Check the quarter glass up/down, fore/aft to body dimensions.
13. Tighten the rear quarter window glass bolts.
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In/Out adjustment
14. Close the convertible top.
15. Close the door.

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17. Check the relative position of the rear quarter window glass to the door window glass. Make sure the
division bar seal enters the convertible top seals completely when the quarter window glass is raised to full
up position and engages the door glass without clipping.
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18. Open the door.
19. Adjust the rear quarter window glass/regulator assembly as necessary.

1. Loosen the rear quarter window glass/regulator assembly nuts.
2. Adjust the rear quarter window glass/regulator assembly as necessary.
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20. Close the door.
21. Check the rear quarter window glass in/out to seals and door glass.
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22. Tighten the rear quarter window glass/regulator assembly nuts.
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All adjustments
23. NOTE: Convertible top removed for clarity.
Check the relative position of the rear quarter window glass to the body seals and door glass.
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25. Check the relative position of the rear quarter window glass to the door window glass.
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Rear Quarter Window Glass - Convertible
Removal
All vehicles
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Right hand side
2. Remove the RTM.

Installation).
All vehicles
NOTE: The convertible top assembly removed for clarity.

4.
Remove the rear quarter window glass interior belt moulding.
1. Remove the nut.
2. Remove the bolt.
3. Remove the rear quarter window glass interior belt moulding.
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5. Position aside the rear quarter window glass exterior moulding.
6. NOTE: If the rear quarter window glass is not in full up position, the rear quarter window glass and rear
quarter window regulator cannot be separated.
NOTE: If the rear quarter window glass is inoperative the rear quarter window regulator motor will have
to be removed to allow movement of the glass to gain access to the bolts.
Raise the rear quarter window glass to full up position.

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7.
Remove the rear quarter panel speaker bracket.
1. Remove the nuts.
3. Detach the retainer and position aside the wiring harness.
8.
Remove the watershield.
wiring harness.
3. Detach the wiring harness retainer and the watershield.
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9.
Remove the rear quarter window glass/regulator assembly.
1. Remove the nuts.
2. Remove the rear quarter window glass/regulator assembly.
10. NOTE: This step only necessary when installing a new rear quarter window glass.
Remove the bolts and the rear quarter window glass.

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Installation
2. Carry out the rear quarter window glass adjustment.


Rear Quarter Window Regulator - Convertible
Removal
All vehicles
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Right hand side
2. Remove RTM.
Installation).
All vehicles
NOTE: The convertible top assembly removed for clarity.

4.
Remove the rear quarter window glass interior belt moulding.
1. Remove the nut.
2. Remove the bolt.
3. Remove the rear quarter window glass interior belt moulding.
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5. Position aside the rear quarter window glass exterior moulding.
6. NOTE: If the rear quarter window glass is not in full up position, the rear quarter window glass and rear
quarter window regulator cannot be separated.
Raise the rear quarter window glass to full up position.

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7.
Remove the rear quarter panel speaker bracket.
1. Remove the nuts.
3. Detach the retainer and position aside the wiring harness.
8.
Remove the watershield.
wiring harness.
3. Detach the wiring harness retainer and the watershield.
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9.
Remove the rear quarter window glass/regulator assembly.
1. Remove the nuts.
2. Remove the rear quarter window glass/regulator assembly.
10. NOTE: This step only necessary when installing a new rear quarter window regulator.
Remove the bolts and the rear quarter window regulator.

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Remove the bolts and the rear quarter window regulator motor.
Installation

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Rear Quarter Window Regulator Motor - Convertible
Removal
1. Remove the rear quarter window regulator.

Refer to: Rear Quarter Window Regulator - Convertible (501-11 Glass, Frames and Mechanisms, Removal
and Installation).
2. Remove the bolts and the rear quarter window regulator motor.
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Installation


Front Door Window Control Switch
Removal
Both doors
Remove the front door window control switch.

1. Remove the front door window control switch and the bezel assembly.
2. Disconnect the front door window control switch electrical connector.
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2. Remove the front door window control switch from the bezel.
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Passenger side

1. Release the retaining tab from the front door window control switch.
2. Remove the front door window control switch from the bezel.
Installation

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Front Door Window Glass
Removal

Refer to: Front Door Speaker LH (415-00A Information and Entertainment System - General Information -
Refer to: Front Door Speaker RH (415-00A Information and Entertainment System - General Information -
2.
Remove the front door upper and the lower watershield.
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2. Remove the front door upper watershield.
3.
Raise the front door window glass to full up position.
1. Remove the adhesive covers.
3. Raise the front door window glass to full up position.
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4.
Remove the front door window glass.
2. Using a non-marring trim tool from the outboard side of the glass, pry the tang on each clip back,
releasing the window glass.
4. Remove the front window glass.
Installation
2. Carry out the door window glass adjustment.

Procedures).
Procedures).
3. If the door is equipped with one-touch up the power window motor must be initialized. Carry out the power
door window initialization.
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Front Door Window Regulator
Removal
1. Remove the front door window glass.

Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
2.
Mark the location and remove the front door window regulator nuts.
1. Remove the adhesive tapes.
2. Disconnect the front door window regulator electrical connector and position aside the wiring
harness.
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3. Mark the location of the nuts for installation.
4. Remove the nuts.
3.
Remove the front door window regulator.
1. Rotate the front half of the window regulator rearward.
2. Rotate the rear half of the window regulator forward.
3. Remove the front door window regulator.
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Remove the front door window regulator motor.

Refer to: Front Door Window Regulator Motor (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
Installation
2. Align the front door window regulator to the marks made previous during removal.

Procedures).
Procedures).

Front Door Window Regulator Motor
Removal
1. Remove the front door window regulator.

Refer to: Front Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2. Remove the retainers and the front door window regulator motor.
Installation

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Procedures).
Procedures).

Front Door Glass Run and Bracket
Removal
Fore front door glass run
1.
Raise the front door window glass to full up position.
2. Raise the front door window glass to full up position.

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3.
Mark the location and remove the fore front door glass run.
1. Mark the location of the retainers for installation.
2. Loosen the top nut.
3. Remove the lower nut and the fore front door glass run.
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Aft front door glass run

5.
Mark the location and remove the aft front door glass run.
1. Mark the location of the retainers for installation.
2. Loosen the top nut.
3. Remove the lower bolt and the aft front door glass run.
Installation

Procedures).
Procedures).
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501-12 Instrument Panel and Console 2016 Mustang
Auxiliary Power Point
501-194
Remover, Power Point
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Removal
1. Open the power point cover.
2. Position the power point extractor so that it engages in the adjacent slots in the power point socket.
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Use Special Service Tool: 501-194 Remover, Power Point.
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3. 1. Install the receiver cup.
2. Install and tighten the wing nut.
4. Tighten the wing nut to pull the power point socket out of the retainer.
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Installation
1. Connect the electrical connector and push the new power point socket into the retainer.

Floor Console
Base Part Number: S043B04
Removal
1. Release the clips and remove the floor console RH side trim panel.
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2. Release the clips and the floor console LH side trim panel.
3. Release the clips and remove the floor console RH side bolt cover.
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4. Release the clips and the floor console LH side bolt cover.
5. Remove the stowage area mat.

6. Remove the floor console upper bolts.
Starting from the front corners, carefully pry up the bezel and position it out of the way.
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9. Open the floor console lid.

10. Remove the RH side front retainers.
11. Remove the LH side front retainers.

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12.
Release the clips, position the gear selector cover aside and remove the floor console upper trim panel.
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13. Remove the floor console stowage bin mat.

14. Remove the two nuts.
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15. Remove the stowage area tray.
16. Remove the 2 front upper floor console bolts.
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17.
Remove the floor console.
1. On both sides.
Release the clips.
2. Remove the screws and position aside the parking brake boot from the console.
Installation

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Glove Compartment
Removal
Glove compartment
1. The glove compartment and the passenger knee air bag are serviced as an assembly.
Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Glove compartment upper stowage bin latch
2. Open the glove compartment.
3. Remove the bolts and the glove compartment upper stowage bin latch.
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Instrument Panel
Base Part Number: S04305
Removal
All vehicles
1. Position both front seats fully rearward.
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2. Depower the SRS.
3. Remove the cowl panel grille.

Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
4. NOTICE: Use new factory bolt and washer assemblies or water leaks may occur.
NOTE: Discard the upper instrument panel cowl bolts.
Remove the instrument panel cowl bolts.

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5. Remove the floor console.
Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
Vehicles with automatic transmission
6. Raise the vehicle on a hoist.

7. Remove the selector lever cable bracket bolt and remove the selector lever cable.
8.
Remove the selector lever assembly.
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All vehicles
9. Remove both A-pillar trim panels.

Refer to: A-Pillar Trim Panel - Convertible (501-05 Interior Trim and Ornamentation, Removal and
Installation).
10. Position aside the weather strip, release the clips and remove the LH instrument panel finish panel.
11. Position aside the weather strip, release the clips and remove the RH instrument panel finish panel.
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12. Release the clips and remove the RH scuff plate.
13. Release the clips and remove the lower RH cowl trim panel.
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14. Release the clips and remove the LH scuff plate.
15. Remove the driver knee airbag.

Refer to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
16. Remove the hood latch release handle.

Refer to: Hood Latch Release Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
17. Release the pin-type retainer, the clips and remove the LH cowl trim panel.
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18. Disconnect the electrical connectors and release the electrical harness retainer.
WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and
NOTE: Secure the steering wheel from rotating to prevent damage to clock spring.
NOTE: Placing the Steering Column in the Tilt UP position will make shaft disconnection easier.
Remove and discard the upper steering column shaft-to-steering column bolt and the position aside the
upper steering column shaft.
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20. Disconnect the electrical connectors, release the electrical harness retainer(s) and position the electrical
harness aside.
21.
Remove the push pins and remove the RH insulation panel.
Remove the insulation panel ambient light.
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22. Disconnect the electrical connectors and detach the connector push pin at the RH lower cowl.
23. Disconnect the electrical connectors behind the glove compartment.

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24. Remove the RH center instrument panel bolts.
25. Remove the LH center instrument panel bolts.

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26. Remove the trim cover.
27. Remove the 2 bolts the push pin and the instrument panel center bracket.
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28. Release the emergency brake.
29. NOTE: The A-pillar to in-vehicle cross beam instrument panel bolts cannot be removed from the A-pillar
with the door attached.
Loosen the RH A-pillar to in-vehicle cross beam instrument panel bolts and slide the bolts outward as far
as possible.
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30. NOTE: The A-pillar to in-vehicle cross beam instrument panel bolts cannot be removed from the A-pillar
with the door attached.
Completely loosen the LH A-pillar to in-vehicle cross beam instrument panel bolts and slide the bolts
outward as far as possible.
31. NOTE: On both sides.
Disconnect the A-pillar electrical connectors and detach the harness retainers.
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32. Remove the LH instrument panel bolts.
33. Remove the RH instrument panel bolt.

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34. NOTE: Seats shown removed for clarity.
NOTE: To avoid damaging the instrument panel, an assistant is required when carrying out this step.
NOTE: Make sure not to damage the instrument panel when removing the instrument panel from the
vehicle.
NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the
instrument panel or damage to the components may occur.
Rotate the instrument panel face down and remove through the LH front door opening.
Installation

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Instrument Panel Center Finish Panel
Removal
1. Release the clips and remove RH instrument panel trim panel.

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2. NOTE: Instrument panel center finish panel with optional ICM shown.
Release the clips and remove the instrument panel center finish panel.
Disconnect the ICM electrical connector, if equipped.
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Installation

Instrument Panel Upper Section
Removal
All vehicles
1. NOTE: Place the instrument panel on a suitable work surface that will allow the instrument panel to be
rotated front to back without damaging the instrument panel.
Remove the instrument panel.

Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
2. Remove the passenger knee airbag.

Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
3. Remove the bolts and the glove compartment upper stowage bin.
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4. Remove the bolts, release the clips and remove the RH instrument panel finish panel.
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5.
Remove the bolts, release the clips and remove the IPC trim panel.
Detach the gap hider from the upper steering column trim cover.
6.
Release the clips and remove the IPC.
Disconnect the electrical connector and release the harness retainer.
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7.
Release the clips and remove the defroster grille panel.
8. Release the clips and remove the instrument panel speaker grille.
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9.
Remove the bolts and the instrument panel speaker.
Disconnect the electrical connectors and release the harness retainer.
Vehicles with AM/FM/CD/SNYC
10.
Remove the bolts and the FCIM.

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11. Remove the bolts and the FCDIM.
12.
Remove the bolts and APIM.
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Vehicles with Touchscreen Display
13.
Remove the bolts and the FCIM.
14.
Remove the bolts and the FDIM.
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All vehicles
15.
Remove the bolts and the ACM.
16.
Remove the bolt, screw and the lower steering column shroud.
1. Torque: 22 lb.in (2.5 Nm)
2. Torque: 22 lb.in (2.5 Nm)
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17. Disconnect the electrical harness, release the harness retainers and position the harness aside.
18.
Remove the steering column.
2. NOTE: The front and rear steering column bolts are not the same, note bolt location before
installation.
Remove and discard the steering column bolts.

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19.
Remove the bolts.
Disconnect the 3 electrical connectors.
20.
From the rear of the instrument panel position the electrical harness aside on the LH side.
1. Remove the instrument panel upper section to in-vehicle cross beam bolts.
2. Release the harness retainers.
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21. From the rear of the instrument panel position the electrical harness aside on the RH side.
1. Remove the instrument panel upper section to in-vehicle cross beam bolts.
2. Release the harness retainers.
22. NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the
instrument panel upper section or damage to the components may occur.
From the front of the instrument panel position remove the 5 instrument panel upper section to in-vehicle
cross beam bolts and remove the instrument panel upper section.
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Installation

Overhead Console
Removal
Coupe
1. Lower the headliner.

Refer to: Headliner - Lowering (501-05 Interior Trim and Ornamentation, Removal and Installation).
2. Release the clips, disconnect the electrical connectors and remove the overhead console.
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Convertible
3. Release the clips, disconnect the electrical connectors and remove the overhead console.
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Installation

501-14 Handles, Locks, Latches and Entry Systems 2016 Mustang
Handles, Locks, Latches and Entry Systems - Overview
Overview
The power lock/unlock feature locks or unlocks the doors upon a customer request from a door lock control
switch, the passive entry system or a RKE transmitter. The doors can also be locked by using a mechanical key in
the driver door lock cylinder.
The passive entry feature automatically locks or unlocks the doors, or releases the luggage compartment lid latch.
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Handles, Locks, Latches and Entry Systems - System Operation and Component Description
System Operation
System Diagram
Without Memory Seat
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With Memory Seat

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BCM Network Input Messages

Message Module
Vehicle speed PCM The BCM uses the vehicle speed data for the autolock and auto-unlock
features.
RKE data RTM Provides the BCM with the lock/unlock status of the driver door latch. The
lock/unlock status is used for the illumination of the door lock status indicator.
Message Module
Door lock switch DDM Provides the BCM with lock/unlock requests based on the input from the
status door lock control switch.
IPC Module Network Input Messages

Module
Message center feature IPC Provides the BCM configuration settings selected by the driver of
configuration the vehicle, such as autolock and auto-unlock settings.
Power Door Locks
The BCM controls the door locks using a series of integrated relays (driver door unlock/passenger doors
unlock/all doors lock). When the relays are not energized, ground is provided on both circuits to the lock motors
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within the latches. When an unlock relay energizes, voltage is provided to one side of the lock motor to unlock the
door(s). When the lock relay energizes, the polarity is reversed and the motors lock the doors.
For vehicles not equipped with a memory seat, the BCM sends voltage signals to the door lock control switches.
When a door lock control switch is pressed, the voltage signal is routed to ground, indicating a request to
lock/unlock the doors. When the BCM detects a lock or unlock request, the BCM energizes the appropriate relays
to lock or unlock the doors.
For vehicles equipped with a memory seat, the DDM and PDM send voltage signals to the door lock control
switches. When a door lock control switch is pressed, the voltage signal is routed to ground, indicating a request
to lock/unlock the doors. When the DDM or PDM detects a lock or unlock request, a message is sent over the
CAN to the BCM to lock or unlock the doors.
In the event of a power door lock failure, the doors can be individually locked using 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 left door,
insert a key and turn clockwise to lock. For the right door, insert a key and turn counterclockwise to lock.
Based on input from the door lock control switches, the passive entry system and the RKE transmitter, the BCM
unlocks the driver door, unlocks all the doors or locks all the doors.
LED Door Lock Indicators
Each door panel has a door lock indicator located on the window sill to indicate the lock or unlock status of that
individual door. The door lock indicators are controlled by the lock/unlock feedback switch located within each
door latch. When powered, they illuminate to indicate a door is locked and are off when a door is unlocked.
The Light Emitting Diodes (LEDs) are powered continuously if the ignition is on, or for 5 minutes after a lock
request if the ignition is off.
The LED door lock indicators brightness level works in conjunction with the backlighting brightness level setting.
For vehicles not equipped with a memory seat, the BCM provides voltage to the door lock indicators.
For vehicles equipped with a memory seat, the DDM and PDM provide voltage to their respective door lock
indicator.
The lock/unlock feedback switch provides a ground path to bypass the indicator. The switch is closed when the
door is unlocked (indicator not illuminated) and open when locked (indicator illuminated). The Body Control Module
B (BCM-B) provides ground for the door lock indicators to illuminate.
The LED door lock indicators are part of the electrical harness and cannot be replaced independently.
Switch Inhibit Feature
The switch inhibit feature prevents unauthorized access to the vehicle from the door lock control switches or the
interior luggage compartment lid release switch. The BCM disables the function of both door lock control switches
and the interior luggage compartment lid release switch 20 seconds after the vehicle is electronically locked. If
any of these switches are activated while they are inhibited, a chime sounds and a message is displayed in the
message center to indicate the switches are inhibited. The BCM enables the function of these switches when the
vehicle is electronically unlocked.
This feature can be configured on/off using the message center.
Power Door Locking Feedback
The exterior lamps and horn provide visual and audible feedback when unlocking and locking the doors under
certain circumstances. Refer to the following table:
Action Status of Status of Luggage Status Visual/Audible Feedback

Door(s) Compartment Lid of Hood
Press the lock button on Open Closed Closed A short flash of the turn signals after all
the door lock control the doors are closed.
switch
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Press the unlock button Closed Closed Closed A long flash of the turn signals.
on a RKE transmitter
Press the lock button on Closed Closed Closed A short flash of the turn signals.
a RKE transmitter
Press the lock button on Open Closed Closed A short flash of the turn signals after all
a RKE transmitter the doors are closed.
Press the lock button on Closed Open Closed A short flash of the turn signals after the
a RKE transmitter luggage compartment lid is closed.
Press the lock button on Closed Closed Open A short flash of the turn signals after the
a RKE transmitter hood is closed.
Press the lock button on Closed Closed Closed The horn chirps twice and the turn
a RKE transmitter twice signals flash twice.
within 3 seconds
Press the lock button on Open Closed Closed The horn immediately chirps twice and
a RKE transmitter twice the turn signals flash twice after all the
within 3 seconds doors are closed.
Press the lock button on Closed Open Closed The horn immediately chirps twice and
a RKE transmitter twice the turn signals flash twice after the
within 3 seconds luggage compartment lid is closed.
Press the lock button on Closed Closed Open The horn immediately chirps twice and
a RKE transmitter twice the turn signals flash twice after the
within 3 seconds hood is closed.
There is also feedback provided by the vehicle to the key for the remote start feature. For additional information
regarding the remote start feedback, refer to the Owner's Literature.
Center Console Storage Compartment Lock (if equipped)
The BCM controls the center console storage compartment solenoid. The center console storage compartment
solenoid locks the storage compartment when the doors are electronically locked and unlocks when the driver
door is electronically locked.
Luggage Compartment Lid Latch Release

The luggage compartment lid latch can be released using:
the interior luggage compartment lid release switch.

the exterior luggage compartment lid release switch.
a valid programmed passive key.
The BCM sends voltage signals to the interior and exterior luggage compartment lid release switches. When a
luggage compartment lid release switch is pressed, the voltage signal is routed to ground, indicating a request to
release the luggage compartment lid latch. The BCM momentarily provides voltage to the luggage compartment
lid latch to actuate the release motor.
When using the luggage compartment lid release switches, the BCM releases the luggage compartment lid only
when the doors are electronically unlocked and the vehicle is in PARK.
When using a programmed RKE transmitter, press the luggage compartment lid release button twice within 3
seconds to release the luggage compartment lid latch. The luggage compartment lid latch releases if the vehicle
speed is 5 km/h (3.1 mph) or less.
The luggage compartment lid latch can also be released using a programmed passive key. Refer to Luggage
Compartment Lid Passive Entry in this section.
RKE
The RKE feature is controlled by the BCM. When a button is pressed, the Transmitter Identification Code (TIC)
and RKE command is received by the RTM. The RTM interprets the information and sends a message to the
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BCM over a LIN circuit, and when the network is awake over the CAN. If the BCM detects a programmed key, it
carries out the command by controlling the door locks, releasing the luggage compartment lid latch or activating
the horn or turn signals as required.
The RKE system can be used to:
unlock the driver door.

unlock all doors.
lock all doors.
release the luggage compartment lid latch (luggage compartment lid release button must be pressed twice
within 3 seconds).
arm/disarm the perimeter alarm.
activate/deactivate the panic alarm.
global open the windows (press the unlock button and then within 10 seconds press and hold the unlock
button for 3 seconds) (if equipped).
global close the windows (press and hold the lock button for 2 seconds) (if equipped).
remotely start the vehicle.
configure the staged lock programming (2-stage unlock or global unlock).
The RKE transmitters have a normal operating range of 30 m (98 ft) in an open air, no obstruction environment.
The RKE transmitters and the BCM also utilize a rolling code to prevent the code from being captured by a code
grabber. The system advances the counter in the RKE transmitter and the BCM every time a RKE transmitter
button is pressed.
The message center displays Key Battery Low Replace Soon when the battery in the key needs to be replaced.
RKE Transmitter Unlock
The RKE feature provides a staged process for unlocking the doors. Upon receipt of the first request for unlocking
the doors, the RKE feature unlocks only the driver door. If another unlock request is received within 3 seconds of
the first, all the doors are unlocked. This feature can be disabled so that all the doors unlock on the first press of
the unlock button (global unlock) using the message center settings.
Vehicles come from the factory set with the 2-stage unlock feature disabled (single press unlocks all doors).
RKE Transmitter Lock
The RKE feature requests all of the doors lock when the lock button is pressed.
RKE Transmitter Luggage Compartment Lid Latch Release

The RKE transmitter provides a luggage compartment lid release/power open function. The luggage compartment
lid release button must be pressed twice within 3 seconds for the luggage compartment lid latch to release.
Global Open/Close (if equipped)
The global open feature is used to open all the windows using the RKE transmitter.
To global open the windows, press the unlock button and then within 10 seconds press and hold the unlock button
for 3 seconds. The windows stop movement if the lock or unlock button is pressed on the RKE.
To global close the windows, press and hold the lock button for 2 seconds.
Panic Alarm (if equipped)
The panic alarm feature provides audible and visual alarms which are evident from the exterior of the vehicle.
When the panic alarm button is initially pressed, the panic alarm feature requests the turn signals flash and the
horn sounds for up to 3 minutes or until deactivation. The flashing of the outputs occurs simultaneously.
The panic alarm can only be activated when the ignition is off. This feature is disabled at all other times.
Deactivation of an active panic alarm is accomplished when:
a second press of the RKE transmitter panic button is detected.

the ignition status changes from off.
a period of 2 minutes and 45 seconds have elapsed since the initial activation.
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Remote Start
NOTE: The remote start feature is not available for vehicles equipped with a manual transmission.
The factory-installed remote start allows the vehicle to be remotely started from outside the vehicle. There is a 2-
way communication between the passive key and the vehicle to provide the remote start status of the vehicle. The
passive key contains a green and a red LED to indicate the remote start status.
LED Status
Blinking green Waiting for status update from vehicle
Blinking red Remote start/stop failed
Solid green Remote start or extension successful
Solid red Remote stop successful (engine off)
To remotely start the vehicle, the buttons on the passive key must be pressed within 3 seconds of each other.
Press the lock button once and then the remote start button twice. The vehicle should remotely start and the LED
on the passive key should be lit solid green.
The vehicle does not remote start if any of the following conditions are present:
The feature is disabled using the message center settings

The hood is not closed
The vehicle is not in PARK
A powertrain system DTC is present, illuminating the service engine soon indicator
The ignition is on
The alarm system is triggered
The vehicle battery voltage is low
For additional information regarding the remote start system, refer to the Owner's Literature.
Autolock
The autolock feature locks all of the doors after all of the following have occurred:
All the doors are closed
The ignition is on
The vehicle is shifted into any gear to put the vehicle in motion
The vehicle attains a speed greater than 20 km/h (12.4 mph)
The autolock feature activates again during the same ignition cycle when all of the following have occurred:
The vehicle speed is reduced to less than 15 km/h (9.3 mph)

A door is opened and then closed
The vehicle attains a speed greater than 20 km/h (12.4 mph)
Auto-Unlock
NOTE: The doors do not auto-unlock if the vehicle has been electronically locked before the driver door is
unlocked.
The auto-unlock feature unlocks all of the doors when all of the following conditions have been met:
All the doors are closed and locked

The ignition was on
The vehicle was shifted out of park and a speed greater than 20 km/h (12.4 mph) was achieved
The vehicle has come to a stop
The ignition transitions to accessory or off and, within 10 minutes, the driver door is opened
The auto-unlock feature can be enabled/disabled using the message center.
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Smart Unlock
The smart unlock feature prevents the vehicle from electronically locking when a passive key is left inside the
vehicle. When the doors are electronically locked while a door is ajar and then closed, the interior of the vehicle is
scanned for a passive key. If a valid programmed passive key is detected inside the vehicle, the BCM unlocks the
doors and chirps the horn twice.
The smart unlock feature also operates to prevent locking a passive key inside the luggage compartment area.
When the luggage compartment lid is closed, the interior of the vehicle is scanned for a passive key. If a passive
key is detected inside the luggage compartment area when the luggage compartment lid is closed, the BCM
releases the luggage compartment lid latch and chirps the horn twice.
To override the smart unlock feature, lock the doors using the keyless entry keypad, the door lock cylinder or
another programmed passive key.
Passive Entry
The passive entry feature unlocks or locks the doors or opens the luggage compartment lid without having to use
a mechanical key blade or the RKE transmitter feature.
When the BCM detects a lock or unlock sensor is touched on an exterior door handle, or the exterior luggage
compartment lid release button is pressed, it activates the low frequency antenna in the corresponding exterior
door handle or inside the luggage compartment area. The low frequency antenna sends out a signal to activate
the passive key. The passive key then responds by sending a high frequency signal back to the RTM. The RTM
interprets the high frequency signal from the passive key and sends the information to the BCM. If the BCM
detects a valid programmed passive key, the BCM either unlocks the driver door, unlocks or locks both doors, or
releases the luggage compartment lid latch.
Door Passive Entry
With a programmed passive key within 1 m (3.28 ft) outside a door, touch the lock or unlock sensor on the
exterior door handle. The doors lock or unlock depending upon which sensor was touched on the handle. The
unlock sensor is located on the inside of the handle and the lock sensor is located on the outside face of the
handle.
The driver front door passive entry feature either unlocks the driver door (if 2-stage unlock is enabled) or both
doors (if 2-staged unlock is disabled). The passive entry feature always locks both doors when the lock button is
touched.
The passenger door passive entry feature always locks or unlocks both doors.
Luggage Compartment Lid Passive Entry
With a programmed passive key within 1 m (3.28 ft) outside the luggage compartment lid, press the exterior
luggage compartment lid release button (above the license plate) at the rear of the vehicle to open the luggage
compartment lid.
Door Lock Control Switches
The door lock control switches are dual pole, single throw momentary contact switches. The BCM (vehicles
without memory seat) or the DDM and PDM (vehicles with memory seat) provide the voltage signals to the door
lock control switches for the lock and unlock requests. When a switch is pressed to lock or unlock, the
corresponding input circuit is routed to ground, indicating a request to lock or unlock the doors.
Door Latches
The door latches are sealed units and contain the door lock actuator, lock/unlock feedback switch, and the door
ajar switch. The door lock actuators operate in 2 directions, depending on the polarity of the voltage. The door
latches can be lubricated, if needed.
Interior Luggage Compartment Lid Release Switch
The interior luggage compartment lid release switch is a momentary contact switch that supplies a ground signal
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to the BCM. When the interior luggage compartment lid release switch is pressed, the signal is routed to ground
indicating a request to the BCM to release the luggage compartment lid latch.
Exterior Luggage Compartment Lid Release Switch
The exterior luggage compartment lid release switch is a momentary contact switch that supplies a ground signal
to the BCM. When the exterior luggage compartment lid release switch is pressed, the signal is routed to ground
indicating a request to the BCM to release the luggage compartment lid latch.
Luggage Compartment Lid Latch
The luggage compartment lid latch contains the luggage compartment lid latch release motor and the luggage
compartment lid ajar switch. The luggage compartment lid latch release motor is momentarily supplied voltage by
the BCM when a valid request to open the luggage compartment lid is detected.
DDM or PDM
When equipped with a memory seat, the DDM and the PDM monitor the door lock control switches and control
the operation of the power windows and the power mirrors. They communicate with each other and the BCM over
the CAN.
The DDM and PDM require PMI when replaced.
Passive Key
The passive key incorporates both the PATS and RKE transmitter functions in a single device.
During key programming procedures, the PATS and RKE transmitter Identification (ID) of a passive key are both
programmed. A maximum of 4 passive keys can be programmed.
The passive key also contains a removable key blade that unlocks the driver door in the event of an electrical
failure (such as a drained battery). The passive key requires 2 batteries. They should always be replaced as a
set. For battery replacement instructions, refer to the Owner's Manual.
To start the vehicle in the event of a passive key battery failure, place the passive key in the backup starting
location.
Exterior Door Handles
The exterior door handles contain a keyless entry antenna and capacitive touch sensor(s). The antennas and
lock/unlock sensors are wired to the BCM. When activated, the antenna transmits a low frequency signal to
activate a passive key.
Keyless Entry Rear Antenna
The keyless entry rear antenna is monitored and activated by the BCM. When activated, it transmits a low
frequency signal to activate a passive key.
RTM
The RTM communicates all RKE and passive key information to the BCM over a LIN-based circuit whether or not
the CAN is active. The RTM is a receiving antenna that receives the high frequency signals from passive keys.
The RTM requires PMI when replaced.
BCM
The BCM is the master module in control of the power door lock system. It is responsible for locking/unlocking the
doors. The BCM receives inputs for the door lock control switches, passive keys and RKE commands over the
CAN.
The BCM requires PMI when replaced. Additionally, at least 2 keys must be programmed and the parameter
reset procedure carried out.
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Locks, Latches and Entry Systems
DTC Chart: BCM
BCM DTC Chart

B10AB:00 Remote Keyless Entry Synchronization: No Sub Type GO to Pinpoint Test O
Information
B10C7:01 Interior Trunk Antenna: General Electrical Failure GO to Pinpoint Test T
B11C6:01 Passenger Door External Antenna: General GO to Pinpoint Test S
Electrical Failure
B11CA:01 Driver Door External Antenna: General Electrical GO to Pinpoint Test S
Failure
B1218:00 Transmitter Identification Code: No Sub Type GO to Pinpoint Test O
Information
B1219:11 Interior Boot/Trunk Release Switch: Circuit Short To GO to Pinpoint Test N
Ground
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B126A:01 Drivers Door Interior Lock Switch: General Electrical GO to Pinpoint Test J
Failure
B1381:11 Left Front Door Handle Proximity Sensor: Circuit GO to Pinpoint Test S
Short To Ground
B1381:15 Left Front Door Handle Proximity Sensor: Circuit GO to Pinpoint Test S
B1381:29 Left Front Door Handle Proximity Sensor: Signal GO to Pinpoint Test S
Invalid
B1382:11 Right Front Door Handle Proximity Sensor: Circuit GO to Pinpoint Test S
Short To Ground
B1382:15 Right Front Door Handle Proximity Sensor: Circuit GO to Pinpoint Test S
B1382:29 Right Front Door Handle Proximity Sensor: Signal GO to Pinpoint Test S
Invalid
B1490:11 Lock Indicator LED Status Output: Circuit Short To GO to Pinpoint Test L
Ground
B1490:15 Lock Indicator LED Status Output: Circuit Short To If the door lock indicator is inoperative, GO to Pinpoint Test L
Battery or Open If the door lock indicator is always on, GO to Pinpoint Test M
C1017:11 Boot/Trunk Primary Switch: Circuit Short To Ground GO to Pinpoint Test N

U0258:87 Lost Communication With Radio Transceiver: Missing GO to Pinpoint Test V
Message
Codes (DTCs) REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic
DTC Chart: RTM
RTM DTC Chart

U0146:00 Lost Communication With Gateway "A": No Sub Type GO to Pinpoint Test U
Information
U0401:00 Invalid Data Received from ECM/PCM A: No Sub Type DIAGNOSE all non-network Diagnostic Trouble Codes (DTCs) from the PCM. Refer to
Information the appropriate section in Group 303 for the procedure.
U0401:82 Invalid Data Received from ECM/PCM A: Alive / DIAGNOSE all non-network Diagnostic Trouble Codes (DTCs) from the PCM. Refer to
Sequence Counter Incorrect / Not Updated the appropriate section in Group 303 for the procedure.
U1A00:00 Private Communication Network: No Sub Type GO to Pinpoint Test V
Information
U2100:00 Initial Configuration Not Complete: No Sub Type PERFORM the PMI using as-built data. CLEAR the Diagnostic Trouble Codes (DTCs)
Information and REPEAT the self-test. If the DTC returns, INSTALL a new RTM.
REFER to: Radio Transceiver Module (RTM) (419-10 Multifunction Electronic Modules,
U3000:04 Control Module: System Internal Failure INSTALL a new RTM.
DTC Chart: DDM
DDM DTC Chart

B1088:83 LIN Bus "B": Value of Signal
Protection Calculation Incorrect REFER to: Glass, Frames and Mechanisms (501-11 Glass, Frames and Mechanisms, Diagnosis and Testing).
B1088:87 LIN Bus "B": Missing Message
REFER to: Glass, Frames and Mechanisms (501-11 Glass, Frames and Mechanisms, Diagnosis and Testing).
B108F:23 Cabin Lock/Unlock Switch: Signal GO to Pinpoint Test J
Stuck Low
B1163:11 Left Mirror Heater Output: Circuit
Short To Ground REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
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B1163:15 Left Mirror Heater Output: Circuit
Short To Battery or Open REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
B1C03:23 Memory #1 Switch: Signal Stuck
Low REFER to: Front Seats (501-10A Front Seats, Diagnosis and Testing).
B1C09:11 Driver Left/Right Mirror Motor:
Circuit Short To Ground REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
B1C09:15 Driver Left/Right Mirror Motor:
Circuit Short To Battery or Open REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
B1C10:11 Driver Up/Down Mirror Motor:
B1C10:15 Driver Up/Down Mirror Motor:
B1C13:11 Driver Up/Down Mirror Motor
Feedback: Circuit Short To REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Ground
B1C13:15 Driver Up/Down Mirror Motor
Battery or Open
B1C14:11 Driver Left/Right Mirror Motor
Ground
B1C14:15 Driver Left/Right Mirror Motor
Battery or Open
B1D06:11 Left Turn Indicator: Circuit Short
To Ground REFER to: Turn Signal and Hazard Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
C1B15:11 Sensor Supply Voltage B: Circuit
U0010:00 Medium Speed CAN The module was unable to communicate on the network at a point in time. The fault is not currently present (the
Communication Bus: No Sub Type module had to communicate with the scan tool to report this DTC). VERIFY the continuity of the connectors and
Information wiring. Refer to Wiring Diagrams Cell 14 Module Communications Network for schematic and connector
information.
U0140:00 Lost Communication With Body GO to Pinpoint Test W
Control Module: No Sub Type
Information
U0208:00 Lost Communication With "Seat GO to Pinpoint Test X
Control Module A": No Sub Type
Information
U0300:00 Internal Control Module Software CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the self-test. If the DTC is retrieved again, INSTALL
Incompatibility: No Sub Type a new DDM.
Information REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
U0300:4A Internal Control Module Software PERFORM the PMI using as-built data. CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
Incompatibility: Incorrect self-test. If the DTC returns, INSTALL a new DDM.
Component Installed REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
U0422:00 Invalid Data Received From Body RETRIEVE and REPAIR all non-network Diagnostic Trouble Codes (DTCs) from the BCM.
Control Module: No Sub Type REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
Information
U0509:00 Invalid Data Received From "Seat RETRIEVE and REPAIR all non-network Diagnostic Trouble Codes (DTCs) from the DSM.
Control Module A": No Sub Type REFER to: Front Seats (501-10A Front Seats, Diagnosis and Testing).
Information
U2010:00 Switch Illumination: No Sub Type
Information REFER to: Instrument Panel and Interior Switches Illumination (413-00 Instrument Panel and Interior Switches
Illumination, Diagnosis and Testing).
U2013:24 Switch Pack: Signal Stuck High
U2014:00 Control Module Hardware: No INSTALL a new DDM.
Sub Type Information REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
U2100:00 Initial Configuration Not Complete: PERFORM the PMI using as-built data. CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
No Sub Type Information self-test. If the DTC returns, INSTALL a new DDM.
U3000:04 Control Module: System Internal INSTALL a new DDM.
Failure REFER to: Driver Door Module (DDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
DTC Chart: PDM
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PDM DTC Chart

B108F:23 Cabin Lock/Unlock Switch: Signal GO to Pinpoint Test J
Stuck Low
B1164:11 Right Mirror Heater Output:
B1164:15 Right Mirror Heater Output:
B1C11:11 Passenger Left/Right Mirror
Motor: Circuit Short To Ground REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Motor: Circuit Short To Battery or REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Open
B1C12:11 Passenger Up/Down Mirror
Motor: Circuit Short To Ground REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
B1C12:15 Passenger Up/Down Mirror
Motor: Circuit Short To Battery or REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Open
B1C15:11 Passenger Up/Down Mirror Motor
Ground
B1C15:15 Passenger Up/Down Mirror Motor
Battery or Open
Motor Feedback: Circuit Short To REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Ground
Motor Feedback: Circuit Short To REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Diagnosis and Testing).
Battery or Open
B1D07:11 Right Turn Indicator: Circuit Short
To Ground REFER to: Turn Signal and Hazard Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
U0010:00 Medium Speed CAN The module was unable to communicate on the network at a point in time. The fault is not currently present (the
Communication Bus: No Sub Type module had to communicate with the scan tool to report this DTC). VERIFY the continuity of the connectors and
Information wiring. Refer to Wiring Diagrams Cell 14 Module Communications Network for schematic and connector
information.
U0140:00 Lost Communication With Body GO to Pinpoint Test W
Information
U0208:00 Lost Communication With "Seat GO to Pinpoint Test X
Control Module A": No Sub Type
Information
U0300:00 Internal Control Module Software CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the self-test. If the DTC is retrieved again, INSTALL
Incompatibility: No Sub Type a new PDM.
Information REFER to: Passenger Door Module (PDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
U0300:4A Internal Control Module Software PERFORM the PMI using as-built data. CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
Incompatibility: Incorrect self-test. If the DTC returns, INSTALL a new PDM.
Component Installed REFER to: Passenger Door Module (PDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
U0422:00 Invalid Data Received From Body RETRIEVE and REPAIR all non-network Diagnostic Trouble Codes (DTCs) from the BCM.
Control Module: No Sub Type REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
Information
U0509:00 Invalid Data Received From "Seat RETRIEVE and REPAIR all non-network Diagnostic Trouble Codes (DTCs) from the DSM.
Control Module A": No Sub Type REFER to: Front Seats (501-10A Front Seats, Diagnosis and Testing).
Information
U2002:24 Switch: Signal Stuck High
U2010:00 Switch Illumination: No Sub Type
Information REFER to: Instrument Panel and Interior Switches Illumination (413-00 Instrument Panel and Interior Switches
Illumination, Diagnosis and Testing).
U2014:00 Control Module Hardware: No CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the self-test. If the DTC returns, INSTALL a new
Sub Type Information PDM.
U2100:00 Initial Configuration Not Complete: PERFORM the PMI using as-built data. CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
No Sub Type Information self-test. If the DTC returns, INSTALL a new PDM.
U3000:04 Control Module: System Internal CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the self-test. If the DTC returns, INSTALL a new
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Failure PDM.
DTC Chart: PCM
PCM DTC Chart

P1594 Forced Engine Shutdown - Remote Start System Fault, No Unattended Vehicle GO to Pinpoint Test Y
Timeout
P1595 Forced Engine Shutdown - Remote Start System Fault, Transmission Range Not GO to Pinpoint Test Y
In Park Position
All other Diagnostic Trouble Codes - REFER to the appropriate 303-14
(DTCs) section.
Symptom Charts
Symptom Chart: Handles, Locks, Latches and Entry Systems - Mechanical

Hard to open or close a door from either door handle Refer to the Pinpoint Test GO to Pinpoint Test A
A door is difficult or does not open from the exterior door handle Refer to the Pinpoint Test GO to Pinpoint Test B
A door is difficult or does not open from the interior door handle Refer to the Pinpoint Test GO to Pinpoint Test C
The exterior door release handle sticks Refer to the Pinpoint Test GO to Pinpoint Test D
The interior door release handle sticks Refer to the Pinpoint Test GO to Pinpoint Test E
Squeak-rattle-chucking noise from door Refer to the Pinpoint Test GO to Pinpoint Test F
The manual door lock cylinder is inoperative Refer to the Pinpoint Test GO to Pinpoint Test G
Symptom Chart: Handles, Locks, Latches and Entry Systems - Electrical

All door locks are inoperative Refer to the Pinpoint Test GO to Pinpoint Test H
A single or more than one door Refer to the Pinpoint Test GO to Pinpoint Test I
lock is inoperative
The door locks operate only one Refer to the Pinpoint Test GO to Pinpoint Test J
way
All door locks are inoperative from Refer to the Pinpoint Test GO to Pinpoint Test K
one door lock control switch
A door lock indicator is Refer to the Pinpoint Test GO to Pinpoint Test L
inoperative
A door lock indicator is always on Refer to the Pinpoint Test GO to Pinpoint Test M
The luggage compertment lid Refer to the Pinpoint Test GO to Pinpoint Test N
latch release is inoperative
The luggage compertment lid Refer to the Pinpoint Test DISCONNECT the luggage compartment lid latch electrical connector and CHECK
does not latch the operation of the latch using a screwdriver.
If the latch does not fully latch (2 clicks), INSTALL a new luggage
compartment lid latch.
If the latch fully latches (2 clicks), REFER to the Wiring Diagrams manual
to identify the possible cause of the circuit short in the luggage
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compartment lid latch release circuit.
The RKE transmitter is inoperative Refer to the Pinpoint Test GO to Pinpoint Test O
An individual button/feature is Refer to the Pinpoint Test GO to Pinpoint Test P

inoperative from the RKE
transmitter
The RKE transmitter has poor Refer to the Pinpoint Test GO to Pinpoint Test Q
range performance
The remote start feature is Refer to the Pinpoint Test GO to Pinpoint Test R
inoperative
The smart unlock is inoperative Refer to the Pinpoint Test DIAGNOSE the passive key not starting the vehicle from various areas within the
interior of the vehicle.
REFER to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft
System (PATS), Diagnosis and Testing).
The 2-stage door unlocking does The 2-stage door PROGRAM the 2-step door unlocking.
not operate correctly unlocking is not REFER to: Staged Unlock Programming (501-14 Handles, Locks, Latches and
programmed Entry Systems, General Procedures).
A door passive entry feature is Refer to the Pinpoint Test GO to Pinpoint Test S
inoperative
The luggage compartment lid Refer to the Pinpoint Test GO to Pinpoint Test T
passive entry feature is
inoperative
Pinpoint Tests
Hard To Open Or Close a Door From Either Door Handle
Normal Operations and Fault Conditions
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.
Possible Cause
Door alignment
Door hinges
Striker adjustment
Door latch
PINPOINT TEST A : HARD TO OPEN OR CLOSE A DOOR FROM EITHER DOOR HANDLE
A1 CHECK THE LATCH OPERATION FROM BOTH DOOR HANDLES
Open the door using both the interior and exterior door handles.
Does the door open normally from one of the door handles?
Yes If the door is difficult/does not open from the exterior door handle, GO to Pinpoint Test B
If the door is difficult/does not open from the interior door handle, GO to Pinpoint Test C
No GO to A2
A2 CHECK THE LATCH OPERATION

Open the door.
Using a screwdriver, fully close the latch (2 clicks).
Verify the latch releases easily while pulling on the interior/exterior door handle.
Does the latch release easily?
Yes GO to A4
No GO to A3
A3 CHECK THE LATCH OPERATION AFTER LUBRICATION

Lubricate the door latch.
REFER to: Door Latch Lubrication (501-14 Handles, Locks, Latches and Entry Systems, General Procedures).
Verify the latch releases easily while pulling on the interior/exterior door handle.
Does the latch release easily?
Yes The concern was caused by an insufficiently lubricated door latch.

No INSTALL a new door latch.
REFER to: Front Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
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A4 CHECK THE STRIKER ADJUSTMENT
Check the adjustment of the striker.
Is the striker adjusted correctly?
Yes GO to A5
No ADJUST the striker as necessary.
A5 CHECK THE DOOR ALIGNMENT

Check the alignment of the door.
Is the door aligned correctly?
Yes LUBRICATE the door hinges.

No ADJUST the door as necessary.
REFER to: Front Door Alignment (501-03 Body Closures, General Procedures).
A Door Is Difficult Or Does Not Open From The Exterior Door Handle
The exterior door handle is connected to the door latch with an actuating cable. When the exterior door handle is pulled, the actuating cable pulls on the latch
lever. When the latch lever moves, the door latch releases, allowing the door to open.
Possible Cause
Broken or binding linkage

Exterior door handle reinforcement
Door latch
PINPOINT TEST B : A DOOR IS DIFFICULT OR DOES NOT OPEN FROM THE EXTERIOR DOOR HANDLE
B1 CHECK THE LATCH OPERATION FROM BOTH DOOR HANDLES
Open and close the door using both the interior and exterior door handles.
Yes If the door is difficult/does not open from only the exterior door handle, GO to B2
If the door is difficult/does not open from only the interior door handle, GO to Pinpoint Test C
B2 CHECK THE EXTERIOR DOOR HANDLE AND CABLE OPERATION

Disconnect the exterior door handle actuating cable from the door latch.
Operate the exterior door handle while observing the linkage and cable.
Are any of the exterior door handle components or linkages binding or broken?
Yes GO to B3
B3 CHECK THE EXTERIOR DOOR HANDLE REINFORCEMENT

Disconnect the exterior door handle actuating cable from the exterior door handle reinforcement.
Pull and release the exterior door handle.
Does the exterior door handle operate correctly?
Yes INSTALL a new exterior door handle cable.

No INSTALL a new exterior door handle reinforcement.
REFER to: Exterior Front Door Handle Reinforcement (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
A Door Is Difficult Or Does Not Open From The Interior Door Handle
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is pulled, the cable pulls on the latch lever. When the
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latch lever moves, the door latch releases, allowing the door to open.
Possible Cause
Broken or binding cable/linkage

Door latch
PINPOINT TEST C : A DOOR IS DIFFICULT OR DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE
C1 CHECK THE LATCH OPERATION FROM BOTH DOOR HANDLES
Open the door using both the interior and exterior door handles.
Yes If the door is difficult/does not open from only the interior door handle, GO to C2
If the door is difficult/does not open from only the exterior door handle, GO to Pinpoint Test B
C2 CHECK THE INTERIOR DOOR HANDLE AND CABLE/LINKAGE OPERATION

Remove the door trim panel.
Install the interior door handle back onto the release cable.
Operate the interior door handle while observing the cable/linkage.
Are any of the interior door handle components or cable/linkages binding or broken?

The Exterior Door Release Handle Sticks
The exterior door handle is connected to the door latch with an actuating cable. When the exterior door handle is pulled, the actuating cable pulls on the latch
lever. When the latch lever moves, 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.
Possible Cause
Binding linkage
Broken handle return spring
Door latch
PINPOINT TEST D : THE EXTERIOR DOOR RELEASE HANDLE STICKS

D1 CHECK FOR A BROKEN RETURN SPRING
Remove the window regulator
REFER to: Front Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Install the exterior door handle strap back onto the exterior door handle reinforcement.
Disconnect the exterior door handle actuating rod from the door latch.
Pull and release the exterior door handle
Does the exterior door handle return to a closed position once released?
Yes GO to D2
No INSTALL a new exterior door handle reinforcement.
REFER to: Exterior Front Door Handle Reinforcement (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
D2 CHECK THE EXTERIOR DOOR HANDLE AND LINKAGE OPERATION

Operate the exterior door handle while observing the linkage.
Are any of the exterior door handle components or linkages binding?

The Interior Door Release Handle Sticks
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The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is pulled, the cable pulls 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.
Possible Cause
Binding cable
Broken handle return spring
Door latch
PINPOINT TEST E : THE INTERIOR DOOR RELEASE HANDLE STICKS

E1 CHECK FOR A BROKEN RETURN SPRING
Remove the interior door handle.
REFER to: Interior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
Pull and release the interior door handle.
Does the interior door handle return to a closed position once released?
Yes GO to E2
No INSTALL a new interior door handle.
REFER to: Interior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
E2 CHECK THE INTERIOR DOOR HANDLE CABLE OPERATION

Remove the interior door latch release cable.
Observe the door latch release cable for any damage or binding.
Is the door latch release cable OK?
Yes INSTALL a new door latch.

No INSTALL a new interior door handle cable.
Squeak-Rattle-Chucking Noise From Door
Possible Cause
Door alignment
Striker adjustment
Door latch
PINPOINT TEST F : SQUEAK-RATTLE-CHUCKING NOISE FROM DOOR

F1 CHECK FOR ANY LOOSE COMPONENTS
Inspect inside the door for any loose components.
Are there any loose components inside the door?

No GO to F2
F2 CHECK THE STRIKER ADJUSTMENT

Check the adjustment of the striker.
Is the striker adjusted correctly?
Yes GO to F3
No ADJUST the striker as necessary.
F3 CHECK THE DOOR ALIGNMENT

Check the alignment of the door.
Is the door aligned correctly?
Yes GO to F4
No ADJUST the door as necessary.
REFER to: Front Door Alignment (501-03 Body Closures, General Procedures).
F4 CHECK THE LATCH OPERATION AFTER LUBRICATION
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Lubricate the door latch.
REFER to: Door Latch Lubrication (501-14 Handles, Locks, Latches and Entry Systems, General Procedures).
Operate the door latch and listen for the noise.
Is the original noise still present after the latch is lubricated?

No The concern was caused by an insufficiently lubricated door latch.
The Manual Door Lock Cylinder Is Inoperative
The door lock cylinder is connected to the door latch via a lock rod and can be used to manually lock/unlock the door.
Possible Cause
Bent or binding lock rod and lever

Door lock cylinder-to-latch rod disconnected
Door lock cylinder
Door latch
PINPOINT TEST G : THE MANUAL DOOR LOCK CYLINDER IS INOPERATIVE

G1 CHECK THE LOCK AND UNLOCK OPERATION
Insert a key into the lock cylinder and rotate the lock cylinder to the lock and unlock positions.
Does the door lock cylinder freely rotate without locking and unlocking the door?
Yes GO to G2
No GO to G5
G2 CHECK THE DOOR LOCK CYLINDER-TO-LATCH ROD CONNECTION

Inspect the door lock cylinder-to-latch rod connections and make sure it is connected correctly.
Is the door lock cylinder-to-latch rod connected correctly?
Yes GO to G3
No CONNECT the cylinder-to-latch rod correctly to the door latch and the door lock cylinder
G3 CHECK THE DOOR LOCK CYLINDER (FREE-SPIN)

Remove the door lock cylinder.
REFER to: Door Lock Cylinder (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
Operate the door lock cylinder with the key while holding the lever on the lock cylinder.
Does the key in the door lock cylinder rotate freely while the lever is stationary?
Yes INSTALL a new door lock cylinder.

No GO to G4
G4 CHECK THE DOOR LOCK CYLINDER LINKAGE CONNECTION

Inspect the door lock cylinder linkage.
Is the door lock cylinder rod and lever disconnected?
Yes CONNECT the door lock cylinder rod and lever.

G5 CHECK THE LOCK CYLINDER OPERATION AFTER LUBRICATION

Spray a lock lubricant (such as Motorcraft® XL-1) into the lock cylinder opening for a couple of seconds.
Operate the door lock cylinder with the key.
Does the door lock and unlock using the door lock cylinder?
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Yes The concern was caused by an insufficiently lubricated lock cylinder. SPRAY a multi-purpose grease (such as Motorcraft® XL-5)
into the lock cylinder for a couple seconds to provide long term lubrication.
No GO to G6
G6 CHECK THE DOOR LOCK CYLINDER FOR BINDING

Remove the door lock cylinder.
Does the door lock cylinder rotate freely?
Yes GO to G7
No INSTALL a new door lock cylinder.
G7 CHECK THE DOOR LOCK CYLINDER LINKAGE

Operate the door lock using the door lock cylinder linkage.
Is the door lock cylinder rod and lever binding, damaged or disconnected?

All Door Locks Are Inoperative
REFER to: Handles, Locks, Latches and Entry Systems - System Operation and Component Description (501-14 Handles, Locks, Latches and Entry Systems,
Possible Cause

BCM
PINPOINT TEST H : 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.
H1 CHECK FOR BCM (BODY CONTROL MODULE) , DDM (DRIVER DOOR MODULE) AND PDM (PASSENGER DOOR MODULE) DIAGNOSTIC
TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform the DDM self-test.
Using a diagnostic scan tool, perform the PDM self-test.
Yes REFER to the BCM DTC Chart, the DDM DTC Chart or the PDM DTC Chart in this section.
No GO to H2
H2 VERIFY THE OPERATION OF BOTH DOOR LOCK CONTROL SWITCHES

Press the lock and unlock buttons on both door lock control switches while observing the door lock operation.
Does any door lock operate?
Yes GO to H3
No GO to H4
H3 CHECK IF THE LOCKS OPERATE IN ONLY ONE DIRECTION

Press the lock and unlock buttons from the driver door lock control switch and then the passenger door lock control switch while observing the door
locks.
Are all the door locks inoperative from both switch positions (lock and unlock) of either door lock control switch?
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Yes GO to Pinpoint Test K
No GO to Pinpoint Test J
H4 CHECK THE BCM (BODY CONTROL MODULE) DOOR LOCK GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect BCM C2280C.
Measure

C2280C-10 Ground
Yes GO to H5
H5 CHECK THE ALL DOOR LOCK CIRCUIT FOR AN OPEN

Disconnect Left Front Door Latch C525.
Measure:

C2280C-35 C525-7
Yes GO to H6
H6 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Disconnect and inspect all the BCM connectors.
Repair:
damaged or bent pins - install new terminals pins
Reconnect the BCM connectors and make sure they seat and latch correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, Click here to
A Single or More Than One Door Lock Is Inoperative
Possible Cause
Fuse
Door latch
BCM
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Check the BCM fuse 24 (30A)
PINPOINT TEST I : A SINGLE OR MORE THAN ONE DOOR LOCK IS INOPERATIVE

I1 CHECK THE DOOR LATCH FOR BINDING
Lock and unlock the inoperative door lock using the manual door lock located just above the door latch opening.
Does the door lock and unlock?
Yes VERIFY the BCM fuse 24 (30A) is OK. If OK, GO to I2

If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.
I2 CHECK THE BCM (BODY CONTROL MODULE) ALL LOCK OUTPUT CIRCUIT FOR AN OPEN
NOTICE: The following step uses a test lamp to simulate normal circuit loads. Use only a Rotunda Test Lamp (SGT27000) or 250-300mA
incandescent bulb test lamp. To avoid connector terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the
vehicle. Do not use the test lamp probe directly on any connector.
Ignition OFF.
Disconnect suspect door latch.
For the suspect door latch, connect:

Left Front Door Latch

C525-7 Ground

Right Front Door Latch

C609-2 Ground
NOTE: The BCM only supplies voltage to the actuator momentarily. It is important to monitor the test lamp while pressing the door lock control
switch.
While pressing the door lock control switch in the lock position, monitor the test lamp.
Does the test lamp momentarily illuminate?
Yes GO to I3
I3 CHECK THE BCM (BODY CONTROL MODULE) UNLOCK OUTPUT


C525-8 Ground


C609-1 Ground
NOTE: The BCM only supplies voltage to the actuator momentarily. It is important to monitor the test lamp while pressing the door lock control
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switch.
While pressing the door lock control switch in the unlock position, monitor the test lamp.

No GO to I4
I4 CHECK THE BCM (BODY CONTROL MODULE) UNLOCK OUTPUT CIRCUIT FOR AN OPEN


C525-8 C2280C-27


C609-1 C2280C-32
Yes GO to I5
I5 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:

The Door Locks Operate Only One Way
BCM DTC Fault Trigger Conditions

B126A:01 Drivers Door Interior Lock Switch: General Sets during an on-demand self-test if the BCM detects a short to ground from one of the door
Electrical Failure lock control switch input circuits.
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DDM/ PDM DTC Fault Trigger Conditions

B108F:23 Cabin Lock/Unlock Switch: Signal Stuck Sets when the DDM/ PDM detects a short to ground from one of the door lock control switch input
Low circuits.
Possible Cause
Fuse
Door lock control switch
PDM
DDM
BCM
PINPOINT TEST J : THE DOOR LOCKS OPERATE ONLY ONE WAY

J1 CHECK FOR AN INOPERATIVE DOOR LOCK
Operate the power door locks using both door lock control switches.
Is any door lock inoperative for both directions?
Yes GO to Pinpoint Test I

No GO to J2
J2 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B108F:23 OR B126A:01

Ignition ON.
For vehicles not equipped with a memory seat, using a diagnostic scan tool, perform the BCM self-test.
For vehicles equipped with a memory seat, using a diagnostic scan tool, perform the DDM and the PDM self-tests.
Is DTC B108F:23 or B126A:01 present?
Yes For vehicles not equipped with a memory seat, GO to J3

For vehicles equipped with a memory seat, GO to J5
No VERIFY the BCM fuse 3 (20A) is OK. If OK, GO to J7
J3 ISOLATE THE DRIVER DOOR LOCK CONTROL SWITCH

Ignition OFF.
Disconnect Driver Door Lock Control Switch C505.
Ignition ON.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the BCM self-test.
Is DTC B126A:01 still present?
Yes GO to J4
No INSTALL a new driver door lock control switch.
J4 ISOLATE THE PASSENGER DOOR LOCK CONTROL SWITCH

Ignition OFF.
Disconnect Passenger Door Lock Control Switch C605.
Ignition ON.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the BCM self-test.
Is DTC B126A:01 still present?
Yes GO to J6
No INSTALL a new passenger door lock control switch.
J5 ISOLATE THE DOOR LOCK CONTROL SWITCH

Ignition OFF.
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Disconnect Driver Door Lock Control Switch C541 (DTC set in DDM).
Disconnect Passenger Door Lock Control Switch C605 (DTC set in PDM).
Ignition ON.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the DDM or the PDM self-test.
Is DTC B108F:23 still present?
Yes GO to J6
No INSTALL a new door lock control switch.
J6 CHECK THE DOOR LOCK CONTROL SWITCH INPUT CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BCM C2280E (DTC set in BCM).
Disconnect DDM C501A (DTC set in DDM).
Disconnect PDM C652A (DTC set in PDM).
If the DTC set in the BCM, measure:

C2280E-4 Ground
C2280E-17 Ground
If the DTC set in the DDM, measure:

C501A-10 Ground
C501A-20 Ground
If the DTC set in the PDM, measure:

C652A-10 Ground
C652A-20 Ground
Yes For the PDM, GO to J13

For the DDM, GO to J14
For the BCM, GO to J15
J7 CHECK THE LOCK REQUEST INPUT CIRCUIT

Ignition OFF.
Disconnect suspect door lock control switch.
Connect:

Driver Door Lock Control Switch (without memory)

C505-4 C505-3

Driver Door Lock Control Switch (with memory)

C541-2 C541-3
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Passenger Door Lock Control Switch

C605-1 C605-2
Remove the fused jumper wire.
Do the doors lock?
Yes GO to J10
No For vehicles not equipped with a memory seat, GO to J8
J8 CHECK THE LOCK REQUEST INPUT CIRCUIT FOR AN OPEN (WITHOUT MEMORY SEAT)
Disconnect BCM C2280E.
Measure:

Driver Door Lock Control Switch

C505-4 C2280E-17


C605-1 C2280E-17
Yes GO to J15
J9 CHECK THE LOCK REQUEST INPUT CIRCUIT FOR AN OPEN (WITH MEMORY SEAT)
Disconnect DDM C501A (driver door lock control switch with memory).
Disconnect PDM C652A (passenger door lock control switch).
Measure:


C541-2 C501A-20


C605-1 C652A-20
Yes For the concern with the passenger door lock control switch, GO to J13
For the concern with the driver door lock control switch, GO to J14
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J10 CHECK THE UNLOCK REQUEST INPUT CIRCUIT
Connect:


C505-2 C505-3


C541-1 C541-3


C605-1 C605-2
For the passenger door lock control switch, momentarily connect:
Do the doors unlock?
Yes INSTALL a new door lock control switch.

No For vehicles not equipped with a memory seat, GO to J11
J11 CHECK THE UNLOCK REQUEST INPUT CIRCUIT FOR AN OPEN (WITHOUT MEMORY SEAT)
Measure:

C505-2 C2280E-4


C605-3 C2280E-4
Yes GO to J15
J12 CHECK THE UNLOCK REQUEST INPUT CIRCUIT FOR AN OPEN (WITH MEMORY SEAT)
Disconnect DDM C501A (driver door lock control switch).
Disconnect PDM C652A (passenger door lock control switch).
For the driver door lock control switch, measure:

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C541-1 C501A-10


C605-3 C652A-10
Yes For the concern with the passenger door lock control switch, GO to J13
For the concern with the driver door lock control switch, GO to J14
J13 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Repair:
Reconnect the PDM connectors and make sure they seat and latch correctly.
J14 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Repair:
Reconnect the DDM connectors and make sure they seat and latch correctly.
J15 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
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All Door Locks Are Inoperative From One Door Lock Control Switch
Possible Cause

Door lock control switch
Check the door lock control switch for damage
PINPOINT TEST K : ALL DOOR LOCKS ARE INOPERATIVE FROM ONE DOOR LOCK CONTROL SWITCH
K1 CHECK FOR COMMUNICATION TO THE DDM (DRIVER DOOR MODULE) AND PDM (PASSENGER DOOR MODULE)
NOTE: If the vehicle is not equipped with a memory seat, proceed to K2.
Ignition ON.
Using a diagnostic scan tool, perform the network test.
Do the DDM and PDM pass the network test?
Yes GO to K2
No
K2 CHECK THE DOOR LOCK CONTROL SWITCH GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect suspect door lock control switch.
Measure:


C505-3 Ground

C541-3 Ground


C605-2 Ground
Yes INSTALL a new door lock control switch in question.

A Door Lock Indicator Is Inoperative
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B1490:11 Lock Indicator LED Status Output: Circuit Short To Ground Sets when the BCM detects a short to ground from the door lock indicator voltage
supply circuit.
B1490:15 Lock Indicator LED Status Output: Circuit Short To Battery Sets when the BCM detects an open from the door lock indicator voltage supply
or Open circuit.
Possible Cause

PDM
DDM
BCM
PINPOINT TEST L : A DOOR LOCK INDICATOR IS INOPERATIVE

L1 CHECK THE DOOR LOCK OPERATION
Ignition OFF.
Check the operation of the door locks using the door lock control switches.
Do the door locks operate correctly?
Yes GO to L2
No REFER to the Symptom Chart: Handles, Locks, Latches and Entry Systems - Electrical in this section.
L2 CHECK THE UNLOCK FEEDBACK CIRCUIT INPUT

Ignition OFF.
Disconnect suspect door lock indicator harness connector.
Lock the doors using a door lock control switch.
Measure:

Left Front Door

C573-2 Ground

Right Front Door

C649-2 Ground
Yes GO to L4
No GO to L3
L3 CHECK THE UNLOCK FEEDBACK CIRCUIT FOR A SHORT TO GROUND

Disconnect corresponding door latch.
Measure:
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Left Front Door

C573-2 Ground

Right Front Door

C649-2 Ground

L4 CHECK FOR VOLTAGE TO THE DOOR LOCK INDICATOR

Ignition ON.
Measure:

Left Front Door

C573-6 Ground

Right Front Door

C649-6 Ground

Yes GO to L5
No For vehicles without a memory seat, GO to L7
For vehicles with a memory seat, GO to L12
L5 CHECK THE DOOR LOCK INDICATOR GROUND CIRCUIT

Measure:

Left Front Door

C573-6 C573-4

Right Front Door

C649-6 C649-4
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Yes INSTALL a new door lock indicator harness.
No GO to L6
L6 CHECK THE DOOR LOCK INDICATOR GROUND CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect Body Control Module B (BCM-B) C4368A.
Measure:

Left Front Door

C573-4 C4368A-24

Right Front Door

C649-4 C4368A-24
Yes GO to L16
L7 CHECK FOR BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B1490:11
Ignition OFF.
Connect suspect door lock indicator harness connector.
Ignition ON.
Using a diagnostic scan tool, carry out the BCM self-test.
Is DTC B1490:11 present?
Yes GO to L8
No GO to L11
L8 CHECK THE LEFT DOOR LOCK INDICATOR FOR A SHORT TO GROUND

Ignition OFF.
Disconnect Left Door Lock Indicator Harness C573.
Ignition ON.
Is DTC B1490:11 still present?
Yes GO to L9
No REPAIR or REPLACE the door lock indicator harness.
L9 CHECK THE RIGHT DOOR LOCK INDICATOR FOR A SHORT TO GROUND

Ignition OFF.
Disconnect Right Door Lock Indicator Harness C649.
Ignition ON.
Is DTC B1490:11 still present?
Yes GO to L10
No REPAIR or REPLACE the door lock indicator harness.
L10 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND (WITHOUT MEMORY)
Ignition OFF.
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Measure:

C2280E-39 Ground
Yes GO to L17
L11 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR AN OPEN (WITHOUT MEMORY)
Ignition OFF.
Measure:

Left Front Door

C573-6 C2280E-39

Right Front Door

C649-6 C2280E-39
Yes GO to L17
L12 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND (WITH MEMORY)
Ignition OFF.
Disconnect DDM C501A (left front door indicator).
Disconnect PDM C652A (right front door indicator).
Measure:

Left Front Door

C501A-3 Ground

Right Front Door

C652A-3 Ground
Yes GO to L13
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L13 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Measure:

Left Front Door

C501A-3 C573-6

Right Front Door

C652A-3 C649-6
Yes For a left front door indicator, GO to L15

For a right front door indicator, GO to L14
L14 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Repair:
L15 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Repair:
L16 CHECK FOR CORRECT BODY CONTROL MODULE B (BCM-B) OPERATION

Disconnect and inspect the Body Control Module B (BCM-B) connector.
Repair:
Reconnect the Body Control Module B (BCM-B) connectors and make sure they seat and latch correctly.
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and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new Body Control
Module B (BCM-B).
L17 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
A Door Lock Indicator Is Always On

B1490:15 Lock Indicator LED Status Output: Circuit Short To Battery Sets when the BCM detects a short to voltage from the door lock indicator voltage
or Open supply circuit.
Possible Cause

PDM
DDM
BCM
PINPOINT TEST M : A DOOR LOCK INDICATOR IS ALWAYS ON

M1 CHECK THE COURTESY LAMP OPERATION
Check the operation of the courtesy lamps from each door.
Do the courtesy lamps operate correctly?
Yes GO to M2
No
REFER to: Interior Lighting (417-02 Interior Lighting, Diagnosis and Testing).
M2 CHECK THE UNLOCK FEEDBACK FOR CORRECT OPERATION

Ignition OFF.
Ignition ON.
Unlock the doors using the door lock control switch.
Measure:

Left Front Door
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C573-6 C573-2

Right Front

C649-6 C649-2
Yes For vehicles not equipped with a memory seat, GO to M4

For vehicles equipped with a memory seat, GO to M5
No GO to M3
M3 CHECK THE UNLOCK FEEDBACK CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect suspect door latch.
Measure:

Left Front Door

C573-2 C525-4

Right Front

C649-2 C609-5

M4 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE (WITHOUT MEMORY)
Ignition OFF.
Lock the doors using the RKE transmitter.
Observe the door lock indicators.
Do the door lock indicators continue to illuminate?

No GO to M8
M5 CHECK THE DOOR LOCK INDICATOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE (WITH MEMORY)
Ignition OFF.
Disconnect DDM C501A (driver door indicator).
Disconnect PDM C652A (passenger door indicator).
Lock the doors using the RKE transmitter.
Observe the door lock indicator in question.
Does the door lock indicator continue to illuminate?
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No For the passenger door lock indicator, GO to M6
For the driver door lock indicator, GO to M7
M6 CHECK FOR CORRECT PDM (PASSENGER DOOR MODULE) OPERATION

Repair:
M7 CHECK FOR CORRECT DDM (DRIVER DOOR MODULE) OPERATION

Repair:
M8 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
The Luggage Compartment Lid Latch Release Is Inoperative
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B1219:11 Interior Boot/Trunk Release Switch: Circuit Short Sets when the BCM detects a short to ground from the interior luggage compartment lid release
To Ground switch input circuit.
C1017:11 Boot/Trunk Primary Switch: Circuit Short To Sets when the BCM detects a short to ground from the exterior luggage compartment lid
Ground release switch input circuit.
Possible Cause
Fuse
Luggage compartment lid release switch
Luggage compartment lid latch
BCM

Inspect the luggage compartment lid release switches for damage
PINPOINT TEST N : THE LUGGAGE COMPARTMENT LID LATCH RELEASE IS INOPERATIVE

N1 CHECK FOR BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B1219:11 AND C1017:11
Ignition ON.
Is DTC B1219:11 or C1017:11 present?
Yes GO to N2
No GO to N4
N2 CHECK THE LUGGAGE COMPARTMENT LID RELEASE SWITCH

Ignition OFF.
Disconnect Interior Luggage Compartment Lid Release Switch C2610 (DTC B1219:11).
Disconnect Exterior Luggage Compartment Lid Release Switch C4333 (DTC C1017:11).
Ignition ON.
Is DTC B1219:11 or C1017:11 still present?
Yes GO to N3
No INSTALL a new luggage compartment lid release switch in question.
N3 CHECK THE LUGGAGE COMPARTMENT LID RELEASE SWITCH INPUT CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BCM C2280B (DTC B1219:11).
Disconnect BCM C2280E (DTC C1017:11).
Measure:

DTC B1219:11

C2280B-1 Ground

DTC C1017:11

C2280E-14 Ground
Yes GO to N11
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N4 CHECK THE LUGGAGE COMPARTMENT LID RELEASE OUTPUT USING THE DECKLID / LIFTGLASS RELEASE OUTPUT STATUS
(DL_LFTGLS_RLS) PID (PARAMETER IDENTIFICATION)
Command the BCM PID DL_LFTGLS_RLS on and then off.
Does the luggage compartmnet lid latch release?
Yes GO to N5
No VERIFY the BCM fuse 16 (15A) is OK. If OK, GO to N8
If not OK, REFER to the Wiring Diagrams manual to identify the possible cause of the circuit short.
N5 CHECK THE SUSPECT LUGGAGE COMPARTMENT LID RELEASE SWITCH

Ignition OFF.
Disconnect Suspect luggage compartment lid release switch.
Unlock the doors using a door lock control switch.
Connect:


C2610-6 C2610-2


C4333-1 C4333-2
Does the luggage compartment lid latch release?
Yes INSTALL a new luggage compartment lid release switch in question.

No GO to N6
N6 CHECK THE SUSPECT LUGGAGE COMPARTMENT LID RELEASE SWITCH GROUND CIRCUIT FOR AN OPEN
Connect:


C2610-6 Ground


C4333-1 Ground

No GO to N7
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N7 CHECK THE SUSPECT LUGGAGE COMPARTMENT LID RELEASE SWITCH INPUT CIRCUIT FOR AN OPEN
Disconnect BCM C2280B (interior luggage compartment lid release switch).
Disconnect BCM C2280E (exterior luggage compartment lid release switch).
Measure:


C2610-6 C2280B-1


C4333-1 C2280E-14
Yes GO to N11
N8 CHECK THE LUGGAGE COMPARTMENT LID LATCH
Ignition OFF.
Disconnect Luggage Compartment Lid Latch C4339.
Connect:

C4339-3 C4339-4
Ignition ON.
NOTE: The BCM only supplies voltage to the latch momentarily. It is important to monitor the test lamp while pressing the luggage compartment lid
release switch.
Press and release the exterior luggage compartment lid release switch while observing the test lamp.
Yes INSTALL a new luggage compartment lid latch.

No GO to N9
N9 CHECK THE LUGGAGE COMPARTMENT LID LATCH GROUND CIRCUIT FOR AN OPEN
Connect:

C4339-3 Ground
NOTE: The BCM only supplies voltage to the latch momentarily. It is important to monitor the test lamp while pressing the luggage compartment lid
release switch.
Press and release the exterior luggage compartment lid release switch while observing the test lamp.

No GO to N10
N10 CHECK THE BCM (BODY CONTROL MODULE) LUGGAGE COMPARTMENT LID LATCH OUTPUT CIRCUIT FOR AN OPEN
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Ignition OFF.
Measure:

C4339-3 C2280C-33
Yes GO to N11
N11 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
The RKE Transmitter Is Inoperative
A loss of synchronization of a RKE transmitter is caused when the button(s) on that RKE transmitter is pressed repeatedly on a continuous basis when the RKE
transmitter is out of range from the vehicle it is programmed to. If a RKE transmitter becomes out of sync, the BCM ignores commands from that RKE
transmitter.

B10AB:00 Remote Keyless Entry Synchronization: No Sets when the BCM detects the rolling counter received from a RKE transmitter is out of
Sub Type Information synchronization with the rolling counter stored in the module.
B1218:00 Transmitter Identification Code: No Sub Type Sets when the BCM detects and invalid Transmitter Identification Code (TIC).
Information
Possible Cause
Key battery
Key
Key button pressed a substantial amount of times while outside the range of the vehicle
Key programming
Network concern
Inspect the key for damage.

Check for aftermarket keys.
PINPOINT TEST O : THE RKE (REMOTE KEYLESS ENTRY) TRANSMITTER IS INOPERATIVE

NOTE: All customer keys need to be present when diagnosing the RKE system.
O1 CHECK FOR THE CORRECT KEYS
Verify all keys present are the correct type for the vehicle. Refer to the PATS Job Aid in the Service Tips tab on the Professional Technician Society
(PTS) web page.
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Are the correct keys present?
Yes GO to O2
No The system cannot be tested without the correct keys. INFORM the customer that all of the correct keys must be present to
proceed with diagnosis of the system.
O2 CHECK FOR REDUCED RANGE
NOTE: Make sure the vehicle is in an open area with no other large metal objects near, such as other vehicles or steel buildings.
Check all keys for normal range performance (approximately 50m (165 ft)).
Do the keys experience poor range?
Yes GO to Pinpoint Test Q

No GO to O3
O3 CHECK THE RKE (REMOTE KEYLESS ENTRY) FUNCTIONALITY OF THE KEYS

Press each RKE button on a key. Repeat this step on a second key.
Are all the RKE functions inoperative from both keys?
Yes GO to O11
No GO to O4
O4 CHECK THE RKE (REMOTE KEYLESS ENTRY) FUNCTIONALITY OF THE SUSPECT KEY
Press each RKE button (twice for the luggage compartment lid latch release) on the suspect key.
Does any RKE function operate?
Yes GO to Pinpoint Test P

No GO to O5
O5 CHECK THE NO (TIC) OUT OF SYNC (TIC-NONE_OOS) PID (PARAMETER IDENTIFICATION)

Ignition ON.
Using a diagnostic scan tool, view the BCM Paramater Identifications (PIDs).
Using a diagnostic scan tool, monitor the BCM PID TIC-NONE_OOS.
Does the PID indicate On?
Yes GO to O8
No GO to O6
O6 RESYNCHRONIZE THE INOPERATIVE PASSIVE KEY
Ignition OFF.
Place the suspect key in the backup starting location.
REFER to: Passive Anti-Theft System (PATS) - System Operation and Component Description (419-01B Passive Anti-Theft System (PATS),
Ignition ON.
Wait 10 seconds.
Ignition OFF.
Within 30 seconds, press any button on the suspect key.
Does the suspect key operate correctly now?
Yes The system is OK. The concern was caused by a key out of synchronization.
No GO to O7
O7 RESYNCHRONIZE THE INOPERATIVE KEY USING THE SECOND KEY

Press any button on the operational key.
Within 30 seconds, press any button on the suspect key.
Check the suspect key for correct operation.
Does the suspect key operate correctly now?
Yes The system is OK. The concern was caused by a key out of synchronization.
No GO to O10
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O8 CHECK THE (RKE) REMOTE BATTERY LOW (RKE_BATT_LOW) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the BCM Paramater Identifications (PIDs).
Using a diagnostic scan tool, monitor the BCM PID RKE_BATT_LOW.
Does the PID indicate Off?
Yes GO to O10
No GO to O9
O9 CHECK THE KEY BATTERIES
NOTE: Do not clean off any grease from the battery terminals on the back surface of the circuit board.
Remove the passive key batteries. Refer to the Owner Guide for battery removal instructions.
Verify the correct batteries are used (CR2025).
Remove both key batteries and measure the voltage.
Are the voltages greater than 2.5 volts?
Yes GO to O10
No REPLACE both key batteries (make sure the batteries are seated correctly). DO NOT reprogram the key (damaged or dead
batteries do not erase keys from memory).
O10 PROGRAM THE SUSPECT KEY

Program the suspect key.
REFER to: Anti-Theft Security Access (419-01B Passive Anti-Theft System (PATS), General Procedures).
Check the RKE functionality of the suspect key.
Does the RKE functionality operate?
Yes The system is OK. The concern was caused by an unprogrammed key.
No REPLACE the suspect key. PROGRAM the new key.
O11 CHECK FOR COMMUNICATION WITH THE BCM (BODY CONTROL MODULE) AND THE RTM (RADIO TRANSCEIVER MODULE)
Ignition ON.
Does the BCM and the RTM pass the network test?
Yes GO to O12
No
O12 CHECK FOR LOW VOLTAGE AND CHARGING SYSTEM-RELATED DIAGNOSTIC TROUBLE CODES (DTCS)
Are any low voltage or charging system-related Diagnostic Trouble Codes (DTCs) present?
Yes DIAGNOSE the low voltage or charging system as necessary. Refer to the appropriate section in Group 414 for the procedure.
No GO to O13
O13 CHECK FOR A NETWORK CONCERN

Are multiple lost communication Diagnostic Trouble Codes (DTCs) for multiple modules present in more than one module?
Yes DIAGNOSE a network concern.

No GO to O14
O14 CHECK FOR RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, perform a RTM module self-test.
Yes REFER to the RTM DTC Chart in this section.
cardiagn.com
No GO to O15
O15 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, perform a BCM module self-test.
Yes REFER to the BCM DTC Chart in this section.

No GO to Pinpoint Test V
An Individual Button/Feature Is Inoperative From The RKE Transmitter
Possible Cause
Door lock system concern

Luggage compartment lid latch release system concern
Horn system concern
Turn signal system concern
Remote start system concern
Key
Inspect the key for damage
PINPOINT TEST P : AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE (REMOTE KEYLESS ENTRY) TRANSMITTER
P1 VERIFY THE DOOR LOCK OPERATION
Press the lock and unlock button on the door lock control switch while observing the door lock operation.
Do the door locks operate?
Yes GO to P2
No GO to Pinpoint Test H
P2 VERIFY THE HORN OPERATION USING THE BCM (BODY CONTROL MODULE) PID (PARAMETER IDENTIFICATION) (HORN_RELAY)
Ignition ON.
Select the BCM horn PID (HORN_RELAY) and active command the horn on then off.
Does the horn sound when commanded on?
Yes GO to P3
No
REFER to: Horn (413-06 Horn, Diagnosis and Testing).
P3 VERIFY THE HAZARD LAMP OPERATION

Activate the hazard lamp function.
Do the hazard lamps operate correctly?
Yes GO to P4
No
REFER to: Turn Signal and Hazard Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
P4 VERIFY THE LUGGAGE COMPARTMENT LID LATCH RELEASE OPERATION

Ignition OFF.
Press the luggage compartment lid release switch.
Yes GO to P5
No GO to Pinpoint Test N
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P5 CHECK THE LOCK AND UNLOCK BUTTONS
Press the lock and then unlock button on the suspect passive key.
Do the doors lock and unlock?
Yes GO to P6
P6 CHECK THE LUGGAGE COMPARTMENT LID RELEASE BUTTON

Press the luggage compartment lid release button twice on the suspect passive key.
Yes GO to P7
P7 VERIFY THE REMOTE START OPERATION

Close all the doors, the hood and the luggage compartment lid.
NOTE: Each button press must be done within 3 seconds of each other.
From outside the vehicle using a passive key:
Press the door lock button.
Press the remote start button twice.
Does the vehicle remotely start?
Yes The RKE transmitter is operating correctly. INFORM the customner of the RKE transmitter operation.
The RKE Transmitter Has Poor Range Performance
Possible Cause
Key
Key batteries
Aftermarket system
Consumer electronic device
High power devices
TV/radio transmission towers
RTM
Inspect the key for damage

Inspect the key batteries
Inspect for aftermarket RKE systems
PINPOINT TEST Q : THE RKE (REMOTE KEYLESS ENTRY) TRANSMITTER HAS POOR RANGE PERFORMANCE
NOTE: At least 2 programmed keys must be present to begin diagnosis of the RKE system.
Q1 CHECK FOR THE CORRECT KEYS
Check that the correct keys are used with the vehicle. Refer to the PATS Job Aid in the Service Tips tab on the Professional Technician Society (PTS)
web page.
Are the correct keys present?
Yes GO to Q2
No The system cannot be tested without the correct keys. INFORM the customer the correct keys must be present to proceed with
diagnosis of the system.
Q2 CHECK ALL KEYS FOR POOR RANGE PERFORMANCE
NOTE: Make sure the vehicle is in an open area with no other large metal objects near, such as other vehicles or steel buildings.
Check all keys for normal range performance (approximately 50m (165 ft.).
cardiagn.com
Do all keys experience poor range?
Yes GO to Q4
No GO to Q3
Q3 CHECK THE KEY BATTERIES
NOTE: Do not clean off any grease from the battery terminals on the back surface of the circuit board.
Remove the passive key batteries. Refer to the Owner Guide for battery removal instructions.
Verify the correct batteries are used (CR2025).
Measure the key batteries voltage.
Are the voltages greater than 2.5 volts?
Yes REPLACE the suspect key. PROGRAM the new key.

No REPLACE both key batteries (make sure the batteries are seated correctly). DO NOT reprogram the key (weak or dead
batteries do not erase keys from memory).
Q4 CHECK THE LOCATION OF THE VEHICLE AND THE APPROACH ANGLES AROUND THE VEHICLE
Make sure the poor performance is consistent in nature and is not from one approaching angle.
The RKE transmitter range performance may be degraded in certain locations. For example, if the vehicle or RKE transmitter is within range of
high-power devices, radio/TV towers, 2-way radios, cell phone charger or other radio communication device, the operating distance of the keys may
be reduced.
Is the poor range performance consistent around the vehicle?
Yes INSTALL a new RTM.

REFER to: Radio Transceiver Module (RTM) (419-10 Multifunction Electronic Modules, Removal and Installation).
No The system is operating correctly at this time. The range may have been affected by environmental interference such as
high-power devices or other radio communication device.
The Remote Start Feature Is Inoperative
Possible Cause
Remote start feature not enabled
Passive key
Hood ajar switch input concern
Door ajar switch input concern
TR input concern
Powertrain concern
BCM
Inspect the passive key for damage
PINPOINT TEST R : THE REMOTE START FEATURE IS INOPERATIVE

NOTE: This pinpoint test does not diagnose dealer installed remote start systems.
R1 CHECK THE REMOTE START FEATURE ENABLE/DISABLE SETTING
Ignition ON.
Using the steering wheel control switch, check the remote start feature setting in the message center.
Is the remote start feature enabled?
Yes GO to R2
No ENABLE the remote start feature.
R2 CHECK THE PARK DETECT SWITCH INPUT

Ignition ON.
Verify the PRNDL displays correctly in the IPC. When the vehicle is in PARK, the P should be highlighted or displayed prominently.
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Does the PRNDL display correctly?
Yes GO to R3
No DIAGNOSE the PRNDL display.
REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning
Chimes, Diagnosis and Testing).
R3 CHECK FOR POWERTRAIN DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, perform the PCM KOEO and KOER self-tests.
Are any PCM Diagnostic Trouble Codes (DTCs) present?
Yes REFER to the PCM DTC chart in this section.

No GO to R4
R4 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Yes REFER to the BCM DTC chart in this section.

No GO to R5
R5 CHECK THE RKE (REMOTE KEYLESS ENTRY) FUNCTIONALITY

Ignition OFF.
Using the RKE function of the passive key, press the luggage compartment lid release button twice, the lock button and then the unlock button.
Do all the functions tested of the RKE transmitter operate (lock, unlock and luggage compartment lid latch release)?
Yes GO to R6
No If all of the functions are inoperative, GO to Pinpoint Test O
If an individual function is inoperative, GO to Pinpoint Test P
R6 CHECK THE WAKE-UP CIRCUIT FOR VOLTAGE AT THE PCM (POWERTRAIN CONTROL MODULE) USING THE BCM (BODY CONTROL
MODULE) PID (PARAMETER IDENTIFICATION) (PCM) WAKE-UP OUTPUT CONTROL (PCM_WKUP_CTRL)
Disconnect PCM B connector.
Ignition ON.
Using a diagnostic scan tool, command the BCM PID PCM_WKUP_CTRL on.
Measure:

2.3L GTDI

C1551B-28 Ground

3.7L Duratec

C1381B-65 Ground

5.0L TIVCT

C175B-65 Ground
cardiagn.com
Yes GO to R8
No GO to R7
R7 CHECK THE WAKE-UP CIRCUIT FOR AN OPEN

Ignition OFF.
Measure:

2.3L GTDI

C1551B-28 C2280F-18

3.7L Duratec

C1381B-65 C2280F-18

5.0L TIVCT

C175B-65 C2280F-18
Yes GO to R9
R8 VERIFY THE REMOTE START FUNCTION IS INOPERATIVE

Ignition OFF.
Connect PCM B connector.
Close all the doors, the hood and the liftgate.
NOTE: Each button press must be done within three seconds of each other.
Using the key:
Press the door lock button.
Press the remote start button twice.
Does the vehicle remotely start?
Yes The system is operating correctly. INFORM the customer of the correct vehicle remote start operation.
No REPLACE the passive key in question. PROGRAM the new passive key.
R9 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
cardiagn.com
A Door Passive Entry Feature Is Inoperative

B11C6:01 Passenger Door External Antenna: General Sets when the BCM detects a fault from one of the circuits to the passenger side keyless entry
Electrical Failure antenna (internal to the front passenger exterior door handle).
B11CA:01 Driver Door External Antenna: General Electrical Sets when the BCM detects a fault from one of the circuits to the driver side keyless entry
Failure antenna (internal to the front driver exterior door handle).
B1381:11 Left Front Door Handle Proximity Sensor: Circuit Sets when the BCM detects a fault from one of the circuits to the left front exterior door handle.
Short To Ground
B1381:15 Left Front Door Handle Proximity Sensor: Circuit Sets when the BCM detects a fault from one of the circuits to the left front exterior door handle.
B1381:29 Left Front Door Handle Proximity Sensor: Signal Set when the BCM detects an activated touch sensor for more than 5 minutes.
Invalid
B1382:11 Right Front Door Handle Proximity Sensor: Sets when the BCM detects a fault from one of the circuits to the right exterior door handle.
B1382:15 Right Front Door Handle Proximity Sensor: Sets when the BCM detects a fault from one of the circuits to the right exterior door handle.
Circuit Short To Battery or Open
B1382:29 Right Front Door Handle Proximity Sensor: Signal Set when the BCM detects an activated touch sensor for more than 5 minutes.
Invalid
Possible Cause

Door lock system concern
RKE system concern
Exterior door handle
BCM
Inspect the exterior door handles for damage

PINPOINT TEST S : A DOOR PASSIVE ENTRY FEATURE IS INOPERATIVE
S1 CHECK THE DOOR LOCK OPERATION
Lock and unlock the doors using a door lock control switch.
Yes GO to S2
No GO to Pinpoint Test H
S2 CHECK THE RKE (REMOTE KEYLESS ENTRY) OPERATION

Press the lock and unlock buttons on a key.
Yes GO to S3
No GO to Pinpoint Test O
S3 CHECK THE PASSIVE ENTRY OPERATION FROM ALL DOORS

Operate the passive entry feature from the left door.
Operate the passive entry feature from the right door.
Is the passive entry feature inoperative from all the doors?
Yes GO to S4
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No GO to S7
S4 CHECK THE EXTERIOR DOOR HANDLE GROUND CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Disconnect BCM C2280D.
Ignition ON.
Measure:

C2280D-20 Ground

No GO to S5
S5 CHECK THE EXTERIOR DOOR HANDLE GROUND CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C2280D-20 Ground
Yes GO to S6
S6 CHECK THE EXTERIOR DOOR HANDLE GROUND CIRCUIT FOR AN OPEN (ALL DOORS PASSIVE ENTRY INOPERATIVE)
Disconnect Left Front Exterior Door Handle C543.
Measure:

C543-4 C2280D-20
Yes GO to S16
S7 CHECK FOR VOLTAGE TO THE EXTERIOR DOOR HANDLE

Ignition OFF.
Disconnect suspect exterior door handle.
Measure:

Left Front

C543-1 Ground

Right Front

C634-1 Ground
cardiagn.com
Yes GO to S10
No GO to S8
S8 CHECK THE EXTERIOR DOOR HANDLE VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND
Measure:

Left Front

C543-1 Ground

Right Front

C634-1 Ground
Yes GO to S9
S9 CHECK THE EXTERIOR DOOR HANDLE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Measure:

Left Front

C543-1 C2280D-21
Right Front

C634-1 C2280D-5
Yes GO to S16
S10 CHECK THE EXTERIOR DOOR HANDLE GROUND CIRCUIT FOR AN OPEN
Measure:

Left Front

C543-4 C2280D-20
cardiagn.com
Right Front

C634-4 C2280D-20
Yes GO to S11
S11 CHECK THE EXTERIOR DOOR HANDLE INTERNAL ANTENNA

Measure:

Action
C543, pin 2, component side C543, pin 3, component side

Action
Is the resistance between 1 and 3 ohms?
Yes GO to S12
No INSTALL a new front exterior handle.
REFER to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
cardiagn.com
S12 CHECK THE EXTERIOR DOOR HANDLE
Remove the opposite side exterior door handle.
Transfer the exterior door handle from the opposite side of the vehicle to the suspect exterior door. For example, if the left front exterior door handle is
suspect, transfer the right front exterior door handle to the left front door.
Connect BCM C2280D.
Operate the keyless entry feature from the suspect door.
Does the keyless entry feature operate from the suspect door?
Yes INSTALL a new exterior handle.

No GO to S13
S13 CHECK THE EXTERIOR DOOR HANDLE ANTENNA CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

Left Front

C543-2 Ground
C543-3 Ground

Right Front

C634-2 Ground
C634-3 Ground

No GO to S14
S14 CHECK THE EXTERIOR DOOR HANDLE ANTENNA CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

Left Front

C543-2 Ground
C543-3 Ground

Right Front

C634-2 Ground
C634-3 Ground
Yes GO to S15
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S15 CHECK THE EXTERIOR DOOR HANDLE ANTENNA CIRCUITS FOR AN OPEN
Measure:

Left Front

C543-2 C2280D-13
C543-3 C2280D-28

Right Front

C634-2 C2280D-12
C634-3 C2280D-29
Yes GO to S16
S16 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, Click here to access Guided
Routine (BCM).
The Luggage Compartment Lid Passive Entry Feature Is Inoperative

B10C7:01 Interior Trunk Antenna: General Electrical Failure Sets when the BCM detects a fault from the keyless entry rear antenna input.
Possible Cause

Keyless entry rear antenna
BCM
PINPOINT TEST T : THE LUGGAGE COMPARTMENT LID PASSIVE ENTRY FEATURE IS INOPERATIVE
cardiagn.com
T1 CHECK THE LUGGAGE COMPARTMENT LID RELEASE SWITCH INPUT
Close the luggage compartment lid.
Ignition ON.
Press the luggage compartment lid release button.
Yes GO to T2
T2 CHECK THE RKE (REMOTE KEYLESS ENTRY) OPERATION

Ignition OFF.
Close the luggage compartment lid.
Press the luggage compartment lid release button twice on a valid programmed key.
Yes GO to T3
No GO to Pinpoint Test O
T3 CHECK THE KEYLESS ENTRY REAR ANTENNA

Ignition OFF.
Disconnect Keyless Entry Rear Antenna C4378.
Measure:

Action

Is the resistance between 1 and 3 ohms?
Yes GO to T4
No INSTALL a new keyless entry rear antenna.
REFER to: Keyless Entry Rear Antenna (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
T4 CHECK THE KEYLESS ENTRY REAR ANTENNA CIRCUITS FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C4378-1 Ground
C4378-2 Ground

No GO to T5
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T5 CHECK THE KEYLESS ENTRY REAR ANTENNA CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C4378-1 Ground
C4378-2 Ground
Yes GO to T6
T6 CHECK THE KEYLESS ENTRY REAR ANTENNA CIRCUITS FOR AN OPEN

Measure:

C4378-1 C2280E-16
C4378-2 C2280E-15
Yes GO to T7
T7 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
Routine (BCM).
U0146:00
The RTM communicates with the GWM over the CAN. If the RTM does not receive messages from the GWM, features such as the keyless entry can be
inoperative.
RTM DTC Fault Trigger Conditions

U0146:00 Lost Communication With Gateway "A": No Sub Type Sets when the RTM detects data messages are missing from the GWM over the
Information CAN.
Possible Cause
Network communication concern

RTM
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GWM
PINPOINT TEST U : U0146:00

U1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Yes GO to U2
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.
U2 CHECK THE COMMUNICATION NETWORK

Does the GWM pass the network test?
Yes GO to U3
No
U3 CHECK FOR CHARGING SYSTEM RELATED DIAGNOSTIC TROUBLE CODES (DTCS)

Are any battery voltage or charging system related Diagnostic Trouble Codes (DTCs) retrieved?
Yes DIAGNOSE the charging system. Refer to the appropriate section in Group 414 for the procedure.
No GO to U4
U4 RECHECK THE RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
been performed.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the RTM self-test.
Is DTC U0146:00 still present?
Yes GO to U5
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.
U5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0146 SET IN OTHER MODULES
Ignition OFF.
Ignition ON.
Wait 30 seconds.
Is DTC U0146 set in other modules?
Yes INSTALL a new GWM.

REFER to: Gateway Module A (GWM) (418-00 Module Communications Network, Removal and Installation).
No INSTALL a new RTM.
U0258:87 or U1A00:00
The RTM communicates with the BCM over a LIN circuit and, when the network is awake, over the CAN.
RTM DTC Fault Trigger Conditions
cardiagn.com
U1A00:00 Private Communication Network: No Sub Type Information Sets when the RTM detects a fault with the LIN circuit to the BCM.

U0258:87 Lost Communication With Radio Transceiver: Missing Sets when the BCM detects a communication fault with the RTM over the LIN
Message circuit.
Possible Cause

RTM
BCM
PINPOINT TEST V : U0258:87 OR U1A00:00

V1 CHECK IF THE RTM (RADIO TRANSCEIVER MODULE) AND THE BCM (BODY CONTROL MODULE) PASS THE NETWORK TEST
Ignition ON.
Using a diagnostic tool, perform the network test.
Does the RTM and the BCM pass the network test?
Yes GO to V2
No
V2 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Disconnect RTM C4458.
Measure:

C4458-2 Ground

No GO to V3
V3 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Connect BCM C2280B.
Ignition OFF.
Measure:

C4458-2 Ground
Yes GO to V4
V4 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Measure:

C4458-2 C2280B-26
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Yes GO to V5
V5 CHECK FOR CORRECT RTM (RADIO TRANSCEIVER MODULE) OPERATION

Disconnect and inspect the RTM connector.
Repair:
Reconnect the RTM connector and make sure it seats and latches correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new RTM.
TEST the system for normal operation. If the concern is still present, GO to V6
V6 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
U0140:00
The DDM/ PDM communicates with the BCM over the CAN. If the DDM/ PDM does not receive messages from the BCM, features such as the puddle lamps,
exterior mirror turn signal and door switch illumination can be inoperative.

U0140:00 Lost Communication With Body Control Module: No Sub-Type Sets when the DDM/ PDM detects data messages are missing from the
Information BCM.
Possible Cause

DDM/ PDM
BCM
PINPOINT TEST W : U0140:00

W1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Yes GO to W2
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condition.
W2 CHECK THE COMMUNICATION NETWORK

Does the BCM pass the network test?
Yes GO to W3
No
W3 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Are any voltage related Diagnostic Trouble Codes (DTCs) present?
Yes
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
No GO to W4
W4 RECHECK THE DDM (DRIVER DOOR MODULE) OR PDM (PASSENGER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
been performed.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the DDM/ PDM self-test.
Yes GO to W5
condition.
W5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0140 SET IN OTHER MODULES
Ignition OFF.
Ignition ON.
Wait 30 seconds.

Yes
No INSTALL a new DDM or PDM.
U0208:00
The DDM/ PDM communicate with the DSM over the CAN. If the DDM/ PDM does not receive messages from the DSM, features such as the memory mirror
position can be inoperative.

U0208:00 Lost Communication With "Seat Control Module A": No Sub-Type Sets when the DDM/ PDM detects data messages are missing from the
Information DSM.
Possible Cause

DDM/ PDM
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DSM
PINPOINT TEST X : U0208:00

X1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Yes GO to X2
condition.
X2 CHECK THE COMMUNICATION NETWORK

Does the DSM pass the network test?
Yes GO to X3
No
X3 CHECK FOR DSM (DRIVER FRONT SEAT MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Are any voltage related Diagnostic Trouble Codes (DTCs) present?
Yes
No GO to X4
X4 RECHECK THE DDM (DRIVER DOOR MODULE) OR PDM (PASSENGER DOOR MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
been performed.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) and repeat the DDM/ PDM self-test.
Yes GO to X5
condition.
X5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0208 SET IN OTHER MODULES
Ignition OFF.
Ignition ON.
Wait 30 seconds.

No INSTALL a new DDM or PDM.
P1594 OR P1595
When the BCM receives a request to remote start the vehicle, it first checks to make sure conditions exist to allow it to start (for example, the hood and doors
closed, vehicle in PARK, no powertrain concerns). If the required conditions are correct, the BCM starts the vehicle and allows it to run for a predetermined
amount of time, determined by the setting selected from the message center.
PCM DTC Fault Trigger Conditions
cardiagn.com
P1594 Forced Engine Shutdown - Remote Start System Fault, No Unattended Sets when the PCM detects the remote start has been active for more than
Vehicle Timeout 30 minutes continuously.
P1595 Forced Engine Shutdown - Remote Start System Fault, Transmission Sets when the PCM detects the remote start is active with the transmission
Range Not In Park Position not in PARK.
Possible Cause

Powertrain concern
BCM
PINPOINT TEST Y : P1594 OR P1595

Y1 CHECK FOR OTHER PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Review the results from the PCM self-test.
Are any other PCM Diagnostic Trouble Codes (DTCs) present?
Yes DIAGNOSE all other PCM Diagnostic Trouble Codes (DTCs) first. Refer to the appropriate section in Group 303 for the
procedure.
No GO to Y2
Y2 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Yes REFER to the BCM DTC Chart in this section.

No GO to Y3
Y3 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
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Door Latch Lubrication
Materials
Name Specification
Motorcraft® Multi-Purpose Grease Spray ESB-M1C93-B
XL-5-A
Activation
NOTE: Typical left front door shown, others similar.
1. Open the door.
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2. Using a flat blade screwdriver, fully close the latch (2 clicks).
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3. NOTICE: Do not over-lubricate the latch. Using excessive grease may damage the internal lock
motor.
Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using the exterior door handle.

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5. Open and close the door several times to circulate the lubricant inside the latch.
6. Open the door.

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7. Wipe off any excess grease.

Staged Unlock Programming
Programming
injury.
2. With the ignition in OFF, press the lock and unlock buttons on the RKE transmitter simultaneously for 4
seconds.
3. The turn signals flash twice to indicate the mode change.
4. Repeat Step 2 to enable/disable the staged unlocking feature.
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Luggage Compartment Lid Lock Cylinder - Convertible
Removal

2.
Detach the luggage compartment lid latch cable.
1. Release the luggage compartment lid lock cylinder retaining tabs.
2. Detach the luggage compartment lid latch cable.
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3.
Remove the luggage compartment lid lock cylinder.
1. Remove the luggage compartment lid lock cylinder retaining clip.
2. Remove the luggage compartment lid lock cylinder.
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Installation

Luggage Compartment Lid Release Switch
Removal
1.
Remove the luggage compartment lid release switch.
1. Release the luggage compartment lid release switch from the bumper cover.
2. Disconnect the electrical connector and remove the luggage compartment lid release switch.
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Installation

Door Lock Control Switch
Removal

2.
Remove the door lock control switch.
1. Release the retaining clips.
2. Remove the door lock control switch.
Installation
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Door Lock Cylinder
Removal
1. Remove the grommet.
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2. Remove the lock cylinder door handle cover.
1. Turn the release screw 8 turns. The handle will release around 6 to 6.5 turns. You must continue to
the full 8 revolutions for installation.
2. Remove the lock cylinder and the door handle cover assembly from the front door.
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3. Remove the door lock cylinder.
Installation

Exterior Front Door Handle
Removal

3. Remove the grommet. cardiagn.com

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4. Remove the lock cylinder door handle cover.
1. Hold the front door handle open.
2. Turn the release screw 8 turns. The handle will release around 6 to 6.5 turns. You must continue to
the full 8 revolutions for installation.
3. Remove the lock cylinder and door handle cover assembly from front door.
5. NOTICE: Do not pull the door handle out of the door too far without disconnecting the handle from
the connector. Damage to the harness will occur.
Disconnect the exterior front door handle connector from the handle from inside the door and remove the
exterior front door handle.
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Installation
1. Connect the exterior front door handle connector to the handle from inside the door and partially install the
front door handle in the front door opening.
2. Install the lock cylinder door handle cover.

1. Install the lock cylinder and door handle cover assembly to the front door.
2. Release the front door handle.
3. Apply light pressure to the front door handle while turning the release screw 8 turns. The handle will
engage and go in around 6 to 6.5 turns. You must continue to the full 8 revolutions for installation
then torque to the specified value.
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3. Install the grommet.
4. Install the front door lower watershield.

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5. Install the front door trim panel.

Exterior Front Door Handle Reinforcement
Removal
1. Remove the front door latch.

Refer to: Front Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
2. NOTE: This step only necessary when installing a new component.
Remove the exterior front door handle reinforcement.
Installation

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Front Door Latch
Removal

2. Remove the exterior front door handle.

Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and
Installation).
3. Remove the aft front door glass run.
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Refer to: Front Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
4.
Position aside the front door window regulator.
2. Position aside the rear portion of the front door window regulator.
5. Remove the exterior door handle reinforcement screw.

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6. Remove the front door latch bolts.

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8.
Remove the front door latch.
1. Route the interior front door handle cable through the door.
2. Remove the front door latch.
Remove the interior front door handle cable from the front door latch.
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Remove the exterior front door handle reinforcement.

1. Tighten the screw releasing the tension on the cable.
2. Detach and position aside the cable from the exterior front door handle reinforcement.
Remove the front door latch.

2. Detach and position aside the cable from the front door latch.
3. Detach the rod and remove the front door latch.
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Installation

Hood Latch
Removal
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2.
Remove the hood latch.
1. Mark the hood latch nuts for reference.
2. Remove the hood latch nuts.
3. Disconnect the hood ajar switch electrical connector.
4. Disconnect the hood latch release cable from the hood latch and remove the hood latch.
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Installation
1.
Install the hood latch.
1. Install the hood latch and connect the hood latch release cable.
2. Connect the hood ajar switch electrical connector.
3. Finger tighten the nuts at this stage.
2. Position the hood latch to the marked reference points and tighten the hood latch nuts.
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3. Install the radiator sight shield and the retainers.

Hood Latch Release Cable
Removal
1. If equipped, remove DSP.

Refer to: Audio Digital Signal Processing (DSP) Module (415-00B Information and Entertainment System - General
Information - Vehicles With: Touchscreen Display, Removal and Installation).
2. Remove the driver door scuff plate.

3. NOTE: Insert a 10mm 1/4 inch drive socket to release the clips.
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Remove the hood latch release handle.
1. Remove the hood latch release handle access cover.
2. Release the clips releasing the hood latch release handle.
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4. Release the clips and remove the LH cowl trim panel.
5.
Remove the hood latch release.
1. Disconnect the hood latch release cable.
2. Remove the bolts and the hood latch release.
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6.
Route the hood latch release cable through the cowl.
1. Release the routing cable clips.
2. Route the hood latch release cable through the cowl.
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8.
Remove the hood latch release cable.
1. Remove the grommet.
2. Remove the clips and position aside the hood latch release cable.
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9.
Remove the hood latch release cable.
1. Release the hood latch release cable from the routing bracket.
2. Disconnect the cable end and remove the hood latch release cable.
Installation

Hood Latch Release Handle
Removal
1. NOTE: Insert a 10 mm 1/4 inch drive socket to release the clips.
Remove the hood latch release handle.

1. Remove the hood latch release handle access cover.
2. Release the clips releasing the hood latch release handle.
Installation

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Interior Front Door Handle
Removal

2.
Remove the interior front door handle.
2. Remove the interior front door handle.

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Remove the door lock control switch.
2. Remove the door lock control switch.
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Installation

Keyless Entry Rear Antenna
Removal
1. Open the luggage compartment lid.
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2.
Remove the luggage compartment scuff plate.
1. Remove the thumb nut type retainers.
2. Remove the luggage compartment scuff plate.
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3. NOTE: Luggage compartment lid removed for clarity.
Remove the keyless entry rear antenna.

1. Disconnect the keyless entry rear antenna electrical connector.
2. Remove the retainers and the keyless entry rear antenna.
Installation

Luggage Compartment Lid Latch - Coupe
Removal
1.
Remove the luggage compartment lid trim panel.
2. Remove the bump stops and the luggage compartment lid trim panel.
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2.
Remove the luggage compartment lid latch.
1. Disconnect the electrical connector and position aside the wiring harness.
2. Remove the nuts and the luggage compartment lid latch.
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Installation

Luggage Compartment Lid Latch - Convertible
Removal
1. Remove the luggage compartment lid lock cylinder.

Refer to: Luggage Compartment Lid Lock Cylinder - Convertible (501-14 Handles, Locks, Latches and
Entry Systems, Removal and Installation).
2.
Remove the luggage compartment lid trim panel.
2. Remove the bump stops and the luggage compartment lid trim panel.
3.
Route the luggage compartment lid latch cable.
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1. Remove the retainer.
2. Position aside the load compartment trim panel.
4. Route the luggage compartment lid latch cable through the load compartment trim panel.
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4.
Remove the luggage compartment lid latch.
1. Disconnect the electrical connector and position aside the wiring harness.
2. Unlock the luggage compartment lid latch cable from the clips.
3. Remove the nuts and the luggage compartment lid latch.
Installation

501-16 Wipers and Washers 2016 Mustang
Wipers and Washers - Overview
Overview
The windshield wiper/washer system is activated by the wiper/washer switch. The following functions/features of
the windshield wiper/washer system are:
Mist wipe
Windshield wash
Courtesy wipe
Windshield wipers (low/high speed)
Intermittent wipers
Speed dependent wipers
Wiper activated exterior lamps
Rain sensitive wipers (if equipped)
There are 6 intermittent/sensitivity settings to choose from for the intermittent/rain sensitive wipers.
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Wipers and Washers - System Operation and Component Description
System Operation
System Diagram
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SCCM Network Input Messages

Module
Vehicle speed PCM The SCCM uses vehicle speed information for the operation of the
speed sensitive wiper function.
Message center feature IPC The SCCM uses the message center feature configuration to
configuration enable/disable the courtesy wipe and the rain sensitive wiper
features.

Message Module
Front wiper SCCM The BCM uses the wiper status information for the operation of the wiper
status activated headlamps feature.
Windshield Wipers
The wiper relay is energized when the ignition is on and provides voltage to the windshield wiper motor and the
rain sensor.
The SCCM monitors the wiper/washer switch inputs and sends the wiper/washer switch data to the windshield
wiper motor through a LIN circuit.
Based on the input, the windshield wiper motor activates the appropriate wash, low, high and intermittent or rain
sense modes. The logic of the wiper operation is contained within the windshield wiper motor.
When the wiper/washer switch is in the high speed setting, the windshield wiper motor also receives a ground
signal directly from the SCCM, bypassing the logic within the windshield wiper motor module. This fail-safe circuit
makes sure the windshield wipers function in high speed mode in the event of a LIN communication failure.
Mist Wipe
When the mist wipe function is activated, the SCCM sends the request to the windshield wiper motor over the LIN
to perform a single wipe of the windshield. The windshield wipers operate for as long as the mist wipe function is
active.
Windshield Washer
When the windshield washer switch is activated, the SCCM sends the washer request to the windshield wiper
motor over the LIN. The windshield wash relay is internal to the windshield wiper motor. When the windshield
wiper motor activates the windshield wash relay, voltage is provided to the washer pump, directing washer solvent
to the windshield. When the switch is released, the windshield wiper motor continues to activate for 3 additional
wipes and then turn off.
Courtesy Wipe
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When the windshield washer is requested, a few seconds after the windshield wash cycle has completed, an
additional wipe of the windshield occurs to clear any washer solvent remaining on the windshield.
The courtesy wipe feature can be configured on/off using the message center.
Intermittent Wipers
When the wiper/washer switch is in an intermittent setting, the windshield wiper motor activates at timed intervals.
The lower the setting, the longer the interval between wipes.
Speed Dependent Wipers
When the wiper/washer switch is in an intermittent setting, the speed dependent feature increases the frequency
of wiping as the vehicle speed increases to compensate for the extra moisture that accumulates on the
windshield.
The SCCM receives the vehicle speed from the PCM. The SCCM then sends the vehicle speed data to the
windshield wiper motor through the LIN.
Rain Sensitive Wipers (if equipped)
When equipped, the rain sensitive wiper feature replaces the intermittent wiper feature. The rain sensitive feature
is active when the wiper/washer switch is in any of the 6 auto/intermittent sensitivity settings. The setting closest
to OFF is the least sensitive to moisture, the highest setting being the most sensitive to moisture.
The rain sensor sends data through the LIN to the windshield wiper motor. Based on the data received from the
rain sensor and the auto/intermittent setting from the wiper/washer switch, the system automatically activates and
adjusts the wiper speed and frequency when moisture is detected on the windshield.
If a fault is detected with the rain sensitive feature, the windshield wipers change to a default intermittent mode.
The timing of the wipers correspond to a standard intermittent setting based on the auto/intermittent sensitivity
setting on the wiper/washer switch.
Wiper Activated Exterior Lamps
When the headlamp switch is set to AUTO, the BCM turns the exterior lamps on within 10 seconds of the
windshield wipers being activated by the wiper/washer switch. Approximately 60 seconds after the windshield
wipers turn off, the BCM turns the exterior lamps off.
If the rain sensitive wipers are activated by moisture detected on the windshield when the headlamp switch is in
the AUTO position, the BCM turns the exterior lamps on after a time delay. Shortly after the rain sensitive wipers
are deactivated (moisture no longer detected on the windshield), the BCM turns the exterior lamps off after a time
delay.
Wiper/Washer Switch
The wiper/washer switch is mounted directly to the SCCM. The windshield wiper/washer inputs to the SCCM are:
Mist wipe
Windshield wash
Off
AUTO 1/INT 1
AUTO 2/INT 2
AUTO 3/INT 3
AUTO 4/INT 4
AUTO 5/INT 5
AUTO 6/INT 6
Low
High
Windshield Wiper Motor
The windshield wiper motor contains a logic module, internal sensors to monitor the wiper arm position, and a
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multi-speed motor. The logic module from the windshield wiper motor continuously monitors the wiper/washer
switch inputs from the SCCM and the rain sensor when the ignition is on. Depending on the input, the wiper motor
activates to achieve the desired request.
The windshield wiper motor is mounted to the wiper and linkage assembly.
Washer Pump
The washer pump is controlled by the windshield wiper motor. The washer pump delivers washer solvent to the
windshield when the windshield wiper motor activates the windshield washer relay (internal to the windshield wiper
motor), which provides voltage to the washer pump. When activated, the washer pump delivers washer solvent to
the windshield.
Rain Sensor
The rain sensor uses an infrared beam to optically sense moisture on the windshield. The intensity of the reflected
beam is measured and compared to the intensity of the transmitted beam. If there is water on the surface of the
windshield the beam distorts, reducing the intensity of the beam. If the beam is not reflected completely, it is
interpreted as rain on the windshield and the windshield wipers are activated.
A gel-type lens is used as the interface between the rain sensor and the windshield. If the lens is missing or
damaged, the rain sensing wipers can be inoperative. The rain sensor gel-type lens cannot be replaced
separately on a rain sensor of this type.

Wipers and Washers
DTC Chart: BCM
BCM DTC Chart

B130F:12 Run Accessory Control: Circuit GO to Pinpoint Test A
Short To Battery
B130F:14 Run Accessory Control: Circuit If the windshield wipers are inoperative, GO to
Short To Ground or Open Pinpoint Test A
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If the windshield wipers operate with the ignition
off, GO to Pinpoint Test D

Trouble Codes (DTCs) REFER to: Body Control Module (BCM) (419-10
Multifunction Electronic Modules, Diagnosis and
Testing).
DTC Chart: SCCM
SCCM DTC Chart

B1008:09 Wiper Mode Switch: INSTALL a new wiper/washer switch.
Component Failure REFER to: Steering Column Multifunction Switch RH
(211-05 Steering Wheel and Column Electrical
Components, Removal and Installation).
CLEAR the DTC and repeat the self-test. If DTC
B1008:09 is retrieved again, INSTALL a new SCCM.
REFER to: Steering Column Control Module (SCCM)
B1051:09 Front Washer Switch: INSTALL a new wiper/washer switch.

B10AD:02 Rain Sensor: General Signal GO to Pinpoint Test F

Failure
B10AD:08 Rain Sensor: Bus Signal / GO to Pinpoint Test F
Message Failure
B10AD:49 Rain Sensor: Internal INSTALL a new rain sensor.
Electronic Failure REFER to: Rain Sensor (501-16 Wipers and Washers,
B10AD:55 Rain Sensor: Not Configured CARRY OUT the PMI for the SCCM using As-Built data.
B1131:02 Wiper motor module: If the wipers are inoperative, or no symptom is
General Signal Failure present, GO to Pinpoint Test A
If the wipers are always on, GO to Pinpoint Test D
B1131:08 Wiper motor module: Bus GO to Pinpoint Test B

Signal / Message Failure
B1131:11 Wiper motor module: Circuit GO to Pinpoint Test B
Short To Ground
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B1131:49 Wiper motor module: Internal INSTALL a new windshield wiper motor.
Electronic Failure REFER to: Windshield Wiper Motor - LHD (501-16 Wipers
and Washers, Removal and Installation).
B1131:55 Wiper motor module: Not CARRY OUT the PMI for the SCCM using As-Built data.
Configured
B1131:9A Wiper motor module: DIAGNOSE the symptom present with the wiper/washer
Component or System system. REFER to the Symptom Chart in this section.
Operating Conditions
B12F7:09 Single Wipe Switch: INSTALL a new wiper/washer switch.

Trouble Codes REFER to: Steering Wheel and Column Electrical
(DTCs) Components (211-05 Steering Wheel and Column Electrical
Components, Diagnosis and Testing).
Symptom Chart
Symptom Chart: Wiper and Washer
Symptom Chart

All windshield wiper modes are inoperative Refer to the GO to Pinpoint
Pinpoint Test Test A
The intermittent and/or low speed windshield wipers are Refer to the GO to Pinpoint
inoperative Pinpoint Test Test B
The high speed windshield wipers are inoperative Refer to the GO to Pinpoint
Pinpoint Test Test C
The windshield wipers stay on continuously Refer to the GO to Pinpoint

Pinpoint Test Test D
The windshield wipers do not operate correctly in the Refer to the GO to Pinpoint
intermittent mode Pinpoint Test Test E
The rain sensitive wiper feature is inoperative Refer to the GO to Pinpoint

Pinpoint Test Test F
The rain sensitive wipers have erratic/inconsistent Refer to the GO to Pinpoint

operation Pinpoint Test Test F
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The rain sensitive wipers are too sensitive/not sensitive Refer to the GO to Pinpoint
enough to moisture Pinpoint Test Test F
The windshield wipers do not park at the correct position Refer to the GO to Pinpoint
Pinpoint Test Test G
The windshield washer is inoperative Refer to the GO to Pinpoint

Pinpoint Test Test H
The windshield washer is always on Refer to the GO to Pinpoint

Pinpoint Test Test I
Pinpoint Tests
All Windshield Wiper Modes Are Inoperative
REFER to: Wipers and Washers - System Operation and Component Description (501-16 Wipers and Washers,

B130F:12 Run Accessory Control: Circuit Short To Sets when the BCM detects a short to voltage from the
Battery wiper relay control circuit.
B130F:14 Run Accessory Control: Circuit Short To Sets when the BCM detects an open from the wiper relay
Ground or Open control circuit.
SCCM DTC Fault Trigger Conditions

B1131:02 Wiper motor module: Sets when the input to the windshield wiper motor from the fail-safe
General Signal Failure circuit does not match the requested input from the SCCM.
Possible Causes
Fuse
Wiper relay
Windshield wiper motor
SCCM
BCM
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Inspect BJB fuse 26 (25A)
PINPOINT TEST A : ALL WINDSHIELD WIPER MODES ARE INOPERATIVE

probe adapter(s) may damage the connector.
A1 CHECK FOR BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B130F:12,
B130F:14 OR SCCM (STEERING COLUMN CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE
CODE) B1131:02
Ignition ON.
Using a diagnostic scan tool, carry out the SCCM self-test.
Is DTC B130F:12, B130F:14 or B1131:02 present?
Yes For DTC B130F:12, GO to A2

For DTC B130F:14, GO to A4
For DTC B1131:02, GO to A12
No GO to A7
A2 CHECK THE WIPER RELAY (DTC (DIAGNOSTIC TROUBLE CODE) B130F:12)

Ignition OFF.
Disconnect Wiper Relay.
Substitute a known good relay.
Ignition ON.
Using a diagnostic scan tool, clear the DTC and repeat the BCM self-test.
Yes REMOVE the known good relay. GO to A3

No REMOVE the known good relay. INSTALL a new windshield wiper relay.
A3 CHECK THE WIPER RELAY CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:
Positive Lead Measurement / Negative

Action Lead
Ground
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Wiper relay, cavity 2

No GO to A16
A4 CHECK THE WIPER RELAY (DTC (DIAGNOSTIC TROUBLE CODE) B130F:14)

Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, clear the DTC and repeat the BCM self-test.
Yes REMOVE the known good relay. GO to A5

No REMOVE the known good relay. INSTALL a new windshield wiper relay.
A5 CHECK THE WINDSHIELD WIPER RELAY COIL VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

Action Lead
Action Lead
Ground
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Yes GO to A6
No VERIFY the BJB fuse 26 (25A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the
Wiring Diagrams Manual to identify the possible cause of the circuit short.
A6 CHECK THE WIPER RELAY CONTROL CIRCUIT FOR AN OPEN

Measure:

Action Lead
C2280F-24

Yes GO to A16
A7 CHECK THE INPUT TO THE SCCM (STEERING COLUMN CONTROL MODULE)

Using a diagnostic scan tool, view the SCCM Parameter Identifications (PIDs).
Using a diagnostic scan tool, view the following SCCM wiper/washer switch Parameter Identifications
(PIDs):
WIPE_SINGLE
F_WASH_SW
F_WIP_INT_D1
F_WIP_INT_D2
F_WIP_INT_D3
F_WIP_INT_D4
F_WIP_INT_D5
F_WIP_INT_D6
F_WIP_SLO_SW
F_WIPE_FAST_SW
Cycle the wiper/washer switch from off to the high speed setting and then back to off.
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Do the Parameter Identifications (PIDs) correspond correctly with each setting selection?
Yes GO to A8
No INSTALL a new wiper/washer switch.
REFER to: Steering Column Multifunction Switch RH (211-05 Steering Wheel and Column
TEST the system for normal operation. If the concern is still present, INSTALL a new
SCCM.
A8 CHECK FOR VOLTAGE TO THE WINDSHIELD WIPER MOTOR

Ignition OFF.
Disconnect Windshield Wiper Motor C1656.
Ignition ON.
Measure:

C1656-8 Ground
Yes GO to A11
No GO to A9
A9 CHECK THE WIPER RELAY VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Ignition OFF.
Measure:

Action Lead
Ground
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Yes GO to A10
A10 CHECK FOR THE WINDSHIELD WIPER MOTOR VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Measure:

Action Lead
C1656-8

Yes INSTALL a new wiper relay.

A11 CHECK THE WINDSHIELD WIPER MOTOR GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C1656-8 C1656-6
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Yes GO to A12
A12 CHECK THE FAIL-SAFE HIGH SPEED WIPER GROUND CIRCUIT CONTROL
NOTICE: This pinpoint test step uses a test lamp to simulate normal circuit loads. Use only a
Rotunda Test Lamp (SGT27000) or 250-300mA incandescent bulb test lamp. To avoid connector
Ignition OFF.
Disconnect Windshield Wiper Motor C1656 (if not previously disconnected).
Connect:

C1656-8 C1656-1
Ignition ON.
Place the wiper/washer switch to the high speed setting and then off.
Ignition OFF.
Does the test lamp illuminate when the wiper washer switch is in the high speed setting?
Yes GO to A14
No GO to A13
A13 CHECK THE FAIL-SAFE HIGH SPEED WIPER GROUND CIRCUIT FOR AN OPEN
NOTE: If steps A2-A12 did not identify the cause of the concern, a double fault may be present. After the
fail-safe ground is diagnosed and repaired, it is necessary to check all operation modes and diagnose any
symptom still present.
Disconnect SCCM C226A.
Measure:

C1656-1 C226A-2
Yes INSTALL a new wiper/washer switch.

TEST the system for normal operation. If the concern is still present, GO to A15
A14 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR OPERATION
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Disconnect and inspect the windshield wiper motor connector.
Repair:
corrosion (install new connector or terminal - clean module pins)
Reconnect the windshield wiper motor connector. Make sure it seats and latches correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new windshield wiper motor.
REFER to: Windshield Wiper Motor - LHD (501-16 Wipers and Washers, Removal and
Installation).
No The system is operating correctly at this time. The concern may have been caused by a
loose or corroded connector. ADDRESS the root cause of any connector or pin issues.
A15 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION
Disconnect and inspect all the SCCM connectors:
Repair:
Reconnect the SCCM connectors. Make sure they seat and latch correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new SCCM.
Disconnect and inspect all the BCM connectors:
Repair:
Yes
The Intermittent And/Or Low Speed Windshield Wipers Are Inoperative
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B1131:08 Wiper motor module: Bus Signal / Sets when the SCCM detects a communication fault with the
Message Failure windshield wiper motor over the LIN.
B1131:11 Wiper motor module: Circuit Short Sets when the SCCM detects a short to ground from the
to Ground windshield wiper motor LIN circuit.
Possible Causes

Wiper/washer switch
Rain sensor
SCCM
Inspect the wiper/washer switch for damage
PINPOINT TEST B : THE INTERMITTENT AND/OR LOW SPEED WINDSHIELD WIPERS ARE
INOPERATIVE
NOTE: It may be necessary to disconnect and then reconnect the battery after the repair to enable the
wiper operation.
B1 CHECK THE HIGH SPEED WIPER OPERATION
Ignition ON.
Place the wiper/washer switch to the high speed setting and observe the windshield wipers. Place the
wiper/washer switch to the off setting.
Do the windshield wipers operate with the wiper/washer switch in the high speed setting?
Yes GO to B2
B2 CHECK THE LOW SPEED WIPER OPERATION

Place the wiper/washer switch to the low speed setting and observe the windshield wipers. Place the
Do the windshield wipers operate with the wiper/washer switch in the low speed setting?
Yes If not equipped with a rain sensor, GO to Pinpoint Test E
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If equipped with a rain sensor, GO to Pinpoint Test F
No GO to B3
B3 CHECK THE INPUT TO THE SCCM (STEERING COLUMN CONTROL MODULE)

Using a diagnostic scan tool, view the SCCM F_WIP_SLO_SW PID.
Place the wiper/washer switch to the low speed setting.
Does the PID indicate the wiper/washer switch is in the low speed setting?
Yes If equipped with a rain sensor, GO to B4

If not equipped with a rain sensor, GO to B5
SCCM.
B4 ISOLATE THE RAIN SENSOR

Ignition OFF.
Disconnect Rain Sensor C914.
Ignition ON.
Do the windshield wipers operate with the wiper/washer switch in the low speed setting?
Yes INSTALL a new rain sensor.

REFER to: Rain Sensor (501-16 Wipers and Washers, Removal and Installation).
No GO to B5
B5 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C1656-4 Ground
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No GO to B6
B6 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C1656-4 Ground
Yes GO to B7
B7 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Measure:

C1656-4 C226A-8
Yes GO to B8
B8 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR OPERATION
Repair:
Installation).
TEST the system for normal operation. If the concern is still present, GO to B9
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B9 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION
Disconnect and inspect all the SCCM connectors.
Repair:
The High Speed Windshield Wipers Are Inoperative
Possible Causes

Wiper/washer switch
SCCM
PINPOINT TEST C : THE HIGH SPEED WINDSHIELD WIPERS ARE INOPERATIVE
C1 CHECK THE INPUT TO THE SCCM (STEERING COLUMN CONTROL MODULE)
Ignition ON.
Using a diagnostic scan tool, view the SCCM F_WIPE_FAST_SW PID.
Place the wiper/washer switch to the high speed setting.
Does the PID indicate the wiper/washer switch is in the high speed setting?
Yes INSTALL a new windshield wiper motor.

Installation).
SCCM.
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The Windshield Wipers Stay On Continuously

B130F:14 Run Accessory Control: Circuit Short To Sets when the BCM detects a short to ground from the
Ground or Open wiper relay control circuit.

B1131:02 Wiper Motor Module: Sets when the input to the windshield wiper motor from the fail-safe
General Signal Failure circuit does not match the requested input from the SCCM.
Possible Causes

Wiper/washer switch
Wiper relay
SCCM
BCM
PINPOINT TEST D : THE WINDSHIELD WIPERS STAY ON CONTINUOUSLY

D1 CHECK THE WINDSHIELD WIPER OPERATION WITH THE IGNITION OFF
Ignition OFF.
Observe the windshield wiper operation.
Do the windshield wipers operate with the ignition off?
Yes GO to D5
No GO to D2
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D2 CHECK THE WIPER/WASHER SWITCH INPUT
Ignition ON.
Make sure the wiper/washer switch is in the off setting.
(PIDs):
WIPE_SINGLE
F_WASH_SW
F_WIP_INT_D1
F_WIP_INT_D2
F_WIP_INT_D3
F_WIP_INT_D4
F_WIP_INT_D5
F_WIP_INT_D6
F_WIP_SLO_SW
F_WIPE_FAST_SW
Do all of the Parameter Identifications (PIDs) indicate the wipers should be off?
Yes GO to D3
SCCM.
D3 CHECK THE WINDSHIELD WIPER OPERATION WITH THE SCCM (STEERING COLUMN
CONTROL MODULE) DISCONNECTED
Ignition OFF.
Ignition ON.
Do the windshield wipers continue to operate?
Yes GO to D4
TEST the system for normal operation. If the concern is still present, GO to D9
D4 CHECK THE HIGH SPEED FAIL-SAFE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C1656-1 Ground
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Yes GO to D8
D5 CHECK FOR BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B130F:14
Ignition ON.
Is DTC B130F:14 present?
Yes GO to D6
No GO to D7
D6 CHECK THE WIPER RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

Action Lead
Action Lead
Ground
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Yes GO to D10
D7 CHECK THE WINDSHIELD WIPER MOTOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO
VOLTAGE
Does the windshield wiper motor continue to operate?

No INSTALL a new wiper relay.
D8 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR OPERATION

Repair:
Installation).
D9 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION

Repair:
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D10 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
Yes
The Windshield Wipers Do Not Operate Correctly In The Intermittent Mode
Possible Causes
Wiper/washer switch
SCCM

PINPOINT TEST E : THE WINDSHIELD WIPERS DO NOT OPERATE CORRECTLY IN THE

INTERMITTENT MODE
E1 VERIFY IF THE VEHICLE IS EQUIPPED WITH A RAIN SENSOR
Inspect the vehicle for a rain sensor.
Is the vehicle equipped with a rain sensor?
Yes GO to E2
No GO to E3
E2 VERIFY THE RAIN SENSITIVE WIPER FEATURE IS DISABLED IN THE VEHICLE MESSAGE
CENTER
Ignition ON.
Access the vehicle settings in the message center using the steering wheel controls and check the rain
sensitive feature setting.
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Is the rain sensitive feature enabled?
Yes DISABLE the rain sensitive feature. INFORM the customer how to disable the rain
sensitive feature, activating the intermittent setting.
No GO to E3
E3 CHECK THE LOW SPEED WIPER OPERATION

Ignition ON.
Do the low speed wipers operate when the low speed setting is selected?
Yes GO to E4
No GO to Pinpoint Test B
E4 CHECK THE INPUT FROM THE WIPER/WASHER SWITCH

(PIDs):
F_WIP_INT_D1
F_WIP_INT_D2
F_WIP_INT_D3
F_WIP_INT_D4
F_WIP_INT_D5
F_WIP_INT_D6
Cycle the wiper/washer switch from off through each of the intermittent settings.

Installation).
SCCM.
The Rain Sensitive Wiper Feature Is Inoperative Or Does Not Operate Correctly
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B10AD:02 Rain Sensor: General Signal Failure Sets when the SCCM detects a communication fault with the
rain sensor.
B10AD:08 Rain Sensor: Bus Signal / Message Sets when the SCCM detects a communication fault with the
Failure rain sensor.
Possible Causes
Fuse
Rain sensitive feature not enabled
Foreign material on windshield, such as dirt, dust or bugs
Wiper blades
Windshield glass
Wiper/washer switch
Rain sensor
SCCM
Inspect the windshield for damage

Inspect the rain sensor mounting for damage
Inspect BJB fuse 72 (5A)
PINPOINT TEST F : THE RAIN SENSITIVE WIPER FEATURE IS INOPERATIVE OR DOES NOT
OPERATE CORRECTLY
F1 CHECK THE LOW SPEED WIPER OPERATION
Do the low speed wipers operate when the low speed setting is selected?
Yes GO to F2
F2 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B10AD:02 OR B10AD:08

Yes For DTC B10AD:02 or B10AD:08, GO to F11

For all other Diagnostic Trouble Codes (DTCs), REFER to the SCCM DTC Chart in this
section.
No GO to F3
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F3 VERIFY THE RAIN SENSITIVE WIPER FEATURE IS ENABLED IN THE VEHICLE MESSAGE
CENTER
Access the vehicle settings in the message center using the steering wheel controls. Check the rain
sensitive feature setting.
Is the rain sensitive feature enabled?
Yes GO to F4
No ENABLE the rain sensitive feature. INFORM the customer how to enable/disable the rain
sensitive feature.
F4 CHECK THE INPUT FROM THE WIPER/WASHER SWITCH

Using a diagnostic scan tool, monitor the following SCCM wiper/washer switch Parameter Identifications
(PIDs):
F_WIP_INT_D1
F_WIP_INT_D2
F_WIP_INT_D3
F_WIP_INT_D4
F_WIP_INT_D5
F_WIP_INT_D6
Cycle the wiper/washer switch from off through each of the auto/intermittent sensitivity settings.
Yes GO to F5
SCCM.
F5 CHECK THE WINDSHIELD FOR DAMAGE
Ignition OFF.
Inspect the windshield glass for any cracks, pits or other visible damage around the area of the rain
sensor.
Is any windshield damage present near the area of the rain sensor?
Yes INSTALL a new windshield.

REFER to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
No GO to F6
F6 CHECK THE WINDSHIELD GLASS FOR STREAKING

Ignition ON.
Turn the wiper/washer switch to the low speed wiper setting and while applying water to the windshield
surface. Observe the wipe quality, especially around the area of the rain sensor.
Is any streaking present on the windshield around the area of the rain sensor?
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Yes GO to F7
No GO to F9
F7 CHECK THE WINDSHIELD WIPER BLADES FOR STREAKING

Ignition OFF.
Clean the windshield glass with glass cleaner.
Clean the wiper blades with isopropyl alcohol swabs. Wipe the entire length of the wiper blades.
Ignition ON.
Place the wiper/washer switch to the low speed wiper setting and while applying water to the windshield
surface. Observe the wipe quality, especially around the area of the rain sensor.
Was there noticeable improvement in the wipe quality after cleaning the glass and the wiper
blades?
Yes GO to F8
No INSTALL new wiper blades. GO to F8
F8 RECHECK THE RAIN SENSITIVE WIPERS OPERATION

Place the wiper/washer switch to the auto/intermittent 5 setting (most sensitive to moisture) while
applying water on the windshield above the rain sensor.
Do the wipers operate when water is applied to the windshield surface?
Yes The system is operating correctly at this time. The concern may have been caused by
poor wipe quality on the windshield around the rain sensor.
No GO to F9
F9 CHECK FOR THE PRESENCE OF THE LENS GEL

Ignition OFF.
Lightly press the rain sensor against the windshield and release the rain sensor clips.
Does the rain sensor remain adhered to the windshield?
Yes ATTACH the retaining clips. GO to F10

No The sensor gel-type lens is missing or damaged. INSTALL a new rain sensor.
F10 INSPECT THE RAIN SENSOR MOUNTING AREA
NOTE: The rain sensor gel-type lens can be damaged or contaminated during rain sensor removal, rain
sensor bracket separation or incorrect installation.
From the outside of the vehicle, inspect the area of the windshield glass where the rain sensor is
mounted. The rain sensor contact area should appear black, with no bubbles, air pockets or contaminants
between the windshield glass and the rain sensor.
Does the rain sensor contact area appear black, with no bubbles, air pockets or contaminants
between the windshield glass and the rain sensor?
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Yes GO to F11
No REMOVE the rain sensor.
CLEAN the mating surfaces between the windshield glass and the rain sensor. INSTALL
the rain sensor correctly. TEST the system for normal operation. If the concern is still
present, INSTALL a new windshield wiper motor.
Installation).
F11 CHECK THE RAIN SENSOR VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect Rain Sensor C914.
Ignition ON.
Measure:

C914-1 Ground
Yes GO to F12
Wiring Diagrams manual to identify the possible cause of the circuit short.
F12 CHECK THE RAIN SENSOR GROUND CIRCUIT FOR AN OPEN

Measure:

C914-1 C914-3
Yes GO to F13
F13 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C914-2 C226A-8
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Yes GO to F14
F14 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION
Repair:
Reconnect all the SCCM connectors. Make sure they seat and latch correctly.
The Windshield Wipers Do Not Park At The Correct Position

Possible Causes
Wiper mounting arm and pivot shaft

Inspect the mounting arm and pivot shaft for damage
PINPOINT TEST G : THE WINDSHIELD WIPERS DO NOT PARK AT THE CORRECT POSITION
G1 CHECK THE WIPER MOUNTING ARM AND PIVOT SHAFT FOR DAMAGE
Ignition OFF.
Inspect the wiper mounting arm and pivot shaft for damage.
Is the wiper mounting arm and pivot shaft OK?
Yes GO to G2
No INSTALL a new wiper mounting arm and pivot shaft.
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REFER to: Windshield Wiper Pivot Arm - LHD (501-16 Wipers and Washers, Removal and
Installation).
G2 CHECK THE WINDSHIELD WIPER PARK RELAY OPERATION

Ignition ON.
Place the wiper/washer switch to the low speed setting. When the wiper blades are in the middle of a
wipe, place the wiper/washer switch off.
Do the windshield wipers immediately stop when the wiper/washer switch is turned off?

Installation).
No ADJUST the pivot arms as necessary.
The Windshield Washer Is Inoperative
Possible Causes

Windshield washer hose
Windshield washer jet
Washer pump
Wiper/washer switch
SCCM
PINPOINT TEST H : THE WINDSHIELD WASHER IS INOPERATIVE

NOTICE: This Pinpoint Test uses a test lamp to simulate normal circuit loads. Use only a Rotunda
Test Lamp (SGT27000) or 250-300mA incandescent bulb test lamp. To avoid connector terminal
damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle. Do not
use the test lamp probe directly on any connector.
H1 CHECK THE AMBIENT AIR TEMPERATURE
Check the ambient air temperature.
Is the ambient air temperature below freezing?
Yes GO to H2
No GO to H4
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H2 CHECK THE WASHER SOLVENT
Check the washer solvent and make sure it is of the correct type to use for the temperature conditions
present.
Is the correct type of washer solvent present?
Yes GO to H3
No ALLOW the vehicle to warm to room temperature. DRAIN and REFILL the windshield
washer reservoir with the correct washer solvent type. INFORM the customer of the
correct type of washer solvent to use for the temperature conditions present.
H3 CHECK FOR WASHER SOLVENT TO THE WASHER JETS

Disconnect the washer hoses from the windshield washer jets and place them in a container to capture
fluid.
Ignition ON.
Momentarily activate the windshield washer function.
Is washer fluid emitted at the washer hoses?
Yes INSTALL a new washer jet in question.

No GO to H4
H4 CHECK FOR WASHER PUMP ACTIVATION

Ignition ON.
While listening for washer pump activation near the right front of the vehicle, have an assistant activate
the windshield washer function.
Does the washer pump activate?
Yes GO to H5
No GO to H6
H5 CHECK FOR DAMAGED WASHER HOSES

Inspect the washer hoses for kinks or damage.
Are the washer hoses OK?
Yes Install a new washer pump.

REFER to: Windshield Washer Pump (501-16 Wipers and Washers, Removal and
Installation).
No REPAIR the washer hoses as necessary.
H6 CHECK THE WIPER/WASHER SWITCH INPUT USING THE WASHER SWITCH (FRONT)
(F_WASH_SW) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Using a diagnostic scan tool, view the SCCM F_WASH_SW PID.
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Activate and release the wash function on the wiper/washer switch.
Does the PID indicate correctly when the switch is activated?
Yes GO to H7
SCCM.
H7 CHECK FOR VOLTAGE TO THE WASHER PUMP

Ignition OFF.
Disconnect Washer Pump C137.
Connect:

C137-1 Ground
Ignition ON.
Use the wiper/washer switch to activate the windshield washer function.
Does the test lamp illuminate when the washer is activated?
Yes GO to H8
No GO to H9
H8 CHECK THE WASHER PUMP GROUND CIRCUIT FOR AN OPEN
Connect:

C137-1 C137-2
Use the wiper/washer switch to activate the windshield washer function.
Does the test lamp illuminate when the washer is activated?
Yes INSTALL a new washer pump.

REFER to: Windshield Washer Pump (501-16 Wipers and Washers, Removal and
Installation).
H9 CHECK THE WASHER PUMP VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND
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Ignition OFF.
Measure:

C1656-7 Ground
Yes GO to H10
H10 CHECK THE WASHER PUMP VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Measure:

C1656-7 C137-1
Yes GO to H11
H11 CHECK FOR CORRECT WINDSHIELD WIPER MOTOR OPERATION

Repair:
Installation).
The Windshield Washer Is Always On
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Possible Causes

Washer pump
Wiper/washer switch
SCCM
PINPOINT TEST I : THE WINDSHIELD WASHER IS ALWAYS ON

I1 CHECK THE WIPER/WASHER SWITCH INPUT USING THE WASHER SWITCH (FRONT)
(F_WASH_SW) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Using a diagnostic scan tool, view the SCCM F_WASH_SW PID.
Does the PID indicate the switch is activated?
Yes INSTALL a new wiper/washer switch.

SCCM.
No GO to I2
I2 CHECK THE WASHER PUMP VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Does the washer pump continue to operate?

No INSTALL a new windshield wiper motor.
Installation).
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Washer Hose Coupling
Disconnect
injury.
2. NOTICE: To prevent damage to the coupler, do not use hand tools to disconnect /connect the
C-lock.
NOTE: Do not remove the lock ring from the C-lock coupler.
NOTE: Hold the female side of the coupler at the hose connection to prevent the coupler from rotating
internally.
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Gently twist the lock ring until it has rotated approximately 90 degrees.
3. NOTICE: The female side of the C-lock coupler contains an o-ring seal. Use care not to lose the
o-ring.
Slide the C-lock coupler apart from the component fitting.

4. NOTICE: Do not leave the lock ring in the unlocked position. This will weaken the lock ring and
prevent it from correctly locking in place when reassembled, resulting in a leak.
Rotate the lock ring back to the original locked position.
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5. To connect, verify the C-lock coupler lock ring is in the locked position.
6. NOTE: The lock ring flexes open slightly to allow the male fitting to enter the C-lock coupler.
NOTE: The lock ring can be heard as it snaps into the lock position.
Insert the male fitting into the C-lock coupler.
7. Gently pull on the C-lock coupler to verify it is seated correctly.

Washer Hose Repair
Repair
NOTE: This procedure may be carried out on rubber hoses only. If a plastic washer hose is damaged, a new
washer hose must be installed.
1. Locate and verify the damaged washer hose.
2. Cut the hose cleanly and remove the damaged portion of the washer hose.
Dimension: 0.5000 in (12.7 mm)
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3. Install a windshield washer hose adapter between the cut ends of the hose.
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4. NOTE: In difficult cases, clamping may be required.
If necessary, install a segment of 6.4 mm (0.25 in) ID black rubber hose over the ends of the washer hose
and clamp both ends of the rubber hose using spring clamps.

Rain Sensor
Materials
Name Specification
ZC-23 (U.S.)
Removal
1. Remove the rain sensor cover.
2. Disconnect the rain sensor electrical connector. cardiagn.com

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3.
Remove the rain sensor.
1. Release the rain sensor retaining clip tabs.
2. Remove the rain sensor from the mounting bracket.
Installation
1. Clean the windshield glass area of foreign materials.

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2. NOTE: If the rain sensor gel pack is damaged, install a new rain sensor.
Inspect the rain sensor gel pack for damage.
3.
Install the rain sensor.
1. Place the rain sensor in the mounting bracket.
2. Install the rain sensor retaining clip.
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4. Connect the rain sensor electrical connector.

Windshield Washer Pump
Fluid Suction Gun
Materials
Name Specification
Motorcraft® Premium Windshield Wash Concentrate with Bitterant (U.S.) WSS-M14P19-A
ZC-32-B2 (U.S.)
Removal
1. Siphon out the windshield washer fluid.

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2. Remove the RH fender splash shield.
3. NOTE: Be prepared to collect escaping fluid.
Disconnect the windshield washer pump electrical connector.

Disconnect the washer hose coupling.
Refer to: Washer Hose Coupling (501-16 Wipers and Washers, General Procedures).
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4. Remove the windshield washer pump.
Installation
NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to
follow this instruction may result in premature pump failure.

Material: Motorcraft® Premium Windshield Wash Concentrate with Bitterant (U.S.) / ZC-32-B2 (U.S.)
(WSS-M14P19-A)

Windshield Washer Reservoir
Fluid Suction Gun
Materials
Name Specification
Motorcraft® Premium Windshield Wash Concentrate with Bitterant (U.S.) WSS-M14P19-A
ZC-32-B2 (U.S.)
Removal
1. Siphon out the windshield washer fluid.
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2. Remove the RH fender splash shield.

3. NOTE: Be prepared to collect escaping fluid.
Disconnect the windshield washer pump electrical connector.

Disconnect the washer hose coupling.
Refer to: Washer Hose Coupling (501-16 Wipers and Washers, General Procedures).
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4.
Remove the windshield washer reservoir.
1. Release the hose routing clips.
2. Remove the mounting bolts and nut.
3. Remove the windshield washer reservoir.
Installation
1. NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to
follow this instruction may result in premature failure.

Material: Motorcraft® Premium Windshield Wash Concentrate with Bitterant (U.S.) / ZC-32-B2 (U.S.)
(WSS-M14P19-A)
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Windshield Wiper Pivot Arm - LHD
Two Leg Puller
Removal
NOTE: The hood is removed in this procedure for clarity.
1. Remove the windshield wiper pivot arm nut covers.
2. Remove the windshield wiper pivot arm nuts.

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3. Remove the windshield wiper pivot arms.
Use the General Equipment: Two Leg Puller
Installation
1. Verify the windshield wiper motor is in the PARK position.

1. Set the ignition switch to the ON position.
2. Set the windshield wiper switch to run the wipers one complete cycle.
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2.
Install the windshield wiper pivot arms.
1. Align the windshield wiper blades inside the marks on the windshield.
2. Install the windshield wiper pivot arm nuts.
3. Turn the ignition switch off.
3. Install the windshield wiper pivot arm nut covers.

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Wiper Linkage Assembly - LHD
Removal
NOTE: The hood is removed in this procedure for clarity.
1. Remove the cowl panel grille.

2. Activate the windshield wipers.

1. Set the ignition switch to the ON position.
2. Set the windshield wiper switch to run the wipers continuously.
3. NOTE: This step is necessary to access all the mounting bolts and remove the wiper linkage assembly
from the wiper motor.
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NOTE: The wiper motor crank must be positioned to the 270 degree down position.
Position the motor crank.

1. Rotate the wiper motor crank 270 degrees.
2. Set the ignition switch to the OFF position.
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4. NOTE: Follow the unique instructions or graphic for this step in the installation.
Remove the wiper linkage assembly mounting bolts, disconnect the windshield wiper motor electrical
connector and remove the wiper linkage assembly.
Remove the wiper linkage assembly links from the motor crank.
1. Remove the left hand link.
2. Remove the right hand link.
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Remove the windshield wiper motor bracket.

1. Remove the mounting bolts.
2. Slide the bracket out.
Remove the wiper linkage assembly from the windshield wiper motor.
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Installation
NOTICE: The windshield wiper motor must be returned to the PARK position before the wiper pivot arms
can be installed. Failure to follow this instruction may result in wiper pivot arm damage.
2. NOTE: Install all the bolts finger tight before final tightening.
Install the wiper linkage assembly.

1. Connect the windshield wiper motor electrical connector.
2. Install the wiper linkage assembly mounting bolt.
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Windshield Wiper Motor - LHD
Removal
1. Remove the wiper linkage assembly.

Refer to: Wiper Linkage Assembly - LHD (501-16 Wipers and Washers, Removal and Installation).
2. NOTICE: Be careful not to damage the link seals during removal. Failure to follow this instruction
may result in poor windshield wiper performance.
Remove the wiper linkage assembly links from the motor crank.
1. Remove the LH link.
2. Remove the RH link.
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3.
Remove the windshield wiper motor bracket.
1. Remove the mounting bolts.
2. Slide the bracket out.
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4. Remove the windshield wiper motor from the wiper linkage assembly.
Installation

501-18 Convertible Top 2016 Mustang
Convertible Top - Component Location
Frame Related Components
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Item Description
1 Convertible top front panel
2 Convertible top tension cable (routed through convertible top material)
3 Stay pad
4 Floating bow
5 Convertible top tension belt (located in the luggage compartment)
6 Rear glass tension rod
7 Convertible top motor (Moveable Roof Control Module (MRCM))
8 Convertible top rear panel lower seal
9 Convertible top center panel side weatherstrip (forward/rear)
10 Convertible top front panel side weatherstrip
Sensors And Switches

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Item Description
1 Overhead console (contains convertible top open/close switch)
2 Tonneau cover (includes magnet for tonneau cover sensor operation)
3 Tonneau cover sensor (PIA to D-tower cover)
4 D-tower cover
5 Convertible top front striker (LH side convertible top striker contains
convertible top latch switch)

Convertible Top - Overview
Overview
The convertible top system is controlled by 2 smart electric motors called the Moveable Roof Control Module A
(MRCMA) and the Moveable Roof Control Module B (MRCMB). The Moveable Roof Control Module A (MRCMA)
is the primary module for the system and communicates with other modules and the Moveable Roof Control
Module B (MRCMB) over the MS-CAN. The convertible top is raised and lowered using the convertible top switch,
the switch must be held in position (up or down) while the roof is raised or lowered. The convertible top can only
be operated when the following conditions are met:
Convertible Top Opening Conditions
Accessory delay relay is active.

Vehicle speed is less than 5 km/h (3 mph).
Convertible top latch switch is open.
Convertible Top Closing Conditions
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Accessory delay relay is active.
Vehicle speed is less than 5 km/h (3 mph).
Tonneau covers (if equipped) are not in place.

Convertible Top - System Operation and Component Description
System Operation
System Diagram
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Network Message Charts
Moveable Roof Control Module A (MRCMA) Network Input Messages
Broadcast Originating Module Message Purpose

Message
Accessory BCM This message is sent to the GWM and then to the Moveable Roof
delay status Control Module A (MRCMA). This message informs the Moveable Roof
Control Module A (MRCMA) of the current accessory delay relay status;
Message
active or not active.
Convertible Top Moveable Roof This message informs the Moveable Roof Control Module A (MRCMA)
Request Control Module B the vehicle occupant has requested the convertible top to be raised.
(MRCMB)
Convertible Top Moveable Roof This message informs the Moveable Roof Control Module A (MRCMA) of
Status Control Module B the current Moveable Roof Control Module B (MRCMB) convertible top
(MRCMB) status; opened, closed, moving, stalled or faulted.
Ignition Status BCM This message is sent to the GWM and then to the Moveable Roof
Control Module A (MRCMA). This message informs the Moveable Roof
Control Module A (MRCMA) of the current ignition status; OFF, ACC,
RUN, START or UNKNOWN.
LH rear window BCMB This message informs the Moveable Roof Control Module A (MRCMA)
down status the LH rear window is in the full down position.
RH rear BCMB This message informs the Moveable Roof Control Module A (MRCMA)
window down the RH rear window is in the full down position.
status
Tonneau Cover Moveable Roof This message informs the Moveable Roof Control Module A (MRCMA) of
Status Control Module B the current Moveable Roof Control Module B (MRCMB) tonneau cover
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(MRCMB) status; installed, not installed, not used or faulted.
Vehicle speed PCM This message is sent to the GWM and then to the Moveable Roof
Control Module A (MRCMA). This message informs the Moveable Roof
Control Module A (MRCMA) of the current vehicle speed.
Moveable Roof Control Module B (MRCMB) Network Input Messages

Message
Accessory BCM This message is sent to the GWM and then to the Moveable Roof Control
delay status Module B (MRCMB). This message informs the Moveable Roof Control
Module B (MRCMB) of the current accessory delay relay status; active or
not active.
Convertible Moveable Roof This message informs the Moveable Roof Control Module B (MRCMB)
Top Request Control Module A the vehicle occupant has requested the convertible top to be lowered.
(MRCMA)
Convertible Moveable Roof This message informs the Moveable Roof Control Module B (MRCMB) of
Top Status Control Module A the current Moveable Roof Control Module A (MRCMA) convertible top
(MRCMA) status; opened, closed, moving, stalled or faulted.
Ignition Status BCM This message is sent to the GWM and then to the Moveable Roof Control
Module B (MRCMB). This message informs the Moveable Roof Control
Module B (MRCMB) of the current ignition status; OFF, ACC, RUN,
START or UNKNOWN.
Tonneau Moveable Roof This message informs the Moveable Roof Control Module B (MRCMB) of
Cover Status Control Module A the current Moveable Roof Control Module A (MRCMA) tonneau cover
(MRCMA) status; installed, not installed, not used or faulted.
Convertible Top Function
The convertible top UP switch position is hard-wired to the Moveable Roof Control Module A (MRCMA) and the
convertible top switch DOWN position is hard-wired to the Moveable Roof Control Module B (MRCMB). When the
convertible top down function requirements have been met (accessory delay relay is active, vehicle speed is less
than 5 km/h (3 mph) and the convertible top latch is released) and the convertible top DOWN switch is activated,
a ground signal is sent to the Moveable Roof Control Module B (MRCMB). The Moveable Roof Control Module B
(MRCMB) sends a convertible top down message over the MS-CAN to the Moveable Roof Control Module A
(MRCMA). The Moveable Roof Control Module A (MRCMA) verifies all down function requirements have been
met and then sends a window down message over the MS-CAN to the BCMB to lower all 4 windows. The BCMB
sends a signal on the global open circuit to the 4 window motors to activate a full down operation of all 4
windows. Once the windows are fully lowered, the full down sensor in each rear quarter window motor sends a
signal to the BCMB indicating the windows are in the full DOWN position. The BCMB sends the rear window
status message to the Moveable Roof Control Module A (MRCMA) over the MS-CAN. After receiving the rear
window status message from the BCMB, the Moveable Roof Control Module A (MRCMA) sends a convertible top
down message to the Moveable Roof Control Module B (MRCMB) and the convertible top is lowered.
When the convertible top up function requirements have been met (accessory delay relay is active, vehicle speed
is less than 5 km/h (3 mph) and the 2 tonneau covers (if equipped) are not in place) and the convertible top switch
UP is activated, a ground signal is sent to the Moveable Roof Control Module A (MRCMA). The Moveable Roof
Control Module A (MRCMA) verifies all up function requirements have been met and then sends a window down
message over the MS-CAN to the BCMB to lower all 4 windows. The BCMB sends a signal on the global open
circuit to the 4 window motors to activate a full down operation of all 4 windows. Once the windows are fully
lowered, the full down sensor in each rear quarter window motor sends a signal to the BCMB indicating the
windows are in the full DOWN position. The BCMB sends the rear window status message to the Moveable Roof
Control Module A (MRCMA) over the MS-CAN. After receiving the rear window status message from the BCMB,
the Moveable Roof Control Module A (MRCMA) sends a convertible top up message to the Moveable Roof
Control Module B (MRCMB) and the convertible top is raised.
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If the convertible top cannot be raised or lowered, the Moveable Roof Control Module A (MRCMA), Moveable
Roof Control Module B (MRCMB) or BCMB sets a DTC. There are no warning indicators associated with the
convertible top system, but messages may be displayed in the message center.
Convertible Top Drop Window Function
When the convertible top switch is operated (to raise or lower the convertible top), the BCMB sends a signal on
the global open circuit to the 4 window motors to activate a full down operation of all 4 windows. When the rear
quarter windows reach the full DOWN position, the full down sensor in each rear quarter window motor sends a
signal to the BCMB indicating the windows are in the full DOWN position. If the BCMB does not see the full down
signal from both rear quarter window motors, the convertible top does not operate. The BCMB also disables the
rear quarter window control switch from operating the rear quarter windows when the convertible top is not in the
full UP or full DOWN position by sending a message (pulses) on the global open circuit (the front door window
motors ignore this message). This function prevents an accidental opening of the convertible top with the windows
in the UP position causing contact between the windows and convertible top which may result in damage to the
convertible top or windows. For additional information on window operation,
Refer to: Glass, Frames and Mechanisms - System Operation and Component Description (501-11 Glass,
Moveable Roof Control Module A (MRCMA) Message Center Messages
The Moveable Roof Control Module A (MRCMA) continually monitors the convertible top system operation and
status using Hall-effect switches. The convertible top latch contains a magnet which activates a Hall-effect switch.
The Hall-effect switch is hard-wired to the Moveable Roof Control Module A (MRCMA) so the module knows the
roof is secured. The optional tonneau covers also each contain a magnet which activates a Hall-effect switch. One
Hall-effect switch is hard-wired to the Moveable Roof Control Module A (MRCMA) and the other is hard-wired to
the Moveable Roof Control Module B (MRCMB). When one or both tonneau covers are installed, the magnet
actives the Hall-effect switch and prevents the convertible top from being raised. The Moveable Roof Control
Module A (MRCMA) receives vehicle speed from the PCM over the HS-CAN1. If the vehicle speed exceeds 5
km/h (3 mph), the Hall-effect switches indicates one or more of the tonneau covers are installed or the convertible
top latch is not fully engaged the Moveable Roof Control Module A (MRCMA) sends a message to the IPC over
the MS-CAN.
When the IPC receives a convertible top status message from the Moveable Roof Control Module A (MRCMA),
one or more of the following messages is displayed in the message center:
TOP DISABLED — REMOVE COVERS – Displays when the vehicle occupants attempt to raise the
convertible top with the optional tonneau covers installed.
TOP DISABLED — REDUCE SPEED – Displays when the vehicle occupants attempt to lower or raise the
convertible top and vehicle speed is greater than 5 km/h (3 mph).
TOP NOT SECURE – Displays when the vehicle occupants have raised convertible top, vehicle speed
exceeds 5 km/h (3 mph) and the convertible top latch has not been fully engaged.
For additional information on the message center,

Refer to: Message Center - System Operation and Component Description (413-01 Instrumentation, Message
Center and Warning Chimes, Description and Operation).
Convertible Top Latch Switch
The convertible top latch switch is a Hall-effect style switch, the switch is activated by a magnet in the convertible
top. When the convertible top is closed and fully latched, the Hall-effect switch closes and sends a signal to the
Moveable Roof Control Module A (MRCMA).
Convertible Top Switch
The convertible top switch is a 3-position (UP, DOWN, NEUTRAL), momentary contact, rocker style switch.
Moveable Roof Control Module A (MRCMA)
The Moveable Roof Control Module A (MRCMA) is the primary electronic control unit for the convertible top
system and communicates with the Moveable Roof Control Module B (MRCMB) and other modules over the
MS-CAN or HS-CAN1 through the GWM. The Moveable Roof Control Module A (MRCMA) monitors all sensor
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inputs and all CAN messages relating to the convertible top and directly controls the convertible top using a motor.
The Moveable Roof Control Module A (MRCMA) also contains a Hall-effect switch to detect convertible top
movement and position (open, closed, moving).
The Moveable Roof Control Module A (MRCMA) and Moveable Roof Control Module B (MRCMB) use their
internal Hall-effect switches and the MS-CAN to synchronize motor speed and direction.
Moveable Roof Control Module B (MRCMB)
The Moveable Roof Control Module B (MRCMB) is the secondary electronic control unit for the convertible top
system and communicates with the Moveable Roof Control Module A (MRCMA) over the MS-CAN and the BCM
over the HS-CAN1 through the GWM. The Moveable Roof Control Module B (MRCMB) monitors one of the
tonneau cover Hall-effect switches and MS-CAN messages from the Moveable Roof Control Module A (MRCMA)
and directly controls the convertible top using a motor. The Moveable Roof Control Module B (MRCMB) also
contains a Hall-effect switch to detect convertible top movement and position (open, closed, moving).
Tonneau Cover Switches
The tonneau cover switches are Hall-effect style switches, the switches are activated by a magnet located in each
tonneau cover (1 magnet per cover). When the tonneau covers are installed, the Hall-effect switches close and
send a signal to the Moveable Roof Control Module A (MRCMA) and the Moveable Roof Control Module B
(MRCMB). One switch is hard-wired to each module.

Convertible Top
Diagnostic Trouble Code (DTC) Charts
Diagnostic Trouble Code (DTC) Chart: Moveable Roof Control Module A (MRCMA)
Moveable Roof Control Module A (MRCMA) DTC Chart

B1070:12 Tonneau Lid Piston Out Sensor: GO to Pinpoint Test B
Circuit Short to Battery
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Circuit Short to Ground or Open
Signal Invalid
B1078:12 Convertible Top Latched Sensor: GO to Pinpoint Test C
Signal Invalid
B1267:24 Convertible / Folding Top Activation GO to Pinpoint Test E
Up Switch: Signal Stuck High
P0604:44 Internal Control Module Random Using a diagnostic scan tool, CLEAR the DTC.
Access Memory (RAM) Error: Data CYCLE the ignition from ON to OFF and back to ON.
Memory Failure CARRY OUT the Moveable Roof Control Module A
(MRCMA) self-test.
If the DTC returns, INSTALL a new Moveable Roof
Control Module A (MRCMA).
REFER to: Convertible Top Motor (501-18 Convertible
Top, Removal and Installation).
P0605:45 Internal Control Module Read Only Using a diagnostic scan tool, CLEAR the DTC.
Memory (ROM) Error: Program CYCLE the ignition from ON to OFF and back to ON.
Memory Failure CARRY OUT the Moveable Roof Control Module A
(MRCMA) self-test.
P062F:46 Internal Control Module EEPROM Using a diagnostic scan tool, CLEAR the DTC.
Error: Calibration / Parameter SET the ignition to OFF and wait 20 seconds. SET the
Memory Failure ignition to ON. CARRY OUT the Moveable Roof Control
Module A (MRCMA) self-test.
P1240:1C Sensor Power Supply - Circuit GO to Pinpoint Test D

Voltage Out of Range
U0140:00 Lost Communication With Body GO to Pinpoint Test F
Information
U0142:00 Lost Communication With Body GO to Pinpoint Test G
Control Module "B": No Sub Type
Information
U020A:00 Lost Communication With GO to Pinpoint Test I
Moveable Roof Control Module "B"
(MRCMB): No Sub Type
Information
U0294:00 Lost Communication With GO to Pinpoint Test H
Powertrain Control Monitor
Module: No Sub Type Information
U2011:64 Motor: Signal Plausibility Failure Using a diagnostic scan tool, CLEAR the DTC.
SET the ignition to ON. Using the convertible top switch,
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OPEN or CLOSE the convertible top.
If the convertible top does not operate, INSTALL a new
U2011:98 Motor: Component or System Over WAIT a minimum of 2 minutes to allow the motor time to
Temperature cool.
Using a diagnostic scan tool, CLEAR the DTC.
If the convertible top does not operate, CARRY OUT the
Moveable Roof Control Module A (MRCMA) self-test.
If the DTC does not return, DIAGNOSE any other
Moveable Roof Control Module A (MRCMA) Diagnostic
Trouble Codes (DTCs), verify all convertible roof
operation entry conditions have been met.
REFER to: Convertible Top - Overview (501-18
Convertible Top, Description and Operation).
If the DTC returns, the system has not had sufficient time
to cool. SET the ignition to OFF and WAIT another 2
minutes, CLEAR the DTC and REPEAT the self-test.
U2013:64 Switch Pack: Signal Plausibility GO to Pinpoint Test E

Failure
U3000:49 Control Module: Internal Electronic Using a diagnostic scan tool, CLEAR the DTC.
Failure SET the ignition to ON. Using the convertible top switch,
Using a diagnostic scan tool, CARRY OUT the Moveable
Roof Control Module A (MRCMA) self-test.
Diagnostic Trouble Code (DTC) Chart: Moveable Roof Control Module B (MRCMB)
Moveable Roof Control Module B (MRCMB) DTC Chart

Signal Invalid
B1268:24 Convertible / Folding Top Activation GO to Pinpoint Test E
Down Switch: Signal Stuck High
P0604:44 Internal Control Module Random Using a diagnostic scan tool, CLEAR the DTC.
Access Memory (RAM) Error: Data CYCLE the ignition from ON to OFF and back to ON.
Memory Failure CARRY OUT the Moveable Roof Control Module B
(MRCMB) self-test.
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Control Module B (MRCMB).
P0605:45 Internal Control Module Read Only Using a diagnostic scan tool, CLEAR the DTC.
Memory (ROM) Error: Program CYCLE the ignition from ON to OFF and back to ON.
Memory Failure CARRY OUT the Moveable Roof Control Module B
(MRCMB) self-test.
P062F:46 Internal Control Module EEPROM Using a diagnostic scan tool, CLEAR the DTC.
Error: Calibration / Parameter SET the ignition to OFF and wait 20 seconds. SET the
Memory Failure ignition to ON. CARRY OUT the Moveable Roof Control
Module B (MRCMB) self-test.
U0140:00 Lost Communication With Body GO to Pinpoint Test F

Information
U0207:00 Lost Communication With GO to Pinpoint Test J
Moveable Roof Control Module "A"
(MRCMA): No Sub Type
Information
U2011:64 Motor: Signal Plausibility Failure Using a diagnostic scan tool, CLEAR the DTC.
If the convertible top does not operate, INSTALL a new
Moveable Roof Control Module B (MRCMB).
U2011:98 Motor: Component or System Over WAIT a minimum of 2 minutes to allow the motor time to
Temperature cool.
If the convertible top does not operate, CARRY OUT the
Moveable Roof Control Module B (MRCMB) self-test.
If the DTC does not return, DIAGNOSE any other
Moveable Roof Control Module B (MRCMB) Diagnostic
Trouble Codes (DTCs), verify all convertible roof
operation entry conditions have been met.
REFER to: Convertible Top - Overview (501-18
Convertible Top, Description and Operation).
If the DTC returns, the system has not had sufficient time
to cool. SET the ignition to OFF and WAIT another 2
minutes, CLEAR the DTC and REPEAT the self-test.
U2013:64 Switch Pack: Signal Plausibility GO to Pinpoint Test E

Failure
U3000:49 Control Module: Internal Electronic Using a diagnostic scan tool, CLEAR the DTC.
Failure SET the ignition to ON. Using the convertible top switch,
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Using a diagnostic scan tool, CARRY OUT the Moveable
Roof Control Module B (MRCMB) self-test.
Diagnostic Trouble Code (DTC) Chart: Body Control Module B (BCMB)
BCMB DTC Chart

B126E:23 Right Rear Window Fully Down GO to Pinpoint Test K
Feedback: Signal Stuck Low
B126E:24 Right Rear Window Fully Down GO to Pinpoint Test K
Feedback: Signal Stuck High
B126F:23 Left Rear Window Fully Down GO to Pinpoint Test K
Feedback: Signal Stuck Low
B126f:24 Left Rear Window Fully Down GO to Pinpoint Test K
Feedback: Signal Stuck High
— All Other BCMB Diagnostic Trouble
Codes (DTCs) REFER to: Body Control Module B (BCMB) (419-10
Multifunction Electronic Modules, Diagnosis and Testing).
Symptom Chart

A module does not Fuse
respond to the Wiring, terminals or REFER to: Communications Network (418-00
diagnostic scan connectors Module Communications Network, Diagnosis and
tool Moveable Roof Testing).
Control Module A
(MRCMA) concern
Moveable Roof
Control Module B
(MRCMB) concern
BCMB concern
The convertible Refer to the GO to Pinpoint Test A
top is inoperative Pinpoint Test
The convertible Convertible top CHECK the convertible top latch installation.
top is difficult to latch front striker REFER to: Convertible Top Front Panel (501-18
latch incorrectly installed Convertible Top, Removal and Installation).
Convertible top REINSTALL as necessary.
latch incorrectly CHECK the convertible top latch front striker
installed installation.
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Convertible top REFER to: Convertible Top Front Striker (501-18
incorrectly installed Convertible Top, Removal and Installation).
REINSTALL as necessary.
CHECK the convertible top installation.
REFER to: Convertible Top Assembly (501-18
Convertible Top, Removal and Installation).
REINSTALL as necessary.
The windows do Wiring, terminals or RETRIEVE and RECORD all BCMB and Moveable
not lower when connectors Roof Control Module A (MRCMA) Diagnostic Trouble
the convertible top Network Codes (DTCs).
is opened or communication DIAGNOSE all retrieved Diagnostic Trouble Codes
closed concern (DTCs). GO to the DTC Chart: BCMB or DTC Chart:
Window motor Moveable Roof Control Module A (MRCMA).
BCMB concern
Moveable Roof
Control Module A
(MRCMA) concern
The message Convertible top CLOSE the convertible top without latching and
center displays incorrect installed VERIFY the top is correctly installed / aligned.
Top Not Secured Convertible top not REINSTALL the convertible top as necessary.
latched correctly LATCH the convertible top and TEST DRIVE the
Latch sensor vehicle above 5 km/h (3 mph). If the message does
concern not return, INFORM the customer of the correct
latching procedure.
RETRIEVE and RECORD all Moveable Roof Control
Module A (MRCMA) Diagnostic Trouble Codes
(DTCs). GO to the DTC Chart: Moveable Roof
The message Tonneau covers are VERIFY the covers are not installed. REMOVE the
center displays installed covers and CLOSE the convertible roof. INFORM the
Top Disabled - Tonneau cover customer the tonneau covers must be removed
Remove Covers sensor concern before closing the convertible roof.
Module A (MRCMA) and Moveable Roof Control
Module B (MRCMB) Diagnostic Trouble Codes
Control Module A (MRCMA) or the DTC Chart:
Moveable Roof Control Module B (MRCMB).
The message Vehicle speed RETRIEVE and RECORD all PCM Diagnostic
center displays concern Trouble Codes (DTCs). DIAGNOSE all vehicle speed
Top Disabled - Network related Diagnostic Trouble Codes (DTCs).
Reduce Speed communication REFER to: Electronic Engine Controls (303-14A
concern Electronic Engine Controls - 2.3L EcoBoost
REFER to: Electronic Engine Controls (303-14B
Electronic Engine Controls - 3.7L Duratec
REFER to: Electronic Engine Controls (303-14C
Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), Diagnosis and Testing).
Module A (MRCMA), Moveable Roof Control Module
B (MRCMB) and GWM Diagnostic Trouble Codes
Control Module A (MRCMA), the DTC Chart:
Moveable Roof Control Module B (MRCMB) or
REFER to: Communications Network (418-00
Module Communications Network, Diagnosis and
Testing).
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Pinpoint Tests
The Convertible Top Is Inoperative
The convertible top is controlled through the use of a switch, the switch must be held in place during convertible
top operation. Voltage for convertible top operation is supplied to the Moveable Roof Control Module A (MRCMA)
and Moveable Roof Control Module B (MRCMB) from the BJB. There are several requirements which must be
met before the convertible top can be opened or closed,
REFER to: Convertible Top - Overview (501-18 Convertible Top, Description and Operation).
For additional convertible
Circuit faults, a convertible top switch failure, network communication errors, invalid network data or an internal
failure of one or more modules listed below prevents the convertible top from operating.
Possible Sources
Fuses
Convertible top switch
Tonneau covers installed
Vehicle speed concern
Rear window concern
BCMB concern
GWM concern
BCM concern
PCM concern
Make sure the tonneau covers are not installed.

Make sure BJB fuses 15 (20A) and 17 (20A) are OK.
PINPOINT TEST A : THE CONVERTIBLE TOP IS INOPERATIVE
probe adapter(s) may cause damage to the connector.
A1 VERIFY THE COMMUNICATION NETWORK
Ignition ON.
Using a diagnostic scan tool, carry out the Network Test.
Do the Moveable Roof Control Module A (MRCMA), Moveable Roof Control Module B (MRCMB),
BCMB, GWM, BCM and PCM all pass the Network Test?
Yes GO to A2
No DIAGNOSE no communication with the unresponsive module.
and Testing).
A2 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS)

Using a diagnostic scan tool, carry out the self test for the following modules:
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BCMB
GWM
BCM
PCM, KOEO
Are any Diagnostic Trouble Codes (DTCs) present in any of the modules listed above?
Yes DIAGNOSE all Diagnostic Trouble Codes (DTCs) before continuing with this test.
For Moveable Roof Control Module A (MRCMA) Diagnostic Trouble Codes (DTCs), GO to
the DTC Chart: Moveable Roof Control Module A (MRCMA).
For Moveable Roof Control Module B (MRCMB) Diagnostic Trouble Codes (DTCs), GO to
the DTC Chart: Moveable Roof Control Module B (MRCMB).
For BCMB Diagnostic Trouble Codes (DTCs),
For GWM Diagnostic Trouble Codes (DTCs),

REFER to: Communications Network (418-00 Module Communications Network,
For BCM Diagnostic Trouble Codes (DTCs),

For PCM Diagnostic Trouble Codes (DTCs),

REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.3L
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 3.7L Duratec
No GO to A3
A3 CHECK THE BCM (BODY CONTROL MODULE) DELAYED ACCESSORY POWER (ACC_DELAY)
PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the BCM ACC_DELAY PID.
Does the PID display Active?
Yes GO to A5
No DIAGNOSE the accessory delay relay.
A4 CHECK THE CONVERTIBLE TOP ACTIVATION UP (TOP_UP_SW) AND DOWN (TOP_DWN_SW)

SWITCH PARAMETER IDENTIFICATIONS (PIDS)
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) TOP_UP_SW PID
while pressing the convertible top UP switch.
Using a diagnostic scan tool, view the Moveable Roof Control Module B (MRCMB) TOP_DWN_SW PID
while pressing the convertible top DOWN switch.
Does the PID display Active when the switch is pressed and Inactive when the switch is released?
Yes GO to A5
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No If the PID displays Active all the time, GO to Pinpoint Test E
If the PID displays Inactive all the time, GO to A9
A5 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) VEHICLE SPEED (VSS) PID
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) VSS PID.
Does the PID display less than 5 km/h (3 mph)?
Yes GO to A6
No DIAGNOSE the vehicle speed concern.
A6 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) FRONT LATCH SENSOR
(FRNT_LATCH_S) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) FRNT_LATCH_S PID.
Does the PID display Inactive with the top open and Active with the top closed?
Yes GO to A7
No GO to Pinpoint Test C
A7 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) CONVERTIBLE TOP LATCH
SENSOR VOLTAGE (LTCH_SNSR_V) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) LTCH_SNSR_V PID.
Is the PID display equal to battery voltage?
Yes If the vehicle is equipped with convertible top tonneau covers, GO to A8

If the vehicle is not equipped with convertible top tonneau covers, the system is operating
correctly at this time. The concern may have been caused by a loose or corroded
connector.
DISCONNECT and INSPECT Moveable Roof Control Module A (MRCMA) C4830,
Moveable Roof Control Module B (MRCMB) C4831, convertible top switch C9013 and
convertible top latch switch C9111 for corrosion, damaged pins, bent pins, pushed-out pins
and spread terminals. REPAIR or INSTALL NEW as necessary.
No GO to Pinpoint Test D
A8 CHECK THE CONVERTIBLE TOP TONNEAU COVER SENSOR PARAMETER IDENTIFICATIONS

(PIDS)
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) tonneau cover sensor
PID with the tonneau covers installed and removed.
Using a diagnostic scan tool, view the Moveable Roof Control Module B (MRCMB) tonneau cover sensor
PID with the tonneau covers installed and removed.
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Do the Parameter Identifications (PIDs) display Active with the covers installed and Inactive with the
covers removed?
Yes The system is operating correctly at this time. The concern may have been caused by a
loose or corroded connector.
DISCONNECT and INSPECT Moveable Roof Control Module A (MRCMA) C4830,
Moveable Roof Control Module B (MRCMB) C4831, convertible top switch C9013,
convertible top latch switch C9111, LH tonneau cover sensor C4525 and RH tonneau cover
sensor C4526 for corrosion, damaged pins, bent pins, pushed-out pins and spread
terminals. REPAIR or INSTALL NEW as necessary.
A9 CHECK THE CONVERTIBLE TOP ACTIVATION SWITCH CIRCUITS FOR AN OPEN

Ignition OFF.
Disconnect Moveable Roof Control Module A (MRCMA) C4830.
Disconnect Moveable Roof Control Module B (MRCMB) C4831.
Disconnect convertible top switch C9013.
Measure:

C4830-8 C9013-4
Measure:

C4831-8 C9013-3

Yes GO to A10
A10 CHECK THE CONVERTIBLE TOP ACTIVATION SWITCH GROUND CIRCUIT FOR AN OPEN
Measure:

C9013-5 Ground
Yes INSTALL a new convertible top switch.

REFER to: Convertible Top Switch (501-18 Convertible Top, Removal and Installation).
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Tonneau Cover Sensor Faults
A tonneau cover sensor is hardwired to the Moveable Roof Control Module A (MRCMA) and a separate tonneau
cover sensor is hardwired to the Moveable Roof Control Module B (MRCMB). Each module sends out a 5 volt
reference signal to the respective Hall-effect switch and receives a voltage signal input from the switch when the
tonneau cover is installed. When a tonneau cover sensor or circuit is faulted, the convertible top may open, but
does not close. Also, depending on the nature of the fault, the message center may display the TOP DISABLED -
REMOVE COVERS.

B1070:12 Tonneau Lid Piston Out This DTC sets if the tonneau cover sensor voltage signal sent to the
Sensor: Circuit Short To Moveable Roof Control Module A (MRCMA) or Moveable Roof Control
Battery Module B (MRCMB) is shorted to battery voltage.
B1070:14 Tonneau Lid Piston Out This DTC sets if the tonneau cover sensor voltage signal sent to the
Sensor: Circuit Short To Moveable Roof Control Module A (MRCMA) or Moveable Roof Control
Ground or Open Module B (MRCMB) is shorted to ground or open.
B1070:29 Tonneau Lid Piston Out This DTC sets if the Moveable Roof Control Module A (MRCMA) or
Sensor: Signal Invalid Moveable Roof Control Module B (MRCMB) or receives an implausible
signal from the tonneau cover sensor.
Possible Sources

LH tonneau cover sensor
RH tonneau cover sensor
PINPOINT TEST B : TONNEAU COVER SENSOR FAULTS

B1 CHECK FOR RETURNING DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the Moveable Roof Control Module A (MRCMA) or Moveable Roof
Control Module B (MRCMB) Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
With the convertible top in the open position, press and hold the convertible top UP switch for 2 seconds.
Using a diagnostic scan tool, carry out the Moveable Roof Control Module A (MRCMA) and Moveable
Roof Control Module B (MRCMB) self-tests.
Does the DTC return?
Yes If DTC B1070:12 or B1070:29 is present, GO to B2

If DTC B1070:14 is present, GO to B3
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No The condition that caused the DTC to set is not present at this time. The concern may
have been caused by a loose or corroded electrical connector or an intermittent concern.
DISCONNECT and INSPECT the suspect tonneau cover sensor C4525 or C4526, and
Moveable Roof Control Module A (MRCMA) C4830 or Moveable Roof Control Module B
(MRCMB) C4831 for corrosion, bent pins, pushed-out pins and spread terminals. REPAIR
or INSTALL new components as necessary.
For all other Moveable Roof Control Module A (MRCMA) and Moveable Roof Control
Module B (MRCMB) Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: Moveable
Roof Control Module A (MRCMA) or Moveable Roof Control Module B (MRCMB).
B2 CHECK THE TONNEAU COVER SENSOR SIGNAL CIRCUIT FOR A SHORT TO BATTERY
VOLTAGE
Ignition OFF.
If Moveable Roof Control Module A (MRCMA) set the DTC:
Disconnect LH tonneau cover sensor C4525.
If Moveable Roof Control Module B (MRCMB) set the DTC:
Moveable Roof Control Module B (MRCMB) C4831.
Disconnect RH tonneau cover sensor C4526.
Ignition ON.
For Moveable Roof Control Module A (MRCMA) measure:

C4830-2 Ground
For Moveable Roof Control Module B (MRCMB) measure:

C4831-2 Ground

No If DTC B1070:29 is not present, INSTALL a new tonneau cover sensor.
REFER to: Tonneau Cover Sensor (501-18 Convertible Top, Removal and Installation).
B3 CHECK THE TONNEAU COVER SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
If Moveable Roof Control Module A (MRCMA) set the DTC:
Disconnect Moveable Roof Control Module A (MRCMA) C4830 (if not previously disconnected).
Disconnect the LH tonneau cover sensor C4525 (if not previously disconnected).
If Moveable Roof Control Module B (MRCMB) set the DTC:
Moveable Roof Control Module B (MRCMB) C4831 (if not previously disconnected).
Disconnect the RH tonneau cover sensor C4526 (if not previously disconnected).
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C4830-2 Ground

C4831-2 Ground
Yes If DTC B1070:29 is not present, INSTALL a new tonneau cover sensor.

B4 CHECK THE TONNEAU COVER SENSOR SIGNAL CIRCUIT FOR AN OPEN


C4830-2 C4525-1

C4831-2 C4526-1
Yes GO to B5
B5 CHECK THE TONNEAU COVER SENSOR SIGNAL CIRCUIT FOR A SHORT TOGETHER

C4830-2 C4830-1
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C4831-2 C4831-1
Yes INSTALL a new tonneau cover sensor.

B1078:12, B1078:14, B1078:29
The convertible top latch switch is hardwired to the Moveable Roof Control Module A (MRCMA). The Moveable
Roof Control Module A (MRCMA) sends out a 5 volt reference signal to the Hall-effect switch and receives a
voltage signal input back from the switch when the latch is open. When the latch switch or circuit is faulted, the
convertible top may close, but does not open. Also, depending on the nature of the fault, the message center may
display the TOP NOT SECURE. The convertible top latch switch is part of the convertible roof latch and striker
assembly.

B1078:12 Convertible Top Latched Sensor: This DTC sets if the convertible top latch switch voltage signal
Circuit Short To Battery sent to the Moveable Roof Control Module A (MRCMA) is shorted
to battery voltage.
B1078:14 Convertible Top Latched Sensor: This DTC sets if the convertible top latch switch voltage signal
Circuit Short To Ground or Open sent to the Moveable Roof Control Module A (MRCMA) is shorted
to ground or open.
B1078:29 Convertible Top Latched Sensor: This DTC sets if the Moveable Roof Control Module A (MRCMA)
Signal Invalid receives an implausible signal from the convertible top latch
switch.
Possible Sources

Convertible top latch assembly
PINPOINT TEST C : B1078:12, B1078:14, B1078:29

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C1 CHECK FOR RETURNING DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the Moveable Roof Control Module A (MRCMA) Diagnostic Trouble
Codes (DTCs).
Ignition OFF.
Ignition ON.
With the convertible top in the closed position, press and hold the convertible top DOWN switch for 2
seconds.
Using a diagnostic scan tool, carry out the Moveable Roof Control Module A (MRCMA) self-test.
Does the DTC return?
Yes If DTC B1078:12 or B1078:29 is present, GO to C2

If DTC B1078:14 is present, GO to C3
DISCONNECT and INSPECT convertible top latch switch C9111 and Moveable Roof
Control Module A (MRCMA) C4830 for corrosion, bent pins, pushed-out pins and spread
terminals. REPAIR or INSTALL new components as necessary.
For all other Moveable Roof Control Module A (MRCMA) Diagnostic Trouble Codes
(DTCs), GO to the DTC Chart: Moveable Roof Control Module A (MRCMA).
C2 CHECK THE CONVERTIBLE LATCH SWITCH SIGNAL CIRCUIT FOR A SHORT TO BATTERY
VOLTAGE
Ignition OFF.
Disconnect convertible top latch switch C9111.
Ignition ON.
Measure:

C4830-7 Ground

No If DTC B1078:29 is not present, INSTALL a new convertible top latch switch.
REFER to: Convertible Top Front Striker (501-18 Convertible Top, Removal and
Installation).
If DTC B1078:29 is present, GO to C3
C3 CHECK THE CONVERTIBLE LATCH SWITCH SIGNAL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect Moveable Roof Control Module A (MRCMA) C4830 (if not previously disconnected).
Disconnect convertible top latch switch C9111 (if not previously disconnected).
Measure:

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C4830-7 Ground
Yes If DTC B1078:29 is not present, INSTALL a new convertible top latch switch.
Installation).
DTC B1078:29 is present, GO to C4

C4 CHECK THE CONVERTIBLE LATCH SWITCH SIGNAL CIRCUIT FOR AN OPEN

Measure:

C4830-7 C9111-1
Yes GO to C5
C5 CHECK THE CONVERTIBLE LATCH SWITCH SIGNAL CIRCUIT FOR A SHORT TOGETHER
Measure:

C4830-7 C4830-1
Yes INSTALL a new convertible top latch switch.

Installation).
P1240:1C
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The convertible top latch switch and the LH tonneau cover switch are hardwired to the Moveable Roof Control
Module A (MRCMA). The Moveable Roof Control Module A (MRCMA) sends battery voltage to both Hall-effect
switches and back to the Moveable Roof Control Module A (MRCMA) for fault detection purposes. When one of
the switches or the volt reference circuit is faulted, the convertible top does not operate.

P1240:1C Sensor Power Supply: This DTC sets if the convertible top latch switch voltage signal sent to
Circuit Voltage Out of Range the Moveable Roof Control Module A (MRCMA) is below a
predetermined limit.
Possible Sources

PINPOINT TEST D : P1240:1C

D1 CHECK FOR RETURNING DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the Moveable Roof Control Module A (MRCMA) Diagnostic Trouble
Codes (DTCs).
Ignition OFF.
Ignition ON.
Does DTC P1240:1C return?
Yes GO to D1
DISCONNECT and INSPECT LH tonneau cover sensor C4525, convertible top latch switch
C9111 and Moveable Roof Control Module A (MRCMA) C4830 for corrosion, bent pins,
pushed-out pins and spread terminals. REPAIR or INSTALL new components as
necessary.
For all other Moveable Roof Control Module A (MRCMA) Diagnostic Trouble Codes
(DTCs), GO to the DTC Chart: Moveable Roof Control Module A (MRCMA).
D2 CHECK THE SENSOR VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Ignition OFF.
Disconnect convertible top latch switch C9111.
Disconnect LH tonneau cover sensor C4525.
Measure:

C4830-1 C9111-2
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Measure:

C4830-1 LH Tonneau Cover Connector Pin-2
Measure:

C4830-1 C4830-3
Yes GO to D3
D3 CHECK THE SENSOR VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND

Measure:

C4830-1 Ground
C4830-3 Ground

Yes GO to D4
D4 VERIFY ALL WIRING CONNECTIONS

Disconnect all Moveable Roof Control Module A (MRCMA) related in-line connectors.
Using a good light source, inspect Moveable Roof Control Module A (MRCMA) C4830 and related in-line
connectors for the following:
corrosion - install new connector or terminal and clean the module pins
damaged or bent pins - install new terminals or pins
spread terminals - install new terminals as necessary
Are the connectors free of corrosion, damaged pins, bent pins, pushed-out pins and spread
terminals?
Yes GO to D5
No REPAIR the affected connectors or terminals.
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D5 VERIFY SENSOR VOLTAGE SUPPLY

Connect Moveable Roof Control Module A (MRCMA) C4830.
Connect convertible top latch switch C9111.
Connect LH tonneau cover sensor C4525.
Connect all disconnected in-line connectors.
Make sure all connectors fully seat and latch correctly.
Ignition ON.
Measure and record the battery
Using a diagnostic scan tool, view the Moveable Roof Control Module A (MRCMA) convertible top latch
sensor voltage (LTCH_SNSR_V) PID and the module supply voltage (VOLT_SUPPLY) PID.
Do both Parameter Identifications (PIDs) display greater than 9 volts?
No If both Parameter Identifications (PIDs) display 9 volts or less, or only the
VOLT_SUPPLY PID displays 9 volts or less, GO to D6
If the VOLT_SUPPLY PID displays greater than 9 volts and the LTCH_SNSR_V PID
displays 9 volts or less, CHECK OASIS for any applicable Technical Service Bulletins
(TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW the TSB
instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new
REFER to: Convertible Top Motor (501-18 Convertible Top, Removal and Installation).
D6 CHECK THE MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN OR EXCESSIVE RESISTANCE
Ignition OFF.
Remove BJB fuse 17 (20A).
Measure:

C4830-6 BJB Fuse 17 (20A) Output Socket
Yes DIAGNOSE the battery and charging system.

REFER to: Charging System - 2.3L EcoBoost (201kW/273PS) (414-00 Charging System -
REFER to: Charging System - 3.7L Duratec (227kW/301PS) (414-00 Charging System -
REFER to: Charging System - 5.0L 32V Ti-VCT (414-00 Charging System - General
B1267:24, B1268:24, U2013:64
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The convertible top switch is a 3-position rocker switch, the UP circuit is hardwired to the Moveable Roof Control
Module A (MRCMA) and the DOWN circuit is hardwired to the Moveable Roof Control Module B (MRCMB). When
the switch is pressed, the applicable module receives a ground signal and roof operation is initiated. The switch is
designed so that both circuits (UP and DOWN) cannot be activated at the same time. The modules share the
convertible top switch status on the MS-CAN. When the switch or one of the circuits is faulted, the convertible top
does not operate. The convertible top switch is located in the overhead console and is serviced with the console
assembly.

B1267:24 Convertible / Folding Top This DTC sets if the Moveable Roof Control Module A (MRCMA)
Activation Up Switch: Circuit Stuck detects a ground signal on the convertible roof switch for longer
High than 30 seconds.
B1268:24 Convertible / Folding Top This DTC sets if the Moveable Roof Control Module B (MRCMB)
Activation Down Switch: Circuit detects a ground signal on the convertible roof switch for longer
Stuck High than 30 seconds.
U2013:64 Switch Pack: Signal Plausibility This DTC sets if both control modules detect a ground signal at
Failure the same time.
Possible Sources

Convertible top switch
PINPOINT TEST E : B1267:24, B1268:24, U2013:64

E1 CHECK FOR RETURNING DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the Moveable Roof Control Module A (MRCMA) and Moveable Roof
Control Module B (MRCMB) Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Attempt to open and close the convertible top using the convertible top switch.
Does DTC B1267:24, B1268:24 or U2013:64 return?
Yes If DTC B1267:24 or U2013:64 is present, GO to E2

If DTC B1268:24 is present, GO to E3
DISCONNECT and INSPECT convertible top switch C9013, Moveable Roof Control
Module A (MRCMA) C4830 and Moveable Roof Control Module B (MRCMB) C4831 for
corrosion, bent pins, pushed-out pins and spread terminals. REPAIR or INSTALL new
components as necessary.
For all other Moveable Roof Control Module A (MRCMA) and Moveable Roof Control
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Module B (MRCMB) Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: Moveable
Roof Control Module A (MRCMA) or Moveable Roof Control Module B (MRCMB).
E2 CHECK THE CONVERTIBLE TOP SWITCH UP CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C4830-8 Ground
Yes If DTC U2013:64 is not present, INSTALL a new convertible top switch.
REFER to: Overhead Console (501-12 Instrument Panel and Console, Removal and
Installation).
If DTC U2013:64 is present, GO to E3

E3 CHECK THE CONVERTIBLE TOP SWITCH DOWN CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C4831-8 Ground
Yes INSTALL a new convertible top switch.

REFER to: Overhead Console (501-12 Instrument Panel and Console, Removal and
Installation).
U0140:00
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With the ignition ON, the BCM sends messages to the Moveable Roof Control Module A (MRCMA) and Moveable
Roof Control Module B (MRCMB) through the GWM over the HS-CAN1. If the Moveable Roof Control Module A
(MRCMA) or Moveable Roof Control Module B (MRCMB) does not receive these messages within a certain time
frame, the module sets a DTC. For information on the messages sent to the Moveable Roof Control Module A
(MRCMA) and Moveable Roof Control Module B (MRCMB) by the BCM, refer to the Network Message Chart.
REFER to: Convertible Top - System Operation and Component Description (501-18 Convertible Top, Description
and Operation).

U0140:00 Lost Communication With Body This DTC sets in the Moveable Roof Control Module A (MRCMA)
Control Module: No Sub Type and Moveable Roof Control Module B (MRCMB) if the accessory
Information delay status or ignition status message is missing from the BCM.
Possible Sources

GWM
BCM
PINPOINT TEST F : U0140:00

F1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Do both the BCM and the GWM pass the Network Test?
Yes GO to F2
No DIAGNOSE the no communication with the BCM or GWM.
and Testing).
F2 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) AND MOVEABLE ROOF
CONTROL MODULE B (MRCMB) CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES
(CMDTCS)
Retrieve and record all Diagnostic Trouble Codes (DTCs) from both modules.
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) from both modules.
Ignition OFF.
Ignition ON.
Is DTC U0140:00 retrieved again?
Yes GO to F3
No GO to F6
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F3 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE GWM (GATEWAY MODULE
A) SELF-TEST
Using a diagnostic scan tool, carry out the GWM self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the GWM?
Yes DIAGNOSE all GWM Diagnostic Trouble Codes (DTCs).

No GO to F4
F4 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE BCM (BODY CONTROL
MODULE) SELF-TEST
Are any Diagnostic Trouble Codes (DTCs) present in the BCM?
Yes DIAGNOSE all BCM Diagnostic Trouble Codes (DTCs).

No GO to F5
F5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0140:XX SET IN OTHER MODULES
Using the diagnostic scan tool, carry out the self-test for all modules.
Retrieve and record the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Is DTC U0140:xx set in 1 or more modules in addition to the Moveable Roof Control Module A
(MRCMA) or Moveable Roof Control Module B (MRCMB)?
Service Bulletins (TSBs) address this concern, Click here to access

No GO to F6
F6 CHECK THE ELECTRICAL CONNECTORS
Ignition OFF.
Disconnect GWM C2431.
Disconnect BCM C2280G.
Using a good light source, inspect each connector for the following:
Using a suitable mating terminal, check the following connector terminals for deformed or enlarged
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contacts:
C4830-9
C4830-10
C4831-9
C4831-10
C2431-19
C2431-20
C2431-22
C2431-23
C2280G-9
C2280G-10
Are all the connectors free of corrosion, pushed-out pins and deformed or enlarged contacts?
Yes The system is operating correctly at this time. The DTC may have been set due to high
network traffic, a loose connector, a corroded connector or an intermittent fault condition.
ADDRESS the root cause of any connector or pin issues.
No REPAIR the affected connector.
U0142:00
When the convertible top is opened, the BCMB sends an "open" request to the rear window smart motors. Once
the windows are open, the smart motors send a reply to the BCMB. The BCMB then sends a message to the
Moveable Roof Control Module A (MRCMA) over the MS-CAN. If the Moveable Roof Control Module A (MRCMA)
does not receive this message within a certain time frame, the module sets a DTC. For information on the
messages sent to the Moveable Roof Control Module A (MRCMA) by the BCMB, refer to the Network Message
Chart.
and Operation).

U0142:00 Lost Communication With Body Control This DTC sets in the Moveable Roof Control Module A
Module "B": No Sub Type Information (MRCMA) if the rear window down status message is
missing from the BCMB.
Possible Sources

BCMB
PINPOINT TEST G : U0142:00

G1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
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Does the BCMB pass the Network Test?
Yes GO to G2
No DIAGNOSE the no communication with the BCMB.
and Testing).
G2 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) CONTINUOUS MEMORY

DIAGNOSTIC TROUBLE CODES (CMDTCS)
Retrieve and record all Diagnostic Trouble Codes (DTCs) from the Moveable Roof Control Module A
(MRCMA).
Using a diagnostic scan tool, clear the Diagnostic Trouble Codes (DTCs) from the Moveable Roof Control
Module A (MRCMA).
Ignition OFF.
Ignition ON.
Yes GO to G3
No GO to G5
G3 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE BCMB (BODY CONTROL
MODULE B) SELF-TEST
Using a diagnostic scan tool, carry out the BCMB self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the BCMB?
Yes DIAGNOSE all BCMB Diagnostic Trouble Codes (DTCs).

No GO to G4
G4 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0142:XX SET IN OTHER MODULES
(MRCMA)?
Service Bulletins (TSBs) address this concern, INSTALL a new BCMB.
No GO to G5
G5 CHECK THE ELECTRICAL CONNECTORS
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Ignition OFF.
Disconnect BCMB C4368A.
contacts:
C4830-9
C4830-10
C4368A-11
C4368A-23
Are both connectors free of corrosion, pushed-out pins and deformed or enlarged contacts?
U0294:00
With the ignition ON, the PCM sends messages to the Moveable Roof Control Module A (MRCMA) through the
GWM over the HS-CAN1. If the Moveable Roof Control Module A (MRCMA) does not receive these messages
within a certain time frame, the module sets a DTC. For information on the messages sent to the Moveable Roof
Control Module A (MRCMA) by the PCM, refer to the Network Message Chart.
and Operation).

U0294:00 Lost Communication With Powertrain This DTC sets in the Moveable Roof Control Module A
Control Monitor Module: No Sub Type (MRCMA) if the vehicle speed message is missing from
Information the PCM.
Possible Sources

PCM
PINPOINT TEST H : U0294:00

H1 CHECK THE COMMUNICATION NETWORK
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Ignition ON.
Do both the PCM and the GWM pass the Network Test?
Yes GO to H2
No DIAGNOSE the no communication with the PCM or GWM.
and Testing).
H2 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) CONTINUOUS MEMORY

(MRCMA).
Module A (MRCMA).
Ignition OFF.
Ignition ON.
Yes GO to H3
No GO to H6
H3 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE GWM (GATEWAY MODULE
A) SELF-TEST

Yes DIAGNOSE all GWM Diagnostic Trouble Codes (DTCs).
No GO to H4
H4 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE PCM (POWERTRAIN
CONTROL MODULE) SELF-TEST
Using a diagnostic scan tool, carry out the PCM self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the PCM?
Yes DIAGNOSE all PCM Diagnostic Trouble Codes (DTCs).

No GO to H5
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H5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0294:XX SET IN OTHER MODULES
(MRCMA)?
REFER to: Powertrain Control Module (PCM) (303-14A Electronic Engine Controls - 2.3L
EcoBoost (231kW/314PS), Removal and Installation).
REFER to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 3.7L
Duratec (227kW/301PS), Removal and Installation).
No GO to H6
H6 CHECK THE ELECTRICAL CONNECTORS
Ignition OFF.
Disconnect GWM C2431.
For 2.3L engine equipped vehicles, disconnect PCM C1551B.
contacts:
C4830-9
C4830-10
C2431-19
C2431-20
C2431-22
C2431-23
C1551B-75, C1381B-75 or C175B-69
C1551B-76, C1381B-76 or C175B-58
Are all the connectors free of corrosion, pushed-out pins and deformed or enlarged contacts?
U020A:00
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With the ignition ON, the Moveable Roof Control Module B (MRCMB) sends messages to the Moveable Roof
Control Module A (MRCMA) over the MS-CAN. If the Moveable Roof Control Module A (MRCMA) does not
receive these messages within a certain time frame, the module sets a DTC. For information on the messages
sent to the Moveable Roof Control Module A (MRCMA) by the Moveable Roof Control Module B (MRCMB), refer
to the Network Message Chart.
and Operation).

U020A:00 Lost Communication With Moveable This DTC sets in the Moveable Roof Control Module A
Roof Control Module "B" (MRCMB): No (MRCMA) if the convertible top status messages are
Sub Type Information missing from the Moveable Roof Control Module B
(MRCMB).
Possible Sources

PINPOINT TEST I : U020A:00

Ignition ON.
Does the Moveable Roof Control Module B (MRCMB) pass the Network Test?
Yes GO to I2
No DIAGNOSE the no communication with the Moveable Roof Control Module B (MRCMB).
and Testing).
I2 CHECK THE MOVEABLE ROOF CONTROL MODULE A (MRCMA) CONTINUOUS MEMORY

(MRCMA).
Module A (MRCMA).
Ignition OFF.
Ignition ON.
Is DTC U020A:00 retrieved again?
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Yes GO to I3
No GO to I5
I3 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE MOVEABLE ROOF
CONTROL MODULE B (MRCMB) SELF-TEST
Using a diagnostic scan tool, carry out the Moveable Roof Control Module B (MRCMB) self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the Moveable Roof Control Module B
(MRCMB)?
Yes DIAGNOSE all Moveable Roof Control Module B (MRCMB) Diagnostic Trouble Codes
(DTCs). GO to the DTC Chart: Moveable Roof Control Module B (MRCMB).
No GO to I4
I4 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U020A:XX SET IN OTHER MODULES
Is DTC U020A:xx set in 1 or more modules in addition to the Moveable Roof Control Module A
(MRCMA)?
Service Bulletins (TSBs) address this concern, INSTALL a new Moveable Roof Control
Module B (MRCMB).
No GO to I5
I5 CHECK THE ELECTRICAL CONNECTORS

Ignition OFF.
contacts:
C4830-9
C4830-10
C4831-9
C4831-10
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U0207:00
With the ignition ON, the Moveable Roof Control Module A (MRCMA) sends messages to the Moveable Roof
Control Module B (MRCMB) over the MS-CAN. If the Moveable Roof Control Module B (MRCMB) does not
receive these messages within a certain time frame, the module sets a DTC. For information on the messages
sent to the Moveable Roof Control Module B (MRCMB) by the Moveable Roof Control Module A (MRCMA), refer
to the Network Message Chart.
and Operation).

U0207:00 Lost Communication With Moveable This DTC sets in the Moveable Roof Control Module B
Roof Control Module "A" (MRCMB): No (MRCMB) if the convertible top status messages are
Sub Type Information missing from the Moveable Roof Control Module A
(MRCMA).
Possible Sources

PINPOINT TEST J : U0207:00
J1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the Moveable Roof Control Module A (MRCMA) pass the Network Test?
Yes GO to J2
No DIAGNOSE the no communication with the Moveable Roof Control Module A (MRCMA).
and Testing).
J2 CHECK THE MOVEABLE ROOF CONTROL MODULE B (MRCMB) CONTINUOUS MEMORY

Retrieve and record all Diagnostic Trouble Codes (DTCs) from the Moveable Roof Control Module B
(MRCMB).
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Module B (MRCMB).
Ignition OFF.
Ignition ON.
Yes GO to J3
No GO to J5
J3 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE MOVEABLE ROOF
CONTROL MODULE A (MRCMA) SELF-TEST
Are any Diagnostic Trouble Codes (DTCs) present in the Moveable Roof Control Module A
(MRCMA)?
Yes DIAGNOSE all Moveable Roof Control Module A (MRCMA) Diagnostic Trouble Codes
(DTCs). GO to the DTC Chart: Moveable Roof Control Module A (MRCMA).
No GO to J4
J4 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0207:XX SET IN OTHER MODULES
Is DTC U0207:xx set in 1 or more modules in addition to the Moveable Roof Control Module B
(MRCMB)?
Service Bulletins (TSBs) address this concern, INSTALL a new Moveable Roof Control
Module A (MRCMA).
No GO to J5
J5 CHECK THE ELECTRICAL CONNECTORS
Ignition OFF.
contacts:
C4830-9
C4830-10
C4831-9
C4831-10
cardiagn.com
Rear Window Down Feedback Signal Faults
After receiving a "window drop" message from the Moveable Roof Control Module A (MRCMA), the BCMB sends
a global open request to the 4 window smart motors. Once the windows have fully lowered, the rear window
smart motors send a ground signal to the BCMB indicating they are in the full down position. The BCMB then
sends a "window down" message to the Moveable Roof Control Module A (MRCMA) and convertible top
operation continues. When there is a fault on the circuit between the BCMB and the smart motors or when there
is a failure of the BCMB or smart motors, the rear windows do not operate when the convertible top is open or
closed which prevents convertible top operation. For additional information on window operation,
REFER to: Glass, Frames and Mechanisms - System Operation and Component Description (501-11 Glass,

B126E:23 Right Rear Window Fully This DTC sets in the BCMB when the accessory delay relay is OFF and
Down Feedback: Signal the right rear window fully down feedback signal is active (low, indicating a
Stuck Low possible short to ground).
B126E:24 Right Rear Window Fully This DTC sets in the BCMB when the right rear window fully down
Down Feedback: Signal feedback signal does not indicate "fully down" within 10 seconds of a
Stuck High "window drop" message from the Moveable Roof Control Module A
(MRCMA) (indicating a possible open circuit).
B126F:23 Left Rear Window Fully This DTC sets in the BCMB when the accessory delay relay is OFF and
Down Feedback: Signal the left rear window fully down feedback signal is active (low, indicating a
Stuck Low possible short to ground).
B126F:24 Left Rear Window Fully This DTC sets in the BCMB when the left rear window fully down feedback
Down Feedback: Signal signal does not indicate "fully down" within 10 seconds of a "window drop"
Stuck High message from the Moveable Roof Control Module A (MRCMA) (indicating
a possible open circuit).
Possible Sources

LH rear window motor
RH rear window motor
BCMB
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PINPOINT TEST K : REAR WINDOW DOWN FEEDBACK SIGNAL FAULTS
K1 CHECK FOR MOVEABLE ROOF CONTROL MODULE A (MRCMA) AND MOVEABLE ROOF
CONTROL MODULE B (MRCMB) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Are any Diagnostic Trouble Codes (DTCs) present in the Moveable Roof Control Module A (MRCMA)
or Moveable Roof Control Module B (MRCMB)?
Yes DIAGNOSE any Moveable Roof Control Module A (MRCMA) and Moveable Roof Control
Module B (MRCMB) Diagnostic Trouble Codes (DTCs), before diagnosing any BCMB
Diagnostic Trouble Codes (DTCs). GO to DTC Chart: Moveable Roof Control Module A
(MRCMA) or DTC Chart: Moveable Roof Control Module B (MRCMB).
No GO to K2
K2 CHECK FOR RETURNING BCMB (BODY CONTROL MODULE B) DIAGNOSTIC TROUBLE

CODES (DTCS)
Using a diagnostic scan tool, clear the BCMB Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Using the convertible top switch, attempt to operate the convertible roof for a minimum of 10 seconds.
Using a diagnostic scan tool, carry out the BCMB self-test.
Does DTC B126E:23, B126E:24, B126F:23 or B126F:24 return?
Yes GO to K3
No The concern may have been caused by a loose or corroded connector causing an
intermittent fault condition.
DISCONNECT BCMB C4368B, LH rear power window motor C3118 and RH rear power
window motor C3119.
INSPECT all 3 connectors for; corrosion, bent pins, pushed-out pins and spread terminals.
REPAIR or INSTALL new as necessary.
For all other BCMB Diagnostic Trouble Codes (DTCs),
K3 VERIFY REAR WINDOW OPERATION

Using the master window control switch, operate the rear windows.
Do the rear windows operate correctly from the master window control switch?
Yes For DTC B126E:23 or B126F:23, GO to K4

For DTC B126E:24 or B126F:24, GO to K5
No DIAGNOSE the inoperative rear windows.
K4 CHECK THE REAR WINDOW DOWN FEEDBACK CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Disconnect BCMB C4368B.
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If DTC B126E:23 is present, disconnect power window motor right rear C3119.
If DTC B126F:23 is present, disconnect power window motor left rear C3118.
If DTC B126E:23 is present, measure:

C4368B-16 Ground
If DTC B126F:23 is present, measure:

C4368B-3 Ground
Yes GO to K6
K5 CHECK THE REAR WINDOW DOWN FEEDBACK CIRCUITS FOR AN OPEN

Ignition OFF.
If DTC B126E:24 is present, disconnect power window motor right rear C3119.
If DTC B126F:24 is present, disconnect power window motor left rear C3118.
If DTC B126E:24 is present, measure:

C4368B-16 C3119-7
If DTC B126F:24 is present, measure:

C4368B-3 C3118-7
Yes GO to K6
K6 CHECK THE ELECTRICAL CONNECTORS
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Ignition OFF.
If DTC B126E:23 or B126E:24 is present, disconnect power window motor right rear C3119.
If DTC B126F:23 or B126F:24 is present, disconnect power window motor left rear C3118.
contacts:
C4368B-3
C4368B-16
C3119-7
C3118-7
Are all connectors free of corrosion, pushed-out pins and deformed or enlarged contacts?
Yes INSTALL a new right rear or left rear power window motor.
REFER to: Rear Quarter Window Regulator Motor - Convertible (501-11 Glass, Frames
and Mechanisms, Removal and Installation).

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Convertible Top Assembly
Removal
NOTICE: Make sure the body of the vehicle is fully covered with fender blankets or equivalent or damage
to the finish may result.
Many procedure views are with the convertible top in the fully closed position showing tension on the convertible
top material.
1. Open the convertible top approximately 50 percent.
From the luggage compartment on both sides, disconnect the convertible top tension belt adjuster bracket
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from body.
1. Push in on the rear of the convertible top tension belt adjuster to release the locking tabs.
2. Pull the rear of the convertible top tension belt adjuster down.
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On both sides, push convertible top tension belt adjuster bracket through body to interior.
4. On both sides, remove the rear quarter panel speakers.

Refer to: Rear Quarter Panel Speaker (415-00B Information and Entertainment System - General
5. Remove the parcel shelf.

Refer to: Parcel Shelf - Convertible (501-05 Interior Trim and Ornamentation, Removal and Installation).

During installation, make sure to position all trough assembly flexible material and convertible top
material in the exact location it was removed from.
On both sides, disconnect both trough hanging retainers (near the rear window belt moulding) from the
body.
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During installation, make sure to position all trough assembly flexible material and convertible top
material in the exact location it was removed from.
On both sides, slide the water bag portion of the trough assembly out of the bracket and position aside.
8. From inside the vehicle, disconnect the trough assembly from the convertible top assembly.
1. Locate the position of the notch on the floating bow and on the convertible top trough assembly for
alignment reference during installation.
2. Pull the convertible top trough assembly up and out of the floating bow track along the back and the
sides.
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9. Fully open the convertible top.
10. On the RH side only, position aside the RTM and bracket assembly.
1. Disconnect the RTM wiring harness clips from the speaker bracket.
2. Remove the RTM bracket nut.
3. Remove the RTM bracket bolt and position the RTM and bracket assembly aside.
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On both sides, remove the rear quarter panel speaker brackets.

1. On both sides, remove the speaker bracket stud.
2. On both sides, remove the speaker bracket nuts and the speaker bracket.
On both sides, disconnect the convertible top harness routing clip retainers and connectors and position
aside.
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Loosen the bolts approximately 13 mm (1/2 in.) for clearance of the guide pins when removing the
convertible top assembly.
On both sides, loosen the convertible top forward mounting bracket bolts.
Remove the remaining convertible top assembly bolts.
1. NOTE: This bolt remains to assist positioning the convertible top assembly during installation.
2. On both sides, remove the remaining convertible top retaining bolts.
15. NOTICE: Make sure the body of the vehicle is fully covered with fender blankets or equivalent or
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damage to the finish may result.
Position the convertible top assembly for removal.

1. Grasping the assembly on both sides in the area of the gears/motors pull the sides together,
releasing the guide pins from the body interior sheet metal.
2. With the help of an assistant, lift/tilt the gears/motors area of the assembly up and rearward, resting
the gears/motors area on top of the body interior sheet metal.
3. Inset is the position off the convertible top gear assembly area after positioning in sub step 2.
16. Measure the distance between the RH and LH sides of the frame assembly.
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On both sides, attach a retaining strap to the bottom of both floating bowl brackets as shown.
18. NOTICE: Reducing the distance between the floating bow brackets by more than 165 mm (6.5 in.)
may cause damage to the assembly.
Tighten the retaining strap so the measurement between the floating bow brackets is reduced by a
maximum of 140 mm (5.5 in.).
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19. NOTE: The sub steps should be performed together as a single step.
With the help of an assistant, lift the RH side of the convertible top assembly above the vehicle body.
1. Lift the RH side of the convertible top assembly.
2. While the convertible top assembly is being raised, push the floating bow area of the convertible top
assembly inward until the RH side of the convertible top assembly including the floating bow is fully
above the vehicle body.
3. Pull the floating bow part of the convertible top assembly outward for clearance to lift out the
convertible top assembly in the next step.
20. NOTE: This step and the next step should be performed together as a single step.
With the help of an assistant, move the convertible top assembly toward the RH side of the vehicle and lift
the LHside above the vehicle body.
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21. With the help of an assistant, carefully remove the convertible top assembly the rear of the vehicle to a
suitable workbench.
22. NOTE: If the convertible top assembly is being removed to service other convertible top components (not
replacing the complete assembly) the motors must be removed to allow free convertible top position
changes for access to remove components.
Skip this step if the complete convertible top assembly is being replaced.
If the convertible top assembly needs to be repositioned for access to other components when on the
workbench, remove both convertible top motors.
Refer to: Convertible Top Motor (501-18 Convertible Top, Removal and Installation).
Installation
1. Transfer parts as necessary.
3. If the complete convertible top assembly was replaced, fully close and latch the convertible top and reopen
to initialize the motors.
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Convertible Top Center Panel Side Weatherstrip
Removal
NOTE: Procedure views are with the convertible top in the fully closed position showing tension on the
convertible top material, actual position should be approximately 25-50 percent open allowing slack in the
convertible top material and other components for serviceability.
This procedure can be used for any of the 4 convertible top center panel side weatherstrips.
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Pull down to remove the convertible top center panel side weatherstrip trim.
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Convertible top headliner removed for clarity.

If any shims are present, note the position for installation.
Remove the convertible top center panel side weatherstrip nuts and the convertible top center panel side
weatherstrip.
Installation
Convertible top headliner removed for clarity.

Install with shim if removed with shim.
Loose install the convertible top center panel side weatherstrip.
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2. Close the convertible top.
Check for correct alignment of the convertible top center panel side weatherstrip and wiggle to seat
properly if needed.
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4. NOTE: Water test the convertible top to verify no water leak exists after repair.
Tighten the convertible top center panel side weatherstrip nuts.

Install the convertible top center panel side weatherstrip trim.

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Convertible Top Front Panel
Rivet Gun
Electric Drill
Removal
Procedure views are with the convertible top in the fully closed position showing tension on the convertible top
material, actual position should be approximately 25-50 percent open allowing slack in the convertible top
material and other components for serviceability.
1.
Release the convertible top.
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1. Lower the convertible top latch handle.
2. Twist the convertible top latch handle clockwise to release the convertible top.

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3. Remove the convertible top latch handle.
4.
Remove the convertible top front panel trim.
1. Remove the convertible top front panel trim retainers on the front of the trim.
2. Release the clips under the back of the convertible top front panel trim and remove the trim.
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5. Remove the headliner push pin retainers along the back of the convertible top front panel.
The headliner tension brackets can remain on the convertible top headliner.
On both sides.
Remove the headliner tension bracket retainers and brackets from the convertible top front panel.
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On both sides.
Remove the convertible top front panel side weatherstrip and bracket assembly.
1. Mark the convertible top front panel side weatherstrip bracket assembly at the retainers for
installation reference.
2. Remove the convertible top front panel side weatherstrip and bracket assembly retainers and
remove the weatherstrip/bracket assembly.
8. Remove the convertible top material push pin retainers at the back of the convertible top front panel.
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9. Disconnect the convertible top material from the front underside of the convertible top front panel.
1. Across the front, pull the convertible top material backward and down to release from the
convertible top front panel clips.
On both sides, pull the convertible top material from the double sided tape securing the material to
the convertible top front panel.
3. Roll the convertible top material forward and up over the convertible top front panel.
10. Fold the front of the convertible top material back to the first crossbow to expose the convertible top
tension cable end and stay pad rivets.
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On both sides.
Disconnect the convertible top tension cable from the convertible top front panel.
On both sides.
Disconnect the stay pad from the convertible top front panel.
1. NOTE: All rivet shavings must be removed from the vehicle and convertible top assembly.
Drill the stay pad rivets from the convertible top front panel.
2. Slide the stay pad to the center of the convertible top front panel to disconnect the stay pad.
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On both sides.
Remove the convertible top front panel.
1. With the help of an assistant.
Remove the frame to convertible top front panel retainers.
2. NOTE: If equipped, retain the shims for installation on both sides.
Installation
On both sides with the help of an assistant, loose install the convertible top front panel.
1. Position the shims as removed.
2. NOTE: The convertible top front panel retainers are loose installed at this point so the alignment of
the panel to frame can be set later in the procedure by closing and latching the convertible top.
Position the convertible top front panel and loose install the retainers.
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On both sides.
Attach the stay pad to the convertible top front panel.
1. Position the stay pad and slide outward to proper position for installing the rivet.
2. Install the stay pad rivets attaching the stay pad to the convertible top front panel.
Use the General Equipment: Rivet Gun
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On both sides.
Connect the convertible top tension cable to the convertible top front panel.
4. Fold the front of the convertible top material over the front of the convertible top front panel.
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5. Connect the convertible top material to the front underside of the convertible top front panel.
On both sides, apply double sided tape to the convertible top front panel as positioned when
removed.
2. NOTE: Sub steps 2 and 3 can be performed together along the front of the convertible top front
panel.
Roll the convertible top material down and rearward over the convertible top front panel.
3. Across the front, attach the convertible top material over the convertible top front panel clips.
6. Position the convertible top material and install the push pin retainers along the back of the convertible top
front panel.
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On both sides.
Install the front panel side weatherstrip and bracket assembly.
1. Align the front panel side weatherstrip and bracket assembly using the marks applied during
removal.
2. Tighten the front panel side weatherstrip and bracket assembly retainers.
8. NOTE: Before tightening, make sure to properly align the bracket so that the headliner to back of front
panel retainers are also aligned for the next step.
RH side shown, LH side similar.
On both sides.
Install the headliner tension bracket to the convertible top front panel.
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9. Position the headliner and install the headliner push pin retainers along the back of the convertible top front
panel.
10. NOTE: The retainer does not need to be tightened at this time.
Close the convertible top and install the convertible top latch handle and retainer.
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11.
Secure the convertible top in the closed position.
1. Pull down on the convertible top to position the latching mechanism properly.
2. Twist the latch handle counter clockwise to fully secure the convertible top.
On both sides.
Tighten the convertible top front panel to frame bracket nuts.
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14. Open the convertible top approximately 25%.

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16.
Install the convertible top front panel trim.
1. Position the convertible top front panel trim and attach the clips under the back of the convertible top
front panel trim.
2. Install the convertible top front panel trim retainers on the front of the trim.
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17. Install the convertible top latch handle.

Convertible Top Front Panel Side Weatherstrip
Rivet Gun
Electric Drill
Vise
Removal
1.
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Release the convertible top.
1. Lower the convertible top latch handle.
2. Open the convertible top approximately 25%.

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4.
Remove the convertible top front panel trim.
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6. NOTE: LH side shown, RH similar.
Remove the headliner tension bracket retainers and bracket from the convertible top front panel.
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7. NOTE: Headliner removed for clarity.
RH side shown, LH similar.
Remove the convertible top front panel side weatherstrip and bracket assembly.
1. NOTE: The reference marks must be used during installation because there is no adjustment for
the convertible top front panel side weatherstrip.
Mark the convertible top front panel side weatherstrip bracket assembly at the retainers for
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Make sure that the bracket does not bend when positioning in the bench vise or when drilling out the
rivets.
With the convertible top front panel side weatherstrip and bracket assembly secured in a bench vise.
Drill out the retaining rivets.
Use the General Equipment: Vise
Installation

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Convertible Top Front Striker
Removal
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Installation).
On both sides.
1. Remove the sun visor cap.
4. If equipped.
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4. Remove the sun visor latch clips.
5.
Remove the windshield header upper trim panel.
1. Release the 3 windshield header upper trim panel clips from the lower trim panel.
2. Release the 4 windshield header upper trim panel clips from the windshield header and remove the
upper header trim panel.
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6. NOTE: Wiring harness and overhead console removed for clarity.
Move the windshield header lower trim panel for access to the convertible top striker lower bolt.
1. Release the 6 windshield header lower trim panel clips from the windshield header.
2. NOTE: Disconnect the wiring harness as necessary for clearance.
Release the 2 windshield header lower trim panel clips (sun visor clips) from the windshield header
and lower the windshield header lower trim panel.
7. NOTE: side shown, RH side similar.
Remove the convertible top front striker lower bolt and on the LH side, disconnect the harness connector .
1. On the LH side only.
Disconnect the convertible top latch switch harness connector.
2. NOTE: The convertible top front striker reference marks must be used during installation for
proper alignment.
Mark the convertible top front striker to header panel for installation reference.
3. Remove the convertible top front striker lower bolt.
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Remove the convertible top front striker.
1. NOTE: The convertible top front striker retainer reference marks must be used during installation.
Mark the convertible top header panel around the retainers for installation reference.
2. Remove the convertible top front striker upper retainers and the striker.
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Installation

Convertible Top Headliner
Rivet Gun
Electric Drill
Removal
Procedure views are with the convertible top in the fully closed position showing tension on the convertible top material,
actual position should be approximately 25-50 percent open allowing slack in the convertible top material and other
components for serviceability.

2. Remove the convertible top front panel trim.

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3. Remove the convertible top headliner push pin type retainers along the back of the convertible top front panel.
On both sides, drill out the rivet to disconnect the convertible top headliner from the convertible top headliner tension
bracket.
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5. Remove the convertible top headliner nylon fabric strap from the floating bow.
1. Remove the convertible top headliner nylon fabric strap retainers from the floating bow.
2. NOTE: During installation, route the nylon fabric strap through the frame as it was removed.
On both sides, route the nylon fabric strap through the frame.
6. NOTE: Fold the convertible top headliner down between each cross bow after rivet removal to expose the next
cross bow.
All rivet shavings must be removed from the vehicle and convertible top assembly.
Drill out the cross bow retaining rivets.
1. NOTE: Inset view is from above with convertible top material removed for clarity.
Remove the rivets from cross bow 1.

2. Remove the rivets from cross bow 2.
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7. Remove the headliner from cross bow 4.
Drill out the rivets from cross bow 4.

2. NOTE: The nylon fabric strap has 2 sided tape holding it to cross bow 4 to aid in positioning during
installation.
The nylon fabric strap can remain routed over cross bow 4 after pushing through the convertible top
headliner.
Pull the end of the nylon fabric strap from the cross bar and push through the convertible top headliner to
release the convertible top headliner from cross bow 4.
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8. NOTE: All rivet, shavings or pieces must be removed from all cross bows and the vehicle interior. Rivet ends left
in any cross bow may result in a rattle condition.
Remove all rivet pieces from inside all of the cross bows.
1. NOTE: It may be necessary to force compressed air into multiple rivet holes in the cross bows to get all
rivet pieces out of the cross bows.
Using an air nozzle and compressed air, blow into each cross bow to force the rivet pieces to the outer ends
of the cross bows for removal.
2. NOTE: Check both ends of each cross bow to make sure all rivet pieces are removed from the vehicle
At the ends of the cross bows, collect all rivet pieces and verify that all rivet ends are accounted for.
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9. NOTE: The convertible top headliner trim ring is permanently attached to the convertible top headliner, and the
rear window glass frame is permanently attached to the convertible top material.
Some retaining clips may stay on the rear window glass frame. Remove from the rear window glass frame and
position all retaining clips on the convertible top headliner trim ring at the location where they were removed.
For installation, begin with the top 2 corners when attaching the convertible top headliner trim ring to the rear
window glass frame. This ensures proper alignment as the convertible top headliner trim ring is attached around
the rear window glass frame.
View shown is with the convertible top off vehicle for clarity.
Carefully pry the convertible top headliner trim ring from the rear window glass frame.
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10. NOTE: View is from outside the vehicle with the convertible top material removed for clarity.
From inside the vehicle, pull the headliner straight out of the floating bow to remove.
Installation

Convertible Top Material
Rivet Gun
Electric Drill
Removal
1. Refer to: Convertible Top Trough Assembly (501-18 Convertible Top, Removal and Installation).
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4. Remove the convertible top headliner push pin retainers along the back of the convertible top front panel.
5. NOTE: The headliner tension bracket will still be attached to the headliner.
On both sides, remove the headliner tension bracket retainers and bracket from the convertible top front panel.
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On both sides, remove the convertible top front panel side weatherstrip and bracket assembly.
1. Mark the convertible top front panel side weatherstrip bracket assembly at the retainers for installation
reference.
2. Remove the convertible top front panel side weatherstrip and bracket assembly retainers and remove the
weatherstrip/bracket assembly.
7. NOTE: Fold the convertible top headliner down between each cross bow after rivet removal to expose the next
cross bow.
Drill out the cross bow retaining rivets.
1. NOTE: Inset view is from above with convertible top material removed for clarity.
Remove the rivets from cross bow 1.

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On both sides, disconnect the rear window defrost harness.
Remove the rear glass tension rod.

1. Using a small flat-bladed screwdriver, press in on the retainer tabs to release the rear glass tension rod.
2. Pull out on the rear glass tension rod to remove from the rear glass frame.
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10. Remove the headliner from cross bow 4.
Drill out the rivets from cross bow 4.

2. NOTE: The nylon fabric strap has 2 sided tape holding it to cross bow 4 to aid in positioning during
installation.
The nylon fabric strap can remain routed over cross bow 4 after pushing through the convertible top
headliner.
Pull the end of the nylon fabric strap from the cross bar and push through the convertible top headliner to
release the convertible top headliner from cross bow 4.
Remove all rivet pieces from inside all of the cross bows.
Using an air nozzle and compressed air, blow into each cross bow to force the rivet pieces to the outer ends
of the cross bows for removal.
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12. NOTE: The convertible top headliner trim ring is permanently attached to the convertible top headliner, and the
rear window glass frame is permanently attached to the convertible top material.
Some retaining clips may stay on the rear window glass frame. Remove from the rear window glass frame and
position all retaining clips on the convertible top headliner trim ring at the location where they were removed.
For installation, begin with the top 2 corners when attaching the convertible top headliner trim ring to the rear
window glass frame. This ensures proper alignment as the convertible top headliner trim ring is attached around
View shown is with the convertible top off vehicle for clarity.
Beginning on the top corners of the rear window glass frame, carefully pry the convertible top headliner trim ring from
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13. Remove the convertible top material push pins at the back of the convertible top front panel.
14. NOTE: The convertible top material to crossbow retaining flaps are attached to the crossbows with 2 sided tape to
align the holes for the same rivets that were removed for the headliner. During installation, make sure to line up
the holes. A standard 2 sided tape can be used to ease alignment retention during installation.
Pull the convertible top material to crossbow retaining flap from the 2 sided tape at each crossbow.
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15. NOTE: During installation, route the convertible top tension cords and nylon fabric straps through the frame exactly
as they were removed.
On both sides, disconnect the convertible top tension cords and nylon fabric straps from the frame assembly.
1. Drill out the rivets to the front set of tension cords at the front side of the frame.
2. Drill out the rivets to the second set of tension cords at the center side of the frame.
3. NOTE: Do not drill out the D-ring retaining rivet.
Route the tension cord through the D-ring.
16. Disconnect the convertible top material from the front underside of the convertible top front panel.
1. Pull the convertible top material backward and down to release from the convertible top front panel clips.
2. On both sides, pull the convertible top material from the double sided tape securing the material to the
convertible top front panel.
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17. Fold the front of the convertible top material back to the first crossbow to expose the convertible top tension cable
ends at the convertible top front panel.
If the convertible top material is to be reinstalled a draw string can be attached to the convertible top tension cable
and left in the convertible top material for pulling the convertible top tension cable back into the convertible top
material during installation.
On both sides, disconnect the convertible top tension cable from the convertible top front panel.
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19. On both sides.
Refer to: Convertible Top Rear Panel Lower Weatherstrip (501-18 Convertible Top, Removal and Installation).
On both sides, release the convertible top material from the frame under the removed convertible top rear panel
lower weatherstrip.
1. Release the convertible top material edge trim from the frame as indicated in all 5 locations under the
removed convertible top rear panel lower weatherstrip.
2. Pull the convertible top material out to fully release from the frame.
On both sides, pull the convertible top material back to access the back of the convertible top tension cable.
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NOTE: Make sure to note the routing of the tension cable through the convertible top material for installation.
On both sides, leaving the convertible top tension cable attached to the frame, pull the front of the convertible top
tension cable out of the convertible top material.
23. NOTE: Make sure to remove the convertible top material retaining clips from the floating bow. The convertible top
material retaining clips must be placed on the convertible top material in the proper locations when installing.
Pull the convertible top material out of the floating bow to remove.
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Installation
1. Transfer parts as necessary.

Convertible Top Motor
Removal
1. On both sides, remove the rear quarter panel speakers.

Refer to: Rear Quarter Panel Speaker (415-00B Information and Entertainment System - General
2. On the RH side only.

Position aside the RTM and bracket assembly.
1. Disconnect the RTM wiring harness clips from the speaker bracket.
2. Remove the RTM bracket nut.
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3. Remove the RTM bracket bolt and position the RTM and bracket assembly aside.
On both sides.
Remove the rear quarter panel speaker brackets.
1. Remove the speaker bracket stud.
2. Remove the speaker bracket nuts and the speaker bracket.
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Disconnect the harness connectors and position harness aside.
Remove the motor guard bracket retainers and position aside.

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Remove the convertible top motor.

Installation
2. To initialize the motors, fully close and latch the convertible top and reopen fully.

Convertible Top Rear Panel Lower Weatherstrip
Electric Drill
Removal
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Drill the rivets from the convertible top rear panel lower weatherstrip.
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Installation

Convertible Top Switch
Removal
1. The roof opening panel switch is replaced as an assembly with the overhead console.
Refer to: Overhead Console (501-12 Instrument Panel and Console, Removal and Installation).
Installation
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Convertible Top Tension Belt
Removal
1. Remove the convertible top assembly.

Refer to: Convertible Top Assembly (501-18 Convertible Top, Removal and Installation).
2. NOTE: Make sure to remove the convertible top material retaining clips from the floating bow. The
convertible top material retaining clips must be placed on the convertible top material in the proper
locations when installing.
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Partially disconnect the convertible top material from the floating bow.
Remove the tension belt.

1. Remove the tension belt retaining screw.
2. Slide the tension belt out of the floating bow.
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Installation

Convertible Top Tension Cable
Rivet Gun
Electric Drill
Draw Cord
Removal
1. On the side needing convertible top tension cable serviced.
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Refer to: Convertible Top Rear Panel Lower Weatherstrip (501-18 Convertible Top, Removal and
Installation).


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On both sides, remove the headliner tension bracket retainers and bracket from the convertible top front
panel.
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1. Mark the convertible top front panel side weatherstrip bracket assembly at the retainers for
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8. On both sides, disconnect the convertible top material from the front underside of the convertible top front
panel.
1. Pull the convertible top material backward and down to release from the convertible top front panel
clips.
2. Pull the convertible top material from the double sided tape securing the material to the convertible
top front panel.
9. Fold the front of the convertible top material back to the first crossbow to expose the tension cable end
and stay pad rivets.
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Disconnect the convertible top tension cable from the convertible top front panel.
Release the convertible top material from the frame under the removed convertible top rear panel lower
weatherstrip.
1. Release the convertible top material edge trim from the frame as indicated in all 5 locations under
the removed convertible top rear panel lower weatherstrip.
2. Pull the convertible top material out to fully release from the frame.
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Position the convertible top material up in the area shown for access to remove the convertible top tension
cable.
Disconnect the convertible top tension cable from the convertible top frame.
Drill out the convertible top tension cable rivet.

2. Disconnect the spring end of the convertible top tension cable from the frame.
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Remove the convertible top tension cable.
1. NOTE: The draw cord is attached to the wiring harness so the harness can be easily routed
through the convertible top material during installation.
Attach a draw cord to the convertible top tension cable.

Use the General Equipment: Draw Cord
2. Pull the convertible top tension cable from the convertible top material leaving the draw cord
exposed on both sides of the convertible top material for installation.
Installation
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Convertible Top Trough Assembly
Removal
Many procedure views are with the convertible top in the fully closed position showing tension on the convertible
top material. Actual position should be approximately 25-50 percent open allowing slack in the convertible top
1. Remove the convertible top assembly.

Refer to: Convertible Top Assembly (501-18 Convertible Top, Removal and Installation).
2. Remove the convertible top trough assembly to inner body panel push pin retainers.
3. NOTE: LH shown, RH side similar. cardiagn.com

The water drain fitting should not be removed from the flexible water bag portion of the convertible top
trough assembly.
On both sides, from inside the convertible top trough assembly.

Carefully pull up on the flexible water bag portion of the convertible top trough assembly and the water
drain fitting to release the water drain fitting from the inner body panel grommet/drain hose.
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4. NOTICE: Make sure the body of the vehicle is fully covered with fender blankets or equivalent or
damage to the finish may result.
Remove the trough assembly from the vehicle.
1. NOTE: Sub steps 1, 2 and 3 should be performed together as a single step.
Pull the RH side of the convertible top trough assembly inward for clearance of the body side
panels.
2. Roll the RH side of the convertible top trough assembly forward and slightly down for clearance of
the rear body panels.
3. Lift the RH rear of the convertible top trough assembly above the body panels.
4. Remove the convertible top trough assembly toward the RH side of the vehicle.
Installation
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Stay Pad
Rivet Gun
Electric Drill
Removal
1. Refer to: Convertible Top Assembly (501-18 Convertible Top, Removal and Installation).

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On both sides, remove the headliner tension bracket retainers and bracket from the convertible top front panel.
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1. Mark the convertible top front panel side weatherstrip bracket assembly at the retainers for installation
reference.
2. Remove the convertible top front panel side weatherstrip and bracket assembly retainers and remove the
weatherstrip/bracket assembly.
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8. On both sides, disconnect the convertible top material from the front underside of the convertible top front panel.
1. Pull the convertible top material backward and down to release from the convertible top front panel clips.
2. Pull the convertible top material from the double sided tape securing the material to the convertible top front
panel.
9. Fold the front of the convertible top material back to the first crossbow to expose the tension cable end and stay pad
rivets.
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Disconnect the stay pad from the convertible top front panel.
Drill the stay pad rivets from the convertible top front panel.
2. Slide the stay pad to the center of the convertible top front panel to disconnect the stay pad.
11. NOTE: Clean all rivet shavings from the vehicle after removing the rivets.
Remove the stay pad to cross bow rivets.

1. Pull the edge of the headliner inward to access the stay pad rivets.
Drill out the stay pad rivets.
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Remove all rivet pieces from inside two center cross bows.
Using an air nozzle and compressed air, blow the two center cross bow to force the rivet pieces to the outer
ends of the cross bows for removal.
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13. NOTE: All rivet, shavings or pieces must be removed from the front and rear cross bows and the vehicle interior.
Rivet ends left in any cross bow may result in a rattle condition.
Remove all rivet pieces from inside the front and rear cross bows.
Using an air nozzle and compressed air, blow into the front and rear cross bows to force the rivet pieces to
the outer ends of the cross bows for removal.
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Remove the wiring harness from the LH stay pad webbing.

1. Disconnect the rear window wiring harness connector and routing connector, if equipped.
2. Route the wiring harness through the stay pad webbing.
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15. NOTE: Make sure to remove the convertible top material retaining clips from the floating bow. The convertible top
material retaining clips must be placed on the convertible top material in the proper locations when installing.
Partially disconnect the convertible top material from the floating bow.
Remove the stay pad.

1. Remove the stay pad retaining screw.
2. Slide the tension belt out of the floating bow.
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Installation

Tonneau Cover Sensor
Removal
The tonneau cover sensor is part of the D-tower cover and must be replaced as an assembly.
1. Remove the load space trim panel as necessary.

Installation).
Disconnect the harness connector.

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Remove the necessary D-tower cover.
1. Remove the bumper stop.
2. Remove the 2 pin-type retainers.
3. Release the clip and remove the cover.
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Installation

501-19 Bumpers 2016 Mustang
Front Bumper
Removal
1. Remove the front bumper cover.

Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2. Position aside the ambient air temperature sensor bracket and wiring harness guide.
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3. If equipped, remove the active grille shutter assembly.
Refer to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).
4. If equipped, remove the CCM and bracket.

Refer to: Cruise Control Module (CCM) (419-03B Cruise Control - Vehicles With: Adaptive Cruise Control,
5. Separate the wiring harness guides.

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6. Remove the bolts and the front bumper.
Installation

Front Bumper - Vehicles With: SVT Performance Package
Removal

Refer to: Front Bumper Cover - Vehicles With: SVT Performance Package (501-19 Bumpers, Removal and
Installation).
2. Position aside the ambient air temperature sensor bracket.
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3. Remove the push pins.
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Remove the pin-type retainers and position the air deflector side panel aside.
5. Remove the bolts and the radiator air deflector.

Torque:
1. Lower radiator air deflector bolts: 71 lb.in (8 Nm)
2. Upper radiator air deflector bolts: 93 lb.in (10.5 Nm)
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6. Separate the wiring harness guides.
7. With the help of an assistant, remove the bolts and the front bumper.
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Installation

Front Bumper Cover
Removal


3. Remove the push pins, screws and the lower air deflector.
Remove the push pins.

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Remove the push pins and position the inner fender liner aside.
6. NOTE: Halogen foglamp shown, LED fog lamp is similar.
NOTE: On both sides.

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Remove the bolt and separate the front bumper cover from the fender bracket.
8. Remove the push pins and the radiator sight shield.

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9. If equipped, remove the screws and the license plate bracket.
Position aside the outer edge of the hood seal and remove the bolt.
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11.
Remove the front bumper cover.
2. Lift the front bumper cover up and off the alignment pins.
3. Pull the front bumper cover forward and off the vehicle.
12. Inspect the fender bracket teeth for damage.

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13. If required.
Remove the bolts and the fender bracket.
Installation

Front Bumper Cover - Vehicles With: SVT Performance Package
Removal
All vehicles


GT-350 vehicles
3.
Remove the air splitter screws.
1. Remove the screws starting with the outward screws and working to the center screws.
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4. Remove the screws starting with the outward screws and working to the center screws and slide the
center air splitter forward to remove.
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NOTE: Access the outer air splitter screws through the opening created from the center air splitter
removal.
Remove the outer air splitter screws and J-nuts.


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Remove the pin-type retainers and position the fender liner aside.
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Remove the retaining clips and the outer air splitters.
GT-350R vehicles
10.
Remove the air splitter screws.
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11. Remove the screw covers.
12. Remove the air splitter screws.

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Remove the pin-type retainers and position the fender liner aside.
Remove the retaining clips.

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17. Remove the screws starting with the outward screws and working to the center screws and slide the
center air splitter forward to remove.
All vehicles
18. Remove the underbody shield front screws.

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Remove the bolt and separate the front bumper cover from the fender bracket.
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Remove the top outer front bumper cover screws.

1. Position aside the outer edge of the hood seal.
2. Remove the top outer bolts.

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23.
Remove the front bumper cover.
1. Lift the front bumper cover up and off the alignment pins.
2. Pull the front bumper cover forward and off the vehicle.
24. Inspect the fender bracket teeth for damage.

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25. .
If required, remove the bolts and the fender bracket
Installation

Rear Bumper
Removal
1. Remove the rear bumper cover.

Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
2. Remove the bolts and the rear bumper.

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Installation

Rear Bumper Cover
Removal

2.
1. Remove the push pins.


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Disconnect the rear bumper harness electrical connector and separate the wiring harness guide.
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4. Remove the rear wheels and tires.
Remove the screw and the pushpins.
6. Remove the bumper cover to bracket screws.

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7. Remove the rear lamp assemblies.
Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
8.
Position the rear bumper cover aside for access to electrical connector.
1. Release the sides of the rear bumper cover from the brackets.
2. Release the center of the rear bumper cover from the rear brackets and position aside.
9. Disconnect the rear bumper wiring harness electrical connector.

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Inspect the side bracket for damage.

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12. Inspect the rear brackets for damage.
13. If required, remove the screws and the side bracket.

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14. If required, remove the screws and the outer rear bracket.
15. If required, remove the screws and the center rear bracket.
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Installation

Rear Bumper Cover - Vehicles With: SVT Performance Package
Removal
All vehicles

2. Remove the push pins and the pin-type retainers.
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3. Remove the rear wheels and tires.
4. On both sides.
Remove the pin-type retainers, the push pins and the screw then position the fenderliner aside.
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Vehicles equipped with small fender lip mouldings
5. On both sides.
Remove the screws and the fender lip moulding.
Vehicles equipped with large fender lip mouldings
6. On both sides.
Remove the screws and the fender lip moulding.
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All vehicles
7. Remove the rear lamp assemblies.

Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
8.
Position the rear bumper cover aside for access to electrical connector.
1. Release the sides of the rear bumper cover from the brackets.
2. Release the center of the rear bumper cover from the rear brackets and position aside.
9. Disconnect the electrical connector and remove the rear bumper cover.
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Inspect the brackets for damage.
11. Inspect the rear brackets for damage.

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12. If required, remove the screws and the side bracket.
13. If required, remove the screws and the outer rear bracket.
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14. If required, remove the screws and the center rear bracket.
Installation

Disassembly and Assembly Procedure revision date: 12/10/2015
Front Bumper Cover
DISASSEMBLY
All vehicles

Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
2. Release the clips and remove the front bumper cover reinforcement.
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3. NOTE: LH shown, RH similar.
Remove the fog lamp brackets.

3. Remove the fog lamp bracket.
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4. Release the tabs and remove the upper radiator grille.
5. Release the tabs and remove the lower radiator grill.

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6. Remove the hood seal.
Vehicles equipped with base spoiler
7. Remove the bolts, push pins and the lower spoiler.

Vehicles equipped with performance spoiler
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8. Remove the bolts, push pins and the lower spoiler.
9. Remove the rivets and the spoiler reinforcement.

ASSEMBLY
1. To assemble, reverse the disassembly procedure.
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Front Bumper Cover - Vehicles With: SVT Performance Package
DISASSEMBLY

Refer to: Front Bumper Cover - Vehicles With: SVT Performance Package (501-19 Bumpers, Removal and
Installation).
Remove the pin-type retainer and the air duct.
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3. Remove the pin-type retainers and the front bumper reinforcement.
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Remove the turn signal assembly bracket.

1. Remove the outer turn signal bracket screws.
2. Remove the inner turn signal bracket screws.
Release the tabs and remove the turn signal trim panel.
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6. Release the tabs and remove the lower radiator grille.
Remove the front bumper cover trim panel.

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Remove the upper radiator grille trim panel.

Remove the upper radiator grille panel.

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10. Release the trim pins and remove the hood seal.
Remove the screws and the lisence plate bracket.

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ASSEMBLY

Rear Bumper Cover
DISASSEMBLY
All vehicles

Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
2. Separate the wiring harness guides from the rear bumper cover reinforcement.
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3. Remove the pin-type retainers, release the tabs and remove the rear bumper cover reinforcement.
4.
Remove the rear bumper wiring harness.
2. Disconnect the wiring guides.
5. Remove the rear park aid sensors.
6. Remove the screws and the reversing lamp.

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Press the tabs and remove the license plate lamp.
8. Press the tabs and remove the decklid release switch.

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Remove the nut, release the tabs and remove the rear reflector.
Release the tab and remove the side marker lamp.

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GT vehicles
11.
Remove the lower bumper cover.
3. Remove the lower bumper cover.
ASSEMBLY

Rear Bumper Cover - Vehicles With: SVT Performance Package
DISASSEMBLY

Refer to: Rear Bumper Cover - Vehicles With: SVT Performance Package (501-19 Bumpers, Removal and
Installation).
2. Disconnect the rear bumper cover wiring harness electrical connectors.
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3. Release the rear bumper cover wiring harness guides and remove the wiring harness.
4. Release the tabs and remove the rear bumper reinforcement.

Press the tabs and remove the license plate lamp.
6. Press the tabs and remove the decklid release switch.

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Remove the screws and the exhaust outlet heat shields.
Release the tab and remove the side marker lamp.

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Remove the nut, release the tabs and remove the and the rear reflector.
10. Remove the screws and the reversing lamp.

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11. Remove the screws, the clips and the lower reinforcement.
12. Remove the lower bumper cover screws.

13. Release the tabs and remove the lower bumper cover.
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ASSEMBLY

501-20A Seatbelt Systems 2016 Mustang
Seatbelt Systems - System Operation and Component Description
System Operation
Emergency Locking Retractor (ELR)
All retractors have an Emergency Locking Retractor (ELR) mode, which is a vehicle-sensitive feature designed to
activate and lock the safety belt webbing during hard braking, cornering, or an impact of approximately 24 km/h
(14.9 mph). The Emergency Locking Retractor (ELR) feature helps reduce the forward movement of the driver
and passengers. For testing, see Functional Test - Safety Belt Retractor, Road Test Inspection,
Refer to: Seatbelt Systems (501-20A Seatbelt Systems, Diagnosis and Testing).
Automatic Locking Retractor (ALR)
The Automatic Locking Retractor (ALR) mode is used when locking a child seat in any passenger seating position.
The Automatic Locking Retractor (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 Automatic Locking Retractor (ALR)
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mode and the safety belt webbing cannot pull back out of the safety belt retractor. The Automatic Locking
Retractor (ALR) mode disengages when the webbing is allowed to fully retract back into the retractor. For testing,
see Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode,
Safety Belt Warning Indicator and Chime
The conditions of operation for the driver and/or front passenger safety belt warning indicator and chime operate
as follows:
If the driver and/or passenger safety belt is not buckled with the ignition ON, then the safety belt warning
indicator illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds.
If the driver and/or passenger safety belt is buckled while the warning indicator is illuminated and the
warning chime is sounding, then the indicator and chime turn off.
If the driver and/or passenger safety belt is buckled before the ignition is in the ON position, the safety belt
warning indicator and chime remain off.
Belt-Minder®
The Belt-Minder® feature is a supplemental warning to the safety belt warning function. This feature provides an
additional reminder 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 IPC.
Either the driver or front passenger safety belt systems may activate the Belt-Minder®. If the Belt-Minder®
warnings have expired (warnings 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 OCS detects a passenger in the right front seat
and the passenger weight exceeds a programmed limit. For information on the OCS,
Refer to: Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) - System Operation and
Component Description (501-20B Supplemental Restraint System, Description and Operation).
When a MyKey® is in the ignition, the Belt-Minder® feature cannot be deactivated. Refer to the Owner's
Literature for further information on MyKey® functionality.
To activate or deactivate the Belt-Minder® feature,

Refer to: Seatbelt Minder Deactivating/Activating (413-01 Instrumentation, Message Center and Warning Chimes,
The Belt-Minder® feature works as follows:

If... Then...
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 1-2
minutes have elapsed since the ignition has been
turned ON...
the driver and/or front passenger safety belt is not the Belt-Minder® feature is activated — the safety belt
buckled before the vehicle has reached at least 9.7 warning indicator illuminates and the warning chime
km/h (6.0 mph) and 1-2 minutes have elapsed since the sounds for 6 seconds every 25 seconds, repeating for
ignition has been turned ON... 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 belt
unbuckled for approximately one minute while the warning indicator illuminates and the warning chime
vehicle is traveling at least 9.7 km/h (6.0 mph) and sounds for 6 seconds every 25 seconds, repeating for
more than 1-2 minutes have elapsed since the ignition approximately 5 minutes or until the safety belt(s) is
has been ON... buckled.
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Child Safety Seat Tether Anchor
Child safety seat tether anchors are located at the rear seating positions and are part of the parcel shelf sheet
metal.
If a child safety seat was in use during a collision, inspect the child safety seat mounting areas and restore the
vehicle to the original production configuration.
Child Safety Seat Tether Anchor - Lower Anchors and Tethers for Children (LATCH)
Lower Anchors and Tethers for Children (LATCH) are located under the rear seat where the backrest and cushion
meet and are released for service.
Refer to: Child Safety Seat Tether Anchor (501-20A Seatbelt Systems, Removal and Installation).
.
If a child safety seat was in use during a collision, inspect the child safety seat mounting areas and restore the
vehicle to the original production configuration.

Seatbelt Systems
Symptom Chart(s)
Before diagnosing or repairing the safety belt system, inspect the following items:
Safety belt webbing integrity (torn, frayed, cut or stretched)

Safety belt buckle and tongue assembly
Symptom Chart: Safety Belt System
Symptom Chart
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The safety belt warning Failed indicator If the air bag warning indicator is not illuminated,
indicator does not operate Wiring, terminals or REFER to: Instrumentation, Message Center and
connectors Warning Chimes (413-01 Instrumentation, Message
IPC Center and Warning Chimes, Diagnosis and Testing).
RCM
The safety belt warning Wiring, terminals or If the air bag warning indicator is illuminated,
chime does not operate connectors REFER to: Airbag Supplemental Restraint System
Safety belt switch (SRS) (501-20B Supplemental Restraint System,
IPC Diagnosis and Testing).
RCM If the air bag warning indicator is not illuminated,
REFER to: Instrumentation, Message Center and
Warning Chimes (413-01 Instrumentation, Message
Center and Warning Chimes, Diagnosis and Testing).
The safety belt retractor Safety belt retractor CARRY OUT Functional Test - Safety Belt Retractor,
webbing does not extract is in Automatic Automatic Locking Retractor (ALR) Mode or
or exhibits excessive Locking Retractor Functional Test — Safety Belt Retractor. INSTALL
pressure on the occupant (ALR) mode new components as directed.
during use Safety belt retractor
binding internally
The safety belt retractor Twisted or CORRECT the twisted safety belt webbing.
webbing does not retract incorrectly routed REFER to: Seatbelt Twisted at the Seatbelt Guide
or has excessive slack safety belt webbing (501-20A Seatbelt Systems, General Procedures).
during use Safety belt retractor REFER to: Seatbelt Tongue Rotated On Belt
binding internally (501-20A Seatbelt Systems, General Procedures).
CARRY OUT Functional Test — Safety Belt Retractor.
INSTALL new components as directed.
The Belt-Minder® feature Belt-Minder® feature Activate the Belt-Minder® feature.
is inoperative is deactivated REFER to: Seatbelt Minder Deactivating/Activating
Wiring, terminals or (413-01 Instrumentation, Message Center and
connectors Warning Chimes, General Procedures).
If the Belt-Minder® is activated, DIAGNOSE the
inoperative Belt-Minder® feature. REFER to:
Instrumentation, Message Center and Warning
Chimes (413-01 Instrumentation, Message Center and
Warning Chimes, Diagnosis and Testing).
The safety belt tongue is Twisted or incorrectly
rotated on the safety belt routed safety belt webbing REFER to: Seatbelt Tongue Rotated On Belt
webbing (501-20A Seatbelt Systems, General Procedures).
The safety belt webbing is Twisted or incorrectly
twisted at the safety belt routed safety belt webbing REFER to: Seatbelt Twisted at the Seatbelt Guide
guide (501-20A Seatbelt Systems, General Procedures).
The safety belt webbing is Dirty or soiled safety belt
dirty or soiled webbing REFER to: Seatbelt Cleaning (501-20A Seatbelt
Systems, General Procedures).
Functional Test - Safety Belt Buckle and Tongue
NOTE: Make sure the safety belt buckle and tongue assembly 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 does not require excessive effort.

A click is heard when the safety belt buckle latches the tongue.
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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
NOTE: Make sure the safety belt retractor is 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 or up 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 make sure the safety belt retractor has remained in the Automatic
Locking Retractor (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 Automatic Locking Retractor (ALR) mode. If the safety belt retractor remains locked in the
Automatic Locking Retractor (ALR) mode, install a new safety belt retractor.
Functional Test - Safety Belt Retractor, Road Test Inspection
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. Fasten the safety belts and proceed to a safe area.
2. Reach a speed of 24 km/h (14.9 mph).
WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, never on
wet pavement or gravel. Failure to follow this instruction may result in serious personal injury.
3. 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).
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Seatbelt Cleaning
Cleaning
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.
1. Refer to the owner's literature for information on safety belt care and the recommended cleaning solution
to use. Follow the manufacturer's instructions provided with the cleaning solution.
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Seatbelt Maintenance
Inspection
1. Periodically inspect the safety belt assemblies for damage 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, inspect the safety belt retaining areas for damage and
distortion. If the retaining points are damaged and distorted, work the sheet metal back to its original
shape and structural integrity.
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3. Install the new safety belt(s) using the appropriate instructions. Carry out the appropriate Functional Test
procedure for all seating positions.

Seatbelt Procedure After a Collision
Inspection
1. Before installing the new safety belt assembly, inspect the safety belt attaching areas for damage and
distortion. If the attaching points are damaged and distorted, work the sheet metal back to its original
shape and structural integrity.
2. Install new safety belt(s) at any seating position(s) where deployment has occurred and the safety belt(s)
were used. Carry out the appropriate Functional Test procedure for all seating positions.
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Seatbelt Tongue Rotated On Belt
Adjustment
1. Fold the safety belt as indicated.
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2. Pull the safety belt tongue over the fold in the safety belt.

Seatbelt Twisted at the Seatbelt Guide
Adjustment
injury.
2. If necessary, remove necessary trim panel(s).
3. NOTE: Typical D-ring shown, others similar.
Grasp the safety belt webbing at the D-ring and fold the twisted portion of the safety belt webbing over
itself.
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4. Feed the folded portion of the safety belt webbing through the D-ring to remove the twist from the safety
belt webbing.
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Child Safety Seat Tether Anchor
Removal

2. Remove the retainers and the child safety seat tether anchor.
Installation
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Front Seatbelt Buckle
Removal
NOTE: LHD passenger seat shown, all other seats similar.

2.
Remove the front safety belt buckle.
1. Remove the wire harness retainers.
2. Disconnect the safety belt buckle electrical connector.
3. Remove the retainer and the safety belt buckle.
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Installation
1. NOTE: During installation, make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupants.
2. Check the active restraint system for correct operation.


Front Seatbelt Retractor and Pretensioner
Removal
All vehicles
1. Depower the SRS.

2. Remove the loadspace trim panel.

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Installation).
Installation).
3. Position the carpet aside.
4. 1. Disconnect the anchor pretensioner electrical connector.

2. Remove the anchor pretensioner bolt.
3. NOTICE: The rear anchor pretensioner bolt must remain attached and flush to the anchor
plate during removal and installation. Failure to follow this instruction prevents correct
installation of the anchor pretensioner, requiring installation of a new safety belt assembly.
While pulling outward on the anchor pretensioner, remove the rear bolt.
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Convertible
5.
For the RH side, remove the RTM.
1. Detach the wire harness retainers.
2. Remove the nut.
3. Remove the bolt.
6.
Remove the speaker and bracket assembly.
1. Detach the wire harness retainer.
5. Remove the nuts.
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7. Remove the D-ring bolt and position the safety belt aside.
8. Disconnect the electrical connector, remove the retainer and the safety belt retractor and pretensioner.
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Coupe
9. NOTE: Follow the unique instructions or graphics for this step in the installation.
Remove the D-ring bolt.

1. Remove the D-ring bolt cover.
2. Remove the D-ring bolt and position the safety belt aside.
10.
Remove the safety belt retractor and pretensioner.
1. Remove the safety belt retractor retainer.
2. Disconnect the electrical connector and remove the safety belt retractor and pretensioner.
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Installation
Convertible
Coupe
2.
Install the safety belt retractor and pretensioner.
1. Connect the electrical connector and position the safety belt retractor and pretensioner.
2. Install the safety belt retractor and pretensioner retainer.
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3.
Install the D-ring bolt.
1. Position the safety belt and install the D-ring bolt.
2. Install the D-ring bolt cover.
4. NOTE: During installation, make sure the safety belt webbing is not twisted between the D-ring and the
safety belt retractor and a single 180 degree twist clockwise LH side or counterclockwise RH side.
Rotate the anchor pretensioner clockwise on the LH side, counterclockwise on the RH side, 180 degrees.
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All vehicles
6. Repower the SRS.



Rear Seatbelt Buckle
Removal

2. Remove the bolt and the safety belt buckle.

Installation
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Rear Seatbelt Retractor - Coupe
Removal

2. Remove the parcel shelf.

Refer to: Parcel Shelf - Coupe (501-05 Interior Trim and Ornamentation, Removal and Installation).
3. Remove the retainer and position the safety belt aside.

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4. Remove the retainers and the safety belt retractor.
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Installation


Rear Seatbelt Retractor - Convertible
Removal
NOTE: LH shown, RH similar.

2. Position the seatbelt guide aside, release the clips and remove the upper loadspace trim panel.
3.
Remove the middle loadspace trim panel.
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1. Release the clips.
2. Pull forward and outward to release the rear tab, position the front and rear safety belts aside and
remove the middle loadspace trim panel.
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4. Remove the retainer and position the seatbelt aside.
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5.
Remove the seatbelt retractor.
1. Remove the D-ring bolt.
2. Remove the seatbelt retractor bolt, position the luggage compartment lid lock cylinder bracket aside
(LH side only), and remove the seatbelt retractor.
Installation
1. NOTE: During installation, make sure the seatbelt webbing is not twisted and the seatbelts and buckles
are accessible to the occupants.

2. Check the seatbelt system for correct operation.
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501-20B Supplemental Restraint System 2016 Mustang
Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) - Component Location
NOTE: LHD vehicle shown, RHD vehicle similar.
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Item Description
1 Front passenger safety belt buckle (includes buckle switch and Belt
Tension Sensor (BTS))
2 OCSM (includes OCS sensor and gel-filled bladder)
3 RCM
4 Passenger front door side impact sensor
5 Overhead console (includes PAD indicator)
6 LH and RH C-pillar side impact sensors (coupe only)
7 RH front impact severity sensor
8 LH front impact severity sensor
9 Seat position sensors
10 Clockspring
11 Driver front door side impact sensor
12 Driver safety belt buckle (includes buckle switch)
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Item Description
1 Driver safety belt retractor (includes retractor pretensioner and anchor
pretensioner)
2 LH side air curtain (coupe only)
3 RH side air curtain (coupe only)
4 Driver upper side airbag (convertible only)
5 Driver side airbag
6 Front passenger safety belt retractor (includes retractor pretensioner
and anchor pretensioner)
7 Passenger upper side airbag (convertible only)
8 Passenger side airbag
9 Driver airbag
10 Deployable steering column
11 Driver knee airbag
12 Passenger knee airbag
13 Passenger airbag
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Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) - Overview
Overview
The RCM continually receives and monitors inputs from the OCSM and various other hard-wired switches and
sensors. If the RCM detects a sudden vehicle deceleration and/or lateral deceleration based on the information
received from the various sensors, and determines that deployment is necessary, the RCM applies voltage and
current to deploy the appropriate SRS components.
The SRS utilizes Connector Position Assurance (CPA) tabs on deployable component connectors. The tabs
disengage the shorting bars of the deployable component from its electrical pins and keep the harness connector
securely attached to the deployable component.
If the connector is attached to the deployable component yet the tab is not fully seated, the pins of the connector
still make contact with the deployable component pins. However, because the tab is not fully seated and the
shorting bars are still applied to the deployable component pins, the RCM detects a fault (circuit resistance below
threshold) during self-diagnostics when the vehicle is powered on (airbag warning indicator is illuminated).
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Airbag and Seatbelt Pretensioner Supplemental Restraint System (SRS) - System Operation and
System Operation
System Diagram - Supplemental Restraint System (SRS)
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Network Message Chart - Supplemental Restraint System (SRS)
Module Network Input Messages - RCM

Module
eCall confirmation APIM Used for SYNC® 911 Assist™ operation. Indicates whether eCall
notification is in progress after an airbag deployment.
Ignition status BCM Used to qualify certain faults during RCM self-diagnostics.
Airbag warning IPC Confirms airbag warning indicator status to the RCM.
indicator status
OCS vehicle OCSM Shares application-specific data for comparison purposes to make
calibration data sure the correct OCSM and RCM are installed.
OCS fault status OCSM Indicates an OCS fault, if present.
OCS sensor data OCSM OCS sensor readings.
OCS serial number OCSM OCSM serial number.
Vehicle configuration BCM Used for verifying vehicle configuration data.
data
System Diagram - Occupant Classification System (OCS)
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Network Message Chart - Occupant Classification System (OCS)
Module Network Input Messages

Module
Front passenger safety belt buckle RCM Used for determining passenger airbag disable
status status.
RCM serial number RCM RCM serial number.
Supplemental Restraint System
The SRS is controlled by the RCM, which continually monitors various inputs. When these inputs indicate a frontal
or side crash, the RCM may deploy some components, based upon the severity of the crash and the sensor
inputs.
Although some deployable devices may not have activated for all occupants during a crash, it does not mean that
something is wrong with the SRS.
The RCM performs a self-test of the complete SRS during each startup. In addition to the self-test at start up, the
RCM continuously monitors all of the SRS components and circuitry for correct operation.
Airbag Warning Indicator
The airbag warning indicator:
proves out by lighting 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.
When the ignition is turned ON during normal operation, the IPC illuminates the airbag warning indicator
continuously for 6 seconds. If the SRS is free of faults, the airbag warning indicator turns off and remains off. If a
SRS fault exists, the airbag warning indicator illuminates and remains illuminated for the rest of the ignition cycle.
The RCM communicates with the IPC via the HS-CAN. The IPC illuminates the airbag warning indicator based on
messaging from the RCM. The IPC also illuminates the airbag warning indicator if there is no communication
between the RCM and IPC.
Event Notification Signal
The event notification feature provides other vehicle subsystems with information pertaining to SRS deployment or
fuel cutoff status. When an impact occurs which exceeds a pre-determined threshold, the RCM sends a signal on
a dedicated circuit to the BCM.
When the BCM receives the crash signal input, it initiates fuel cutoff to disable the fuel system.
After the fuel system is disabled, the vehicle can be re-started after carrying out the following steps:
a. Turn the ignition ON and wait 10 seconds.

b. Turn the ignition OFF.
c. Turn the ignition ON.
d. Turn the ignition OFF.
e. Turn the ignition ON.
Occupant Classification System (OCS)
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The OCS classifies the size of the front passenger seat occupant and provides this information to the RCM.
Pressure is applied to the OCS bladder when weight of any occupant or object in the front passenger seat is
present. The pressure is then transferred through a tube and sensed by the OCS pressure sensor within the
OCSM. The OCSM sends information concerning the weight of any occupant or object on the front passenger
seat to the RCM via the HS-CAN. The RCM uses this information when determining if the passenger airbag or
side airbag needs to be deployed in the event of a crash.
The OCS is also used for operation of the passenger Belt-Minder®. For information about Belt-Minder®,
Refer to: Seatbelt Systems - System Operation and Component Description (501-20A Seatbelt Systems,
To deactivate or reactivate the passenger Belt-Minder® feature,

Refer to: Seatbelt Minder Deactivating/Activating (413-01 Instrumentation, Message Center and Warning Chimes,
Passenger Airbag Deactivation (PAD) Indicator
The RCM controls the PAD indicator through a direct, hard-wired connection, based on information provided by
the OCS. The PAD indicator illuminates to indicate the passenger airbag is disabled. An exception to this is when
the front passenger seat is determined to be empty and indication of a deactivated passenger airbag is not
necessary. In all other cases, the PAD indicator is off when the passenger airbag is enabled.
The RCM briefly activates the PAD indicator to prove out the indicator function and verify proper functional
operation of the PAD indicator to the front occupants.
The following table indicates the passenger airbag and PAD indicator status based on the size of the front
passenger occupant.
Occupant Size Passenger Safety Belt Buckle Status Passenger Airbag Status PAD Indicator Status
Empty Unbuckled Disabled Unlit
Empty Buckled Disabled Lit
Small Buckled or Unbuckled Disabled Lit
Large Buckled or Unbuckled Enabled Unlit
Airbag Second Stage Deployment Check
The driver and passenger front airbags each have 2 deployment stages. After an airbag deployment, it is possible
that stage 1 has deployed and stage 2 has not. If a front airbag has deployed, the front airbag must be remotely
deployed using the appropriate airbag disposal procedure to make sure both stages have been deployed. For
information on driver airbag and/or passenger airbag remote deployment,
Refer to: Pyrotechnic Device Disposal (501-20B Supplemental Restraint System, General Procedures).
SOS Post-Crash Alert System™
The SOS Post-Crash Alert System™ is controlled by the BCM, but initiated by the RCM.
When a deployment or fuel cutoff event occurs, the RCM sends a message on the HS-CAN2 (via the GWM) to
the BCM. The BCM flashes the turn signal lamps and sounds the horn (except when 911 Assist™ is active) until it
is turned off. The system can be turned off 10 seconds after a crash event by pressing the hazard switch. The
BCM also unlocks the doors and illuminates the courtesy lamps after a crash event.
Vehicle Spin-out Detection
When internal RCM sensors detect that the vehicle has spun out, the ABS module receives this data on a
dedicated HS-CAN and sends a message to the BCM on the HS-CAN2 (via the GWM). The BCM then activates
the hazard warning flashers and displays a message in the IPC to indicate the hazard warning flashers are
activated due to the spin-out.
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Front Impact Severity Sensor
The front impact severity sensors measure acceleration (g-rate) and are hardwired to the RCM. Mounting position
and orientation is critical for correct operation of the front impact severity sensors.
Occupant Classification System (OCS)
The OCS is found only on the front passenger seat. The OCS classifies the size of the front passenger seat
occupant.
The OCS is comprised of a silicone gel-filled bladder mounted between the seat cushion foam and pan, an OCSM
which is mounted to the seat frame, and a pressure sensor that is internal to the OCSM. Pressure is applied to
the OCS bladder when weight of any occupant or object in the front passenger seat is present. The pressure is
then transferred through a tube and sensed by the OCS pressure sensor and OCSM. The components of an OCS
bladder system (bladder, tube, and OCSM with integrated pressure sensor) are serviced as an assembly, and the
OCS bladder system is serviced as a kit with the seat cushion and seat heater mat (if applicable).
The Belt Tension Sensor (BTS) is a Hall-effect sensor that modifies a reference voltage supplied by the OCSM.
As the amount of tension applied to the belt varies, so does the voltage that returns to the OCSM. The Belt
Tension Sensor (BTS) is part of the front passenger safety belt anchor and can only be serviced with the front
passenger safety belt retractor and pretensioner.
Safety Belt Buckle Sensor
The safety belt buckles contain integrated sensors that are Hall-effect switches. The safety belt buckle sensors
are serviced with the safety belt buckle.
Safety Belt Tension Sensor (BTS)
The safety Belt Tension Sensor (BTS) is a 3-wire Hall-effect sensor that is part of the front passenger safety belt
buckle and cannot be serviced separately from the front passenger safety belt buckle assembly.
Seat Position Sensor
The seat position sensor is a Hall-effect sensor which indicates the position of the seat along the seat track. The
sensor detects the presence of a shunt bracket on the track, indicating the seat has moved past a certain point in
the adjustment range.
Side Impact Sensor - Front Door

The front door side impact sensors monitor air pressure within the door in order to detect certain crashes, such
as a side impact. Mounting position and orientation is critical for correct operation of the front door side impact
sensors.
Side Impact Sensor - Second Row (coupe only)
The second row side impact sensors measure acceleration (g-rate), and are hardwired to the RCM. Mounting
position and orientation is critical for correct operation of the second row side impact sensors.
Deployable Steering Column
The deployable steering column includes a device that, once deployed, reduces the amount of force necessary to
collapse the steering column during a crash event. The deployable device is activated by the RCM, depending on
the driver seat position and the force of the crash. After deployment, a new steering column must be installed.
Driver Airbag
The driver airbag is a dual-stage airbag. Upon receiving a flow of current, it deploys at 1 of 2 different rates,
depending upon vehicle impact severity and sensor input.
Driver Knee Airbag
The driver knee airbag is part of the steering column opening trim panel and deploys upon receiving current flow
from the RCM.
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Passenger Airbag
The passenger airbag is a dual-stage airbag which deploys at 1 of 2 different rates depending upon vehicle
impact severity and sensor input.
Passenger Airbag Canister Vent
The passenger airbag canister vent is a deployable device that is part of the passenger airbag. Canister venting
controls the inflation rate of the passenger airbag and the escape rate of gases from the airbag. The canister vent
cannot be serviced separately from the passenger airbag.
Passenger Airbag Deactivation (PAD) Indicator
The PAD indicator is a LED which is hard-wired to the RCM. The PAD indicator is part of the overhead console
and cannot be serviced separately.
Passenger Knee Airbag
The passenger knee airbag is part of the glovebox door and deploys upon receiving current flow from the RCM.
The passenger knee airbag is only serviced with the glovebox.
Safety Belt Anchor and Pretensioner
The safety belt anchor pretensioner is a pyrotechnic device that removes excess of webbing slack from the safety
belts when deployed. One is included as part of each front row outboard safety belt assembly and cannot be
serviced separately.
To diagnose any pretensioner Diagnostic Trouble Codes (DTCs),

Refer to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and
Testing).
Safety Belt Retractor and Pretensioner
The safety belt retractor and pretensioner is a pyrotechnic device that removes excess of webbing slack from the
safety belts when deployed. The retractor and pretensioner are serviced together with the front row outboard
safety belt assembly.
To diagnose any pretensioner Diagnostic Trouble Codes (DTCs),

Refer to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and
Testing).
For any concerns regarding safety belt retractor function,

Side Air Curtain (coupe only)
The side air curtain is a single-stage airbag which is designed to protect the vehicle occupant(s) during certain
side impact crashes.
Side Airbag
The side airbag is a single-stage airbag which is designed to provide protection for the seat occupant's torso. It
deploys upon receipt of current flow during certain side impact crashes and is attached to the outboard side of
each front seat. It is used in conjunction with the side air curtain or upper side airbag, depending on body style.
Upper Side Airbag (convertible only)
The upper side airbag is a single-stage airbag which is designed to provide protection for the seat occupant's
head. It deploys upon receipt of current flow during certain side impact crashes and is attached to the outboard
side of each front seat.
Clockspring
The clockspring allows for continuous electrical connections between the driver airbag and the RCM. A
spiral-wound cable wraps around the center of the clockspring and as the steering wheel is turned, the spiral
cable inside expands or contracts in diameter as the 2 halves of the clockspring turn.
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Restraints Control Module (RCM)
NOTE: This vehicle may be equipped with SYNC®, which contains the 911 Assist™ option. Refer to the
Owner's Literature for information about this feature.
The RCM monitors various sensor inputs and uses that data for controlling SRS outputs such as event notification
function and airbag deployment.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the airbags 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.
The RCM requires PMI when being replaced. Refer to the diagnostic scan tool instructions to carry out PMI.

Airbag Supplemental Restraint System (SRS)
DTC Chart: Restraint Control Module (RCM)
NOTE: Unlisted Diagnostic Trouble Codes (DTCs) are often retrieved as a result of incorrect repair procedures.
Before attempting any repairs for unlisted Diagnostic Trouble Codes (DTCs), check the vehicle service history
for recent repairs. For RCM Diagnostic Trouble Codes (DTCs) not listed in this chart,
Repair all other RCM Diagnostic Trouble Codes (DTCs) before attempting to repair any Diagnostic Trouble
Codes (DTCs) not listed in this chart.
If no other RCM Diagnostic Trouble Codes (DTCs) are retrieved, CLEAR the RCM Diagnostic Trouble
Codes (DTCs) and REPEAT the self-test. If the RCM Diagnostic Trouble Codes (DTCs) return, VERIFY
that the RCM is the correct part number for the vehicle application, and INSTALL As-Built data following
scan tool instructions under Module Programming > As-Built.
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RCM DTC Chart

B0001:11 Driver Frontal Stage 1
Deployment Control: REFER to: Pinpoint Test - DTC: A (501-20B Supplemental Restraint
Circuit Short to Ground System, Diagnosis and Testing).
Circuit Short to Battery System, Diagnosis and Testing).
Circuit Open System, Diagnosis and Testing).
B0001:1A Driver Frontal Stage 1
Circuit Resistance Below System, Diagnosis and Testing).
Threshold
B0001:2B Driver Frontal Stage 1
Deployment Control: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Signal Cross Coupled System, Diagnosis and Testing).
Deployment Control: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Incorrect Component System, Diagnosis and Testing).
Installed
Deployment Control: REFER to: Pinpoint Test - DTC: B (501-20B Supplemental Restraint
Threshold
B0002:2B Driver Frontal Stage 2
Installed
B0004:11 Driver Knee Bolster
Deployment Control: REFER to: Pinpoint Test - DTC: C (501-20B Supplemental Restraint
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B0004:1A Driver Knee Bolster
Threshold
B0004:2B Driver Knee Bolster
B0004:4A Driver Knee Bolster
Installed
B0005:11 Collapsible Steering
Column Deployment REFER to: Pinpoint Test - DTC: D (501-20B Supplemental Restraint
Control: Circuit Short to System, Diagnosis and Testing).
Ground
Control: Circuit Short to System, Diagnosis and Testing).
Battery
Control: Circuit Open System, Diagnosis and Testing).
B0005:1A Collapsible Steering
Control: Circuit System, Diagnosis and Testing).
Resistance Below
Threshold
B0005:2B Collapsible Steering
Column Deployment REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Control: Signal Cross System, Diagnosis and Testing).
Coupled
B0005:4A Collapsible Steering
Column Deployment REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Control: Incorrect System, Diagnosis and Testing).
Component Installed
B0010:11 Passenger Frontal Stage
1 Deployment Control: REFER to: Pinpoint Test - DTC: E (501-20B Supplemental Restraint
B0010:1A Passenger Frontal Stage
Threshold
B0010:2B Passenger Frontal Stage
1 Deployment Control: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
1 Deployment Control: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
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2 Deployment Control: REFER to: Pinpoint Test - DTC: F (501-20B Supplemental Restraint
Threshold
B0011:2B Passenger Frontal Stage
2 Deployment Control: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
2 Deployment Control: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B0013:11 Passenger Knee Bolster
Deployment Control: REFER to: Pinpoint Test - DTC: G (501-20B Supplemental Restraint
B0013:1A Passenger Knee Bolster
Threshold
B0013:2B Passenger Knee Bolster
B0013:4A Passenger Knee Bolster
Installed
B0050:11 Driver Seatbelt Sensor:
Circuit Short to Ground REFER to: Pinpoint Test - DTC: H (501-20B Supplemental Restraint
System, Diagnosis and Testing).
Circuit Short to Battery REFER to: Pinpoint Test - DTC: H (501-20B Supplemental Restraint
Circuit Open REFER to: Pinpoint Test - DTC: H (501-20B Supplemental Restraint
B0050:1D Driver Seatbelt Sensor:
Circuit Current Out of REFER to: Pinpoint Test - DTC: H (501-20B Supplemental Restraint
Range System, Diagnosis and Testing).
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B0050:2B Driver Seatbelt Sensor:
Signal Cross Coupled REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B0050:4A Driver Seatbelt Sensor:
Incorrect Component REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed System, Diagnosis and Testing).
B0052:11 Passenger Seatbelt
Sensor: Circuit Short to REFER to: Pinpoint Test - DTC: I (501-20B Supplemental Restraint
Ground System, Diagnosis and Testing).
Sensor: Circuit Short to REFER to: Pinpoint Test - DTC: I (501-20B Supplemental Restraint
Battery System, Diagnosis and Testing).
Sensor: Circuit Open REFER to: Pinpoint Test - DTC: I (501-20B Supplemental Restraint
B0052:1D Passenger Seatbelt
Sensor: Circuit Current REFER to: Pinpoint Test - DTC: I (501-20B Supplemental Restraint
Out of Range System, Diagnosis and Testing).
B0052:2B Passenger Seatbelt
Sensor: Signal Cross REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Coupled System, Diagnosis and Testing).
B0052:4A Passenger Seatbelt
Sensor: Incorrect REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Component Installed System, Diagnosis and Testing).
B0070:11 Driver Seatbelt
Pretensioner "A" REFER to: Pinpoint Test - DTC: J (501-20B Supplemental Restraint
Deployment Control: System, Diagnosis and Testing).
Circuit Short to Ground
Circuit Open
B0070:1A Driver Seatbelt
Circuit Resistance Below
Threshold
B0070:2B Driver Seatbelt
Pretensioner "A" REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Signal Cross Coupled
B0070:4A Driver Seatbelt
Pretensioner "A" REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Incorrect Component
Installed
Pretensioner "A" REFER to: Pinpoint Test - DTC: K (501-20B Supplemental Restraint
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Circuit Open
Threshold
B0072:2B Passenger Seatbelt
Pretensioner "A" REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Pretensioner "A" REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Incorrect Component
Installed
B007E:11 Driver Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: L (501-20B Supplemental Restraint
Circuit Open
B007E:1A Driver Seatbelt
Threshold
B007E:2B Driver Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B007E:4A Driver Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Incorrect Component
Installed
B007F:11 Passenger Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: M (501-20B Supplemental Restraint
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Circuit Open
B007F:1A Passenger Seatbelt
Threshold
B007F:2B Passenger Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B007F:4A Passenger Seatbelt
Pretensioner "C" REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Incorrect Component
Installed
B0080:4A Driver Seatbelt Load
Limiter Deployment REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Component Installed
B00A0:09 Occupant Classification
System: Component REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint
Failures System, Diagnosis and Testing).
B00A0:4A Occupant Classification
System: Incorrect REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint
System: Circuit / REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint
Component Protection System, Diagnosis and Testing).
Time-Out
System: Signal REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint
Plausibility Failure System, Diagnosis and Testing).
System: Event REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint
Information System, Diagnosis and Testing).
B00B5:11 Driver Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: O (501-20B Supplemental Restraint
Sensor: Circuit Short to System, Diagnosis and Testing).
Ground
Battery
Sensor: Circuit Open System, Diagnosis and Testing).
B00B5:1D Driver Seat Track
Sensor: Circuit Current System, Diagnosis and Testing).
Out of Range
B00B5:2B Driver Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
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Sensor: Signal Cross System, Diagnosis and Testing).
Coupled
B00B5:4A Driver Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Sensor: Incorrect System, Diagnosis and Testing).
Component Installed
B00C5:11 Passenger Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: P (501-20B Supplemental Restraint
Ground
Battery
Sensor: Circuit Open System, Diagnosis and Testing).
B00C5:1D Passenger Seat Track
Sensor: Circuit Current System, Diagnosis and Testing).
Out of Range
B00C5:2B Passenger Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
Sensor: Signal Cross System, Diagnosis and Testing).
Coupled
B00C5:4A Passenger Seat Track
Position Restraints REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Sensor: Incorrect System, Diagnosis and Testing).
Component Installed
B00D5:11 Restraint System
Passenger Disable REFER to: Pinpoint Test - DTC: AR (501-20B Supplemental Restraint
Indicator: Circuit Short to System, Diagnosis and Testing).
Ground
Indicator: Circuit Short to System, Diagnosis and Testing).
Battery
Indicator: Circuit Open System, Diagnosis and Testing).
B00D5:4A Restraint System
Passenger Disable REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Indicator: Incorrect System, Diagnosis and Testing).
Component Installed
B1193:00 Crash Event Storage Full This DTC indicates the vehicle has been in a crash. INSTALL a new RCM
and Locked: No Sub and impact sensors.
Type Information REFER to: Inspection and Repair after a Supplemental Restraint System
(SRS) Deployment (501-20B Supplemental Restraint System, General
Procedures).
B11CF:11 Passenger Frontal
Airbag Canister Vent: REFER to: Pinpoint Test - DTC: Q (501-20B Supplemental Restraint
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B11CF:1A Passenger Frontal
Threshold
B11CF:2B Passenger Frontal
Airbag Canister Vent: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B11CF:4A Passenger Frontal
Airbag Canister Vent: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B11D8:12 Restraint Event
Notification: Circuit Short REFER to: Pinpoint Test - DTC: R (501-20B Supplemental Restraint
to Battery System, Diagnosis and Testing).
B11D8:14 Restraint Event
Notification: Circuit Short REFER to: Pinpoint Test - DTC: R (501-20B Supplemental Restraint
to Ground or Open System, Diagnosis and Testing).
B1404:11 Driver Side Airbag
Deployment Control: REFER to: Pinpoint Test - DTC: S (501-20B Supplemental Restraint
B1404:1A Driver Side Airbag
Threshold
B1404:2B Driver Side Airbag
B1404:4A Driver Side Airbag
Installed
B1405:11 Driver Side Curtain For coupe,
Deployment Control 1: REFER to: Pinpoint Test - DTC: T, Coupe (501-20B Supplemental
Circuit Short to Ground Restraint System, Diagnosis and Testing).
For convertible,
REFER to: Pinpoint Test - DTC: AN, Convertible (501-20B
Supplemental Restraint System, Diagnosis and Testing).

Circuit Short to Battery Restraint System, Diagnosis and Testing).
For convertible,
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Circuit Open Restraint System, Diagnosis and Testing).
For convertible,
B1405:1A Driver Side Curtain For coupe,

Circuit Resistance Below Restraint System, Diagnosis and Testing).
Threshold For convertible,
B1405:2B Driver Side Curtain

Deployment Control 1: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B1405:4A Driver Side Curtain
Deployment Control 1: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B1407:11 Passenger Side Airbag
Deployment Control: REFER to: Pinpoint Test - DTC: U (501-20B Supplemental Restraint
B1407:1A Passenger Side Airbag
Threshold
B1407:2B Passenger Side Airbag
B1407:4A Passenger Side Airbag
Installed
B1408:11 Passenger Side Curtain For coupe,
Deployment Control 1: REFER to: Pinpoint Test - DTC: V, Coupe (501-20B Supplemental
For convertible,
REFER to: Pinpoint Test - DTC: AO, Convertible (501-20B

Circuit Short to Battery Restraint System, Diagnosis and Testing).
For convertible,
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Circuit Open Restraint System, Diagnosis and Testing).
For convertible,
B1408:1A Passenger Side Curtain For coupe,

Circuit Resistance Below Restraint System, Diagnosis and Testing).
Threshold For convertible,
B1408:2B Passenger Side Curtain

Deployment Control 1: REFER to: Pinpoint Test - DTC: AA (501-20B Supplemental Restraint
B1408:4A Passenger Side Curtain
Deployment Control 1: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B1413:11 Driver Frontal Restraints
Sensor: Circuit Short to REFER to: Pinpoint Test - DTC: W (501-20B Supplemental Restraint
Ground System, Diagnosis and Testing).
B1413:4A Driver Frontal Restraints
Sensor: Incorrect REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
B1413:81 Driver Frontal Restraints INSTALL a new LH front impact severity sensor.
Sensor: Invalid Serial REFER to: Front Impact Severity Sensor (501-20B Supplemental
Data Received Restraint System, Removal and Installation).
B1413:93 Driver Frontal Restraints
Sensor: No Operation REFER to: Pinpoint Test - DTC: W (501-20B Supplemental Restraint
B1413:96 Driver Frontal Restraints INSTALL a new LH front impact severity sensor.
Sensor: Component REFER to: Front Impact Severity Sensor (501-20B Supplemental
Internal Failure Restraint System, Removal and Installation).
B1414:11 Driver Side Restraints For coupe,
Sensor 1: Circuit Short REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
to Ground Restraint System, Diagnosis and Testing).
For convertible,
REFER to: Pinpoint Test - DTC: AP, Convertible (501-20B
B1414:4A Driver Side Restraints

Sensor 1: Incorrect REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
B1414:81 Driver Side Restraints INSTALL a new driver door side impact sensor.
Sensor 1: Invalid Serial REFER to: Front Door Side Impact Sensor (501-20B Supplemental
Data Received Restraint System, Removal and Installation).
B1414:93 Driver Side Restraints For coupe,
Sensor 1: No Operation REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
For convertible,
REFER to: Pinpoint Test - DTC: AP, Convertible (501-20B
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B1414:96 Driver Side Restraints INSTALL a new driver door side impact sensor.
Sensor 1: Component REFER to: Front Door Side Impact Sensor (501-20B Supplemental
Internal Failure Restraint System, Removal and Installation).
B1415:11 Driver Side Restraints
Sensor 2: Circuit Short REFER to: Pinpoint Test - DTC: Y, Coupe (501-20B Supplemental
to Ground Restraint System, Diagnosis and Testing).
B1415:4A Driver Side Restraints
Sensor 2: Incorrect REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
B1415:81 Driver Side Restraints INSTALL a new LH B-pillar side impact sensor.
Sensor 2: Invalid Serial REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint
Data Received System, Removal and Installation).
B1415:93 Driver Side Restraints
Sensor 2: No Operation REFER to: Pinpoint Test - DTC: Y, Coupe (501-20B Supplemental
B1415:96 Driver Side Restraints INSTALL a new LH B-pillar side impact sensor.
Sensor 2: Component REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint
Internal Failure System, Removal and Installation).
B1417:11 Passenger Frontal
Restraints Sensor: REFER to: Pinpoint Test - DTC: Z (501-20B Supplemental Restraint
B1417:4A Passenger Frontal
Restraints Sensor: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B1417:81 Passenger Frontal INSTALL a new RH front impact severity sensor.
Restraints Sensor: REFER to: Front Impact Severity Sensor (501-20B Supplemental
Invalid Serial Data Restraint System, Removal and Installation).
Received
B1417:93 Passenger Frontal
Restraints Sensor: No REFER to: Pinpoint Test - DTC: Z (501-20B Supplemental Restraint
Operation System, Diagnosis and Testing).
B1417:96 Passenger Frontal INSTALL a new RH front impact severity sensor.
Restraints Sensor: REFER to: Front Impact Severity Sensor (501-20B Supplemental
Component Internal Restraint System, Removal and Installation).
Failure
B1418:11 Passenger Side For coupe,
Restraints Sensor 1: REFER to: Pinpoint Test - DTC: Y, Coupe (501-20B Supplemental
For convertible,
REFER to: Pinpoint Test - DTC: AQ, Convertible (501-20B
B1418:4A Passenger Side

Restraints Sensor 1: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B1418:81 Passenger Side INSTALL a new passenger door side impact sensor.
Restraints Sensor 1: REFER to: Front Door Side Impact Sensor (501-20B Supplemental
Invalid Serial Data Restraint System, Removal and Installation).
Received
B1418:93 Passenger Side For coupe,
Restraints Sensor 1: No REFER to: Pinpoint Test - DTC: Y, Coupe (501-20B Supplemental
Operation Restraint System, Diagnosis and Testing).
For convertible,
REFER to: Pinpoint Test - DTC: AQ, Convertible (501-20B
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B1418:96 Passenger Side INSTALL a new passenger door side impact sensor.
Restraints Sensor 1: REFER to: Front Door Side Impact Sensor (501-20B Supplemental
Component Internal Restraint System, Removal and Installation).
Failure
B1419:11 Passenger Side
Restraints Sensor 2: REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
B1419:4A Passenger Side
Installed
B1419:81 Passenger Side INSTALL a new RH B-pillar side impact sensor.
Restraints Sensor 2: REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint
Invalid Serial Data System, Removal and Installation).
Received
B1419:93 Passenger Side
Restraints Sensor 2: No REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
Operation Restraint System, Diagnosis and Testing).
B1419:96 Passenger Side INSTALL a new RH B-pillar side impact sensor.
Restraints Sensor 2: REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint
Component Internal System, Removal and Installation).
Failure
B1424:11 Pedestrian Protection
Sensor Center: Circuit REFER to: Pinpoint Test - DTC: Y, Coupe (501-20B Supplemental
Short to Ground Restraint System, Diagnosis and Testing).
B1424:4A Pedestrian Protection
Sensor Center: Incorrect REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
B1427:11 Pedestrian Protection
Sensor Driver Outer: REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
B1427:4A Pedestrian Protection
Sensor Driver Outer: REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Installed
B142D:00 Pyrotechnic End of Life INSTALL a new RCM and CARRY OUT PMI. Use As-Built data when
Activation Performed: No carrying out PMI for this DTC.
Sub Type Information REFER to: Restraints Control Module (RCM) (501-20B Supplemental
Restraint System, Removal and Installation).
B1469:4A Unused Satellite
Installed
B146A:4A Unused Satellite
Installed
B147D:11 Driver Side Hood Hinge DEPOWER the SRS.
Deployment Control: REFER to: Supplemental Restraint System (SRS) Depowering (501-20B
Circuit Short to Ground Supplemental Restraint System, General Procedures).
DISCONNECT RCM C310A and C310B. MEASURE the resistance
between RCM C310B-7 and ground, and between RCM C310B-8 and
ground. TURN ON the ignition and MEASURE the voltage between RCM
C310B-7 and ground, and between RCM C310B-8 and ground. If either
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resistance is less than 10,000 ohms, or if any voltage is present on either
circuit, REPAIR the circuit(s) as necessary. If the resistances are greater
than 10,000 ohms and there is not any voltage present, INSTALL a new
RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental
B147D:4A Driver Side Hood Hinge
Installed
B147E:11 Passenger Side Hood DEPOWER the SRS.
Hinge Deployment REFER to: Supplemental Restraint System (SRS) Depowering (501-20B
Control: Circuit Short to Supplemental Restraint System, General Procedures).
Ground DISCONNECT RCM C310A and C310B. MEASURE the resistance
between RCM C310B-5 and ground, and between RCM C310B-6 and
ground. TURN ON the ignition and MEASURE the voltage between RCM
C310B-5 and ground, and between RCM C310B-6 and ground. If either
resistance is less than 10,000 ohms, or if any voltage is present on either
circuit, REPAIR the circuit(s) as necessary. If the resistances are greater
than 10,000 ohms and there is not any voltage present, INSTALL a new
RCM.
B147E:4A Passenger Side Hood
Hinge Deployment REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Component Installed
B14EB:11 Pedestrian Protection
Sensor Passenger REFER to: Pinpoint Test - DTC: X, Coupe (501-20B Supplemental
Outer: Circuit Short to Restraint System, Diagnosis and Testing).
Ground
B14EB:4A Pedestrian Protection
Sensor Passenger REFER to: Pinpoint Test - DTC: AB (501-20B Supplemental Restraint
Outer: Incorrect System, Diagnosis and Testing).
Component Installed
C0061:68 Lateral Acceleration
Sensor: Event REFER to: Pinpoint Test - DTC: AC (501-20B Supplemental Restraint
C0062:68 Longitudinal Acceleration
C0063:68 Yaw Rate Sensor: Event
Information REFER to: Pinpoint Test - DTC: AC (501-20B Supplemental Restraint
C0064:68 Roll Rate Sensor: Event
Information REFER to: Pinpoint Test - DTC: AC (501-20B Supplemental Restraint
C0065:68 Vertical Acceleration
U0100:00 Lost Communication with
ECM/PCM A: No Sub REFER to: Pinpoint Test - DTC: AD (501-20B Supplemental Restraint
Type Information System, Diagnosis and Testing).
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Body Control Module: REFER to: Pinpoint Test - DTC: AE (501-20B Supplemental Restraint
No Sub Type Information System, Diagnosis and Testing).
Restraints Occupation REFER to: Pinpoint Test - DTC: AF (501-20B Supplemental Restraint
Classification System System, Diagnosis and Testing).
Module: No Sub Type
Information
Instrument Panel Cluster REFER to: Pinpoint Test - DTC: AG (501-20B Supplemental Restraint
(IPC) Control Module: System, Diagnosis and Testing).
No Sub Type Information
U0253:00 Lost Communication
With Accessory Protocol REFER to: Pinpoint Test - DTC: AH (501-20B Supplemental Restraint
Interface Module: No System, Diagnosis and Testing).
Sub Type Information
U0300:00 Internal Control Module CARRY OUT PMI. RETRIEVE RCM Diagnostic Trouble Codes (DTCs). If
Software Incompatibility: RCM DTC U0300:00 is retrieved on-demand during self-test, INSTALL a
No Sub Type Information new RCM.
U0401:00 Invalid Data Received NOTE: This DTC sets in a module that is reporting a missing or invalid
From ECM/PCM A: No message from another module on the data bus. The module that reports
Sub Type Information the fault is not the problem module. Do not install a new RCM as part of
the repair unless directed to do so in a pinpoint test.
CHECK for additional RCM and PCM Diagnostic Trouble Codes (DTCs).
DIAGNOSE and REPAIR any Diagnostic Trouble Codes (DTCs) that are
retrieved. For RCM Diagnostic Trouble Codes (DTCs), REFER to the
RCM DTC Chart. To diagnose PCM Diagnostic Trouble Codes (DTCs),
Refer to the appropriate section in Group 303 for the procedure.
From Body Control message from another module on the data bus. The module that reports
Module: No Sub Type the fault is not the problem module. Do not install a new RCM as part of
Information the repair unless directed to do so in a pinpoint test.
CHECK for additional RCM and BCM Diagnostic Trouble Codes (DTCs).
RCM DTC Chart. For BCM Diagnostic Trouble Codes (DTCs),
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic
From Body Control message from another module on the data bus. The module that reports
Module: Invalid Serial the fault is not the problem module. Do not install a new RCM as part of
Data Received the repair unless directed to do so in a pinpoint test.
CHECK for additional RCM and BCM Diagnostic Trouble Codes (DTCs).
RCM DTC Chart. For BCM Diagnostic Trouble Codes (DTCs),
REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic
U0554:00 Invalid Data Received CHECK for additional RCM and APIM Diagnostic Trouble Codes (DTCs).
From Accessory For RCM Diagnostic Trouble Codes (DTCs), REFER to the RCM DTC
Protocol Interface Chart. For APIM Diagnostic Trouble Codes (DTCs), Refer to the
Module: No Sub Type appropriate section in Group 415 for the procedure.
Information
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U0557:82 Invalid Data Received CHECK for additional RCM and FCIM Diagnostic Trouble Codes (DTCs).
From Front Controls For RCM Diagnostic Trouble Codes (DTCs), RETURN to the beginning of
Interface Module "A": No this chart. For FCIM Diagnostic Trouble Codes (DTCs), Refer to the
Sub Type Information appropriate section in Group 415 for the procedure.
U2100:00 Initial Configuration Not CHECK vehicle history for recent service actions related to this module.
Complete: No Sub Type This DTC sets due to incomplete or improper PMI procedures. If there
Information have been recent service actions with this module, REPEAT the PMI
procedure as directed by the diagnostic scan tool using As-Built data.
U2101:00 Control Module CARRY OUT PMI using As-Built data. RETRIEVE RCM Diagnostic
Configuration Trouble Codes (DTCs). If RCM DTC U2101:00 is retrieved on-demand,
Incompatible: No Sub INSTALL a new RCM. Use As-Built data when carrying out PMI for this
Type Information DTC.
U2200:00 Control Module INSTALL a new RCM. Use As-Built data when CARRYING OUT PMI
Configuration Memory during the RCM installation.
Corrupt: No Sub Type REFER to: Restraints Control Module (RCM) (501-20B Supplemental
Information Restraint System, Removal and Installation).
U2300:55 Central Configuration:
Not Configured REFER to: Pinpoint Test - DTC: AI (501-20B Supplemental Restraint
U2300:64 Central Configuration:
Signal Plausibility Failure REFER to: Pinpoint Test - DTC: AI (501-20B Supplemental Restraint
U3000:46 Control Module: INSTALL a new RCM. Use As-Built data when CARRYING OUT PMI
Calibration / Parameter during the RCM installation.
Memory Failure REFER to: Restraints Control Module (RCM) (501-20B Supplemental
U3000:49 Control Module: Internal INSTALL a new RCM. Using a diagnostic scan tool, CARRY OUT RCM
Electronic Failure PMI. If DTC U2200:00 is also present, USE As-Built data when
CARRYING OUT PMI during the RCM installation.
U3003:16 Battery Voltage: Circuit
Voltage Below Threshold REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint
Voltage Above Threshold REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint
DTC Chart: Occupant Classification System Module (OCSM)
OCSM DTC Chart

Tension Sensor: Circuit REFER to: Pinpoint Test - DTC: AK (501-20B Supplemental Restraint
Short To Ground System, Diagnosis and Testing).
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Short To Battery System, Diagnosis and Testing).
Open System, Diagnosis and Testing).
Tension Sensor: Internal REFER to: Pinpoint Test - DTC: AK (501-20B Supplemental Restraint
Electronic Failure System, Diagnosis and Testing).
Tension Sensor: Signal REFER to: Pinpoint Test - DTC: AK (501-20B Supplemental Restraint
Plausibility Failure System, Diagnosis and Testing).
B00C0:11 Passenger Seat INSPECT the OCS for any damage and for correct installation.
Occupant Classification If damage is found, REPAIR the root cause of the damage and
Sensor "A": Circuit Short INSTALL a new OCS, as necessary.
to Ground REFER to: Occupant Classification System (OCS) Sensor
(501-20B Supplemental Restraint System, Removal and
Installation).
If any installation concerns are found, CORRECT the OCS
installation, referring to the OCS Removal and Installation
procedure as needed to make sure the sensor hose is free from
kinks and correctly routed.
REFER to: Occupant Classification System (OCS) Sensor
Installation).
If no damage or installation concerns are found, INSTALL a new
OCS.
Installation).
B00C0:12 Passenger Seat INSTALL a new OCS sensor.

Occupant Classification REFER to: Occupant Classification System (OCS) Sensor (501-20B
Sensor "A": Circuit Short Supplemental Restraint System, Removal and Installation).
to Battery
Sensor "A": Circuit Supplemental Restraint System, Removal and Installation).
Voltage Below Threshold
Sensor "A": Internal Supplemental Restraint System, Removal and Installation).
Electronic Failure
B00C0:7B Passenger Seat INSPECT the OCS for any damage and for correct installation.
Occupant Classification If damage is found, REPAIR the root cause of the damage and
Sensor "A": Low Fluid INSTALL a new OCS, as necessary.
Level REFER to: Occupant Classification System (OCS) Sensor
Installation).
If any installation concerns are found, CORRECT the OCS
installation, referring to the OCS Removal and Installation
procedure as needed to make sure the sensor hose is correctly
routed.
Installation).
If no damage or installation concerns are found, INSTALL a new
OCS.
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Installation).
B00C2:11 Passenger Seat

Occupant Classification REFER to: Pinpoint Test - DTC: AL (501-20B Supplemental Restraint
Sensor "C": Circuit Short System, Diagnosis and Testing).
to Ground
B00C2:12 Passenger Seat
Occupant Classification REFER to: Pinpoint Test - DTC: AL (501-20B Supplemental Restraint
Sensor "C": Circuit Short System, Diagnosis and Testing).
to Battery
B1193:00 Crash Event Storage Full CLEAR the OCSM Diagnostic Trouble Codes (DTCs) and REPEAT the
and Locked: No Sub self-test. If DTC B1193:00 returns, INSTALL a new OCS sensor.
Type Information INSTALL a new OCS sensor.
REFER to: Occupant Classification System (OCS) Sensor (501-20B
Supplemental Restraint System, Removal and Installation).
ECM/PCM A: No Sub REFER to: Pinpoint Test - DTC: AD (501-20B Supplemental Restraint
Type Information System, Diagnosis and Testing).
Restraints Control REFER to: Pinpoint Test - DTC: AM (501-20B Supplemental Restraint
Module: No Sub Type System, Diagnosis and Testing).
Information
U0401:00 Invalid Data Received CARRY OUT the PCM self-test. REFER to the appropriate workshop
from ECM/PCM A: No manual section. Refer to the appropriate section in Group 303 for the
Sub Type Information procedure.
U3000:41 Control Module: General INSTALL a new OCS sensor.
Checksum Failure REFER to: Occupant Classification System (OCS) Sensor (501-20B
U3000:42 Control Module: General INSTALL a new OCS sensor.
Memory Failure REFER to: Occupant Classification System (OCS) Sensor (501-20B
U3000:46 Control Module: INSTALL a new OCS sensor.
Calibration / Parameter REFER to: Occupant Classification System (OCS) Sensor (501-20B
Memory Failure Supplemental Restraint System, Removal and Installation).
U3000:54 Control Module: Missing Using a diagnostic scan tool, CARRY OUT the OCS Reset. FOLLOW all
Calibration instructions on the diagnostic scan tool. If the OCS Reset was not
successful, VERIFY correct installation of the OCS. VERIFY the pressure
sensor hose is correctly routed and CORRECT the installation as
necessary. REPEAT the self-test. If DTC U3000:54 is still present,
INSTALL a new OCS sensor.
REFER to: Occupant Classification System (OCS) Sensor (501-20B
Voltage Below Threshold REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint
Voltage Above Threshold REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint
DTC Chart: Body Control Module (BCM)
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OCSM DTC Chart

B11D8:01 Restraint Event Notification: CARRY OUT the RCM self-test. DIAGNOSE and
General Electrical Failure REPAIR the RCM Diagnostic Trouble Codes (DTCs).
REFER to DTC Chart: RCM.
All other BCM –
Diagnostic Trouble REFER to: Body Control Module (BCM) (419-10
Codes (DTCs) Multifunction Electronic Modules, Diagnosis and Testing).
Symptom Chart(s)
Symptom Chart: Supplemental Restraint System
Symptom Chart

respond to the Diagnostic scan REFER to: Communications Network (418-00 Module
diagnostic scan tool tool Communications Network, Diagnosis and Testing).
DLC
Wiring, terminals
or connectors
Module
An audible tone sounds SRS fault or CARRY OUT the RCM and IPC self-tests. For RCM
within 60 seconds of airbag warning Diagnostic Trouble Codes (DTCs), REFER to DTC
ignition ON indicator fault Chart: RCM. For IPC Diagnostic Trouble Codes
(DTCs),
The airbag indicator is SRS fault CARRY OUT the RCM and OCSM self tests. REFER
flashing to DTC Chart: RCM or REFER to DTC Chart: OCSM.
The airbag warning Fuse CARRY OUT the RCM and OCSM self tests. REFER
indicator is illuminated Wiring, terminals to DTC Chart: RCM or REFER to DTC Chart: OCSM.
continuously or connectors If no Diagnostic Trouble Codes (DTCs) were
IPC retrieved from the RCM or OCSM,
RCM or OCSM REFER to: Instrumentation, Message Center and
If the OCSM or RCM does not respond to the
diagnostic scan tool,
REFER to: Communications Network (418-00 Module
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Communications Network, Diagnosis and Testing).

Pinpoint Test - DTC: A
B0001:11, B0001:12, B0001:13 and B0001:1A
The RCM continuously monitors the driver airbag stage 1 circuits for the following faults:
Resistance out of range

Unexpected voltage
Short to ground
Faulted driver airbag
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 IPC to illuminate the airbag
warning indicator.
The RCM analyzes the deployment loop resistance to determine if a fault exists. The value displayed in the PID is the deployment loop resistance 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. Small variations in resistance can occur due to the effect of road vibrations on terminal
fit. Crimps and terminals can be affected by stress and harness movement and can cause an increase in resistance due to wire strain. 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 the time of diagnosis. Following this direction helps make sure that minor changes in resistance do not create a
repeat concern. This test uses process of elimination to diagnose each part of the deployment loop circuit including:
Wiring
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Connections
Clockspring
Driver airbag
RCM

B0001:11 Driver Frontal Stage 1 Deployment Control: Circuit A fault is indicated when the RCM senses a short to ground on either driver airbag stage 1
Short to Ground circuit for more than 6 seconds.
B0001:12 Driver Frontal Stage 1 Deployment Control: Circuit A fault is indicated when the RCM senses a short to voltage on either driver airbag stage 1
Short to Battery circuit for more than 6 seconds.
B0001:13 Driver Frontal Stage 1 Deployment Control: Circuit A fault is indicated when the RCM measures more than the desired resistance range between
Open driver airbag stage 1 circuits for more than 6 seconds.
B0001:1A Driver Frontal Stage 1 Deployment Control: Circuit A fault is indicated when the RCM measures less than the desired resistance range between
Resistance Below Threshold driver airbag stage 1 circuits for more than 6 seconds.
Possible Sources

Clockspring
Driver airbag
RCM
PINPOINT TEST A : B0001:11, B0001:12, B0001:13 AND B0001:1A
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may cause damage to 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 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 parts catalog or equivalent to make sure the correct component is being installed. If an incorrect
SRS component is installed, Diagnostic Trouble Codes (DTCs) may set.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
A1 RETRIEVE RCM (RESTRAINTS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to
follow this instruction may result in serious personal injury.
REFER to: Pyrotechnic Device Health and Safety Precautions (100-00 General Information, Description and Operation).
Ignition ON.
Using a diagnostic scan tool, perform RCM self-test.
Was DTC B0001:11, B0001:12, B0001:13 or B0001:1A retrieved on-demand during self-test?
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved on-demand during self-test.
If DTC U3003:16 or U3003:17 is retrieved on-demand, DIAGNOSE those Diagnostic Trouble Codes (DTCs) first.
REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint System, Diagnosis and Testing).
If DTC U3003:16 or U3003:17 is not retrieved on-demand during self-test, DIAGNOSE the driver airbag Diagnostic Trouble Codes
(DTCs).
For DTC B0001:13 or B0001:1A, GO to A2
No This is an intermittent fault when present as a Continuous Memory Diagnostic Trouble Code (CMDTC) only.
If DTC U3003:16 or U3003:17 is not retrieved on-demand during self-test, DIAGNOSE the driver airbag Continuous Memory Diagnostic
Trouble Codes (CMDTCs).
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A2 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL RESISTANCE (DEPLOY_00_R) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view RCM Parameter Identifications (PIDs).
Monitor and record the resistance value displayed by the DEPLOY_00_R PID.
Does the PID value read between 1.62 and 4.46 ohms?
Yes GO to A19
No GO to A3
A3 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL RESISTANCE (DEPLOY_00_R) PID (PARAMETER IDENTIFICATION) WHILE
CARRYING OUT THE HARNESS TEST
Remove the steering column shrouds to access the clockspring connectors.
REFER to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and Installation).
While monitoring the DEPLOY_00_R PID, carry out the harness test of the driver airbag circuits and accessible connectors (including any inline connectors)
by wiggling and flexing the wire harness, connectors, tilting and rotating the steering wheel frequently. Record the resistance value indicated by the PID.
Does the PID value read between 1.62 and 4.46 ohms while carrying out the harness test?
Yes DEPOWER the SRS.

REPAIR the connector, terminals or wire harness or INSTALL a new clockspring as needed. REFER to: Clockspring (501-20B

GO to A24
No For PID value less than 1.62 ohms, GO to A4
For PID value greater than 4.46 ohms, GO to A8
A4 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED)
NOTE: This pinpoint test step attempts to change the fault reported by the RCM by inducing a different fault condition. If the reported fault changes, this
indicates the RCM is functioning correctly and is not the source of the fault.
Ignition OFF.
Depower the SRS.
Remove the driver airbag.
REFER to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Repower the SRS. Do not prove out the SRS at this time.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag disconnected, open circuit faults are normally retrieved on stages 1
and 2.
Did the on-demand DTC change from B0001:1A to B0001:13?

Yes GO to A17
No GO to A5
A5 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED) (CLOCKSPRING DISCONNECTED)
Ignition OFF.
Depower the SRS.
Disconnect Clockspring C218A.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the clockspring disconnected, open circuit faults are normally retrieved on stages 1
and 2.
Yes GO to A18
No GO to A6
A6 CHECK FOR A SHORT BETWEEN DRIVER AIRBAG STAGE 1 CIRCUITS
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Ignition OFF.
Measure:

C218A-11 C218A-12
Yes GO to A19
No GO to A7
A7 CHECK THE RCM (RESTRAINTS CONTROL MODULE) FOR LOW RESISTANCE

Depower the SRS.
Disconnect RCM C310A and C310B.
Measure:

Action
C310A, pin 29, component side C310A, pin 30, component side
Yes REPAIR the driver airbag stage 1 circuit(s) for a short together.
GO to A24
No GO to A19
A8 CHECK THE DRIVER AIRBAG STAGE 1 CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-29 C216A-1
C310A-30 C216A-2
Are the resistances less than 1 ohm?
Yes GO to A10
No GO to A9
A9 CHECK THE DRIVER AIRBAG STAGE 1 CIRCUITS FOR AN OPEN (CLOCKSPRING DISCONNECTED)
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Measure:

C310A-29 C218A-12
C310A-30 C218A-11
Are the resistances less than 0.5 ohm?
Yes GO to A18
GO to A24
A10 CHECK THE DRIVER AIRBAG STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN
INDICATED)
Connect RCM C310A and C310B.
Connect a fused jumper wire:

C216A-1 C216A-2
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag stage 1 circuits shorted together, a low resistance fault is normally
retrieved on stage 1. Stage 2 shows an open circuit fault because the driver airbag is disconnected.
Was DTC B0001:1A retrieved on-demand during self-test?
Yes REMOVE the fused jumper wire and GO to A17

No REMOVE the fused jumper wire and GO to A11
A11 CHECK THE DRIVER AIRBAG STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN
INDICATED)
Ignition OFF.
Depower the SRS.

C218A-11 C218A-12
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag stage 1 circuits shorted together, a low resistance fault is normally
retrieved on stage 1. Stage 2 shows an open circuit fault because the clockspring is disconnected.

A12 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE
(SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
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Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag disconnected, open circuit faults are normally retrieved on stages 1
and 2.
Did the on-demand DTC change from B0001:11 to B0001:13?
Yes GO to A17
No GO to A13
(SHORT TO GROUND INDICATED) (CLOCKSPRING DISCONNECTED)
Ignition OFF.
Ignition ON.
and 2.
Yes GO to A18
No GO to A14
A14 CHECK THE DRIVER AIRBAG STAGE 1 CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C218A-11 Ground
C218A-12 Ground
Yes GO to A19
No Due to the shorting bar feature in the RCM electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting
bar. REPAIR the circuit(s).
GO to A24
(SHORT TO BATTERY INDICATED) (CLOCKSPRING DISCONNECTED)
Ignition OFF.
Depower the SRS.
Ignition ON.
and 2.
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Yes GO to A18
No GO to A16
A16 CHECK THE DRIVER AIRBAG STAGE 1 CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C218A-11 Ground
C218A-12 Ground
Yes Due to the shorting bar feature in the RCM electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting
bar. REPAIR the circuit(s).
GO to A24
No GO to A19
A17 CONFIRM THE DRIVER AIRBAG FAULT
NOTE: Make sure all SRS components and the RCM electrical connectors are connected before carrying out the self-test. If not, Diagnostic Trouble Codes
(DTCs) will be recorded.
Ignition OFF.
Depower the SRS.
Prior to reconnecting any previously disconnected SRS component:
inspect connector(s) (including any inline connectors) for pushed-out, loose or spread terminals and loose or frayed wire connections at terminals.
inspect wire harness for any damaged, pinched, cut or pierced wires.
inspect RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct operation.
inspect Driver Airbag C216A and make sure the Connector Position Assurance (CPA) tabs are not broken and the clip is not damaged.
repair any concerns found.
Install the driver airbag.
Ignition ON.
Was the original DTC retrieved on-demand during self-test?
Yes INSTALL a new driver airbag.

GO to A24
No In the process of diagnosing the fault, the fault condition has become intermittent. Do not install any new SRS components at this time.
Install SRS components only when directed to do so in the pinpoint test.
A18 CONFIRM THE CLOCKSPRING FAULT
Ignition OFF.
Depower the SRS.
Connect Clockspring C218A.
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Connect RCM C310A and C310B (if previously disconnected).
Ignition ON.
Yes INSTALL a new clockspring.

REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and Installation).
GO to A24
A19 CONFIRM THE RCM (RESTRAINTS CONTROL MODULE) FAULT
Ignition OFF.
Depower the SRS.
Install the driver airbag (if previously removed).
Connect Clockspring C218A (if previously disconnected).
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and Installation).
GO to A24
A20 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL RESISTANCE (DEPLOY_00_R) PID (PARAMETER IDENTIFICATION) FOR AN
INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT FAULT
Ignition OFF.
Ignition ON.
While monitoring the DEPLOY_00_R PID, attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness,
tilting and rotating the steering wheel frequently. Record the resistance value indicated by the PID.
Yes 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 directed to do so in the pinpoint test. GO to A23
No If the driver airbag PID indicates incorrect resistance only when the steering wheel is rotated, INSTALL a new clockspring.
REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and Installation).
For all other faults, DEPOWER the SRS and REPAIR as necessary.
GO to A24
A21 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO GROUND FAULT
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Ignition OFF.
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness, tilting and rotating the steering wheel
frequently.
Was DTC B0001:11 retrieved on-demand during self-test?
Yes DEPOWER the SRS and REPAIR as necessary.

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
A22 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness, tilting and rotating the steering wheel
frequently.

GO to A24
A23 CHECK THE HARNESS AND CONNECTORS

Ignition OFF.
Depower the SRS.
Inspect connector(s) (including any inline connectors) for corrosion, loose or spread terminals and loose or frayed wire connections at terminals.
Inspect wire harness for any damage, pinched, cut or pierced wires.
Inspect RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct operation.
Inspect Driver Airbag C216A Connector Position Assurance (CPA) tab to verify that it is correctly seated and free of damage.

GO to A24
A24 CHECK FOR ADDITIONAL SRS (SUPPLEMENTAL RESTRAINT SYSTEM) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition OFF.
Reconnect all SRS components (if previously disconnected).
If previously directed to depower the SRS, repower the SRS. Do not prove out the SRS at this time.
Ignition ON.
NOTE: When selecting Restraints from the Self Test menu, DTCs are retrieved from the RCM and OCSM.
Using a diagnostic scan tool, perform Restraints self-test.
Are any RCM and/or OCSM Diagnostic Trouble Codes (DTCs) retrieved on-demand during self-test?
Yes Do not clear any Diagnostic Trouble Codes (DTCs) until all Diagnostic Trouble Codes (DTCs) have been resolved. DIAGNOSE and
REPAIR the RCM and/or OCSM Diagnostic Trouble Codes (DTCs).
No The repair is complete. RETURN the vehicle to the customer.
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Pinpoint Test - DTC: B
B0002:11, B0002:12, B0002:13 and B0002:1A
The RCM continuously monitors the driver airbag stage 2 circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver airbag
If a fault is detected, the RCM stores DTC B0002:11, B0002:12, B0002:13 or B0002:1A in memory and sends a
message to the IPC to illuminate the airbag warning indicator.
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The RCM analyzes the deployment loop resistance to determine if a fault exists. The value displayed in the PID is
the deployment loop resistance 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. Small variations in resistance can occur due to the effect of
road vibrations on terminal fit. Crimps and terminals can be affected by stress and harness movement and can
cause an increase in resistance due to wire strain. 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 the time of diagnosis. Following this direction helps
make sure that minor changes in resistance do not create a repeat concern. This test uses process of elimination
to diagnose each part of the deployment loop circuit including:
Wiring
Clockspring
Driver airbag
Connections
RCM

B0002:11 Driver Frontal Stage 2 Deployment A fault is indicated when the RCM senses a short to ground on
Control: Circuit Short to Ground either driver airbag stage 2 circuit for more than 6 seconds.
B0002:12 Driver Frontal Stage 2 Deployment A fault is indicated when the RCM senses a short to voltage
Control: Circuit Short to Battery on either driver airbag stage 2 circuit for more than 6 seconds.
B0002:13 Driver Frontal Stage 2 Deployment A fault is indicated when the RCM measures more than the
Control: Circuit Open desired resistance range between driver airbag stage 2
circuits for more than 6 seconds.
B0002:1A Driver Frontal Stage 2 Deployment A fault is indicated when the RCM measures less than the
Control: Circuit Resistance Below desired resistance range between driver airbag stage 2
Threshold circuits for more than 6 seconds.
Possible Sources

Clockspring
Driver airbag
RCM
WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental

Restraint System (SRS) deployment. Never compromise or depart from these instructions. Failure
to precisely follow all instructions could result in serious personal injury from an accidental
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deployment.
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 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 parts
catalog to make sure the correct component is being installed. If an incorrect SRS component is installed,
Diagnostic Trouble Codes (DTCs) may set.
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings
in section 100-00 General Information. Failure to follow this instruction may result in serious
personal injury.
REFER to: Pyrotechnic Device Health and Safety Precautions (100-00 General Information, Description
and Operation).
Ignition ON.
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved
on-demand during self-test.
If DTC U3003:16 or U3003:17 is retrieved on-demand, DIAGNOSE those Diagnostic
Trouble Codes (DTCs) first.
REFER to: Pinpoint Test - DTC: AJ (501-20B Supplemental Restraint System, Diagnosis
and Testing).
If DTC U3003:16 or U3003:17 is not retrieved on-demand during self-test, DIAGNOSE the
driver airbag Diagnostic Trouble Codes (DTCs).
No This is an intermittent fault when present as a Continuous Memory Diagnostic Trouble
Code (CMDTC) only.
and Testing).
driver airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT CONTROL RESISTANCE

(DEPLOY_01_R) PID (PARAMETER IDENTIFICATION)
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Yes GO to A18
No GO to A3

(DEPLOY_01_R) PID (PARAMETER IDENTIFICATION) WHILE CARRYING OUT THE HARNESS TEST
While monitoring the DEPLOY_01_R PID, carry out the harness test of the driver airbag circuits and
accessible connectors (including any inline connectors) by wiggling and flexing the wire harness,
connectors, tilting and rotating the steering wheel frequently. Record the resistance value indicated by the
PID.
Yes DEPOWER the SRS.

REFER to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental
Restraint System, General Procedures).
REPAIR the connector, terminals or wire harness or INSTALL a new clockspring as
needed. REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and
Installation).

GO to A23
A4 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT CONTROL DTC (DIAGNOSTIC

TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE INDICATED)
NOTE: This pinpoint test step attempts to change the fault reported by the RCM by inducing a different
fault condition. If the reported fault changes, this indicates the RCM is functioning correctly and is not the
source of the fault.
Ignition OFF.
Depower the SRS.
REFER to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System,
REFER to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System,
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag disconnected,
open circuit faults are normally retrieved on stages 1 and 2.
Yes GO to A16
No GO to A5
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TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE INDICATED) (CLOCKSPRING
DISCONNECTED)
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag / clockspring
disconnected, open circuit faults are normally retrieved on stages 1 and 2.
Yes GO to A17
No GO to A6
A6 CHECK FOR A SHORT BETWEEN DRIVER AIRBAG STAGE 2 CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

C218A-9 C218A-10
Yes GO to A18
No REPAIR the circuits.
GO to A23
A7 CHECK THE DRIVER AIRBAG STAGE 2 CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
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Measure:

C310A-22 C216B-1
C310A-21 C216B-2
Are the resistances less than 1 ohm?
Yes GO to A9
No GO to A8
A8 CHECK THE DRIVER AIRBAG STAGE 2 CIRCUITS FOR AN OPEN (CLOCKSPRING

DISCONNECTED)
Measure:

C310A-22 C218A-9
C310A-21 C218A-10
Yes GO to A17
GO to A23
A9 CHECK THE DRIVER AIRBAG STAGE 2 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE
CODE) FOR A FAULT STATUS CHANGE (OPEN INDICATED)

C216B-1 C216B-2
Ignition ON.
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DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag stage 2 circuits
shorted together, a low resistance fault is normally retrieved on stage 2. Stage 1 shows an open circuit
fault because the driver airbag is disconnected.

A10 CHECK THE DRIVER AIRBAG STAGE 2 DEPLOYMENT CONTROL DTC (DIAGNOSTIC
TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN INDICATED)
Ignition OFF.
Depower the SRS.

C218A-9 C218A-10
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag stage 2 circuits
shorted together, a low resistance fault is normally retrieved on stage 2. Stage 1 shows an open circuit
fault because the driver airbag is disconnected.

TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
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Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver airbag disconnected,
Yes GO to A16
No GO to A12
(CLOCKSPRING DISCONNECTED)
Ignition OFF.
REFER to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the clockspring disconnected,
Yes GO to A17
No GO to A13
A13 CHECK THE DRIVER AIRBAG STAGE 2 CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C218A-9 Ground
C218A-10 Ground
Yes GO to A18
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GO to A23
TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO BATTERY INDICATED)
(CLOCKSPRING DISCONNECTED)
Ignition OFF.
Depower the SRS.
REFER to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the clockspring disconnected,
Yes GO to A17
No GO to A15
A15 CHECK THE DRIVER AIRBAG STAGE 2 CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C218A-9 Ground
C218A-10 Ground
Yes REPAIR the circuit(s).
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GO to A23
No GO to A18
A16 CONFIRM THE DRIVER AIRBAG FAULT
NOTE: Make sure all SRS components and the RCM electrical connectors are connected before carrying
out the self-test. If not, Diagnostic Trouble Codes (DTCs) will be recorded.
Ignition OFF.
Depower the SRS.
inspect connector(s) (including any inline connectors) for pushed-out, loose or spread terminals
and loose or frayed wire connections at terminals.
inspect RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct
operation.
inspect Driver Airbag C216B and make sure the Connector Position Assurance (CPA) tabs are not
broken and the clip is not damaged.
Ignition ON.
Yes INSTALL a new driver airbag.

REFER to: Driver Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A23
No In the process of diagnosing the fault, the fault condition has become intermittent. Do not
install any new SRS components at this time. Install SRS components only when directed
to do so in the pinpoint test.
A17 CONFIRM THE CLOCKSPRING FAULT
Ignition OFF.
Depower the SRS.
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operation.
Connect Clockspring C218A.
Ignition ON.
Yes INSTALL a new clockspring.

REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A23
Ignition OFF.
Depower the SRS.
operation.
Install the driver airbag (if previously removed).
Ignition ON.
Service Bulletins (TSBs) address this concern, INSTALL a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System,
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GO to A23

(DEPLOY_01_R) PID (PARAMETER IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE
OR OPEN CIRCUIT FAULT
Ignition OFF.
Ignition ON.
While monitoring the DEPLOY_01_R PID, attempt to recreate the fault by wiggling connectors (including
any inline connectors) and flexing the wire harness, tilting and rotating the steering wheel frequently.
Record the resistance value indicated by the PID.
Yes 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 directed to do so in the
pinpoint test. GO to A22
No If the driver airbag PID indicates incorrect resistance only when the steering wheel is
rotated, INSTALL a new clockspring.
REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and
Installation).
For all other faults, DEPOWER the SRS and REPAIR as necessary.
GO to A23
A20 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT CONTROL CIRCUITS FOR AN
INTERMITTENT SHORT TO GROUND FAULT
Ignition OFF.
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire
harness, tilting and rotating the steering wheel frequently.

GO to A23
No The fault is not present and cannot be recreated at this time. Do not install any new SRS
A21 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT CONTROL CIRCUITS FOR AN
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INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
harness, tilting and rotating the steering wheel frequently.

GO to A23

Ignition OFF.
Depower the SRS.
Inspect connector(s) (including any inline connectors) for corrosion, loose or spread terminals and
loose or frayed wire connections at terminals.
Inspect RCM C216B Connector Position Assurance (CPA) lever/lock for correct operation.
Inspect Driver Airbag C216B Connector Position Assurance (CPA) tab to verify that it is correctly
seated and free of damage.

GO to A23
A23 CHECK FOR ADDITIONAL SRS (SUPPLEMENTAL RESTRAINT SYSTEM) DIAGNOSTIC

Ignition OFF.
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Ignition ON.
NOTE: When selecting Restraints from the Self Test menu, DTCs are retrieved from the RCM and
OCSM.
Yes Do not clear any Diagnostic Trouble Codes (DTCs) until all Diagnostic Trouble Codes
(DTCs) have been resolved.

Pinpoint Test - DTC: C
The RCM continuously monitors the driver knee airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver knee airbag
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Wiring
Connections
Driver knee airbag
RCM

B0004:11 Driver Knee Bolster Deployment A fault is indicated when the RCM senses a short to ground on
Control: Circuit Short to Ground either driver knee airbag circuit for more than 6 seconds.
B0004:12 Driver Knee Bolster Deployment A fault is indicated when the RCM senses a short to voltage
Control: Circuit Short to Battery on either driver knee airbag circuit for more than 6 seconds.
B0004:13 Driver Knee Bolster Deployment A fault is indicated when the RCM measures more than the
Control: Circuit Open desired resistance between the driver knee airbag circuits for
more than 6 seconds.
B0004:1A Driver Knee Bolster Deployment A fault is indicated when the RCM measures less than the
Control: Circuit Resistance Below desired resistance between the driver knee airbag circuits for
Threshold more than 6 seconds.
Possible Sources

Driver knee airbag
RCM

deployment.
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may not be compatible even if they appear physically similar. Check the part number listed in the Ford
parts catalog to make sure the correct component is being installed. If an incorrect SRS component is
installed, Diagnostic Trouble Codes (DTCs) may set.
personal injury.
and Operation).
Ignition ON.
Was DTC B0004:11, B0004:12, B0004:13 and B0004:1A retrieved on-demand during self-test?
and Testing).
driver knee airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
driver knee airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE DRIVER KNEE BOLSTER DEPLOYMENT CONTROL (DEPLOY_02_R) PID

Yes GO to A12
No GO to A3
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(PARAMETER IDENTIFICATION) WHILE CARRYING OUT THE HARNESS TEST
While monitoring the DEPLOY_02_R PID, carry out the harness test of the driver knee airbag circuits and
accessible connectors (including any inline connectors) by wiggling and flexing the wire harness and
connectors frequently. Record the resistance value indicated by the PID.
Yes DEPOWER the SRS and REPAIR the connector, terminals or wire harness as needed.
GO to A17
A4 CHECK THE DRIVER KNEE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE
CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE INDICATED)
Ignition OFF.
Depower the SRS.
Remove the driver knee airbag.
REFER to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver knee airbag
disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DRIVER KNEE AIRBAG CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

C2432-3 C2432-4
cardiagn.com
Yes GO to A12
GO to A17
A6 CHECK THE DRIVER KNEE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-7 C2432-3
C310A-8 C2432-4
Yes GO to A7
GO to A17

C2432-3 C2432-4
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver knee airbag circuits
shorted together, a low resistance fault is normally retrieved.
cardiagn.com
Did the on-demand DTC change from B0004:13 to B0004:1A?

CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver knee airbag
Yes GO to A11
No GO to A9
A9 CHECK THE DRIVER KNEE AIRBAG CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Depower the SRS.
Measure:

C2432-3 Ground
C2432-4 Ground
Yes GO to A12
GO to A17
cardiagn.com
A10 CHECK THE DRIVER KNEE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C2432-3 Ground
C2432-4 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DRIVER KNEE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
Inspect connector(s) (including any inline connectors) for pushed-out, loose or spread terminals
Inspect wire harness for any damaged, pinched, cut or pierced wires.
Inspect RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct
operation.
Inspect Driver Knee Airbag C2432 and make sure the Connector Position Assurance (CPA) tabs
are not broken and the clip is not damaged.
Repair any concerns found.
Install the driver knee airbag.
Ignition ON.
cardiagn.com
Yes INSTALL a new driver knee airbag.
REFER to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Install the driver knee airbag (if previously removed).
Ignition ON.
GO to A17
(PARAMETER IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT
FAULT
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any inline connectors) and flexing the wire harness frequently. Record the resistance value indicated by
the PID.
No DEPOWER the SRS.
REPAIR as necessary.
GO to A17
A14 CHECK THE DRIVER KNEE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE DRIVER KNEE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com
Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Knee Airbag C2432 Connector Position Assurance (CPA) tab to verify that it is
correctly seated and free of damage.

GO to A17

Ignition OFF.
Install the driver knee airbag.
Ignition ON.
OCSM.
(DTCs) have been resolved. DIAGNOSE and REPAIR the RCM and/or OCSM Diagnostic
Trouble Codes (DTCs).
cardiagn.com
Pinpoint Test - DTC: D
B0005:11, B0005:12, B0005:13, B0005:1A
The RCM continuously monitors the deployable steering column circuits for the following faults:

Unexpected voltage
Short to ground
Faulted deployable steering column
cardiagn.com
Wiring
Connections
Deployable steering column
RCM

B0005:11 Collapsible Steering Column A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either deployable steering column circuit for more than 6
Ground seconds.
B0005:12 Collapsible Steering Column A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either deployable steering column circuit for more than 6
Battery seconds.
B0005:13 Collapsible Steering Column A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the deployable steering column
B0005:1A Collapsible Steering Column A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the deployable steering column
Resistance Below Threshold circuits for more than 6 seconds.
Possible Sources

RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
deployable steering column Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
deployable steering column Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE COLLAPSIBLE STEERING COLUMN DEPLOYMENT CONTROL (DEPLOY_04_R)

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Yes GO to A12
No GO to A3

PID (PARAMETER IDENTIFICATION) WHILE CARRYING OUT THE HARNESS TEST
While monitoring the DEPLOY_04_R PID, carry out the harness test of the deployable steering column
circuits and accessible connectors (including any inline connectors) by wiggling and flexing the wire
harness and connectors frequently. Record the resistance value indicated by the PID.
GO to A17
A4 CHECK THE DEPLOYABLE STEERING COLUMN DEPLOYMENT CONTROL DTC (DIAGNOSTIC

Ignition OFF.
Depower the SRS.
Disconnect Deployable Steering Column C2360.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the deployable steering column
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DEPLOYABLE STEERING COLUMN CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

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C2360-1 C2360-2
Yes GO to A12
GO to A17
A6 CHECK THE DEPLOYABLE STEERING COLUMN CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-11 C2360-1
C310A-12 C2360-2
Yes GO to A7
GO to A17

C2360-1 C2360-2
Ignition ON.
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circuits shorted together, a low resistance fault is normally retrieved.


Ignition OFF.
Depower the SRS.
Ignition ON.
Yes GO to A11
No GO to A9
A9 CHECK THE DEPLOYABLE STEERING COLUMN CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Depower the SRS.
Measure:

C2360-1 Ground
C2360-2 Ground
Yes GO to A12
GO to A17
cardiagn.com
A10 CHECK THE DEPLOYABLE STEERING COLUMN CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C2360-1 Ground
C2360-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DEPLOYABLE STEERING COLUMN FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Deployable Steering Column C2360 and make sure the Connector Position Assurance
(CPA) tabs are not broken and the clip is not damaged.
Connect Deployable Steering Column C2360.
Ignition ON.
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Yes INSTALL a new steering column (includes deployable device).
REFER to: Steering Column (211-04 Steering Column, Removal and Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Deployable Steering Column C2360 (if previously disconnected).
Ignition ON.

GO to A17

PID (PARAMETER IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT
FAULT
the PID.
cardiagn.com
No DEPOWER the SRS.
GO to A17
A14 CHECK THE DEPLOYABLE STEERING COLUMN DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE DEPLOYABLE STEERING COLUMN DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com
Ignition OFF.
Depower the SRS.
operation.
Inspect Deployable Steering Column C2360 Connector Position Assurance (CPA) tab to verify that
it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: E
B0010:11, B0010:12, B0010:13 and B0010:1A
The RCM continuously monitors the passenger airbag stage 1 circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger airbag
If a fault is detected, the RCM stores DTC B0010:11, B0010:12, B0010:13 or B0010:1A in memory and sends a message to the IPC to illuminate the airbag
warning indicator.
The RCM analyzes the deployment loop resistance to determine if a fault exists. The value displayed in the PID is the deployment loop resistance 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. Small variations in resistance can occur due to the effect of road vibrations on terminal
fit. Crimps and terminals can be affected by stress and harness movement and can cause an increase in resistance due to wire strain. 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 the time of diagnosis. Following this direction helps make sure that minor changes in resistance do not create a
repeat concern. This test uses process of elimination to diagnose each part of the deployment loop circuit including:
Wiring
cardiagn.com
Connections
Passenger airbag
RCM

B0010:11 Passenger Frontal Stage 1 Deployment Control: A fault is indicated when the RCM senses a short to ground on either passenger airbag stage
Circuit Short to Ground 1 circuit for more than 6 seconds.
B0010:12 Passenger Frontal Stage 1 Deployment Control: A fault is indicated when the RCM senses a short to voltage on either passenger airbag
Circuit Short to Battery stage 1 circuit for more than 6 seconds.
B0010:13 Passenger Frontal Stage 1 Deployment Control: A fault is indicated when the RCM measures more than the desired resistance range
Circuit Open between the passenger airbag stage 1 circuits for more than 6 seconds.
B0010:1A Passenger Frontal Stage 1 Deployment Control: A fault is indicated when the RCM measures less than the desired resistance range between
Circuit Resistance Below Threshold the passenger airbag stage 1 circuits for more than 6 seconds.
Possible Sources

Passenger airbag
RCM
Inspect for damaged wiring harness(es).

Inspect for loose or damaged connectors.
connector.
physically similar. Check the part number listed in the Ford parts catalog to make sure the correct component is being installed. If an incorrect SRS
component is installed, Diagnostic Trouble Codes (DTCs) may set.
Ignition ON.
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved on-demand during self-test.
If DTC U3003:16 or U3003:17 is not retrieved on-demand during self-test, DIAGNOSE the passenger airbag Diagnostic Trouble Codes
(DTCs).
No This is an intermittent fault when present as a Continuous Memory Diagnostic Trouble Code (CMDTC) only.
If DTC U3003:16 or U3003:17 is not retrieved on-demand during self-test, DIAGNOSE the passenger airbag Continuous Memory
Diagnostic Trouble Codes (CMDTCs).
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A2 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT CONTROL RESISTANCE (DEPLOY_05_R) PID (PARAMETER IDENTIFICATION)
Yes GO to A13
No GO to A3
WHILE CARRYING OUT THE HARNESS TEST
Remove the glove compartment.
REFER to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation).
While monitoring the DEPLOY_05_R PID, carry out the harness test of the passenger airbag circuits and accessible connectors (including any inline
connectors) by wiggling and flexing the wire harness and connectors frequently. Record the resistance value indicated by the PID.
Yes DEPOWER the SRS and REPAIR the connector, terminals or wire harness.
GO to A18
A4 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE
(LOW RESISTANCE INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect Passenger Airbag C256.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag disconnected, open circuit faults are normally retrieved on
passenger airbag stages 1 and 2, and for the passenger airbag canister vent.

Yes GO to A12
No GO to A5
A5 CHECK FOR A SHORT BETWEEN PASSENGER AIRBAG STAGE 1 CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

C256-1 C256-2
Yes GO to A13
No GO to A6

Measure:
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Action
C310A, pin 28, component side C310A, pin 27, component side
Yes REPAIR the passenger airbag stage 1 circuits for a short together.
GO to A18
No GO to A13
A7 CHECK THE PASSENGER AIRBAG STAGE 1 CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-27 C256-2
C310A-28 C256-1
Yes GO to A8
GO to A18
A8 CHECK THE PASSENGER AIRBAG STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE
(OPEN INDICATED)

C256-1 C256-2
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag stage 1 circuits shorted together, a low resistance fault is
normally retrieved on stage 1. Stage 2 and the passenger airbag canister vent both show an open circuit fault due to the passenger airbag being
disconnected.
cardiagn.com
A9 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE
(SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag disconnected, open circuit faults are normally retrieved on
passenger airbag stages 1 and 2, and for the passenger airbag canister vent.
Yes GO to A12
No GO to A10
A10 CHECK THE PASSENGER AIRBAG STAGE 1 CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C256-1 Ground
C256-2 Ground
Yes GO to A13
No Due to the shorting bar feature in the RCM electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting
bar.
REPAIR the circuit(s).
GO to A18
A11 CHECK THE PASSENGER AIRBAG STAGE 1 CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C256-1 Ground
C256-2 Ground
Yes Due to the shorting bar feature in the RCM electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting
bar.
REPAIR the circuit(s).
cardiagn.com
GO to A18
No GO to A13
A12 CONFIRM THE PASSENGER AIRBAG FAULT
Ignition OFF.
Depower the SRS.
inspect Passenger Airbag C256 and make sure the Connector Position Assurance (CPA) tabs are not broken and the clip is not damaged.
Connect Passenger Airbag C256 (if previously disconnected).
Ignition ON.
Yes INSTALL a new passenger airbag.

REFER to: Passenger Airbag (501-20B Supplemental Restraint System, Removal and Installation).
GO to A18
Ignition OFF.
Depower the SRS.
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and Installation).
GO to A18
FOR AN INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT FAULT
While monitoring the DEPLOY_05_R PID, attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness
frequently. Record the resistance value indicated by the PID.
Yes The fault is not present and cannot be recreated at this time. Do not install any new SRS components at this time. Install SRS
cardiagn.com
No DEPOWER the SRS and REPAIR as necessary.
GO to A18
A15 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO GROUND FAULT
Attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness frequently.

GO to A18
A16 CHECK THE PASSENGER FRONTAL STAGE 1 DEPLOYMENT CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
Attempt to recreate the fault by wiggling connectors (including any inline connectors) and flexing the wire harness frequently.

GO to A18

Ignition OFF.
Depower the SRS.
Inspect connector(s) (including any inline connectors) for corrosion, loose or spread terminals and loose or frayed wire connections at terminals.
Inspect Passenger Airbag C256 and make sure the Connector Position Assurance (CPA) tabs are not broken and the clip is not damaged.

GO to A18
Ignition OFF.
Ignition ON.
Yes Do not clear any Diagnostic Trouble Codes (DTCs) until all Diagnostic Trouble Codes (DTCs) have been resolved.
cardiagn.com
Pinpoint Test - DTC: F
B0011:11, B0011:12, B0011:13, B0011:1A
The RCM continuously monitors the passenger airbag stage 2 circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger airbag
cardiagn.com
Wiring
Connections
Passenger airbag
RCM

B0011:11 Passenger Frontal Stage 2 A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either passenger airbag stage 2 circuit for more than 6
Ground seconds.
B0011:12 Passenger Frontal Stage 2 A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either passenger airbag stage 2 circuit for more than 6
Battery seconds.
B0011:13 Passenger Frontal Stage 2 A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the passenger airbag stage 2
B0011:1A Passenger Frontal Stage 2 A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the passenger airbag stage 2
Resistance Below Threshold circuits for more than 6 seconds.
Possible Sources

Passenger airbag
RCM

cardiagn.com
deployment.
personal injury.
and Operation).
Ignition ON.
and Testing).
passenger airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
passenger airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE PASSENGER FRONTAL STAGE 2 DEPLOYMENT CONTROL (DEPLOY_06_R) PID

cardiagn.com
Yes GO to A12
No GO to A3

While monitoring the DEPLOY_06_R PID, carry out the harness test of the passenger airbag circuits and
GO to A17
A4 CHECK THE PASSENGER AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE

Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag
disconnected, an open circuit fault is normally retrieved for passenger airbag stage 2. An open circuit fault
is also retrieved for passenger airbag stage 1 and the passenger airbag canister vent, due to the
passenger airbag connector being disconnected.
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER AIRBAG CIRCUITS

Ignition OFF.
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Depower the SRS.
Measure:

C256-4 C256-5
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-23 C256-4
C310A-24 C256-5
Yes GO to A7
GO to A17


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C256-4 C256-5
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag stage 2
circuits shorted together, a low resistance fault is normally retrieved. An open circuit fault is also retrieved
for passenger airbag stage 1 and the passenger airbag canister vent, due to the passenger airbag
connector being disconnected.


Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag
disconnected, an open circuit fault is normally retrieved for passenger airbag stage 2. An open circuit fault
is also retrieved for passenger airbag stage 1 and the passenger airbag canister vent, due to the
passenger airbag connector being disconnected.
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER AIRBAG CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C256-4 Ground
C256-5 Ground
Yes GO to A12
GO to A17
A10 CHECK THE PASSENGER AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C256-4 Ground
C256-5 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER AIRBAG FAULT
Ignition OFF.
Depower the SRS.
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operation.
Inspect Passenger Airbag C256 and make sure the Connector Position Assurance (CPA) tabs are
not broken and the clip is not damaged.
Connect Passenger Airbag C256.
Ignition ON.
Yes INSTALL a new passenger airbag.

REFER to: Passenger Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
cardiagn.com
GO to A17
FAULT
the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE PASSENGER AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN

harness frequently.

GO to A17
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A15 CHECK THE PASSENGER AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17

Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Airbag C256 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

cardiagn.com
Ignition OFF.
Ignition ON.
OCSM.

Pinpoint Test - DTC: G
B0013:11, B0013:12, B0013:13, B0013:1A
The RCM continuously monitors the passenger knee airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger knee airbag
cardiagn.com
Wiring
Connections
Passenger knee airbag
RCM

B0013:11 Passenger Knee Bolster Deployment A fault is indicated when the RCM senses a short to ground
Control: Circuit Short to Ground on either passenger knee airbag circuit for more than 6
seconds.
B0013:12 Passenger Knee Bolster Deployment A fault is indicated when the RCM senses a short to voltage
Control: Circuit Short to Battery on either passenger knee airbag circuit for more than 6
seconds.
B0013:13 Passenger Knee Bolster Deployment A fault is indicated when the RCM measures more than the
Control: Circuit Open desired resistance between the passenger knee airbag
B0013:1A Passenger Knee Bolster Deployment A fault is indicated when the RCM measures less than the
Control: Circuit Resistance Below desired resistance between the passenger knee airbag
Possible Sources

Passenger knee airbag
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
passenger knee airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
passenger knee airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE PASSENGER KNEE BOLSTER DEPLOYMENT CONTROL (DEPLOY_07_R) PID

cardiagn.com
Yes GO to A12
No GO to A3

While monitoring the DEPLOY_07_R PID, carry out the harness test of the passenger knee airbag
GO to A17
A4 CHECK THE PASSENGER KNEE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC

Ignition OFF.
Depower the SRS.
Disconnect Passenger Knee Airbag C2600.
Lower the glove compartment.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger knee airbag
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER KNEE AIRBAG CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C2600-1 C2600-2
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER KNEE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310A-5 C2600-1
C310A-6 C2600-2
Yes GO to A7
GO to A17


C2600-1 C2600-2
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Ignition ON.


Ignition OFF.
Depower the SRS.
Ignition ON.
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER KNEE AIRBAG CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C2600-1 Ground
C2600-2 Ground
Yes GO to A12
cardiagn.com
GO to A17
A10 CHECK THE PASSENGER KNEE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C2600-1 Ground
C2600-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER KNEE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Knee Airbag C2600 and make sure the Connector Position Assurance (CPA)
tabs are not broken and the clip is not damaged.
Connect Passenger Knee Airbag C2600.
Ignition ON.
cardiagn.com
Yes INSTALL a new passenger knee airbag.

REFER to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal
and Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Knee Airbag C2600 (if previously disconnected).
Ignition ON.
GO to A17
cardiagn.com
FAULT
the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE PASSENGER KNEE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE PASSENGER KNEE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com

Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Knee Airbag C2600 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: H
B0050:11, B0050:12, B0050:13, B0050:1D
The RCM continuously 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
cardiagn.com

B0050:11 Driver Seatbelt Sensor: A fault is indicated when the RCM senses a short to ground on the
Circuit Short to Ground driver safety belt buckle switch circuit for more than 6 seconds.
B0050:12 Driver Seatbelt Sensor: A fault is indicated when the RCM senses a short to voltage on the
Circuit Short to Battery driver safety belt buckle switch circuit for more than 6 seconds.
B0050:13 Driver Seatbelt Sensor: A fault is indicated when the RCM senses an open on either driver
Circuit Open safety belt buckle switch circuit for more than 6 seconds.
B0050:1D Driver Seatbelt Sensor: A fault is indicated when the RCM measures current outside of an
Circuit Current Out of Range acceptable range on the driver safety belt buckle switch circuit for
Possible Sources

Driver safety belt buckle switch
RCM
Inspect for a damaged driver safety belt buckle.

PINPOINT TEST A : B0050:11, B0050:12, B0050:13 AND B0050:1D

deployment.
personal injury.
and Operation).
Ignition ON.
cardiagn.com
Was DTC B0050:11, B0050:12, B0050:13 and B0050:1D retrieved on-demand during self-test?
and Testing).
driver safety belt buckle switch Diagnostic Trouble Codes (DTCs).
For DTC B0050:11 or B0050:1D, GO to A2
No If DTC U3003:16 or U3003:17 is retrieved on-demand, DIAGNOSE those Diagnostic
and Testing).
driver safety belt buckle switch Continuous Memory Diagnostic Trouble Codes (CMDTCs).
This is an intermittent fault when present as a Continuous Memory Diagnostic Trouble
Code (CMDTC) only. GO to A10
A2 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH DTC (DIAGNOSTIC TROUBLE CODE)
FOR A FAULT STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT OF RANGE INDICATED)
Ignition OFF.
Disconnect Driver Safety Belt Buckle C3201.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver safety belt buckle
switch disconnected, an open circuit fault is normally retrieved.
Did the on-demand DTC change from B0050:11 or B0050:1D to B0050:13?
Yes GO to A8
No For DTC B0050:11, GO to A3
For DTC B0050:1D, GO to A9
A3 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

cardiagn.com
C3201-5 Ground
Yes GO to A9
GO to A11
A4 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Disconnect Driver Side Airbag (Inline) C345.
Ignition ON.
Measure:

C3201-5 Ground

GO to A11
No GO to A9
A5 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH DTC (DIAGNOSTIC TROUBLE CODE)
FOR A FAULT STATUS CHANGE (OPEN INDICATED)
Ignition OFF.
Depower the SRS.

cardiagn.com
C3201-5 C3201-6
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver safety belt buckle
switch circuits shorted together, a short to ground fault is normally retrieved.

A6 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-54 C3201-5
Is the resistance less than 0.5 ohm?
Yes GO to A7
GO to A11
A7 CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH GROUND CIRCUIT FOR AN OPEN
Measure:

C3201-6 C310B-53
Yes GO to A9
GO to A11
cardiagn.com
A8 CONFIRM THE DRIVER SAFETY BELT BUCKLE SWITCH FAULT
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Side Airbag (Inline) C345 (if previously disconnected).
Connect Driver Safety Belt Buckle C3201.
Ignition ON.
Yes INSTALL a new driver safety belt buckle (includes safety belt buckle switch).
REFER to: Front Seatbelt Buckle (501-20A Seatbelt Systems, Removal and Installation).
GO to A11
to do so in the pinpoint test. GO to A10
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Safety Belt Buckle C3201.
cardiagn.com
Ignition ON.
GO to A11
A10 CHECK FOR AN INTERMITTENT FAULT

Ignition OFF.
Depower the SRS.
operation.
Connect all previously disconnected component(s) / connector(s).
Ignition ON.

Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
OCSM.

Pinpoint Test - DTC: I
B0052:11, B0052:12, B0052:13, B0052:1D
The RCM continuously monitors the passenger safety belt buckle switch circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted passenger 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
cardiagn.com

B0052:11 Passenger Seatbelt Sensor: A fault is indicated when the RCM senses a short to ground on the
Circuit Short to Ground passenger safety belt buckle switch circuit for more than 6 seconds.
B0052:12 Passenger Seatbelt Sensor: A fault is indicated when the RCM senses a short to voltage on the
Circuit Short to Battery passenger safety belt buckle switch circuit for more than 6 seconds.
B0052:13 Passenger Seatbelt Sensor: A fault is indicated when the RCM senses an open on either
Circuit Open passenger safety belt buckle switch circuit for more than 6 seconds.
B0052:1D Passenger Seatbelt Sensor: A fault is indicated when the RCM measures current outside of an
Circuit Current Out of Range acceptable range on the passenger safety belt buckle switch circuit
for more than 6 seconds.
Possible Sources

Passenger safety belt buckle switch
RCM
Inspect for a damaged passenger safety belt buckle.

PINPOINT TEST A : B0052:11, B0052:12, B0052:13 AND B0052:1D

deployment.
personal injury.
and Operation).
Ignition ON.
cardiagn.com
and Testing).
passenger safety belt buckle switch Diagnostic Trouble Codes (DTCs).
and Testing).
passenger safety belt buckle switch Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
A2 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH DTC (DIAGNOSTIC TROUBLE
CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT OF RANGE
INDICATED)
Ignition OFF.
Disconnect Passenger Safety Belt Buckle C3238.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger safety belt
buckle switch disconnected, an open circuit fault is normally retrieved. A Belt Tension Sensor (BTS) circuit
fault will also be present in the OCSM, since the passenger safety belt buckle switch shares a connector
with the Belt Tension Sensor (BTS).
Did the on-demand DTC change from B0052:11 or B0052:1D to B0052:13?
Yes GO to A8
No For DTC B0052:11, GO to A3
For DTC B0052:1D, GO to A9
A3 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C3238-5 Ground
Yes GO to A9
GO to A11
A4 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF.
Depower the SRS.
Disconnect Passenger Side Airbag (Inline) C219.
Ignition ON.
Measure:

C3238-5 Ground
cardiagn.com
GO to A11
No GO to A9
A5 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH DTC (DIAGNOSTIC TROUBLE
Ignition OFF.
Depower the SRS.

C3238-5 C3238-6
Ignition ON.
buckle switch circuits shorted together, a short to ground fault is normally retrieved. A Belt Tension
Sensor (BTS) circuit fault will also be present in the OCSM, since the passenger safety belt buckle switch
shares a connector with the Belt Tension Sensor (BTS).

A6 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-55 C3238-5
cardiagn.com
Yes GO to A7
GO to A11
A7 CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH GROUND CIRCUIT FOR AN OPEN
Measure:

C3238-6 Ground
Yes GO to A9
GO to A11
A8 CONFIRM THE PASSENGER SAFETY BELT BUCKLE SWITCH FAULT
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Side Airbag (Inline) C219 (if previously disconnected).
Connect Passenger Safety Belt Buckle C3238.
Ignition ON.
Yes INSTALL a new passenger safety belt buckle (includes safety belt buckle switch).
GO to A11
cardiagn.com
Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
GO to A11

Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
cardiagn.com

Ignition OFF.
Depower the SRS.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: J
B0070:11, B0070:12, B0070:13, B0070:1A
The RCM continuously monitors the driver safety belt anchor pretensioner circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver safety belt anchor pretensioner
cardiagn.com
Wiring
Connections
Driver safety belt anchor pretensioner
RCM

B0070:11 Driver Seatbelt Pretensioner "A" A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either driver safety belt anchor pretensioner circuit for
Ground more than 6 seconds.
B0070:12 Driver Seatbelt Pretensioner "A" A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either driver safety belt anchor pretensioner circuit for
Battery more than 6 seconds.
B0070:13 Driver Seatbelt Pretensioner "A" A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the driver safety belt anchor
pretensioner circuits for more than 6 seconds.
B0070:1A Driver Seatbelt Pretensioner "A" A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the driver safety belt anchor
Resistance Below Threshold pretensioner circuits for more than 6 seconds.
Possible Sources

Driver safety belt anchor pretensioner
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
anchor pretensioner Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
anchor pretensioner Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE DRIVER SEATBELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL

(DEPLOY_29_RES) PID (PARAMETER IDENTIFICATION)
Monitor and record the resistance value displayed by the DEPLOY_29_RES PID.
cardiagn.com
Yes GO to A12
No GO to A3

(DEPLOY_29_RES) PID (PARAMETER IDENTIFICATION) WHILE CARRYING OUT THE HARNESS
TEST
While monitoring the DEPLOY_29_RES PID, carry out the harness test of the driver safety belt anchor
pretensioner circuits and accessible connectors (including any inline connectors) by wiggling and flexing
the wire harness and connectors frequently. Record the resistance value indicated by the PID.
GO to A17
A4 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL DTC
(DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect Driver Safety Belt Anchor Pretensioner C3065.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver safety belt anchor
pretensioner disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DRIVER SAFETY BELT ANCHOR PRETENSIONER
CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C3065-1 C3065-2
Yes GO to A12
GO to A17
A6 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-16 C3065-1
C310B-15 C3065-2
Yes GO to A7
GO to A17
(DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN INDICATED)

C3065-1 C3065-2
cardiagn.com
Ignition ON.
pretensioner circuits shorted together, a low resistance fault is normally retrieved.

(DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Yes GO to A11
No GO to A9
A9 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
Depower the SRS.
Measure:

C3065-1 Ground
C3065-2 Ground
Yes GO to A12
cardiagn.com
GO to A17
A10 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3065-1 Ground
C3065-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DRIVER SAFETY BELT ANCHOR PRETENSIONER FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Safety Belt Anchor Pretensioner C3065 and make sure the Connector Position
Assurance (CPA) tabs are not broken and the clip is not damaged.
Connect Driver Safety Belt Anchor Pretensioner C3065.
Ignition ON.
cardiagn.com
Yes INSTALL a new driver safety belt retractor (includes anchor pretensioner).
REFER to: Front Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems,
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Safety Belt Anchor Pretensioner C3065 (if previously disconnected).
Ignition ON.
GO to A17

(DEPLOY_29_RES) PID (PARAMETER IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE
cardiagn.com
While monitoring the DEPLOY_29_RES PID, attempt to recreate the fault by wiggling connectors
(including any inline connectors) and flexing the wire harness frequently. Record the resistance value
indicated by the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL
CIRCUITS FOR AN INTERMITTENT SHORT TO GROUND FAULT
harness frequently.

GO to A17
A15 CHECK THE DRIVER SAFETY BELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL
CIRCUITS FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com

Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Safety Belt Anchor Pretensioner C3065 Connector Position Assurance (CPA) tab to
verify that it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: K
B0072:11, B0072:12, B0072:13, B0072:1A
The RCM continuously monitors the passenger safety belt anchor pretensioner circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger safety belt anchor pretensioner
cardiagn.com
Wiring
Connections
Passenger safety belt anchor pretensioner
RCM

B0072:11 Passenger Seatbelt Pretensioner "A" A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either passenger safety belt anchor pretensioner circuit
Ground for more than 6 seconds.
B0072:12 Passenger Seatbelt Pretensioner "A" A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either passenger safety belt anchor pretensioner circuit
Battery for more than 6 seconds.
B0072:13 Passenger Seatbelt Pretensioner "A" A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the passenger safety belt anchor
B0072:1A Passenger Seatbelt Pretensioner "A" A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the passenger safety belt anchor
Possible Sources

Passenger safety belt anchor pretensioner
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
anchor pretensioner Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
anchor pretensioner Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE PASSENGER SEATBELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL

(DEPLOY_30_RES) PID (PARAMETER IDENTIFICATION)
Monitor and record the resistance value displayed by the DEPLOY_30_RES PID.
cardiagn.com
Yes GO to A12
No GO to A3

(DEPLOY_30_RES) PID (PARAMETER IDENTIFICATION) WHILE CARRYING OUT THE HARNESS
TEST
While monitoring the DEPLOY_30_RES PID, carry out the harness test of the passenger safety belt
anchor pretensioner circuits and accessible connectors (including any inline connectors) by wiggling and
flexing the wire harness and connectors frequently. Record the resistance value indicated by the PID.
GO to A17
A4 CHECK THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER DEPLOYMENT CONTROL

DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE
INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect Passenger Safety Belt Anchor Pretensioner C3066.
Ignition ON.
anchor pretensioner disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER
CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C3066-1 C3066-2
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-13 C3066-1
C310B-14 C3066-2
Yes GO to A7
GO to A17

DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN INDICATED)

C3066-1 C3066-2
cardiagn.com
Ignition ON.
anchor pretensioner circuits shorted together, a low resistance fault is normally retrieved.


DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND
INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
anchor pretensioner disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR A SHORT
TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C3066-1 Ground
C3066-2 Ground
cardiagn.com
Yes GO to A12
GO to A17
A10 CHECK THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER CIRCUITS FOR A SHORT
TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3066-1 Ground
C3066-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER SAFETY BELT ANCHOR PRETENSIONER FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Safety Belt Anchor Pretensioner C3066 and make sure the Connector Position
Connect Passenger Safety Belt Anchor Pretensioner C3066.
cardiagn.com
Ignition ON.
Yes INSTALL a new passenger safety belt retractor (includes anchor pretensioner).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Safety Belt Anchor Pretensioner C3066 (if previously disconnected).
Ignition ON.
GO to A17
cardiagn.com
(DEPLOY_30_RES) PID (PARAMETER IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE
While monitoring the DEPLOY_30_RES PID, attempt to recreate the fault by wiggling connectors
(including any inline connectors) and flexing the wire harness frequently. Record the resistance value
indicated by the PID.
No DEPOWER the SRS.
GO to A17
harness frequently.

GO to A17
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

cardiagn.com
GO to A17

Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Safety Belt Anchor Pretensioner C3066 Connector Position Assurance (CPA)
tab to verify that it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: L
B007E:11, B007E:12, B007E:13, B007E:1A
The RCM continuously monitors the driver safety belt retractor pretensioner circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver safety belt retractor pretensioner
If a fault is detected, the RCM stores DTC B007E:11, B007E:12, B007E:13 or B007E:1A in memory and sends a
cardiagn.com
Wiring
Connections
Driver safety belt retractor pretensioner
RCM

B007E:11 Driver Seatbelt Pretensioner "C" A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either driver safety belt retractor pretensioner circuit for
Ground more than 6 seconds.
B007E:12 Driver Seatbelt Pretensioner "C" A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either driver safety belt retractor pretensioner circuit for
Battery more than 6 seconds.
B007E:13 Driver Seatbelt Pretensioner "C" A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the driver safety belt retractor
B007E:1A Driver Seatbelt Pretensioner "C" A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the driver safety belt retractor
Possible Sources

Driver safety belt retractor pretensioner
RCM
PINPOINT TEST A : B007E:11, B007E:12, B007E:13 AND B007E:1A

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
Was DTC B007E:11, B007E:12, B007E:13 and B007E:1A retrieved on-demand during self-test?
and Testing).
retractor pretensioner Diagnostic Trouble Codes (DTCs).
For DTC B007E:13 or B007E:1A, GO to A2
For DTC B007E:11, GO to A8
Code (CMDTC) only.
and Testing).
retractor pretensioner Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE DRIVER SEATBELT RETRACTOR PRETENSIONER DEPLOYMENT CONTROL

cardiagn.com
Yes GO to A12
No GO to A3

While monitoring the DEPLOY_23_R PID, carry out the harness test of the driver safety belt retractor
pretensioner circuits and accessible connectors (including any inline connectors) by wiggling and flexing
GO to A17
A4 CHECK THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER DEPLOYMENT CONTROL

DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW RESISTANCE
INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect Driver Safety Belt Retractor Pretensioner C323.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver safety belt retractor
Did the on-demand DTC change from B007E:1A to B007E:13?
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER
CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C323-1 C323-2
Yes GO to A12
GO to A17
A6 CHECK THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-52 C323-1
C310B-51 C323-2
Yes GO to A7
GO to A17

DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN INDICATED)

C323-1 C323-2
cardiagn.com
Ignition ON.
pretensioner circuits shorted together, a low resistance fault is normally retrieved.
Did the on-demand DTC change from B007E:13 to B007E:1A?


DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND
INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Did the on-demand DTC change from B007E:11 to B007E:13?
Yes GO to A11
No GO to A9
A9 CHECK THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
Depower the SRS.
Measure:

C323-1 Ground
C323-2 Ground
cardiagn.com
Yes GO to A12
GO to A17
A10 CHECK THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR A SHORT
TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C323-1 Ground
C323-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DRIVER SAFETY BELT RETRACTOR PRETENSIONER FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Safety Belt Retractor Pretensioner C323 and make sure the Connector Position
Connect Driver Safety Belt Retractor Pretensioner C323.
Ignition ON.
cardiagn.com
Yes INSTALL a new driver safety belt retractor (includes retractor pretensioner).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Safety Belt Retractor Pretensioner C323 (if previously disconnected).
Ignition ON.
GO to A17

cardiagn.com
the PID.
No DEPOWER the SRS.
GO to A17
harness frequently.
Was DTC B007E:11 retrieved on-demand during self-test?

GO to A17
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.
Was DTC B007E:12 retrieved on-demand during self-test?

GO to A17
cardiagn.com

Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Safety Belt Retractor Pretensioner C323 Connector Position Assurance (CPA) tab
to verify that it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: M
B007F:11, B007F:12, B007F:13, B007F:1A
The RCM continuously monitors the passenger safety belt retractor pretensioner circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger safety belt retractor pretensioner
If a fault is detected, the RCM stores DTC B007F:11, B007F:12, B007F:13 or B007F:1A in memory and sends a
cardiagn.com
Wiring
Connections
Passenger safety belt retractor pretensioner
RCM

B007F:11 Passenger Seatbelt Pretensioner "C" A fault is indicated when the RCM senses a short to ground
Deployment Control: Circuit Short to on either passenger safety belt retractor pretensioner circuit
Ground for more than 6 seconds.
B007F:12 Passenger Seatbelt Pretensioner "C" A fault is indicated when the RCM senses a short to voltage
Deployment Control: Circuit Short to on either passenger safety belt retractor pretensioner circuit
Battery for more than 6 seconds.
B007F:13 Passenger Seatbelt Pretensioner "C" A fault is indicated when the RCM measures more than the
Deployment Control: Circuit Open desired resistance between the passenger safety belt
retractor pretensioner circuits for more than 6 seconds.
B007F:1A Passenger Seatbelt Pretensioner "C" A fault is indicated when the RCM measures less than the
Deployment Control: Circuit desired resistance between the passenger safety belt
Resistance Below Threshold retractor pretensioner circuits for more than 6 seconds.
Possible Sources

Passenger safety belt retractor pretensioner
RCM
PINPOINT TEST A : B007F:11, B007F:12, B007F:13 AND B007F:1A

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
Was DTC B007F:11, B007F:12, B007F:13 and B007F:1A retrieved on-demand during self-test?
and Testing).
retractor pretensioner Diagnostic Trouble Codes (DTCs).
For DTC B007F:13 or B007F:1A, GO to A2
Code (CMDTC) only.
and Testing).
retractor pretensioner Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE PASSENGER SEATBELT RETRACTOR PRETENSIONER DEPLOYMENT CONTROL

cardiagn.com
Yes GO to A12
No GO to A3

While monitoring the DEPLOY_24_R PID, carry out the harness test of the passenger safety belt
retractor pretensioner circuits and accessible connectors (including any inline connectors) by wiggling and
flexing the wire harness and connectors frequently. Record the resistance value indicated by the PID.
GO to A17
A4 CHECK THE PASSENGER SAFETY BELT RETRACTOR PRETENSIONER DEPLOYMENT

CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect Passenger Safety Belt Retractor Pretensioner C303.
Ignition ON.
retractor pretensioner disconnected, an open circuit fault is normally retrieved.
Did the on-demand DTC change from B007F:1A to B007F:13?
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER SAFETY BELT RETRACTOR

PRETENSIONER CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C303-1 C303-2
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR AN

OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-49 C303-1
C310B-50 C303-2
Yes GO to A7
GO to A17

CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (OPEN
INDICATED)

C303-1 C303-2
cardiagn.com
Ignition ON.
retractor pretensioner circuits shorted together, a low resistance fault is normally retrieved.
Did the on-demand DTC change from B007F:13 to B007F:1A?


CONTROL DTC (DIAGNOSTIC TROUBLE CODE) FOR A FAULT STATUS CHANGE (SHORT TO
GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
retractor pretensioner disconnected, an open circuit fault is normally retrieved.
Did the on-demand DTC change from B007F:11 to B007F:13?
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR A

SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C303-1 Ground
C303-2 Ground
cardiagn.com
Yes GO to A12
GO to A17
A10 CHECK THE PASSENGER SAFETY BELT RETRACTOR PRETENSIONER CIRCUITS FOR A
SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C303-1 Ground
C303-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER SAFETY BELT RETRACTOR PRETENSIONER FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Safety Belt Retractor Pretensioner C303 and make sure the Connector
Position Assurance (CPA) tabs are not broken and the clip is not damaged.
Connect Passenger Safety Belt Retractor Pretensioner C303.
cardiagn.com
Ignition ON.
Yes INSTALL a new passenger safety belt retractor (includes retractor pretensioner).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Safety Belt Retractor Pretensioner C303 (if previously disconnected).
Ignition ON.
GO to A17
cardiagn.com
the PID.
No DEPOWER the SRS.
GO to A17

CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO GROUND FAULT
harness frequently.
Was DTC B007F:11 retrieved on-demand during self-test?

GO to A17
CONTROL CIRCUITS FOR AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.
Was DTC B007F:12 retrieved on-demand during self-test?

cardiagn.com
GO to A17

Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Safety Belt Retractor Pretensioner C303 Connector Position Assurance (CPA)
tab to verify that it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: N
B00A0:09, B00A0:4A, B00A0:63, B00A0:64 and B00A0:68
The RCM is in constant communication with various control modules on the High Speed Controller Area Network 2
(HS2-CAN). One of those modules is the OCSM. The RCM continuously monitors the High Speed Controller Area
Network 2 (HS2-CAN) for fault messages reported by the OCSM. The RCM also checks for the correct
identification of the OCSM. If the RCM receives fault message(s) from the OCSM, it stores DTC B00A0:09,
B00A0:4A, B00A0:63, B00A0:64 or B00A0:68 in memory and sends a message to the IPC to illuminate the
airbag warning indicator.
cardiagn.com

B00A0:09 Occupant Classification System: A fault is indicated when the RCM receives a message from
Component Failure the OCSM that a fault exists within the OCS.
B00A0:4A Occupant Classification System: A fault is indicated when the RCM senses the OCSM is
Incorrect Component Installed present but not configured.
B00A0:63 Occupant Classification System: A fault is indicated when the RCM receives 8 or more invalid
Circuit / Component Protection states from the OCSM.
Time-Out
B00A0:64 Occupant Classification System: Signal A fault is indicated when the RCM receives messages
Plausibility Failure containing upper or lower data limits other than limits stored
in memory.
B00A0:68 Occupant Classification System: Event A fault is indicated when the RCM receives a message from
Information the OCSM that indicates an OCS fault is present.
Possible Sources
OCSM
OCSM Diagnostic Trouble Codes (DTCs)
RCM
PINPOINT TEST A : B00A0:09, B00A0:4A, B00A0:63, B00A0:64 AND B00A0:68

personal injury.
REFER to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Ignition ON.
Was DTC B00A0:09, B00A0:4A, B00A0:63, B00A0:64 or B00A0:68 retrieved on-demand during
self-test?
For DTC B00A0:09, B00A0:63 or B00A0:68, RETRIEVE Diagnostic Trouble Codes
(DTCs) from the OCSM and REFER to DTC Chart: OCSM for diagnostic direction.
For DTC B00A0:4A or B00A0:64, GO to A2
No CHECK for causes of the intermittent fault.
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
cardiagn.com
only when directed to do so in the pinpoint test. GO to A5
A2 VERIFY THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) PART NUMBER

Using the Log Viewer function of the diagnostic scan tool, retrieve and record the OCSM part number.
Check the part number recorded against the number listed in the parts catalog and verify the correct
OCSM is present in the vehicle.
Is the correct OCSM installed?
Yes GO to A3
No INSTALL the correct OCSM.
REFER to: Occupant Classification System (OCS) Sensor (501-20B Supplemental
GO to A5
A3 VERIFY THE RCM (RESTRAINTS CONTROL MODULE) PART NUMBER

Using the Log Viewer function of the diagnostic scan tool, retrieve and record the RCM part number.
Check the part number recorded against the number listed in the parts catalog and verify the correct
RCM is present in the vehicle.
Is the correct RCM installed?
Yes GO to A4
No INSTALL the correct RCM.
GO to A5
A4 VERIFY THE RCM (RESTRAINTS CONTROL MODULE) CONFIGURATION

Carry out PMI for the RCM. Manually enter As-Built data. Refer to the diagnostic scan tool instructions
when carrying out PMI.
Was DTC B00A0:4A retrieved on-demand during self-test?
GO to A5
No The fault is corrected. GO to A5

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com

Pinpoint Test - DTC: O
B00B5:11, B00B5:12, B00B5:13, B00B5:1D
The RCM continuously monitors the driver seat track position sensor circuits for the following faults:
Open circuit
Short to voltage
Short to ground
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
cardiagn.com

B00B5:11 Driver Seat Track Position A fault is indicated when the RCM senses a short to ground on
Restraints Sensor: Circuit Short to the driver seat track position sensor circuit for more than 6
Ground seconds.
B00B5:12 Driver Seat Track Position A fault is indicated when the RCM senses a short to voltage on
Restraints Sensor: Circuit Short to the driver seat track position sensor circuit for more than 6
Battery seconds.
B00B5:13 Driver Seat Track Position A fault is indicated when the RCM senses an open on either
Restraints Sensor: Circuit Open driver seat track position sensor circuit for more than 6 seconds.
B00B5:1D Driver Seat Track Position A fault is indicated when the RCM measures current outside of
Restraints Sensor: Circuit Current an acceptable range on the driver seat track position sensor
Out of Range circuit for more than 6 seconds.
Possible Sources

Driver seat track position sensor
RCM
Inspect for a damaged driver seat track position sensor.

PINPOINT TEST A : B00B5:11, B00B5:12, B00B5:13 AND B00B5:1D

deployment.
personal injury.
cardiagn.com
and Operation).
Ignition ON.
Was DTC B00B5:11, B00B5:12, B00B5:13 and B00B5:1D retrieved on-demand during self-test?
If DTC U3003:16 or U3003:17 is also retrieved on-demand,
and Testing).
driver seat track position sensor Diagnostic Trouble Codes (DTCs).
For DTC B00B5:11 or B00B5:1D, GO to A2
For DTC B00B5:12, GO to A4
No If DTC U3003:16 or U3003:17 is also retrieved on-demand,
and Testing).
driver seat track position sensor Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
A2 CHECK THE DRIVER SEAT TRACK POSITION SENSOR DTC (DIAGNOSTIC TROUBLE CODE)
FOR A FAULT STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT OF RANGE INDICATED)
Ignition OFF.
Disconnect Driver Seat Position Sensor C356.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver seat track position
sensor disconnected, an open circuit fault is normally retrieved.
Did the on-demand DTC change from B00B5:11 or B00B5:1D to B00B5:13?
Yes GO to A8
No For DTC B00B5:11, GO to A3
For DTC B00B5:1D, GO to A9
A3 CHECK THE DRIVER SEAT TRACK POSITION SENSOR CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C356-2 Ground
Yes GO to A9
GO to A11
A4 CHECK THE DRIVER SEAT TRACK POSITION SENSOR CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C356-2 Ground

GO to A11
No GO to A9
A5 CHECK THE DRIVER SEAT TRACK POSITION SENSOR DTC (DIAGNOSTIC TROUBLE CODE)
FOR A FAULT STATUS CHANGE (OPEN INDICATED)
Ignition OFF.
Depower the SRS.
cardiagn.com
C356-2 C356-1
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver seat track position
sensor circuits shorted together, a short to ground fault is normally retrieved.
Did the on-demand DTC change from B00B5:13 to B00B5:11?

A6 CHECK THE DRIVER SEAT TRACK POSITION SENSOR CIRCUIT FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-23 C356-2

Yes GO to A7
GO to A11
A7 CHECK THE DRIVER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR AN OPEN
Measure:

C356-1 C310B-53
Yes GO to A9
cardiagn.com
GO to A11
A8 CONFIRM THE DRIVER SEAT TRACK POSITION SENSOR FAULT
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Seat Position Sensor C356.
Ignition ON.
Yes INSTALL a new driver seat track position sensor.

REFER to: Seat Position Sensor (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A11
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Seat Position Sensor C356.
cardiagn.com
Ignition ON.
GO to A11

Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
Was DTC B00B5:11, B00B5:12, B00B5:13 and B00B5:1D retrieved on-demand during self-test?
For DTC B00B5:11 or B00B5:1D, GO to A2

Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
OCSM.

Pinpoint Test - DTC: P
B00C5:11, B00C5:12, B00C5:13, B00C5:1D
The RCM continuously monitors the passenger seat track position sensor circuits for the following faults:
Open circuit
Short to voltage
Short to ground
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
cardiagn.com

B00C5:11 Passenger Seat Track Position A fault is indicated when the RCM senses a short to ground on
Restraints Sensor: Circuit Short to the passenger seat track position sensor circuit for more than 6
Ground seconds.
B00C5:12 Passenger Seat Track Position A fault is indicated when the RCM senses a short to voltage on
Restraints Sensor: Circuit Short to the passenger seat track position sensor circuit for more than 6
Battery seconds.
B00C5:13 Passenger Seat Track Position A fault is indicated when the RCM senses an open on either
Restraints Sensor: Circuit Open passenger seat track position sensor circuit for more than 6
seconds.
B00C5:1D Passenger Seat Track Position A fault is indicated when the RCM measures current outside of
Restraints Sensor: Circuit Current an acceptable range on the passenger seat track position
Out of Range sensor circuit for more than 6 seconds.
Possible Sources

Passenger seat track position sensor
RCM
Inspect for a damaged passenger seat track position sensor.

PINPOINT TEST A : B00C5:11, B00C5:12, B00C5:13 AND B00C5:1D

deployment.
personal injury.
cardiagn.com
and Operation).
Ignition ON.
Was DTC B00C5:11, B00C5:12, B00C5:13 and B00C5:1D retrieved on-demand during self-test?
and Testing).
passenger seat track position sensor Diagnostic Trouble Codes (DTCs).
For DTC B00C5:11 or B00C5:1D, GO to A2
For DTC B00C5:12, GO to A4
and Testing).
passenger seat track position sensor Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
A2 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR DTC (DIAGNOSTIC TROUBLE
CODE) FOR A FAULT STATUS CHANGE (SHORT TO GROUND OR CURRENT OUT OF RANGE
INDICATED)
Ignition OFF.
Disconnect Passenger Seat Position Sensor C3240.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger seat track
position sensor disconnected, an open circuit fault is normally retrieved.
Did the on-demand DTC change from B00C5:11 or B00C5:1D to B00C5:13?
Yes GO to A8
No For DTC B00C5:11, GO to A3
For DTC B00C5:1D, GO to A9
A3 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C3240-2 Ground
Yes GO to A9
GO to A11
A4 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3240-2 Ground

GO to A11
No GO to A9
A5 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR DTC (DIAGNOSTIC TROUBLE
Ignition OFF.
Depower the SRS.
cardiagn.com

C3240-2 C3240-1
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger seat track
position sensor circuits shorted together, a short to ground fault is normally retrieved.
Did the on-demand DTC change from B00C5:13 to B00C5:11?

A6 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR CIRCUIT FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-24 C3240-2
Yes GO to A7
GO to A11
A7 CHECK THE PASSENGER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR AN OPEN
Measure:

C3240-1 Ground
cardiagn.com
Yes GO to A9
GO to A11
A8 CONFIRM THE PASSENGER SEAT TRACK POSITION SENSOR FAULT
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Seat Position Sensor C3240.
Ignition ON.
Yes INSTALL a new passenger seat track position sensor.

REFER to: Seat Position Sensor (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A11
Ignition OFF.
Depower the SRS.
operation.
cardiagn.com
Connect Passenger Seat Position Sensor C3240.
Ignition ON.
GO to A11

Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
Was DTC B00C5:11, B00C5:12, B00C5:13 and B00C5:1D retrieved on-demand during self-test?
For DTC B00C5:11 or B00C5:1D, GO to A2

Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
OCSM.

Pinpoint Test - DTC: Q
B11CF:11, B11CF:12, B11CF:13, B11CF:1A
The RCM continuously monitors the passenger airbag adaptive canister vent circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger airbag adaptive canister vent
If a fault is detected, the RCM stores DTC B11CF:11, B11CF:12, B11CF:13 or B11CF:1A in memory and sends a
cardiagn.com
Wiring
Connections
Passenger airbag adaptive canister vent
RCM

B11CF:11 Passenger Frontal Airbag Canister A fault is indicated when the RCM senses a short to ground on
Vent: Circuit Short to Ground either passenger airbag adaptive canister vent circuit for more
than 6 seconds.
B11CF:12 Passenger Frontal Airbag Canister A fault is indicated when the RCM senses a short to voltage on
Vent: Circuit Short to Battery either passenger airbag adaptive canister vent circuit for more
than 6 seconds.
B11CF:13 Passenger Frontal Airbag Canister A fault is indicated when the RCM measures more than the
Vent: Circuit Open desired resistance between the passenger airbag adaptive
canister vent circuits for more than 6 seconds.
B11CF:1A Passenger Frontal Airbag Canister A fault is indicated when the RCM measures less than the
Vent: Circuit Resistance Below desired resistance between the passenger airbag adaptive
Threshold canister vent circuits for more than 6 seconds.
Possible Sources

Passenger airbag adaptive canister vent
RCM
PINPOINT TEST A : B11CF:11, B11CF:12, B11CF:13 AND B11CF:1A

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
Was DTC B11CF:11, B11CF:12, B11CF:13 and B11CF:1A retrieved on-demand during self-test?
and Testing).
passenger airbag adaptive canister vent Diagnostic Trouble Codes (DTCs).
For DTC B11CF:13 or B11CF:1A, GO to A2
For DTC B11CF:11, GO to A8
No This is an intermittent fault when present as a CMDTC only.
and Testing).
passenger airbag adaptive canister vent Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
A2 CHECK THE PASSENGER FRONTAL AIRBAG CAN VENT CONTROL (DEPLOY_08_R) PID
Yes GO to A12
cardiagn.com
No GO to A3
While monitoring the DEPLOY_08_R PID, carry out the harness test of the passenger airbag adaptive
canister vent circuits and accessible connectors (including any inline connectors) by wiggling and flexing
GO to A17
A4 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT DEPLOYMENT CONTROL DTC
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger airbag adaptive
canister vent disconnected, an open circuit fault is normally retrieved. An open circuit fault is also retrieved
on passenger airbag stages 1 and 2, due to the passenger airbag connector being disconnected.
Did the on-demand DTC change from B11CF:1A to B11CF:13?
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT
CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
cardiagn.com
C256-7 C256-8
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310A-10 C256-7
C310A-9 C256-8
Yes GO to A7
GO to A17

C256-7 C256-8
Ignition ON.
cardiagn.com
canister vent circuits shorted together, a low resistance fault is normally retrieved. An open circuit fault is
also retrieved on passenger airbag stages 1 and 2, due to the passenger airbag connector being
disconnected.
Did the on-demand DTC change from B11CF:13 to B11CF:1A?

Ignition OFF.
Depower the SRS.
Ignition ON.
canister vent disconnected, an open circuit fault is normally retrieved. An open circuit fault is also retrieved
on passenger airbag stages 1 and 2, due to the passenger airbag connector being disconnected.
Did the on-demand DTC change from B11CF:11 to B11CF:13?

Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
Depower the SRS.
Measure:

C256-7 Ground
C256-8 Ground
cardiagn.com
Yes GO to A12
GO to A17
A10 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C256-7 Ground
C256-8 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect the passenger airbag and make sure the Connector Position Assurance (CPA) tabs on
each deployable connector are not broken and the clip is not damaged.
cardiagn.com
Connect Passenger Airbag C256.
Ignition ON.
Yes INSTALL a new passenger airbag (includes passenger airbag canister vent).
REFER to: Passenger Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
GO to A17
cardiagn.com
FAULT
the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT DEPLOYMENT CONTROL
harness frequently.
Was DTC B11CF:11 retrieved on-demand during self-test?

GO to A17
A15 CHECK THE PASSENGER AIRBAG ADAPTIVE CANISTER VENT DEPLOYMENT CONTROL
Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
harness frequently.
Was DTC B11CF:12 retrieved on-demand during self-test?

GO to A17

Ignition OFF.
Depower the SRS.
operation.
Inspect the passenger airbag and make sure the Connector Position Assurance (CPA) tabs on
each deployable connector are correctly seated and the clip is not damaged.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com

Pinpoint Test - DTC: R
B11D8:12 and B11D8:14
The RCM transmits an event notification signal which communicates crash status and SRS deployment status to
the BCM. When the BCM receives an event notification signal which indicates a crash, it initiates fuel cut-off.
The RCM monitors the event notification signal circuit for the following faults:
Short to voltage
Short to ground
Open circuit
cardiagn.com
If a fault is detected, the RCM stores DTC B11D8:12 or B11D8:14 in memory. The airbag warning indicator does
not illuminate if B11D8:12 or B11D8:14 is set.

B11D8:12 Restraint Event Notification: A fault is indicated when the RCM senses a short to voltage on
Circuit Short to Battery the event notification signal circuit for more than 15 seconds.
B11D8:14 Restraint Event Notification: A fault is indicated when the RCM senses a short to ground or an
Circuit Short to Ground or Open open on the event notification signal circuit for more than 15
seconds.
Possible Sources

BCM
RCM
PINPOINT TEST A : B11D8:12 AND B11D8:14

deployment.
NOTE: Install new components only when directed to do so in the pinpoint test.
injury.
and Operation).
Ignition ON.
Using a diagnostic scan tool, perform the RCM self-test to retrieve Diagnostic Trouble Codes (DTCs).
Was DTC B11D8:12 or B11D8:14 retrieved on-demand during self-test?
on-demand during the self-test.
For DTC B11D8:14, GO to A2
cardiagn.com
A2 CHECK THE EVENT NOTIFICATION SIGNAL CIRCUIT FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-42 C2280E-49
Yes GO to A3
GO to A9
A3 CHECK THE EVENT NOTIFICATION SIGNAL CIRCUIT FOR A SHORT TO GROUND

Measure:

C2280E-49 Ground
Yes GO to A4
GO to A9
A4 CONFIRM THE BCM (BODY CONTROL MODULE) OR RCM (RESTRAINTS CONTROL MODULE)
FAULT
NOTE: Make sure all SRS electrical connectors and the BCM electrical connector are connected before
carrying out the self-test. If not, Diagnostic Trouble Codes (DTCs) will be recorded.
cardiagn.com
Connect BCM C2280E.
Ignition ON.
Was DTC B11D8:14 retrieved on-demand during self-test?

CLEAR the RCM Diagnostic Trouble Codes (DTCs) and REPEAT the RCM self-test.
If DTC B11D8:14 returns, INSTALL a new RCM.
GO to A9
If DTC B11D8:14 does not return, GO to A9
install any new SRS components at this time. SRS components should only be installed
when directed to do so in the pinpoint test. GO to A8
A5 CHECK THE EVENT NOTIFICATION SIGNAL CIRCUIT DTC (DIAGNOSTIC TROUBLE CODE) FOR
A FAULT STATUS CHANGE
fault condition. If the fault reported changes, this indicates the RCM is functioning correctly and is not the
Was DTC B11D8:12 retrieved on-demand during self-test?
Yes GO to A6
No CHECK OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for

GO to A9
A6 CHECK THE EVENT NOTIFICATION SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
Measure:

C2280E-49 Ground

GO to A9
No GO to A7
NOTE: Make sure all SRS electrical connectors and the BCM electrical connector are connected before
carrying out the self-test. If not, Diagnostic Trouble Codes (DTCs) will be recorded.
Ignition OFF.
Depower the SRS.
inspect wire harness for any damage, pinched, cut or pierced wires.
Connect BCM C2280E.
Ignition ON.
GO to A9

Ignition OFF.
Depower the SRS.
cardiagn.com
inspect connector(s) (including any inline connectors) for loose or spread terminals and loose or
frayed wire connections at terminals.
Connect BCM C2280E.
Ignition ON.
Was DTC B11D8:12 or B11D8:14 retrieved on-demand during self-test?
Yes The fault condition is now present. This fault cannot be cleared until it is corrected and the
DTC is no longer retrieved on-demand during the 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. Only install SRS
components when directed to do so in the pinpoint test. REPAIR any intermittent concerns
found. GO to A9

Ignition OFF.
Reconnect all connectors (if previously disconnected).
Ignition ON.
NOTE: When selecting Restraints from the Self Test menu, Diagnostic Trouble Codes (DTCs) are
retrieved from the RCM and OCSM.
Using a diagnostic scan tool, perform the Restraints self-test.
Are any RCM and/or OCSM Diagnostic Trouble Codes (DTCs) retrieved?
cardiagn.com
Pinpoint Test - DTC: S
B1404:11, B1404:12, B1404:13, B1404:1A
The RCM continuously monitors the driver side airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver side airbag
cardiagn.com
Wiring
Connections
Driver side airbag
RCM

B1404:11 Driver Side Airbag Deployment A fault is indicated when the RCM senses a short to ground on
Control: Circuit Short to Ground either driver side airbag circuit for more than 6 seconds.
B1404:12 Driver Side Airbag Deployment A fault is indicated when the RCM senses a short to voltage on
Control: Circuit Short to Battery either driver side airbag circuit for more than 6 seconds.
B1404:13 Driver Side Airbag Deployment A fault is indicated when the RCM measures more than the
Control: Circuit Open desired resistance between the driver side airbag circuits for
B1404:1A Driver Side Airbag Deployment A fault is indicated when the RCM measures less than the
Control: Circuit Resistance Below desired resistance between the driver side airbag circuits for
Possible Sources

Driver side airbag
RCM


cardiagn.com
deployment.
personal injury.
and Operation).
Ignition ON.
and Testing).
driver side airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
driver side airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE LEFT SIDE AIRBAG DEPLOYMENT CONTROL (DEPLOY_10_R) PID (PARAMETER
IDENTIFICATION)
cardiagn.com
Yes GO to A12
No GO to A3
IDENTIFICATION) WHILE CARRYING OUT THE HARNESS TEST
While monitoring the DEPLOY_10_R PID, carry out the harness test of the driver side airbag circuits and
GO to A17
A4 CHECK THE DRIVER SIDE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC TROUBLE
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver side airbag
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DRIVER SIDE AIRBAG CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

C3206-3 C3206-4
cardiagn.com
Yes GO to A12
GO to A17
A6 CHECK THE DRIVER SIDE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-40 C3206-3
C310B-39 C3206-4
Yes GO to A7
GO to A17

C3206-3 C3206-4
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver side airbag circuits
cardiagn.com

Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver side airbag
Yes GO to A11
No GO to A9
A9 CHECK THE DRIVER SIDE AIRBAG CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Depower the SRS.
Measure:

C3206-3 Ground
C3206-4 Ground
Yes GO to A12
GO to A17
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A10 CHECK THE DRIVER SIDE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3206-3 Ground
C3206-4 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DRIVER SIDE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Side Airbag C367 and make sure the Connector Position Assurance (CPA) tabs are
not broken and the clip is not damaged.
Connect Driver Side Airbag (Inline) C3206.
Ignition ON.
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Yes REMOVE and INSPECT the driver seat backrest harness for damage.
REFER to: Side Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
If a concern is found, REPAIR as necessary.

GO to A17
If a concern is not found, INSTALL a new driver side airbag.
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
GO to A17
cardiagn.com
IDENTIFICATION) FOR AN INTERMITTENT LOW RESISTANCE OR OPEN CIRCUIT FAULT
the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE DRIVER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE DRIVER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com

Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Side Airbag C367 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: T, Coupe
B1405:11, B1405:12, B1405:13, B1405:1A
The RCM continuously monitors the LH side air curtain circuits for the following faults:

Unexpected voltage
Short to ground
Faulted LH side air curtain
cardiagn.com
Wiring
Connections
LH side air curtain
RCM

B1405:11 Driver Side Curtain Deployment A fault is indicated when the RCM senses a short to ground
Control 1: Circuit Short to Ground on either LH side air curtain circuit for more than 6 seconds.
B1405:12 Driver Side Curtain Deployment A fault is indicated when the RCM senses a short to voltage
Control 1: Circuit Short to Battery on either LH side air curtain circuit for more than 6 seconds.
B1405:13 Driver Side Curtain Deployment A fault is indicated when the RCM measures more than the
Control 1: Circuit Open desired resistance between the LH side air curtain circuits for
B1405:1A Driver Side Curtain Deployment A fault is indicated when the RCM measures less than the
Control 1: Circuit Resistance Below desired resistance between the LH side air curtain circuits for
Possible Sources

LH side air curtain
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
driver side air curtain Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
driver side air curtain Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE LEFT CURTAIN DEPLOYMENT CONTROL 1 (DEPLOY_11_R) PID (PARAMETER

IDENTIFICATION)
Yes GO to A12
No GO to A3
cardiagn.com
While monitoring the DEPLOY_11_R PID, carry out the harness test of the LH side air curtain circuits and
GO to A17
A4 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL DTC (DIAGNOSTIC
Ignition OFF.
Depower the SRS.
Disconnect LH Side Air Curtain C9031.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the LH side air curtain

Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE LH (LEFT-HAND) SIDE AIR CURTAIN CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:

C9031-1 C9031-2
cardiagn.com
Yes GO to A12
GO to A17
A6 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-25 C9031-1
C310B-26 C9031-2
Yes GO to A7
GO to A17

C9031-1 C9031-2
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the LH side air curtain circuits
cardiagn.com
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the LH side air curtain
Yes GO to A11
No GO to A9
A9 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C9031-1 Ground
C9031-2 Ground
Yes GO to A12
GO to A17
A10 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
Measure:

C9031-1 Ground
C9031-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE LH (LEFT-HAND) SIDE AIR CURTAIN FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect LH Side Air Curtain C9031 and make sure the Connector Position Assurance (CPA) tabs
Connect LH Side Air Curtain C9031.
Ignition ON.
Yes INSTALL a new LH side air curtain.

REFER to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A17
cardiagn.com
Ignition OFF.
Depower the SRS.
operation.
Connect LH Side Air Curtain C9031 (if previously disconnected).
Ignition ON.
GO to A17
the PID.
cardiagn.com
No DEPOWER the SRS.
GO to A17
A14 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE LH (LEFT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17

Ignition OFF.
Depower the SRS.
cardiagn.com
operation.
Inspect LH Side Air Curtain C9031 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: U
B1407:11, B1407:12, B1407:13, B1407:1A
The RCM continuously monitors the passenger side airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger side airbag
cardiagn.com
Wiring
Connections
Passenger side airbag
RCM

B1407:11 Passenger Side Airbag Deployment A fault is indicated when the RCM senses a short to ground
Control: Circuit Short to Ground on either passenger side airbag circuit for more than 6
seconds.
B1407:12 Passenger Side Airbag Deployment A fault is indicated when the RCM senses a short to voltage
Control: Circuit Short to Battery on either passenger side airbag circuit for more than 6
seconds.
B1407:13 Passenger Side Airbag Deployment A fault is indicated when the RCM measures more than the
Control: Circuit Open desired resistance between the passenger side airbag circuits
B1407:1A Passenger Side Airbag Deployment A fault is indicated when the RCM measures less than the
Control: Circuit Resistance Below desired resistance between the passenger side airbag circuits
Threshold for more than 6 seconds.
Possible Sources

Passenger side airbag
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
passenger side airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
passenger side airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE RIGHT SIDE AIRBAG DEPLOYMENT CONTROL (DEPLOY_13_R) PID (PARAMETER
IDENTIFICATION)
Yes GO to A12
cardiagn.com
No GO to A3
A3 CHECK THE RIGHT SIDE AIRBAG DEPLOYMENT CONTROL (DEPLOY_13_R) PID (PARAMETER
While monitoring the DEPLOY_13_R PID, carry out the harness test of the passenger side airbag circuits
and accessible connectors (including any inline connectors) by wiggling and flexing the wire harness and
GO to A17
A4 CHECK THE PASSENGER SIDE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC

Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger side airbag
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER SIDE AIRBAG CIRCUITS

Ignition OFF.
Depower the SRS.
Measure:

C219-3 C219-4
cardiagn.com
Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER SIDE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-37 C219-3
C310B-38 C219-4
Yes GO to A7
GO to A17

C219-3 C219-4
Ignition ON.
cardiagn.com


Ignition OFF.
Depower the SRS.
Ignition ON.
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER SIDE AIRBAG CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Depower the SRS.
Measure:

C219-3 Ground
C219-4 Ground
Yes GO to A12
GO to A17
cardiagn.com
A10 CHECK THE PASSENGER SIDE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C219-3 Ground
C219-4 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER SIDE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Side Airbag C3459 and make sure the Connector Position Assurance (CPA)
Connect Passenger Side Airbag (Inline) C219.
Ignition ON.
cardiagn.com
Installation).

GO to A17
If a concern is not found, INSTALL a new passenger side airbag.
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Ignition ON.
GO to A17
cardiagn.com
A13 CHECK THE RIGHT SIDE AIRBAG DEPLOYMENT CONTROL (DEPLOY_13_R) PID
FAULT
the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE PASSENGER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE PASSENGER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
cardiagn.com

Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Side Airbag C3459 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: V, Coupe
B1408:11, B1408:12, B1408:13, B1408:1A
The RCM continuously monitors the RH side air curtain circuits for the following faults:

Unexpected voltage
Short to ground
Faulted RH side air curtain
cardiagn.com
Wiring
Connections
RH side air curtain
RCM

B1408:11 Passenger Side Curtain Deployment A fault is indicated when the RCM senses a short to ground
Control 1: Circuit Short to Ground on either RH side air curtain circuit for more than 6 seconds.
B1408:12 Passenger Side Curtain Deployment A fault is indicated when the RCM senses a short to voltage
Control 1: Circuit Short to Battery on either RH side air curtain circuit for more than 6 seconds.
B1408:13 Passenger Side Curtain Deployment A fault is indicated when the RCM measures more than the
Control 1: Circuit Open desired resistance between the RH side air curtain circuits
B1408:1A Passenger Side Curtain Deployment A fault is indicated when the RCM measures less than the
Control 1: Circuit Resistance Below desired resistance between the RH side air curtain circuits
Threshold for more than 6 seconds.
Possible Sources

RH side air curtain
RCM

deployment.
cardiagn.com
personal injury.
and Operation).
Ignition ON.
and Testing).
RH side air curtain Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
RH side air curtain Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE RIGHT CURTAIN DEPLOYMENT CONTROL 1 (DEPLOY_14_R) PID (PARAMETER

IDENTIFICATION)
Yes GO to A12
No GO to A3
cardiagn.com
While monitoring the DEPLOY_14_R PID, carry out the harness test of the RH side air curtain circuits
and accessible connectors (including any inline connectors) by wiggling and flexing the wire harness and
GO to A17
A4 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL DTC

Ignition OFF.
Depower the SRS.
Disconnect RH Side Air Curtain C9032.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the RH side air curtain

Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE RH (RIGHT-HAND) SIDE AIR CURTAIN CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:

C9032-1 C9032-2
cardiagn.com
Yes GO to A12
GO to A17
A6 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-17 C9032-1
C310B-18 C9032-2
Yes GO to A7
GO to A17


C9032-1 C9032-2
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the RH side air curtain circuits
cardiagn.com

Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the RH side air curtain
Yes GO to A11
No GO to A9
A9 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C9032-1 Ground
C9032-2 Ground
Yes GO to A12
GO to A17
A10 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
cardiagn.com
Ignition ON.
Measure:

C9032-1 Ground
C9032-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE RH (RIGHT-HAND) SIDE AIR CURTAIN FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect RH Side Air Curtain C9032 and make sure the Connector Position Assurance (CPA) tabs
Connect RH Side Air Curtain C9032.
Ignition ON.
Yes INSTALL a new RH side air curtain.

REFER to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and
Installation).
GO to A17
cardiagn.com
Ignition OFF.
Depower the SRS.
operation.
Connect RH Side Air Curtain C9032 (if previously disconnected).
Ignition ON.
GO to A17
the PID.
cardiagn.com
No DEPOWER the SRS.
GO to A17
A14 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL CIRCUITS FOR
AN INTERMITTENT SHORT TO GROUND FAULT
harness frequently.

GO to A17
A15 CHECK THE RH (RIGHT-HAND) SIDE AIR CURTAIN DEPLOYMENT CONTROL CIRCUITS FOR
AN INTERMITTENT SHORT TO BATTERY FAULT
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17

Ignition OFF.
Depower the SRS.
cardiagn.com
operation.
Inspect RH Side Air Curtain C9032 Connector Position Assurance (CPA) tab to verify that it is

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com
Pinpoint Test - DTC: W
B1413:11 and B1413:93
The RCM monitors the LH front impact severity sensor 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 B1413:11 or B1413:93 in memory and sends a message to the IPC to
illuminate the airbag warning indicator.
cardiagn.com

B1413:11 Driver Frontal Restraints A fault is indicated when the RCM senses a short to ground on the LH
Sensor: Circuit Short to front impact severity sensor feed circuit.
Ground
B1413:93 Driver Frontal Restraints A fault is indicated when the RCM senses a faulted LH front impact
Sensor: No Operation severity sensor, a short to voltage on the sensor feed circuit or an
open feed or return circuit.
Possible Causes

LH front impact severity sensor
RCM
Inspect for a damaged LH front impact severity sensor.

Inspect the LH front impact severity sensor mounting and orientation.
PINPOINT TEST A : B1413:11 AND B1413:93

deployment.
NOTE: Do not probe any impact sensor. The impact sensor cannot be tested using a multi-meter
personal injury.
and Operation).
Ignition ON.
cardiagn.com
Was DTC B1413:11 or B1413:93 retrieved on-demand during self-test?
If DTC U3003:16 or U3003:17 is also retrieved on-demand, DIAGNOSE those Diagnostic
and Testing).
impact sensor Diagnostic Trouble Codes (DTCs).
and Testing).
impact sensor Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE LEFT FRONTAL RESTRAINTS SENSOR DTC (DIAGNOSTIC TROUBLE CODE) FOR
A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Disconnect LH Front Impact Severity Sensor C1465.
Remove the air cleaner. Refer to the appropriate section in Group 303 for the procedure.
Ignition ON.
Yes INSTALL a new LH front impact severity sensor.

REFER to: Front Impact Severity Sensor (501-20B Supplemental Restraint System,
GO to A11
No GO to A3
A3 CHECK THE LH (LEFT-HAND) FRONT IMPACT SEVERITY SENSOR FEED CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF.
Depower the SRS.
cardiagn.com
Measure:

C1465-1 Ground
Yes GO to A4
GO to A11
A4 CHECK FOR A SHORT BETWEEN LH (LEFT-HAND) FRONT IMPACT SEVERITY SENSOR

CIRCUITS
Measure:

C1465-1 C1465-2
Yes GO to A9
GO to A11
A5 CHECK THE LH (LEFT-HAND) FRONT IMPACT SEVERITY SENSOR AND RCM (RESTRAINTS
CONTROL MODULE) CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Inspect the LH Front Impact Severity Sensor electrical connector C1465 to make sure it is fully seated
and locked. Seat and lock the connector as necessary.
Gain access to the RCM and inspect C310A and C310B to make sure they are fully seated and locked.
Seat and lock the connector as necessary
Ignition ON.
Yes GO to A6
No The fault has been corrected. GO to A11
cardiagn.com
A6 CHECK THE LH (LEFT-HAND) FRONT IMPACT SEVERITY SENSOR FEED CIRCUIT FOR A
SHORT TO VOLTAGE (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C1465-1 Ground

GO to A11
No GO to A7
A7 CHECK THE LH (LEFT-HAND) FRONT IMPACT SEVERITY SENSOR CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310A-17 C1465-1
C310A-18 C1465-2
Yes GO to A8
GO to A11
A8 CHECK THE LEFT FRONTAL RESTRAINTS SENSOR DTC (DIAGNOSTIC TROUBLE CODE) FOR
A FAULT STATUS CHANGE (NO OPERATION INDICATED)
cardiagn.com
Connect a fused jumper wire as shown:

C1465-1 C1465-2
Ignition ON.
Yes REMOVE the fused jumper wire and INSTALL a new LH front impact severity sensor.
GO to A11
Ignition OFF.
Depower the SRS.
operation.
Connect LH Front Impact Severity Sensor C1465.
Ignition ON.
GO to A11
cardiagn.com

Ignition OFF.
Depower the SRS.
Inspect:
harness and component connectors for loose or spread terminals and loose or frayed wire
connections at terminals.
wire harness for any damage, pinched, cut or pierced wires.
RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct operation.
Connect LH Front Impact Severity Sensor C1465.
Ignition ON.
Was DTC B1413:11 or B1413:93 retrieved on-demand during the self-test?

Ignition OFF.
Ignition ON.
OCSM.
cardiagn.com

Pinpoint Test - DTC: X, Coupe
B1414:11, B1414:93, B1419:11, B1419:93, B1427:11, B14EB:11
The RCM monitors the driver front door and RH B-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 RH B-pillar side impact sensor
NOTE: A short to ground on either impact sensor feed circuit sets Diagnostic Trouble Codes (DTCs) B1414:11
cardiagn.com
and B1419:11. A short to voltage on either impact sensor feed or return circuit sets Diagnostic Trouble Codes
(DTCs) B1414:93 and B1419:93.
If a fault is detected, the RCM stores DTC B1414:11, B1414:93, B1419:11, B1419:93, B1427:11 or B14EB:11 in
memory and sends a message to the IPC to illuminate the airbag warning indicator.
The RCM communicates with each impact sensor. If the RCM is unable to communicate with the sensor, a DTC is
stored in memory. A CMDTCno operation (failure type: 93) can be set by a short to voltage on the return circuit
of the impact sensor.
Some vehicles may be equipped with wiring for pedestrian protection system sensors, although the vehicle is not
equipped with the sensors themselves. On these vehicles, if a short to ground condition occurs on the pedestrian
protection sensor wiring, short to ground Diagnostic Trouble Codes (DTCs) set for the side impact sensors, in
addition to short to ground Diagnostic Trouble Codes (DTCs) for pedestrian protection sensors. Alternatively, if a
short to ground condition occurs on the side impact sensor circuits, then pedestrian protection sensor Diagnostic
Trouble Codes (DTCs) set as well.

B1414:11 Driver Side Restraints A fault is indicated when the RCM senses a shorted driver front door side
Sensor 1: Circuit impact sensor, a shorted RH B-pillar side impact sensor, a short to ground on
Short to Ground the driver front door side impact sensor feed circuit or a short to ground on
the RH B-pillar side impact sensor feed circuit. If equipped with wiring for
pedestrian protection sensors, a short to voltage on those circuits may also
set this DTC.
B1414:93 Driver Side Restraints A fault is indicated when the RCM senses a faulted driver front door side
Sensor 1: No impact sensor, a short to voltage on the feed or return circuit of the driver
Operation front door side impact sensor, a short to voltage on the feed or return circuit
of RH B-pillar side impact sensor or an open feed or return circuit of the
driver front door side impact sensor.
B1419:11 Passenger Side A fault is indicated when the RCM senses a shorted driver front door side
Restraints Sensor 2: impact sensor, a shorted RH B-pillar side impact sensor, a short to ground on
Circuit Short to the driver front door side impact sensor feed circuit or a short to ground on
Ground the RH B-pillar side impact sensor feed circuit. If equipped with wiring for
pedestrian protection sensors, a short to voltage on those circuits may also
set this DTC.
B1419:93 Passenger Side A fault is indicated when the RCM senses a faulted RH B-pillar side impact
Restraints Sensor 2: sensor, a short to voltage on the feed or return circuit of RH B-pillar side
No Operation impact sensor, a short to voltage on the feed or return circuit of the driver
front door side impact sensor or an open feed or return circuit of the RH
B-pillar side impact sensor.
B1427:11 Pedestrian Protection If equipped with wiring for pedestrian protection sensors, a fault is indicated
Sensor Driver Outer: when the RCM senses a shorted driver front door side impact sensor, a
Circuit Short to shorted RH B-pillar side impact sensor, a short to ground on the driver front
Ground door side impact sensor feed circuit, a short to ground on the RH B-pillar side
impact sensor feed circuit, or a short to ground on the wiring for pedestrian
protection sensors.
B14EB:11 Pedestrian Protection If equipped with wiring for pedestrian protection sensors, a fault is indicated
Sensor Passenger when the RCM senses a shorted driver front door side impact sensor, a
Outer: Circuit Short to shorted RH B-pillar side impact sensor, a short to ground on the driver front
Ground door side impact sensor feed circuit, a short to ground on the RH B-pillar side
impact sensor feed circuit, or a short to ground on the wiring for pedestrian
protection sensors.
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Possible Causes

Driver front door side impact sensor
RH B-pillar side impact sensor
RCM
PINPOINT TEST A : B1414:11, B1414:93, B1419:11, B1419:93, B1427:11, B14EB:11

deployment.
NOTE: Do not probe any impact sensor. The impact sensor cannot be tested using a multi-meter.
personal injury.
and Operation).
Ignition ON.
Were any Diagnostic Trouble Codes (DTCs) retrieved on-demand during self-test?
Yes The fault(s) cannot be cleared until corrected and the Diagnostic Trouble Codes (DTCs)
are no longer retrieved on-demand during self-test.
and Testing).
For DTC B1414:11 and B1419:11 and, if equipped, B1427:11 and B14EB:11, GO to A2
For DTC B1414:93 AND B1419:93, GO to A6
For DTC B1414:93 ONLY, GO to A8
For any other Diagnostic Trouble Codes (DTCs),
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and Testing).
The fault is intermittent when present as a CMDTC only. GO to A15
A2 CHECK THE DRIVER SIDE RESTRAINTS SENSOR 1 DTC (DIAGNOSTIC TROUBLE CODE) FOR
Ignition OFF.
Depower the SRS.
Disconnect Driver Front Door Side Impact Sensor C567.
Ignition ON.
Did the on-demand Diagnostic Trouble Codes (DTCs) change from B1414:11 and B1419:11 and, if
equipped, B1427:11 and B14EB:11 to B1414:93?
Yes INSTALL a new driver front door side impact sensor.

REFER to: Front Door Side Impact Sensor (501-20B Supplemental Restraint System,
GO to A16
No GO to A3
A3 CHECK THE PASSENGER SIDE RESTRAINTS SENSOR 2 DTC (DIAGNOSTIC TROUBLE CODE)
FOR A FAULT STATUS CHANGE (SHORT TO GROUND INDICATED)
Ignition OFF.
Depower the SRS.
Connect Driver Front Door Side Impact Sensor C567.
Disconnect RH B-pillar Side Impact Sensor C3212.
Ignition ON.
Did the on-demand DTC change from B1414:11 and B1419:11 and, if equipped, B1427:11 and
B14EB:11 to B1419:93?
Yes INSTALL a new RH B-pillar side impact sensor.
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REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental Restraint System,
GO to A16
No GO to A4
A4 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT TO
GROUND AND SHORT BETWEEN SENSOR CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:

C567-1 C567-2
Measure:

C567-1 Ground
If equipped, measure:

C310B-19 Ground
C310B-29 Ground

C310B-19 C310B-20
C310B-29 C310B-30
Yes GO to A5
No REPAIR the affected circuit(s).
GO to A16
A5 CHECK THE RH (RIGHT-HAND) B-PILLAR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT
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TO GROUND AND SHORT BETWEEN SENSOR CIRCUITS
Measure:

C3212-1 C3212-2
Measure:

C3212-1 Ground
Yes GO to A14
GO to A16
A6 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR CIRCUITS FOR A SHORT TO
VOLTAGE (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C567-1 Ground
C567-2 Ground
Yes REPAIR the affected circuits.

GO to A16
No GO to A7
A7 CHECK THE RH (RIGHT-HAND) B-PILLAR SIDE IMPACT SENSOR CIRCUITS FOR A SHORT TO
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Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3212-1 Ground
C3212-2 Ground

GO to A16
No GO to A14
A8 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR AND RCM (RESTRAINTS CONTROL
MODULE) CONNECTIONS (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Gain access to the driver front door side impact sensor and inspect C567 to make sure it is fully seated
and locked. Seat and lock the connector as necessary.
Seat and lock the connector(s) as necessary.
Ignition ON.
Yes GO to A9
A9 CHECK THE DRIVER FRONT DOOR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN (NO
OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
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Measure:

C310B-44 C567-1
C310B-43 C567-2
Yes GO to A10
GO to A16

C567-1 C567-2
Ignition ON.
Did the DTC change from B1414:93 to B1414:11 and B1419:11 and, if equipped, B1427:11 and
B14EB:11?
Yes REMOVE the fused jumper wire and INSTALL a new driver front door side impact sensor.
GO to A16
A11 CHECK THE RH (RIGHT-HAND) B-PILLAR SIDE IMPACT SENSOR AND RCM (RESTRAINTS
Ignition OFF.
Depower the SRS.
Gain access to the RH B-pillar side impact sensor and inspect C3212 to be fully seated and locked. Seat
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and lock the connector as necessary.
Gain access to the RCM and inspect C310A and C310B to be fully seated and locked. Seat and lock the
connector(s) as necessary.
Ignition ON.
Yes GO to A12
A12 CHECK THE RH (RIGHT-HAND) B-PILLAR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN (NO
Ignition OFF.
Depower the SRS.
Measure:

C310B-32 C3212-1
C310B-31 C3212-2

Yes GO to A13
GO to A16
FOR A FAULT STATUS CHANGE (NO OPERATION INDICATED)

C3212-1 C3212-2
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Ignition ON.
Did the DTC change from B1419:93 to B1414:11 and B1419:11 and, if equipped, B1427:11 and
B14EB:11?
Yes REMOVE the fused jumper wire and INSTALL a new RH B-pillar side impact sensor.
GO to A16
Ignition OFF.
Depower the SRS.
operation.
Connect RH B-pillar Side Impact Sensor C3212 (if previously disconnected).
Connect Driver Front Door Side Impact Sensor C567 (if previously disconnected).
Ignition ON.
GO to A16

Ignition OFF.
Depower the SRS.
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Inspect:
RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct operation
Connect RH B-pillar Side Impact Sensor C3212.
Connect Driver Front Door Side Impact Sensor C567.
Ignition ON.
Was DTC B1414:11, B1414:93, B1419:11, B1419:93, B1427:11 or B14EB:11 retrieved on-demand
during self-test?
Yes The fault(s) cannot be cleared until corrected and the DTC is no longer retrieved
For DTC B1414:11 and B1419:11 and, if equipped, B1427:11 and B14EB:11, GO to A2

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: Y, Coupe
B1415:11, B1415:93, B1418:11, B1418:93, B1424:11
The RCM monitors the passenger front door and LH B-pillar side impact sensors and circuits for the following
faults:
Open circuit
Short to voltage
Short to ground
Faulted passenger front door side impact sensor
Faulted LH B-pillar side impact sensor
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NOTE: A short to ground on either impact sensor feed circuit sets DTC B1415:11 and B1418:11. A short to
voltage on either impact sensor feed or return circuit sets DTC B1415:93 and B1418:93.
If a fault is detected, the RCM stores DTC B1415:11, B1415:93, B1418:11, B1418:93 or B1424:11 in memory
and sends a message to the IPC to illuminate the airbag warning indicator.
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.
Some vehicles may be equipped with wiring for pedestrian protection system sensors, although the vehicle is not
equipped with the sensors themselves. On these vehicles, if a short to ground condition occurs on the pedestrian
protection sensor wiring, short to ground Diagnostic Trouble Codes (DTCs) set for the side impact sensors, in
addition to short to ground Diagnostic Trouble Codes (DTCs) for pedestrian protection sensors. Alternatively, if a
short to ground condition occurs on the side impact sensor circuits, then pedestrian protection sensor Diagnostic
Trouble Codes (DTCs) set as well.

B1415:11 Driver Side A fault is indicated when the RCM senses a shorted passenger door side
Restraints Sensor 2: impact sensor, a shorted LH B-pillar side impact sensor, a short to ground on
Circuit Short to the passenger front door side impact sensor feed circuit or a short to ground
Ground on the LH B-pillar side impact sensor feed circuit.
B1415:93 Driver Side A fault is indicated when the RCM senses a faulted LH B-pillar side impact
Restraints Sensor 2: sensor, a short to voltage on the feed or return circuit of the LH B-pillar side
No Operation impact sensor, a short to voltage on the feed or return circuit of passenger
front door side impact sensor or an open feed or return circuit of the passenger
front door impact sensor.
B1418:11 Passenger Side A fault is indicated when the RCM senses a shorted passenger front door side
Restraints Sensor 1: impact sensor, a shorted LH B-pillar side impact sensor, a short to ground on
Circuit Short to the passenger front door side impact sensor feed circuit or a short to ground
Ground on the LH B-pillar side impact sensor feed circuit.
B1418:93 Passenger Side A fault is indicated when the RCM senses a faulted passenger front door side
Restraints Sensor 1: impact sensor, a short to voltage on the feed or return circuit of passenger
No Operation front door side impact sensor, a short to voltage on the feed or return circuit of
the LH B-pillar side impact sensor or an open feed or return circuit of the
passenger front door side impact sensor.
B1424:11 Pedestrian If equipped with wiring for pedestrian protection sensors, a fault is indicated
Protection Sensor when the RCM senses a shorted passenger front door side impact sensor, a
Center: Circuit Short shorted LH B-pillar side impact sensor, a short to ground on the passenger
to Ground front door side impact sensor feed circuit, a short to ground on the LH B-pillar
side impact sensor feed circuit, or a short to ground on the wiring for
pedestrian protection sensors.
Possible Causes

Passenger front door side impact sensor
LH B-pillar side impact sensor
RCM
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PINPOINT TEST A : B1415:11, B1415:93, B1418:11, B1418:93, B1424:11

deployment.
NOTE: 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.
NOTE: Do not probe any impact sensor. The impact sensor cannot be tested using a multi-meter.
personal injury.
and Operation).
Ignition ON.
Were any Diagnostic Trouble Codes (DTCs) retrieved on-demand during self-test?
Yes The fault(s) cannot be cleared until corrected and the Diagnostic Trouble Codes (DTCs)
are no longer retrieved on-demand during self-test.
and Testing).
For DTC B1415:11, B1418:11 and, if equipped, B1424:11, GO to A2
For any other Diagnostic Trouble Codes (DTCs),
and Testing).
The fault is intermittent when present as a Continuous Memory Diagnostic Trouble Code
(CMDTC) only. GO to A15
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Ignition OFF.
Depower the SRS.
Disconnect LH B-pillar Side Impact Sensor C3210.
Ignition ON.
Did the on-demand Diagnostic Trouble Codes (DTCs) change from B1415:11, B1418:11 and, if
equipped, B1424:11 to B1415:93?
Yes INSTALL a new LH B-pillar side impact sensor.

GO to A16
No GO to A3
Ignition OFF.
Depower the SRS.
Connect LH B-pillar Side Impact Sensor C3210.
Disconnect Passenger Front Door Side Impact Sensor C644.
Ignition ON.
Did the on-demand DTC change from B1415:11, B1418:11 and, if equipped, B1424:11 to B1418:93?
Yes INSTALL a new passenger front door side impact sensor.

GO to A16
No GO to A4
A4 CHECK THE LH (LEFT-HAND) B-PILLAR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT
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Ignition OFF.
Depower the SRS.
Measure:

C3210-1 C3210-2
Measure:

C3210-1 Ground

C310B-22 Ground

C310B-22 C310B-21
Yes GO to A5
GO to A16
A5 CHECK THE PASSENGER FRONT DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT
Measure:

C644-1 C644-2
Measure:
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C644-1 Ground
Yes GO to A14
GO to A16
A6 CHECK THE LH (LEFT-HAND) B-PILLAR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT
TO VOLTAGE (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3210-1 Ground
C3210-2 Ground
Yes REPAIR the circuits.

GO to A16
No GO to A7
A7 CHECK THE PASSENGER FRONT DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT
TO VOLTAGE (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:
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C644-1 Ground
C644-2 Ground

GO to A16
No GO to A14
A8 CHECK THE LH (LEFT-HAND) B-PILLAR SIDE IMPACT SENSOR AND RCM (RESTRAINTS
Ignition OFF.
Depower the SRS.
Gain access to the LH B-pillar side impact sensor and inspect C3210 to make sure it is fully seated and
locked. Seat and lock the connector as necessary.
Ignition ON.
Yes GO to A9
A9 CHECK THE LH (LEFT-HAND) B-PILLAR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN (NO
Ignition OFF.
Depower the SRS.
Measure:

C310B-33 C3210-1
C310B-34 C3210-2
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Yes GO to A10
GO to A16

C3210-1 C3210-2
Ignition ON.
Did the DTC change from B1415:93 to B1415:11, B1418:11 and, if equipped, B1424:11?
Yes REMOVE the fused jumper wire and INSTALL a new LH B-pillar side impact sensor.
GO to A16
A11 CHECK THE PASSENGER FRONT DOOR SIDE IMPACT SENSOR AND RCM (RESTRAINTS
Ignition OFF.
Depower the SRS.
Gain access to the passenger front door side impact sensor and inspect C644 to make sure it is fully
seated and locked. Seat and lock the connector as necessary.
Ignition ON.
Yes GO to A12
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No Fault corrected. GO to A16
A12 CHECK THE PASSENGER FRONT DOOR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN (NO
Ignition OFF.
Depower the SRS.
Measure:

C310B-45 C644-1
C310B-46 C644-2
Yes GO to A13
GO to A16

C644-1 C644-2
Ignition ON.
Did the DTC change from B1418:93 to B1415:11, B1418:11 and, if equipped, B1424:11?
Yes REMOVE the fused jumper wire and INSTALL a new passenger front door side impact
sensor.
GO to A16
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Ignition OFF.
Depower the SRS.
operation.
Connect LH B-pillar Side Impact Sensor C3210 (if previously disconnected).
Connect Passenger Front Door Side Impact Sensor C644 (if previously disconnected).
Ignition ON.
GO to A16

Ignition OFF.
Depower the SRS.
Inspect:
Connect LH B-pillar Side Impact Sensor C3210.
Connect Passenger Front Door Side Impact Sensor C644.
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Ignition ON.
Was DTC B1415:11, B1415:93, B1418:11, B1418:93 or B1424:11 retrieved on-demand during
self-test?
Yes The fault(s) cannot be cleared until corrected and the DTC is no longer retrieved
For DTC B1415:11, B1418:11 and, if equipped, B1424:11, GO to A2

Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, perform the Restraints self-test.
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Pinpoint Test - DTC: Z
B1417:11 and B1417:93
The RCM monitors the RH front impact severity sensor circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted RH front impact severity sensor
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B1417:11 Passenger Frontal Restraints A fault is indicated when the RCM senses a short to ground on the
Sensor: Circuit Short to Ground RH front impact severity sensor feed circuit.
B1417:93 Passenger Frontal Restraints A fault is indicated when the RCM senses a faulted RH front impact
Sensor: No Operation severity sensor, a short to voltage on the feed circuit or an open
feed or return circuit.
Possible Causes

RH front impact severity sensor
RCM
Inspect for a damaged RH front impact severity sensor.

Inspect the RH front impact severity sensor mounting and orientation.

deployment.
personal injury.
and Operation).
Ignition ON.
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and Testing).
and Testing).
A2 CHECK THE RIGHT FRONTAL RESTRAINTS SENSOR DTC (DIAGNOSTIC TROUBLE CODE)
Ignition OFF.
Depower the SRS.
Disconnect RH Front Impact Severity Sensor C1466.
Ignition ON.

Yes INSTALL a new RH front impact severity sensor.
GO to A11
No GO to A3
A3 CHECK THE RH (RIGHT-HAND) FRONT IMPACT SEVERITY SENSOR FEED CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C1466-1 Ground
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Yes GO to A4
GO to A11
A4 CHECK FOR A SHORT BETWEEN RH (RIGHT-HAND) FRONT IMPACT SEVERITY SENSOR

CIRCUITS
Measure:

C1466-1 C1466-2
Yes GO to A9
GO to A11
A5 CHECK THE RH (RIGHT-HAND) FRONT IMPACT SEVERITY SENSOR AND RCM (RESTRAINTS
Ignition OFF.
Depower the SRS.
Inspect the RH Front Impact Severity Sensor C1466 to make sure it is fully seated and locked. Seat and
lock the connector as necessary.
Seat and lock the connector as necessary.
Ignition ON.
Yes GO to A6
A6 CHECK THE RH (RIGHT-HAND) FRONT IMPACT SEVERITY SENSOR FEED CIRCUIT FOR A
SHORT TO VOLTAGE (NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
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Ignition ON.
Measure:

C1466-1 Ground

GO to A11
No GO to A7
A7 CHECK THE RH (RIGHT-HAND) FRONT IMPACT SEVERITY SENSOR CIRCUITS FOR AN OPEN
(NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Measure:

C310A-16 C1466-1
C310A-15 C1466-2
Yes GO to A8
GO to A11
A8 CHECK THE RIGHT FRONTAL RESTRAINTS SENSOR DTC (DIAGNOSTIC TROUBLE CODE)
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Connect: RCM C310A and C310B.

C1466-1 C1466-2
Ignition ON.
Yes REMOVE the fused jumper wire and INSTALL a new RH front impact severity sensor.
GO to A11
Ignition OFF.
Depower the SRS.
operation.
Connect RH Front Impact Severity Sensor C1466.
Ignition ON.
GO to A11
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Ignition OFF.
Depower the SRS.
Inspect:
Connect RH Front Impact Severity Sensor C1466.
Ignition ON.
Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AA
BXXXX:2B (any BXXXX DTC with a 2B failure type) Signal Cross Coupled
The RCM monitors all deployable device and sensor circuits for a signal cross coupled (short) between
components. Signal cross coupled Diagnostic Trouble Codes (DTCs) are present when one or both circuits of a
component are shorted to one or both circuits of another component. Signal cross coupled Diagnostic Trouble
Codes (DTCs) do not set when the circuits of a single device are shorted together, a different DTC is present (for
example, a DTC for circuit resistance below threshold). The RCM sends a message to the IPC to illuminate the
airbag warning indicator. When a normal loop fault is present (one loop is either shorted to battery/ground, open
circuit or low resistance), then signal cross coupled diagnostics are not active. Once the normal loop fault is
repaired, the signal cross coupled diagnostics resume.
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B0001:2B Driver Frontal Stage 1 If the RCM detects a short between the driver airbag stage 1
Deployment Control: Signal circuits and the circuits of another SRS component, it sets this DTC
Cross Coupled and the DTC of the corresponding SRS component.
B0002:2B Driver Frontal Stage 2 If the RCM detects a short between the driver airbag stage 2
B0004:2B Driver Knee Bolster If the RCM detects a short between the driver lower airbag circuits
Deployment Control: Signal and the circuits of another SRS component, it sets this DTC and the
Cross Coupled DTC of the corresponding SRS component.
B0005:2B Collapsible Steering Column If the RCM detects a short between the deployable steering column
B0010:2B Passenger Frontal Stage 1 If the RCM detects a short between the passenger airbag stage 1
B0011:2B Passenger Frontal Stage 2 If the RCM detects a short between the passenger airbag stage 2
B0013:2B Passenger Knee Bolster If the RCM detects a short between the passenger knee bolster
B0050:2B Driver Seatbelt Sensor: Signal If the RCM detects a short between the driver safety belt buckle
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 Sensor: If the RCM detects a short between the passenger safety belt
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.
B0070:2B Driver Seatbelt Pretensioner If the RCM detects a short between the driver safety belt anchor
"A" Deployment Control: Signal pretensioner circuits and the circuits of another SRS component, it
Cross Coupled sets this DTC and the DTC of the corresponding SRS component.
B0072:2B Passenger Seatbelt If the RCM detects a short between the passenger safety belt
Pretensioner "A" Deployment anchor 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.
B007E:2B Driver Seatbelt Pretensioner If the RCM detects a short between the driver safety belt retractor
"C" Deployment Control: Signal pretensioner circuits and the circuits of another SRS component, it
Cross Coupled sets this DTC and the DTC of the corresponding SRS component.
B007F:2B Passenger Seatbelt If the RCM detects a short between the passenger safety belt
Pretensioner "C" Deployment retractor 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.
B00B5:2B Driver Seat Track Position If the RCM detects a short between the LH seat track position
Restraints Sensor: Signal sensor circuits and the circuits of another SRS component, it sets
Cross Coupled this DTC and the DTC of the corresponding SRS component.
B00C5:2B Passenger Seat Track Position If the RCM detects a short between the RH seat track position
Restraints Sensor: Signal sensor circuits and the circuits of another SRS component, it sets
Cross Coupled this DTC and the DTC of the corresponding SRS component.
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B11CF:2B Passenger Frontal Airbag If the RCM detects a short between the passenger airbag canister
Canister Vent: Signal Cross vent circuits and the circuits of another SRS component, it sets this
Coupled DTC and the DTC of the corresponding SRS component.
B1404:2B Driver Side Airbag Deployment If the RCM detects a short between the driver side airbag circuits
Control: Signal Cross Coupled and the circuits of another SRS component, it sets this DTC and the
DTC of the corresponding SRS component.
B1405:2B Driver Curtain Deployment If the RCM detects a short between the LH side air curtain circuits
Control 1: Signal Cross and the circuits of another SRS component, it sets this DTC and the
Coupled DTC of the corresponding SRS component.
B1407:2B Passenger Side Airbag If the RCM detects a short between the passenger side airbag
B1408:2B Passenger Curtain Deployment If the RCM detects a short between the RH side air curtain circuits
Control 1: Signal Cross and the circuits of another SRS component, it sets this DTC and the
Coupled DTC of the corresponding SRS component.
Possible Sources

RCM
Inspect the affected wiring harness(es) for damage, if accessible.
PINPOINT TEST A : BXXXX:2B (ANY BXXXX DTC (DIAGNOSTIC TROUBLE CODE) WITH A 2B
FAILURE TYPE) SIGNAL CROSS COUPLED

deployment.
personal injury.
and Operation).
Ignition ON.
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Were any signal cross coupled Diagnostic Trouble Codes (DTCs) retrieved on-demand during
self-test?
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during
the on-demand self test. If DTC U3003:16 or U3003:17 is also retrieved on-demand,
DIAGNOSE those Diagnostic Trouble Codes (DTCs) first.
and Testing).
If DTC U3003:16 or U3003:17 are not retrieved on-demand, GO to A2

No If DTC U3003:16 or U3003:17 is retrieved on-demand as well, DIAGNOSE those
Diagnostic Trouble Codes (DTCs) first.
and Testing).
If DTC U3003:16 or U3003:17 are not retrieved on-demand, DIAGNOSE the signal cross-
coupled Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE AFFECTED CIRCUITS FOR A SIGNAL CROSS COUPLED FAULT

Ignition OFF.
Depower the SRS.
Using the signal cross coupled Diagnostic Trouble Codes (DTCs) present on-demand, identify the
affected SRS devices.
NOTE: Most signal cross coupled faults are due to connector and/or wiring harness damage. Carry out
a thorough inspection of connector(s) and/or wiring harness for damage.
Disconnect all of the affected SRS devices.
Using the following table, measure the resistance between the circuits of one affected SRS device to the
other affected SRS device.
Example: If Diagnostic Trouble Codes (DTCs) B0001:2B and B0002:2B are being diagnosed,
measure the resistance between circuit CR101 to circuits CR102 and RR102. Then measure the
resistance between circuit RR101 to circuits CR102 and RR102.
Device/Loop (DTC) Connector
Driver airbag stage 1 (B0001:2B) C216A-1
C216A-2
Driver airbag stage 2 (B0002:2B) C216B-1
C216B-2
Driver knee airbag (B0004:2B) C2432-3
C2432-4
Deployable steering column (B0005:2B) C2360-1
C2360-2
Passenger airbag stage 1 (B0010:2B) C256-1
C256-2
Passenger airbag stage 2 (B0011:2B) C256-4
C256-5
Passenger knee airbag (B0013:2B) C2600-1
C2600-2
Driver safety belt buckle switch (B0050:2B) C3201-5
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Passenger safety belt buckle switch (B0052:2B) C3238-5
Driver safety belt anchor pretensioner (B0070:2B) C3065-1
C3065-2
Passenger safety belt anchor pretensioner (B0072:2B) C3066-1
C3066-2
Driver safety belt retractor pretensioner (B007E:2B) C323-1
C323-2
Passenger safety belt retractor pretensioner (B007F:2B) C303-1
C303-2
Driver seat position sensor (B00B5:2B) C356-2
Passenger seat track position sensor (B00C5:2B) C3240-2
Passenger airbag canister vent (B11CF:2B) C256-7
C256-8
Driver side airbag (B1404:2B) C3206-3 (Inline)
C3206-4 (Inline)
LH side air curtain (B1405:2B, coupe only) C9031-1
C9031-2
Driver upper side airbag (B1405:2B, convertible only) C3206-1 (Inline)
C3206-2 (Inline)
Passenger side airbag (B1407:2B) C219-3 (Inline)
C219-4 (Inline)
RH side air curtain (B1408:2B, coupe only) C9032-1
C9032-2
Passenger upper side airbag (B1408:2B, convertible only) C219-1 (Inline)
C219-2 (Inline)
Are the resistances greater than 10,000 ohms between the affected circuits?
Yes GO to A3
No REPAIR the affected circuits.
GO to A5
operation.
Connect all previously disconnected restraint system component(s).
Ignition ON.
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self-test?
GO to A5
NOTE: Most cross link faults are due to connector and/or wiring harness damage. Carry out a thorough
inspection of connector(s) and/or wiring harness for damage.
Ignition OFF.
Depower the SRS.
Disconnect all of the affected SRS devices.
Inspect the wiring harness(es) for any type of damage. If damage is found, repair as necessary.
Ignition ON.
self-test?
on-demand during self-test. GO to A2
No The fault is not present and cannot be recreated at this time. CHECK for causes of the
intermittent fault. 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 A5

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AB
BXXXX:4A (any BXXXX DTC with a 4A failure type) Incorrect Component Installed
The RCM monitors all SRS device connections. If the RCM detects a connection or device connected that is not
stored in memory or is not configured for the component, the RCM sets a DTC and sends a message to the IPC
to illuminate the airbag warning indicator.

B0001:4A Driver Frontal Stage 1 Deployment Control: This DTC sets if the RCM detects the device but
Incorrect Component Installed it is not configured for this component.
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B0002:4A Driver Frontal Stage 2 Deployment Control: This DTC sets if the RCM detects the device but
B0004:4A Driver Knee Bolster Deployment Control: Incorrect This DTC sets if the RCM detects the device but
Component Installed it is not configured for this component.
B0005:4A Collapsible Steering Column Deployment Control: This DTC sets if the RCM detects the device but
B0010:4A Passenger Frontal Stage 1 Deployment Control: This DTC sets if the RCM detects the device but
B0011:4A Passenger Frontal Stage 2 Deployment Control: This DTC sets if the RCM detects the device but
B0013:4A Passenger Knee Bolster Deployment Control: This DTC sets if the RCM detects the device but
B0050:4A Driver Seatbelt Sensor: Incorrect Component This DTC sets if the RCM detects the device but
Installed it is not configured for this component.
B0052:4A Passenger Seatbelt Sensor: Incorrect Component This DTC sets if the RCM detects the device but
Installed it is not configured for this component.
B0070:4A Driver Seatbelt Pretensioner "A" Deployment This DTC sets if the RCM detects the device but
Control: Incorrect Component Installed it is not configured for this component.
B0072:4A Passenger Seatbelt Pretensioner "A" Deployment This DTC sets if the RCM detects the device but
B007E:4A Driver Seatbelt Pretensioner "C" Deployment This DTC sets if the RCM detects the device but
B007F:4A Passenger Seatbelt Pretensioner "C" Deployment This DTC sets if the RCM detects the device but
B0080:4A Driver Seatbelt Load Limiter Deployment Control: This DTC sets if the RCM detects the device but
B00B5:4A Driver Seat Track Position Restraints Sensor: This DTC sets if the RCM detects the device but
B00C5:4A Passenger Seat Track Position Restraints Sensor: This DTC sets if the RCM detects the device but
B00D5:4A Restraint System Passenger Disable Indicator: This DTC sets if the RCM detects the device but
B11CF:4A Passenger Frontal Airbag Canister Vent: Incorrect This DTC sets if the RCM detects the device but
B1404:4A Driver Side Airbag Deployment Control: Incorrect This DTC sets if the RCM detects the device but
B1405:4A Driver Curtain Deployment Control 1: Incorrect This DTC sets if the RCM detects the device but
B1407:4A Passenger Side Airbag Deployment Control: This DTC sets if the RCM detects the device but
B1408:4A Passenger Curtain Deployment Control 1: This DTC sets if the RCM detects the device but
B1413:4A Driver Frontal Restraints Sensor: Incorrect This DTC sets if the RCM detects the device but
B1414:4A Driver Side Restraints Sensor 1: Incorrect This DTC sets if the RCM detects the device but
B1415:4A Driver Side Restraints Sensor 2: Incorrect This DTC sets if the RCM detects the device but
B1417:4A Passenger Frontal Restraints Sensor: Incorrect This DTC sets if the RCM detects the device but
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B1418:4A Passenger Side Restraints Sensor 1: Incorrect This DTC sets if the RCM detects the device but
B1419:4A Passenger Side Restraints Sensor 2: Incorrect This DTC sets if the RCM detects the device but
B1424:4A Pedestrian Protection Sensor Center: Incorrect This DTC sets if the RCM detects an unexpected
Component Installed impact sensor.
B1427:4A Pedestrian Protection Sensor Driver Outer: This DTC sets if the RCM detects an unexpected
Incorrect Component Installed impact sensor.
B1469:4A Unused Satellite Restraints Sensor 1: Incorrect This DTC sets if the RCM detects an unexpected
B146A:4A Unused Satellite Restraints Sensor 2: Incorrect This DTC sets if the RCM detects an unexpected
B147D:4A Driver Side Hood Hinge Deployment Control: This DTC sets if the RCM detects the device but
B147E:4A Passenger Side Hood Hinge Deployment Control: This DTC sets if the RCM detects the device but
B14EB:4A Pedestrian Protection Sensor Passenger Outer: This DTC sets if the RCM detects an unexpected
Incorrect Component Installed impact sensor.
Possible Sources
RCM not configured or configured incorrectly

Incorrect RCM installed
Incorrect impact sensor installed
Review recent service history to identify repairs where an incorrect component may have been installed.
PINPOINT TEST A : BXXXX:4A (ANY BXXXX DTC (DIAGNOSTIC TROUBLE CODE) WITH A 4A
FAILURE TYPE) INCORRECT COMPONENT INSTALLED

deployment.
personal injury.
and Operation).
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Ignition ON.
Were any incorrect component installed Diagnostic Trouble Codes (DTCs) retrieved on-demand
during self-test?
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during
self-test.
If DTC B00A0:4A was retrieved,
REFER to: Pinpoint Test - DTC: N (501-20B Supplemental Restraint System, Diagnosis
and Testing).
If DTC U3003:16 or U3003:17 is retrieved on-demand as well, DIAGNOSE those

and Testing).
For all other incorrect component installed Diagnostic Trouble Codes (DTCs), GO to A2
No If DTC U3003:16 or U3003:17 is retrieved on-demand as well, DIAGNOSE those
and Testing).
If DTC U3003:16 or U3003:17 are not retrieved on-demand, DIAGNOSE the Continuous
Memory Diagnostic Trouble Codes (CMDTCs).
A2 CHECK THE RCM (RESTRAINTS CONTROL MODULE) PART NUMBER

Ignition ON.
Check the vehicle repair history. Using the Log Viewer function of the diagnostic scan tool, retrieve and
record the RCM part number.
Check the part number recorded against the number listed in the Ford parts catalog and verify the correct
RCM is installed in the vehicle.
Is the correct RCM installed?

Yes GO to A3
No INSTALL the correct RCM.
GO to A6
A3 VERIFY THE RCM (RESTRAINTS CONTROL MODULE) CONFIGURATION

Carry out PMI for the RCM. Use As-Built data when carrying out PMI. Refer to the scan tool instructions
to carry out PMI.
during self-test?
Yes For DTC B1413:4A, B1414:4A, B1415:4A, B1417:4A, B1418:4A or B1419:4A, GO to A4

For all other incorrect component installed Diagnostic Trouble Codes (DTCs), CHECK
OASIS for any applicable Technical Service Bulletins (TSBs). If a TSB exists for this
concern, DISCONTINUE this test and FOLLOW TSB instructions. If no Technical Service
Bulletins (TSBs) address this concern, INSTALL a new RCM.
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GO to A6
A4 VERIFY THE SUSPECT IMPACT SENSOR PART NUMBER

Ignition OFF.
Depower the SRS.
Gain access to the suspect impact sensor(s) for which incorrect component installed Diagnostic Trouble
Codes (DTCs) were retrieved. Refer to the table for the appropriate procedure(s).
DTC Component Procedure

B1413:4A LH front impact severity
sensor REFER to: Front Impact Severity Sensor (501-20B
B1414:4A Driver front door side
impact sensor REFER to: Front Door Side Impact Sensor (501-20B
B1415:4A LH B-pillar side impact
sensor REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental
B1417:4A RH front impact severity
sensor REFER to: Front Impact Severity Sensor (501-20B
B1418:4A Passenger front door side
impact sensor REFER to: Front Door Side Impact Sensor (501-20B
B1419:4A RH B-pillar side impact
sensor REFER to: B-Pillar Side Impact Sensor (501-20B Supplemental
Record the part number from each suspect impact sensor.
Check the part number(s) recorded against the number listed in the Ford parts catalog and verify that
each suspect impact sensor installed in the vehicle is correct.
Do the part numbers of all suspect impact sensors match the part numbers listed in the Ford parts
catalog?
Service Bulletins (TSBs) address this concern, INSTALL a new RCM. GO to A6
No INSTALL the correct impact sensor(s) as necessary. For DTC B1413:4A or B1417:4A,
For DTC B1414:4A or B1418:4A,
For DTC B1415:4A or B1419:4A,
GO to A6
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Using a diagnostic scan tool, clear RCM Diagnostic Trouble Codes (DTCs).
Using a diagnostic scan tool, perform RCM self-test to retrieve Diagnostic Trouble Codes (DTCs).
during self-test?
GO to A6
No 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 A6

Ignition OFF.
Ignition ON.
OCSM.
No CLEAR all RCM and OCSM Continuous Memory Diagnostic Trouble Codes (CMDTCs).
PROVE OUT the SRS. The repair is complete. RETURN the vehicle to the customer.
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Pinpoint Test - DTC: AC
C0061:68, C0062:68, C0063:68, C0064:68, C0065:68
Diagnostic Overview
The RCM provides the stability/traction control system with acceleration sensor data over the HS-CAN2. In
addition to transmitting the data, the RCM monitors this data internally to make sure that the data is within an
expected range.
If the data is outside of the expected range and a fault is detected, the RCM stores DTC C0061:68, C0062:68,
C0063:68, C0064:68, and/or C0065:68 in memory. However, the RCM does not request that the IPC illuminate
the airbag warning indicator when these faults are present.
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C0061:68 Lateral Acceleration Sensor: A fault is indicated when the lateral acceleration sensor is
Event Information transmitting data that is outside of the range expected by the RCM.
C0062:68 Longitudinal Acceleration A fault is indicated when the longitudinal acceleration sensor is
Sensor: Event Information transmitting data that is outside of the range expected by the RCM.
C0063:68 Yaw Rate Sensor: Event A fault is indicated when the yaw rate sensor is transmitting data that
Information is outside of the range expected by the RCM.
C0064:68 Roll Rate Sensor: Event A fault is indicated when the roll rate sensor is transmitting data that
Information is outside of the range expected by the RCM.
C0065:68 Vertical Acceleration Sensor: A fault is indicated when the vertical acceleration sensor is
Event Information transmitting data that is outside of the range expected by the RCM.
Possible Sources
Aggressive driving conditions or rough roads

RCM mounting
RCM
PINPOINT TEST A : C0061:68, C0062:68, C0063:68, C0064:68, C0065:68
WARNING: Do not handle, move or change the original horizontal mounting position of the
Restraints Control Module (RCM) while the Restraints Control Module (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.
Ignition ON.
Were Diagnostic Trouble Codes (DTCs) C0061:68, C0062:68, C0063:68, C0064:68, or C0065:68 the
only Diagnostic Trouble Codes (DTCs) retrieved?
Yes CLEAR the RCM Diagnostic Trouble Codes (DTCs). GO to A2

No DIAGNOSE all other RCM Diagnostic Trouble Codes (DTCs) first.
A2 CHECK FOR A RETURNING FAULT
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Test drive the vehicle. Choose a route with LH and RH turns. Avoid rough roads and do not drive the
vehicle aggressively.
Were Diagnostic Trouble Codes (DTCs) C0061:68, C0062:68, C0063:68, C0064:68, or C0065:68 the
only RCM Diagnostic Trouble Codes (DTCs) retrieved?
Yes GO to A3
No If no RCM Diagnostic Trouble Codes (DTCs) were retrieved, the Diagnostic Trouble Codes
(DTCs) may have been triggered by aggressive driving or rough road conditions. INFORM
the customer that aggressive driving conditions or rough road conditions can set these
Diagnostic Trouble Codes (DTCs). RETURN the vehicle to the customer.
If any other RCM Diagnostic Trouble Codes (DTCs) were retrieved, DIAGNOSE those
Diagnostic Trouble Codes (DTCs).
A3 CHECK THE RCM (RESTRAINTS CONTROL MODULE) INSTALLATION

Ignition OFF.
Depower the SRS.
Inspect the RCM installation and make sure that the hardware is fully seated and tightened correctly.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and
Installation).
Inspect the RCM mounting surface for damage, corrosion, or foreign materials.
Is the RCM mounted correctly and is the mounting surface clean and free from damage?
Yes GO to A4
No REPAIR the mounting or INSTALL new hardware, as necessary. GO to A6

operation.
Ignition ON.
Using a diagnostic scan tool, clear all RCM Diagnostic Trouble Codes (DTCs).
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GO to A6

Ignition OFF.
Depower the SRS.
Inspect RCM C310A and C310B for pushed-out, loose or spread terminals and loose or frayed wire
Inspect wire harnesses for any damaged, pinched, cut or pierced wires.

GO to A6

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
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, perform the Restraints self-test to retrieve Diagnostic Trouble Codes
(DTCs).
No CLEAR all RCM and OCSM Continuous Memory Diagnostic Trouble Codes (CMDTCs).
PROVE OUT the SRS. The repair is complete. RETURN the vehicle to the customer.
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Pinpoint Test - DTC: AD
U0100:00
The OCSM and RCM both use information contained in messages from the PCM sent on the HS-CAN.

U0100:00 Lost Communication with ECM/PCM “A”: No This DTC sets if the OCSM does not receive an
Sub Type Information expected message from the PCM.
U0100:00 Lost Communication with ECM/PCM “A”: No This DTC sets if the RCM does not receive an
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Sub Type Information expected message from the PCM.
Possible Causes
Network traffic
PCM
RCM
OCSM
PINPOINT TEST A : U0100:00

A1 VERIFY DIAGNOSTIC SCAN TOOL COMMUNICATION WITH THE PCM (POWERTRAIN
CONTROL MODULE)
injury.
and Operation).
Ignition ON.
Connect the diagnostic scan tool.
Check that a vehicle session can be established using the diagnostic scan tool.
Can a vehicle session be established?

Yes If DTC U0100:00 was retrieved from the OCSM, GO to A2
If DTC U0100:00 was retrieved from the RCM, GO to A3
No To diagnose no communication with the PCM,
and Testing).
A2 CHECK THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) CONTINUOUS MEMORY

Using a diagnostic scan tool, perform OCSM self-test.
Using a diagnostic scan tool, clear OCSM Diagnostic Trouble Codes (DTCs).
Wait 10 seconds.
Yes GO to A4
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A3 CHECK THE RCM (RESTRAINTS CONTROL MODULE) CONTINUOUS MEMORY DIAGNOSTIC
TROUBLE CODES (CMDTCS)
Wait 10 seconds.
Yes GO to A4
A4 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE PCM
(POWERTRAIN CONTROL MODULE) KOEO (KEY ON, ENGINE OFF) SELF-TEST
Check for recorded Diagnostic Trouble Codes (DTCs) from the PCM KOEO self-test.
Is DTC P0562 or P0563 recorded?
Yes DIAGNOSE the PCM Diagnostic Trouble Codes (DTCs). Refer to the appropriate section
No If DTC U0100:00 was originally retrieved from the OCSM, GO to A5
If DTC U0100:00 was originally retrieved from the RCM, GO to A6
A5 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE OCSM
(OCCUPANT CLASSIFICATION SYSTEM MODULE) SELF-TEST
Check for recorded Diagnostic Trouble Codes (DTCs) from the OCSM self-test.
Is DTC U3003:16 or U3003:17 recorded?

Yes
and Testing).
No GO to A7
A6 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE RCM
(RESTRAINTS CONTROL MODULE) SELF-TEST
Check for recorded Diagnostic Trouble Codes (DTCs) from the RCM self-test.
Yes
and Testing).
No GO to A8
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A7 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0100:00 SET IN MODULES OTHER THAN
THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE)
Using a diagnostic scan tool, perform self-test for all modules.
Is DTC U0100:00 set in the ABS module or in the RCM?
Service Bulletins (TSBs) address this concern, INSTALL a new PCM. Refer to the
Service Bulletins (TSBs) address this concern, INSTALL a new OCSM.
A8 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0100:00 SET IN OTHER MODULES OTHER
THAN THE RCM (RESTRAINTS CONTROL MODULE)
Is DTC U0100:00 set in the ABS module or in the OCSM?
Service Bulletins (TSBs) address this concern, INSTALL a new PCM. Refer to the
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Pinpoint Test - DTC: AE
U0140:00
The RCM uses information contained in messages from the BCM sent on the HS-CAN2.

U0140:00 Lost Communication with Body Control Module: This DTC sets if the RCM does not receive an
No Sub Type Information expected message from the BCM.
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Possible Sources
Network traffic
BCM
RCM
personal injury.
and Operation).
Ignition ON.
Using a diagnostic scan tool, carry out a network test.
Does the BCM pass the network test?

Yes GO to A2
No To diagnose no communication with the BCM,
and Testing).

Ignition ON.
Wait 10 seconds.
Yes GO to A3
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Check the recorded Diagnostic Trouble Codes (DTCs) from the RCM self-test.
Yes
and Testing).
No GO to A4
A4 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE BCM (BODY
CONTROL MODULE) SELF-TEST
Check for recorded Diagnostic Trouble Codes (DTCs) from the BCM self-test.
Yes
No GO to A5
A5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0140:00 SET IN OTHER MODULES
Ignition ON.
Is DTC U0140:00 set in the ABS Module or in the IPC?

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Pinpoint Test - DTC: AF
U0154:00
The RCM uses information contained in messages from the OCSM sent on the High Speed Controller Area
Network 2 (HS2-CAN).

U0154:00 Lost Communication with Restraints Occupant This DTC sets if the RCM does not receive
Classification System Module: No Sub Type Information an expected message from the OCSM.
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Possible Sources
Network traffic
OCSM
RCM
personal injury.
and Operation).
Ignition ON.
Does the OCSM pass the network test?

Yes GO to A2
No To diagnose no communication with the OCSM,
and Testing).

Ignition ON.
Wait 10 seconds.
Yes GO to A3
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Yes
and Testing).
No GO to A4
Check for recorded Diagnostic Trouble Codes (DTCs) from the OCSM self-test.
Yes
and Testing).
REPEAT the RCM self-test. If DTC U0154:00 returns, INSTALL a new OCS sensor.
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Pinpoint Test - DTC: AG
U0155:00
The RCM uses information contained in messages from the IPC sent on the HS-CAN.

U0155:00 Lost Communication with Instrument Panel Cluster This DTC sets if the RCM does not receive an
(IPC) Control Module: No Sub Type Information expected message from the IPC for 6 seconds.
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Possible Causes
Network traffic
IPC
RCM

personal injury.
and Operation).
Ignition ON.
Does the IPC pass the network test?
Yes GO to A2
No To diagnose no communication with the IPC,
and Testing).
Wait 10 seconds.
Yes GO to A3
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Yes
and Testing).
No GO to A4
A4 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE IPC
(INSTRUMENT PANEL CLUSTER) SELF-TEST
Using a diagnostic scan tool, perform IPC self-test.
Check for recorded Diagnostic Trouble Codes (DTCs) from the IPC self-test.
Yes
No GO to A5
Is DTC U0155:00 set in the BCM, ACM, or APIM (if equipped)?

Guided Routine (IPC).
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Pinpoint Test - DTC: AH
U0253:00
The RCM uses information contained in messages from the APIM sent on the High Speed Controller Area

U0253:00 Lost Communication with Accessory Protocol This DTC sets if the RCM does not receive an
Interface Module: No Sub Type Information expected message from the APIM.
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Possible Sources
Network traffic
APIM
RCM
Ignition ON.
Does the APIM pass the network test?
Yes GO to A2
No To diagnose no communication with the APIM,
and Testing).
Ignition ON.
Wait 10 seconds.
Yes GO to A3
Check for recorded Diagnostic Trouble Codes (DTCs) from the RCM self-test.
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Yes
and Testing).
No GO to A4
A4 RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE APIM (SYNC
MODULE) SELF-TEST
Using a diagnostic scan tool, perform APIM self-test.
Check for recorded Diagnostic Trouble Codes (DTCs) from the APIM self-test.
Yes REFER to the appropriate section to DIAGNOSE the battery voltage Diagnostic Trouble
Codes (DTCs). Refer to the appropriate section in Group 415 for the procedure.
No GO to A5
Ignition ON.
Is DTC U0253:00 set in the ACM?
Service Bulletins (TSBs) address this concern, INSTALL a new APIM. Refer to the
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Pinpoint Test - DTC: AI
U2300:55, U2300:64
NOTE: DTC U2300:55 is set in every new RCM that has not previously been installed or that has previously
been installed but has not yet successfully received configuration data messages from the BCM. DO NOT
replace any components for this DTC unless directed to do so by the following pinpoint test.
The RCM receives a configuration data message from the BCM when the RCM proves out during the very first
ignition cycle after it is installed. During prove-out at the beginning of each subsequent ignition cycle, the BCM
sends configuration data to the RCM and the RCM compares the message to the message that was received
during the very first ignition cycle.
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U2300:55 Central This DTC is present in every new RCM. Once the new RCM is installed and it
Configuration: Not successfully receives a configuration data message from the BCM, this DTC
Configured reports as a Continuous Memory Diagnostic Trouble Code (CMDTC). If the RCM
reports this DTC on-demand, it means that the configuration data message has
not been received from the BCM.
U2300:64 Central If the RCM receives a configuration data message that does not match the
Configuration: configuration data that was previously received and stored, it sets this DTC. This
Signal Plausibility DTC can set on-demand during the RCM prove-out, but change to a Continuous
Failure Memory Diagnostic Trouble Code (CMDTC) later on in the ignition cycle if the
correct message is eventually received. If PMI has not been carried out for the
BCM, this DTC sets.
Possible Sources
RCM or BCM configuration

BCM
RCM
PINPOINT TEST A : U2300:55, U2300:64
injury.
Ignition ON.
Record the RCM Diagnostic Trouble Codes (DTCs) that were retrieved during the self-test.
Is DTC U2300:55 or U2300:64 retrieved on-demand?
Yes GO to A2
No If DTC U2300:55 or U2300:64 is retrieved as a Continuous Memory Diagnostic Trouble
Code (CMDTC), CLEAR the RCM Diagnostic Trouble Codes (DTCs) and REPEAT the
self-test.
If DTC U2300:55 or U2300:64 does not return, RELEASE the vehicle to the customer.
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If DTC U2300:55 or U2300:64 returns on-demand, GO to A2
A2 CHECK FOR THE CORRECT BCM (BODY CONTROL MODULE)

Using the Log Viewer function of the diagnostic scan tool, retrieve and record the BCM part number.
Check the recorded part number against the number listed in the Ford parts catalog.
Does the recorded part number match the number listed in the Ford parts catalog?
Yes GO to A3
No INSTALL the correct BCM and USE As-Built data when carrying out PMI.
GO to A4
A3 CHECK FOR THE CORRECT RCM (RESTRAINTS CONTROL MODULE)

Using the Log Viewer function of the diagnostic scan tool, retrieve and record the RCM part number.
Check the recorded part number against the number listed in the Ford parts catalog.
Does the recorded part number match the number listed in the Ford parts catalog?
Yes CARRY OUT PMI for the BCM using As-Built data. CLEAR the Diagnostic Trouble Codes
(DTCs) and REPEAT the RCM self-test.
If DTC U2300:55 or U2300:64 are retrieved, CARRY OUT PMI for the RCM using As-Built
data.
GO to A4
No INSTALL the correct RCM and use As-Built data when carrying out PMI.
GO to A4
A4 CHECK FOR ADDITIONAL RCM (RESTRAINTS CONTROL MODULE) OR BCM (BODY CONTROL
MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Were any Diagnostic Trouble Codes (DTCs) retrieved from the RCM or BCM during self-test?
Yes If RCM Diagnostic Trouble Codes (DTCs) were retrieved, do not clear any Diagnostic
Trouble Codes (DTCs) until all Diagnostic Trouble Codes (DTCs) have been resolved.
If BCM Diagnostic Trouble Codes (DTCs) were retrieved, diagnose the BCM.
No CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs). PROVE OUT the
SRS. The repair is complete. RETURN the vehicle to the customer.
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Pinpoint Test - DTC: AJ
U3003:16 and U3003:17
NOTE: Diagnostic Trouble Codes (DTCs) 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 - RCM
The RCM continuously monitors the input voltage for correct operation. If the RCM detects input voltage below
9.0 volts while a fault is present, or below 6.0 volts, whether or not a fault is present, it stores DTC U3003:16 in
memory. If the RCM detects input voltage above 16 volts while a fault is present, or above 18 volts, regardless of
fault status, it stores DTC U3003:17 in memory. If the RCM sets DTC U3003:16 or U3003:17, it sends a message
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to the IPC to illuminate the airbag warning indicator.
Normal Operation - OCSM
The OCSM continuously monitors the input voltage for correct operation. If the OCSM detects input voltage below
8 volts, it stores DTC U3003:16 in memory. If the OCSM detects input voltage above 18 volts, it stores DTC
U3003:17 in memory. If the OCSM sets DTC U3003:16 or U3003:17, it sends a fault message to the RCM. The
RCM then sends a message to the IPC to illuminate the airbag warning indicator.

U3003:16 Battery Voltage: Circuit This DTC sets if the RCM detects voltage below 9 volts with certain
Voltage Below Threshold SRS faults present or below 6 volts, whether or not a SRS fault exists.
U3003:17 Battery Voltage: Circuit This DTC sets if the RCM detects voltage above 16 volts with certain
Voltage Above Threshold SRS faults present or above 18 volts without a SRS fault.
U3003:16 Battery Voltage: Circuit This DTC sets if the OCSM detects voltage below 8 volts.
U3003:17 Battery Voltage: Circuit This DTC sets if the OCSM detects voltage above 18 volts.
Voltage Above Threshold
Possible Sources

OCSM
RCM

PINPOINT TEST A : U3003:16 AND U3003:17

deployment.
NOTE: Install new components only when directed to do so in the pinpoint test.
A1 RETRIEVE ALL CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODES (CMDTCS) IN ALL
MODULES
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injury.
and Operation).
Ignition ON.
Using a diagnostic scan tool, retrieve ALL Continuous Memory Diagnostic Trouble Codes (CMDTCs).
Is DTC B1317, B1318, B1676, U3003:16 or U3003:17 present in one or more modules AND are any
charging system Diagnostic Trouble Codes (DTCs) present in the PCM?
Yes DIAGNOSE the charging system. Refer to the appropriate section in Group 414 for the
procedure.
No GO to A2
A2 TEST BATTERY CONDITION

Ignition OFF.
Yes If the battery passed the condition test but required a recharge, DIAGNOSE the charging
system. Refer to the appropriate section in Group 414 for the procedure. CLEAR all
Continuous Memory Diagnostic Trouble Codes (CMDTCs).
If the battery passed the condition test and did not require a recharge, GO to A3
CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A3 CHECK THE CHARGING SYSTEM VOLTAGE

Start the engine.
Measure the voltage of the battery.
For DTC U3003:17, turn off all accessories while measuring the battery voltage.
For DTC U3003:16, turn on headlights and HVAC fan on high while measuring the battery voltage.
Is the voltage between 13 and 15.2 volts?
Yes For DTC U3003:16, GO to A4

For DTC U3003:17, GO to A6
No DIAGNOSE the charging system. Refer to the appropriate section in Group 414 for the
procedure. CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs).
A4 CHECK FOR OPEN IGNITION CIRCUIT TO THE MODULE

Ignition OFF.
Depower the SRS. Refer to
Disconnect the module with the concern:
For the RCM, disconnect C310A and C310B.
For the OCSM, disconnect C3159.
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For the RCM, measure:

C310A-19 C2280A-4
For the OCSM, measure:

C3043-1 C2280C-23
Is the resistance less than 1 ohm?
Yes GO to A5
No REPAIR the circuit as necessary.
A5 CHECK FOR OPEN GROUND TO THE MODULE

For the RCM, measure:

RCM mounting bracket Ground
For the OCSM, measure:

C3043-6 Ground
Is the resistance less than 1 ohm?
Yes GO to A6
No For the RCM, VERIFY there is no corrosion between the RCM and the mounting surface.
VERIFY the fasteners are clean and tightened to specification with no corrosion. REPAIR
as necessary.
For the OCSM, REPAIR the circuit.

A6 CHECK FOR MODULE OPERATION

Ignition OFF.
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If not previously directed to do so, depower the SRS.
Disconnect the module with the concern:
For the RCM, disconnect C310A and C310B (if not previously disconnected).
For the OCSM, disconnect OCSM C3043 (if not previously disconnected).
Check for the following:
Connect the module with the concern:
For the RCM, connect C310A and C310B. Make sure the connector seats correctly and engages
the Connector Position Assurance (CPA) lever/lock.
For the OCSM, connect C3043. Make sure the connector seats correctly.
Repower the SRS.
this concern, DISCONTINUE this test and FOLLOW TSB instructions.
If no Technical Service Bulletins (TSBs) address this concern and DTC U3003:16 or
U3003:17 was present in the RCM, INSTALL a new RCM. REFER to
If no Technical Service Bulletins (TSBs) address this concern and DTC U3003:16 or
U3003:17 was present in the OCSM, INSTALL a new OCSM.
loose or corroded connector.

Pinpoint Test - DTC: AK
B0061:11, B0061:12, B0061:13, B0061:49 and B0061:64
The Belt Tension Sensor (BTS) operates in conjunction with the OCS. The OCS interprets a variable voltage signal provided by the Belt Tension Sensor (BTS) to
identify the possible presence of a child safety seat in the front passenger seat. The voltage output of the Belt Tension Sensor (BTS) is proportional to the
amount of tension applied to the sensor by the belt: no belt tension causes a low voltage (approximately 0.95 volt) to be output and high belt tension causes a
high voltage (approximately 3.8 volts) to be returned to the OCSM.
The OCSM monitors the Belt Tension Sensor (BTS) and related circuits for the following faults:

Unexpected voltage
Short to ground
Faulted Belt Tension Sensor (BTS) (part of RH front passenger safety belt buckle)
If a fault is detected, the OCSM stores DTC B0061:11, B0061:12, B0061:13, B0061:49 or B0061:64 in memory and sends a message to the RCM over the
HS-CAN2 indicating that an OCS fault is present. Upon receipt of this message, the RCM sets DTC B00A0:09 and sends a message to the IPC to illuminate the
airbag warning indicator.
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B0061:11 Passenger Seatbelt Tension A fault is indicated when the OCSM measures voltage below a predetermined threshold on the Belt Tension
Sensor: Circuit Short to Ground Sensor (BTS) signal circuit. An open Belt Tension Sensor (BTS) VREF circuit can also set this DTC.
B0061:12 Passenger Seatbelt Tension A fault is indicated when the OCSM measures voltage above a predetermined threshold on the Belt Tension
Sensor: Circuit Short to Battery Sensor (BTS) signal circuit. An open Belt Tension Sensor (BTS) return circuit can also set this DTC.
B0061:13 Passenger Seatbelt Tension A fault is indicated when the OCSM senses an open on either Belt Tension Sensor (BTS) circuit.
Sensor: Circuit Open
B0061:49 Passenger Seatbelt Tension A fault is indicated when the OCSM senses an internal fault on the Belt Tension Sensor (BTS) signal circuit.
Sensor: Internal Electronic Failure
B0061:64 Passenger Seatbelt Tension A fault is indicated when the passenger safety belt is unbuckled and the OCSM measures voltage on the Belt
Sensor: Signal Plausibility Failure Tension Sensor (BTS) signal circuit greater than the maximum voltage returned during normal sensor
operation.
Possible Sources

Belt Tension Sensor (BTS) (part of RH front passenger safety belt buckle)
OCSM
Inspect for a damaged passenger safety belt buckle or Belt Tension Sensor (BTS).
Inspect for a damaged passenger seat cushion wiring harness.
Inspect for a loose or damaged OCSM or Belt Tension Sensor (BTS) connector.
Inspect for a damaged OCSM.
PINPOINT TEST A : B0061:11, B0061:12, B0061:13, B0061:49 AND B0061:64
connector.
physically similar. Check the part number listed in the Ford parts catalog to make sure the correct component is being installed. If an incorrect SRS
component is installed, Diagnostic Trouble Codes (DTCs) may set.
A1 RETRIEVE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Was DTC B0061:11, B0061:12, B0061:13, B0061:49 or B0061:64 retrieved on-demand during self-test?
Yes This fault cannot be cleared until it is corrected and the DTC is no longer retrieved on-demand during the self-test.
For DTC B0061:49, INSTALL a new OCS sensor.
REFER to: Occupant Classification System (OCS) Sensor (501-20B Supplemental Restraint System, Removal and Installation).
GO to A13
No This is an intermittent fault when present as a Continuous Memory Diagnostic Trouble Code (CMDTC) only. GO to A12
A2 CHECK THE BELT TENSION SENSOR (BTS)
NOTE: This pinpoint test step attempts to change the fault reported by the OCSM by inducing a different fault condition. If the fault reported changes, this
indicates the OCSM is functioning correctly and is not the source of the fault.
Ignition OFF.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the Belt Tension Sensor (BTS) disconnected, an open circuit fault is normally
retrieved. The Belt Tension Sensor (BTS) shares a connector with the passenger safety belt buckle switch, and a passenger safety belt buckle switch circuit
fault will also be present in the RCM.
Yes GO to A3
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No INSTALL a new front passenger safety belt buckle.
GO to A13
A3 CHECK THE BELT TENSION SENSOR (BTS) CIRCUITS FOR A SHORT TO GROUND OR A SHORT TOGETHER
Ignition OFF.
Disconnect OCSM C3043.
Measure:

C3238-1 Ground
Measure:

C3238-1 C3238-2
Yes GO to A4
GO to A13
A4 CHECK THE BELT TENSION SENSOR (BTS) VREF CIRCUIT FOR AN OPEN
Measure:

C3043-5 C3238-2
Yes GO to A11
GO to A13
A5 CHECK THE BELT TENSION SENSOR (BTS) SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C3043-6 Ground

GO to A13
No GO to A6
A6 CHECK THE BELT TENSION SENSOR (BTS) GROUND CIRCUIT FOR AN OPEN
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Ignition OFF.
Depower the SRS.
Measure:

C3238-3 Ground
Yes GO to A10
GO to A13
NOTE: This pinpoint test step will attempt to change the fault reported by the OCSM by inducing a different fault condition. If the fault reported changes, this
indicates the OCSM is functioning correctly and is not the source of the fault.
Ignition OFF.
Depower the SRS.

C3238-1 C3238-3
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the Belt Tension Sensor (BTS) circuits shorted together, a short to ground fault is
normally retrieved. The Belt Tension Sensor (BTS) shares a connector with the passenger safety belt buckle switch, and a passenger safety belt buckle
switch circuit fault will also be present in the RCM.
Yes INSTALL a new front passenger safety belt buckle.

GO to A13
No GO to A8
A8 CHECK THE BELT TENSION SENSOR (BTS) SIGNAL CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C3238-1 C3043-6
Yes GO to A10
GO to A13
A9 CHECK THE BELT TENSION SENSOR (BTS) SIGNAL CIRCUIT FOR A SHORT TO THE BELT TENSION SENSOR (BTS) VREF CIRCUIT
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 accidental deployment.
Ignition OFF.
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Measure:

C3238-2 C3238-1
Yes GO to A10
GO to A13
A10 CHECK BELT TENSION SENSOR (BTS) VOLTAGE OUTPUT

Ignition OFF.
Depower the SRS.
Connect OCSM C3043.
Connect fused jumper wires:
Lead 1 Measurement / Lead 2

Action
C3238, pin 2, harness side C3238, pin 2, component side

Lead 1 Measurement / Lead 2
Action
C3238, pin 3, harness side C3238, pin 3, component side
Ignition ON.
Measure:

Ground
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C3238, pin 1, component side
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?
Yes REMOVE the fused jumper wires and GO to A11

No REMOVE the fused jumper wires and INSTALL a new front passenger safety belt buckle.
GO to A13
A11 CONFIRM THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) FAULT
NOTE: Make sure all OCS components, SRS electrical connectors and the RCM electrical connectors are connected before carrying out the self-test. If not,
Diagnostic Trouble Codes (DTCs) will be recorded.
Ignition OFF.
Inspect connector(s) (including any inline connectors) for pushed-out, loose or spread terminals and loose or frayed wire connections at terminals.
Connect OCSM C3043.
Connect Passenger Safety Belt Buckle C3238 (if previously disconnected).
If previously directed to disconnect Passenger Side Airbag (Inline) C219, depower the SRS.
Ignition ON.
FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new OCS sensor.
GO to A13
SRS components should only be installed when directed to do so in the pinpoint test. GO to A12

Ignition OFF.
Inspect connector(s) (including any inline connectors) for loose or spread terminals and loose or frayed wire connections at terminals.
Ignition ON.
Was DTC B0061:11, B0061:12, B0061:13, B0061:49 or B0061:64 retrieved on-demand during self-test?
Yes The fault condition is now present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved on-demand during
the self-test.
For DTC B0061:49, INSTALL a new OCS sensor.
GO to A13
No CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition
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frequently. ACTIVATE other system in the same wire harness. Do not install any new SRS components at this time. Only install SRS
components when directed to do so in the pinpoint test. REPAIR any intermittent concerns found. GO to A13
Ignition OFF.
Ignition ON.
Yes Do not clear any Diagnostic Trouble Codes (DTCs) until all Diagnostic Trouble Codes (DTCs) have been resolved.

Pinpoint Test - DTC: AL
B00C2:11 and B00C2:12
The Belt Tension Sensor (BTS) operates in conjunction with the OCS. The OCSM provides a reference voltage to
the Belt Tension Sensor (BTS), which changes as it passes through the sensor, based on how much tension is
applied to the safety belt and Belt Tension Sensor (BTS).
The OCSM monitors the Belt Tension Sensor (BTS) reference voltage circuit for a short to voltage or a short to
ground.
If a fault is detected, the OCSM stores DTC B00C2:11 or B00C2:12 in memory and sends a message to the
RCM over the HS-CAN2 indicating that an OCS fault is present. Upon receipt of this message, the RCM sets DTC
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B00A0:09 and sends a message to the IPC to illuminate the airbag warning indicator.

B00C2:11 Passenger Seat Occupant Classification A fault is indicated when the OCSM senses a short to
Sensor "C": Circuit Short to Ground ground on the Belt Tension Sensor (BTS) reference voltage
circuit.
B00C2:12 Passenger Seat Occupant Classification A fault is indicated when the OCSM senses a short to
Sensor "C": Circuit Short to Battery voltage on the Belt Tension Sensor (BTS) reference
voltage circuit.
Possible Sources

Belt Tension Sensor (BTS) (part of RH front passenger safety belt buckle)
OCSM
Inspect for a damaged passenger safety belt buckle or Belt Tension Sensor (BTS).
Inspect for a damaged passenger seat cushion wiring harness.
Inspect for a loose or damaged OCSM or Belt Tension Sensor (BTS) connector.
Inspect for a damaged OCSM.
PINPOINT TEST A : B00C2:11 AND B00C2:12

deployment.
A1 RETRIEVE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) DIAGNOSTIC TROUBLE
CODES (DTCS)
personal injury.
Ignition ON.
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Was DTC B00C2:11 or B00C2:12 retrieved on-demand during self-test?
on-demand during the self-test.
NOTE: This pinpoint test step attempts to change the fault reported by the OCSM by inducing a different
fault condition. If the fault reported changes, this indicates the OCSM is functioning correctly and is not the
Ignition OFF.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the Belt Tension Sensor (BTS)
disconnected, an open circuit fault is normally retrieved. The Belt Tension Sensor (BTS) shares a
connector with the passenger safety belt buckle switch, and a passenger safety belt buckle switch circuit
fault will also be present in the RCM.
Was DTC B00C2:11 retrieved on-demand during self-test?
Yes GO to A3
No INSTALL a new passenger safety belt buckle.
GO to A7
A3 CHECK THE BELT TENSION SENSOR (BTS) VREF CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C3238-2 Ground
Yes GO to A5
GO to A7
A4 CHECK THE BELT TENSION SENSOR (BTS) VREF CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
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Depower the SRS.
Ignition ON.
Measure:

C3238-2 Ground

GO to A7
No GO to A5
A5 CONFIRM THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) FAULT
NOTE: Make sure all OCS system components, restraint system sensor electrical connectors and the
RCM electrical connectors are connected before carrying out the self-test. If not, Diagnostic Trouble
Codes (DTCs) will be recorded.
Ignition OFF.
Connect OCSM C3043 (if previously disconnected).
Ignition ON.
Service Bulletins (TSBs) address this concern, INSTALL a new OCS sensor.
GO to A7
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Ignition OFF.
inspect connector(s) (including any inline connectors) for loose or spread terminals and loose or
frayed wire connections at terminals.
Ignition ON.
Using a diagnostic scan tool, perform OCSM self-test to retrieve Diagnostic Trouble Codes (DTCs).
Was DTC B00C2:11 or B00C2:12 retrieved on-demand during self-test?
Yes The fault condition is now present. This fault cannot be cleared until it is corrected and the
DTC is no longer retrieved on-demand during the 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 system in the same
wire harness. Do not install any new SRS components at this time. Only install SRS
components when directed to do so in the pinpoint test. REPAIR any intermittent concerns
found. GO to A7

Ignition OFF.
Ignition ON.
OCSM.
No CLEAR all RCM and OCSM Diagnostic Trouble Codes (DTCs). PROVE OUT the SRS.
The repair is complete. RETURN the vehicle to the customer.
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Pinpoint Test - DTC: AM
U0151:00
The OCSM uses information contained in messages from the RCM sent on the High Speed Controller Area

U0151:00 Lost Communication with Restraints Control This DTC sets if the OCSM does not receive an
Module: No Sub Type Information expected message from the RCM.
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Possible Sources
Network traffic
OCSM
RCM
personal injury.
and Operation).
Ignition ON.
Does the RCM pass the network test?

Yes GO to A2
No To diagnose no communication with the RCM,
and Testing).
A2 CHECK THE OCSM (OCCUPANT CLASSIFICATION SYSTEM MODULE) CONTINUOUS MEMORY

Using a diagnostic scan tool, clear OCSM Diagnostic Trouble Codes (DTCs).
Wait 10 seconds.
Yes GO to A3
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Yes
and Testing).
No GO to A4
Check the recorded Diagnostic Trouble Codes (DTCs) from the OCSM self-test.
Yes
and Testing).
No GO to A5
Ignition ON.
Is DTC U0151:00 set in the ABS module or in the BCM?
Service Bulletins (TSBs) address this concern, INSTALL a new OCS sensor.
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Pinpoint Test - DTC: AN, Convertible
B1405:11, B1405:12, B1405:13, B1405:1A
The RCM continuously monitors the driver upper side airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted driver upper side airbag
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Wiring
Connections
Driver upper side airbag
RCM

B1405:11 Driver Side Curtain Deployment A fault is indicated when the RCM senses a short to ground on
Control 1: Circuit Short to Ground either driver upper side airbag circuit for more than 6 seconds.
B1405:12 Driver Side Curtain Deployment A fault is indicated when the RCM senses a short to voltage on
Control 1: Circuit Short to Battery either driver upper side airbag circuit for more than 6 seconds.
B1405:13 Driver Side Curtain Deployment A fault is indicated when the RCM measures more than the
Control 1: Circuit Open desired resistance between the driver upper side airbag
B1405:1A Driver Side Curtain Deployment A fault is indicated when the RCM measures less than the
Control 1: Circuit Resistance Below desired resistance between the driver upper side airbag
Possible Sources

Driver upper side airbag
RCM

deployment.
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personal injury.
and Operation).
Ignition ON.
and Testing).
driver upper side airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
driver upper side airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).

IDENTIFICATION)
Yes GO to A12
No GO to A3
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While monitoring the DEPLOY_11_R PID, carry out the harness test of the driver upper side airbag
GO to A17
A4 CHECK THE DRIVER UPPER SIDE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC
Ignition OFF.
Depower the SRS.
Disconnect Driver Upper Side Airbag (Inline) C3206.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the driver upper side airbag

Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE DRIVER UPPER SIDE AIRBAG CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:

C3206-1 C3206-2
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Yes GO to A12
GO to A17
A6 CHECK THE DRIVER UPPER SIDE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-25 C3206-1
C310B-26 C3206-2
Yes GO to A7
GO to A17

C3206-1 C3206-2
Ignition ON.
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Ignition OFF.
Depower the SRS.
Ignition ON.
Yes GO to A11
No GO to A9
A9 CHECK THE DRIVER UPPER SIDE AIRBAG CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C3206-1 Ground
C3206-2 Ground
Yes GO to A12
GO to A17
A10 CHECK THE DRIVER UPPER SIDE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
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Ignition ON.
Measure:

C3206-1 Ground
C3206-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE DRIVER UPPER SIDE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Upper Side Airbag C3464 and make sure the Connector Position Assurance (CPA)
Connect Driver Upper Side Airbag (Inline) C3206.
Ignition ON.
Installation).

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GO to A17
If a concern is not found, INSTALL a new driver upper side airbag.
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Upper Side Airbag (Inline) C3206 (if previously disconnected).
Ignition ON.
GO to A17
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the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE DRIVER UPPER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE DRIVER UPPER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
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Ignition OFF.
Depower the SRS.
operation.
Inspect Driver Upper Side Airbag C3464 Connector Position Assurance (CPA) tab to verify that it
is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AO, Convertible
B1408:11, B1408:12, B1408:13, B1408:1A
The RCM continuously monitors the passenger upper side airbag circuits for the following faults:

Unexpected voltage
Short to ground
Faulted passenger upper side airbag
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Wiring
Connections
Passenger upper side airbag
RCM

B1408:11 Passenger Side Curtain Deployment A fault is indicated when the RCM senses a short to ground on
Control 1: Circuit Short to Ground either passenger upper side airbag circuit for more than 6
seconds.
B1408:12 Passenger Side Curtain Deployment A fault is indicated when the RCM senses a short to voltage
Control 1: Circuit Short to Battery on either passenger upper side airbag circuit for more than 6
seconds.
B1408:13 Passenger Side Curtain Deployment A fault is indicated when the RCM measures more than the
Control 1: Circuit Open desired resistance between the passenger upper side airbag
B1408:1A Passenger Side Curtain Deployment A fault is indicated when the RCM measures less than the
Control 1: Circuit Resistance Below desired resistance between the passenger upper side airbag
Possible Sources

Passenger upper side airbag
RCM

deployment.
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personal injury.
and Operation).
Ignition ON.
and Testing).
passenger upper side airbag Diagnostic Trouble Codes (DTCs).
Code (CMDTC) only.
and Testing).
passenger upper side airbag Continuous Memory Diagnostic Trouble Codes (CMDTCs).

IDENTIFICATION)
Yes GO to A12
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No GO to A3

While monitoring the DEPLOY_14_R PID, carry out the harness test of the passenger upper side airbag
GO to A17
A4 CHECK THE PASSENGER UPPER SIDE AIRBAG DEPLOYMENT CONTROL DTC (DIAGNOSTIC
Ignition OFF.
Depower the SRS.
Disconnect Passenger Upper Side Airbag (Inline) C219.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the passenger upper side
airbag disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A5
A5 CHECK FOR A SHORT BETWEEN THE PASSENGER UPPER SIDE AIRBAG CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:

C219-1 C219-2
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Yes GO to A12
GO to A17
A6 CHECK THE PASSENGER UPPER SIDE AIRBAG CIRCUITS FOR AN OPEN

Ignition OFF.
Depower the SRS.
Measure:

C310B-17 C219-1
C310B-18 C219-2
Yes GO to A7
GO to A17

C219-1 C219-2
Ignition ON.
airbag circuits shorted together, a low resistance fault is normally retrieved.
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Ignition OFF.
Depower the SRS.
Ignition ON.
airbag disconnected, an open circuit fault is normally retrieved.
Yes GO to A11
No GO to A9
A9 CHECK THE PASSENGER UPPER SIDE AIRBAG CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Depower the SRS.
Measure:

C219-1 Ground
C219-2 Ground
Yes GO to A12
GO to A17
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A10 CHECK THE PASSENGER UPPER SIDE AIRBAG CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C219-1 Ground
C219-2 Ground

GO to A17
No GO to A12
A11 CONFIRM THE PASSENGER UPPER SIDE AIRBAG FAULT
Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Upper Side Airbag C3465 and make sure the Connector Position Assurance
(CPA) tabs are not broken and the clip is not damaged.
Connect Passenger Upper Side Airbag (Inline) C219.
Ignition ON.
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Yes REMOVE and INSPECT the passenger seat backrest harness for damage.
Installation).

GO to A17
If a concern is not found, INSTALL a new passenger upper side airbag.
Installation).
GO to A17
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Upper Side Airbag (Inline) C219 (if previously disconnected).
Ignition ON.
GO to A17
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the PID.
No DEPOWER the SRS.
GO to A17
A14 CHECK THE PASSENGER UPPER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
harness frequently.

GO to A17
A15 CHECK THE PASSENGER UPPER SIDE AIRBAG DEPLOYMENT CONTROL CIRCUITS FOR AN
Ignition OFF.
Depower the SRS.
Ignition ON.
harness frequently.

GO to A17
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Ignition OFF.
Depower the SRS.
operation.
Inspect Passenger Upper Side Airbag C3465 Connector Position Assurance (CPA) tab to verify
that it is correctly seated and free of damage.

GO to A17

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AP, Convertible
B1414:11 and B1414:93
The RCM monitors the driver door side impact sensor circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted driver door side impact sensor
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B1414:11 Driver Side Restraints Sensor A fault is indicated when the RCM senses a short to ground on the
1: Circuit Short to Ground driver door side impact sensor feed circuit.
B1414:93 Driver Side Restraints Sensor A fault is indicated when the RCM senses a faulted driver door side
1: No Operation impact sensor, a short to voltage on the sensor feed circuit or an open
feed or return circuit.
Possible Causes

Driver door side impact sensor
RCM


deployment.
personal injury.
and Operation).
Ignition ON.
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and Testing).
and Testing).
Ignition OFF.
Depower the SRS.
Ignition ON.
Yes INSTALL a new driver door side impact sensor.

GO to A10
No GO to A3
A3 CHECK THE DRIVER DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT TO GROUND
AND A SHORT BETWEEN SENSOR CIRCUITS
Ignition OFF.
Depower the SRS.
Measure:
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C567-1 Ground
Measure:

C567-1 C567-2
Yes GO to A8
GO to A10
A4 CHECK THE DRIVER DOOR SIDE IMPACT SENSOR AND RCM (RESTRAINTS CONTROL
Ignition OFF.
Depower the SRS.
Inspect the Driver Front Door Side Impact Sensor electrical connector C567 to make sure it is fully
Ignition ON.
Yes GO to A5
A5 CHECK THE DRIVER DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT TO VOLTAGE
(NO OPERATION INDICATED)
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:
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C567-1 Ground

GO to A10
No GO to A6
A6 CHECK THE DRIVER DOOR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-44 C567-1
C310B-43 C567-2
Yes GO to A7
GO to A10

C567-1 C567-2
Ignition ON.
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Yes REMOVE the fused jumper wire and INSTALL a new driver door side impact sensor.
GO to A10
Ignition OFF.
Depower the SRS.
operation.
Connect Driver Door Side Impact Sensor C567.
Ignition ON.

GO to A10

Ignition OFF.
Depower the SRS.
Disconnect Driver Door Side Impact Sensor C567.
Inspect:
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Connect Driver Door Side Impact Sensor C567.
Ignition ON.

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AQ, Convertible
B1418:11 and B1418:93
The RCM monitors the passenger door side impact sensor circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted passenger door side impact sensor
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B1418:11 Passenger Side Restraints A fault is indicated when the RCM senses a short to ground on the
Sensor 1: Circuit Short to passenger door side impact sensor feed circuit.
Ground
B1418:93 Passenger Side Restraints A fault is indicated when the RCM senses a faulted passenger door
Sensor 1: No Operation side impact sensor, a short to voltage on the sensor feed circuit or an
open feed or return circuit.
Possible Causes

Passenger door side impact sensor
RCM


deployment.
personal injury.
and Operation).
Ignition ON.
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and Testing).
and Testing).
Ignition OFF.
Depower the SRS.
Ignition ON.
Yes INSTALL a new passenger door side impact sensor.

GO to A10
No GO to A3
A3 CHECK THE PASSENGER DOOR SIDE IMPACT SENSOR FEED CIRCUITS FOR A SHORT TO
GROUND OR A SHORT TOGETHER
Ignition OFF.
Depower the SRS.
Measure:
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C644-1 Ground
Measure:

C644-1 C644-2
Yes GO to A8
GO to A10
A4 CHECK THE PASSENGER DOOR SIDE IMPACT SENSOR AND RCM (RESTRAINTS CONTROL
Ignition OFF.
Depower the SRS.
Inspect the Passenger Front Door Side Impact Sensor electrical connector C644 to make sure it is fully
Ignition ON.
Yes GO to A5
A5 CHECK THE PASSENGER DOOR SIDE IMPACT SENSOR FEED CIRCUIT FOR A SHORT TO
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:
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C644-1 Ground

GO to A10
No GO to A6
A6 CHECK THE PASSENGER DOOR SIDE IMPACT SENSOR CIRCUITS FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C310B-45 C644-1
C310B-46 C644-2
Yes GO to A7
GO to A10

C644-1 C644-2
Ignition ON.
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Yes REMOVE the fused jumper wire and INSTALL a new passenger door side impact sensor.
GO to A10
Ignition OFF.
Depower the SRS.
operation.
Connect Passenger Door Side Impact Sensor C644.
Ignition ON.

GO to A10

Ignition OFF.
Depower the SRS.
Disconnect Passenger Door Side Impact Sensor C644.
Inspect:
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Connect Passenger Door Side Impact Sensor C644.
Ignition ON.

Ignition OFF.
Ignition ON.
OCSM.
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Pinpoint Test - DTC: AR
B00D5:11, B00D5:12 and B00D5:13
The RCM briefly activates the PAD indicator to prove-out and verify correct functional operation of the PAD
indicator to the occupants.
The RCM monitors the PAD indicator power supply and LED circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Faulted PAD indicator
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If a fault is detected, the RCM stores DTC B00D5:11, B00D5:12 or B00D5:13 in memory and sends a message
to the IPC to illuminate the airbag warning indicator.

B00D5:11 Restraint System Passenger A fault is indicated when the RCM senses a short to ground on the
Disable Indicator: Circuit Short PAD indicator LED circuit.
to Ground
B00D5:12 Restraint System Passenger A fault is indicated when the RCM senses a short to voltage on the
Disable Indicator: Circuit Short PAD indicator LED circuit.
to Battery
B00D5:13 Restraint System Passenger A fault is indicated when the RCM senses an open on the PAD
Disable Indicator: Circuit Open indicator LED circuit. An open on the ignition voltage supply circuit
to the PAD indicator also sets this DTC.
Possible Causes

PAD indicator
RCM
PINPOINT TEST A : B00D5:11, B00D5:12 AND B00D5:13

deployment.
personal injury.
and Operation).
Ignition ON.
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Was DTC B00D5:11, B00D5:12 or B00D5:13 retrieved on-demand during self-test?
A2 CHECK THE PAD (PASSENGER AIRBAG DEACTIVATION) INDICATOR 'OFF' LED (LIGHT
EMITTING DIODE) CONTROL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect PAD Indicator C9801.
Measure:

C9801-2 Ground
Yes GO to A9
No GO to A3

Depower the SRS.
Measure:

C9801-2 Ground
Yes GO to A9
GO to A11
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EMITTING DIODE) CIRCUIT FOR AN OPEN
Ignition OFF.
Depower the SRS.
Measure:

C9801-2 C310A-20
Yes GO to A5
GO to A11
A5 CHECK THE IGNITION CIRCUIT AT THE PAD (PASSENGER AIRBAG DEACTIVATION) INDICATOR
FOR VOLTAGE
Ignition ON.
Measure:

C9801-3 Ground
Yes GO to A6
No VERIFY BCM fuse 19 (5A) 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. GO to A11
A6 CHECK THE PAD (PASSENGER AIRBAG DEACTIVATION) INDICATOR

Ignition OFF.
Connect PAD Indicator C9801.

C310A-20 Ground
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Ignition ON.
Monitor the PAD indicator.
Does the PAD indicator LED illuminate?

No REMOVE the fused jumper wire, INSTALL a new PAD indicator and GO to A11
EMITTING DIODE) CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Depower the SRS.
Ignition ON.
Measure:

C9801-2 Ground

GO to A11
No GO to A8
A8 CHECK THE RCM (RESTRAINTS CONTROL MODULE)
Ignition OFF.
Depower the SRS.
Ignition ON.
DIAGNOSTIC TIP: When viewing Diagnostic Trouble Codes (DTCs) with the PAD indicator disconnected,
an open circuit fault is normally retrieved.
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Did the on-demand DTC change from B00D5:12 to B00D5:13?
Yes INSTALL a new PAD indicator. GO to A11

No GO to A9
Ignition OFF.
Depower the SRS.
operation.
Connect PAD Indicator C9801.
Ignition ON.
GO to A11

Ignition OFF.
Connect PAD Indicator C9801 (if previously disconnected).
operation.
Ignition ON.
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Was DTC B00D5:11, B00D5:12 or B00D5:13 retrieved on-demand during self-test?
No CHECK for causes of intermittent open, short to ground or short to voltage on the PAD
indicator circuit. 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

Ignition OFF.
Ignition ON.
OCSM.
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Clockspring Adjustment
Adhesive Tape
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 serious personal
NOTE: Typical clockspring shown, others similar.
NOTE: This procedure is not for use on vehicles with adaptive steering.
1. 1. NOTICE: Do not over-rotate the clockspring rotor. The internal ribbon wire is connected to
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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.
Turn the clockspring rotor counterclockwise, carefully feeling for resistance to turning.
2. Turn the clockspring rotor clockwise so the electrical connector is in the 12 o'clock position.
3. NOTE: After final positioning, do not allow the clockspring rotor to rotate from this position.
Turn the clockspring rotor clockwise through 3 complete turns ending with the clockspring rotor
electrical connector in the 12 o'clock position.
2. Use the General Equipment: Adhesive Tape

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Inspection and Repair after a Supplemental Restraint System (SRS) Deployment
Inspection
NOTE: Deployable devices such as airbags, pretensioners and inflatable belt inflators, 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.
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 RCM has DTC 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 of all impact sensors and
installation of new impact sensors and the removal and installation of a new RCM. Diagnostic Trouble
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Codes (DTCs) must be cleared from all required modules after repairs are carried out.
2. NOTE: After installation of new OCS components, use a diagnostic scan tool to carry out the OCS Reset
procedure as instructed in the workshop manual.
When a vehicle has been involved in a collision and the OCSM has DTC B1193:00 stored in memory, the
repair of the OCS is to include the following procedures for the specified system:
3. For a weight sensor bolt-type OCS , inspect the passenger side floorpan for damage and repair as
necessary. Install a new seat track with OCS weight sensor bolts. The DTC must be cleared from
the OCSM before carrying out OCS Reset. Do not install a new OCSM unless DTC B1193:00
cannot be cleared.
For a bladder-type OCS , inspect for damage and repair as necessary. If installation of an OCS
component is required, an OCS service kit must be installed.
4. 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.
5. When the driver airbag has deployed, install a new steering wheel, clockspring and steering column.
6. 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.
7. New second row safety belt systems (including retractors, buckles and inflators) must be installed if the
vehicle is involved in a collision that results in deployment of the rear inflatable safety belt system.
8. Inspect the entire vehicle for damage, including the following components:
9. Steering column lower shaft (verify the length is correct)

Steering column (deployable column if equipped)
Instrument panel knee bolsters and mounting points
Safety Canopy® and mounting points
Instrument panel braces and brackets
Instrument panel and mounting points
Seats and seat mounting points
Safety belts, safety belt buckles, safety belt retractors and safety belt anchors.
SRS wiring, wiring harnesses and connectors
10. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
11. Inspect the fuel system for damage or leaks. Repair the system and install new components as necessary.
12. Connect a diagnostic scan tool and view the BCM CRASH PID.
If the BCM CRASH PID is present and reads 'Yes', use the diagnostic scan tool to carry out the
BCM Crash Status Reset under "Electrical - Service Functions".
If the BCM CRASH PID reads 'No' or is not present, complete any necessary repairs before
returning the vehicle to the customer.
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Pyrotechnic Device Disposal
Disposal
Disposal of Deployable Devices and Pyrotechnic Devices That Are Undeployed-Inoperative
NOTE: All inoperative airbags, safety belt pretensioners and inflatable safety belt inflators have been placed on
the Mandatory Return List. Treat all discolored or damaged airbags the same as any inoperative live airbag
being returned.
1. Depower the SRS

2. Remove the undeployed/inoperative device. Refer to the appropriate procedure in this section or in the
safety belt system section.
3. NOTE: When installing a new airbag or inflatable safety belt inflator, a prepaid return postcard is
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provided with the replacement part. The serial number for the new part and the VIN must be recorded
and sent to Ford Motor Company.
If installing a new airbag, or inflatable safety belt inflator, record the necessary information and return the
inoperative airbag to Ford Motor Company.
Disposal of Deployable Devices and Pyrotechnic Devices That Are Deployed
4. Depower the SRS.

5. Remove the deployed device. Refer to the appropriate procedure in this section or in the safety belt
system section.
6. NOTE: If a dual stage driver or passenger airbag has deployed due to a crash event, the airbag requires
manual deployment to make sure both stages and the active canister vent (if equipped) have deployed
before scrapping the vehicle or disposing of the airbag.
Determine if the vehicle is equipped with dual stage driver or passenger airbags.
7. REFER to: Disposal of Deployable Devices and Pyrotechnic Devices That Require Manual Deployment in
this procedure.
8. 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
NOTE: 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.
9. To determine the deployable devices a vehicle is equipped with:

10. 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.
11. Driver airbag

Inflatable safety belt inflators
Knee airbag
Passenger airbag
Seat side airbag
Safety Canopy®
Side air curtain
12. To determine the pyrotechnic devices a vehicle is equipped with:

13. 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.
14. Inflatable safety belt inflators

Safety belt buckle pretensioners
Safety belt retractor pretensioners
Safety belt anchor pretensioners
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Adaptive load-limiting retractors
15. NOTE: If a dual stage driver or passenger airbag has deployed due to a crash event, the airbag requires
manual deployment to make sure both stages and the active canister vent (if equipped) have deployed
before scrapping the vehicle or disposing of the airbag.
To determine if a vehicle is equipped with dual stage driver or passenger airbags:

16. If a dual stage driver or passenger airbag has deployed due to a crash event, the airbag requires manual
deployment to make sure both stages and the active canister vent have deployed before scrapping the
vehicle or disposing of the airbag. Refer to Driver, Passenger, Knee and Seat Side Airbags - Remote
Deployment in this procedure.
Driver, Passenger, Knee and Seat Side Airbags - Remote Deployment
NOTE: For airbags with multiple loops, deploy all of the loops on the airbag.
NOTE: Some driver and passenger front airbags have 2 deployment stages and an active canister vent. After a
collision it is possible that Stage 1 has deployed and Stage 2 and the active canister vent have not. If a front
airbag has deployed, it is mandatory the front airbag be remotely deployed using the appropriate airbag
disposal procedure.
NOTE: A typical airbag disposal is shown that is similar for all vehicles.
17. NOTE: The tires must be of sufficient size to accommodate the airbag.
Obtain a tire and wheel assembly and 4 additional 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.
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18. Depower the SRS
19. Remove the airbag. Refer to the appropriate procedure in this section.
20. If the airbag does not have a hard-wired pigtail, cut each of the airbag wires near the electrical connector
that connects to the vehicle wire harness.
21. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires.
22. NOTE: Typical driver airbag with 2 loops shown, other airbags with multiple loops or multiple features
(canister vent, active tether) similar.
For airbags with multiple loops, twist together a wire from each loop then repeat for the remaining wires
from each loop.
23. Make a jumper harness to deploy the airbag module by obtaining 2 wires (20 gauge minimum) at
least 9.14 m (30 ft).
At one end of the jumper harness, connect the wires together.
24. Using the end of the jumper harness where the wires are not connected together, attach each wire of the
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jumper harness to each wire of the airbag or to the twisted-together wires if multiple loops. Use tape or
other insulating material to make sure the leads do not make contact with each other.
25. NOTE: Make sure the airbag connections are maintained.
For driver airbags, with the stack of tires upright and the wheel on the bottom, carefully place the driver
airbag, with the trim cover facing up, on the wheel.
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For passenger, knee and seat side airbags, tip the stack of tires on its side.
Place the airbag inside the center tire, making sure that there are 2 tires beneath the tire containing
the airbag and 2 tires (including the tire and wheel assembly) above the tire containing the airbag.
Place the tire stack upright, with the wheel on top.
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27. Remain at least 9.14 m (30 ft) away from the airbag.
28. From the end of the jumper harness that is not connected to the airbag, disconnect the 2 wires of the
jumper harness from each other.
29. Deploy the airbag by touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt
battery.
30. To allow for cooling, wait at least 10 minutes before approaching the deployed airbag.
31. Dispose of the deployed airbag in the same manner as any other part to be scrapped.
Safety Belt Anchor-Buckle-Retractor Pretensioners, Adaptive Load Limiting Retractors and Safety Belt
Inflators - Remote Deployment
32. NOTE: The tires must be of sufficient size to accommodate the safety belt anchor, buckle,
retractor or inflator.
Obtain a tire and wheel assembly and 4 additional 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.
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33. Depower the SRS.
34. Remove the safety belt anchor, buckle, retractor or inflator. Refer to the appropriate procedure in the
safety belt system section.
35. If the safety belt anchor, buckle, retractor or inflator does not have a hard-wired pigtail, cut each of the
wires near the electrical connector that connects to the vehicle wire harness.
36. When deploying a safety belt buckle pretensioner, install a nut and bolt of sufficient length and the same
diameter used to retain it to the seat.
38. Make a jumper harness to deploy the safety belt anchor, buckle, retractor or inflator by obtaining 2
wires (20 gauge minimum) at least 9.14 m (30 ft).
39. NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners, buckle
pretensioners, load-limiting retractors and safety belt inflators similar.
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 safety belt anchor, buckle, retractor or inflator. Use tape or other
insulating material to make sure the leads do not make contact with each other.
Tip the stack of tires on its side.

Place the safety belt anchor, buckle, retractor or inflator inside the center tire, making sure that
there are 2 tires beneath the tire containing the airbag and 2 tires (including the tire and wheel
assembly) above the tire containing the airbag.
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Place the tire stack upright, with the wheel on top.
41. Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle, retractor or inflator.
42. From the end of the jumper harness that is not connected to the safety belt anchor, buckle, retractor or
inflator, disconnect the 2 wires of the jumper harness from each other.
43. Deploy the safety belt anchor, buckle, retractor or inflator by touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
44. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor, buckle,
retractor or inflator.
45. Dispose of the deployed safety belt anchor, buckle, retractor or inflator in the same manner as any other
part to be scrapped.
Safety Belt Anchor-Buckle-Retractor Pretensioners, and Adaptive Load Limiting Retractors - In-Vehicle
Deployment
46. Depower the SRS

47. Access the safety belt anchor, buckle or retractor electrical connectors. Refer to the appropriate procedure
in the safety belt system section.
48. Cut each of the safety belt anchor, buckle or retractor wires, leaving at least 101.6 mm (4 in) to work with.
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50. Make a jumper harness to deploy the safety belt anchor, buckle or retractor by obtaining 2 wires (20
gauge minimum) at least 9.14 m (30 ft).
51. NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners, buckle
pretensioners and load-limiting retractors are similar.
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 safety belt anchor, buckle or retractor. Use tape or other insulating
material to make sure the leads do not make contact with each other.
52. Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle or retractor.
53. Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle, retractor or inflator.
54. From the end of the jumper harness that is not connected to the safety belt anchor, buckle or retractor,
disconnect the 2 wires of the jumper harness from each other.
55. Deploy the safety belt anchor, buckle or retractor by touching the ends of the 2 wires of the jumper harness
to the terminals of a 12-volt battery.
56. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor, buckle or
retractor.
57. Dispose of the deployed safety belt anchor, buckle or retractor in the same manner as any other part to be
scrapped.
Safety Canopy® and Side Air Curtains - In-Vehicle Deployment
NOTE: The Safety Canopy® deployment for a scrapped vehicle occurs in its installed position in the vehicle.
NOTE: A typical Safety Canopy® disposal is shown.
58. Depower the SRS

59. Access the Safety Canopy® /side air curtain electrical connectors. For additional information, refer to the
appropriate procedure in this section.
60. Cut each of the Safety Canopy® /side air curtain wires, leaving at least 101.6 mm (4 in) to work with.
62. NOTE: Typical Safety Canopy® /side air curtain with 2 loops shown, other Safety Canopy® /side air
curtains with 2 loops are similar.
For Safety Canopy® /side air curtains with multiple loops, twist together a wire from each loop then repeat
for the remaining wires from each loop.
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63. Make a jumper harness to deploy the safety belt anchor, buckle or retractor by obtaining 2 wires (20
gauge minimum) at least 9.14 m (30 ft).
jumper harness to each wire of the Safety Canopy® /side air curtain or to the twisted-together wires if
multiple loops. Use tape or other insulating material to make sure the leads do not make contact with each
other.
65. From the end of the jumper harness that is not connected to the Safety Canopy® /side air curtain,
disconnect the 2 wires of the jumper harness from each other.
66. Deploy the Safety Canopy® /side air curtain by touching the ends of the 2 wires of the jumper harness to
the terminals of a 12-volt battery.
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67. To allow for cooling, wait at least 10 minutes before approaching the deployed Safety Canopy® /side air
curtain.
68. Dispose of the deployed Safety Canopy® /side air curtain in the same manner as any other part to be
scrapped.
Deployable Steering Column - In-Vehicle Deployment
69. Depower the SRS

70. 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.
71. NOTE: If the deployable steering column does not have a hard-wired pigtail, 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.
73. Make a jumper harness to deploy the deployable steering column by obtaining 2 wires (20 gauge
minimum) at least 9.14 m (30 ft).
jumper harness to each wire of the deployable steering column. Use tape or other insulating material to
make sure the leads do not make contact with each other.
75. Remain at least 9.14 m (30 ft) away from the deployable steering column.
76. From the end of the jumper harness that is not connected to the deployable steering column, disconnect
the 2 wires of the jumper harness from each other.
77. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to the
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terminals of a 12-volt battery.
78. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column.
79. Dispose of the deployed steering column in the same manner as any other part to be scrapped.

Supplemental Restraint System (SRS) Depowering
Depower
WARNING: Incorrect repair techniques or actions can cause an accidental Supplemental Restraint
System (SRS) deployment. Never compromise or depart from these instructions. Failure to precisely
follow all instructions could result in serious personal injury from an accidental deployment.
injury.
2. Determine if a SRS fault is present. Turn the ignition OFF and wait 10 seconds, then turn the ignition ON
and monitor the airbag warning indicator. The airbag warning indicator illuminates continuously for
approximately 6 seconds and then turns off. Continue to monitor the airbag warning indicator for
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approximately 30 seconds as this is the time required for the RCM to complete testing of the SRS.
3. If a SRS fault is present the airbag warning indicator either fails to light, remains lit continuously or
repairs.
If after the ignition has been turned ON for 30 seconds the airbag warning indicator remains unlit
No SRS Fault Present (with ignition ON, airbag warning indicator stays off after prove out)
4. 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 one minute before continuing vehicle service.
SRS Fault Present
5. Turn the ignition OFF.
6. Remove the RCM fuse. Refer to Wiring Diagram Cell 11/Section 700-01 for fuse and relay information.
7. Turn the ignition ON.
8. Using a diagnostic scan tool, carry out a Network Test. Verify that the RCM does not respond to the
Network Test. If the RCM passes the Network Test, remove the correct RCM fuse and repeat the Network
Test to verify before proceeding.
9. Turn the ignition OFF.

11. Wait at least one minute before continuing vehicle service.

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Supplemental Restraint System (SRS) Repowering
Repower
System (SRS) deployment. Never compromise or depart from these instructions. Failure to precisely
follow all instructions could result in serious personal injury from an accidental deployment.
injury.
No SRS Fault Present At Beginning of Repair
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approximately 30 seconds as this is the time required for the RCM to complete testing of the SRS.
3. If a SRS fault is present, the airbag warning indicator either fails to light, remains lit continuously or
repairs.
SRS Fault Present At Beginning of Repair
4. Verify the ignition is OFF.
5. Install the RCM fuse. Refer to Wiring Diagram Cell 11/Section 700-01 for fuse and relay information.
6. Connect the battery.

7. Sit in the driver seat in an upright position. Make sure no objects are between you and any pyrotechnic
device. Move the driver seat to the rearmost position to maintain the maximum possible distance from the
driver airbag.
8. Turn the ignition from OFF to ON.
9. Prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF. Wait 10 seconds,
continuously for approximately 6 seconds and then turns off. Continue to monitor the airbag warning
indicator for approximately 30 seconds, as this is the time required for the RCM to complete testing of the
SRS.
10. If a SRS fault is present, the airbag warning indicator either fails to light, remains lit continuously or
repairs.
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Clockspring
Removal
WARNING: The following procedure prescribes critical repair steps required for correct restraint
system operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions
may result in incorrect operation of the restraint system and increases the risk of serious personal injury
NOTE: Removal steps in this procedure may contain installation details .
1. NOTE: Follow the unique instructions or graphic for this step in installation.
Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation).
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2. Refer to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3. Remove the screws and the clockspring.

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Installation
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.
2. NOTE: This step is only necessary if adjustment is required.
Adjust the clockspring.

Refer to: Clockspring Adjustment (501-20B Supplemental Restraint System, General Procedures).
3. NOTE: To install, remove the anti-rotation key from a new clockspring after installing the steering wheel.
Install the steering wheel.

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B-Pillar Side Impact Sensor
Removal
1. Depower the SRS.

2. Remove the load space trim panel.

Refer to: Loadspace Trim Panel - Convertible (501-05 Interior Trim and Ornamentation, Removal
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and Installation).
Installation).
3. 1. Disconnect the electrical connector.

2. Remove the bolt.
3. Remove the side impact sensor.
Installation
1. NOTE: The impact sensor mating surfaces must be smooth and allow for a flush attachment to each
other.

2. Repower the SRS.
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Driver Airbag
Removal
1. Depower the SRS.

2. At the side of the steering wheel cover, locate the hole and insert a 3 mm (0.125 inch) Allen key.
3. NOTE: The driver airbag has been removed for clarity.

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Angle the inserted end of the Allen key up and toward the front of the vehicle for ideal contact with the
spring clip.
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4. 1. Push in on the steering wheel spring clip to release the driver airbag retainer.
2. Pull the driver airbag out and separate it from the steering wheel.
5. At the side of the steering wheel cover, locate the hole and insert a 3 mm (0.125 inch) Allen key.
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6. NOTE: The driver airbag has been removed for clarity.
Angle the inserted end of the Allen key up and toward the front of the vehicle for ideal contact with the
spring clip.
7. 1. Push in on the steering wheel spring clip to release the driver airbag retainer.
2. Pull the driver airbag out and separate it from the steering wheel.
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8. Disconnect the 3 driver airbag electrical connectors.
Installation
System deployment. Make sure the restraint system is depowered before reconnecting the component.
Refer to the Supplemental Restraint System depowering General Procedure in section 501-20B. Failure to
precisely follow depowering instructions could result in serious personal injury from an accidental
deployment.
1. Connect the 3 driver airbag electrical connectors.

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2. Align the driver airbag to the steering wheel and push in, engaging the driver airbag retainers to the spring
clips.
3. Repower the SRS.


Driver Knee Airbag
Removal
NOTE: LH drive shown, RH drive similar except where called out.
All vehicles
1. Depower the SRS.
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2. Release the clips and remove LH instrument panel trim panel.
3. 1. Remove the screw.

2. Release the clips and detach the lighting switch trim panel.
3. Disconnect the electrical connector and remove the lighting switch trim panel.
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4. 1. Remove the screws.
2. Detach the trim panel.
3. Disconnect the electrical connector and remove the trim panel.
5. 1. Detach the ambient air temp grille panel.

3. Detach the tether and remove the ambient air temp grille panel.
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6. 1. From under the instrument panel, remove the nuts.
3. Disengage the clips and separate the driver knee airbag from the instrument panel.
Left hand drive vehicles
7. Detach and disconnect the electrical connector and remove the driver knee airbag.
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Right hand drive vehicles
8. Detach the driver knee airbag wire harness pin-type retainer.
9. Detach and disconnect the electrical connector and remove the driver knee airbag.
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Installation
deployment.
2. Repower the SRS.


Front Door Side Impact Sensor
Removal
1. Depower the SRS.


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3. Remove the side impact sensor.
Installation
1. NOTE: The impact sensor mating surfaces must be smooth and allow for a flush attachment to each
other.
2. Repower the SRS.

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Front Impact Severity Sensor
Removal
WARNING: The following procedure prescribes critical repair steps required for correct restraint system
operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions may result in
incorrect operation of the restraint system and increases the risk of serious personal injury or death in a crash.
1. Depower the SRS.

Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General
Procedures).
2. Remove the retainers and the radiator upper air deflector.
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2. Remove the nut.
3. Remove the front impact severity sensor.
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Installation
1. NOTE: The impact sensor mating surfaces must be smooth and allow for a flush attachment to each other.
2. Repower the SRS.

Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General
Procedures).

Occupant Classification System (OCS) Sensor
Removal
NOTICE: To prevent system failure, carry out the OCS reset when a front passenger seat cushion is
disassembled, a new trim cover is installed or an OCS service kit is installed. Use a scan tool to carry out
the OCS reset command.
NOTICE: The cushion heater mat on a front outboard passenger seat is not serviced separately. If a new
cushion heater mat is needed on the front passenger seat, install an OCS service kit equipped with a
heater mat. Failure to follow this instruction may result in incorrect operation of the OCS.
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NOTE: OCS components (seat cushion foam pad, bladder with 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
OCSM) must be installed as an assembly.
NOTE: LH drive passenger seat shown, RH drive passenger seat similar.
1. Remove the front passenger seat.

2. Remove the clip and the recline handle.
3. Remove the 2 cushion side shield screws.

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4. 1. Pull the rear of the cushion side shield out.
2. Firmly grasp the cushion side shield, lift up and out, separating the cushion side shield from the
recliner bracket.
3. If equipped with a manual seat track, from underneath, squeeze the retainers together and pull out
on the cushion side shield.
4. Slide the cushion side shield forward and for a manual seat track, remove the cushion side shield.
5. If equipped with a power seat track, disconnect the seat control switch electrical connector and remove the
cushion side shield.
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6. Detach the 2 electrical connector pin-type retainers and position aside.
7. Detach the 2 backrest cover straps and position the backrest cover aside.
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8. Detach the 2 cushion cover J-clips and position the cushion cover aside.
9. NOTICE: Using excessive force when bending the bracket tab can damage the OCS sensor
housing.
NOTE: Follow the unique instructions or graphic for this step in the installation.
Disconnect the electrical connector, bend the bracket tab away and slide the OCS sensor off the bracket.
10. 1. On both sides.
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Detach the cushion cover J-clips.
2. Detach the cushion cover J-clip.
11. If equipped with OE (original equipment) OCS, remove the cushion foam pad and cover.
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12. NOTE: Typical OE OCS shown, service kit similar.
Remove the 2 pin-type retainers.
13. NOTE: Note the location of the OCS hose as it passes through the seat springs for proper installation.
Route out the OCS hose and sensor from between the seat cushion support wires.
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14. NOTICE: Use care when separating the seat cushion from the hook-and-arrow or the hook may be
torn from the seat cushion foam pad.
NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strips or
the hook-and-loop strips may be torn from the seat cushion foam pad.
Remove the seat cushion cover.

1. Invert the seat cushion cover.
2. Release hook-and-loop strips.
3. Release the hook and arrows.
Installation
1. NOTICE: Inspect the OCS bladder, seat cushion pan and support assembly for any foreign objects
before installing the OCS to the seat cushion pan. Remove any foreign objects. Failure to follow
these instructions may result in incorrect operation of the OCS and may cause system failure.
NOTICE: Do not trap the pressure sensor hose incorrectly over the seat's suspension or spring.
Route the hose so that it lays in a natural bend, and is not twisted due to being forced into an
unnatural position. Failure to follow these instructions may result in component damage and/or
system failure.
2. Bend the OCS sensor bracket tab back.
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3. Install the front passenger seat. Do not prove out the SRS at this time.
reset.
process.
repairs.
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Passenger Airbag
Removal
WARNING: The following procedure prescribes critical repair steps required for correct supplemental
restraint system operation during a crash. Follow all notes and steps carefully. Failure to follow step
instructions may result in incorrect operation of the supplemental restraint system and increases the risk
of serious personal injury or death in a crash.
NOTE: LH drive shown, RH drive similar.
1. Depower the SRS.

2. Remove the instrument panel upper section.
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Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and
Installation).
3. NOTE: RH side shown, LH similar.
On both sides.
Remove the screws and the demister duct.
4. Remove the screws and the air conditioning duct.

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5. Remove the screws and brackets.
6. 1. Pull the passenger airbag deployment chute away from the passenger airbag.
2. Rotate the passenger airbag out of the deployment chute and disengage the 4 passenger airbag
retainers.
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7. Continue to rotate the passenger airbag and remove it from the deployment chute.
Installation
deployment.
1. WARNING: Before installing the passenger air bag module assembly:
Inspect the passenger air bag module and instrument panel/deployment chute cavity for any
damage or foreign material.
Remove any foreign material from the passenger air bag module and instrument
panel/deployment chute cavity.
Install new parts if damaged.
Failure to follow these instructions may result in the passenger air bag deploying incorrectly,
which increases the risk of serious personal injury or death in a crash.
1. Position the passenger airbag to the deployment chute.

2. Engage the 5 passenger airbag retainers to the deployment chute.
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2. 1. Pull the passenger airbag deployment chute out, making room for the passenger airbag to pass.
2. Rotate the passenger airbag down and into the deployment chute.
3. Engage the passenger airbag retainers to the deployment chute.
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4. Install the brackets and screws.
5. Install the air conditioning duct and screws.

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6. NOTE: RH side shown, LH similar.
On both sides.
Install the demister duct and screws.
7. Install the instrument panel upper section.

Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and
Installation).
8. Repower the SRS.

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Passenger Knee Airbag
Removal
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1. Depower the SRS.
2. Release the clips and remove the RH instrument panel trim panel.
3. NOTE: Instrument panel center finish panel with optional ICM shown.
Release the clips and remove the instrument panel center finish panel.
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4. Open the glove box.
5. 1. Detach the glove box door damper.

2. Push each side of the glove box door, disengaging the stops.
3. Open the glove box door past its stops.
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6.
1. Disconnect and detach the electrical connector and wire harness.
2. Remove the upper screws.
3. Remove the lower screws.
4. Separate the glove box assembly from the instrument panel.
7. Disconnect the electrical connector and remove the glove box assembly.
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Installation
deployment.
2. Repower the SRS.


Restraints Control Module (RCM)
Removal
NOTE: The PMI process must begin with the current RCM installed. If the current RCM does not respond
to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
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Using a diagnostic scan tool, begin the PMI process for the RCM following the on-screen instructions.
2. Depower the SRS.


4. Detach the wire harness retainer.
5. 1. Disconnect the RCM electrical connectors.

2. Remove the nuts.
3. Remove the RCM.
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Installation
2. Repower the SRS. For a new RCM, do not prove out the SRS at this time.
Using a diagnostic scan tool, complete the PMI process for the RCM following the on-screen instructions.
4. For a new RCM, prove out the SRS. Verify all airbags are installed and connected and the ignition is OFF.
Wait 10 seconds then turn the ignition ON and monitor the airbag warning indicator. The airbag warning
indicator illuminates continuously for approximately 6 seconds and turns off. Continue to monitor the airbag
warning indicator for approximately 30 seconds, as this is the time required for the RCM to complete
testing of the SRS.
repairs.

Seat Position Sensor
Removal
1. NOTE: RH manual seat shown, other seats similar.

3. Remove the seat position sensor.
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Installation

Side Airbag
Hog Ring Plier
Removal
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Side airbag and upper side airbag

2.
1. Releases the wire harness electrical connector retainers.
3.
1. Remove the pin-type retainers.
2. Position the backrest cover upwards and remove the insert.
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4.
2. Position the backrest cover from between the seat cushion and backrest.
Partially invert the backrest cover to access the side airbag deployment chute.
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8. Release the 4 backrest cover J-clip type retainers and position the backrest cover upward.
Side airbag
9. Remove the side airbag nuts.

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10. 1. Detach the side airbag from the backrest frame.
2. Slide the locking wedge out, disconnect the electrical connector and remove the side airbag.
Upper side airbag
11. Release the J-clip from the backrest frame.

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12. Remove the hog rings.
Detach the hook-and-loop strips.

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14. Remove the side airbag bolt.

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Installation
deployment.
WARNING: If the seat side airbag cover has been damaged or separated from its mounting, or
if the airbag material has been exposed, install a new seat side airbag assembly. Never try to repair
the seat side airbag assembly. Failure to follow these instructions may result in the seat side
airbag deploying incorrectly, which increases the risk of serious personal injury or death in a
crash.
2. Use the General Equipment: Hog Ring Plier

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Side Curtain Airbag
Removal
1. Depower the SRS.

2. Remove the headliner.
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Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
Disconnect the electrical connector and remove the screws.
Remove the screws.

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5. Remove the pin-type retainers at the A-pillar.
6. Disengage the retainer and position the side curtain airbag away from the A-pillar.
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7. Disengage the pin-type retainers.

2. Slide the side curtain airbag forward and out, disengaging the T-tab from the sheet metal and
remove the side curtain airbag.
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Installation
deployment.
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
NOTE: During installation, ensure that the side curtain airbag is not twisted 360° between attachment points.
2.
Tighten the screws in the sequence shown.
1. Tighten screws 1 and 2.
2. Tighten screws 3 through 7.
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3. Repower the SRS.

Side Airbag - Vehicles With: Recaro Seats
Removal

2. Detach the backrest cover J-clips and position the backrest cover upward.
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3. Detach the side airbag deployment chute J-clips from the backrest frame.
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4. Remove the side airbag nuts.
5. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the backrest foam pad.
NOTICE: Use care when separating the backrest cover from the hook-and-arrows, or the hooks
can be torn from the backrest foam pad.
Detach the hook-and-loop strips, the hook-and-arrows and position the backrest cover up.
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6. Position the deployment chute through the backrest foam.
7. Separate the side airbag from the backrest frame.

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8. Separate the deployment chute from the side airbag studs.
9. Position the side airbag back into the backrest foam pad.
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10. Detach the hook-and-arrows and position the backrest cover up.

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Installation
deployment.

501-25 Body Repairs - General Information 2016 Mustang
Specifications
Item Specification
Plug Weld hole 8 mm (0.315 in)
Weld Wire ER70S-3 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Weld Wire ER70S-6 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Weld Nugget Chart
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Test Thickness of Metal Nugget Size
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) 4.7 mm (0.185 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) 8.7 mm (0.3425 in)
3 mm (0.1181 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 2 mm (0.0787 in) 4.7 mm (0.185 in)
2 mm (0.0787 in) + 0.9 mm (0.0354 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
Ford Recommended Steel Repairability Matrix
Grade Trade Welding Method Cold Use of Temperature Maximum

Descriptions Repairs Heat Range Heat
MIG Squeeze-Type MIG
for
Resistance Braze
Repair
Spot Welding
(STRW)
Mild Steel Mild Yes Yes N/A Yesa Yes Up to 650° C 90
(1,200° F) seconds x
2
Laminate Steel Quiet Steel No Yes No Yesa NA NA NA
Bake Hardened Bake Hardened Yes Yes Yesb Yesa Yes Up to 650° C 90
Steel (BH) Steel (BH) 180, (1,200° F) seconds x
200, 210, 220, 250, 2
280
Solid Solution - Yes Yes Yesb Yesa Yes Up to 650° C 90
Strengthened (1,200° F) seconds x
2
High-Strength High-Strength Low Yes Yes Yesb Yesa Yes Up to 650° C 90
Low Alloy Alloy (HSLA) 200, (1,200° F) seconds x
(HSLA) High-Strength Low 2
Alloy (HSLA 250,
High-Strength Low
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Alloy (HSLA 260,
High-Strength Low
Alloy (HSLA 300,
High-Strength Low
Alloy (HSLA 340,
High-Strength Low
Alloy (HSLA 350,
High-Strength Low
Alloy (HSLA 500,
High-Strength Low
Alloy (HSLA) 550
Dual Phase Dual Phase Steel Yes Yes Yesb Yesa No NA NA
Steel (DP) (DP) 500, Dual
Phase Steel (DP)
600
Dual Phase Dual Phase Steel Yesd Yes Yesb No No NA NA
Steel (DP)c (DP) 700, Dual
Phase Steel (DP)
900 and Dual
Phase Steel (DP)
1,000
Ultra High Boron, Martensitic Yesa Yes Yesb No No NA NA
Strength Steel
(UHSS)
(Martensitic,
Boron)e
Transformation Transformation NA NA NA NA NA NA NA
Induced Induced Plasticity
Plasticity Steel Steel (TRIP) 590,
(TRIP) Transformation
Induced Plasticity
Steel (TRIP) 780,
Transformation
Induced Plasticity
Steel (TRIP) 980
aCold repairs can be performed if damage excludes kinks. May section only if approved procedure in workshop manual.
bMetal Inert Gas (MIG) braze allowed for non-structural applications only.
cDual phase steels DP 700 class, DP 900 class and DP 1,000 class must be replaced at factory joints, no sectioning
unless approved procedure in workshop manual.
dFor DP 900, 1,000 and Boron use Metal Inert Gas (MIG) plug welding only, no stitch welding.
eBoron and Ultra High Strength Steel (UHSS)-Mortensite components must be replaced at factory joints, no sectioning
allowed.
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Noise, Vibration and Harshness
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 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 if applied prior to
mastic installation.
The following serve as a reference to indicate mastic patch (butyl) locations. Additional insulators and sound
deadeners are used beyond those indicated in the illustrations.
Floor Pan
Roof Panel
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Front Door

Plastic Repairs
Plastic Components
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 plastics repair. Typically components with moulded-in color or a textured
finish are not considered repairable components.
Front Exterior Plastic Components
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Item Description Material
1 Front bumper cover lower Thermoplastic olefin (TPO)
2 Hood scoop insert Acrylonitrile butadiene styrene (ABS)
3 Rocker panel moulding Thermoplastic olefin (TPO)
Rear Exterior Plastic Components

Item Description Material
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1 Rear spoiler Polypropelyne (PP)
2 Luggage compartment lid moulding Polypropelyne (PP)
3 Rear bumper cover Thermoplastic olefin (TPO)
Repair Considerations
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?
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, Sheet-Molded Composite (SMC) is
strong and rigid.
Sheet-Molded Composite (SMC) is similar to, but not identical to fiberglass. Ford Motor Company uses
Sheet-Molded Composite (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 a 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 the 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. Polyolefins are used in bumper covers, fan shrouds and wheel housings.
Proper identification of the various types of plastic is necessary to select the appropriate repair method(s) to
carry out high quality plastic repairs.
For additional information, refer to: Plastic Repairs (501-25 Body Repairs - General Information, General
Procedures).
.
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Sealer, Underbody Protection Material and Adhesives
Adhesives
NOTE: The following illustrations are examples of structural adhesive application and are not all inclusive.
The correct adhesive bonding is essential to repairing the vehicle correctly. Adhesives are used in many areas of
the body structure in place of welding. In addition to providing a structural bond between component, adhesives
can also help prevent wind noise, water leaks, exhaust fumes and dust from entering the vehicle. They also
provide anti-corrosion barriers.
Hood
NOTE: Adhesive applied between inner and outer panels prior to assembly.
Front Door
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Bodyside
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Sealers
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.
NOTE: The following illustrations are examples of sealer application and are not all inclusive.
Hood
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Front Door
Roof Panel
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Bodyside

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Underbody
Underbody Protection Material
Underbody protection is necessary for permanent, elastic corrosion protection of vehicle underbodies. It is
paintable, very durable and has good resistance to abrasion. This material may be applied in many manners. It
may be sprayed, rolled or brushed on (obtain locally).
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Corrosion Prevention
300-SAT12740
UBE Gun
300-SAT9795
HRS Rust Gun
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Materials
Name Specification
ZC-31-A
ValuGard™ Premium Undercoating -
VG101, VG101A
ValuGard™ Rust Inhibitor -
VG104, VG104A
Repair
NOTE: Undercoating
NOTE: The following illustrations are not vehicle specific and are intended for reference only.
1. WARNING: Before beginning any service procedure in this section, REFER to Safety Warnings
personal injury.
Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information,
2. 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.
3. Thoroughly clean and degrease metal surfaces to remove wax and grease.
Material: Motorcraft® Metal Surface Prep / ZC-31-A
4. For best results, the vehicle should be at room temperature.
5. Canister attaches directly to the dispensing gun. Attach the undercoating canister to the special tool .
Use Special Service Tool: 300-SAT12740 UBE Gun.
Material: ValuGard™ Premium Undercoating / VG101, VG101A
6. Undercoating should be applied after the welding and refinishing process. Product cannot be welded
through.
7. Air pressure setting for applicator gun is 552 kPa (80.06 psi) – 621 kPa (90.07 psi).
8. Apply light mist coats, applicator sprays in fogging pattern. Material displaces moisture.
9. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
10. NOTE: Frame rail exterior spot-weld flange view.
Apply Premium Undercoating material to the exterior exposed edges after carrying out the welding and
refinishing process.
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11. 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. Depress trigger and
wait 2-3 seconds and slowly pull the wand to make sure the area is completely fogged.
12. NOTE: Full frame vehicle, front rail-to-mid rail section repair shown.
Apply Premium Undercoating to the exposed surfaces after carrying out the welding process. Make sure to
completely cover any bare metal areas.
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Repair
NOTE: Rust Inhibitor
1. The surfaces must be free of oil, dirt and other foreign material. Carry out the process in the following
sequence.
2. Thoroughly clean and degrease metal surfaces to remove wax and grease.
3. For best results, the vehicle should be at room temperature. Attach the rust inhibitor canister to the special
tool .
Use Special Service Tool: 300-SAT9795 HRS Rust Gun.
Material: ValuGard™ Rust Inhibitor / VG104, VG104A
4. Rust inhibitor should be applied after the welding and refinishing process. Product cannot be welded
through.
5. Air pressure setting for applicator gun is 448 kPa (64.97 psi) - 517 kPa (74.98 psi).
6. Use the appropriate length wand when spraying enclosed areas. 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. Apply
the material in light mist coats. Material displaces moisture.
7. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
8. NOTE: Door assembly lower view.
Apply 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.
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9. NOTE: Quarter panel inner view.
Apply to the closed channel portion of the spot weld flange areas. Apply to the exposed edges after
carrying out the welding process. Make sure horizontal surfaces are well protected as they are more
susceptible to corrosion.
10. NOTE: Door frame opening view.
Apply to the closed channel portion of the spot weld flange areas. Make sure horizontal surfaces are well
protected as they are more susceptible to corrosion.
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Joining Techniques
Resistance Spotwelding Equipment

Grinder
Plasma Cutter
Air Body Saw
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Materials
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Name Specification
Metal Bonding Adhesive -
TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
ZC-31-A
ValuGard™ Premium Undercoating -
VG101, VG101A
ValuGard™ Rust Inhibitor -
VG104, VG104A
Repair
NOTE: Weld Bonding - Squeeze-Type Resistance Spot Welding (STRW) Method
personal injury.
2. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
3. Remove damaged panels. Remove only large portions of the damaged panel. Avoid cutting into mating
flanges or adjacent parts.
Use the General Equipment: Air Body Saw
Use the General Equipment: Plasma Cutter
4. Drill out the spot welds and remove the remaining portions of the panel to be replaced.
Use the General Equipment: Spot Weld Drill Bit
5. Prepare any damaged flanges on the vehicle using hammer and dolly.
6. Grind the mating surface of the original flanges no greater than 25 mm (0.9843 in) where the metal bonding
adhesive will be applied.
7. 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 surface prep.
8. Dry-fit and clamp the replacement service parts to verify a correct fit.
9. Remove the service part after verifying correct fit and alignment.
10. Prepare the adhesive. Dispense a small amount of 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.
Material: Metal Bonding Adhesive / TA-1, 3M™ 08115, Fusor® 108B
11. 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.
12. Prepare the metal and adhesive as described. Apply a 6 mm (0.2362 in) - 9 mm (0.3543 in) bead of
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adhesive and weld the sample.
Use the General Equipment: Resistance Spotwelding Equipment
13. 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.
Refer to: Specifications (501-25 Body Repairs - General Information, Specifications).
14. Apply a 6 mm (0.2362 in) - 9 mm (0.3543 in) bead of adhesive to the vehicle prepared flange surface.
15. Place the service part(s) in the correct position on the vehicle.
16. 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.
17. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
18. NOTE: Refer to the 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.
19. NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material when
welding is carried out.
Complete the spot welding process following Ford recommendations and welder manufacturer procedures
and settings.
20. 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.
21. Mix and apply primer surfacer per Ford-approved paint recommendations.
22. Seal wherever a cosmetic seam sealer is required.

Material: Seam Sealer / TA-2-B
23. Refinish using a Ford approved paint system.
24. Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
Repair
NOTE: Weld Bonding - Metal Inert Gas (MIG) Welding Method
personal injury.
2. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
3. Remove damaged panels. Remove only large portions of the damaged panel. Avoid cutting into mating
flanges or adjacent parts.
4. Drill out the spot welds and remove the remaining portions of the panel to be replaced.
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5. After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a
hammer and dolly.
6. 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.
Use the General Equipment: Grinder
7. 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.
8. Repeat the procedure on the mating surface of the replacement service part(s).
9. Prepare the new service panel for plug welds.
10. Using the original panel as a reference, drill or punch 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 the potential of
corrosion to a minimum.
Use the General Equipment: 8 mm Drill Bit
11. Clean all mating surfaces on both the vehicle and replacement panel.
12. Dry-fit and clamp the replacement service parts to verify a correct fit and alignment.
13. Remove the service part after verifying correct fit and alignment.
14. The vehicle prepared flange areas where plug welds will be located must be kept free of adhesive. Apply
25 mm (0.9843 in) tape to the plug weld areas to prevent contamination from the adhesive.
15. Prepare the adhesive. Dispense a small amount of 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.
16. NOTE: Refer to the product label for cure times and handling instructions.
Apply a 6 mm (0.2362 in)-9 mm (0.3543 in) wide bead of adhesive to the vehicle prepared flange surface.
Remove the tape from the plug weld areas.
17. Place the service part(s) in the correct position on the vehicle.
18. 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.
19. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
20. 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.
21. Complete the plug-welding process following Ford recommendations.

Use the General Equipment: MIG/MAG Welding Equipment
22. 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.
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23. Mix and apply primer surfacer per Ford-approved paint recommendations.
24. Seal wherever a cosmetic seam sealer is required.


Plastic Repairs
ALCV-200
Materials
Name Specification
Plastic Bonding Adhesive -
TA-9
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Inspection
NOTE: Plastics Identification
personal injury.
2. NOTE: In some instances, a code or material designation is moulded or stamped on the component
indicating the plastic type.
Thermoplastics are solvent reactive. Types of thermoplastics include Thermoplastic Olefin (TPO), Polyvinyl
Chloride (PVC), Sheet-Molded Composite (SMC) 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.
3. 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.
4. 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.
5. Generally, thermosetting plastics are rigid or semi-rigid. Sheet-Molded Composite (SMC) is reinforced with
glass and other fibers and are strong and rigid. Sheet-Molded Composite (SMC) is used for large panels
such as hoods, liftgates, fenders and quarter panels.
6. 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.
7. In deciding whether to repair or install a new component, follow these guidelines.
8. 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?
9. 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.
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.
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.
Panels to be repaired should be dry and at room temperature 18 C (64.4 F) to 24 C (75.2 F) prior to
carrying out any repairs. Both sides of the panel must be thoroughly cleaned before sanding or grinding.
Repair
NOTE: Sheet-Molded Composite (SMC) Panel Repair
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1. Cover the break in the Sheet-Molded Composite (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 Sheet-Molded Composite (SMC).
2. 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.
3. 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.
Use Special Service Tool: ALCV-200.
4. Create a reinforcing patch using a piece of scrap Sheet-Molded Composite (SMC) that conforms well to
the back of the damaged area or form a patch from fiberglass cloth.
5. Cut a section of cloth large enough to cover the repair, plus around the repair area. Cut a section of plastic
film backing approximately larger than the cloth. Lay the plastic on a smooth, flat surface where it will be
used to create a pyramid patch.
6. Follow manufacturer's directions and apply 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.
Material: Plastic Bonding Adhesive / TA-9
7. 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.
8. 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 Dual Action (D/A) sander or hand-sand with
80-grit sandpaper.
9. Build a pyramid patch using fiberglass cloth or equivalent and adhesive. Following manufacturer's
directions, apply patch to damaged area.
10. Rough-grind area to remove excess adhesive. Sand repair area with 80-grit sandpaper, making sure to cut
slightly below the Sheet-Molded Composite (SMC) finished surface. This will allow for a finish coat of
plastic repair filler material.
11. Apply a finish coat of plastic repair filler material per manufacturer's directions.
12. Finish-sand, prime and topcoat using Ford-approved paint systems.
Repair
NOTE: Thermoplastic Compounds Repair
1. Select the correct repair method by identifying the type of plastic being repaired.
2. 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.
3. 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.
4. 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.
5. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air.
6. Apply a plastics adhesion promoter per label directions to the repair area.
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7. For small repairs, a 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.
8. 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.
9. Apply 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.
10. Contour and sand to shape the repair as necessary. Avoid sanding through the repair.
11. Finish-sand the area and carry out any required paint operations using Ford-approved paint systems.
Repair
NOTE: Tab Repair
1. NOTE: Illustration is not vehicle specific.
NOTE: Inspect the component 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.
Clean the broken tab(s) with a plastics wax and grease remover.
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2. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air.
3. Apply a plastics adhesion promoter per label directions to the repair area.
4. 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.
5. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area.
6. 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.
Repair
NOTE: Plastics Refinishing
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.
2. 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.
3. 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.
4. NOTICE: Grained components may only be lightly sanded through use of a gray scuff pad. Failure
to follow this direction may result in graining being flattened.
After cleaning, lightly sand with 600-grit or finer sandpaper. Remove sanding residue with plastic cleaner
and wipe dry.
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. Interior trim components may be refinished using Motorcraft® Interior Spray Paint or any Ford-approved
paint system procedures. Steps may vary between paint manufacturers.
10. Proceed with the refinish process and follow the Ford-approved paint system procedures. Steps may vary
between paint manufacturers.
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Welding Precautions
Check
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
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: SRS components should always be depowered and disconnected before beginning any welding
procedure.
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NOTICE: Electronic modules and related wiring can be damaged when exposed to heat from welding
procedures. Carefully disconnect and remove, or position away from heat affected areas.
1. A test weld should always be carried out on a test sample.
2. The correct protective clothing should always be worn.
3. Always work in a well ventilated area to avoid accumulation of noxious and oxygen displacing gases.
4. Place protective covers around components and wiring harnesses to protect from welding spatter.
5. Use grinding discs and wire brushes dedicated to the type of material being welded.
6. Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being
used. ER70S-3 or ER70S-6 wire is typically used for MIG welding on steel.
7. Disconnect and isolate battery ground cable.
8. Components made of Boron, Martensitic, HSS (high-strength steel) and UHSS (ultra high-strength) steel
should not be heated to straighten or repair. Severely bent or kinked components should be replaced with
new ones.
9. Factory welds may be substituted with either STRW (squeeze-type resistance welding) spot welds or MIG
plug welds.
10. MIG plug welds must equal factory welds in both location and quantity.
11. MIG plug weld holes should equal 8 mm (0.31 in) diameter.
12. Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld
location.
13. Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when
welding.
14. Use of a weld-through primer is recommended where applicable.
15. When welding, always place the ground clamp as close as possible to the weld area.
16. Never connect the welder ground clamp to the vehicle subframe.
17. Never weld a vehicle subframe, steering or suspension component. Service is through replacement only.
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501-26 Body Repairs - Vehicle Specific Information and Tolerance 2016 Mustang
Checks
Body and Frame
Body
The body consists of the following:
High-Strength Low Alloy (HSLA), dual-phase (DP), Boron and mild steels
Coupe and convertible body styles
Aluminum hood
Steel luggage compartment lid
Body side outer panels constructed of mild steel
Dual-phase steel (DP) in select body structure components
Bolted, removable front fenders, hinged doors and hood
Aluminum front fenders
Ultra high-strength steel (UHSS) front and rear bumper beam
Underbody components constructed of mild, boron and high-strength steels
Mastic pads used on floor pan for sound deadening
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Body Dimensions
Body Margins - Front Panels
NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.
NOTE: Dimensions apply to coupe and convertible.

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Item Description Margin Specification Flushness Specification
1 Hood-to-fascia 4.0 mm ± 2.3 mm -0.75 mm ± 2.3 mm
2 Hood scoop-to-hood 2.0 mm ± 1.0 mm -0.5 mm ± 0.75 mm
3 Headlamp-to-hood — —
4 Headlamp-to-fascia 2.0 mm ± 1.5 mm —
5 Headlamp-to-fender 2.0 mm ± 1.5 mm —
6 Fascia-to-fender 0.0 mm ± 0.5 mm 0.75 mm ± 1.5 mm
7 Hood-to-fender 3.5 mm ± 1.7 mm ± 1.5 mm
8 Hood-to-cowl filler 3.5 mm ± 1.7 mm 0.0 mm ± 1.7 mm
Body Margins - Side Panels

1 Fender-to-rocker moulding 0.0 mm ± 1.1 mm 0.75 mm ± 1.1 mm
2 Door-to-fender 3.4 mm ± 1.5 mm -0.75 mm ± 1.1 mm
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3 Door-to-rocker moulding 5.0 mm ± 2.0 mm —
4 Door-to-body side 3.4 mm ± 1.5 mm 0.0 mm ± 2.0 mm
5 Door glass-to-quarter glass 10.0 mm ± 1.5 mm 0.0 mm ± 2.0 mm
6 Body side-to-rocker moulding 0.0 mm ± 1.1 mm 0.75 mm ± 1.2 mm
7 Rear fascia-to-body side 0.0 mm + 0.5 mm ± 0.0 mm -0.75 mm ± 1.7 mm
8 Fuel door-to-body side 2.2 mm ± 1.2 mm -1.0 mm ± 1.2 mm
Body Margins - Rear Panels
Item Description Margin Flushness Specification
Specification
1 Tail lamp-to-fascia 2.0 mm ± 2.0 mm —
2 Tail lamp-to-body side 2.0 mm ± 1.5 mm 1.5 mm ± 1.7 mm
3 Luggage compartment lid-to-body side 3.0 mm ± 1.5 mm 0.0 mm ± 2.0 mm
4 Rear window-to-body side 3.0 mm ± 1.7 mm -3.0 mm ± 1.5 mm
5 CHMSL-to-roof 3.0 ± 1.0 mm -1.5 mm ± 1.5 mm
6 CHMSL-to-rear window 2.5 mm ± 2.2 mm —
7 Luggage compartment lid moulding-to-Luggage — -2.0 mm + 1.4 mm ± 0.0
compartment lid mm
8 Luggage compartment lid moulding-to-fascia 6.0 mm ± 3.4 mm —
9 Rear window-to-luggage compartment lid 3.0 mm ± 1.5 mm —
10 Tail lamp-to-luggage compartment lid moulding 4.8 mm ± 3.0 mm 0.0 mm ± 3.0 mm
11 Luggage compartment lid-to-tail lamp — —
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Body Margins - Convertible Front

1 Convertible top-to-roof 9.25 mm ± 2.0 mm 1.5 mm ± 1.9 mm
2 Convertible top-to-A-pillar 8.8 mm ± 2.4 mm 1.5 mm ± 2.7 mm
3 Door glass-to-quarter window glass 8.0 mm ± 1.5 mm 0.0 mm ± 1.5 mm
4 Convertible top-to-seal retainer 8.5 mm ± 2.7 mm 1.5 mm ± 2.5 mm
Body Margins - Convertible Rear

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Item Description Margin Specification Flushness
Specification
1 Convertible top moulding-to-body 0.0 mm at point A to 5.0 mm at point B —
side
2 Convertible top-to-luggage 5.0 mm ± 4.7 mm (margin parallelism within —
compartment lid 3.7 mm)
3 Luggage compartment lid-to-CHMSL 1.0 mm ± 0.8 mm 0.5 mm ± 0.8 mm
Under Hood Dimensions
NOTE: All measurements are on center unless otherwise indicated.

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Front Door Opening Dimensions - Coupe
Front Door Opening Dimensions - Convertible

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Rear Body Dimensions
Dimensions apply to coupe and convertible.
Under Body Measurements
Dimensions apply to coupe and convertible.

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Datum Height Dimensions

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Checks
Vehicle Specific Body Construction
For recommended metal repair guidelines and recommendations, refer to the following illustrations and:
For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications).
Steel Type Legend
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Item Steel Type Color
1 Mild Steel Yellow
2 Bake Hardened Steel (BH) Light Blue
3 Solid Solution Strength Pink
4 High Strength Low Alloy (HSLA) Dark Blue
5 Dual Phase (DP) 500, 600 Class Steel Green
6 Dual Phase (DP) 700, 800, 900, 1000 Class Steel Fuchsia
7 Laminate Steel Teal
8 Ultra High Strength Steel (UHSS) Martensitic, Boron Red
9 Transformation Induced Plasticity Steel (TRIP) Gold
10 Aluminum Purple
Front Structure Components
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Item Description Steel Type

1 Fender reinforcement Mild steel
2 Fender mounting bracket Mild steel
3 Fender mounting bracket Mild steel
4 Fender apron assembly Mild steel
5 Fender mounting bracket High-Strength Low Alloy (HSLA) 350 steel
6 Fender apron reinforcement Bake Hardened Steel (BH)
7 Reinforcement Mild steel
8 Battery tray RH side only Mild steel
9 Front floor side member High-Strength Low Alloy (HSLA) 350 steel
10 Radiator support High-Strength Low Alloy (HSLA) 350 steel
11 Reinforcement High-Strength Low Alloy (HSLA) 350 steel
12 Fender apron assembly Mild steel
13 Housing Mild and High-Strength Low Alloy (HSLA) 350 steel
14 Reinforcement (part of fender apron assembly) Mild steel
15 Fender bracket High-Strength Low Alloy (HSLA) 350 steel
Body Side Inner Panels-Convertible
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1 A-pillar inner reinforcement Dual Phase Steel (DP) 1000 steel
2 A-pillar bracket Dual Phase Steel (DP) 1000 steel
3 Bracket Dual Phase Steel (DP) 1000 steel
4 Inner wheelhouse panel Mild steel
5 Quarter panel outer Mild steel
6 C-pillar reinforcement Mild steel
7 Filler panel Mild steel
8 Quarter panel extension Mild steel
9 Inner quarter panel and wheelhouse Dual Phase Steel (DP) 500 steel
10 B-pillar inner assembly Boron steel
11 Rocker panel reinforcement Martensite 1100
12 A-pillar assembly High-Strength Low Alloy (HSLA) 350 steel
Body Side Outer Panels-Convertible
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1 Door frame panel Mild steel
2 Body side panel Mild steel
Body Side Inner Panels-Coupe

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1 A-pillar inner reinforcement Dual Phase Steel (DP) 1000 steel
2 A-pillar bracket Dual Phase Steel (DP) 1000 steel
3 Inner wheelhouse panel Mild steel
4 Inner quarter panel and wheelhouse Dual Phase Steel (DP) 500 steel
5 Filler panel Mild steel
6 Quarter panel extension Mild steel
7 B-pillar inner assembly Boron steel
8 Rocker panel reinforcement Martensite 1100 steel
9 A-pillar assembly High-Strength Low Alloy (HSLA) 350 steel
10 A-pillar reinforcement Mild steel
11 B-pillar inner reinforcement Boron steel
Body Side Outer Panels-Convertible
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1 Door frame panel Mild steel
2 Body side panel Mild steel
Roof Panel-Convertible
Item
1
Description
Windshield header
Steel Type
Dual Phase Steel (DP) 1000 steel cardiagn.com
2 Windshield header reinforcement Dual Phase Steel (DP) 1000 steel
3 Windshield reinforcement Mild steel
4 Roof panel brace Mild steel
5 Roof panel assembly Mild steel
Roof Panel-Coupe
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1 Roof panel Bake Hardened (BH) 180 steel
2 Rear window frame Dual Phase Steel (DP) 1000 steel
3 Windshield header reinforcement Dual Phase Steel (DP) 1000 steel
Front Door

1 Door shell assembly Mild steel
2 Door outer panel Bake hardened (BH) 180 steel
3 Door intrusion beam Boron steel
Front Floor Pan
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1 Floor side member Boron steel
2 Crossmember Mild steel
3 Crossmember Mild steel
4 Support High-Strength Low Alloy (HSLA) 350 steel
5 Floor panel Mild steel
6 Bracket Mild steel
7 Floor side member High-Strength Low Alloy (HSLA) 350 steel
Center and Rear Floor Pan-Convertible
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1 Crossmember Boron steel
3 Reinforcememt High-Strength Low Alloy (HSLA) 350 steel
4 Reinforcement Dual Phase Steel (DP) 800 steel
5 Center floor pan Mild steel
9 Rear floor pan Mild steel
11 Support Mild steel
13 Bracket High-Strength Low Alloy (HSLA) 350 steel
14 Floor side member reinforcement High-Strength Low Alloy (HSLA) 350 steel
16 Bumper mounting bracket High-Strength Low Alloy (HSLA) 350 steel
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17 Floor side member Dual Phase Steel (DP) 800 steel
20 Brace Mild steel
21 Brace High-Strength Low Alloy (HSLA) 350 steel
22 Crossmember High-Strength Low Alloy (HSLA) 350 steel
Center and Rear Floor Pan-Coupe

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1 Crossmember Boron steel
3 Reinforcememt High-Strength Low Alloy (HSLA) 350 steel
5 Center floor pan Mild steel
9 Rear floor pan Mild steel
14 Floor side member reinforcement High-Strength Low Alloy (HSLA) 350 steel
15 Bumper mounting bracket High-Strength Low Alloy (HSLA) 350 steel
19 Brace High-Strength Low Alloy (HSLA) 350 steel
20 Crossmember Dual Phase Steel (DP) 800 steel
Rear Panels and Package Tray- Coupe
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1 Strainer Mild steel
2 Back panel Mild steel
3 Package tray panel Mild steel
4 Strainer Mild steel
5 Back panel assembly Mild steel
6 Back panel inner assembly Mild steel
Rear Panels and Package Tray- Convertible
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1 Quarter panel wheelhouse support Mild steel
2 Back panel Mild steel
3 Package tray panel Mild steel
4 Quarter panel wheelhouse support Mild steel
5 Back panel assembly Mild steel
6 Back panel inner assembly Mild steel
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Checks
Body Panel Sectioning

Spherical Cutter
Plasma Cutter
Air Body Saw
Spot Weld Drill Bit
Materials
Name Specification
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Seam Sealer -
TA-2-B
Repair
NOTICE: Do not begin removal of the vehicle body side until the replacement panel is available for
reference.
NOTICE: Do not carry out body side sectioning repairs in areas of door hinge, safety belt or striker
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise
structural integrity during a collision.
NOTICE: Sectioning within the door hinge portion of the A-pillar, B-pillar or dog leg portion of the quarter
panel is not approved by Ford Motor Company.
1. Only remove as much of the outer body side panel material as necessary using available tools.
2. Body side replacement panels are released as 2-part panels.

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3. As a general rule, sectioning cut points should be chosen to result in the smallest repair area possible.
Use the General Equipment: Spherical Cutter
4. Detrim the vehicle as necessary and remove spot welds from the damaged area.
5. NOTE: Use resistance spotwelding equipment where possible. This will produce a higher quality repair.
NOTE: When welding overlapping surfaces or substrates, apply a high quality weld-through primer
between the surfaces prior to welding.
Where possible, create a lap-joint backer plate using a portion of the old panel. This will create a stronger
joint.
6. Rough finish all sectioning joints with a fibre-based body filler, final finish sectioning joints and plug welds
with a conventional body filler.
7. Properly seal all horizontal joints to prevent moisture intrusion. Water and moisture migrate toward
horizontal joints and corrosion tends to occur more rapidly in these areas.
8. Proceed with the refinishing process using a Ford approved paint system and manufacturers
recommendations.
10. Reinstall vehicle trim as necessary.
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501-27 Front End Sheet Metal Repairs 2016 Mustang
Fender Apron Panel Reinforcement

Grinder
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
Seam Sealer -
TA-2-B
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Removal

1. Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
2. Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
3. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
2. RH side.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
3. If required, dimensionally restore vehicle to pre-accident condition.

Drill out the spot welds from upper fender apron reinforcement.
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5. Grind welds at rear flange of the reinforcement.
6. Remove the upper fender apron reinforcement.

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7. Drill out the welds from upper fender apron reinforcement bracket and remove.
8. Drill out the welds on the lower fender apron reinforcement as indicated.
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9. Remove the welds at the rear inner flange of the reinforcement.
10. Drill out the welds at the reinforcement bracket.

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11. Remove the lower fender apron reinforcement.
Installation
1. Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
2. Install the apron panel reinforcement to the lower apron panel reinforcement and spot weld.
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3. 1. Drill plug weld holes in the replacement panel.
4. Install the lower fender apron panel reinforcement and plug weld.
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5. Weld the bracket reinforcement to the fender apron panel.
6. Plug weld the rear inner flange of the lower fender apron panel.
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7. Install the upper fender apron reinforcement and bracket weld.
8. Finish the repair area using typical metal finishing techniques.
9. Sealing work: All areas must be sealed to production level.

11. Restore corrosion protection.

Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
13. RH side.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
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Front Side Member and Fender Apron Panel LH

Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
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Seam Sealer -
TA-2-B
Removal

2. Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and
Installation).

1. Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
2. Refer to: Front Subframe - 2.3L EcoBoost (201kW/273PS) (502-00 Uni-Body, Subframe and
Mounting System, Removal and Installation).
3. Refer to: Front Subframe - 3.7L Duratec (227kW/301PS)/5.0L 32V Ti-VCT/5.2L 32V Ti-VCT
(502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
4. Refer to: Radiator (303-03A Engine Cooling - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
5. Refer to: Radiator (303-03B Engine Cooling - 3.7L Duratec (227kW/301PS), Removal and
Installation).
6. Refer to: Radiator (303-03C Engine Cooling - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
7. Refer to: Engine (303-01A Engine - 2.3L EcoBoost (231kW/314PS), Removal).
8. Refer to: Engine (303-01B Engine - 3.7L Duratec (227kW/301PS), Removal).
9. Refer to: Engine (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Removal).
NOTE: Individual apron panels can be serviced as required.
Overview
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5. Overview
6. Drill out the spot welds in the fender apron bracket and remove the bracket.
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7. Drill out the spot welds.
8. Remove the panel.

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13. NOTE: Cutline option depending on extent of damage.
Mark cutline and cut through inner frame rail.

14. NOTE: Cutline option depending on extent of damage.
Mark cutline and cut through outer frame rail.

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Installation
2. NOTE: Frame member portion of service assembly shown for clarity.
Mark and cut outer frame member from the replacement part.
3. NOTE: Frame member portion of service assembly shown for clarity.
Mark and cut inner frame member from the replacement part.
4. NOTE: Check for dimensional accuracy before welding.
Install and weld the outer frame member.

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5. Install and weld the inner frame member.

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6. Spot weld the frame member assembly.
7. Drill plug weld holes in the replacement panel.

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8. Install the apron reinforcement panel and weld.

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11. Install the fender apron bracket and weld.

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12. Complete all sectioning seams using typical metal finishing techniques.

16. Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and
Installation).

Installation).
Installation).
7. Refer to: Engine (303-01A Engine - 2.3L EcoBoost (231kW/314PS), Installation).
8. Refer to: Engine (303-01B Engine - 3.7L Duratec (227kW/301PS), Installation).
9. Refer to: Engine (303-01C Engine - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), Installation).

Front Side Member Section
Air Body Saw

8 mm Drill Bit
Locking Pliers
Materials
Name Specification
Seam Sealer -
TA-2-B
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Removal

Installation).
Installation).

Mark a cutline and cut through the inner frame rail as indicated.
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4. Mark a cutline and cut through the outer frame rail as indicated.
5. Remove the sectioned portion of the frame rail.

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Installation
2. NOTE: Inner frame rail portion of the service assembly shown for clarity.
Mark and cut replacement portion of the inner frame rail from the service replacement assembly.
3. NOTE: Outer frame rail portion of the service assembly shown for clarity.
Mark and cut replacement portion of the outer frame rail from the service replacement assembly.
4. Check for dimensional accuracy before welding.
5. NOTE: Create a backer from a piece of the frame rail. This will create a strong joint.
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Install the frame rail replacement section and seam weld the outer frame rail.
6. Seam weld along the joint on the inner frame rail.

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7. Metal finish the repair area using typical metal finishing techniques.



Installation).
Installation).

501-28 Roof Sheet Metal Repairs 2016 Mustang
Roof Panel

Spherical Cutter
Grinder
Knife
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
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TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
Roof Ditch Sealer -
3M™ 08307, Fusor® 122EZ
Fusor® Flexible Foam Repair -
3M™ 08463, Fusor® 121
Removal
NOTICE: Adequately protect all glass, exterior finish and interior trim during entire repair procedure.

1. Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
2. Refer to: High Mounted Stoplamp - Coupe (417-01 Exterior Lighting, Removal and Installation).
3. Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
4. Refer to: Audio Unit Antenna (415-00A Information and Entertainment System - General Information
- Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
5. Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).

3. Drill out the spot welds from the front and rear roof panel flanges.
4. NOTE: Leave as much NVH foam intact on the roof reinforcements as possible.
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Cut the NVH foam between the front and rear roof reinforcements and the roof panel.
5. Using a spherical cutter or equivalent, cut the roof panel along the edge near the roof ditch flange and
remove the roof panel.
Use the General Equipment: Spherical Cutter
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Installation
NOTICE: Adequately protect all glass, exterior finish and interior trim during entire repair procedure.
1. 1. Remove any remaining roof flange material and level the weld nuggets.
2. Clean the area and remove any remaining residue.
2. 1. Abrade the flange area of the replacement roof panel.

2. Clean the area and remove any remaining residue.
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3. Locate and reference mark the replacement roof panel. Remove the roof panel after marking.
4. Apply a bead of adhesive to the roof rail flange.

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5. Apply NVH foam to the front and rear roof reinforcements.
Material: Fusor® Flexible Foam Repair / 3M™ 08463, Fusor® 121
6. NOTE: Do not lift the panel from the body once installed. If the panel requires repositioning, slide the
panel to correct alignment location.
NOTE: To assure complete bonding, check all locations for full adhesive contact. Add additional
adhesive as necessary.
NOTE: Inspect the roof panel-to-roof reinforcement contact points for full contact. Fill any voids with
additional NVH foam.
Install the roof panel, locate the roof panel to the reference marks and spot weld.
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7. Spot weld the rear roof panel flange.
8. Metal finish the repair area using typical metal finishing procedures.

10. Sand and prime the entire repair area with a Ford approved paint system.
11. Apply sealant to the roof ditch.

Material: Roof Ditch Sealer / 3M™ 08307, Fusor® 122EZ
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2. Refer to: High Mounted Stoplamp - Coupe (417-01 Exterior Lighting, Removal and Installation).
3. Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
4. Refer to: Audio Unit Antenna (415-00A Information and Entertainment System - General Information
- Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
5. Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).

501-29 Side Panel Sheet Metal Repairs 2016 Mustang
A-Pillar Outer Panel

Hot Air Gun
Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
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Name Specification
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal
1. Available service part-Coupe.
2. Available service part-Convertible.

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1. Refer to: A-Pillar Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Installation).
4. Refer to: Front Door (501-03 Body Closures, Removal and Installation).
5. Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
6. NOTE: Coupe only.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
5. Position the carpet and wiring harness away from the repair area
6. Remove the front door hinges at the A-pillar.
7. NOTE: Coupe shown, convertible similar.
Carefully cut the outer body panel only.

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9. NOTE: Do not heat the area above 170° C.
Using a hot air gun, heat the area to aid in softening the NVH foam.
Use the General Equipment: Hot Air Gun
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10. Remove the A-pillar panel.
Installation
1. Drill holes for plug welds in the replacement panel.

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2. Apply NVH expanding foam to the inner reinforcement in the indicated area.
3. Install and seam weld the replacement A-pillar outer panel.

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4. Spot weld the flange areas.
5. MIG weld the remaining portion of the A-pillar panel.

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7. Apply a Ford approved primer to the repair area.
8. NOTE: Apply seam sealer after priming the area.
Sealing work: All areas must be sealed to production level.


11. Install the front door hinges to the A-pillar.
12. Reposition the carpet and wiring harness.

Installation).
Installation).
Installation).
5. NOTE: Coupe only.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
6.
14. Align the hood as necessary.


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A-Pillar Outer Panel Section and Reinforcement

Grinder
Hot Air Gun
Knife
Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
cardiagn.com
Materials
Name Specification
TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal

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Installation).
Installation).
Installation).

5. Position the carpet and wiring harness away from the repair area
6. Remove the front door hinges at the A-pillar.
7. NOTE: Due to construction and design of the A-pillar reinforcements, no sectioning can be performed on
these components. The inner reinforcements must be replaced at the factory seams.
Coupe shown, convertible similar.
Carefully cut the outer body panel only.

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Using a hot air gun, heat the area to aid in softening the NVH foam and remove the panel.
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10. Drill out the spot welds from the upper A-pillar reinforcement.
11. Drill out the spot welds and grind the seam welds.
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Using a hot air gun, heat the area to aid in softening the NVH foam and remove the upper A-pillar
reinforcement.
13. Drill out the welds on lower A-pillar reinforcement.

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Using a hot air gun, heat the area to aid in softening the NVH foam and remove the lower A-pillar
reinforcement.
Installation
1. Drill plug weld holes in the replacement A-pillar lower reinforcement.

2. Apply adhesive and NVH expanding foam as indicated.
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3. Install and spot weld the A-pillar lower reinforcement.
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4. Plug weld the A-pillar lower reinforcement.
5. Drill plug weld holes in the replacement A-pillar upper reinforcement.

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6. Apply adhesive to the upper flange of the A-pillar lower reinforcement.
7. Install and weld the A-pillar upper reinforcement.

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8. Complete welding the A-pillar upper reinforcement.
9. Cut a section from the replacement panel and drill holes for plug welding.
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10. Install the replacement panel and weld.
11. Spot weld the A-pillar panel.

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12. MIG plug weld the A-pillar panel.
13. Metal finish the repair areas using typical metal finishing techniques.
14. Apply a Ford approved primer to the repair area.


18. Install the front door hinges to the A-pillar.

Installation).
21. Align the hood as necessary.

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B-Pillar and Reinforcement - Coupe

8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
Seam Sealer -
TA-2-B
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3M™ 08463, Fusor® 121
Removal


1. Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
2. Refer to: Quarter Panel - Coupe (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
3. Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
NOTICE: B-pillar reinforcement components are constructed of Boron steel and can not be sectioned.
Replacement must be done at factory joints.
3. Position aside the carpet and wiring harness from the repair area.
4. Remove the bolts from the rear floor crossmember to B-pillar.

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5. Remove the NVH foam at the base of the B-pillar.
6. Drill out the spot welds on the B-pillar panel.

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7. Drill out the spot welds from the rear roof reinforcement on both sides.
8. Remove the rear roof reinforcement assembly.

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9. Drill out the spot welds on the B-pillar panel at the rear roof reinforcement flange.
10. Remove the B-pillar assembly.

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12. Remove the inner reinforcement.

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Installation
1. Drill holes for plug welding in the replacement panel.

2. Install the inner reinforcement and spot weld.

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3. Install the B-pillar assembly and spot weld.
4. Weld the B-pillar at the rear roof reinforcement flange.

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5. MIG weld the B-pillar panel.
6. Install the rear roof reinforcement panel and weld on both sides.
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7. Apply NVH expanding foam.
8. Install the rear floor crossmember bolts.

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11. Restore the corrosion protection.



B-Pillar and Reinforcement - Convertible

Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
cardiagn.com
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal


2. Refer to: Quarter Panel - Convertible (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
NOTICE: B-pillar reinforcement components are constructed of Boron steel and can not be sectioned.
Replacement must be done at factory joints.
3. Position aside the carpet and wiring harness from the repair area.
4. Remove the bolts from the rear floor crossmember to B-pillar.

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5. Remove the NVH foam at the base of the B-pillar.

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7. Remove the B-pillar assembly.

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9. Remove the inner reinforcement.
Installation
1. Drill holes for plug welding in the replacement panel.

2. Install the inner reinforcement and resistance spot weld.
3. Install the B-pillar assembly and resistance spot weld.

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4. MIG weld the B-pillar panel.
5. Apply NVH expanding foam.

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6. Install the rear floor crossmember bolts.


10. Reposition carpeting and wiring harness.

Installation).
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Front Door Skin Panel
Grinder
Hot Air Gun
Knife
Locking Pliers
Materials
Name Specification
TA-1, 3M™ 08115, Fusor® 108B
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Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal
1. Inspect the upper and lower door hinges for wear or damage, install new or rebuild as necessary.

1. Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
3. Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
4. Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal
and Installation).
5. Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and
Installation).
3. Carefully cut through the outer panel only.

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4. Remove the outer door panel.
5. Remove the remaining portion of the front door panel hem flange.
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Installation
1. Remove all adhesive and foreign materials from the door shell to outer door panel mating surfaces.
2. Remove the e-coat from the mating surface.

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3. Install NVH mastic pads to the replacement door panel as required.
4. Apply adhesive to the door shell mating surface.

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5. Apply anti-flutter NVH expanding foam as indicated.
6. Install the outer door panel and partially crimp the flange.
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7. Temporarily install the door on the vehicle.
8. Check for proper alignment and adjust as necessary.

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9. Carefully open the door and tack weld to lock panel in place.
10. Remove the door from the vehicle.

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11. NOTE: Smooth any residual adhesive squeeze-out in to the seam to act as a sealer.
Complete the flanging process.
12. Remove all foreign material.

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13. Apply a Ford approved primer to the flange area.

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15. Refinish the door shell flange using a Ford approved paint system.
16. Install the door.

Refer to: Front Door (501-03 Body Closures, Removal and Installation).
17. Sand and refinish the exterior repair area using a Ford approved paint system.


1. Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
2. Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
3. Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal
and Installation).
4. Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and
Installation).

Rocker Panel

Air Body Saw
Spot Weld Drill Bit
Materials
Name Specification
Seam Sealer -
TA-2-B
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Removal

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Installation).
3. Refer to: Front Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and
Installation).
4. Position aside the carpet and wiring harness in the repair area.
NOTE: Coupe shown, convertible is similar.
5. NOTE: Partial replacement due to damage for the outer panel only.
Carefully cut the outer panel only.

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7. Remove the rocker panel section.

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Installation
1. Cut section from the replacement part.

2. Install and seam weld the rocker panel section.

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3. Resistance spot weld the panel.
5. Prime the repair area using a Ford approved paint system.


9. Position the wiring harness and carpet to original position.

Installation).
3. Refer to: Front Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and
Installation).
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Rocker Panel Inner Reinforcement

Hot Air Gun
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
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TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
Removal

NOTE: The rocker panel inner reinforcement is made of martensitic steel and cannot be sectioned. It must be
replaced at factory seams.
Coupe shown, convertible is similar.
2. Available service part.

Refer to: Quarter Panel - Convertible (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
2. Refer to: B-Pillar and Reinforcement - Coupe (501-29 Side Panel Sheet Metal Repairs, Removal
and Installation).
Refer to: B-Pillar and Reinforcement - Convertible (501-29 Side Panel Sheet Metal Repairs,
Installation).
Installation).
4. Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs,
4. Position the carpet and wiring harness away from the repair area.
5. Remove the bolt from the inner rocker panel reinforcement.
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6. Remove the spot welds from the rocker panel.
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7. Remove the rocker panel assembly.
Installation
NOTE: The rocker panel inner reinforcement is made of martensitic steel and cannot be sectioned. It must be
replaced at factory seams.
1. Drill holes for plug welding in the replacement rocker panel.

2. Apply adhesive to the flange area of the inner reinforcement structure.
3. Install the rocker panel assembly and MIG weld.

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4. Resistance spot weld the rocker panel.
5. Install the bolt in the rocker panel reinforcement.

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7. Prime the repair area using a Ford approved paint system.



Installation).
2. Refer to: B-Pillar and Reinforcement - Coupe (501-29 Side Panel Sheet Metal Repairs, Removal
and Installation).
Refer to: B-Pillar and Reinforcement - Convertible (501-29 Side Panel Sheet Metal Repairs,
Installation).
Installation).
4. Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs,

501-30 Rear End Sheet Metal Repairs 2016 Mustang
Back Panel and Reinforcement

Hot Air Gun
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
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TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
Removal
1. If required , dimensionally restore the vehicle to pre-accident condition.


1. Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
2. Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
3. Reposition the carpeting and the wiring harness away from the working area.
5. Drill out the spot welds from the back panel.

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6. NOTE: Heat may be applied, not to exceed 170°C to aid in softening the adhesive .
Remove the back panel assembly.

7. Drill out the spot welds from the back panel reinforcement.
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8. NOTE: Heat may be applied, not to exceed 170°C to aid in softening the adhesive.
Remove the back panel reinforcement.

Installation
1. Drill holes in the replacement back panel reinforcement for plug welding.
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2. NOTE: Make sure the surface is clean and free of foreign material.
Apply metal bonding adhesive to the floor pan flange.

3. NOTE: Make sure that the component is clean and free of foreign material and lubricant.
Apply metal bonding adhesive to the back panel reinforcement upper flanges.
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4. Install the back panel reinforcement and spot weld.
5. MIG weld the panel.

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6. Drill holes in the back panel for plug welding.
7. NOTE: Make sure that the component is clean, free of foreign material and lubricant.
Apply metal bonding adhesive to the back panel.

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8. Install the back panel and spot weld.

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10. Metal finish the repair area using typical metal finishing procedures.

14. Reposition the wiring harness and carpet.


Quarter Panel - Coupe

Hot Air Gun
Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
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Name Specification
TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal


3. Refer to: Luggage Compartment Lid (501-03 Body Closures, Removal and Installation).
4. LH side
Refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
5. LH side as equipped.
Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS),
Refer to: Fuel Tank Filler Pipe (310-01B Fuel Tank and Lines - 3.7L Duratec (227kW/301PS),
Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).
Installation).
8. Refer to: Loadspace Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and
Installation).
9. Refer to: Rear Quarter Trim Panel (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3. Remove the door striker from the affected side.
4. Position aside the carpet and wiring harness.

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6. NOTICE: Cut through outer panel only.
Cut the quarter panel flange at the rocker and roof rail.

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10. NOTE: Heat may be applied, not to exceed 170°C to aid in softening the adhesive and NVH foam.
Remove the quarter panel assembly.

Installation
1. Drill holes in the replacement panel for plug welding.

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2. Apply NVH expanding foam and metal bonding adhesive to indicated areas.
3. Install the quarter panel and seam weld.

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4. Resistance spot weld the panel.

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7. Resistance spot weld the panel along the roof rail.

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8. Metal finish the repair area(s) using typical metal finishing techniques.


13. Install the door striker.

4. LH side
Installation).
Installation).
8. Refer to: Loadspace Trim Panel - Coupe (501-05 Interior Trim and Ornamentation, Removal and
Installation).
Installation).

Quarter Panel - Convertible

Hot Air Gun
Knife
Air Body Saw
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
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Name Specification
TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal


4. LH side
Installation).
Installation).
7. Refer to: Loadspace Trim Panel - Convertible (501-05 Interior Trim and Ornamentation, Removal
and Installation).
Installation).
3. Remove the door striker from the affected side.

4. Position aside the carpet and wiring harness.
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6. NOTICE: Cut through outer panel only.
Cut the quarter panel flange and drill out the spot welds.

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Remove the quarter panel assembly.

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Installation

2. Apply NVH expanding foam and metal bonding adhesive to indicated areas.
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3. Install the quarter panel and seam weld.
4. Weld the panel at the door opening.

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5. MIG weld the panel along flange areas.
6. Weld the panel along upper flange areas.

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7. Metal finish the repair area(s) using typical metal finishing techniques.
8. Sealing work: All areas must be sealed to production level


12. Install the door striker.

4. LH side
Installation).
Installation).
7. Refer to: Loadspace Trim Panel - Convertible (501-05 Interior Trim and Ornamentation, Removal
and Installation).
Installation).

Rear Floor Panel

Scraper for Straight Edges
Hot Air Gun
Knife
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
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Name Specification
TA-1, 3M™ 08115, Fusor® 108B
Seam Sealer -
TA-2-B
3M™ 08463, Fusor® 121
Removal

2. Position the carpeting and the wiring harness away from the working area.

1. As equipped
Refer to: Evaporative Emission Canister (303-13A Evaporative Emissions - 2.3L EcoBoost
Refer to: Evaporative Emission Canister (303-13B Evaporative Emissions - 3.7L Duratec
Refer to: Evaporative Emission Canister (303-13C Evaporative Emissions - 5.0L 32V Ti-VCT/5.0L
2. As equipped
Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 3.7L Duratec (227kW/301PS), Removal and
Installation).
Refer to: Fuel Tank (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and Installation).
3. Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and
Installation).
4. As equipped
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (231kW/314PS), Removal
and Installation).
Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.7L Duratec (227kW/301PS), Removal
and Installation).
Refer to: Muffler and Tailpipe (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
5. Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
6. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
7.
4. NOTE: Overview
Possible sectioning cut points depending on extent of damage.
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5. NOTE: Convertible only.
Drill out the spot welds on the crossmember.

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Remove the crossmember.
7. NOTE: Heat may be applied, not to exceed 170°C to aid in softening the NVH (noise, vibration and
harshness) mastic material.
Remove the NVH mastic material.

Use the General Equipment: Scraper for Straight Edges
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8. Drill out the spot welds and grind off the brazed material at the floor panel seams.
Drill out the spot welds on the lower extension of the quarter panel.
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Remove the foam carrier strip between the floor panel and quarter panel extension.
11. NOTE: Heat may be applied, not to exceed 170°C to aid in softening the adhesive.
Remove the floor pan assembly.

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Installation

3. Apply adhesive to the floor panel seams and flanges and install the floor panel assembly.
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4. MIG weld the floor panel to the reinforcements.
MIG braze the floor panel seams and plug weld the floor panel extension.
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Weld the floor panel to the quarter panel extension.

Install and weld the underbody crossmember.

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Apply NVH expanding foam to the foam carrier strip and install.

13. Apply NVH material (obtain locally) in original locations.
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1. As equipped
2. As equipped
Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 3.7L Duratec (227kW/301PS), Removal and
Installation).
Installation).
4. As equipped
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (231kW/314PS), Removal
and Installation).
Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.7L Duratec (227kW/301PS), Removal
and Installation).
Installation).
7.
15. Reposition the carpeting and the wiring harness.

Rear Side Member
Materials
Name Specification
Seam Sealer -
TA-2-B
Removal
NOTICE: The rear side member(s) are constructed of Dual-Phase (DP) 800 steel and cannot be sectioned.
Side member assembly must be replaced at factory joints.

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2. NOTE: Coupe
Overview
Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and
Tolerance Checks, Description and Operation).
3. NOTE: Convertible
Overview
Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and
Tolerance Checks, Description and Operation).
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Installation).
2. Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
3. As equipped
4. As equipped
5. As equipped
Installation).
5. Position the carpet and wiring harness away from the working area.
6. Remove spot welds as required and remove rear side member from damaged side(s).
Installation
2. Metal finish repair area as required using typical metal finishing techniques.



Installation).
2. Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
3. As equipped
4. As equipped
5. As equipped
Installation).
7. Reposition the carpeting and wiring harness.
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Rear Wheelhouse Outer

Air Body Saw
Locking Pliers
Materials
Name Specification
Seam Sealer -
TA-2-B
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Removal


Installation).
3. Reposition the carpeting and the wiring harness away from the working area.
NOTE: Cutline shown as a general guideline, depending on extent of the damage. LH side shown, RH similar.
4. NOTE: Coupe shown, convertible similar.
Mark a cutline on the wheelhouse panel.

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5. Cut and remove the damaged portion of the wheelhouse panel.
Installation
1. Cut section from the replacement panel.

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2. Install and weld the replacement section.
3. Weld the panel at seams.

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4. Metal finish as required using typical metal finishing techniques.

8. Reposition the carpet and the wiring harness.

Installation).

Water Drain Panel

Knife
8 mm Drill Bit
Spot Weld Drill Bit
Locking Pliers
Materials
Name Specification
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Seam Sealer -
TA-2-B
Plastic Bonding Adhesive -
TA-9
3M™ 08463, Fusor® 121
Removal


Installation).
3. As damage requires.
Refer to: Quarter Panel - Coupe (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Installation).
3. Position the carpeting and wiring harness away from the working area.
Drill out the welds.

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5. Drill out the spot welds on the lamp mounting panel.
6. Cut the NVH expanding foam between the quarter panel and rear lamp mounting panel.
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Drill out the welds in the reinforcement and remove the water drain panel assembly.
Installation

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3. Apply NVH expanding foam the quarter panel.
4. Apply metal bonding adhesive and weld the reinforcement of the panel assembly.
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5. Weld the drain panel to the quarter panel and package tray.
6. Metal finish as required using typical metal finishing techniques.


Installation).
3. As damage required.
Refer to: Quarter Panel - Coupe (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Installation).
11. Reposition the carpeting and wiring harness.
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501-36 Paint - General Information 2016 Mustang
Paintwork Defects and Damage
Materials
Name Specification
Motorcraft® Acid Neutralizer -
ZC-1-A
Motorcraft® Alkaline Neutralizer -
ZC-2-A
Repair
NOTE: Refinishing - Environmental Damage
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2. 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.
3. Prepare the acid neutralizer by mixing 8 parts of water to 1 part neutralizer in a bucket.
Material: Motorcraft® Acid Neutralizer / ZC-1-A
4. NOTICE: To avoid paint failure, do not allow the product to dry on the vehicle.
NOTE: Use a separate clean twisted lambs wool wash mitt for each product applied to the vehicle. Rinse
frequently to remove any particles trapped in the fibers.
Working quickly and beginning at the top of the vehicle and working to the sides, apply the 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.
5. Rinse the vehicle completely with cold water to remove the product.
6. Dry only the horizontal surfaces of the vehicle, do not dry the glass at this time.
7. NOTICE: To avoid damage to the paint surface, do not apply the alkaline neutralizer directly to the
vehicle plastic trim.
NOTE: Use a separate clean twisted lambs wool wash mitt for each product applied to the vehicle. Rinse
frequently to remove any particles trapped in the fibers.
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 closed-loop wash mitt.
Material: Motorcraft® Alkaline Neutralizer / ZC-2-A
8. 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.
9. Rinse the vehicle completely with cold water to remove the product.
10. Using a clean closed-loop wash mitt and locally available car wash soap, shampoo the entire vehicle
exterior 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.
12. 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.
13. Apply machine glaze to the vehicle surface as recommended by the product manufacturer.
14. 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.
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15. Apply a final polish material by hand, with a dual-action sander and foam pad, or with an orbital polisher
and appropriate polishing bonnet.
16. Using a locally available car wash soap, wash and dry the vehicle.
Repair
NOTE: Refinishing - Manufacturing Damage
2. Wash the repair area with pH-neutral soap and water.
3. Remove any trim, emblems and hardware from the area to be repaired.
4. NOTE: All delamination must be removed.
Sand or media blast the damaged surface, keeping the repair area as minimal as possible.
5. Treat any bare metal surface to prevent flash corrosion, and prime and block sand as necessary prior to
refinishing.
6. Mask the adjacent panels to protect from overspray.
7. Spot repair the base coat as necessary, following the paint manufacturer's prescribed procedures.
8. Following the paint manufacturer's prescribed procedure, apply clear coat to the entire panel.
9. Reapply any trim, emblems and hardware previously removed from the repair area.

502-00 Uni-Body, Subframe and Mounting System 2016 Mustang
Frame Assembly - Overview
Overview
Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts and
drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the
doors are often caused by improperly tightened bolts and body misalignment.
Every structural member and outer panel is designed to offer the maximum protection in the event of a collision.
The front subframe is bolted to the body and is used to:
aid in structural support

provide mounting surfaces for the front suspension control arms
provide a mounting point for the engine isolators
provide a mounting surface for the steering gear
The front crossmember is bolted to the body and is used to:
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provide a mounting surface for the front stabilizer bar
support the radiator, cooling fan and evaporator
The crossmember brace is bolted to the front subframe and front crossmember. It is used to aid in structural
support.
The rear subframe is bolted to the body and is used to:

provide mounting surfaces for the rear suspension lower arms and upper arms
The transmission crossmember is bolted to the body and is used to:

provide a mounting surface for the transmission support insulator
support the transmission
For body dimension specifications,


Rear Subframe
300-OTC1585AE
Powertrain Lift
Removal
NOTICE: Suspension fasteners are critical parts that affect the 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.
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1. Remove both rear halfshafts.
Refer to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
2. Remove both toe links.

Refer to: Toe Link (204-02 Rear Suspension, Removal and Installation).
3. Remove both rear springs.

Refer to: Spring (204-02 Rear Suspension, Removal and Installation).
4. Remove the rear stabilizer bar.

Refer to: Rear Stabilizer Bar (204-02 Rear Suspension, Removal and Installation).
5. NOTE: If equipped with dynamic suspension.
Remove both rear ride height sensors.

Refer to: Rear Suspension Height Sensor (204-05 Vehicle Dynamic Suspension, Removal and Installation).
6.
1. Index mark the driveshaft and the pinion flange for reference during installation.
2. Remove and discard the driveshaft-to-pinion flange bolts.
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7. NOTICE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube.
Damage to the CV-joint can result.
1. Support the driveshaft.

2. Using a screwdriver inserted into the slot on the pinion flange, pry the driveshaft from the pinion
flange.
3. Separate the driveshaft from the pinion flange.
8. If equipped.
Disconnect the differential fluid temperature sensor electrical connector.
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9. If equipped.
1. Remove the differential cooling return line retaining clip.
2. Remove the differential cooling return line and position aside.
10. If equipped.
1. Remove the differential cooling supply line retaining clip.
2. Remove the differential cooling supply line and position aside.
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11. Disconnect the differential vent tube.
12. On both sides.

Index mark the rear subframe for reference during installation.
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13. Position the powertrain lift under the rear subframe.
Use Special Service Tool: 300-OTC1585AE Powertrain Lift.
14. 1. Remove and discard the 2 rear subframe forward bolts.

2. Remove the 4 rear subframe bracket bolts and remove the brackets.
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15. Remove and discard the 2 rear subframe rearward bolts.
16. Using the powertrain lift, lower the rear subframe from the vehicle.
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Installation
1. Using the powertrain lift, raise the rear subframe to the vehicle.
2. NOTE: Only tighten the bolts finger tight at this stage.
Install the 2 new rear subframe rearward bolts.

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3. 1. NOTE: Only tighten the bolts finger tight at this stage.
Position the brackets and install the 4 rear subframe bracket bolts.
2. Install the 2 new rear subframe forward bolts.
4. On both sides.
Align the index marks made during removal.
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5. 1. Tighten the 4 rear subframe bracket bolts.
2. Tighten the 2 new rear subframe forward bolts.
6. Tighten the 2 new rear subframe rearward bolts.

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7. Connect the differential vent tube.
8. If equipped.
Connect the differential fluid temperature sensor electrical connector.
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9. If equipped.
1. Install the differential cooling supply line.
2. Install the differential cooling supply line retaining clip.
10. If equipped.
1. Install the differential cooling return line.
2. Install the differential cooling return line retaining clip.
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11. Position the driveshaft to the pinion flange and align the index mark made during removal.
12. Install the driveshaft-to-pinion flange bolts.

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Install both rear ride height sensors.

Refer to: Rear Suspension Height Sensor (204-05 Vehicle Dynamic Suspension, Removal and Installation).
14. Install the rear stabilizer bar.

Refer to: Rear Stabilizer Bar (204-02 Rear Suspension, Removal and Installation).
15. Install both rear springs.

Refer to: Spring (204-02 Rear Suspension, Removal and Installation).
16. Install both toe links.

Refer to: Toe Link (204-02 Rear Suspension, Removal and Installation).
17. Install both rear halfshafts.

18. Check the differential fluid level.

Refer to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).

Transmission Support Crossmember
Vehicle/Axle Stands
Wooden Block
Removal
NOTICE: The transmission crossmember must be installed in the same orientation as it was removed. An
incorrectly installed crossmember will change the driveline angle and cause a shudder when accelerating
from a stop or above average engine presence.

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Using a jackstand and a wooden block, support the transmission.
1. Remove the 2 transmission support insulator-to-transmission support crossmember nuts.

2. Remove the 4 transmission support crossmember bolts and the transmission support crossmember.
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Installation
1. With the same orientation as removed, position the transmission support crossmember and loosely install
the 2 transmission support insulator-to-transmission support crossmember nuts.
2. Loosely install the 4 transmission support crossmember bolts.

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3. NOTE: The transmission crossmember must be neutralized.
Slide the transmission support crossmember forward, rearward and side-to-side until the gaps between
the transmission support insulator studs and the transmission support crossmember are equal.
4. With the transmission support crossmember neutralized, tighten the 2 transmission support insulator-
to-transmission support crossmember nuts.
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5. With the transmission support crossmember neutralized, tighten the 4 transmission support crossmember
bolts.

204-00 Suspension System - General Information 2016 Mustang
Specifications
Alignment Specifications
NOTE: Measurements listed at curb load. Curb load is defined as "full service fluids, full fuel tank(s), no
passengers and no cargo".
Item LH RH Total/Split
Front
Camber — (Base Coupe, Base Convertible, Performance Package -0.72° ± -0.72° ± 0.0° ± 0.75°
Convertible, Track Package Convertible) 0.75° 0.75°
Camber — (Performance Package Coupe, Track Package Coupe) -1.03° ± -1.03° ± 0.0° ± 0.75°
0.75° 0.75°
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Caster — (Base Coupe, Base Convertible, Performance Package 7.12° ± 7.12° ± 0.0° ± 0.75°
Convertible, Track Package Convertible) 0.75° 0.75°
Caster — (Performance Package Coupe, Track Package Coupe) 6.91° ± 6.91° ± 0.0° ± 0.75°
0.75° 0.75°
Toe — (All Models) — — 0.0° ± 0.20°
Rear
Camber — (All Models) -1.50° ± -1.50° ± —
0.75° 0.75°
Toe — (All Models) 0.12° ± 0.12° ± 0.23° ±
0.20° 0.20° 0.20°
Ride Height
NOTE: Measurements listed at curb load. Curb load is defined as "full service fluids, full fuel tank(s), no
passengers and no cargo".
Item Specification
Front Ride Height
All Models 48.8 mm (1.921 in) ± 12 mm (0.472 in)
Rear Ride Height
All Models 32.1 mm (1.264) ± 10 mm (0.394 in)
Vehicle Lean Side-To-Side Differences
Front — Maximum 7.5 mm (0.295 in)

Rear — Maximum 6.3 mm (0.248 in)
Item Specification
Thrust Angle — Rear
All Models 0.0° ± 0.5°
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Suspension System
1. Road test the vehicle:

If any suspension alignment or ride height concerns are present, REFER to Symptom Chart:
Suspension System.
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are
present, REFER 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 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.
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Front or rear suspension components.
Suspension fastener(s).
Incorrect spring usage Spring(s).
Shock absorber(s).
Strut(s).
Suspension bushing(s).
Steering system components.
Wheel bearing and wheel hub(s).
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.
Symptom Chart: Suspension System

Vehicle drifts/pulls Refer to the Diagnostic Routine. GO to Pinpoint Test A
Wander Overloaded, unevenly or NOTIFY the customer of incorrect vehicle loading.
incorrectly loaded vehicle
Ball joint(s) INSPECT ball joints. INSTALL new control arm(s)
as necessary.
REFER to: Front Lower Arm (204-01 Front
Suspension, Removal and Installation).
or REFER to: Rear Lower Arm (204-01 Front
Damaged or missing front strut INSTALL a new front strut mount bearing(s) as
mount bearing(s) necessary.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
Loose, worn or damaged front INSPECT the wheel bearings. INSTALL new wheel
wheel bearing(s) bearings as necessary.
REFER to: Front Wheel Bearing and Wheel Hub
Installation).
Loose, worn or damaged INSTALL new suspension component(s) as
suspension component(s) necessary.
Loose suspension fasteners INSPECT the suspension fasteners. TIGHTEN to
specifications.
Steering components INSPECT the steering system. INSTALL new
Wheel alignment (excessive total ADJUST as necessary.
front toe out) REFER to: Front Toe Adjustment (204-00
Suspension System - General Information, General
Procedures).
Front bottoming or Worn, damaged or incorrect MEASURE the ride height.
riding low springs REFER to: Ride Height Measurement (204-00
Procedures).
INSTALL new springs as necessary. REFER to:
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Front Strut and Spring Assembly (204-01 Front
Worn front strut(s) INSTALL new struts as necessary.
Installation).
Abnormal/incorrect tire Incorrect tire pressure (rapid ADJUST the tire pressure. REFER to VC label.
wear center rib or inner and outer edge
wear)
Incorrect tire rotation intervals REFER to Owners Literature for correct tire
rotation intervals.
High-speed cornering
Excessive front or rear toe REFER to: Wheels and Tires (204-04A Wheels and
(inner or outer edge wear) Tires, Diagnosis and Testing).
Excessive negative or
positive camber (inner or
outer edge wear)
Front or rear suspension INSPECT the front and rear suspension system.
components REPAIR or INSTALL new suspension components
as necessary.
Sticky steering, poor Damaged or worn front strut INSTALL a new front strut mount bearing(s) as
returnability mount bearing(s) necessary.
Installation).
Binding ball joints INSPECT ball joints. INSTALL new control arm(s)
as necessary.
REFER to: Front Lower Arm (204-01 Front
or REFER to: Rear Lower Arm (204-01 Front
Steering wheel Unequal front or rear toe setting CHECK the wheel alignment.
off-center (side-to-side) REFER to: Front Toe Adjustment (204-00
Procedures).
or REFER to: Rear Toe Adjustment (204-00
Procedures).
Sway or roll Overloaded, unevenly or NOTIFY the customer of incorrect vehicle loading.
incorrectly loaded vehicle
Loose wheel nut(s) TIGHTEN the wheel nut(s) to specification.
REFER to: Wheel and Tire (204-04A Wheels and
Tires, Removal and Installation).
Strut(s) or shock absorber(s) INSTALL new struts or shock absorbers as
necessary.
Installation).
or REFER to: Rear Shock Absorber (204-02 Rear
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Loose stabilizer bracket-to-frame TIGHTEN the bolts to specification.
bolts REFER to: Front Stabilizer Bar (204-01 Front
Worn stabilizer bar bushings or INSTALL new stabilizer bar bushings, stabilizer bar
links links or stabilizer bar assembly as necessary.
REFER to: Front Stabilizer Bar Bushing (204-01
Front Suspension, Removal and Installation).
or REFER to: Front Stabilizer Bar Link (204-01
Front Suspension, Removal and Installation).
or REFER to: Front Stabilizer Bar (204-01 Front
Damaged or broken stabilizer bar INSTALL a new stabilizer bar or stabilizer bar
assembly as necessary.
REFER to: Front Stabilizer Bar (204-01 Front
Worn spring(s) INSTALL new springs as necessary.
Installation).
or REFER to: Spring (204-02 Rear Suspension,
Vehicle leans to one Unevenly loaded or overloaded NOTIFY the customer of incorrect vehicle loading.
side vehicle
Front or rear suspension INSPECT the front and rear suspension systems.
components INSTALL new suspension components as
necessary.
Incorrect drive axle(s) ride height. MEASURE the ride height.
Side-to-side lean out of REFER to: Ride Height Measurement (204-00
specification Suspension System - General Information, General
Procedures).
INSPECT the front and rear suspension systems.
REPAIR or INSTALL new components as
necessary.
If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before
If the fault is not visually evident, REFER to Symptom Chart or REFER to Symptom Chart: NVH.
Symptom Chart: NVH
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, Glossary of Terms
Testing).
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 to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and
Harshness, Diagnosis and Testing).
for the next likely system and continue diagnosis.
Additional diagnostics may be necessary to further isolate the concern. An electronic listening tool such as
Chassis Ear® may be used. Follow the tool manufacturer’s instructions and the Possible Sources found in the
following NVH chart to determine the connection points.
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Front suspension noise — a squeak, creak Strut top nut INSPECT and TIGHTEN to
or rattle noise. Occurs mostly over bumps specification.
or rough roads due to the suspension REFER to: Front Strut and Spring
moving in an up/down motion. Assembly (204-01 Front
Suspension, Removal and
Installation).
Jounce bumper INSPECT, LUBRICATE or
INSTALL new components as
necessary.
Stabilizer bar insulators and/or INSPECT for out-of-position
Stabilizer bar links bushings, isolators or locating pins.
necessary.
REFER to: Front Stabilizer Bar
(204-01 Front Suspension,
or REFER to: Front Stabilizer Bar
Bushing (204-01 Front
Installation).
or REFER to: Front Stabilizer Bar
Link (204-01 Front Suspension,
Steering gear and/or Tie rod INSPECT the steering gear and tie
ends rod ends. INSTALL new
REFER to: Power Steering
(211-02 Power Steering,
Front brake caliper INSPECT the front brake
caliper(s).
REFER to: Brake System (206-00
Brake System - General
Information, Diagnosis and
Testing).
Lower control arm / ball joint INSPECT ball joints. INSTALL new
control arm(s) as necessary.
REFER to: Front Lower Arm
or REFER to: Rear Lower Arm
Hub INSPECT hub(s). REPAIR or
REPLACE as necessary.
REFER to: Front Wheel Bearing
and Wheel Hub - Vehicles With:
SVT Performance Package
Exhaust system INSPECT the exhaust system.
REFER to: Exhaust System
(309-00A Exhaust System - 2.3L
EcoBoost (231kW/314PS),
or REFER to: Exhaust System
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Powertrain mounts INSPECT the powertrain mounts.
REFER to: Engine Mount LH
(303-01B Engine - 3.7L Duratec
(227kW/301PS), Removal and
Installation).
REFER to: Engine Mount RH
Installation).
or REFER to: Engine Mount LH
Installation).
Installation).
Installation).
Installation).
Subframe welds or insulators INSPECT subframe. REPAIR or
REFER to: Front Subframe - 2.3L
EcoBoost (201kW/273PS)
(502-00 Uni-Body, Subframe and
Mounting System, Removal and
Installation).
Rear suspension noise — a squeak, creak Loose or damaged rear shock INSPECT the rear shock
or rattle noise. Occurs mostly over bumps absorber(s) or shock absorber absorber(s) or shock absorber
or rough roads due to the suspension bushing(s) bushing(s). INSTALL new
moving in an up/down motion. components as necessary.
REFER to: Rear Shock Absorber
(204-02 Rear Suspension,
Damaged spring(s) or spring INSPECT the rear spring(s) and
mount(s) spring mount(s). REPLACE
damaged components as
necessary.
REFER to: Spring (204-02 Rear
Installation).
Worn or damaged stabilizer bar INSPECT the stabilizer bar
bushing(s) or link(s) bushing(s) or link(s). REPLACE
damaged or worn components as
necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear Suspension,
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or REFER to: Rear Stabilizer Bar
Link (204-02 Rear Suspension,
Worn or damaged lower control INSPECT for worn or damaged
arms, toe link ball joints or lower control arms, toe link ball
cross-axis joints joints or cross-axis joints.
REPLACE damaged or worn
Noise from front suspension when turning Strut top nut INSPECT and TIGHTEN to
— crunch or ratcheting noise. Occurs as a specification.
result of the suspension twisting and REFER to: Front Strut and Spring
flexing. Assembly (204-01 Front
Installation).
Worn or damaged front strut INSPECT for worn or damaged
bearing(s) strut bearing. INSTALL new
REFER to: Front Strut and Spring
Assembly (204-01 Front
Installation).
Coil Spring INSPECT springs. REPLACE as
necessary.
Installation).
Strut brackets or seat(s) INSPECT strut brackets or
seat(s). REPAIR as necessary.
Stabilizer bar INSPECT the stabilizer bar.
REPAIR or REPLACE as
necessary.
Steering gear INSPECT the steering gear.
REFER to: Power Steering
(211-02 Power Steering,
Tie rod ends INSPECT tie rod ends. INSTALL
new components as necessary.
REFER to: Tie Rod End (211-02
Power Steering, Removal and
Installation).
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Noise from front suspension when turning Steering stops Normal condition. No action
— Crunch clunk or grunt noise from the required.
front suspension occurring when turning to
full left or right stop.
Noise while braking — Noises occurring Front brake caliper INSPECT the front brake
during this condition result from rearward caliper(s).
and downward force applied to the REFER to: Brake System (206-00
suspension and subframe such as Brake System - General
rearward force applied to the lower Information, Diagnosis and
control arm. Testing).
Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Noise while accelerating — Noises Body (inner fender, bulkhead, INSPECT and REPAIR as
occurring during this condition result from seams and pinch welds) necessary.
powertrain torque and flex, such as torque
on the powertrain mounts during
acceleration.
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Installation).
Installation).
Installation).
Installation).
Installation).
Installation).
Exhaust system INSPECT the exhaust system.
REFER to: Exhaust System
Installation).
Noise while entering driveways or driving Body (inner fender, bulkhead, INSPECT and REPAIR as
over dips or depressions — Noises seams and pinch welds) necessary.
occurring during this condition result from
Stabilizer bar links INSPECT the stabilizer bar links.
the body , subframe or suspension
INSTALL new stabilizer bar links
twisting or flexing such as the tension on
as necessary.
body structure welds.
Link (204-01 Front Suspension,
or REFER to: Rear Stabilizer Bar
Link (204-02 Rear Suspension,
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Installation).
Clunk or pop or thump/thud — noise may Loose fasteners INSPECT for loose nuts or bolts.
be thought of as a loose part striking an
Worn or damaged bushings INSPECT for out-of-position or
adjacent part or a secure part coming
damaged components.
loose when force is applied. A clunk is
often rhythmic, repeatable and metallic in Struts & shocks INSPECT for worn or damaged
nature. struts or shocks. REPLACE as
necessary.
Installation).
or REFER to: Rear Shock
Absorber (204-02 Rear
Installation).
Coil spring or spring seat out of INSPECT for out-of-position or
position damaged components. ADJUST or
Worn or damaged ball joint(s) INSPECT ball joints. INSTALL new
Rattle — noise occurs mostly over bumps, Loose fasteners or INSPECT for loose nuts or bolts.
rough roads or uneven surfaces at low brackets TIGHTEN to specification.
speeds (i.e. parking lot). A rattle is often a Loose or damaged front INSPECT for out-of-position or
rapid, repetitive noise that can be metallic struts, shock absorber(s) damaged components. ADJUST or
or non-metallic in nature. or shock absorber INSTALL new components as
bushing(s), dust boot(s), necessary.
jounce bumper(s)
Damaged spring or
spring mount(s)
Damaged or worn
control/radius arm
bushing(s)
Worn or damaged
stabilizer bar bushings or
link(s)
Whine, roar or groan — noise generally Loose or damaged wheel INSPECT the front or rear wheel
occurs over 30 mph and is often more bearings bearing(s). INSTALL new
noticeable with steering input. bearing(s) as necessary.
Shimmy Loose wheel nut(s) TIGHTEN the nut(s) to
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specification.
REFER to: Wheel and Tire
(204-04A Wheels and Tires,
Loose front suspension TIGHTEN the fastener(s) to
fastener(s) specifications.
Loose front wheel bearing(s) INSPECT the front wheel
bearing(s). INSTALL new
bearing(s) as necessary.
Strut(s) or shock absorber(s) INSTALL new struts or shock
absorbers as necessary.
Installation).
Installation).
Shimmy — most noticeable on Excessive positive caster INSPECT the front suspension.
coast/deceleration. Also hard steering REPAIR or INSTALL new
condition suspension components as
necessary.
Rough/harsh ride Incorrect tire pressure ADJUST the tire pressure. REFER
to VC label.
Strut(s) or shock absorber(s) INSTALL new struts or shock
absorbers as necessary.
Installation).
Installation).
Spring(s) MEASURE the ride height.
REFER to: Ride Height
Measurement (204-00 Suspension
System - General Information,
INSTALL new springs as
necessary. REFER to: Front Strut
and Spring Assembly (204-01
Front Suspension, Removal and
Installation).
or REFER to: Spring (204-02 Rear
Installation).
Damaged suspension INSTALL new suspension
component(s) component(s) as necessary.
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Pinpoint Tests
Vehicle Drifts, Pulls
Diagnostic Overview
Possible Causes
Unevenly loaded vehicle

Tire pressure
Tire forces
Brake drag
Incorrect vehicle alignment
Bent/damaged vehicle components
Steering system
PINPOINT TEST A : VEHICLE DRIFTS, PULLS

A1 CHECK FOR UNEVENLY LOADED VEHICLE
Visually check the vehicle for an uneven loading condition.
Is the vehicle unevenly loaded?
Yes 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 VC label. REFER to:
REFER to: Identification Codes (100-01 Identification Codes, Description and Operation).
Check the tires for uneven/abnormal wear: REFER to: REFER to: Wheels and Tires (204-04A Wheels
and Tires, Diagnosis and Testing).
Are the tire pressures and tire conditions OK?

Yes GO to A3
No ADJUST the tire pressures to the specified pressure or INSTALL new tires as necessary.
A3 ISOLATE TIRE DRIFT/PULL CONDITION

Cross the front wheel and tire assemblies from left-to-right.
Does the vehicle drift/pull?
Yes If the vehicle drifts/pulls in the opposite direction, tire forces are causing the drift/pull.
ROTATE the wheel and tire assemblies front-to-rear. If the vehicle drifts/pulls in the same
direction, GO to A4
No Tire forces were causing the drift/pull and the concern has been corrected.
A4 CHECK FOR BRAKE DRAG

Spin all four wheel and tire assemblies by hand and check for brake drag.
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Do the wheels spin freely?
Yes GO to A5
No
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and
Testing).
to diagnose brake drag condition.
A5 CHECK THE WHEEL ALIGNMENT

Using alignment equipment and the manufacturer's instructions, check the wheel alignment.
Is the wheel alignment out of specification?
Yes ADJUST the alignment as necessary.

REFER to: Front Toe Adjustment (204-00 Suspension System - General Information,
No
REFER to: Power Steering (211-02 Power Steering, Diagnosis and Testing).
to diagnose steering system drift/pull/wander condition.

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Front Camber Adjustment
Wheel Alignment System
Adjustment
1. Using alignment equipment and the manufacturer's instructions, measure the front camber.
Use the General Equipment: Wheel Alignment System
2. Remove the wheels and tires.

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3. On both sides.
Unclip and position aside the wheel speed sensor harness.
4. On both sides.
Remove and discard the strut-to-spindle bolts and nuts.
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5. NOTE: Do not fully tighten the strut-to-spindle bolts and nuts until the alignment has been corrected.
NOTE: Original equipment bolts are splined, service bolts are smooth and smaller in diameter which
allows for camber adjustment.
On both sides.
Position the wheel spindle and install the 2 new service strut-to-spindle bolts and nuts and tighten until
snug.
6. On both sides.
Position the wheel speed sensor harness.
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7. Install the wheels and tires.
8. Using alignment equipment and the manufacturer's instructions, measure the front camber.
9. On both sides.
Tighten the strut-to-spindle bolts and nuts.
10. Recheck alignment to verify camber change and adjust front toe if necessary.
Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).
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Front Toe Adjustment
Adjustment
NOTE: Make sure that the vehicle is standing on a level surface.
1. Steering wheel in straight ahead position.
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2. Using alignment equipment and the manufacturer's instructions, check the front toe setting on both sides.
Loosen the outer tie rod end jamb nut.
2. On both sides.
Position aside the steering gear boot clamp.
3. NOTE: Do not allow the steering gear bellows to twist when the inner tie rod is rotated.
On both sides.
Rotate the inner tie rods until the toe reading is within specifications.
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4. Recheck the toe settings and adjust as necessary.

Rear Camber Adjustment
Adjustment
1. Using alignment equipment and the manufacturer's instructions, measure the rear camber.
2. Loosen the upper control arm inboard nut approximately 2 turns, and slide the upper control arm inboard or
outboard to adjust the rear camber.
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3. Recheck alignment to verify camber change and adjust rear toe if necessary.
Refer to: Rear Toe Adjustment (204-00 Suspension System - General Information, General Procedures).

Rear Toe Adjustment
Adjustment
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2. Using alignment equipment and the manufacturer's instructions, check the rear toe setting on both sides.
3. 1. NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Loosen the toe link nut approximately one full turn.

2. Rotate the toe link bolt to achieve the specified toe setting.
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4. Recheck the rear toe settings and adjust as necessary.

Ride Height Measurement
Surface Gauge
Check
Ride Height Measurement — Front
1. 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. Ride height = 3-2

2. Measure the distance between the flat level surface and the center of the rear control arm ball joint
cap (measurement 2)
3. Measure the distance between the flat level surface and the center of the rear control arm inboard
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bolt (measurement 3)
Use the General Equipment: Surface Gauge
2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge
position (measurement 2) and (measurement 3).
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3. Subtract measurement 2 from measurement 3 to obtain the front ride height.
Ride Height Measurement — Rear
4. 1. Ride height = 2-3

2. Measurement 2
3. Measurement 3
Use the General Equipment: Surface Gauge
5. Measure the distance between the flat level surface and the center of the toe link inboard cam bolt
(measurement 2).
6. Measure the distance between the flat level surface and the center of the toe link outboard bolt
(measurement 3).
7. Subtract measurement 3 from measurement 2 to obtain the rear ride height.
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204-01 Front Suspension 2016 Mustang
Front Suspension
The front suspension consists of the following components:
Front and rear lower arms

Stabilizer bar and links
Strut and spring assembly
Wheel bearing and wheel hub
Wheel spindle
The front suspension system incorporates a strut assembly that takes the place of the upper arm and ball joint.
The strut carries out the function of a shock absorber and is encompassed by a coil spring. The strut and spring
assembly supports the weight of the vehicle and is also the pivot point for the steering spindle. This system uses
front and rear lower control arms and ball joints for the lower (unloaded) pivot points of the steering spindle and/or
knuckle.
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Front Suspension
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
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Front Lower Arm
204-592
Separator, Lower Arm Ball Joint
TKIT-2006C-FFMFLM
TKIT-2006C-LM
TKIT-2006C-ROW
Vehicle/Axle Stands
Removal
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2. NOTICE: The front suspension height sensor must be disconnected from the lower control arm
prior to servicing suspension components or damage to the suspension height sensor and/or the
vehicle dynamic suspension system may occur. The sensor will need to be recalibrated after
reassembly.
NOTE: If equipped with dynamic suspension.
1. Remove the ride height sensor arm bracket bolt.

2. Position the ride height sensor arm bracket aside.
3. Remove and discard the front lower arm outboard nut.

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4. 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.
Separate the front lower arm from the wheel spindle.

Use Special Service Tool: 204-592 Separator, Lower Arm Ball Joint.
5. Remove and discard the front lower arm-to-frame bolt and remove the front lower arm.
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Installation
1. NOTE: Only tighten the bolt finger tight at this stage.
Position the front lower arm and install the new front lower arm-to-frame bolt.
2. 1. Attach the front lower arm to the wheel spindle.

2. Install the new front lower arm outboard nut.
Torque:
Non SVT: 85 lb.ft (115 Nm)
SVT: 76 lb.ft (103 Nm)
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3. Support the suspension at curb height.
4. NOTICE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight
of the vehicle resting on the wheels and tires, otherwise incorrect clamp load and bushing damage
may occur.
Tighten the front lower arm-to-frame bolt.

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1. Position the ride height sensor arm bracket.

2. Install the ride height sensor arm bracket bolt.
6. Install the wheel and tire.

7. Check and if necessary adjust front toe.

8. If equipped with dynamic suspension, calibrate the suspension system. Connect the scan tool and carry out
the Ride Height Calibration routine. Follow the scan tool directions.
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Front Stabilizer Bar
Removal
1. Remove the wheels and tires.

2. On both sides.
1. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway
torque.
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NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing the
stabilizer bar link nut.
Remove and discard the front stabilizer bar link lower nut.
2. Position aside the front stabilizer bar link.

Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.3L EcoBoost (231kW/314PS),
Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - 3.7L Duratec (227kW/301PS),
Refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - 5.2L 32V Ti-VCT, Removal and
Installation).
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5. NOTE: All vehicles except vehicles equipped with 5.0L engine.
On both sides.
Remove and discard the front stabilizer bar bushing bracket bolts.
6. NOTE: Shield located on LH side of vehicle.
If equipped.
Position the splash shield up out of the way to gain access to the rearward front stabilizer bar bushing
bracket bolt.
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7. NOTE: Vehicles equipped with 5.0L engine.
NOTE: On vehicles equipped with 5.0L engine, the rearward front stabilizer bar bushing bracket bolt is
under the alternator and must be removed through the wheel opening.
On both sides.
8. Remove the stabilizer bar.

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Installation
1. Install the stabilizer bar.
2. NOTE: Shield located on LH side of vehicle.
If equipped.
Position the splash shield up out of the way to gain access to the rearward front stabilizer bar bushing
bracket bolt.
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under the alternator and must be installed through the wheel opening.
On both sides.
Install the new front stabilizer bar bushing bracket bolts.
On both sides.
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5. Position the degas bottle and install the bolts.
6. Install the air cleaner.

Installation).
7. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while installing the stabilizer bar
link nut.
On both sides.
1. Position the front stabilizer bar link.
2. Install the new front stabilizer bar link lower nut.
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8. Install the wheels and tires.

Front Stabilizer Bar Bushing
Removal
NOTE: Vehicles equipped with performance package, front stabilizer bushings are not serviceable separately.
Replace the front stabilizer bar.

Installation).
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On both sides.
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Remove the LH wheel and tire.

under the alternator and must be removed through the wheel opening.
On both sides.
6. NOTE: Non performance package vehicle front stabilizer bushing shown.

1. Remove the front stabilizer bar bushing bracket.
2. Remove the front stabilizer bar bushing.
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Installation
1. NOTICE: Do not use any lubrication on the stabilizer bar or the bushings or damage to the
bushings may occur.
1. NOTE: Stabilizer bar bushings must be installed with slits facing the rear of the vehicle.
Install the front stabilizer bar bushing.

2. Install the front stabilizer bar bushing bracket.

under the alternator and must be installed through the wheel opening.
On both sides.
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Install the LH wheel and tire.

On both sides.
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5. Position the degas bottle and install the bolts.
6. Install the air cleaner.

Installation).
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Front Stabilizer Bar Link
Removal
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the
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Remove and discard the 2 front stabilizer bar link nuts and remove the front stabilizer bar link.
Installation

Front Strut and Spring Assembly
Removal

NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the
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Remove and discard the front stabilizer bar link upper nut and separate the front stabilizer bar link from the
strut and spring assembly.
3. 1. If equipped with dynamic suspension.

Remove the dynamic suspension strut wire harness bracket bolt and position the bracket and wire
harness aside.
2. Disconnect the 2 wheel speed sensor retainers and the 1 dynamic suspension strut wire harness
retainer.
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4. 1. If equipped.
Disconnect the brake sensor electrical connector.
2. If equipped with dynamic suspension.
Disconnect the dynamic suspension strut wire harness connector.
3. If equipped.
Unclip the brake sensor electrical connector and the 2 wire retainers from the strut.
5. NOTE: Base brakes shown, other applications similar.
Position aside the brake caliper assembly.

1. Remove and discard the 2 brake caliper anchor plate bolts.
2. Position aside the brake caliper assembly.
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6. 1. NOTE: Original strut-to-wheel spindle bolts are splined and may need to be driven out.
Remove and discard the 2 strut-to-wheel spindle bolts and nuts.

2. Separate the wheel spindle from the front strut and spring assembly.
7. 1. Remove and discard the 3 upper strut mount nuts.

2. Remove the front strut and spring assembly.
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Installation
1. 1. Install the front strut and spring assembly.

2. Install the 3 new upper strut mount nuts.
2. 1. Attach the wheel spindle to the front strut and spring assembly.
2. Install the 2 new strut-to-wheel spindle bolts and nuts.
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3. Position the brake caliper assembly and install the 2 new brake caliper anchor plate bolts.
4. 1. If equipped.
Clip the brake sensor electrical connector and the 2 wire retainers to the strut.
Connect the dynamic suspension strut wire harness connector.
3. If equipped.
Connect the brake sensor electrical connector.
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5. 1. Connect the 2 wheel speed sensor retainers and the 1 dynamic suspension strut wire harness
retainer.
Position the dynamic suspension strut wire harness bracket install the bolt.
6. 1. Position the front stabilizer bar link.
torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or
installing the stabilizer bar link nut.
Install the front stabilizer bar link upper nut.

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8. Check and if necessary adjust front camber.

Refer to: Front Camber Adjustment (204-00 Suspension System - General Information, General
Procedures).

Front Wheel Bearing and Wheel Hub
Removal
1. Remove the brake disc.

Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
2. Remove and discard the wheel hub grease cap.
3. Remove and discard the wheel hub nut.

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4. Remove the front wheel bearing and wheel hub.
Installation
1. Install the front wheel bearing and wheel hub.

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2. Install the new the wheel hub nut.
3. Install the new wheel hub grease cap.

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4. Install the brake disc.

Front Wheel Bearing and Wheel Hub - Vehicles With: SVT Performance Package
Removal

2. Remove and discard the 4 front wheel bearing and wheel hub bolts and remove the front wheel bearing
and wheel hub.
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Installation
1. NOTE: Tighten the front wheel bearing and wheel hub bolts in a cross pattern.
Install the front wheel bearing and wheel hub and install the 4 new front wheel bearing and wheel hub bolts.
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Rear Lower Arm
204-592
TKIT-2006C-FFMFLM
TKIT-2006C-LM
TKIT-2006C-ROW
Vehicle/Axle Stands
Removal
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reassembly.

3. Remove and discard the rear lower arm outboard nut.

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Separate the rear lower arm from the wheel spindle.

5. Remove and discard the rear lower arm-to-frame bolt and remove the rear lower arm.
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Installation
Position the rear lower arm and install the new rear lower arm-to-frame bolt.
2. 1. Attach the rear lower arm to the wheel spindle.

2. Install the new rear lower arm outboard nut.
Torque:
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may occur.
Tighten the rear lower arm-to-frame bolt.

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Wheel Knuckle - Vehicles With: SVT Performance Package
204-592
TKIT-2006C-FFMFLM
TKIT-2006C-LM
TKIT-2006C-ROW
Tie Rod End Remover
Removal
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1. NOTICE: Disconnect the battery ground cable anytime the steering gear is being serviced or
damage to the steering gear internal power relay may occur resulting in steering gear replacement.
Disconnect the battery ground cable.

2. Remove the front wheel bearing and hub assembly.

Refer to: Front Wheel Bearing and Wheel Hub - Vehicles With: SVT Performance Package (204-01 Front
3. Remove the brake disc shield.

Refer to: Brake Disc Shield (206-03 Front Disc Brake, Removal and Installation).
4. 1. Remove the front wheel speed sensor bolt.

2. Position the front wheel speed sensor aside.
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5. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or damage
to the wheel knuckle may result.
NOTICE: Use care when installing the tie rod separator or damage to the outer tie-rod end boot
may occur.
1. Remove and discard the tie rod end nut.

2. Disconnect the tie rod end from the wheel knuckle.
Use the General Equipment: Tie Rod End Remover
reassembly.

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Separate the front lower arm from the wheel knuckle.
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Separate the rear lower arm from the wheel knuckle.

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11. 1. Remove and discard the 2 strut-to-wheel knuckle bolts and nuts.
2. Remove the wheel knuckle.
Installation
1. 1. Position the wheel knuckle.

2. Install the 2 new strut-to-wheel knuckle bolts and nuts.
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2. 1. Attach the rear lower arm to the wheel knuckle.
3. 1. Attach the front lower arm to the wheel knuckle.

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5. 1. Attach the tie rod end to the wheel knuckle.

2. Install the new tie rod end nut.
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6. 1. Position the front wheel speed sensor.
2. Install the front wheel speed sensor bolt.
7. Install the brake disc shield.

8. Install the front wheel bearing and hub assembly.

9. Connect the battery ground cable.

Procedures).
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Wheel Spindle
204-592
TKIT-2006C-FFMFLM
TKIT-2006C-LM
TKIT-2006C-ROW
Tie Rod End Remover
Removal
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1. NOTICE: Disconnect the battery ground cable anytime the steering gear is being serviced or
damage to the steering gear internal power relay may occur resulting in steering gear replacement.

2. Remove the front wheel bearing and hub assembly.

Refer to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
3. Remove the brake disc shield.

4. 1. Remove the front wheel speed sensor bolt.

2. Position the front wheel speed sensor aside.
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5. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel spindle or damage
to the wheel spindle may result.
NOTICE: Use care when installing the tie rod separator or damage to the outer tie-rod end boot
may occur.
1. Remove and discard the tie rod end nut.

2. Disconnect the tie rod end from the wheel spindle.

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7. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel spindle.
NOTICE: Use care when releasing the lower arm and wheel spindle into the resting position or
Separate the front lower arm from the wheel spindle.


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9. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel spindle.
NOTICE: Use care when releasing the lower arm and wheel spindle into the resting position or
Separate the rear lower arm from the wheel spindle.

10. 1. Remove and discard the 2 strut-to-wheel spindle bolts and nuts.
2. Remove the wheel spindle.
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Installation
1. 1. Position the wheel spindle.

2. Install the 2 new strut-to-wheel spindle bolts and nuts.
2. 1. Attach the rear lower arm to the wheel spindle.

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3. 1. Attach the front lower arm to the wheel spindle.
4. 1. Attach the tie rod end to the wheel spindle.

2. Install the new tie rod end nut.
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5. 1. Position the front wheel speed sensor.
2. Install the front wheel speed sensor bolt.
6. Install the brake disc shield.

7. Install the front wheel bearing and hub assembly.


Procedures).
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Wheel Studs
Hydraulic Press
Removal
1. Remove the wheel bearing and wheel hub.

2. Press the wheel stud from the wheel bearing and wheel hub.
Use the General Equipment: Hydraulic Press
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3. Inspect the wheel bearing and wheel hub for damage. Replace as necessary.
Installation
1. Press the wheel stud into the wheel bearing and wheel hub.
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2. Install the wheel bearing and wheel hub.

Front Strut and Spring Assembly
Spring Compressor
Vise
DISASSEMBLY
1. NOTE: Typical strut and spring assembly shown.
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Compress the coil spring enough to relieve the tension on the strut assembly.
Use the General Equipment: Spring Compressor
NOTE: Do not use an impact wrench on the strut rod nut.
NOTE: Utilize the hex holding feature to prevent the strut rod from turning while removing the strut rod
nut.
Disassemble the front strut and spring assembly by removing the components as listed.
1. Cap.
2. Strut rod nut. (Discard)
3. Upper strut mount.
4. Upper spring seat.
5. Spring.
6. Dust boot.
7. Jounce bumper.
8. Lower spring seat.
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ASSEMBLY
1. NOTE: Make sure that the components are installed to the position noted before removal.
To assemble, reverse the disassembly procedure.
2. NOTE: Make sure that the spring is centered in the lower spring seat.
Make sure that the lower spring seat is properly installed.

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3. NOTE: If bearing is properly seated, there should be equal spacing on all sides.
Make sure that the bearing is properly seated in the mount.
4. NOTE: Typical strut and spring assembly shown.
1. NOTE: Utilize the hex holding feature to prevent the strut rod from turning while installing the strut
rod nut.
Install the new strut rod nut.

Use the General Equipment: Spring Compressor
2. Install the cap.
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204-02 Rear Suspension 2016 Mustang
Rear Suspension - Component Location
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Item Description
1 Coil spring
2 Stabilizer and links
3 Shock absorber
4 Wheel knuckle
5 Wheel bearing and wheel hub assembly
6 Wheel studs
7 Lower arm vertical link
8 Toe link
9 Lower arm and bushing assembly
10 Upper arm

Rear Suspension - Overview
Overview
The rear suspension consists of the following components:
Coil springs
Lower arm and bushing assemblies
Shock absorbers
Stabilizer bar and links
Toe links
Upper arms
Lower arm vertical links
Wheel bearing and wheel hub assemblies
Wheel knuckles
Wheel studs
The rear suspension uses 2 parallel arms (1 upper and 1 lower). Each arm has a mounting position to the chassis
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and an attachment at the wheel knuckle. This suspension allows the wheels to react to road imperfections
independent of each other. The shock absorber mounts to the lower arm and along with the spring, controls
vertical movement. The stabilizer bar and links control suspension lean/sway.

Rear Suspension
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
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Lower Arm
Vehicle/Axle Stands
Removal

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3. Remove and discard the 2 lower shock absorber bolts.

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Remove the ride height sensor arm bracket bolt and position the bracket aside.
5. Remove and discard the lower arm vertical link lower bolt and position the lower arm vertical link aside.
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6. 1. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway
torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing the
Remove and discard the stabilizer bar link lower nut and position the stabilizer bar link aside.
2. Remove and discard the lower control arm-to-wheel knuckle bolt.
7. NOTE: The muffler and tailpipe must be removed for clearance for the lower control arm rearward bolts.
Remove the muffler and tailpipe.

Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (231kW/314PS), Removal and
Installation).
Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.7L Duratec (227kW/301PS), Removal and
Installation).
Refer to: Muffler and Tailpipe (309-00D Exhaust System - 5.2L 32V Ti-VCT, Removal and Installation).
8. Remove and discard the forward lower control arm-to-frame bolt.
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9. 1. Support the coil spring.
2. Remove and discard the rearward lower control arm-to-frame bolt.
3. Remove the lower control arm.
Installation
1. Inspect the lower coil spring seat. Make sure it is properly aligned in the lower control arm.
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2. 1. Position the lower control arm.
Install the new rearward lower control arm-to-frame bolt.
3. Make sure that the coil spring is properly positioned in the lower coil spring seat.
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Install the new forward lower control arm-to-frame bolt.
5. NOTE: The muffler and tailpipe were removed for clearance for the lower control arm rearward bolts.
Install the muffler and tailpipe.

Installation).
Installation).
6. 1. NOTE: Only tighten the bolt finger tight at this stage.
Install the new lower control arm-to-wheel knuckle bolt.
torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while installing the
Position the stabilizer bar link and install the new stabilizer bar link lower nut.
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Position the lower arm vertical link and install the new lower arm vertical link lower bolt.
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Position the ride height sensor arm bracket and install the ride height sensor arm bracket bolt.
9. Install the 2 new lower shock absorber bolts.

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may occur.
1. Tighten the rearward lower control arm-to-frame bolt.

2. Tighten the lower control arm-to-wheel knuckle bolt.
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may occur.
Tighten the forward lower control arm-to-frame bolt.

may occur.
Tighten lower arm vertical link lower bolt.

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15. Check and if necessary, adjust rear camber.

Refer to: Rear Camber Adjustment (204-00 Suspension System - General Information, General
Procedures).

Lower Arm Vertical Link
Vehicle/Axle Stands
Removal


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3. Remove and discard the 2 lower arm vertical link bolts and remove the lower arm vertical link.
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Installation
NOTICE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the
vehicle resting on the wheels and tires, otherwise incorrect clamp load and bushing damage may occur.
1.
Position the lower arm vertical link and install the 2 new lower arm vertical link bolts.
1. Tighten the lower arm vertical link upper bolt.
2. Tighten the lower arm vertical link lower bolt.

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Rear Shock Absorber
Vehicle/Axle Stands
Removal

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2. Support the rear suspension.
Disconnect the rear shock absorber electrical connector.

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4. Remove and discard the 2 rear shock absorber lower bolts.
5. Remove and discard the 2 rear shock absorber upper bolts and remove the rear shock absorber.
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NOTE: If equipped.
Remove the rear shock absorber rod nut cap.
7. NOTICE: Do not use power tools to remove the nut.
NOTE: Use the hex-holding feature to prevent the shock absorber rod from turning while removing the
shock absorber rod nut.
Remove and discard the rear shock absorber rod nut.

Installation
NOTE: Use the hex-holding feature to prevent the shock absorber rod from turning while installing the
shock absorber rod nut.
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Install the new rear shock absorber rod nut.
NOTE: If equipped.
Install the rear shock absorber rod nut cap.

3. Install the rear shock absorber and install the 2 new rear shock absorber lower bolts.
4. 1. Compress the rear shock absorber and align the rear shock absorber upper mount under the body
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alignment pins.
2. Install the 2 new rear shock absorber upper bolts.
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Connect the rear shock absorber electrical connector.


Rear Stabilizer Bar
Removal
1. Remove the RH rear wheel and tire.

2. NOTICE: Do not use power tools to remove or install the stabilizer bar link nuts. Damage to the
stabilizer bar link ball joints and boots may occur.
NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing the stabilizer bar
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link nut.
On both sides.
Remove and discard the stabilizer bar link upper nut and position the stabilizer bar link aside.
3. Remove and discard the 4 stabilizer bar bracket bolts, remove the stabilizer bar brackets and remove the
stabilizer bar.
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Installation
1. Position the stabilizer bar, the stabilizer bar brackets and install the 4 new stabilizer bar bracket bolts.
Position the stabilizer bar link.
2. NOTE: Use the hex-holding feature to prevent the ball stud from turning while installing the
On both sides.
Install the new stabilizer bar link upper nut.
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3. Install the RH rear wheel and tire.

Rear Stabilizer Bar Bushing
Removal

2. On both sides.
1. Remove and discard the rear stabilizer bar bushing bracket bolts.
2. Remove the rear stabilizer bar bushing bracket.
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3. On both sides.
Remove the rear stabilizer bar bushing.
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Installation
1. NOTICE: Do not use any lubrication on the stabilizer bar or the bushings or damage to the
bushings may occur.
NOTE: Stabilizer bar bushings must be installed with slits facing the front of the vehicle.
On both sides.
Install the rear stabilizer bar bushing.
2. NOTE: Water may be applied to the bracket to aid in installation.
On both sides.
1. Install the rear stabilizer bar bushing bracket.
2. Install the new rear stabilizer bar bushing bracket bolts.
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Rear Stabilizer Bar Link
Removal
1. NOTICE: Do not use power tools to remove or install the stabilizer bar link nuts. Damage to the
stabilizer bar link ball joints and boots may occur.
NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing the stabilizer bar
link nut.
Remove and discard the 2 rear stabilizer bar link nuts and remove the rear stabilizer bar link.
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Installation

Spring
Removal
1. Remove the lower arm.

Refer to: Lower Arm (204-02 Rear Suspension, Removal and Installation).
2. Remove the spring.
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3. Inspect the upper spring seat for damage. Replace as necessary.
Installation
1. Install the spring.

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2. Make sure that the spring is correctly located in the upper spring seat.
3. Install the lower arm.

Refer to: Lower Arm (204-02 Rear Suspension, Removal and Installation).

Toe Link
Removal

3. 1. Index mark both the inner and outer cam wheels for use during assembly.
2. Remove and discard the toe link-to-knuckle bolt and nut, the toe link-to-frame bolt and nut and
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remove the toe link.
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Installation
1. NOTE: Align reference marks made during removal.
Position the toe link.

1. Install the new toe link-to-frame bolt and nut.
2. Install the new toe link-to-knuckle bolt and nut.
3. Recheck rear toe and adjust as necessary.

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Upper Arm
Removal

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may occur.
1. Remove and discard the upper arm-to-wheel knuckle bolt and nut.
2. Remove and discard the upper arm-to-frame flag-bolt and nut and remove the upper arm.
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Installation
2. Check and if necessary adjust rear camber.

Refer to: Rear Camber Adjustment (204-00 Suspension System - General Information, General
Procedures).

Wheel Bearing and Wheel Hub
205-D070 (D93P-1175-B)
Remover, Front Wheel Hub
Removal
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2. Remove and discard the spindle nut.
3. Press the halfshaft from the hub.

Use Special Service Tool: 205-D070 (D93P-1175-B) Remover, Front Wheel Hub.
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Refer to: Brake Disc (206-04 Rear Disc Brake, Removal and Installation).
5. Remove and discard the 4 wheel bearing and wheel hub bolts and remove the wheel bearing and wheel
hub.
Installation
1. NOTE: Tighten the wheel bearing and wheel hub bolts in a cross pattern.
Position the wheel bearing and wheel hub and install the 4 new wheel bearing and wheel hub bolts.
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3. NOTE: Apply the brake to keep the halfshaft from rotating.
Install the new spindle nut.

Torque:
Stage 2: 45°

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Wheel Knuckle
Removal

Refer to: Wheel Bearing and Wheel Hub (204-02 Rear Suspension, Removal and Installation).
2. 1. Remove the wheel speed sensor bolt and position aside the wheel speed sensor.
2. Remove the parking brake cable bracket bolt and position the parking brake cable bracket aside.
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4. Remove the lower arm vertical link.
Refer to: Lower Arm Vertical Link (204-02 Rear Suspension, Removal and Installation).
5. NOTE: Support the halfshaft.
1. Remove and discard the wheel knuckle-to-upper arm bolt and nut.
2. Remove and discard the wheel knuckle-to-toe link bolt and nut.
3. Remove and discard the wheel knuckle-to-lower arm bolt. Remove the knuckle.
Installation
1. 1. Position the wheel knuckle and install the new wheel knuckle-to-lower arm bolt.
2. Install the new wheel knuckle-to-toe link bolt and nut.
3. Install the new wheel knuckle-to-upper arm bolt and nut.
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2. 1. Position the parking brake cable bracket and install the parking brake cable bracket bolt.
2. Position the wheel speed sensor and install the wheel speed sensor bolt.
3. Install the lower arm vertical link.
Refer to: Lower Arm Vertical Link (204-02 Rear Suspension, Removal and Installation).

5. Check and if necessary adjust rear toe.

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Wheel Studs
Hydraulic Press
Removal

2. Press the wheel stud from the wheel bearing and wheel hub.
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3. Inspect the wheel bearing and wheel hub for damage. Replace as necessary.
Installation
1. Press the wheel stud into the wheel bearing and wheel hub.
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204-04A Wheels and Tires 2016 Mustang
Safety Precautions - Overview
Overview
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
NOTICE:
Ford Recommends The Following For Vehicles With Carbon Fiber And Alloy Wheels:
Tire Changer:
Ford requires center clamp style tire changers such as Hunter® Auto 34, Revolution, TC3900
or equivalent. Anything else, especially table top style machines, are highly likely to damage
the wheel which is not warrantable. Do not use table top design machines that grab onto the
inside of the wheel and that ride on the front wheel flange to remove the tire. Wheel damage
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will occur.
Tire Balancer:
Ford requires the use of wheel balancers that do not contact the wheel face such as,
Hunter® Road Force Touch GSP9700. Do not use machines that contact the wheel face.
Wheel damage will occur.
Alignment Machine:
Ford requires non-spade style alignment machines such as Hunter® Hawkeye Elite, or
equivalent. Anything else is highly likely to damage the wheel which is not warrantable. Do
not use machines that grab onto or contact the outside edge of the wheel. Wheel damage
will occur.
NOTICE: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents or
damage to the wheel finish may occur.
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, the tires should be rotated at recommended intervals.

Wheels and Tires
1. Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent,
Refer to the Symptom Chart: NVH.
2. 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.
3. 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.
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.
tire sizes.
speed rating.
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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.
Inspect the tires for signs of uneven wear. the following descriptions to identify the type of wear.
Check the tires for:
cuts.
stone bruises.
abrasions.
blisters.
embedded objects.
Check the valve stems for:
cracks.
cuts.
Install a new valve stem when damage is found or anytime a new tire or wheel is installed.
Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the indicator bands
become less than measurement 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
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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 and the tire is not causing a vehicle performance (noise/vibration) concern.
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: Right Front 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: Right Front tire shown, others similar.

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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(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 serious personal injury.
Symptom Chart: Tire Wear

Inner Excessive toe out and/or GO to Pinpoint Test A
edge/shoulder negative camber
wear Incorrect wheel and tire
assembly rotation intervals
Outer Excessive toe in and/or GO to Pinpoint Test B

edge/shoulder positive camber
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wear Incorrect wheel and tire
Heel/toe wear Excessive toe in/out ROTATE the wheel and tire assemblies. CHECK the
Incorrect wheel and tire alignment, ADJUST as necessary.
Diagonal wear Excessive toe in/out GO to Pinpoint Test C

Incorrect tire rotation
intervals
Loose, worn or damaged

suspension components REFER to: Suspension System (204-00 Suspension
Symptom Chart: NVH
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: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Description and
Operation).
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 to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and
Harshness, Description and Operation).
for the next likely system and continue diagnosis.

Sources
Sources
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 Radial Runout Measurement - Loaded Hunter Road Force® Method
shake or Radial Runout Measurement - Dial Indicator Method.
Vehicle Tires/wheels REFER to Radial Runout Measurement - Loaded Hunter Road Force® Method
vibration or Radial Runout Measurement - Dial Indicator Method.
Pinpoint Tests
Inner Edge, Shoulder Wear
Diagnostic Overview
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PINPOINT TEST A : INNER EDGE, SHOULDER WEAR
A1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or similar tool, measure the inside edge/shoulder tread depth.
Is the tread depth greater than 1.588 mm (0.0625 in) ?
Yes ROTATE the wheel and tire assemblies.

CHECK and ADJUST the toe to nominal +0.15 degrees (toe in). CHECK and ADJUST
caster and camber to nominal.
REFER to: Front Camber Adjustment (204-00 Suspension System - General Information,
No INSTALL a new tire(s). CHECK and ADJUST the toe to nominal. CHECK and ADJUST
Outer Edge, Shoulder Wear
Diagnostic Overview
PINPOINT TEST B : OUTER EDGE, SHOULDER WEAR

B1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or similar tool, measure the outside edge/shoulder tread depth.
Yes ROTATE the wheel and tire assemblies.

CHECK and ADJUST the toe to nominal -0.15 degrees (toe out). CHECK and ADJUST
No INSTALL a new tire(s). CHECK and ADJUST the toe to nominal. CHECK and ADJUST
Diagonal Wear
Diagnostic Overview
PINPOINT TEST C : DIAGONAL WEAR

C1 MEASURE THE TREAD DEPTH
Using a tread depth gauge or similar tool, measure the tread depth of the wear pattern.
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Yes If no performance concerns (noise/vibration) are present, the tire can remain in service.
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.
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.
Component Test- 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
Radial Runout Measurement - Loaded Hunter Road Force® Method
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 198.8 mi (320 km).
Some initial tire/wheel vibration issues (such as flat spotting) may correct themselves after the tires have been
in service for 198.8 mi (320 km). 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 (204-04A Wheels and Tires, Removal and Installation).
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3. NOTE: Use only a digital tire pressure 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.
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
60.0 psi (414 kPa) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer adapters
as shown.
Item Description
1 Wheel balancer
Item Description
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.
Radial Runout Measurement - Dial Indicator Method
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
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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.
NOTE: The following procedures should be used if normal diagnostics leads to a potential runout issue.
NOTE: 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.
NOTE: Use only a digital tire pressure gauge any time tire pressures are measured to be sure that accurate
values are obtained.
1. 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.

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
60.0 psi (414 kPa) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer adapters
as shown.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
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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.
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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.

Wheel to Hub Runout Minimization
Check
NOTE: 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.
1. 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.
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.
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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.

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Wheel to Tire Runout Minimization
Check
NOTE: Road Force® values in illustrations are shown in pounds.
NOTE: 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.
NOTE: Position the wheel and tire assembly on a tire machine and put a reference mark on the tire sidewall at
the valve stem position.
1. 1. Valve stem
2. Reference mark
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2. NOTICE: For vehicles equipped with a TPMS, the sensor may be damaged by incorrect tire
mounting or dismounting. Dismount the tire from the wheel as instructed in the 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.
Marker. Using a suitable tire machine, separate the tire beads from the wheel.
3. 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.
4. 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.
5. 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.
6. 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).
7. 1. First high spot on the tire
2. Second high spot on the tire
8. 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
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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.
9. 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 (0.0449 in), install a new wheel, balance the assembly and install on the vehicle using
the Wheel-to-Hub Optimization procedure.
Refer to: Wheel to Hub Runout Minimization (204-04A Wheels and Tires, General Procedures).

11. 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).

13. Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth turn) in the direction of
the arrow.
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Wheel and Tire
Materials
Name Specification
XL-2
Removal

2. NOTICE: Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel bearing
can occur.
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Remove the wheel nuts.
Installation
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: Make sure to apply a thin coat of anti-seize lubricant only to the interface between the
wheel pilot bore and the hub pilot. Do not allow the anti-seize to make contact with the wheel-
to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or brake disc friction
surfaces or damage to components may occur.
Clean the mounting surface of the wheel. Apply the substance from the specified tube.
2. NOTE: Only tighten the nuts finger tight at this stage.
Position the wheel and install the wheel nuts.
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3. 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 accelerates the development of brake roughness, shudder and vibration.
NOTE: The wheel nut torque specification is for clean, dry wheel stud and wheel nut threads.
NOTE: Final tightening to be performed with vehicle resting on tires.
Tighten the wheel nuts in a star pattern.

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Wheel and Tire
Wooden Block
DISASSEMBLY
NOTICE: Failure to follow the instructions below may result in damage to the TPMS.
NOTICE: The 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.
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2. NOTICE: The valve stem is connected to the TPMS sensor. Do not pull the valve stem from the
wheel, or damage to the sensor will occur.
NOTE: If a new TPMS sensor is being installed, remove and discard the valve stem-to-sensor screw and
the sensor.
Remove the valve stem core and fully deflate all air from the tire.
3. 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 TPMS sensor may occur.
NOTICE: Tire and valve stem position is critical to prevent damage to theTPMS 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.
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.
NOTE: Paddle type shown, roller type similar.

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.
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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.
1. Remove and discard the TPMS sensor-to-valve stem screw.

2. Separate the TPMS sensor from the valve stem.
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7. NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Using a suitable valve stem remover/installer, remove and discard the valve stem.
NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse theTPMS
sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor is reused.
NOTE: If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new sensor as
necessary.
8. NOTICE: To prevent 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.
Position the new valve stem onto the TPMS sensor and install the new screw.
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ASSEMBLY
NOTICE: Damage to the TPMS sensor may result if the tire mounting is not carried out as instructed.
1. NOTICE: It is important to pull the valve stem and 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 TPMS
sensor assembly.
NOTE: 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.
Using a suitable valve stem installer, install the new valve stem and TPMS sensor assembly.
2. 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.
3. 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.
4. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and mount the
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top bead of the tire.
5. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
Inflate the tire to the pressure specified on the VC label located on the driver door or door pillar.
NOTE: Proceed to the next step if the tire beads do not seat at the specified inflation pressure.
6. 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 steps listed below. Failure to follow these steps may result
in serious personal injury.
NOTICE: 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.


204-04B Tire Pressure Monitoring System (TPMS) 2016 Mustang
Tire Pressure Monitoring System (TPMS) - Component Location
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Item Description
1 TPMS sensor (4 required)
2 BCM
3 RTM, convertible (1 required)
4 RTM, coupe (1 required)

Tire Pressure Monitoring System (TPMS) - Overview
Overview
The BCM uses tire pressure sensors to monitor tire pressure. The sensors use radio signals to transmit the tire
pressure to the RTM. The RTM sends the information to the BCM over a LIN. The tire pressure sensors are
battery operated and mounted to the valve stems. The IPC illuminates the TPMS warning indicator and the
message center displays a message when a fault is present or when the tire pressure falls below the low
pressure limit.
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Tire Pressure Monitoring System (TPMS) - System Operation and Component Description
System Operation
System Diagram
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RTM TPMS Network Input Messages

TPMS data RTM Communicates tire pressure information to the BCM
TPMS Function
NOTE: When directed to train any TPMS sensors, use only the sensor training procedure outlined in this
manual. Do not use the TPMS reset procedure outlined in the Owner's Literature as this procedure does not
program new sensors to the module.
The TPMS uses 4 valve stem mounted sensors to monitor tire pressure. These sensors wirelessly transmit tire
pressure data to the RTM. The RTM is a radio signal receiver which collects the tire pressure data and sends the
information to the BCM along a LIN. All TPMS functions are controlled by the BCM. The BCM compares the tire
pressure data sent by the RTM with a programmed tire pressure. This programmed pressure is specified on the
VC label and cannot be changed. If the actual tire pressure is less than the programmed tire pressure, the BCM
sends a low tire pressure message to the IPC along the MS-CAN. The IPC responds by illuminating the TPMS
warning indicator and displaying a low tire pressure message in the message center. The TPMS sensors are
trained (calibrated) to the BCM which records the unique identifier for each TPMS sensor and records the location
of each sensor based on the training (calibration) order. The BCM sends messages to the RTM by first sending
the information along the HS-CAN1 to the GWM which then sends the information to the RTM along the MS-CAN.
The diagnostic scan tool is useful in diagnosing TPMS concerns and may be used to verify the accuracy of the tire
pressure data transmitted by the TPMS sensors. This is accomplished by comparing the BCM tire pressure PID
data to the actual tire pressure using a digital tire pressure gauge.
It is not necessary to train the sensors after a tire rotation on vehicles with the same front and rear tire pressures
however, the BCM cannot recognize the sensor identifiers have been moved to different positions and retains the
original position information for each sensor.
Wheel Rotation and Sensor Training Techniques
Training known good sensors from another vehicle can help determine whether the concern is with a sensor or the
RTM. This technique cannot help determine whether the concern is due to RFI as some RFI source could be
preventing the RTM from receiving the tire pressure status from the known good sensors as well as the original
sensors.
If the RTM in the suspect vehicle cannot train any of the original sensors and, likewise, cannot train known good
sensors from another vehicle, then the concern is with the module or RFI and not with the original sensors. The
original sensors should not be replaced. If a sensor in a certain location has caused several events, yet the
sensor trains and seems to operate normally, moving that particular wheel to a different location on the vehicle is
a good way to isolate the concern to a certain sensor/wheel location. Rotate the wheels and road test the vehicle.
This can be done in an attempt to replicate the concern and help determine if the concern followed the sensor or
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remained in the original sensor location.
If the vehicle has been stationary for more than 30 minutes, the sensors go into a "sleep mode" to conserve
battery power and need to be "woken up" so they transmit the latest tire pressure information to the RTM.
Refer to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire Pressure Monitoring System
(TPMS), General Procedures).
Training Sensors in a Different Order
If the first sensor fails the TPMS training procedure, the BCM aborts the entire procedure. Starting the training
procedure at a different wheel is a technique which can be used to determine if the remaining sensors can train to
the module. This can help save time determining if one sensor is damaged, other sensors are having concerns or
the BCM is experiencing training difficulties with a certain TPMS sensor location.
TPMS Warning Indicator
The TPMS warning indicator is used to indicate both a low tire pressure event and a possible system fault
condition. The message center displays additional information associated with the low tire pressure event or the
system fault condition. Occasionally, the warning indicator and message center indicate faults that cannot be
resolved by the customer. Treat these as TPMS faults that must be serviced.
TPMS Warning Indicator Illuminates Continuously
The TPMS warning indicator remains on continuously and the message center displays LOW TIRE PRESSURE
when any of the tire pressures fall below the low pressure limit. When this condition exists, adjust the tire
pressure to the recommended cold tire pressure indicated on the VC label.
Tire Pressure Monitoring System (TPMS) Warning Indicator Flashes
The TPMS warning indicator flashes for 70 seconds and then remains on continuously when the ignition is set to
ON and the TPMS is malfunctioning. The TPMS status (TPMS_STATUS) PID can be used to determine why the
TPMS warning indicator is flashing.
Tire Pressure Sensor Fault — The message center displays TIRE PRESSURE SENSOR FAULT when a
TPMS sensor is malfunctioning.
No communication with the BCM — The TPMS warning indicator illuminates when the IPC has not received
any signals from the BCM for more than 5 seconds. The message center displays TIRE PRESSURE
MONITOR FAULT.
Tire Pressure Monitor Fault — The message center displays TIRE PRESSURE MONITOR FAULT when
the TPMS is malfunctioning.
TPMS PID Definitions

The BCM monitors the TPMS status. Use the diagnostic scan tool to view the current status of the TPMS status
(TPMS_STATUS) PID. This helps identify the current system status and may aid in diagnosing the system. The
PID has 4 valid states:
TPMS_STATUS PID displays SENSOR FAULT if the BCM has not received the tire pressure data from 1 to
3 TPMS sensors for 20 minutes when vehicle speed is above 32.2 km/h (20 mph).
TPMS_STATUS PID displays SYSTEM FAULT if the BCM has not received the tire pressure data from all
4 TPMS sensors for 20 minutes when vehicle speed is above 32.2 km/h (20 mph).
TPMS_STATUS PID displays LOW if the BCM has detected that at least 1 TPMS sensor is reporting low
tire pressure.
TPMS_STATUS PID displays SYSTEM ACTIVE if the TPMS is functioning normally.
Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event Parameter Identifications (PIDs) to store detailed information about
the last 5 times the TPMS warning indicator was activated. These Parameter Identifications (PIDs) can be used
to acquire more information about a particular TPMS event, but must be used carefully.
PID Definition
EVT1_AGE_IGN The number of key cycles since the TPMS was activated. This PID cycles from zero to
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through 255 and then starts over from zero again. This can be used to determine how long ago a
EVT5_AGE_IGN TPMS event occurred and the time (in key cycles) between events.
EVT1_TR_LOC This is the last programmed location for the TPMS sensor identifier causing each TPMS
through event. Due to tire rotation, the sensor may no longer be at the original location. It is
EVT5_TR_LOC suggested that all the Parameter Identifications (PIDs) be recorded, the system
retrained, and then the sensor identifier Parameter Identifications (PIDs) be used to
pinpoint the actual location of each sensor.
EVT1_PRES_BP This is the tire pressure associated with each TPMS indicator event. This can be used
through along with the function code to clearly identify the TPMS events that were strictly due to
EVT5_PRES_BP low pressure. It can also be used to determine when a sensor is transmitting inaccurate
tire pressure.
EVT1_SNSR_ST Describes the warning status of each TPMS event by using the information
through received from the TPMS_STATUS PID. If there is a communication concern, the
EVT5_SNSR_ST status could be NORMAL.
UNKNOWN
NORMAL (normal operation)
LOW (low pressure event)
FAULT (sensor fault or system fault)
EVT1_SNSR_ID This is the identifier of the sensor involved in each TPMS event. EVT1 is the most recent
through event that triggered the TPMS warning indicator.
EVT5_SNSR_ID
Radio Frequency Interference (RFI)
RFI can be caused by:
Video equipment has been found to cause RFI especially when the video and power supply lines are near
the TPMS.
Anti-theft alarms (even those installed by the dealership) have been found to create enough RFI to cause
the TPMS to malfunction or lose considerable range. These anti-theft alarms can be difficult to locate, as
they are usually hidden somewhere out of the way for reduced accessibility.
Many in-vehicle cell phone chargers have been found to cause considerable RFI. The vehicles with the
power point closest to the RTM are the most affected. It must be noted that most cell phone chargers do
not produce high levels of RFI all the time. This depends on the state of charge of the cell phone battery.
The phone battery must be almost completely discharged in some cases.
Power supplies and DC/ AC inverters typically create a lot of RFI. Most consumer grade equipment has
very little filtering or shielding.
Using Hit Rate Parameter Identifiers (PIDs) to Determine the Presence of Radio Frequency Interference
(RFI)
If an intermittent RFI issue is suspected, the information contained in the last 5 TPMS warning event Parameter
Identifiers (PIDs) can be combined with specific Parameter Identifiers (PIDs) from the BCM to determine which
TPMS sensors are being affected and if a RFI source is currently present in the vehicle.
The BCM module contains Parameter Identifiers (PIDs) that keep track of the number of TPMS messages
received from the 4 trained TPMS sensors. These Parameter Identifiers (PIDs) can provide insight on the
performance of the TPMS, and can help establish the presence of an Frequency Interference (RFI) source.
TPM_HITS_LF (Tire Pressure Monitor Hit Rate Left Front) – The number of TPMS messages received by
the BCM module from the LH front sensor
TPM_HITS_RF (Tire Pressure Monitor Hit Rate Right Front) – The number of TPMS messages received
by the BCM module from the RH front sensor.
TPM_HITS_LRO (Tire Pressure Monitor Hit Rate Left Rear Outer) – The number of TPMS messages
received by the BCM module from the LH rear sensor
TPM_HITS_RRO (Tire Pressure Monitor Hit Rate Right Rear Outer) – The number of TPMS messages
received by the BCM module from the RH rear sensor.
Method for determining if a RFI issue has been affecting the TPMS:
1. Collect the last 5 TPMS events and determine if they were due to system faults or low tire air pressure.
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2. Collect the TPMS Hit Rate PID counters and compare them to the last 5 TPMS events.
3. If the TPMS Hit Rate PID counters are significantly different from each other or if the locations with lower
hit rate values show up as fault locations in last 5 TPMS events and BCM DTC B124D:02 (Tire Pressure
Sensor: General Signal Failure) is present, an intermittent RFI source is most likely preventing the signals
from these TPMS sensors from reaching the RTM.
4. An intermittent RFI source can also be the case when all 4 TPMS sensors show up in the last 5 fault
events and BCM DTC B1182:00 (Tire Pressure Monitoring System (TPMS): No Sub Type Information) is
present. The possible cause would a strong source of RFI noise.
Original Equipment Manufacturer (OEM) Modules
In some cases the RFI may actually be caused by a module or ground on the vehicle. Depending on the severity
of the concern, a dirty ground, improperly built ground shield or module can disable the system. Modules which
have microcontrollers using clock circuits to create timing pulses for the microprocessor may radiate RFI.
Using Customer Electronics to Pinpoint Radio Frequency Interference (RFI)
This method can be a way to determine the cause of a concern before the sensors and module are replaced with
little or no effect on system performance. Discuss with the customer what types of devices were being used when
the event occurred. Determine which power points were being used and, if necessary, ask the devices be
activated to determine their affect on the TPMS.
Options for Eliminating Intermittent TPMS Operation Caused by Radio Frequency Interference (RFI)
If an Original Equipment Manufacturer (OEM) component or customer device is causing a RFI concern,
replace the device.
If a phone charger is causing a RFI concern, the customer should consult with their cell phone provider to
acquire a different battery charger.
If a device such as a dealer installed anti-theft alarm is causing a RFI concern, move the device to another
location in the vehicle. In the case of a portable device move the power cord to another power point
location.
In summary, if the RFI source is present and cannot be moved or replaced, the intermittent concern remains. The
TPMS must accept the unwanted system operation the RFI can cause.
Ambient Temperature Change and Tire Pressure
Tire pressures fluctuate with temperature changes. For this reason, tire pressures must be set 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, the tire inflation pressure must be adjusted 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 warning indicator.
As the ambient temperature decreases by -12.2° C (10° F), tire pressure decreases 6.9 kPa (1 psi). Adjust the
tire pressure by 6.9 kPa (1 psi) for each -12.2° C (10° F) of ambient temperature drop as necessary to keep the
tire at the specified VC label pressure. To adjust the tire pressure indoors for colder outside temperatures, refer
to the following table.
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BCM
The BCM is a multifunction module which monitors all sensor inputs and all CAN messages relating to the TPMS.
The BCM records and retains the unique sensor identifier of each TPMS sensor.
The BCM retains the previous sensor location information following a tire rotation. For the BCM to learn the new
sensor location, the sensors must be trained (calibrated) to the BCM.
Refer to: Tire Pressure Monitoring System (TPMS) Sensor Location Calibration (204-04B Tire Pressure
Monitoring System (TPMS), General Procedures).
Additionally, the sensors must be trained when a new BCM is installed.
When installing a new BCM, there are several procedures that must be carried out in order for the module to
function correctly. These procedures include, but are not limited to; PMI, anti-theft parameter reset, programming
keyless entry remote and setting customer preferences.
Refer to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Removal and Installation).
RTM
The RTM is a radio signal receiver which collects the tire pressure data from the TPMS sensors.
TPMS Sensor
Each of the 4 TPMS sensors contain a battery, a tire pressure sensor and a radio transmitter. The TPMS sensor
radio transmissions are sent approximately once every 60 seconds when the vehicle speed exceeds 32.2 km/h
(20 mph).
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Tire Pressure Monitoring System (TPMS)
DTC Charts
RTM DTC Chart

U0146:00 Lost Communication with GO to Pinpoint Test H
Gateway "A": No Sub Type
Information
U0401:00 Invalid Data Received from GO to Pinpoint Test J
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ECM / PCM "A": No Sub Type
Information
U0401:82 Invalid Data Received from GO to Pinpoint Test J
ECM / PCM "A": Alive /
Sequence Counter Incorrect /
Not Updated
U1A00:00 Private Communication GO to Pinpoint Test I
Network: No Sub Type
Information
U2100:00 Initial Configuration Not This DTC is present when a new RTM is installed, or when the
Complete: No Sub Type RTM is incorrectly flashed or reconfigured. This DTC clears
Information when the RTM is correctly configured.
Using a diagnostic scan tool, CONFIGURE the RTM.
FOLLOW all diagnostic scan tool instructions.
U3000:04 Control Module: System CHECK vehicle service history for recent service actions
Internal Failure related to this module. This DTC sets due to incomplete or
improper PMI procedures. If there have been recent service
actions with this module, REPEAT the PMI procedure as
directed by the diagnostic scan tool.
If there have been no recent service actions, INSTALL a new
RTM to correct the failure to retain configuration data.
REFER to: Radio Transceiver Module (RTM) (419-10
Multifunction Electronic Modules, Removal and Installation).
BCM DTC Chart

B1182:00 Tire Pressure Monitoring GO to Pinpoint Test A
System: No Sub Type
Information
B1182:55 Tire Pressure Monitoring This DTC is only present when a new BCM is installed, or
System: Not Configured the BCM is flashed or reconfigured. This DTC clears when
the BCM is correctly configured, all 4 TPMS sensors are
trained to the BCM and the BCM self-test completes
successfully.
Using a diagnostic scan tool, CONFIGURE the BCM.
TRAIN the TPMS sensors,
REFER to: Tire Pressure Monitoring System (TPMS) Sensor
Location Calibration (204-04B Tire Pressure Monitoring
System (TPMS), General Procedures).
CARRY OUT a BCM self-test to clear the DTC.
B124D:02 Tire Pressure Sensor: General GO to Pinpoint Test E

Signal Failure
B1251:00 Tire Pressure Sensor Low GO to Pinpoint Test C
Battery: No Sub Type
Information
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B1254:51 Right Rear (Outside on Dual This DTC is only present when a new BCM is installed, or
Wheel) Tire Pressure Sensor the BCM is flashed or reconfigured. This DTC is cleared
and Transmitter Assembly: Not after the TPMS senors locations are trained to the BCM.
Programmed TRAIN the TPMS sensors,
B1255:51 Left Rear (Outside On Dual This DTC is only present when a new BCM is installed, or
Wheel) Tire Pressure Sensor the BCM is flashed or reconfigured. This DTC is cleared
and Transmitter Assembly: Not after the TPMS senors locations are trained to the BCM.
Programmed TRAIN the TPMS sensors,
C1A56:51 Left Front Tire Pressure Sensor This DTC is only present when a new BCM is installed, or
and Transmitter Assembly: Not the BCM is flashed or reconfigured. This DTC is cleared
Programmed after the TPMS senors locations are trained to the BCM.
C1A58:51 Right Front Tire Pressure This DTC is only present when a new BCM is installed, or
Sensor and Transmitter the BCM is flashed or reconfigured. This DTC is cleared
Assembly: Not Programmed after the TPMS senors locations are trained to the BCM.
U0559:56 Invalid Data Received from CHECK the service history for recent service actions related
Radio Transceiver: Invalid / to the RTM. This DTC sets due to incomplete or improper
Incomplete Configuration PMI procedures.
If there have been recent service actions with the RTM,
REPEAT the PMI procedure as directed by the diagnostic
scan tool.
If there have been no recent service actions with the RTM,
INSTALL a new RTM to correct the failure to retain the
configuration data.
REFER to: Radio Transceiver Module (RTM) (419-10
Multifunction Electronic Modules, Removal and Installation).
— All Other BCM Diagnostic

Trouble Codes (DTCs) REFER to: Body Control Module (BCM) (419-10 Multifunction
Electronic Modules, Diagnosis and Testing).
Symptom Chart
Symptom Chart: Tire Pressure Monitoring System
Symptom Chart
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A module does not respond to Fuse
the diagnostic scan tool Wiring, terminals or REFER to: Communications Network (418-00
connectors Module Communications Network, Diagnosis
Communication and Testing).
network concern
BCM
TPMS warning indicator is on Refer to the Pinpoint Test GO to Pinpoint Test E

continuously and the message
center displays LOW TIRE
PRESSURE
TPMS warning indicator is on Diagnostic Trouble Codes Using a diagnostic scan tool,
continuously and the message (DTCs) present in the BCM or RETRIEVE all Diagnostic Trouble
center does not display LOW RTM Codes (DTCs) from the BCM and the
TIRE PRESSURE RTM.
For any BCM Diagnostic Trouble Codes
(DTCs), GO to the DTC Chart: BCM.
For any RTM Diagnostic Trouble Codes
(DTCs), GO to the DTC Chart: RTM.
The BCM does not enter TPMS Refer to the Pinpoint Test GO to Pinpoint Test F
sensor training mode
The TPMS warning indicator is Communication
never or always on network concern REFER to: Instrumentation, Message Center
IPC and Warning Chimes (413-01 Instrumentation,
Message Center and Warning Chimes,
One or more TPMS sensors do Refer to the Pinpoint Test GO to Pinpoint Test G
not train and no Diagnostic
Trouble Codes (DTCs) are
present
Pinpoint Tests
B1182:00
REFER to: Tire Pressure Monitoring System (TPMS) - System Operation and Component Description (204-04B
Tire Pressure Monitoring System (TPMS), Description and Operation).
Communication between the RTM and the TPMS sensors can be interrupted by Radio Frequency Interference
(RFI), which causes intermittent issues that are not vehicle concerns. Radio Frequency Interference (RFI) is
generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters
and portable entertainment equipment.

B1182:00 Tire Pressure Monitoring Set by the BCM in continuous memory when all 4 of the tire pressure
System (TPMS): No Sub sensors are faulted, not communicating with the RTM or when sensor
Type Information data is not received by the BCM from the RTM.
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Possible Sources

RTM communication concern
TPMS sensor(s)
GWM
BCM
Inspect for cell phone chargers or GPS units.

Inspect for Non-Original Equipment Manufacturer (OEM) wheels or run-flat tires.
Verify horn operation.
Verify spare tire is not in use.
NOTE: Make sure all aftermarket electronic equipment has been disconnected (if possible) and the customer
has been questioned about the electronic equipment they may have been using in the vehicle when this concern
was identified.
PINPOINT TEST A : B1182:00

A1 CHECK FOR COMMUNICATION WITH THE GWM (GATEWAY MODULE A) , THE RTM (RADIO
TRANSCEIVER MODULE) AND THE BCM (BODY CONTROL MODULE)
Ignition ON.
Does the GWM, the RTM and the BCM all pass the Network Test?
Yes GO to A2
No DIAGNOSE the GWM, RTM or BCM does not respond to the scan tool.
and Testing).
A2 CHECK FOR RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, carry out the RTM self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the RTM?
Yes DIAGNOSE all RTM Diagnostic Trouble Codes (DTCs). GO to the DTC Chart: RTM.
No GO to A3
A3 CHECK THE BCM (BODY CONTROL MODULE) TPMS (TIRE PRESSURE MONITORING
SYSTEM) STATUS (TPMS_STATUS) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the BCM TPMS_STATUS PID.
Does the TPMS_STATUS PID display SYSTEM FAULT?
Yes GO to A4
No GO to A6
A4 CARRY OUT THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSOR TRAINING
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PROCEDURE
Train all 4 TPMS sensors.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor Location Calibration (204-04B Tire Pressure
Did all of the TPMS sensors train and did the horn sound when each sensor was trained?
Radio Frequency Interference (RFI). For information on locating sources of Radio
Frequency Interference (RFI),
REFER to: Tire Pressure Monitoring System (TPMS) - System Operation and Component
Description (204-04B Tire Pressure Monitoring System (TPMS), Description and
Operation).
No GO to A5
A5 REPEAT THE TPMS (TIRE PRESSURE MONITORING SYSTEM) TRAINING

NOTE: A spare tire cannot be programmed to the vehicle. If a damaged road wheel is located in the
vehicle and the RTM cannot communicate with it, or if the damaged wheel has been dropped off at a
repair facility, the BCM sets a TPMS sensor fault. Repair and remount the road wheel as necessary to
restore system operation.
If the spare tire is in use, repair and remount the road wheel as necessary to restore system operation.
Move the vehicle to rotate the wheels at least one-fourth of a turn. Leave the vehicle doors open. Start
the sensor training procedure at a different wheel.
Did any of the TPMS sensors train and did the horn sound when each sensor was trained?
Yes If only some of the sensors trained, INSTALL a new TPMS sensor for each sensor that
failed to train.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor (204-04B Tire Pressure
Monitoring System (TPMS), Removal and Installation).
If all the sensors trained, the concern may have been caused by Radio Frequency
Interference (RFI). For information on locating sources of Radio Frequency Interference
(RFI),
Operation).
No GO to A6

Ignition OFF.
Repair:
corrosion (replace connector or terminals - clean module pins)
damaged or bent pins - replace terminals or pins
pushed-out pins - replace pins as necessary
Connect the BCM connectors. Make sure they seat and latch correctly.
Yes The sensors may not be present. DISMOUNT the tires and VERIFY the sensors are
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present and mounted to the wheels.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
If a sensor is missing, INSTALL a new sensor.

If all the sensors are present, CHECK OASIS for any applicable Technical Service
Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW
the TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,

Operation).
B124D:02
Communication between the RTM and the TPMS sensors can be interrupted by Radio Frequency Interference
(RFI), which causes intermittent issues that are not vehicle concerns. Radio Frequency Interference (RFI) is
generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters
and portable entertainment equipment.

B124D:02 Tire Pressure Sensor: Set by the BCM in continuous memory when 1, 2 or 3 of the tire pressure
General Signal Failure sensors are faulted, not communicating with the RTM or when sensor data
is not received by the BCM from the RTM.
Possible Sources

One or more TPMS sensors not trained
TPMS sensor(s)
Inspect for customer electronic devices, such as cell phone chargers or GPS units.
Verify spare tire is not in use.
PINPOINT TEST B : B124D:02

B1 CHECK THE BCM (BODY CONTROL MODULE) TPMS (TIRE PRESSURE MONITORING
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SYSTEM) STATUS (TPMS_STATUS) PID (PARAMETER IDENTIFICATION) AND SENSOR IDENTIFIERS
Ignition ON.
Using a diagnostic scan tool, view and record the following BCM Parameter Identifications (PIDs):
Left Front Tire Transmitter Identifier (TPM_S_ID_LF)
Right Front Tire Transmitter Identifier (TPM_S_ID_RF)
Left Rear Tire Transmitter Identifier (TPM_S_ID_LRO)
Right Rear Tire Transmitter Identifier (TPM_S_ID_RRO)
View the BCM TPMS_STATUS PID.
Does the BCM TPMS_STATUS PID display SENSOR FAULT?
Yes GO to B2
No If the TPMS_STATUS PID displays SYSTEM FAULT, GO to Pinpoint Test A
B2 CARRY OUT THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSOR TRAINING
PROCEDURE
Yes Using a diagnostic scan tool, LOCATE the updated TPMS sensor identifiers trained to the
BCM.
COMPARE these values to those recorded prior to the TPMS sensor training procedure.
Disregarding sensor position, any sensor identifiers not matching those retrieved from the
module were changed, but not retrained. The sensors are now trained to the vehicle,
diagnosis is complete.
DOCUMENT all TPMS sensor identifiers on the applicable warranty claim.
No GO to B3
B3 ATTEMPT TO TRAIN THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSORS AGAIN
Move the vehicle to rotate the wheels at least one-fourth of a turn. Starting at a different wheel, train all 4
TPMS sensors.
Did any of the TPMS sensors train and did the horn sound when each sensor was trained?
Yes If only some of the sensors trained, INSTALL a new TPMS sensor for each sensor that
failed to train.
If all the sensors trained, the concern may have been caused by Radio Frequency
Interference (RFI). For information on locating sources of Radio Frequency Interference
(RFI),
Operation).
No GO to B4
B4 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION
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Ignition OFF.
Repair:
corrosion (replace connector or terminals - clean module pins)
damaged or bent pins - replace terminals or pins
pushed-out pins - replace pins as necessary
Yes The sensors may not be present. DISMOUNT the tires and VERIFY the sensors are
present and mounted to the wheels.
REFER to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
If the sensors are missing, INSTALL new sensors.

CLEAR the Diagnostic Trouble Codes (DTCs).
If all the sensors are present, CHECK OASIS for any applicable Technical Service
Bulletins (TSBs). If a TSB exists for this concern, DISCONTINUE this test and FOLLOW
TSB instructions. If no Technical Service Bulletins (TSBs) address this concern,

module connections. ADDRESS the root cause of any connector or pin issues. CLEAR the
B1251:00
When one or more of the TPMS sensors have a low battery, the TPMS warning indicator flashes for 70 seconds
and then remains on continuously when the ignition is turned to the ON position, and the message center displays
TIRE PRESSURE SENSOR FAULT.

B1251:00 Tire Pressure Sensor Low Battery: No Sets in continuous memory when attempting to train a
Sub Type Information TPMS sensor with a low battery.
Possible Sources

One or more TPMS sensors not trained
TPMS sensor
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PINPOINT TEST C : B1251:00

C1 TRAIN THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSORS TO DETERMINE THE
INOPERATIVE SENSOR
Train all 4 tire pressure sensors.
Yes The system is operating correctly at this time.

No Before installing a new sensor(s): If a sensor does not respond, 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. 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 TPMS sensor(s).
Diagnosing Radio Frequency Interference Faults
One or more TPMS sensors not being trained or missing, RTM wiring and BCM wiring, or an internal failure of the
RTM, GWM or BCM can all present symptoms similar to Radio Frequency Interference (RFI).
Possible Sources

Not all TPMS sensors are installed
TPMS sensor(s) not trained
TPMS sensor(s)
Intermittent TPMS operation due to Radio Frequency Interference (RFI)
RTM
GWM
BCM
Inspect for customer electronic devices, such as a cell phone charger or GPS unit.
Inspect for aftermarket wheels or run-flat tires (tires with steel body cord plies in the tire sidewall).
Verify horn operation
NOTE: Make sure that all aftermarket electronic equipment has been disconnected (if possible) and the
customer has been questioned about the electronic equipment they may have been using in the vehicle when
this concern was identified.
PINPOINT TEST D : DIAGNOSING RADIO FREQUENCY INTERFERENCE FAULTS

D1 CHECK FOR COMMUNICATION WITH THE GWM (GATEWAY MODULE A) AND THE RTM (RADIO
TRANSCEIVER MODULE)
Ignition ON.
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Do the GWM and the RTM pass the Network Test?
Yes GO to D2
No DIAGNOSE the GWM or RTM does not respond to the scan tool.
and Testing).
D2 CHECK FOR RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Are there any Diagnostic Trouble Codes (DTCs) present in the RTM?
Yes DIAGNOSE all RTM Diagnostic Trouble Codes (DTCs). REFER to the DTC Chart: RTM.
No GO to D3
D3 VIEW THE BCM (BODY CONTROL MODULE) TPMS (TIRE PRESSURE MONITORING SYSTEM)
STATUS (TPMS_STATUS) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Using a diagnostic scan tool, view the BCM TPMS_STATUS PID.
Does the TPMS_STATUS PID display SYSTEM FAULT?
Yes GO to D4
No GO to D6
D4 CARRY OUT THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSOR TRAINING
PROCEDURE
NOTE: Before beginning TPMS sensor training, make sure the vehicle is away from other vehicles or
devices which may cause Radio Frequency Interference (RFI) such as electric motors or radio
transmitters.
Operation).
No GO to D5
D5 ATTEMPT TO CARRY OUT THE SENSOR TRAINING PROCEDURE AGAIN USING KNOWN
GOOD SENSORS
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Move the vehicle to rotate the wheels at least one-fourth of a turn. Leave the vehicle doors open.
Attempt to train known good TPMS sensors from another vehicle.
Did all of the known good TPMS sensors train and did the horn sound when each known good
sensor was trained?
Yes If some of the sensors trained, INSTALL a new TPMS sensor for each sensor that failed
to train.
If all the known good sensors trained, INSTALL new TPMS sensors.
No INSTALL a new RTM.
If the concern is still present, GO to D6

Ignition OFF.
Repair:
corrosion (install new connector or terminals – clean module pins).
damaged or bent pins – install new terminals or pins.
pushed-out pins – install new pins as necessary.
TPMS Warning Indicator Is On Continuously And The Message Center Displays Low Tire Pressure
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B124D:02 Tire Pressure Sensor: General This DTC sets in continuous memory if any of the TPMS sensors
Signal Failure fail to transmit any tire pressure data.
Possible Sources
Tire pressure not set to specifications listed on the VC label

Spare tire currently in use
TPMS sensor
Verify the spare tire is not in use.

Verify the air pressure in all 4 tires matches the pressure indicated on the VC label.
PINPOINT TEST E : TPMS (TIRE PRESSURE MONITORING SYSTEM) WARNING INDICATOR IS ON

CONTINUOUSLY AND THE MESSAGE CENTER DISPLAYS LOW TIRE PRESSURE
E1 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, carry out the BCM Diagnostic Trouble Codes (DTCs).
Is DTC B124D:02 present?
Yes GO to E2
No For other BCM Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: BCM.
If there are no Diagnostic Trouble Codes (DTCs) present in the BCM, GO to E3
E2 VERIFY BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B124D:02
Ignition OFF.
Ignition ON.
Activate each TPMS sensor.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire Pressure
Using a diagnostic scan tool, carry out the BCM Diagnostic Trouble Codes (DTCs).
Is DTC B124D:02 present?
Yes GO to E3
No If the TPMS warning indicator is on continuously and the message center is displaying low
tire pressure, GO to E3
If the TPMS warning indicator is not illuminated and the message center does not display
low tire pressure, the system is operating correctly at this time. The concern may have
been caused by Radio Frequency Interference (RFI). For information on locating sources
of Radio Frequency Interference (RFI),
Operation).
E3 CHECK FOR SPARE TIRE IN USE

NOTE: A spare tire cannot be programmed to the vehicle. If a damaged road wheel is located in the
vehicle and the RTM cannot communicate with it, or if the damaged wheel has been dropped off at a
repair facility, the BCM sets a TPMS sensor fault. Repair and remount the road wheel as necessary to
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restore system operation.
Check the spare tire location.
Is the spare tire in use?
Yes REPAIR and REMOUNT the wheel to the vehicle.

ADJUST tire pressures to the required pressure as defined on the VC label.

No GO to E4
E4 CHECK FOR LOW TIRE PRESSURE

Measure and record the pressure in all 4 tires using a digital tire pressure gauge.
Adjust the pressure for those found to be below the specification listed on the VC label.
To clear the low pressure warning indicator, drive the vehicle for at least 2 minutes above 32.2 km/h (20
mph) or activate each sensor at least twice.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire Pressure
Do not train the sensors at this time.
Has the TPMS warning indicator gone out?
Yes The system is operating correctly at this time. The cause was low tire pressure.
No GO to E5
E5 TRAIN ALL 4 TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSORS

Yes GO to E6
No GO to Pinpoint Test G
E6 CHECK THE TIRE PRESSURES USING THE BCM (BODY CONTROL MODULE) TPMS (TIRE
PRESSURE MONITORING SYSTEM) SENSOR PARAMETER IDENTIFICATIONS (PIDS)
Using a diagnostic scan tool, view the following BCM Parameter Identifications (PIDs):
Left Front Tire Pressure (TPM_PRES_LF)
Right Front Tire Pressure (TPM_PRES_RF)
Left Rear Tire Pressure (TPM_PRES_LRO)
Right Rear Tire Pressure (TPM_PRES_RRO)
Do the tire pressures indicated by the Parameter Identifications (PIDs) match the tire pressures
measured previously, ±20.7 kPa (3 psi)?
Yes The system is operating normally at this time. The concern may have been caused by an
incomplete or incorrectly performed sensor calibration or low tire pressure.
No INSTALL a new TPMS sensor(s) for the sensor(s) displaying inaccurate tire pressure.
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The BCM Does Not Enter TPMS Sensor Training Mode
The training (calibration) can be carried out manually or by using a diagnostic scan tool,
When one or more new TPMS sensors are installed or a new BCM is installed, the sensors must be trained
(calibrated) to the BCM. For the manual training procedure, the BCM must receive a valid ignition signal, a valid
brake pedal position signal and a valid vehicle speed signal. The start-stop switch signal and the brake pedal
position signal are both direct inputs to the BCM, the vehicle speed signal is sent to the BCM from the PCM over
the HS-CAN1.
If the vehicle has been stationary for more than 30 minutes, the TPMS sensors enter a "sleep mode" to conserve
battery power. It becomes necessary to wake them up so they transmit the latest tire pressure information to the
RTM.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire Pressure Monitoring
Possible Sources

Stoplamp switch concern
Start-stop switch concern
PCM concern
BCM
Inspect for non-Original Equipment Manufacturer (OEM) wheel or run-flat tires.
PINPOINT TEST F : THE BCM (BODY CONTROL MODULE) DOES NOT ENTER TPMS (TIRE
PRESSURE MONITORING SYSTEM) SENSOR TRAINING MODE
F1 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Are there any "Lost Communication" or "Invalid Data" Diagnostic Trouble Codes (DTCs) present in
the BCM?
Yes DIAGNOSE all BCM Diagnostic Trouble Codes (DTCs).

No GO to F2
F2 CHECK THE IGNITION SWITCH INPUT

Ignition ON.
Observe the start-stop switch LED indicator after entering RUN mode.
Is the start-stop switch LED indicator flashing?
Yes GO to F3
No DIAGNOSE the start-stop switch.
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F3 CHECK FOR VEHICLE SPEED-RELATED DIAGNOSTIC TROUBLE CODES (DTCS) IN THE PCM
(POWERTRAIN CONTROL MODULE)
Ignition ON.
Using a diagnostic scan tool, carry out the PCM KOEO self-test.
Are there any Diagnostic Trouble Codes (DTCs) present in the PCM?
Yes DIAGNOSE the PCM DTC.

No GO to F4
F4 CHECK THE STOPLAMP OPERATION

Press and release the brake pedal while monitoring the stoplamps.
Do the stoplamps operate correctly?
Yes GO to F5
No DIAGNOSE the stoplamp switch and stoplamps.
F5 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
corrosion (install new connector or terminals – clean module pins).
damaged or bent pins – install new terminals or pins.
pushed-out pins – install new pins as necessary.

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One or More TPMS Sensors Do Not Train and No Diagnostic Trouble Codes (DTCs) are Present
If the vehicle has been stationary for more than 30 minutes, the TPMS sensors enter a "sleep mode" to conserve
battery power. It becomes necessary to wake them up so they transmit the latest tire pressure information to the
RTM.
REFER to: Tire Pressure Monitoring System (TPMS) Sensor Activation (204-04B Tire Pressure Monitoring
Possible Sources
TPMS sensors
Inspect for non-Original Equipment Manufacturer (OEM) wheel or run-flat tires.
PINPOINT TEST G : ONE OR MORE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSORS DO
NOT TRAIN AND NO DIAGNOSTIC TROUBLE CODES (DTCS) ARE PRESENT
G1 ATTEMPT TO TRAIN THE TPMS (TIRE PRESSURE MONITORING SYSTEM) SENSORS
NOTE: The BCM has a 2-minute time limit between sensor responses. If the BCM does not recognize any
of the 4 TPMS sensors during this time limit, the horn sounds twice and the message center displays TIRE
NOT TRAINED REPEAT. The entire procedure must be repeated.
TRAIN all 4 TPMS sensors.
Operation).
No If one or more TPMS sensors trained, GO to G2
If none of the TPMS sensors trained, GO to Pinpoint Test D
G2 CHECK FOR RADIO FREQUENCY INTERFERENCE

Ignition ON.
Move the vehicle to rotate the wheels at least one-fourth turn.
TRAIN all 4 TPMS sensors.
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Operation).
No For each sensor that did not train, INSTALL a new TPMS sensor.
U0146:00
With the ignition ON, the GWM sends messages to the RTM using the MS-CAN 1. If the RTM does not receive
these messages within a predetermined time frame, the RTM sets a DTC.

U0146:00 Lost Communication with This DTC sets in continuous memory if any of the following
Gateway "A": No Sub Type messages is missing from the GWM or contain invalid information;
Information ignition status, TPMS status or vehicle configuration data.
Possible Sources

GWM
RTM
PINPOINT TEST H : U0146:00

H1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the GWM pass the Network Test?
Yes GO to H2
No DIAGNOSE the GWM does not respond to the scan tool.
and Testing).
H2 RECHECK THE RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the RTM Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Yes GO to H3
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H3 RETRIEVE ALL DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE GWM (GATEWAY MODULE
A)
Are any Diagnostic Trouble Codes (DTCS) present in the GWM?
Yes DIAGNOSE the GWM Diagnostic Trouble Codes (DTCS).

No GO to H4
H4 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0146:00 SET IN OTHER MODULES
Using a diagnostic scan tool, carry out the self-test to retrieve all Continuous Memory Diagnostic Trouble
Codes (CMDTCs) from all modules.
Is DTC set in 1 or more modules in addition to the RTM?
Service Bulletins (TSBs) address this concern, INSTALL a new GWM.
REFER to: Gateway Module A (GWM) (418-00 Module Communications Network,
Service Bulletins (TSBs) address this concern, INSTALL a new RTM.
U1A00:00
With the ignition ON, the BCM and the RTM communicate using a LIN. If the RTM is unable to communicate with
the BCM using this LIN, the RTM sets a DTC.

U1A00:00 Private Communication This DTC sets in continuous memory if the RTM communication bus
Network: No Sub Type reset counter reaches zero. This is most likely due to a circuit failure in
Information the LIN, an internal failure of the BCM or an internal failure of the RTM.
Possible Sources

BCM
RTM
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PINPOINT TEST I : U1A00:00
Ignition ON.
Do the RTM and the BCM pass the Network Test?
Yes GO to I2
No DIAGNOSE the RTM or BCM does not respond to the scan tool.
and Testing).
I2 CHECK FOR BCM (BODY CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Yes DIAGNOSE the Diagnostic Trouble Codes (DTCs).

No GO to I6
I3 CHECK THE RTM (RADIO TRANSCEIVER MODULE) BATTERY VOLTAGE INPUT FOR AN OPEN
Ignition OFF.
Disconnect RTM C4458.
Measure:
C2280C-22 C4458-6
Yes GO to I4
I4 CHECK THE RTM (RADIO TRANSCEIVER MODULE) BATTERY VOLTAGE INPUT FOR A SHORT
TO GROUND
Measure:

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C4458-6 Ground
Yes GO to I5
VERIFY BCM fuse 32 (10A) is OK. INSTALL a new fuse as necessary.
I5 CHECK THE RTM (RADIO TRANSCEIVER MODULE) GROUND CIRCUIT FOR AN OPEN
Measure:

C4458-1 Ground
Yes GO to I6
I6 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Measure:

C2280B-26 Ground
Yes GO to I7
I7 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN

Measure:

C2280B-26 C4458-2
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Yes GO to I8
I8 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Connect BCM C2280B.
Ignition ON.
Measure:

C4458-2 Ground
Is a steady voltage greater than 3 volts present?

No GO to I9
I9 CHECK FOR CORRECT RTM (RADIO TRANSCEIVER MODULE) OPERATION

Ignition OFF.
Inspect the RTM electrical connector.
Repair:
Connect RTM C4458, make sure the connector seats and latches correctly.
Connect all previously disconnected BCM electrical connectors, make sure the connectors seat and latch
correctly.

Service Bulletins (TSBs) address this concern, INSTALL a new RTM.
U0401:00, U0401:82
With the ignition ON, the PCM sends vehicle speed data messages to the GWM along the HS-CAN1. The GWM
relays the messages to the RTM using the MS-CAN 1. If the vehicle speed data messages are invalid or faulted,
the RTM sets a DTC and the TPMS warning indicator is illuminated.
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U0401:00 Invalid Data Received from ECM / PCM This DTC sets in continuous memory if the vehicle speed
"A": No Sub Type Information message from the PCM is "invalid" or "faulted" instead of
the actual vehicle speed data.
U0401:82 Invalid Data Received from ECM / PCM This DTC sets in continuous memory if the vehicle speed
"A": Alive / Sequence Counter Incorrect / message from the PCM does not refresh.
Not Updated
Possible Sources

GWM
PCM
RTM
PINPOINT TEST J : U0401:00, U0401:82

J1 CHECK THE RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Is DTC U0146:00 also present?
Yes DIAGNOSE DTC U0146:00 before diagnosing DTC U0401:00 or U0401:82, GO to

Pinpoint Test H
No GO to J2
J2 CHECK THE COMMUNICATION NETWORK

Ignition ON.
Does the GWM and the PCM pass the Network Test?
Yes GO to J3
No DIAGNOSE the GWM or the PCM does not respond to the diagnostic scan tool.
and Testing).
J3 RECHECK THE RTM (RADIO TRANSCEIVER MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, clear the RTM Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Test drive the vehicle for a minimum of 2 minutes at a speed greater than 24 km/h (15 mph).
Is DTC U0401:00 or U0401:82 present?
Yes GO to J4
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J4 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE GWM (GATEWAY MODULE
A)
Are there any Diagnostic Trouble Codes (DTCs) present in the GWM?
Yes DIAGNOSE the GWM Diagnostic Trouble Codes (DTCs).

No GO to J5
J5 RETRIEVE ANY DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE PCM (POWERTRAIN
CONTROL MODULE)
Are there any Diagnostic Trouble Codes (DTCs) present in the PCM?
Yes DIAGNOSE the PCM DTC.

No GO to J6
J6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0146:XX OR U0447:XX SET IN OTHER
MODULES
Using a diagnostic scan tool, carry out the self-test for all modules.
Is DTC U0146:xx or U0447:xx set in 2 or more modules?
No GO to J7
J7 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0401 OR U0401:XX SET IN OTHER
MODULES
Retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Is DTC U0401 or U0401:xx set in 1 or more modules in addition to the RTM?
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Tire Pressure Monitoring System (TPMS) Sensor Activation
204-D081
TPM Activation Tool
Activation
1. 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.
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Turn the ignition switch to the ON position.
2. Position the special tool against the Left Front (LF) tire sidewall at the tire valve stem.
Use Special Service Tool: 204-D081 TPM Activation Tool.
3. NOTE: The special tool should 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 special 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 special 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 TPMS indicator remains illuminated after adjusting and activating each sensor,
Refer to: Tire Pressure Monitoring System (TPMS) (204-04B Tire Pressure Monitoring System (TPMS),

Tire Pressure Monitoring System (TPMS) Sensor Location Calibration
204-D081
TPM Activation Tool
Ford Diagnostic Equipment
Programming
NOTE: The TPMS can be placed into learn mode using a diagnostic scan tool or manually where a diagnostic
scan tool is not available.
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NOTE: Enter Training Mode With Scan Tool
1. NOTE: The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN Left Front (LF) TIRE.
1. Select Chassis.
2. Select TPMS.
3. Select Training Mode.
Use the General Equipment: Ford Diagnostic Equipment
Programming
NOTE: Enter Training Mode Without Scan Tool
1. NOTE: The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN Left Front (LF) TIRE.
With the ignition OFF, press and release the brake pedal.
2. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the RUN position.
3. Press and release the brake pedal.
4. Position the ignition to OFF position.
5. Using the start/stop switch, position the ignition from OFF to RUN 3 times, ending in the RUN position.
Programming
NOTE: TPMS Sensor Training Procedure
1. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the special tool
must remain in place at the valve stem.
Place the special tool on the Left Front (LF) tire sidewall at the valve stem. Press and release the test
button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been
recognized by the BCM.
2. Within 2 minutes of the horn sounding, place the special tool on the Right Front (RF) tire sidewall at the
valve stem and press and release the test button to train the Right Front (RF) tire pressure sensor.
3. Repeat Step 1 for the Right Rear (RR) and Left Rear (LR) tires. The procedure is completed after the last
tire has been trained. When the training procedure is complete, the message center (if equipped) will
display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful
completion of the training procedure will be verified by positioning the ignition to OFF without the horn
sounding. If the horn sounds twice when the ignition is positioned to OFF, the training procedure was not
successful.
4. Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and document them on
the applicable warranty claim.
5. This step is required to clear DTC B1182:55, cause the BCM to exit the manufacturing mode and to make
sure there are no other concerns with a newly programmed BCM.
6. If the sensors are being trained due to the installation of a new BCM, clear any DTC and carry out the
BCM On-Demand Self Test.
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Tire Pressure Monitoring System (TPMS) Sensor
Removal
injury.
2. 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 Tire Pressure Monitoring System (TPMS) sensors, follow the correct procedures for hazardous
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material disposal. Failure to follow these instructions may result in serious personal injury.
NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without disassembly of
the wheel and tire.
NOTE: The maximum shelf life of a TPMS snap in valve stems before being mounted to a wheel is 1
year. The production date / week / year is marked on the TPMS sensor / valve stem itself. Snap in valve
stems which are older than 1 year are to be scrapped. TPMS snap in sensors with valve stems older than
one year should not be mounted but the valve stem should be replaced.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).
Installation
1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be installed without disassembly of
the wheel and tire.

204-05 Vehicle Dynamic Suspension 2016 Mustang
Vehicle Dynamic Suspension - Component Location
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Item Description
1 Strut (2 required)
2 VDM
3 Rear height sensor (2 required)
4 Shock (2 required)
5 Front height sensor (2 required)

Vehicle Dynamic Suspension - Overview
Overview
The semi-active, computer-controlled suspension damping system utilizes vehicle sensors and magneto-
rheological fluid-filled dampers to offer improved handling, comfort and stability by continuously adjusting the
adaptive shock absorber force to the current road and driving conditions.
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Vehicle Dynamic Suspension - System Operation and Component Description
System Operation
System Diagram
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Module Network Input Messages - VDM

Message Module
ABS active ABS module Indicates the current ABS activity, on or off.
Ambient air PCM This message is sent to the GWM and then to the VDM. Indicates the
temperature current ambient air temperature.
Brake pedal PCM This message is sent to the GWM and then to the VDM. Indicates whether
applied or not the driver is applying the brake pedal.
Brake torque ABS module This message indicates the current amount of braking requested by the
request ABS module. The VDM adjusts the suspension to prevent nose-diving
during hard braking maneuvers.
Driven wheel torque PCM This message is sent to the GWM and then to the VDM. Indicates the
actual current amount of torque being applied to the rear wheels in Newton
meters.
Driven wheel torque PCM This message is sent to the GWM and then to the VDM. Indicates the
request current amount of torque being requested by the driver through the launch
control system.
Message Module
Engine coolant PCM This message is sent to the GWM and then to the VDM. Indicates the
temperature current engine coolant temperature in degrees Celsius.
Ignition status BCM This message is sent to the GWM and then to the VDM. Indicates the
current ignition status; off, accessory, run, start, invalid or unknown.
Odometer master IPC This message is sent to the GWM and then to the VDM. Indicates the
value current odometer reading in kilometers.
Stability control ABS module Indicates the current ESC activity, on or off.
brake active
Steering wheel ABS module Indicates the current steering wheel angle relative to the straight ahead
angle position. Used to determine the amount of dampening required during
vehicle operation.
Traction control ABS module Indicates the current traction control activity, on or off.
mode
Vehicle BCM This message is sent to the GWM and then to the VDM. Indicates the
configuration data current vehicle configuration and optional equipment.
Vehicle lateral RCM Indicates the current lateral acceleration as measured by the sensors in
acceleration the RCM. Used to determine the amount of dampening required during
vehicle operation.
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Vehicle longitudinal RCM Indicates the current longitudinal acceleration as measured by the sensors
acceleration in the RCM. Used to determine the amount of dampening required during
vehicle operation.
Vehicle roll rate RCM Indicates the current roll rate as measured by the sensors in the RCM.
Used to determine the amount of dampening required during vehicle
operation.
Vehicle speed PCM This message is sent to the GWM and then to the VDM. Indicates the
current vehicle speed in kilometers per hour.
Vehicle yaw rate RCM Indicates the current yaw rate as measured by the sensors in the RCM.
Used to determine the amount of dampening required during vehicle
operation.
Vehicle Dynamic Suspension
The VDM is connected to the HS-CAN to communicate with the ABS module, the RCM, the BCM and the PCM to
monitor vehicle roll, pitch, cornering, braking and acceleration. Using the information received from other modules
and the information from the 4 vehicle height sensors, the VDM calculates the best action for each of the 4
suspension dampers.
The driver is also able to select 1 of 4 preset system modes (Tour, Sport, Track or Drag) using the message
center. When a mode is selected, the VDM regulates the magnetic field of the damper piston to keep the
suspension "feel" relational to the selected mode.
When the VDM is initialized (ignition ON), it carries out a preliminary electrical check of the height sensors, height
sensor circuits, damper piston electromagnetic coils and damper piston electromagnetic coil circuits. Any
malfunction detected in the system causes the VDM to set a DTC and send a message over the HS-CAN2 to the
GWM. The GWM relays this message to the IPC over the HS-CAN3 and the IPC responds by displaying a
message in the message center.
Depending on the DTC present, the VDM may deactivate the dynamic suspension resulting in a firm suspension
feel.
Vehicle Dynamics Control Module (VDM)

The VDM monitors all sensor inputs and all HS-CAN messages relating to the vehicle dynamic suspension and
directly controls the damper piston electromagnetic coils. The VDM sends an individual electrical current to each
damper piston to control the amount of damping required.
When a new VDM is installed, it must be programmed with the correct vehicle information for proper dynamic
suspension operation. New module programming is carried out using a diagnostic scan tool, follow all diagnostic
scan tool instructions.
Refer to: Module Configuration (418-01 Module Configuration) .
When one of the following components is installed new, disassembled, disconnected or removed the VDM must
be calibrated.
VDM
Suspension height sensor
Front lower control arm
Front strut assembly
Rear lower control arm
Rear shock
The calibration routine is required for the system to learn the zero-position of the vehicle which means the vehicle
must be on a level surface, must not be moving and cannot contain any passengers or cargo. The calibration
routine is carried out using a diagnostic scan tool. The calibration routine should not be performed with the vehicle
raised off the ground or immediately after lowering the vehicle as the suspension will not be in a neutral position.
The suspension must be neutralized before performing the calibration routine by driving the vehicle for a short
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distance such as around a parking lot.
Height Sensor
The height sensor is an electronic device which behaves like a potentiometer to send a variable amount of voltage
back to the VDM. The sensor has 3 circuits, one circuit is for the 5 volt sensor supply, one circuit is for sensor
ground and one circuit is for the sensor output.
Damper Piston Electromagnetic Coils
Each damper piston contains 2 sets of electromagnetic coils wound around the damper piston. The coils produce
a magnetic field restricting flow of fluid in the damper. The VDM uses a PWM output to increase or decrease the
magnetic field of the damper piston coils. The higher the PWM, the stronger the magnetic field, resulting in a
"firm" suspension feel.

Vehicle Dynamic Suspension
DTC Chart: Vehicle Dynamics Control Module (VDM)
VDM DTC Chart

B14C1:64 Damper Temperature: GO to Pinpoint Test C
Signal Plausibility Failure
C103E:00 Suspension System The vehicle is fitted with spacers designed to maintain a very
Shipping Blocks Not high vehicle trim height in order to protect against front splitter or
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Removed: No Sub Type rear diffuser damage. If all 4 height sensors have been correctly
Information configured and there are no height sensor Diagnostic Trouble
Codes (DTCs) present, the VDM sets this DTC if there is no
change in ride height information.
REMOVE the shipping blocks from the front struts and rear
shock absorbers.
C110C:11 Left Front Damper GO to Pinpoint Test C

Solenoid: Circuit Shorted to
Ground
Battery
Solenoid: Circuit Open
Solenoid: Circuit Current
Above Threshold
C110C:1A Left Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Below
Threshold
C110C:1B Left Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Above
Threshold
C110D:11 Right Front Damper GO to Pinpoint Test C
Ground
Battery
Above Threshold
C110D:1A Right Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Below
Threshold
C110D:1B Right Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Above
Threshold
C110E:11 Left Rear Damper GO to Pinpoint Test C
Ground
Battery
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Above Threshold
C110E:1A Left Rear Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Below
Threshold
C110E:1B Left Rear Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Above
Threshold
C110F:11 Right Front Damper GO to Pinpoint Test C
Ground
Battery
Above Threshold
C110F:1A Right Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Below
Threshold
C110F:1B Right Front Damper GO to Pinpoint Test C
Solenoid: Circuit
Resistance Above
Threshold
C1121:4B Damper Solenoid(s): Over DIAGNOSE all other damper solenoid Diagnostic Trouble Codes
Temperature (DTCs) before diagnosing DTC C1121:4B.
CYCLE the ignition from ON to OFF and back to ON. Using a
diagnostic scan tool, CARRY OUT the VDM self-test.
If the DTC returns, INSPECT the front struts and rear shock
absorbers for signs of leakage or damage. INSTALL new
C1124:55 Height Sensor(s): Not This DTC is automatically set in a new VDM and indicates the system
Configured requires height sensor calibration. Once the system is calibrated, the
DTC can be cleared. CALIBRATE the VDM and sensors. FOLLOW the
diagnostic scan tool instructions. CLEAR the DTCs. REPEAT the VDM
self-test.
C1124:56 Height Sensor(s): Invalid / This DTC is automatically set in a new VDM and indicates the system
Incompatible Configuration requires height sensor calibration. Once the system is calibrated, the
DTC can be cleared. CALIBRATE the VDM and sensors. FOLLOW the
diagnostic scan tool instructions. CLEAR the DTCs. REPEAT the VDM
self-test.
C1A03:12 Left Front Height Sensor: GO to Pinpoint Test D
Circuit Shorted to Battery
Circuit Shorted to Ground
or Open
C1A03:2A Left Front Height Sensor: GO to Pinpoint Test D
Signal Stuck In Range
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C1A04:12 Right Front Height Sensor: GO to Pinpoint Test D
or Open
C1A04:2A Right Front Height Sensor: GO to Pinpoint Test D
C1A05:12 Left Rear Height Sensor: GO to Pinpoint Test D
or Open
C1A05:2A Left Rear Height Sensor: GO to Pinpoint Test D
C1A06:12 Right Rear Height Sensor: GO to Pinpoint Test D
or Open
C1A06:2A Right Rear Height Sensor: GO to Pinpoint Test D
C1B14:16 Sensor Supply Voltage A: GO to Pinpoint Test D
Circuit Voltage Below
Threshold
C1B14:17 Sensor Supply Voltage A: GO to Pinpoint Test D
Circuit Voltage Above
Threshold
P0562:16 System Voltage Low: GO to Pinpoint Test A
Circuit Voltage Below
Threshold
P0563:17 System Voltage High: GO to Pinpoint Test B
Threshold
P0601:52 Internal Control Module CHECK the service history for recent service actions related to
Memory Checksum Error: the VDM. This DTC sets due to incomplete or improper PMI
Not Activated procedures.
If there have been recent service actions with the VDM, REPEAT
the PMI procedure, FOLLOW all diagnostic scan tool
instructions. CARRY OUT the ride height sensor calibration
routine, FOLLOW all diagnostic scan tool directions.
VDM to correct the failure to retain the configuration data.
REFER to: Vehicle Dynamics Control Module (VDM) (204-05
Vehicle Dynamic Suspension, Removal and Installation).
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P1674:48 Control Module Software CHECK the service history for recent service actions related to
Corrupted: Supervision the VDM. This DTC sets due to incomplete or improper PMI
Software Failure procedures.
If there have been recent service actions with the VDM, REPEAT
P1794:17 Battery Voltage Circuit: GO to Pinpoint Test B

Threshold
P1794:18 Battery Voltage Circuit: GO to Pinpoint Test A
Circuit Current Below
Threshold
U0121:00 Lost Communication with GO to Pinpoint Test F
Anti-Lock Brake System
(ABS) Control Module: No
U0146:00 Lost Communication With GO to Pinpoint Test E
Gateway "A": No Sub Type
Information
U0151:00 Lost Communication with GO to Pinpoint Test G
Restraints Control Module:
U0300:57 Internal Control Module CHECK the service history for recent service actions related to
Software Incompatibility: the VDM. This DTC sets due to incomplete or improper PMI
Invalid / Incompatible procedures.
Software Component If there have been recent service actions with the VDM, REPEAT
U0415:68 Invalid Data Received from This DTC sets if the VDM receives invalid or faulted steering
Anti-Lock Brake System wheel angle information or total brake torque information from
(ABS) Control Module: the ABS module.
Event Information Using a diagnostic scan tool, RETRIEVE and DIAGNOSE all
ABS module Diagnostic Trouble Codes (DTCs).
REFER to: Anti-Lock Brake System (ABS) and Stability Control
(206-09 Anti-Lock Brake System (ABS) and Stability Control,
If the diagnostic scan tool cannot communicate with the ABS
module,
Communications Network) .
If there are no Diagnostic Trouble Codes (DTCs) in the ABS
module, the DTC may be caused by an intermittent concern.
SET the ignition to OFF. DISCONNECT and INSPECT all VDM
and ABS module electrical connectors and related in-line
connectors for corrosion, bent pins, pushed-out pins and spread
terminals. REPAIR as necessary.
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U0447:68 Invalid Data Received This DTC sets if the VDM receives invalid or faulted engine, body
From Gateway "A": Event or instrument cluster information from the GWM. For additional
Information information on PCM, BCM and IPC messages received by the
VDM, REFER to the VDM Network Message Input Chart.
REFER to: Vehicle Dynamic Suspension - System Operation and
Component Description (204-05 Vehicle Dynamic Suspension,
Using a diagnostic scan tool, RETRIEVE and DIAGNOSE all
GWM Diagnostic Trouble Codes (DTCs).
If the diagnostic scan tool cannot communicate with the GWM,
If there are no Diagnostic Trouble Codes (DTCs) in the GWM,
the DTC may be caused by an intermittent concern.
SET the ignition to OFF. DISCONNECT and INSPECT all VDM,
GWM, PCM, BCM and IPC electrical connectors and related
in-line connectors for corrosion, bent pins, pushed-out pins and
spread terminals. REPAIR as necessary.
U0452:68 Invalid Data Received from This DTC sets if the VDM receives invalid or faulted vehicle yaw
Restraints Control Module: rate, lateral acceleration, longitudinal acceleration or roll rate
Event Information information from the RCM.
Using a diagnostic scan tool, RETRIEVE and DIAGNOSE all
RCM Diagnostic Trouble Codes (DTCs).
REFER to: Airbag Supplemental Restraint System (SRS)
(501-20B Supplemental Restraint System, Diagnosis and
Testing).
If the diagnostic scan tool cannot communicate with the RCM,
If there are no Diagnostic Trouble Codes (DTCs) in the RCM, the
DTC may be caused by an intermittent concern.
SET the ignition to OFF and WAIT one minute. DISCONNECT
and INSPECT all VDM and RCM electrical connectors and
related in-line connectors for corrosion, bent pins, pushed-out
pins and spread terminals. REPAIR as necessary.
Symptom Chart
Symptom Chart: Vehicle Dynamic Suspension

A module does not respond to the Fuse
diagnostic scan tool Wiring, terminals or REFER to: Communications Network
connectors (418-00 Module Communications
VDM concern Network) .
Message center displays, DRIVE Diagnostic Trouble RETRIEVE and DIAGNOSE all VDM
CONTROL MALFUNCTION Codes (DTCs) Diagnostic Trouble Codes (DTCs).
SERVICE REQUIRED present in the VDM
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Rough or harsh ride Vehicle dynamic RETRIEVE and DIAGNOSE all VDM
suspension system Diagnostic Trouble Codes (DTCs).
disabled If no Diagnostic Trouble Codes (DTCs)
are present,
REFER to: Suspension System (204-00
Suspension System - General
Pinpoint Tests
P0562:16, P1794:18, U3006:2F
The VDM requires an operating voltage between 9 and 16 volts. The VDM receives this voltage from the BCM
and has a single ground circuit. Excessive resistance or an open in one or more of these circuits, a discharged
battery or a inoperative charging system results in the VDM setting a DTC.

P0562:16 Battery Voltage Low: This DTC sets in continuous memory if the voltage supplied to the VDM falls
Circuit Voltage Below below 9 volts for more than 3 seconds.
Threshold
P1794:18 Battery Voltage This DTC sets in continuous memory if the voltage supplied to the VDM falls
Circuit: Circuit Current below 9 volts for more than 60 seconds.
Below Threshold
U3006:2F Control Module Input This DTC sets in continuous memory if the power reset indicates an irregular
Power "A": Signal shutdown and power up has been detected. This is usually caused by a
Erratic sudden loss of vehicle battery voltage due to an open circuit, a disconnected
electrical connector or disconnected battery terminal.
Possible Sources
Fuses
VDM
Make sure the vehicle battery terminals and cables are free of any corrosion and other contaminants.
Make sure the vehicle battery terminals are tightened to their correct torque specifications.
Make sure BJB fuse 66 (5A) is OK.
Make sure BCM fuse 25 (30A) is OK.
PINPOINT TEST A : P0562:16, P1794:18, U3006:2F

A1 RECHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE
CODES (DTCS)
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Using a diagnostic scan tool, clear the VDM Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, carry out the VDM self-test.
Is DTC P0562:16, P1794:18 or U3006:2F still present?
Yes GO to A2
No The system is operating correctly at this time. The DTC may have set due to a previous
low battery voltage condition.
A2 CHECK FOR CHARGING SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) IN THE PCM
(POWERTRAIN CONTROL MODULE)
Yes DIAGNOSE the vehicle charging concern.

No GO to A3
A3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE

REFER to: Battery (414-01 Battery, Mounting and Cables) .
Yes GO to A4
A4 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) VOLTAGE (VDM_SUPPLY_V) PID
Ignition ON.
Using a diagnostic scan tool, monitor the VDM_Supply_V PID.
Is the PID) display within 0.2 volt of the recorded battery voltage?
Yes GO to A7
No GO to A5
A5 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) VOLTAGE SUPPLY

Ignition OFF.
Disconnect VDM C4585A.
Ignition ON.
Measure:
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C4585A-16 Ground
C4585A-32 Ground
Is the voltage within 1 volt of the recorded battery voltage?
Yes GO to A6
No VERIFY BJB fuse 66 (5A) and BCM fuse 25 (30A) are OK.
If OK, REPAIR the affected circuit for high resistance or an open.
If not OK, REFER to the Wiring Diagrams manual to identify the cause of the circuit short.
A6 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) GROUND CIRCUIT FOR AN OPEN
Measure:

C4585A-47 Ground
Yes GO to A8
A7 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect all VDM related in-line electrical connectors.
Using a good light source, inspect all disconnected electrical connectors for the following:
terminals?
Yes GO to A8
No REPAIR the connector or terminals.
A8 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION

Connect VDM C4585A and all related in-line electrical connectors. Make sure they seat and latch
correctly.
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Service Bulletins (TSBs) address this concern, INSTALL a new VDM.
REFER to: Vehicle Dynamics Control Module (VDM) (204-05 Vehicle Dynamic
P0563:17, P1794:17
The VDM requires an operating voltage that is between 9 and 16 volts. The VDM receives this voltage from the
BCM and has a single ground circuit. Excessive resistance or an open in one or more of these circuits, a
discharged battery or a inoperative charging system results in the VDM setting a DTC.
An overcharging condition in the charging system results in the VDM setting a DTC. This DTC may also set in the
VDM due to battery charging or vehicle jump starting events.

P0563:17 System Voltage High: Circuit This DTC sets in continuous memory and on-demand if the voltage
Voltage Above Threshold supplied to the VDM is above 16 volts for more than 3 seconds.
P1794:17 Battery Voltage Circuit: Circuit This DTC sets in continuous memory and on-demand if the voltage
Voltage Above Threshold supplied to the VDM is above 16 volts for more than 60 seconds.
Possible Sources
Charging system concern

VDM
PINPOINT TEST B : P0563:17, P1794:17

B1 CHECK FOR HIGH VOLTAGE DIAGNOSTIC TROUBLE CODES (DTCS) SET IN OTHER
MODULES

No GO to B2
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B2 CHECK THE BATTERY VOLTAGE
Turn off all interior lights, exterior lights and accessories.
NOTE: Do not allow the engine speed to increase above 2,000 RPM while performing this step or the
generator may self-excite and result in default charging system output voltage. If engine speed goes
above 2,000 RPM, turn the engine off and restart the engine before performing this step.
Start and run the engine at approximately 1,500 RPM for 3 minutes while monitoring the battery voltage.
Is the battery voltage between 13 and 15.2 volts?
Yes GO to B3
No DIAGNOSE the overcharging condition.
B3 RECHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) FOR DTC (DIAGNOSTIC
TROUBLE CODE) U3003:17
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, clear the VDM Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Is DTC P0563:17 or P1794:17 still present?
Yes GO to B4
No The system is operating normally at this time. The DTC may have been set previously
during battery charging or while jump starting the vehicle.
B4 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect and inspect VDM C4585A and related in-line electrical connectors.
terminals?
Yes GO to B5
B5 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION

Connect VDM C4585A and all related in-line electrical connectors. Make sure they seat and latch
correctly.
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Damper Solenoid Electrical Fault Diagnostic Trouble Codes (DTCs)
The VDM sends a PWM voltage to the shock absorber solenoids based on sensor input and HS-CAN messages.
The VDM continually monitors the shock absorber solenoid circuits and sets a DTC when a circuit fault is
detected. A shorted or open shock absorber solenoid also causes the VDM to set a DTC.

C110C:11 Left Front Damper This DTC sets in continuous memory when the VDM
C110D:11 Solenoid: Circuit Short to detects a short to ground on one or both of the shock
C110E:11 Ground absorber solenoid circuits for longer than 3 seconds.
C110F:11 Right Front Damper
Solenoid: Circuit Short to
Ground
Left Rear Damper
Ground
Right Rear Damper
Ground
C110D:12 Solenoid: Circuit Short to detects a short to battery voltage on one or both of the
C110E:12 Battery shock absorber solenoid circuits for longer than 3
C110F:12 Right Front Damper seconds.
Battery
Left Rear Damper
Battery
Right Rear Damper
Battery
C110D:13 Solenoid: Circuit Open detects an open circuit on one or both of the shock
C110E:13 Right Front Damper absorber solenoid circuits for longer than 3 seconds.
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C110F:13 Solenoid: Circuit Open
Left Rear Damper
Right Rear Damper
C110D:19 Solenoid: Circuit Current detects the shock absorber commanded current is higher
C110E:19 Above Threshold than the calibrated threshold.
C110F:19 Right Front Damper
Above Threshold
Left Rear Damper
Above Threshold
Right Rear Damper
Above Threshold
C110C:1A Left Front Damper This DTC sets in continuous memory when the estimated
C110D:1A Solenoid: Circuit shock absorber solenoid resistance is less than 0.4 ohms.
C110E:1A Resistance Below
C110F:1A Threshold
Right Front Damper
Solenoid: Circuit
Resistance Below
Threshold
Left Rear Damper
Solenoid: Circuit
Resistance Below
Threshold
Right Rear Damper
Solenoid: Circuit
Resistance Below
Threshold
C110C:1B Left Front Damper This DTC sets in continuous memory when the estimated
C110D:1B Solenoid: Circuit shock absorber solenoid resistance is greater than 4
C110E:1B Resistance Above ohms.
C110F:1B Threshold
Right Front Damper
Solenoid: Circuit
Resistance Above
Threshold
Left Rear Damper
Solenoid: Circuit
Resistance Above
Threshold
Right Rear Damper
Solenoid: Circuit
Resistance Above
Threshold
Possible Sources

Shock or Strut (solenoid is serviced as an assembly with the shock or strut)
VDM
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Make sure the solenoid harness is routed correctly and is undamaged.

Make sure the solenoid electrical connector is free from any corrosion or other contaminants.
PINPOINT TEST C : DAMPER SOLENOID ELECTRICAL FAULT DIAGNOSTIC TROUBLE CODES

(DTCS)
C1 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Is DTC C110X:11 or C110X:1A present?
Yes GO to C2
No If DTC C110X:12 is present, GO to C3
If DTC C110X:13, C110X:19 or C110X:1B is present, GO to C4
For all other VDM Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: Vehicle
Dynamics Control Module (VDM).
C2 CHECK THE SHOCK ABSORBER SOLENOID CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Disconnect the suspect shock absorber solenoid electrical connector.
For the LH front shock absorber solenoid, measure:

C4585A-30 Ground
C4585A-31 Ground
For the RH front shock absorber solenoid, measure:

C4585A-27 Ground
C4585A-28 Ground
For the LH rear shock absorber solenoid, measure:

C4585A-42 Ground
C4585A-43 Ground
For the RH rear shock absorber solenoid, measure:

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C4585A-45 Ground
C4585A-46 Ground
Yes GO to C5
C3 CHECK THE DAMPER SOLENOID CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF.
Ignition ON.

C4585A-30 Ground
C4585A-31 Ground

C4585A-27 Ground
C4585A-28 Ground

C4585A-42 Ground
C4585A-43 Ground

C4585A-45 Ground
C4585A-46 Ground
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No GO to C5
C4 CHECK THE SHOCK ABSORBER SOLENOID CIRCUITS FOR AN OPEN

Ignition OFF.

C4585A-30 C1668-2
C4585A-31 C1668-1

C4585A-27 C1669-2
C4585A-28 C1669-1

C4585A-42 C4044-2
C4585A-43 C4044-1

C4585A-45 C4045-2
C4585A-46 C4045-1
Yes GO to C5
C5 CHECK THE SHOCK ABSORBER SOLENOID CIRCUITS FOR A SHORT TOGETHER

Ignition OFF.

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C4585A-30 C4585A-31

C4585A-27 C4585A-28

C4585A-42 C4585A-43

C4585A-45 C4585A-46
Yes GO to C6
C6 CHECK THE SHOCK ABSORBER SOLENOID RESISTANCE

Ignition OFF.

C1668-1Component Side C1668-2Component Side


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Is the resistance between 2.8 and 4.5 ohms?
Yes GO to C7
No INSTALL a new front strut or rear shock absorber.
REFER to: Front Strut and Spring Assembly (204-01 Front Suspension, Removal and
Installation).
REFER to: Rear Shock Absorber (204-02 Rear Suspension, Removal and Installation).
C7 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect all VDM and shock absorber solenoid related in-line electrical connectors.
terminals?
Yes GO to C8
C8 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION
Connect VDM C4585A. Make sure it seats and latches correctly.
Connect all VDM and shock absorber solenoid related in-line electrical connectors. Make sure they seat
and latch correctly.
Connect the suspect damper solenoid electrical connector. Make sure it seats and latches correctly.
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Height Sensor Electrical Fault Diagnostic Trouble Codes (DTCs)
The VDM continually monitors the height sensor circuits and sets a DTC when a circuit fault is detected. A shorted
height sensor also causes the VDM to set a DTC.

C1A03:12 Left Front Height This DTC sets in continuous memory when the VDM detects
C1A04:12 Sensor: Circuit Short to a short to battery on one or more of the height sensor
C1A05:12 Battery circuits.
C1A06:12 Right Front Height
Sensor: Circuit Short to
Battery
Left Rear Height
Battery
Right Rear Height
Battery
C1A03:14 Left Front Height This DTC sets in continuous memory when the VDM detects
C1A04:14 Sensor: Circuit Short to a short to ground or an open on one or more of the height
C1A05:14 Ground or Open sensor circuits.
C1A06:14 Right Front Height
Ground or Open
Left Rear Height
Ground or Open
Right Rear Height
Ground or Open
C1A03:2A Left Front Damper This DTC sets in continuous memory when the VDM does not
C1A04:2A Solenoid: Signal Stuck detect sufficient movement in the height sensor. This could be
C1A05:2A In Range due to a mechanical failure or excessive resistance in the
C1A06:2A Right Front Damper circuit.
Solenoid: Signal Stuck
In Range
Left Rear Damper
In Range
Right Rear Damper
In Range
C1A03:64 Left Front Damper This DTC sets in continuous memory when one of the height
C1A04:64 Solenoid: Signal sensors does not agree with the other sensors.
C1A05:64 Plausibility Failure
C1A06:64 Right Front Damper
Solenoid: Signal
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Plausibility Failure
Left Rear Damper
Solenoid: Signal
Right Rear Damper
Solenoid: Signal
Possible Sources

Height sensor
VDM
Make sure the height sensor harness is routed correctly and is undamaged.
Make sure the height sensor electrical connector is free from any corrosion or other contaminants.
Make sure the height sensor and linkage are installed and connected correctly.
PINPOINT TEST D : HEIGHT SENSOR ELECTRICAL FAULT DIAGNOSTIC TROUBLE CODES (DTCS)
D1 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Is DTC C1A0X:14, C1A0X:2A or C1A0X:64 present?
Yes GO to D2
No If DTC C1A03:12, C1A04:12, C1A05:12 or C1A06:12 is present, GO to D4
For all other VDM Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: Vehicle
Dynamics Control Module (VDM)
D2 CHECK THE HEIGHT SENSOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Disconnect the suspect height sensor electrical connector(s).
For the LH front height sensor, measure:

C1733-1 Ground
C1733-2 Ground
C1733-3 Ground
For the RH front height sensor, measure:

C1151-1 Ground
C1151-2 Ground
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C1151-3 Ground
For the LH rear height sensor, measure:

C4092-1 Ground
C4092-2 Ground
C4092-3 Ground
For the RH rear height sensor, measure:

C4093-1 Ground
C4093-2 Ground
C4093-3 Ground
Are the resistance greater than 10,000 ohms?
Yes GO to D3
No For front height sensor concerns, INSPECT connectors C1733 and C1153 for corrosion,
pushed out pins, bent pins and spread terminals. REPAIR as necessary.
If the connectors are OK, REPAIR the affected circuit(s).
For rear height sensor concerns, INSPECT connectors C4092 and C4093 for corrosion,
D3 CHECK THE HEIGHT SENSOR CIRCUITS FOR AN OPEN


C1733-1 C4585A-6
C1733-2 C4585A-21
C1733-3 C4585A-36

C1151-1 C4585A-3
C1151-2 C4585A-18
C1151-3 C4585A-34
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C4092-1 C4585A-17
C4092-2 C4585A-2
C4092-3 C4585A-33

C4093-1 C4585A-20
C4093-2 C4585A-5
C4093-3 C4585A-35
Are the resistance less than 3 ohms?
Yes If DTC C1A0X:64 is present, GO to D4

If DTC C1A0X:14 or C1A0X:2A is present, GO to D5
D4 CHECK THE HEIGHT SENSOR CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect VDM C4585A (if not previously disconnected).
Disconnect the suspect height sensor electrical connector(s) (if not previously disconnected).
Ignition ON.

C1733-1 Ground
C1733-2 Ground
C1733-3 Ground

C1151-1 Ground
C1151-2 Ground
C1151-3 Ground
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C4092-1 Ground
C4092-2 Ground
C4092-3 Ground

C4093-1 Ground
C4093-2 Ground
C4093-3 Ground
Yes For front height sensor concerns, INSPECT connectors C1733 and C1153 for corrosion,
No GO to D5
D5 CHECK THE HEIGHT SENSOR CIRCUITS FOR A SHORT TOGETHER

Ignition OFF.

C1733-1 C1733-2
C1733-1 C1733-3
C1733-2 C1733-3

C1151-1 C1151-2
C1151-1 C1151-3
C1151-2 C1151-3
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C4092-1 C4092-2
C4092-1 C4092-3
C4092-2 C4092-3

C4093-1 C4093-2
C4093-1 C4093-3
C4093-2 C4093-3
Yes INSTALL a new height sensor.

REFER to: Front Suspension Height Sensor (204-05 Vehicle Dynamic Suspension,
REFER to: Rear Suspension Height Sensor (204-05 Vehicle Dynamic Suspension,
U0146:00
With the ignition ON, the GWM sends messages to the VDM over the HS-CAN2. If the VDM does not receive
these messages within a certain time frame, the module sets Diagnostic Trouble Codes (DTCs). For information
on the messages sent to the VDM by the GWM, go to the Module Network Input Messages - VDM.
REFER to: Vehicle Dynamic Suspension - System Operation and Component Description (204-05 Vehicle
Dynamic Suspension, Description and Operation).

U0146:00 Lost Communication With Gateway "A": This DTC sets in continuous memory if any one of the
No Sub Type Information BCM, IPC or PCM messages are missing.
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Possible Sources

GWM
PINPOINT TEST E : U0146:00

E1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the GWM pass the Network Test?
Yes GO to E2
No DIAGNOSE the GWM does not respond to the diagnostic scan tool.
E2 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Clear the Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Record the VDM Diagnostic Trouble Codes (DTCs).
Yes GO to E3
E3 REVIEW THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE VDM (VEHICLE
DYNAMICS CONTROL MODULE) SELF-TEST
Check the recorded Diagnostic Trouble Codes (DTCs) from the VDM self-test.
Is DTC P0562:16, P0563:17, P1794:17 or P1794:18 present in the VDM?
Yes If DTC P0562:16 or P1794:18 is present, GO to Pinpoint Test A

If DTC P0563:17 or P1794:17 is present, GO to Pinpoint Test B
No GO to E4
E4 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) IN THE GWM (GATEWAY MODULE A)
Yes GO to the DTC Chart: GWM.

No GO to E5
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E5 CHECK FOR OTHER CAUSES OF COMMUNICATION NETWORK CONCERN
NOTE: If new modules were installed prior to the DTC being set, the module configuration can be
incorrectly set during the PMI or the PMI may not have been carried out.
Check the vehicle service history for recent service actions related to the VDM or GWM. If recent service
history is found:
verify the correct replacement module was installed.
HVBOM may be used to verify correct part fitment.
verify the configuration of replacement module was correct.
re-configure the module using as-built data if prior configuration is suspect.
verify the module was not obtained from a like vehicle and installed into customer vehicle.
return the swapped module to source vehicle and obtain new replacement module.
Operate the system and determine if the observable symptom is still present.
Is the observable symptom still present?
Yes GO to E6
No The system is operating correctly at this time. The concern may have been due to
incorrect parts replacement procedures or incorrect module configuration.
E6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0146:XX SET IN OTHER MODULES
Is DTC U0146:xx set in 1 or more modules in addition to the VDM?
No GO to E7
E7 VERIFY ALL WIRING CONNECTIONS
Ignition OFF.
Disconnect all VDM electrical connectors and related in-line electrical connectors.
terminals?
Yes GO to E8
E8 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION

Connect all VDM electrical connectors and all related in-line electrical connectors. Make sure they seat
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U0121:00
With the ignition ON, the ABS module sends messages to the VDM over the HS-CAN2. If the VDM does not
receive these messages within a certain time frame, the module sets Diagnostic Trouble Codes (DTCs). For
information on the messages sent to the VDM by the ABS module, go to the Module Network Input Messages -
VDM.

U0121:00 Lost Communication With Anti-Lock Brake System This DTC sets in continuous memory if any of
(ABS) Control Module: No Sub Type Information the following ABS module messages is missing.
Possible Sources

ABS module

F1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the ABS module pass the Network Test?
Yes GO to F2
No DIAGNOSE the ABS module does not respond to the diagnostic scan tool.
F2 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
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Ignition OFF.
Ignition ON.
Yes GO to F3
F3 REVIEW THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE VDM (VEHICLE

No GO to F4
F4 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) IN THE ABS (ANTI-LOCK BRAKE
SYSTEM) MODULE
Using a diagnostic scan tool, carry out the ABS module self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the ABS module?
Yes DIAGNOSE the ABS module Diagnostic Trouble Codes (DTCs).

REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake
System (ABS) and Stability Control, Diagnosis and Testing).
No GO to F5
F5 CHECK FOR OTHER CAUSES OF COMMUNICATION NETWORK CONCERN
Check the vehicle service history for recent service actions related to the VDM or ABS module. If recent
service history is found:
Yes GO to F6
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F6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0121:XX SET IN OTHER MODULES
Service Bulletins (TSBs) address this concern, INSTALL a new ABS module.
No GO to F7
F7 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
terminals?
Yes GO to F8
F8 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION

U0151:00
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With the ignition ON, the RCM sends messages to the VDM over the HS-CAN2. If the VDM does not receive
these messages within a certain time frame, the module sets Diagnostic Trouble Codes (DTCs). For information
on the messages sent to the VDM by the RCM, go to the Module Network Input Messages - VDM.

U0151:00 Lost Communication With RCM: No Sub This DTC sets in continuous memory if any of the RCM
Type Information messages is missing.
Possible Sources

RCM
PINPOINT TEST G : U0151:00

Ignition ON.
Does the RCM pass the Network Test?
Yes GO to G2
No DIAGNOSE the RCM does not respond to the diagnostic scan tool.
G2 CHECK THE VDM (VEHICLE DYNAMICS CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition OFF.
Ignition ON.
Yes GO to G3
G3 REVIEW THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE VDM (VEHICLE
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No GO to G4
G4 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) IN THE RCM (RESTRAINTS CONTROL
MODULE)
Using a diagnostic scan tool, carry out the RCM self-test.
Are any Diagnostic Trouble Codes (DTCs) present in the RCM?
Yes DIAGNOSE the RCM Diagnostic Trouble Codes (DTCs).

No GO to G5
G5 CHECK FOR OTHER CAUSES OF COMMUNICATION NETWORK CONCERN
Check the vehicle service history for recent service actions related to the VDM or RCM. If recent service
history is found:

Yes GO to G6
G6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0151:XX SET IN OTHER MODULES
No GO to G7
G7 VERIFY ALL WIRING CONNECTIONS
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Ignition OFF.
terminals?
Yes GO to G8
G8 CHECK FOR CORRECT VDM (VEHICLE DYNAMICS CONTROL MODULE) OPERATION


Front Suspension Height Sensor
Removal

NOTE: LH height sensor assembly shown, RH similar.
1. Disconnect the front suspension height sensor electrical connector.

2. Remove the front suspension height sensor arm bracket-to-lower arm bolt.
3. Remove the front suspension height sensor bracket mounting bolt and remove the sensor.
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Installation
1. NOTICE: The linkage must be in a vertical position after installation. Failure to follow these
instructions may result in component damage and/or failure.
NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle.
2. Calibrate the suspension system. Connect the scan tool and carry out the Ride Height Calibration routine.
Follow the scan tool directions.

Rear Suspension Height Sensor
Removal

NOTE: LH height sensor assembly shown, RH similar.
Disconnect the rear suspension height sensor electrical connector.

Remove the rear suspension height sensor arm bracket-to-lower arm bolt.
Remove the rear suspension height sensor bracket bolt and remove the sensor.
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Installation
1. NOTICE: The linkage must be in a vertical position after installation. Failure to follow these
instructions may result in component damage and/or failure.
NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle.
2. Calibrate the suspension system. Connect the scan tool and carry out the Ride Height Calibration routine.
Follow the scan tool directions.

Vehicle Dynamics Control Module (VDM)
Removal
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
1. Remove the load space floor panel.
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2. Remove the load space rear trim panel.
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3. Position aside the RH load space trim panel.
4. 1. Disconnect the VDM electrical connector.

2. Remove the VDM retainers and remove the VDM.
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Installation
2. Calibrate the VDM. Connect the scan tool and carry out the Ride Height Calibration routine. Follow the
scan tool directions.

205-01 Driveshaft 2016 Mustang
Specifications
Materials
Name Specification
Premium Long-Life Grease ESA-M1C75-B
XG-1-E1
Lubricants, Fluids, Sealers and Adhesives
Item Specifications
Material: Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B) ESA-M1C75-B
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Item Specifications
Driveshaft runout 0.6 mm (0.024
in)
Driveshaft to transmission joint angle @ curb ride height (2.3L EcoBoost Auto Transmission) 0.45 degrees
Driveshaft to transmission joint angle @ curb ride height (2.3L EcoBoost Manual 0.46 degrees
Transmission)
Driveshaft to transmission joint angle @ curb ride height (3.7L Duratec Auto Transmission) 0.26 degrees
Driveshaft to transmission joint angle @ curb ride height (3.7L Duratec Manual Transmission) 0.24 degrees
Driveshaft to transmission joint angle @ curb ride height (5.0L 32V Ti-VCT Auto Transmission) 0.58 degrees
Driveshaft to transmission joint angle @ curb ride height (5.0L 32V Ti-VCT Manual 0.55 degrees
Transmission)
Driveshaft to transmission joint angle @ curb ride height (5.2L 32V Ti-VCT Manual 0.70 degrees
Transmission)
Driveshaft center bearing joint angle @ curb ride height (2.3L EcoBoost Auto Transmission) 0.63 degrees
Driveshaft center bearing joint angle @ curb ride height (2.3L EcoBoost Manual Transmission) 0.64 degrees
Driveshaft center bearing joint angle @ curb ride height (3.7L Duratec Auto Transmission) 0.42 degrees
Driveshaft center bearing joint angle @ curb ride height (3.7L Duratec Manual Transmission) 0.40 degrees
Driveshaft center bearing joint angle @ curb ride height (5.0L 32V Ti-VCT Auto Transmission) 0.76 degrees
Driveshaft center bearing joint angle @ curb ride height (5.0L 32V Ti-VCT Manual 0.79 degrees
Transmission)
Driveshaft center bearing joint angle @ curb ride height (5.2L 32V Ti-VCT Manual 0.73 degrees
Transmission)
Driveshaft to rear differential joint angle @ curb ride height (All except 5.0L 32V Ti-VCT and 0.0 degrees
5.2L 32V Ti-VCT Manual Transmission)
Driveshaft to rear differential joint angle @ curb ride height (5.0L 32V Ti-VCT and 5.2L 32V 0.54 degrees
Ti-VCT Manual Transmission only)
Torque Specifications
Item Nm lb-ft lb-in

Center bearing support bolts 48 35 -
Front driveshaft (3 bolt flange) 110 81 -
Front driveshaft (4 bolt flange) 109 80 -
Muffler inlet pipe clamp 48 35 -
Rear driveshaft-to-pinion flange bolts 55 41 -
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Driveshaft
Principles of Operation
proceeding to the next step
Symptom Chart(s)
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Symptom Chart: NVH
Symptom Chart

Driveline clunk - loud clunk when Damaged or worn INSPECT the driveshaft CV joint
shifting from REVERSE to DRIVE driveshaft CV joint and/or u-joint for wear or damage.
and/or u-joint INSTALL a new driveshaft as
necessary.
REFER to: Driveshaft (205-01
Driveshaft, Removal and Installation).
Driveline clunk — occurs as the Worn driveshaft CV INSPECT the driveshaft CV joint
vehicle starts to move forward joint and/or u-joint and/or u-joint for a worn condition.
following a stop with excessive play INSTALL a new driveshaft if
necessary.
Buzz – buzzing noise is the same at Incorrect driveline CHECK for correct driveline angles.
cruise or coast/deceleration angles REFER to: Driveshaft Angle
Measurement (205-01 Driveshaft,
Rumble or Boom – noise occurs at Driveshaft out of CHECK the driveshaft for damage,
coast/ deceleration, usually driveshaft balance missing weights or undercoating.
speed-related and noticeable over a INSTALL a new driveshaft as
wide range of speeds necessary.
Grunting — normally associated with Driveshaft CV joint INSTALL a new driveshaft as

a shudder experienced during and/or u-joint necessary.
acceleration from a complete stop binding REFER to: Driveshaft (205-01
Driveline shudder – occurs during Driveline angles out CHECK for correct driveline angles.
acceleration from a slow speed or of specification REFER to: Driveshaft Angle
stop Measurement (205-01 Driveshaft,
Binding or damaged INSPECT the driveshaft CV joint

driveshaft CV joint and/or u-joint and coupling shaft for
and/or u-joint wear or damage. INSTALL a new
driveshaft as necessary.
Driveline vibration - occurs at cruising Worn or damaged CHECK the insulator for damage or
speeds driveshaft center wear. ROTATE the driveshaft and
bearing support CHECK for rough operation. INSTALL
a new driveshaft as necessary.
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Loose axle pinion INSPECT the axle pinion flange.
flange bolts TIGHTEN the pinion flange bolts to
specification.
Excessive axle CARRY OUT a runout check.

pinion flange runout REPAIR as necessary.
REFER to: Specifications (205-02
Rear Drive Axle/Differential,
Specifications).
Driveshaft is out of CHECK the driveshaft for damage ,

balance missing balance weights or
undercoating. CHECK the driveshaft
balance.
REFER to: Driveshaft Runout and
Balancing (205-01 Driveshaft,
Binding or damaged INSPECT the driveshaft CV joint

driveshaft CV joint and/or u-joint for wear or damage.
and/or u-joint INSTALL a new driveshaft as
necessary.
Excessive CARRY OUT a runout check.

driveshaft runout REFER to: Driveshaft Runout and
Balancing (205-01 Driveshaft,
Driveline angles out CHECK for correct driveline angles.

of specification REFER to: Driveshaft Angle
Measurement (205-01 Driveshaft,
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Driveshaft Angle Measurement
Check
NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in some
driveshafts. This check is for single-cross and roller-style joints found in the driveshafts.
NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation.
NOTE: An incorrect driveline angle can cause a vibration or shudder.
NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle
pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts.
1. NOTE:
Special Tool(s): Anglemaster II Driveline Inclinometer/Protractor 164-R2402. Carry out the following
preliminary setup steps:
1. Inspect the U-joints for correct operation.
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2. Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment rack.
3. Verify the curb position ride height is within specifications with the vehicle unloaded and all of the tires are
inflated to their normal operating pressures.
4. Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat level section of the
frame rail and press the ALT-ZERO button.
Vehicles with flat-flanged, split-pin or slip-flanged U-joints
2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure the
Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup.
NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify taking
measurements.
Special Tool(s): Anglemaster II Driveline Inclinometer/Protractor 164-R2402. Check and record the flange angle as
angle A.
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3. Special Tool(s): Anglemaster II Driveline Inclinometer/Protractor 164-R2402. Measure the slope of the connecting
component. Record the measurement of the component angle as angle B.
Multiple piece driveshafts
4. NOTE: Repeat this step for each center support bearing on the driveshaft.
NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements.
Special Tool(s): Anglemaster II Driveline Inclinometer/Protractor 164-R2402. Measure the slope of the components
in front and behind the center support bearing U-joint in the area indicated. Record the front component as angle A
and the rear component as angle B.
All vehicles
5. NOTE: When 2 connected components slope in the same direction, subtract the smallest number from the larger
number to find the U-joint operating angle. When 2 connected components slope in the opposite direction, add the
measurements to find the U-joint operating angle.
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Calculate the difference in the slope of the components to determine the U-joint operating angle.
6. NOTE:
The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing kit. Ideally, the
operating angles on each connection of the driveshaft must:
1. be equal or within one degree of each other.

2. have a 3 degree maximum operating angle.
3. have at least one-half of one degree continuous operating angle.
7. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine mounts,
transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle mounting or the frame
for wear or damage.

Driveshaft Runout and Balancing
100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
Inspection
NOTE: Driveline vibration exhibits a higher frequency and lower amplitude then high-speed shake. Driveline
vibration is directly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration can
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be perceived as a tremor in the floorpan or heard as a rumble, hum or boom.
NOTE: Refer to Specifications in this section for runout specifications.
1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure or
the vehicle load.
Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by
reproducing it during the road test.
The concern should be directly related to vehicle road speed. not affected by acceleration or
deceleration or could be reduced by coasting in NEUTRAL.
2. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
3. NOTE: The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use a
twin-post hoist or a frame hoist with jackstands.
Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the
driveshaft slowly by hand and feel for binding or end play in the U-joint trunions. Remove the
driveshaft. Inspect the slip yoke splines for any galling, dirt, rust or incorrect lubrication. Clean the
driveshaft or install new U-joints as necessary. Install a new driveshaft if damaged. After any
corrections or new components are installed, recheck for the vibration at the road test speed.
If the vibration persists after inspection, measure the driveshaft runout.
Check
1. NOTE:
Measure and check for the specified maximum value. Install the Dial Indicator Gauge with Holding
Fixture. Rotate the driveshaft by turning the axle and measure the runout at the front, center and
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rear of the driveshaft. Multiple piece driveshaft measure each section at the front, center and rear.
1. If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft.
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
2. If the front and center is within 1 mm (0.040 in) , but the rear runout is not, index-mark the rear
runout high point and proceed to step 2.
3. If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If the
vibration persists, balance the driveshaft. Refer to Driveshaft Balancing in this procedure.
2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round pinion
flanges are limited to 2 positions. CV joint pinion flanges that have 6 bolts, can be turned in 60 degree or
one-sixth increments.
Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees.
Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft.
1. If the runout is still over specification, mark the high point and proceed to Step 3.
2. If the runout is within specification, check for the vibration at the road test speed. If the vibration is
still present, balance the driveshaft. Refer to Driveshaft Balancing in this procedure.
3. NOTE:
Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find
the source, compare the 2 high points previously determined.
1. If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a new
driveshaft.
2. If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion
flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds
specifications, a bent pinion is indicated.
3. If the pinion flange and pinion runouts are within specifications, road test and check for the vibration
at the road test speed. If the vibration persists, balance the driveshaft. Refer to Driveshaft
Balancing in this procedure.
Driveshaft Balancing – Using the Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer
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(Vetronix)
4. Special Tool(s): Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) 257-00018.
Working under the vehicle, install an accelerometer. The accelerometer can be attached and mounted near
either the transmission or differential end of the driveshaft.
5. NOTE:
Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer
sensor. The sensor should be placed at approximately a 20-degree angle from perpendicular to
the surface of the reflective tape. Make sure the sensor does not get moved during the balance
procedure.
1. Reflective tape.
2. Photo-tachometer sensor.
Run a driveshaft balance test with the driveshaft unmodified.
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
Vehicles with tapped pinion flanges
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7. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the remaining
holes 2, 3, 4, (depending on flange type, 5 and 6 may also be needed). Label in the direction of rotation.
Run a second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on
the pinion flange.
9. Remove the test weight, then install the weight combination directed by the Mastertech® Series MTS 4000
Driveline Balance and NVH Analyzer (Vetronix).
Vehicles without tapped pinion flanges
10. NOTE:
Special Tool(s): Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix)
257-00018. Run a second test with a test weight. Using a metal band, secure the test weight to the
end of the driveshaft. The weight should be placed at the end of the driveshaft tube, as close to the
tube-to-yoke weld seam as possible. Mark the location of the test weight on the driveshaft, as
shown in the figure below.
1. Test weight.
2. Tube-to-yoke weld seam.
3. Driveshaft pinion flange.
Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller
driveshafts use 5 g (0.176 oz).
11. NOTE:
Remove the test weight, then install the recommended weight at the position directed by the
Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal
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band and epoxy, secure the test weight to the driveshaft, as shown in the figure below.
1. Test weight.
2. Measure in this direction.
3. Driveshaft diameter.
4. Directional rotation.
5. Balance weight relative to test weight centerline.
The results are displayed with respect to the location to where the test weight was placed.
All vehicles
Run a third test to verify the repair.
Driveshaft Balancing – Hose Clamp Method
13. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be
determined through trial and error.
14. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4.
Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below. Check
for vibration at road speed. Recheck with the clamp at each of the other positions to find the position that
shows minimum vibration. If 2 adjacent positions show equal improvement, position the clamp head
between them.
15. If the vibration persists, add a second clamp at the same position and recheck for vibration.
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16. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best position
determined in Step 14. Separate the clamp heads about 13 mm (1/2 in) and recheck for vibration at the
road speed.
17. Repeat the process with increasing separation until the best combination is found or the vibration is
reduced to an acceptable level.

Driveshaft
Removal
NOTE: The maximum articulation of the flex coupling is 4 degrees. The maximum articulation of any u-joint is
15 degrees. If the flex coupling or any u-joint of the driveshaft is articulated further then the maximum allowable
degrees damage may occur.
1. Remove the muffler and tailpipe.

Installation).
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Installation).
2. 1. Index mark the driveshaft and the pinion flange for reference during installation.
2. Remove and discard the driveshaft to pinion flange bolts.
3. NOTICE: Do not over articulate the driveshaft or damage may occur.

2. NOTE: The driveshaft coupler is a tight fit, and may not be able to remove from the PTU coupler
until the center bearing retainers are removed.
Using a screwdriver inserted into the slot on the pinion flange, pry the driveshaft from the pinion
flange.
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If equipped with 3 bolt flange.

1. Mark the driveshaft flex coupling to the transmission flange.
2. Remove and discard the driveshaft to transmission flange bolts. Position and support the driveshaft
aside.

1. Mark the driveshaft to the transmission flange.
2. Remove and discard the driveshaft to transmission flange bolts. Position and support the driveshaft
aside.
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6. NOTICE: The help of a assistant may be needed. Do not over articulate the driveshaft or damage
may occur.
If equipped.
Remove and discard the driveshaft center bearing bolts and remove the driveshaft.
Installation
Inspect the flex coupling for cracks. If cracks are present, replace the flex coupling.
2. NOTICE: The help of a assistant may be needed. Do not over articulate the driveshaft or damage
may occur.
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NOTE: Align the flex coupling before installing the center bearing bolts.
If equipped.
Install the driveshaft and the new driveshaft center bearing bolts.
NOTE: Do not force the flex coupling bushing on the transmission output shaft or damage will occur.
If equipped with 3 bolt flex coupling.

1. Align the index-mark on driveshaft flex coupling to the transmission flange.
2. Install the new driveshaft flex coupling to transmission flange bolts.
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1. Align the index-mark on driveshaft to the transmission flange.
2. Install the new driveshaft to transmission flange bolts.
5. NOTICE: The help of a assistant will be needed. Do not over articulate the driveshaft or damage
may occur.
NOTICE: Make sure the mating surfaces are free of any contamination including removing any blue
Loctite from any mating surfaces.
Align the index-mark on driveshaft to the rear axle pinion flange.

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6. NOTICE: Make sure the drive shaft is fully seated in the rear pinion before starting bolts.
Install the new driveshaft-to-pinion flange bolts in a star pattern.

7. Install the muffler and tailpipe.

Installation).
Installation).
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Driveshaft Universal Joint
205-086 (T74P-4635-C)
Installer/Remover, C-Frame and Screw
DISASSEMBLY
NOTICE: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar
holding fixture. Denting or localized fracturing may result, causing driveshaft failure during vehicle
operation.
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1. Remove the driveshaft.
Refer to: Driveshaft (205-01 Driveshaft, Removal and Installation).
2. NOTE: If the components are not marked and therefore installed incorrectly, driveshaft imbalance can
occur.
Index-mark the driveshaft for reassembly.
3. Remove and discard the snap rings.

4. Using the special tool, press the u-joint bearing cups out of the driveshaft yoke and remove the driveshaft
yoke.
Use Special Service Tool: 205-086 (T74P-4635-C) Installer/Remover, C-Frame and Screw.
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5. Using the special tool, press the u-joint bearing cups out of the driveshaft yoke and remove the u-joint.
Use Special Service Tool: 205-086 (T74P-4635-C) Installer/Remover, C-Frame and Screw.
6. Clean and inspect the u-joint bearing cup surfaces.

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ASSEMBLY
NOTE: Install the u-joint kits as complete assemblies only. Do not mix components from other u-joint kits.

205-02 Rear Drive Axle/Differential 2016 Mustang
Specifications
Materials
Name Specification
Motorcraft® Additive Friction Modifier (U.S.) EST-M2C118-A
XL-3 (U.S.)
Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant WSS-M2C942-A
XY-75W85-QL
Capacities
Item Liters
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear 3.15-3.30 pt (1.49-1.56 L) a
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Lubricant / XY-75W85-QL (WSS-M2C942-A)
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear 3.93 – 4.08 pt (1.858 – 1.929 L ) –
Lubricant / XY-75W85-QL (WSS-M2C942-A) Cooler package b
Material: Motorcraft® Additive Friction Modifier (U.S.) / XL-3 (U.S.) 3.0-3.5 oz (0.089-0.104 L)
(EST-M2C118-A)
Material: Motorcraft® Additive Friction Modifier (U.S.) / XL-3 (U.S.) 4.0 – 6.0 Oz (0.118-0.177 L) –
(EST-M2C118-A) Cooler package
aThe fill level is approximately 9mm below the fill plug opening. This level includes friction modifier.
bFill axle to bottom of fill plug opening, operate the axle cooler pump using computer diagnostic tool to prime the cooler
system, then refill axle to ~9mm below the fill plug level. This level includes friction modifier.
Item Nm lb-ft lb-in

Differential cooler line adaptors 23 17 –
Differential cooler line support bolts 11 – 97
Differential cooler oil pump bracket bolts 11 – 97
Differential vent 14 – 124
Item Specification
Maximum differential case ring gear flange runout 0.076 mm (0.003 in)
Maximum pinion flange runout 0.25 mm (0.009 in)
Minimum rotational torque (Traction-Lok®) 27 Nm (20 lb-ft)
Pinion bearing preload 1.8-3.3 Nm (16-29 lb-in)
Ring gear backlash 0.203-0.304 mm (0.008-0.012 in)
Rear Axle Backlash Shim Adjustment Table
Backlash Change Required Thickness Change Required

mm In mm In
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
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0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart 4067
Stripes and Color Code Dimension A

mm Inch
3 - Purple 5.9182 0.233
4 - Purple 5.969 0.235
5 - Purple 6.0198 0.237
6 - Purple 6.0706 0.239
1 - Purple 6.1214 0.241
2 - Purple & 1 - Black 6.1468 0.242
2 - Purple 6.1722 0.243
1 - Orange & 1 - Black 6.1976 0.244
2 - Orange & 1 - Black 6.2484 0.246
3 - Orange & 1 - Black 6.2992 0.248
4 - Orange & 1 - Black 6.35 0.250
5 - Orange & 1 - Black 6.4008 0.252
1 – Yellow & 1 – Black 6.4516 0.254
2 – Yellow & 1 – Black 6.5024 0.256
3 – Yellow & 1 – Black 6.5532 0.258
4 – Yellow & 1 – Black 6.604 0.260
4 – Yellow 6.6294 0.261
5 – Yellow & 1 – Black 6.6548 0.262
5 – Yellow 6.6802 0.263
1 – White & 1 – Black 6.7056 0.264
1 - WH 6.731 0.265
2 – White & 1 – Black 6.7564 0.266
2 – White 6.7818 0.267
3 – White & 1 – Black 6.8072 0.268
3 – White 6.8326 0.269
4 – White & 1 – Black 6.858 0.270
4 – White 6.8834 0.271
5 – White & 1 - Black 6.9088 0.272
5- White 6.9342 0.273
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1 - Green & 1 - Black 6.9596 0.274
1 - Green 6.985 0.275
2 - Green & 1 - Black 7.0104 0.276
2 - Green 7.0358 0.277
3 - Green & 1 - Black 7.0612 0.278
3 - Green 7.0866 0.279
4 - Green & 1 - Black 7.112 0.280
4 - Green 7.1374 0.281
5 - Green & 1 - Black 7.1628 0.282
5 - Green 7.1882 0.283
1 - Pink & 1 - Black 7.2136 0.284
1 - Pink 7.239 0.285
2 - Pink & 1 - Black 7.2644 0.286
2 - Pink 7.2898 0.287
3 - Pink & 1 - Black 7.3152 0.288
3 - Pink 7.3406 0.289
4 - Pink & 1 - Black 7.366 0.290
4 - Pink 7.3914 0.291
5 - Pink 7.4422 0.293
1 - Blue 7.493 0.295
2 - Blue 7.5438 0.297
3 - Blue 7.5946 0.299
4 - Blue 7.6454 0.301
5 - Blue 7.6962 0.303
1 - Black 7.747 0.305
2 - Black 7.7978 0.307
Differential Clutch Pack Selective Shim Chart
Feeler Gauge Thickness Part Number Description

0.072 - 0.080 EOAZ-4A324-G 0.025 inch
0.081 - 0.085 EOAZ-4A324-H 0.030 inch
0.086 - 0.090 EOAZ-4A324-C 0.035 inch
0.091 - 0.095 EOAZ-4A324-D 0.040 inch
0.096 - 0101 EOAZ-4A324-F 0.045 inch
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Rear Drive Axle and Differential - Overview
The 8.8-inch ring gear rear differential is the IRS (Independent Rear Suspension) type. The 8.8-inch rear axle has
3.15, 3.31, 3.55, and 3.73 gear ratio versions.
Rear Drive Axle and Differential
The rear axle assembly consists of the following:
Integral-type housing hypoid gear design (center of the pinion set below the centerline of the ring gear)
Hypoid differential ring gear and pinion consisting of a 8.8-inch ring gear and an overhung drive pinion that
is supported by 2 opposed tapered roller bearings
Pinion bearing preload that is maintained by a drive pinion collapsible spacer on the differential pinion shaft
and adjusted by the pinion nut
Cast center section with a cast differential housing cover
Differential housing cover using silicone rubber based sealant as a gasket
Differential pinion shaft that is retained by a threaded differential pinion shaft lock bolt attached to the
differential case
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Differential case that is mounted in the rear axle housing between 2 opposing differential bearings that are
retained in the rear axle housing by 2 removable bearing caps
Differential bearing preload and ring gear backlash which are adjusted by differential bearing shims that are
located between the differential bearing cups and the rear axle housing
Limited slip axle - (Traction-Lok) 3.15, 3.31 and 3.55 ratio axles
Limited slip axle - (Torsen) 3.73 ratio axles
The rear drive axle receives rotational torque from the driveshaft. The direction of the rotation determines
movement of the vehicle. The rotation enters the rear drive axle through the drive pinion flange, turning the drive
pinion and rotating the ring gear. The ring gear is bolted to the differential case. The differential case houses the
pinion shaft upon which the differential pinion gears ride. The pinion gears are in mesh with the differential side
gears to which the halfshafts are splined. It is the unique arrangement of the differential that allows the halfshafts
to be driven at different speed when needed, such as when driving around corners.
The Torsen rear differential carrier is serviced as a assembly only.
Overview
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1 Rear differential mounting bolts
2 Rear differential vibration dampners (if equipped)
3 Differential vent tube
4 Front differential mounting bolts
5 IRS (Independent Rear Suspension) Differential
Overview
1 Differential cooler oil pump
2 Differential oil cooler
3 Differential oil cooler lines
4 Differential fluid temperature sensor
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Differential Oil Cooler System
DTC Chart: PCM
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.
DTC Chart - PCM
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P1888 Differential Oil Temperature GO to Pinpoint Test A
Sensor Circuit Failure
P1889 Oil Pressure Pump Performance GO to Pinpoint Test B
P188A Differential Oil Temperature Too GO to Pinpoint Test B
High / Too Low
P188E Oil Pressure Pump Control GO to Pinpoint Test C
Circuit
- All Other PCM DTCs
REFER to: Electronic Engine Controls (303-14D Electronic Engine
Controls - 5.2L 32V Ti-VCT, Diagnosis and Testing).
Symptom Chart
In most circumstances, the PCM sets DTCs to help guide with diagnostics. Refer to the DTC Chart before using
the symptom chart. The Symptom column lists the vehicle condition. The Possible Sources column lists a detailed
vehicle condition. The Action column lists the action to be performed to determine the cause of the condition. Each
action lists the components that can cause the system and the individual components in that system. The
components are listed in order of disassembly. Use the list of components and the required action to focus on
disassembly inspections for the root cause of the concern.
Symptom Chart - Four-Wheel Drive Systems

The PCM does not Fuse
respond to the scan tool Wiring, terminals or REFER to: Communications Network (418-00 Module
connectors Communications Network, Diagnosis and Testing).
PCM
The differential oil pump Fuse GO to Pinpoint Test D
never runs Wiring, terminals or
connectors
Temperature sensor
Differential oil pump
relay
PCM
The differential oil pump Fuse GO to Pinpoint Test D

runs continuously Wiring, terminals or
connectors
Temperature sensor
relay
PCM
Pinpoint Tests
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DTC P1888
The temperature sensor is hardwired to the PCM. The PCM utilizes a fixed resistor (pull-up resistor) in series with
the temperature sensor to monitor the entire temperature sensor circuit. As the differential oil temperature
changes, the resistance in the temperature sensor changes which causes a variation in total circuit current flow
resulting in a varying voltage drop across the pull-up resistor. The voltage signal used by the PCM to determine oil
temperature is equal to the reference voltage minus the voltage drop across the pull-up resistor. Any circuit faults
in the temperature sensor circuits or in the temperature sensor cause the PCM to set a DTC.

Constant velocity joints
Differential oil temperature sensor
PCM
PINPOINT TEST A : DTC P1888

A1 CHECK THE TEMPERATURE SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Disconnect Differential Oil Temperature Sensor C379.
Measure:

C379-1 Ground
C379-2 Ground

No GO to A2
A2 CHECK THE TEMPERATURE SENSOR CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C379-1 Ground
C379-2 Ground
Yes GO to A3
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A3 CHECK THE TEMPERATURE SENSOR CIRCUITS FOR AN OPEN
Measure:

C379-1 C175B-55
C379-2 C175B-51
Yes GO to A4
A4 CHECK THE TEMPERATURE SENSOR CIRCUITS FOR A SHORT TOGETHER

Measure:

C379-1 C379-2
Yes GO to A5
No GO to A5
A5 CHECK THE PCM TEMPERATURE SENSOR OUTPUT
Connect PCM C175B.
Ignition ON.
Measure:

C379-1 Ground
Yes INSTALL a new differential oil temperature sensor.

No GO to A6
A6 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE)
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Ignition OFF.
Disconnect all PCM connectors.
Reconnect all PCM connectors. Make sure they seat and latch correctly.
Yes CHECK OASIS for any applicable TSBs. If a TSB exists for this concern, DISCONTINUE
this test and FOLLOW TSB instructions. If no TSBs address this concern, INSTALL a new
PCM.
REFER to: Powertrain Control Module (PCM) (303-14D Electronic Engine Controls - 5.2L
32V Ti-VCT, Removal and Installation).
PROGRAM the PCM with the latest calibration level.
REFER to: Transmission Strategy Download (307-01 Automatic Transmission - 6-Speed
Automatic Transmission - 6R80, General Procedures).
module connections. Address the root cause of any connector or pin issues.
DTC P1889 or P188A
When the differential oil temperature reaches a predetermined level, the PCM grounds the differential oil pump
relay which activates the differential oil pump. Once the oil temperature is reduced to another predetermined level,
the PCM stops grounding the relay. While the relay is activated, the PCM continues to monitor the differential oil
temperature and expects to see a reduction in the temperature. If the PCM does not see a reduction in the
temperature or if the temperature continues to rise, a DTC is set. Blocked air flow through the oil cooler, a
blockage or restriction in the cooling hoses/tubes or an inoperative oil pump all contribute to poor cooling system
performance.

P1889 Oil Pressure Pump This DTC sets in continuous memory when the differential oil temperature
Performance exceeds system capability due to blockage, a component failure or system
failure.
P188A Differential Oil Temperature This DTC sets in continuous memory when the differential oil temperature
Too High / Too Low exceeds 145° C (293° F).
Possible Causes
Restricted air flow through the differential oil cooler

Restricted oil flow through the differential oil cooler system
Differential oil pump relay
Differential oil temperature sensor
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Make sure the differential oil is at the correct level.

Make sure the differential and differential cooler system are free of any leaks.
Make sure there are no air flow blockages or restrictions through the oil cooler.
PINPOINT TEST B : DTC P1889 OR P188A

B1 CHECK FOR OTHER PCM DTCS
Ignition ON.
Using a scan tool, carry out the PCM KOEO self-test.
Is DTC P1888 or P188E present?
Yes For DTC P1888, GO to Pinpoint Test A For DTC P188E, GO to Pinpoint Test C
No For all other PCM DTCs,
If no other PCM DTCs are present, GO to B2
B2 CHECK THE DIFFERENTIAL OIL PUMP OPERATION

Using a scan tool, toggle the rear differential fluid pump (R_DIFF_PUMP)PID ON.
Does the pump motor run?
Yes TOGGLE the R_DIFF_PUMP PID OFF. GO to B3

No TOGGLE the R_DIFF_PUMP PID OFF. GO to Pinpoint Test D
B3 CHECK THE DIFFERENTIAL COOLER SYSTEM FOR BLOCKAGES AND RESTRICTIONS

Inspect the following items for damage, blockages or restrictions:
Oil cooler
Oil cooler fins
Oil cooler hoses
Differential outlet port
Differential inlet port
Are any damage, blockages or restrictions present?
Yes REPAIR or INSTALL new components as necessary.

No INSTALL a new differential cooler oil pump.
REFER to: Oil Pump (205-02 Rear Drive Axle/Differential, Removal and Installation).
DTC P188E
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the PCM stops grounding the relay.

P188E Oil Pressure Pump This DTC sets in continuous memory and on-demand when the PCM detects a short
Control Circuit to ground or an open in the differential oil pump relay control circuit. Also, an open in
the relay or the relay power supply circuit can cause this DTC to set.
Possible Causes
Fuse
PCM
Make sure BJB fuse 46 (20A) and fuse 85 (15A) are OK

Make sure the differential oil pump relay is present and fully seated in the BJB.
PINPOINT TEST C : DTC P188E

C1 CHECK THE VOLTAGE TO THE DIFFERENTIAL OIL PUMP RELAY
Ignition OFF.
Disconnect Differential Oil Pump Relay .
Measure:

Relay Cavity 1 Ground
Yes GO to C2
No VERIFY BJB fuse 46 (5A) and fuse 85 (15A) are OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams Manual to identify the possible causes of the circuit short
C2 CHECK THE DIFFERENTIAL OIL PUMP RELAY

Carry out the mini ISO relay component test.
INSTALL a new relay.
Yes GO to C3
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C3 CHECK THE DIFFERENTIAL OIL PUMP RELAY CONTROL CIRCUIT FOR AN OPEN
Measure:

Relay Cavity 1 C175B-98
Yes GO to C4
C4 CHECK THE DIFFERENTIAL OIL PUMP RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:

C175B-98 Ground
Yes GO to C5
Ignition OFF.
Operate the system and verify the concern is still present
Yes CHECK OASIS for any applicable TSBs. If a TSB exists for this concern, DISCONTINUE
this test and FOLLOW TSB instructions. If no TSBs address this concern, INSTALL a new
PCM.
PROGRAM the PCM with the latest calibration level.
REFER to: Transmission Strategy Download (307-01 Automatic Transmission - 6-Speed
Automatic Transmission - 6R80, General Procedures).
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The Differential Cooler Pump Never Runs Or Runs Continuously
the PCM stops grounding the relay.
Possible Causes
Make sure BJB fuses 46 (20A) and 85 (15A) are OK.

PCM
BJB fuse 85 (15A)

Make sure the differential oil pump relay is present and fully seated in the BJB .
PINPOINT TEST D : THE DIFFERENTIAL COOLER PUMP NEVER RUNS OR RUNS CONTINUOUSLY
D1 CHECK THE DIFFERENTIAL OIL PUMP OPERATION
Ignition ON.
Listen for differential oil pump operation.
Is the differential oil pump operating?
Yes GO to D2
No GO to D3
D2 CHECK THE DIFFERENTIAL OIL PUMP RELAY
Is the differential oil pump still operating?

No INSTALL a new relay.
D3 CHECK THE VOLTAGE TO THE DIFFERENTIAL OIL PUMP RELAY

Ignition OFF.
Ignition ON.
Measure:

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Relay Cavity 1 C4379-4
Yes GO to D4
No VERIFY BJB fuse 46 (20A) is OK. If OK, REPAIR circuit CBB46 (WH/BU). VERIFY BJB
fuse 85 (15A) is OK. If OK, REPAIR the circuit. If either fuse is not OK, REFER to the
Wiring Diagrams Manual to identify the possible causes of the circuit short.
D4 CHECK THE DIFFERENTIAL PUMP VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO GROUND
Measure:

C3427-1 Ground
C3427-2 Ground
Yes GO to D5
D5 CHECK THE DIFFERENTIAL PUMP VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Measure:

Yes GO to D6
No , REPAIR the circuit.
D6 CHECK THE DIFFERENTIAL PUMP GROUND CIRCUIT FOR AN OPEN

Measure:
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C3427-3 Ground
Yes INSTALL a new differential cooler oil pump. For the appropriate procedure,
REFER to: Oil Pump (205-02 Rear Drive Axle/Differential, Removal and Installation).

Rear Drive Axle and Differential
1. Visually inspect the housing, seals, and pinion flange for obvious signs of mechanical damage.
3. If the cause is not visually evident, verify the symptom and REFER to Symptom Chart: NVH.
Symptom Chart(s)
Symptom Chart: NVH
Symptom Chart
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Axle howling or whine Axle lubricant low CHECK the lubricant level. FILL the axle
to specification.
REFER to: Differential Fluid Level Check
(205-02 Rear Drive Axle/Differential,
Axle housing damage INSPECT and INSTALL a new axle

REFER to: Axle Assembly (205-02 Rear
Drive Axle/Differential, Removal and
Installation).
Damaged, worn or INSPECT and INSTALL a new ring and

incorrect ring and pinion pinion set as necessary. Refer to,
gear contact Contact Pattern of this procedure, or
REFER to: Drive Pinion (205-02 Rear
Drive Axle/Differential, Removal and
Installation).
Driveline clunk - loud clunk Incorrect axle lubricant CHECK the lubricant level. FILL the axle
when shifting from level to specification.
REVERSE to DRIVE REFER to: Differential Fluid Level Check
(205-02 Rear Drive Axle/Differential,
Excessive backlash in the CHECK for excessive axle backlash.

axle ADJUST backlash as necessary.
REFER to: Ring Gear Backlash
Adjustment (205-02 Rear Drive
Axle/Differential, General Procedures).
Driveline clunk — occurs as Pinion gears CHECK and REPLACE as necessary

the vehicle starts to move REFER to: Drive Pinion Front Bearing
forward following a stop (205-02 Rear Drive Axle/Differential,
Analysis of Leakage
Clean up the leaking area enough to identify the exact source.
A plugged Rear axle housing vent can cause excessive pinion seal lip wear due to internal pressure buildup.
Verify the differential lubricant level is at the correct level.

REFER to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
Axle Vent
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the
vent. If the vent cannot be cleared, install a new vent.
Drive Pinion Seal
Leaks at the drive pinion seal originate from the following causes:
Damaged seal
Worn seal journal surface
A new drive pinion flange must be installed if any of these conditions exist.
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Any damage to the seal bore (dings, dents, gouges or other imperfections) distorts the seal casing and
allows leakage past the outer edge of the drive pinion seal.
The drive pinion seal can be torn, cut or gouged if it is not installed correctly. The spring that holds the drive
pinion seal against the pinion flange may be knocked out and allow fluid to pass the lip.
Metal chips trapped at the sealing lip can cause oil leaks. These can cause a wear groove on the drive
pinion flange and result in pinion seal wear.
When a seal leak occurs, install a new drive pinion seal and check the vent to make sure it is clean and
free of foreign material.
Differential Seals
NOTICE: When installing shafts, do not allow splines to contact seals during installation or damage to
the seals may occur.
Halfshaft pilot bearing housing seals are susceptible to the same types of damage as drive pinion seals if
incorrectly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The
seal journal surface must be free of nicks, gouges and rough surface texture.
Contact Pattern
In general, desirable ring gear tooth patterns must have the following characteristics:
Drive pattern on the drive side ring gear well centered on the tooth.
Coast pattern on the coast side ring gear well centered on the tooth.
Clearance between the pattern and the top of the tooth.
No hard lines where the pressure is high.
Acceptable ring gear tooth patterns for all axles.

Correct backlash with a thinner pinion position shim required.
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Correct backlash with a thicker pinion position shim required.
Correct pinion position shim that requires a decrease in backlash.

Correct pinion position shim that requires an increase in backlash.
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Axle and Differential Draining and Filling
Materials
Name Specification
XL-3 (U.S.)
XY-75W85-QL
Draining
All vehicles
NOTE: Removal steps may contain installation information.
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Vehicles with a drain plug
2. Drain the differential gear lubricant.

Vehicles equipped with a differential cooler
3. 1. Remove the cooling line retaining clip.

2. Remove the cooling line and position aside.
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4. 1. Remove the differential cooling line fitting.
2. Inspect the differential cooling line fitting.
Vehicles without a drain plug
5. Remove the differential housing cover to drain the fluid.

Refer to: Differential Housing Cover (205-02 Rear Drive Axle/Differential, Removal and Installation).
Filling
1. Remove the differential fill plug.

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2. Fill the differential with 1.50 L (3.18 pts) of clean differential gear lubricant.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL
(WSS-M2C942-A)
3. Fill the differential with 4.0 oz (0.118 L) of clean friction modifier.

Material: Motorcraft® Additive Friction Modifier (U.S.) / XL-3 (U.S.) (EST-M2C118-A)
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4. Install the differential fill plug.
5. NOTE: The differential gear lubricant level should be within 9mm (0.354 in.) from the fluid level fill plug
opening.
If equipped with a differential cooler, operate the differential cooler pump with a scan tool for two minutes
and top off differential fluid.
(WSS-M2C942-A)

Differential Fluid Level Check
Materials
Name Specification
XY-75W85-QL
Check

2. Remove the differential fluid fill plug.
3. Check and top off the differential with clean differential gear lubricant. The differential gear lubricant level
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should be within 9mm (0.354 in.) from the fluid level fill plug opening.
Refer to: Specifications (205-02 Rear Drive Axle/Differential, Specifications).
(WSS-M2C942-A)
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4. Install the differential fluid fill plug.
5. If equipped with a differential cooler, operate the differential cooler pump with a scan tool for two minutes
and repeat steps 1 thru 4.

Ring Gear Backlash Adjustment
205-220
Installer, Differential Shim
TKIT-1985-FH
308-021 (T75L-4201-A)
Gauge, Clutch Housing
Dial Indicator
Tire Lever
Wooden Block
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Copper Hammer
Adjustment
1. Install the dial indicator gauge with holding fixture, with the dial indicator at a 90 degree angle from the ring
gear tooth.
Use the General Equipment: Dial Indicator
2. Using the dial indicator check the ring gear backlash. Rotate the ring gear and carrier back and forth
through the free play only.
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3. To correct for high or low backlash, increase the thickness of one differential bearing shim and
decrease the thickness of the other differential bearing shim by the same amount.
If a zero backlash condition had occurred, add 0.50 mm (0.020 in) to the RH side shim and subtract
0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Recheck backlash.
Using the backlash chart, determine the thickness of differential shim needed:
4. NOTE: The differential bearing caps and differential bearing cap bolts need to be installed in the same
location as removed.
1. Mark the differential bearing caps.

2. Remove the differential bearing cap bolts.
3. Remove the differential bearing caps.
5. NOTE: If the old differential bearing cups and shims are to be reused, they need to be installed in the
same location as removed.
Mark the differential shims.

Mark the differential carrier bearing cups.
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6. Install the Dial Indicator and special tool. Position the tip of the clutch housing gauge on the inside of the
axle housing guide hole. Zero the dial indicator.
Use Special Service Tool: 308-021 (T75L-4201-A) Gauge, Clutch Housing.
7. Install a 12” / 300mm C-Clamp on the axle housing at the 12:00 O'clock and 6:00 O'clock positions. Install
2” x 2” x ¾” blocks of wood between the C-Clamp and the housing to prevent housing cracks.
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8. Tighten the C-Clamp until the housing spreads 0.020” / 0.50mm.
9. With the dial indicator removed. Position a wood block on the housing sealing surface. Using the tire lever,
block of wood and a wrench remove the differential carrier, differential carrier bearing cups and the
differential shims.
Use the General Equipment: Tire Lever
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10. NOTE: Have the selected shims available at this time. It will be required to hold the differential carrier
and the differential carrier bearing cups in until shims are installed.
Remove the dial indicator. Install the differential carrier and the differential carrier bearing cups.
11. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
Install the selected or original RH differential bearing shim. If the original RH shim is not available,
install the largest shim available.
NOTE: The differential bearing cap bolts should only be finger tight at this time.
Position the differential to the RH side of the differential housing. Install the RH differential bearing
cap and the differential bearing cap bolts.
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12. NOTE: The C-Clamp can be removed after the selected ring gear backlash shim is installed.
Using the special tool and a soft face copper mallet, install the LH selected differential bearing shim. If the
selected or original LH shim is not available, use the largest shim that can be installed by hand.
Use Special Service Tool: 205-220 Installer, Differential Shim.
Use the General Equipment: Copper Hammer
13. NOTE: The differential bearing cap bolts should only be finger tight at this time.
Install the LH differential bearing cap and the differential bearing cap bolts.
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14. Tighten the differential bearing cap bolts.
15. Rotate the differential several times, to assure the differential assembly rotates freely.
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16. Using the dial indicator gauge with holding fixture, do a final check of the ring gear backlash.

Axle Assembly

Transmission Jack
Removal
1. Remove the muffler and tailpipe assembly.

Installation).
Installation).
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2. Remove both rear halfshafts.

3. 1. Index mark the driveshaft and the pinion flange for reference during installation.
2. Remove and discard the driveshaft-to-pinion flange bolts.
4. NOTICE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube.
Damage to the CV-joint can result.

2. Using a screwdriver inserted into the slot on the pinion flange, pry the driveshaft from the pinion
flange.
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5. If equipped.
Disconnect the differential fluid temperature sensor connector.
6. If equipped.
1. Remove the differential cooling return line retaining clip.
2. Remove the differential cooling return line and position aside.
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7. If equipped.
1. Remove the differential cooling supply line retaining clip.
2. Remove the differential cooling supply line and position aside.
8. Disconnect the differential vent tube.

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9. NOTICE: The rear differential is heavy and will require to be supported by a transmission jack
before the fasteners are removed.
Using a transmission jack, remove and discard the differential mounting bolts and remove the differential.
Use the General Equipment: Transmission Jack
Installation
1. NOTE: Only install the differential mounting bolts hand tight at this time.
Using a transmission jack, install the differential and the new differential mounting bolts hand tight.
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2. 1. Tighten the forward differential mounting bolts.
2. Tighten the rear differential mounting bolts.
3. Connect the differential vent tube.

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4. If equipped.
Connect the differential fluid temperature sensor connector.
5. If equipped.
1. Install the differential cooling supply line.
2. Install the differential cooling supply line retaining clip.
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6. If equipped.
1. Install the differential cooling return line.
2. Install the differential cooling return line retaining clip.
7. Position the driveshaft to the pinion flange and align the index mark made during removal.
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8. NOTE: Make sure the driveshaft is fully seated into the pinion flange before installing the driveshaft to
pinion flange bolts.
Install the driveshaft-to-pinion flange bolts.

9. Install both rear halfshafts.

10. Install the muffler and tailpipe assembly.

Installation).
Installation).

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Differential Carrier
205-220
Installer, Differential Shim
TKIT-1985-FH
307-003 (T57L-500-B)
Holding Fixture, Transmission
308-021 (T75L-4201-A)
Gauge, Clutch Housing
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Dial Indicator
Tire Lever
Wooden Block
Copper Hammer
Removal
1. Remove the differential housing cover.

Refer to: Differential Housing Cover (205-02 Rear Drive Axle/Differential) .
2. Mount the differential carrier to the holding fixture.

Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.
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3. NOTE: The differential bearing caps and differential bearing cap bolts need to be installed in the same
location as removed.
1. Mark the differential bearing caps.

2. Remove the differential bearing cap bolts.
3. Remove the differential bearing caps.
4. NOTE: If the old differential bearing cups and shims are to be reused, they need to be installed in the
same location as removed.
Mark the differential shims.

Mark the differential carrier bearing cups.
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8. With the dial indicator removed. Position a wood block on the housing sealing surface. Using the tire lever,
block of wood and a wrench remove the differential carrier, differential carrier bearing cups and the
differential shims.
Use the General Equipment: Tire Lever
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9. With the C-clamp removed inspect the differential case.
Installation
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4. NOTE: Have the selected shims or the previously removed shims available at this time. It will be
required to hold the differential carrier and the differential carrier bearing cups in until shims are
installed.
NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
With the dial indicator removed, install the differential carrier and the differential carrier bearing cups.
5. Install the RH ring gear back lash shim.
NOTE: The differential bearing cap bolts should only be finger tight at this time.
Position the differential to the RH side of the differential housing. Install the RH differential bearing
cap and the differential bearing cap bolts.
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6. NOTE: The C-Clamp can be removed after the selected ring gear backlash shim is installed.
Using the special tool and a soft face copper mallet, install the LH selected ring gear back lash shim.
Use Special Service Tool: 205-220 Installer, Differential Shim.
7. NOTE: The differential bearing cap bolts should only be finger tight at this time.
Install the LH differential bearing cap and the differential bearing cap bolts.
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8. Tighten the differential bearing cap bolts.
9. Check the ring gear backlash.

Refer to: Ring Gear Backlash Adjustment (205-02 Rear Drive Axle/Differential, General Procedures).
10. Remove the differential carrier from the holding fixture.

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11. Install the differential housing cover.
Refer to: Differential Housing Cover (205-02 Rear Drive Axle/Differential) .

Differential Fluid Temperature Sensor
Removal
1. Disconnect the differential fluid temperature sensor connector.
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2. Remove and discard the differential temperature sensor.
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Installation

Differential Housing Cover
Plastic Scraper
Materials
Name Specification
TA-30
Removal
1. Drain the differential assembly.
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Refer to: Axle and Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General
Procedures).
2. Remove the differential assembly.

Refer to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
3. NOTE: The differential housing cover bolts are low profile external torx. Use an EPL16 socket to remove
the bolts.
Remove the differential cover bolts and the differential cover.
Installation
1. Clean the differential cover and differential housing mating surfaces.

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2. NOTE: If equipped with a differential oil cooler, excessive gasket material bead may cause the
differential cooling system to not properly cool the differential oil.
Apply the differential cover gasket material in a 2mm bead.

3. Install the differential housing cover, and the differential housing cover bolts.
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4. Install the differential assembly.
Refer to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
5. Fill the differential with clean differential fluid.

Procedures).

Drive Pinion
205-024 (T67P-4616-A)
Installer, Drive Pinion Bearing Cup
205-1014
Gauge Disc
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
205-1015
Gauge Tube
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TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
205-110 (T76P-4020-A10)
Adapter for 205-S127
205-111 (T76P-4020-A11)
Adapter for 205-S127 Pinion Depth Gauge
205-160 (T80T-4020-F43)
Adapter for 205-S156 Pinion Depth Gauge
205-229 (T85T-4209-AH)
Protector, Drive Pinion Thread
TKIT-1985-FH-1
205-387 (T97T-4628-A)
Installer, Rear Axle Bearing Cup
TKIT-1997-F/FLM/LT
TKIT-1998-LM (NavigatoR)
205-488
Installer, Drive Pinion Bearing
TKIT-1999S-FLM/LT
205-852
Inner Pinion Bearing Cup Installer
TKIT-2006UP-FLM
TKIT-2006UP-ROW
205-937
Adapter, Pinion Aligning
TKIT-2009C-F
TKIT-2009C-ROW
205-D064 (D84L-1123-A)
Puller, Bearing
Rubber Mallet
Hydraulic Press
Punch
Copper Hammer
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Removal
1. Remove the differential carrier.

Refer to: Differential Carrier (205-02 Rear Drive Axle/Differential, Removal and Installation).
2. Remove the drive pinion seal.

Refer to: Drive Pinion Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
3. Remove the drive pinion outer shim.
4. Using the special tool and a soft face mallet, tap drive pinion free of the of the drive pinion outer bearing.
Use Special Service Tool: 205-229 (T85T-4209-AH) Protector, Drive Pinion Thread.
Use the General Equipment: Rubber Mallet
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5. Remove the drive pinion and remove and discard the drive pinion outer bearing.
6. Remove and discard the drive pinion collapsible spacer.

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7. Using the bearing puller and a hydraulic press, remove and discard the inner drive pinion bearing.
Use Special Service Tool: 205-D064 (D84L-1123-A) Puller, Bearing.
8. Remove the inner drive pinion bearing shim.

9. Using the general equipment, remove and discard the drive pinion bearing cups.
Use the General Equipment: Punch
Installation
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1. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may
occur.
Using the special tools, install the new inner and new outer drive pinion bearing cups.
Use Special Service Tool: 205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup. , 205-852 Inner
Pinion Bearing Cup Installer. , 205-387 (T97T-4628-A) Installer, Rear Axle Bearing Cup.
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2. NOTE: Only tighten finger tight at this stage.
Assemble the special tools in the differential housing.

Use Special Service Tool: 205-110 (T76P-4020-A10) Adapter for 205-S127. , 205-160 (T80T-4020-F43)
Adapter for 205-S156 Pinion Depth Gauge. , 205-937 Adapter, Pinion Aligning. , 205-1014 Gauge Disc.
3. Install the special tool.

Use Special Service Tool: 205-111 (T76P-4020-A11) Adapter for 205-S127 Pinion Depth Gauge.
NOTE: This step duplicates final drive pinion bearing preload
Tighten the special tool to the specified torque.

Slowly rotate and record the rotational torque readings.
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4. Check for proper location of special tools.
5. Position the special tool. Install the differential bearing caps and differential bearing cap bolts.
Use Special Service Tool: 205-1015 Gauge Tube.
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6. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not
attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube.
This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results
in a deep tooth contact in the final assembly of integral axle assemblies.
Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
7. NOTE: The differential bearing caps need to stay in the correct orientation for installation.
Remove the differential bearing cap bolts and differential bearing caps, remove the special tools.
Use Special Service Tool: 205-1015 Gauge Tube.
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8. Remove the special tool.
Use Special Service Tool: 205-111 (T76P-4020-A11) Adapter for 205-S127 Pinion Depth Gauge.
9. Remove the special tools.

Use Special Service Tool: 205-110 (T76P-4020-A10) Adapter for 205-S127. , 205-160 (T80T-4020-F43)
Adapter for 205-S156 Pinion Depth Gauge. , 205-937 Adapter, Pinion Aligning. , 205-1014 Gauge Disc.
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10. Install the drive pinion inner bearing and selected drive pinion bearing adjustment shim until they are firmly
seated on the drive pinion.
Use Special Service Tool: 205-488 Installer, Drive Pinion Bearing.
11. Install the new drive pinion collapsible spacer.

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12. NOTE:
Install the new outer differential pinion bearing, outer differential pinion shim and the differential pinion.
13. NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the
drag torque (torque to turn) should be 2.5 to 3.5 Nm (23-33 in-lbs).
Install the drive pinion seal.

14. Install the differential carrier.

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Drive Pinion Flange
205-126 (T78P-4851-A)
Holding Fixture, Drive Pinion Flange
205-233 (T85T-4851-AH)
Installer, Drive Pinion Flange
TKIT-1985-FH-1
Three Leg Puller

Punch
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Copper Hammer
Removal
1. NOTE: The rear brake calipers and brake pads must be removed for accurate pinion nut drag torque
readings.
Remove the rear brake pads.

Refer to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).

3. NOTE: Rotational torque of the drive pinion flange must be measured and recorded using a Nm (lb-in)
torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn
measurement.
Using a dial type torque wrench, measure and record the rotational torque of the drive pinion.
4. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.
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5. Mark the drive pinion flange and the drive pinion stem for reassembly.
6. Using the general equipment, remove the pinion flange.

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Installation
1. If necessary, install a new drive pinion seal.

2. NOTE: Mure sure drive pinion flange and drive pinion stem are phased correctly using previously
applied mark.
Using the special tool, install the pinion flange.

Use Special Service Tool: 205-233 (T85T-4851-AH) Installer, Drive Pinion Flange.
3. NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the
drag torque (torque to turn) should be 2.5 to 3.5 Nm (23-33 in-lbs).
NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the
pinion nut in small increments until it is 0 .00 Nm to +0.3 Nm (0 lb-in to 3 lb-in) of the reference
measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new
collapsible spacer will be required.
Using the special tool to hold the pinion flange, install the new pinion nut.
Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.
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4. Using a general equipment, stake the pinion nut.
5. Install the driveshaft.

6. Install the rear brake pads.
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Drive Pinion Front Bearing
NOTE: The outer differential bearing cup needs to be replaced when replacing the outer differential bearing.
1. Refer to: Drive Pinion (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Drive Pinion Seal
Base Part Number: 3N134
205-208 (T83T-4676-A)
Installer, Drive Pinion Oil Seal
TKIT-1983-F
TKIT-1983-FLM
TKIT-1983-FX
Removal
1. Remove the drive pinion flange.

Refer to: Drive Pinion Flange (205-02 Rear Drive Axle/Differential, Removal and Installation).
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2. Using a flat blade screwdriver, remove and discard the drive pinion seal.
Installation
1. Using the special tool, install the drive pinion seal.

Use Special Service Tool: 205-208 (T83T-4676-A) Installer, Drive Pinion Oil Seal.
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2. Install the drive pinion flange.
Refer to: Drive Pinion Flange (205-02 Rear Drive Axle/Differential, Removal and Installation).

Oil Cooler
Removal
NOTE: Removal steps may contain installation directions.
1. Drain the differential fluid.

Procedures).
2. 1. Remove the rear underbody shield rear bolts.

2. Remove the rear under body shield push pin retainers.
3. Remove the rear underbody shield front bolts.
4. Remove the rear under body shield rivet style push pin retainers.
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3. 1. Remove the differential cooler line clip retainers.
2. Remove the differential cooler lines from the differential cooler and position them aside.
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4. Remove the differential cooler bolts and the differential cooler.
Installation
2. Fill the differential fluid.

Procedures).

Oil Pump
Removal
NOTE: Removal steps may contain installation directions.
1. Drain the differential fluid.

Procedures).
2. 1. Remove the rear underbody shield rear bolts.

2. Remove the rear under body shield push pin retainers.
3. Remove the rear underbody shield front bolts.
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4. Remove the rear under body shield rivet style push pin retainers.
3. Disconnect the differential oil pump connector.

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4. Remove the differential oil pump line bolts and position the differential oil pump lines aside.
5. Remove the differential oil pump bolts and the differential oil pump.
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Installation
2. Fill the differential fluid.

Procedures).

Rear Halfshaft Seal
205-1013
Installer, Rear Axle pilot bearing
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
205-504
Installer, Halfshaft Pilot Bearing
TKIT-2002N-F/FM
TKIT-2002N-FLM
TKIT-2002N-LM
205-907
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Handle, 32 Driver
TKIT-2008DH-FLM
206-034 (T88P-20202-B)
Installer, Wheel Speed Sensor Ring
TKIT-1988-FLM
TKIT-1988-LM
308-047 (T77F-1102-A)
Remover, Bearing Cup
Slide Hammer
Removal
1. Remove the rear halfshafts.

2. Remove and discard the rear half halfshaft seal.

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3. Remove and discard the rear halfshaft pilot bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.
Use the General Equipment: Slide Hammer
Installation
1. Install the new rear halfshaft pilot bearing.

Use Special Service Tool: 205-907 Handle, 32 Driver. , 205-504 Installer, Halfshaft Pilot Bearing. ,
205-1013 Installer, Rear Axle pilot bearing.
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2. Install the new rear half halfshaft seal.
Use Special Service Tool: 206-034 (T88P-20202-B) Installer, Wheel Speed Sensor Ring. , 205-907
Handle, 32 Driver.
3. Install the rear halfshaft.



Differential Carrier
205-1016
Installer, Differential Bearing
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
205-135
Gauge, Differential Clutch
205-153 (T80T-4000-W)
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Handle
205-384 (T97T-4205-A)
Gauge, Differential (Traction Lock)
TKIT-1997-F/FLM/LT
TKIT-1998-LM (NavigatoR)
205-D061 (D83T-4205-C2)
Step Plate
205-D072 (D97L-4221-A)
2 Jaw Puller
Feeler Gauge
Rubber Mallet
Punch
Copper Hammer
Vise
Materials
Name Specification
XL-3 (U.S.)
XY-75W85-QL
DISASSEMBLY
NOTE: This differential is serviced as an assembly with the differential spider gears and the differential side
gears.
NOTE: Conventional differential carrier assembly shown, limited slip differential assembly similar.
1. Remove the differential carrier.
2. Using the general equipment, remove and discard the differential bearings.
Use Special Service Tool: 205-D072 (D97L-4221-A) 2 Jaw Puller. , 205-D061 (D83T-4205-C2) Step
Plate.
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3. Remove and discard the ring gear bolts.
4. Using the brass punch and a soft face hammer, remove the ring gear.
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5. 1. Remove and discard the differential pinion shaft lock bolt.
2. Remove the differential pinion shaft.
6. NOTE: Due to the spring tension, care must be used when removing the differential s-spring.
Remove the differential s-spring.

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7. Remove the differential pinion gears and the pinion gear thrust washers.
8. NOTE: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The
differential clutch packs must be reassembled in the same sequence.
Remove the differential side gears and disassemble the clutch assemblies.
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ASSEMBLY
1. Lubricate the differential steel clutch plates. Soak the differential friction plates for no less than 15 minutes.
Material: Motorcraft® Additive Friction Modifier (U.S.) / XL-3 (U.S.) (EST-M2C118-A)
2. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.
Assemble the differential clutch packs on their respective differential side gear.
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3. Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and
differential clutch pack (without the shim and spacer) on the tool.
Use Special Service Tool: 205-135 Gauge, Differential Clutch.
4. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.
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5. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch
pack. Use the differential clutch pack chart to determine the correct thickness clutch shim to use.
6. NOTE: Do not use more than 2 shims per side.
With the special tool removed, Install the selective shim on the differential side gear and clutch pack
assembly.
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7. Lube and install the differential side gear assemblies in the differential case.
(WSS-M2C942-A)
8. Lube and install the differential pinion gear and differential pinion thrust washer assemblies in the differential
case.
(WSS-M2C942-A)
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9. NOTE: The s-spring has tension and may need to be tapped in with a soft faced mallet.
Install the differential S-spring.

10. Install the differential pinion shaft.

Install the new differential pinion shaft bolt.
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11. NOTE: Tighten the ring gear bolts in a cross pattern.
Install the ring gear and the new ring gear bolts.
12. Using the special tools, install the new differential bearings.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 205-1016 Installer, Differential Bearing.
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13. NOTE: The initial minimum break-away torque, if original clutch plates are used, must be within the
specification below. The minimum rotating torque required to keep the differential side gear turning with
new clutch plates may vary.
Using the special tool, check the torque required to rotate one differential side gear.
Use Special Service Tool: 205-384 (T97T-4205-A) Gauge, Differential (Traction Lock).
14. Install the differential carrier.


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205-05 Rear Drive Halfshafts 2016 Mustang
Rear Drive Halfshafts
Principles of Operation
Symptom Chart(s)
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Symptom Chart: NVH
Symptom Chart

Driveline clunk - loud clunk when Damaged or INSPECT the CV joints for wear or
shifting from REVERSE to DRIVE worn CV joints damage. INSTALL a new halfshaft as
necessary.
REFER to: Rear Halfshaft (205-05 Rear
Drive Halfshafts, Removal and
Installation).
Loose hub nut CHECK the torque on the hub nut.

REPLACE the hub nut if the torque is not
at specification. For hub nuts.
REFER to: Wheel Bearing and Wheel
Hub (204-02 Rear Suspension, Removal
and Installation).
Driveline clunk — occurs as the vehicle Loose hub nut CHECK the torque on the hub nut.
starts to move forward following a stop REPLACE the hub nut if the torque is not
at specification.
Installation).
and Installation).
Grunting — normally associated with a Halfshaft CV CHECK the outer CV joint for correct
shudder experienced during joint binding seating into the hub. REPAIR as
acceleration from a complete stop necessary.
Installation).
Driveline vibration - occurs at cruising Binding or CHECK the outer CV joint for correct
speeds damaged CV seating into the hub. REPAIR as
joint necessary.
Installation).
and Installation).
Differential Seals
NOTICE: When installing shafts, do not allow splines to contact seals during installation or damage to
the seals may occur.
Halfshaft seals are susceptible to the same types of damage as drive pinion seals if incorrectly installed. The seal
bore must be clean and the lip handled carefully to avoid cutting or tearing it. The seal journal surface must be
free of nicks, gouges and rough surface texture.
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For information on differential seals,
REFER to: Rear Halfshaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).

Inner Constant Velocity (CV) Joint Boot

Boot Clamp Pliers
Rubber Mallet
Three Leg Puller
Materials
Name Specification
Constant Velocity Joint Grease (High Temperature) WSS-M1C258-A1
XG-5
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Removal
1. Remove the halfshaft.

2. 1. Remove and discard the large CV boot clamp.

2. Position the CV boot to access the inner CV housing retaining ring.
3. Remove and discard the inner CV housing retaining ring.

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4. Remove the inner CV joint housing.
5. NOTE: The CV joint cage balls are free to fall out.
Remove and discard the CV joint cage circlip.

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6. NOTE: The CV joint cage balls are free to fall out.
Using a 3-leg puller, remove the CV joint cage.

7. Remove and discard the small clamp and remove the CV joint boot.
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Installation
1. NOTE: CV cage is shown assembled.
Clean and inspect the CV joint cage.
2. Using boot clamp pliers, install the new CV joint boot and the new small CV joint boot clamp.
Use the General Equipment: Boot Clamp Pliers
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3. NOTE: The CV joint cage is a snug fit and may need to tapped on with a soft face mallet.
Using a soft face mallet, install the CV joint cage.

4. Install the new CV joint cage circlip.

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5. Install the grease sachet evenly in the CV joint boot and housing.
Material: Constant Velocity Joint Grease (High Temperature) / XG-5 (WSS-M1C258-A1)
6. NOTE: When installing the CV joint housing, insert a small flat blade screwdriver under the CV joint boot
seat to allow air to escape.
Install the inner CV housing.

1. Using a flat blade screw driver to allow air to escape, install the CV joint housing.
2. Using boot clamp pliers, install the new large CV joint boot clamp.
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7. Install the halfshaft.

Outer Constant Velocity (CV) Joint Boot

Boot Clamp Pliers
Removal
NOTE: Only the RH halfshaft outer CV joint boot is serviceable.
1. Remove the inner CV joint boot.

Refer to: Inner Constant Velocity (CV) Joint Boot (205-05 Rear Drive Halfshafts, Removal and Installation).
2. 1. Remove and discard the CV joint boot clamps.

2. Remove the CV joint boot.
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Installation
1. Clean and inspect the CV joint cage. Install The grease sachet evenly in the CV joint boot and housing.
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2. Install the CV joint housing.
1. NOTE: When installing the CV joint housing, insert a small flat blade screwdriver under the CV
joint boot seat to allow air to escape.
Using a flat blade screw driver to allow air to escape, install the CV joint housing.
2. Using boot clamp pliers, install the new CV joint boot clamps.
3. Install the halfshaft.

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Rear Halfshaft
Removal
NOTICE: Never pick up or hold the halfshaft by only the inner or outer Constant Velocity (CV) joint.
Damage to the CV joint will occur.
NOTICE: Never use a hammer to remove or install the halfshafts. Damage to the CV joint may occur.
NOTICE: Never use the halfshaft assembly as a lever to position other components. Damage to the
halfshaft or CV joint may occur.
NOTICE: Do not allow the boots to contact sharp edges or hot exhaust components. Damage to the
halfshaft boots will occur.
NOTICE: Do not drop assembled halfshafts. The impact may cut the boots from the inside without
evidence of external damage.
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1. Remove the wheel knuckle.
Refer to: Wheel Knuckle (204-02 Rear Suspension, Removal and Installation).
2. Using a pry bar, remove the halfshaft.
3. Inspect the inner halfshaft seal surface and splines for damage. Remove and discard the inner halfshaft
circlip.
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Installation
1. NOTE: The halfshaft seal has to be replaced whenever the halfshaft is removed.
Replace the halfshaft seal.

Refer to: Rear Halfshaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
2. Install a new inner halfshaft circlip.
3. NOTICE: After insertion, pull the halfshaft inner end to make sure the circlip is locked.
NOTE: When seated correctly, the halfshaft retainer circlip can be felt as it snaps into the differential side
gear groove.
Install the halfshaft until the halfshaft circlip is fully seated.
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4. Install the wheel knuckle.
Refer to: Wheel Knuckle (204-02 Rear Suspension, Removal and Installation).
5. Check and top off the rear differential fluid.


206-00 Brake System - General Information 2016 Mustang
Specifications
Specifications
Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid / PM-20 WSS-M6C65-A2
Item Nm lb-ft lb-in
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Front caliper bleeder screw-vehicles with 2 piston brake caliper 11 - 97
Rear caliper bleeder screw-all except SVT Performance Package 11 - 97
Front and rear caliper bleeder screw-SVT Performance Package 14 - 124
Master cylinder brake tube fittings 27.5 - 20
Item Specification
Front brake disc minimum thickness-vehicles with 2 piston brake caliper 1.122 in (28.5 mm)
Front brake disc minimum thickness-SVT Performance Package 1.339 in (34 mm)
Rear brake disc minimum thickness-solid 0.390 in (9.9 mm)
Rear brake disc minimum thickness-vented 0.925 in (23.5 mm)
Rear brake disc minimum thickness-SVT Performance Package 0.945 in (24 mm)
Brake pad minimum thickness 0.118 in (3 mm)
Brake pad maximum taper wear (in any direction) 0.118 in (3 mm)

Specifications
Specifications
Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid / PM-20 WSS-M6C65-A2
Item Nm lb-ft lb-in
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Rear caliper bleeder screw-all except SVT Performance Package 11 - 97
Front and rear caliper bleeder screw-SVT Performance Package 14 - 124
Master cylinder brake tube fittings 27.5 - 20
Item Specification
Front brake disc minimum thickness-SVT Performance Package 1.339 in (34 mm)
Rear brake disc minimum thickness-solid 0.390 in (9.9 mm)
Rear brake disc minimum thickness-vented 0.925 in (23.5 mm)
Rear brake disc minimum thickness-SVT Performance Package 0.945 in (24 mm)
Brake pad minimum thickness 0.118 in (3 mm)
Brake pad maximum taper wear (in any direction) 0.118 in (3 mm)

Brake System
Symptom Chart(s)
Symptom Chart: Brake System

The red brake warning Diagnostic Trouble Codes CHECK for ABS diagnostic trouble codes (DTCs).
indicator and the yellow ABS (DTCs) in the ABS REFER to: Anti-Lock Brake System (ABS) and
warning indicator are Stability Control (206-09 Anti-Lock Brake System
illuminated (ABS) and Stability Control, Diagnosis and Testing).
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The red brake warning Brake fluid level
indicator is always/never on switch REFER to: Instrumentation, Message Center and
Parking brake Warning Chimes (413-01 Instrumentation, Message
switch Center and Warning Chimes, Diagnosis and Testing).
connectors
IPC
BCM
Vehicle pulls or drifts during Brake calipers INSPECT the brake system components. INSTALL
braking and/or guide pins new components as necessary.
Brake flexible hose
Brake pads
Brake discs
Tires
REFER to: Wheels and Tires (204-04A Wheels and
Tires, Diagnosis and Testing).
Suspension component(s)
and/or wheel alignment REFER to: Suspension System (204-00 Suspension
System - General Information, Diagnosis and
Testing).
Brake pedal goes down fast Brake fluid leaks and/or INSPECT the system for leaks. REPAIR as
or eases down slowly air in the system necessary. BLEED the system.
REFER to: Brake System Pressure Bleeding (206-00
Brake System - General Information, General
Procedures).
Brake master cylinder CARRY OUT the Brake Master Cylinder - Bypass
Condition Component Test.
HCU
REFER to: Anti-Lock Brake System (ABS) and
Stability Control (206-09 Anti-Lock Brake System
(ABS) and Stability Control, Diagnosis and Testing).
Brake pedal INSPECT the brake pedal simulator spring, cam and
interface-to-booster. INSTALL a new brake pedal and
bracket as necessary.
Brakes lock up under light Brake pads INSPECT the brake system components. INSTALL
brake pedal force Brake flexible hose new components as necessary.
Brake disc
Brake calipers
and/or guide pins
ABS
Excessive brake pedal travel Brake fluid leaks and/or INSPECT the system for leaks. REPAIR as
(low/spongy pedal) air in the system necessary. BLEED the system.
REFER to: Brake System Pressure Bleeding (206-00
Brake System - General Information, General
Procedures).
Brake master cylinder CARRY OUT the Brake Master Cylinder - Bypass
Condition Component Test.
Brake calipers and/or INSPECT the brake calipers and guide pins. INSTALL
guide pins new components as necessary.
Brake flexible hose INSPECT the brake flexible hoses during brake
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application. INSTALL a new brake hose as
necessary.
REFER to: Front Brake Flexible Hose (206-03 Front
Disc Brake, Removal and Installation).
REFER to: Front Brake Flexible Hose - Vehicles With:
SVT Performance Package (206-03 Front Disc
Brake, Removal and Installation).
REFER to: Rear Brake Flexible Hose (206-04 Rear
Disc Brake, Removal and Installation).
REFER to: Rear Brake Flexible Hose - Vehicles With:
SVT Performance Package (206-04 Rear Disc
Erratic brake pedal travel Brake pedal INSPECT the brake pedal for binding, obstructions
and correct interface to booster rod. REPAIR as
necessary. CHECK the brake pedal fasteners for
correct torque.
REFER to: Brake Pedal and Bracket - 6-Speed
Manual Transmission - 3160/6-Speed Manual
Transmission - MT82 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
REFER to: Brake Pedal and Bracket - 6-Speed
Automatic Transmission - 6R80 (206-06 Hydraulic
Brake Actuation, Removal and Installation).
ABS
Brake drag Parking brake component INSPECT the parking brake system. INSTALL new
Brake caliper INSPECT the brake system components. INSTALL
and/or guide pins new components as necessary.
Brake flexible hose
Brake booster
Brake master cylinder CARRY OUT the Brake Master Cylinder -

Compensator Port Component Test.
Hydraulic Control Unit
(HCU) REFER to: Anti-Lock Brake System (ABS) and
Stoplamp switch VERIFY correct installation of the stoplamp switch.
REFER to: Stoplamp Switch (417-01 Exterior
Lighting, Removal and Installation).
Excessive brake pedal effort Insufficient vacuum CARRY OUT the Brake Booster Component Test in
for brake booster this section.
operation
Brake booster
manifold vacuum
hose
Brake booster
Brake booster
check valve
Brake booster
vacuum pump
Brake pads INSPECT the brake pads.INSTALL new components

as necessary.
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REFER to: Brake Pads - Vehicles With: 2-Piston
Brake Caliper (206-03 Front Disc Brake, Removal
and Installation).
and Installation).
and Installation).
REFER to: Brake Pads - Vehicles With: SVT
Performance Package (206-03 Front Disc Brake,
REFER to: Brake Pads (206-04 Rear Disc Brake,
Performance Package (206-04 Rear Disc Brake,
Symptom Chart: NVH

Vibration when the brakes are Brake disc(s)/ GO to Pinpoint Test A
applied Suspension
components
Brake vibration/shudder — Brake drag REFER to Symptom Chart: Brake System

occurs when the brake pedal
is released
Rattling noise Caliper guide pins INSPECT the caliper guide pins and guide pin
or guide pin bolts bolts. INSTALL new components as
Missing or necessary.
damaged anti-rattle INSPECT the brake pads for missing clips or
clips or springs broken springs. INSTALL new components as
Loose brake disc necessary.
shield TIGHTEN the brake disc shield bolts to
specification.
REFER to: Brake Pads - Vehicles With:
2-Piston Brake Caliper (206-03 Front Disc
Performance Package (206-03 Front Disc
REFER to: Brake Pads (206-04 Rear Disc
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Performance Package (206-04 Rear Disc
Squealing noise — occurs on Brake pads Acceptable condition. Caused by humidity and low
first (morning) brake brake pad temperature.
application
Squealing noise — a Brake pads INSPECT the brake pads. INSTALL new
continuous squeal components as necessary.
and Installation).
and Installation).
and Installation).
Performance Package (206-03 Front Disc Brake,
REFER to: Brake Pads (206-04 Rear Disc Brake,
Performance Package (206-04 Rear Disc Brake,
Squealing noise — an Brake pads Acceptable condition. Caused by cold, heat, water,
intermittent squeal mud or snow.
Groaning noise — occurs at Brake pads Acceptable condition.
low speeds with brake lightly
applied (creeping)
Grinding/moaning noise — Brake pads INSPECT the brake pads, brake discs and attaching
continuous Brake disc hardware for damage. VERIFY brake components
are within specifications. INSTALL new components
as necessary.
Pinpoint Tests
Vibration When Brakes Are Applied
During moderate to heavy braking, noise from the 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 BRAKES ARE APPLIED

A1 ROAD TEST THE VEHICLE -LIGHT BRAKING
Road test the vehicle. Warm the brakes by slowing the vehicle from 80 to 32 km/h (50 to 20 mph) using
light brake force. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using light pedal force.
Is there a vibration/shudder felt in the steering wheel, seat or brake pedal?
Yes GO to A4
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No GO to A2
A2 ROAD TEST THE VEHICLE -MODERATE TO HEAVY BRAKING

Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using a moderate
to heavy pedal force.
Is there a vibration/shudder?
Yes GO to A3
No The concern is not present at this time.
A3 CHECK ABS (ANTI-LOCK BRAKE SYSTEM) OPERATION
NOTE: 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 operation of the ABS. Pedal
pulsation or steering wheel nibble with the frequency proportional to vehicle speed indicates a concern
with a brake or suspension component.
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?
Yes This is a normal operating condition of the ABS.

No GO to A5
A4 ISOLATE BRAKE VIBRATION
NOTE: This test step is not applicable to vehicles with drum-in-hat type or electronic parking brakes. For
vehicles with drum-in-hat or electronic parking brakes, 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.
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?
Yes GO to A7
No GO to A5
A5 CHECK THE FRONT SUSPENSION

Check the front suspension.
Are all the suspension components in satisfactory condition?
Yes GO to A6
No REPAIR or INSTALL new components as necessary. TEST the system for normal
operation.
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A6 CHECK THE FRONT BRAKE DISCS
Inspect the front brake discs. MACHINE or INSTALL new brake discs as necessary.
REFER to: Brake Disc Machining (206-00 Brake System - General Information, General Procedures).
REFER to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
REFER to: Brake Disc - Vehicles With: SVT Performance Package (206-03 Front Disc Brake, Removal
and Installation).
Road test the vehicle.
Is the vibration/shudder present?
Yes GO to A7
No The concern has been repaired.
A7 CHECK THE REAR SUSPENSION

Check the rear suspension.
Are all the suspension components in satisfactory condition?
Yes INSPECT the rear brake discs. MACHINE or INSTALL new brake discs as necessary.
REFER to: Brake Disc Machining (206-00 Brake System - General Information, General
Procedures).
REFER to: Brake Disc (206-04 Rear Disc Brake, Removal and Installation).
REFER to: Brake Disc - Vehicles With: SVT Performance Package (206-04 Rear Disc
No REPAIR or INSTALL new components as necessary. TEST the system for normal
operation.
Component Test- Brake Booster
1. Disconnect the brake booster vacuum sensor/check valve from the brake booster and connect a suitable
vacuum/pressure tester to the booster side of the vacuum sensor/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. Verify that vacuum is available at the vacuum sensor/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 vacuum sensor/check valve and
continue with Step 5.
If specified vacuum is not available, continue with Step 4.
4. Disconnect the vacuum sensor/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.
For vehicles equipped with a brake vacuum pump, if specified vacuum is not available, inspect the
vacuum hose and install new as necessary. If the vacuum hose is ok, install a new vacuum pump.
For vehicles not equipped with a brake vacuum pump, if specified vacuum is not available, stop the
engine, connect the vacuum hose to the check valve and 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.
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If the brake pedal does not move, install a new brake booster.
REFER to: Brake Booster - 2.3L EcoBoost (201kW/273PS) (206-07 Power Brake Actuation,
REFER to: Brake Booster - 3.7L Duratec (227kW/301PS) (206-07 Power Brake Actuation,
REFER to: Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT (206-07 Power Brake Actuation,
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 vacuum sensor/check
valve and retest.
If condition still exists, install a new brake booster.
REFER to: Brake Booster - 2.3L EcoBoost (201kW/273PS) (206-07 Power Brake Actuation,
REFER to: Brake Booster - 3.7L Duratec (227kW/301PS) (206-07 Power Brake Actuation,
REFER to: Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT (206-07 Power Brake Actuation,
If the brake pedal feels the same as noted with the engine operating, the vacuum sensor/check
valve is functioning properly.
Component Test- Brake Master Cylinder - Bypass Condition
1. Inspect the master cylinder.
2. Disconnect the brake tubes from the master cylinder.
3. NOTE: Make sure the outlet port plugs do not show signs of leakage.
Plug the outlet ports of the master cylinder.
4. 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 specification.
REFER to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).
After installation, bleed the brake system.REFER to: Brake System Pressure Bleeding (206-00 Brake
Component Test- Brake Master Cylinder - Compensator Port
1. Inspect the master cylinder.
2.
REFER to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
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 stoplamp switch and the brake pedal free play to verify 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.
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If the brake drag is no longer present, install a new brake booster.
REFER to: Brake Booster - 2.3L EcoBoost (201kW/273PS) (206-07 Power Brake Actuation, Removal and
Installation).
REFER to: Brake Booster - 3.7L Duratec (227kW/301PS) (206-07 Power Brake Actuation, Removal and
Installation).
REFER to: Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT (206-07 Power Brake Actuation, Removal
and Installation).
If the brake drag is still present, install a new master cylinder.
REFER to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).

Brake Disc Machining
Repair
NOTE: On-Vehicle Brake Lathe Training Videos
1. Vehicle preparation.
Click here to view a video version of this procedure.
2. Mounting the machine.
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3. Lateral runout adjustment.
4. Making the cut.
5. Cutting the opposite side.
6. Lathe maintenance.
Repair
NOTE: On-Vehicle 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: 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 specification.
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 hose 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. NOTICE: On some vehicle applications the axle on the opposing side may rotate during the
machining process. On these applications the brake disc must be secured or damage may occur.
If necessary, secure the opposing brake disc by installing 2 wheel nuts finger tight.
4. Install the hub adapter using four wheel nuts on a 4, 7 or 8-stud wheel hub.
Install the hub adapter using five wheel nuts on a 5 or 10-stud wheel hub.
Install the hub adapter using six wheel nuts on a 6-stud wheel hub.
5. Install the cutting lathe.
6. 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
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machining, then the final brake disc runout will be within specification and a runout measurement is not
necessary after machining.
If the lathe is not self-adjusting, adjust the lathe oscillation using a dial indicator.
7. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
8. 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.
9. Remove the lathe and the silencer.
10. Remove the wheel nuts and hub adapter.
11. Remove the metal shavings.
12. Measure the brake disc thickness. If the measurement is below the minimum specification, install a new
brake disc.
13. NOTE: It is not required to install new brake pads if friction material is within specifications.
Position the brake caliper or brake caliper and anchor plate assembly and install the bolts.
Refer to: Brake Caliper Anchor Plate (206-03 Front Disc Brake, Removal and Installation).
Refer to: Brake Caliper Anchor Plate (206-04 Rear Disc Brake, Removal and Installation).

Brake System Pressure Bleeding
Brake/Clutch System Pressure Bleeder/Filler

Fluid Container
Bleeding
All vehicles
NOTICE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with
cold water.
NOTE: The HCU bleeding procedure and a second brake system pressure bleed must be carried out if a new
HCU has been installed.
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1. NOTE: Make sure the area around the master cylinder cap is clean and free of foreign material.
Remove the brake fluid reservoir cap.
2. Make sure the fluid reservoir is filled with clean specified brake fluid.
Refer to: Specifications (206-00 Brake System - General Information, Specifications).
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3. 1. 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.
Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler
2. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Open the valve on the bleeder tank and apply 207-345 kPa (30-50 psi) to the brake system.

5. Bleeding steps must be followed in the order indicated in the graphic. For vehicles equipped with 4 or 6
piston brake calipers, bleed the inner bleeder screw first, followed by the outer bleeder screw.
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6. If equipped, remove the bleeder screw cap.
7. Partially fill a clean brake fluid container with clean specified brake fluid.
Use the General Equipment: Fluid Container
8. Submerge a hose into the brake fluid in the container and connect the hose to bleeder screw.
9. 1. Loosen the bleeder screw.

Loosen:
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: 180°
2. Leave open until clear, bubble-free brake fluid flows, then tighten the bleeder screw.
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Vehicles with rear integral parking brake calipers
10. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is
necessary to apply and release the parking brake during the bleed procedure.
1. Apply and release the parking brake 5 times.

2. Loosen the bleeder screw.
Loosen: 180°
3. Leave open until clear, bubble-free fluid flows and then tighten the bleeder screw.
4. Repeat as necessary.
All vehicles
11. 1. Tighten the bleeder screw to specification abd remove the hose and brake fluid container.
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12. If equipped, install the bleeder screw cap.
13. NOTE: For vehicles equipped with 4 or 6 piston brake calipers, bleed the inner bleeder screw first,
followed by the outer bleeder screw.
Repeat steps 5-12 at the remaining wheel ends.
14. Lower the vehicle.
15. Close the bleeder tank valve and release the pressure.
Remove the General Equipment: Brake/Clutch System Pressure Bleeder/Filler
16. Fill the reservoir with clean, specified brake fluid.

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17. Install the brake fluid reservoir cap.
Vehicles with new hydraulic control unit (HCU) installed
NOTE: The HCU bleeding procedure and a second brake system pressure bleed must be carried out if a new
HCU has been installed.
18. Using the diagnostic scan tool, follow the ABS Service Bleed instructions.
19. Repeat brake system pressure bleeding steps.

Component Bleeding
Master Cylinder Bleeding Set
Bleeding
cold water.
Master Cylinder
NOTE: When a new brake master cylinder has been installed, it should be primed to prevent air from entering
the system.
1. NOTE: Make sure the area around the master cylinder cap is clean and free of foriegn material.
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Remove the brake fluid reservoir cap.

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3. Loosen and remove the brake tube fittings.
4. Install the master cylinder bleeding set.

Use the General Equipment: Master Cylinder Bleeding Set
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5. Have an assistant pump the brake pedal slowly until clear bubble free fluid flows from the brake tubes.
6. Remove the master cylinder bleeding set.

Use the General Equipment: Master Cylinder Bleeding Set
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7. Tighten the brake tube fittings.

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9. Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General
Procedures).
Brake Caliper, Wheel Cylinder, Brake Hose or Brake Tube
10. NOTE: Pressure bleeding the brake system is required anytime a hydraulic brake system component has
been disconnected.
Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General
Procedures).

206-03 Front Disc Brake 2016 Mustang
Front Disc Brake
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
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Brake Caliper - Vehicles With: 2-Piston Brake Caliper
Removal
NOTICE: Make sure that all openings are sealed.
cold water.

2. Remove the brake caliper flow bolt and disconnect the brake hose. Discard the washers.
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3. Remove the 2 guide pin bolts and the brake caliper.
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Installation
2. Bleed the brake system.
Procedures).

Removal
cold water.
1. Remove the brake pads.

Refer to: Brake Pads - Vehicles With: 4-Piston Brake Caliper (206-03 Front Disc Brake, Removal and
Installation).
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3. Remove the 2 bolts and the brake caliper. Discard the bolts.
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Installation
Procedures).

Removal
cold water.

Installation).
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3. Remove the 2 bolts and the brake caliper. Discard the bolts.
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Installation
Procedures).

Brake Caliper Anchor Plate
Removal

Installation).
2. Remove the 2 bolts and the anchor plate. Discard the bolts.
Installation
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Brake Disc
Materials
Name Specification
PM-4-A, PM-4-B (U.S.)
Removal
NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose may
occur.
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All brake calipers
1. Remove the wheel and Tire.

2-piston brake caliper
2. Remove the 2 bolts and position the brake caliper and brake pads aside.
3. Remove the 2 bolts and position the brake caliper and brake pads aside. Discard the bolts.
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4. Remove the 2 bolts and position the brake caliper and brake pads aside. Discard the bolts.
All brake calipers

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Installation
2. Clean the brake disc mating surfaces using a wire brush and the specified material.
3. Apply the brake pedal several times to verify correct brake system operation.

Brake Disc Shield
Removal
All brake calipers

2. Remove the 3 bolts and the brake disc shield.

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6-piston brake caliper-automatic transmission and convertable

6-piston brake caliper-manual transmission

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Installation

Brake Pads - Vehicles With: 2-Piston Brake Caliper
Removal
1. Remove wheel and tire.

2. NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose
may occur.
Remove the 2 brake caliper guide pin bolts and position the brake caliper aside.
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Remove the brake pads.

4. NOTE: There are two different brake pad clips. The brake pad clip with the tab must be installed at the
top position on the anchor plate.
Remove the top and bottom brake pad clips.
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Installation
NOTE: If installing new brake pads, make sure to install all new hardware and lubricant supplied with the brake
pad kit. Refer to the brake pad instruction sheet when applying lubricant.
2. If installing new brake pads.

Use a C-clamp and a worn brake pad to compress the brake caliper pistons into the brake caliper bore.
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3. Depress the brake pedal, check the brake fluid level in the brake fluid reservoir and top up as necessary
with brake fluid.

Removal

2. 1. Remove brake pad spring.

2. Remove the brake pad pin clip.
3. Remove the 2 brake pad pins.
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3. Compress the brake caliper pistons using a brake pad spreader tool and remove the brake pads.
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Installation
with brake fluid.

Removal

2. 1. Remove the 2 brake pad pins.

2. Remove the brake pad spring retainer clip.
3. Remove the brake caliper pin bolt.
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3. Compress the brake caliper pistons using a brake pad spreader tool.
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Installation
1. NOTE: If installing new brake pads, make sure to install all new hardware and lubricant supplied with the
brake pad kit. Refer to the brake pad instruction sheet when applying lubricant.
with brake fluid.

Front Brake Flexible Hose
Removal
NOTE: Make sure all openings are sealed.
NOTE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold
water.
1. Remove the brake caliper flow bolt and detach the front brake flexible hose.
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All brake calipers
4. 1. Disconnect the brake tube fitting.

2. Remove the bolt and the front brake flexible hose.
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Installation

Procedures).

Brake Caliper - Vehicles With: SVT Performance Package
Removal
cold water.
NOTE: Remove the brake caliper flow bolt and disconnect the brake hose. Discard the washers.
2. Remove the bolts and the brake caliper. Discard the bolts.
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3. Remove the brake pad pins.

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5. Remove the brake pad spring retainer clip.
Installation

Procedures).

Brake Disc - Vehicles With: SVT Performance Package
Removal

may occur.
Remove the bolts and position the brake caliper and brake pads aside. Discard the bolts.
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3. NOTICE: Use care when handling the brake disc.
Remove the brake disc.

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Installation

Brake Disc Shield - Vehicles With: SVT Performance Package
Removal

Refer to: Brake Disc - Vehicles With: SVT Performance Package (206-03 Front Disc Brake, Removal and
Installation).
2. Remove the bolts and the brake disc shield.

Installation
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Brake Pads - Vehicles With: SVT Performance Package
Removal
NOTICE: Do not pry in the caliper sight hole to retract the pistons as this can damage the pistons and
boots.
NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur.

2. Remove and discard the upper brake caliper bolt.

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3. Loosely install a larger bolt (M14 x 180) turning 7 full turns.
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4. Remove and discard the lower brake caliper bolt.
5. Loosely install a larger bolt (M14 x 180) turning 7 full turns.

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6. 1. NOTICE: Make sure the wheels are in the straight-ahead position before moving the brake
caliper or damage to the brake hose may occur.
Slide the brake caliper back on the longer bolts.
2. NOTICE: Use care when handling the brake disc.
Remove the brake disc.
7. Compress the brake caliper pistons using the brake pad spreader tool.
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8. Remove the brake pad pins.

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Installation
with brake fluid.

Front Brake Flexible Hose - Vehicles With: SVT Performance Package
Removal
NOTICE: Make sure all openings are sealed.
cold water.
1. Remove the brake caliper flow bolt and disconnect the front brake flexible hose. Discard the washers.

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2. Remove the bolt and the front brake flexible hose.
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Installation

Procedures).

206-04 Rear Disc Brake 2016 Mustang
Rear Disc Brake
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Brake Caliper
Removal
cold water.

2. Loosen the parking brake cable adjustment nut.
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3. 1. Disconnect the parking brake cable from the lever.
2. Detach the parking brake cable from the bracket and position aside the parking brake cable.
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4. NOTICE: Make sure that all openings are sealed.
Remove the brake caliper flow bolt and disconnect the brake hose from the brake caliper. Discard the
washers.
5. Remove the 2 bolts and the brake caliper.

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Installation

Procedures).
3. Adjust park brake system.

Refer to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation, General Procedures).

Brake Caliper Anchor Plate
Removal

2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or
damage to the hose may occur.
Remove the 2 bolts and the brake caliper anchor plate. Discard the bolts.
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Installation

Brake Disc
Materials
Name Specification
PM-4-A, PM-4-B (U.S.)
Removal

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2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or
damage to the hose may occur.
Remove the 2 bolts and position the brake caliper and anchor plate assembly aside. Discard the bolts.

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Installation
2. Clean the brake disc mating surfaces using a wire brush and the specified material.

Brake Disc Shield
Removal


Installation cardiagn.com

Brake Pads
Brake Caliper Piston Retractor
Removal

may occur.
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Remove the 2 bolts and position the brake caliper aside.

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4. Remove the clips.
5. NOTE: Make sure the notch on the piston is aligned with the pin on the inboard brake pad before
installing the brake caliper. A moderate to heavy force toward the caliper piston must be applied. If
sufficient force is not applied, the internal park brake mechanism clutch cone will not engage and the
piston will not compress.
If installing new brake pads.

Retract the brake caliper pistons into the brake caliper bore.
Use the General Equipment: Brake Caliper Piston Retractor
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Installation
with brake fluid.

Rear Brake Flexible Hose
Removal
cold water.

2. Remove the brake caliper flow bolt and disconnect the brake hose from the brake caliper. Discard the
washers.
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2. Remove the 2 brake hose bracket bolts and the brake hose.
Torque:
2.: 18 lb.ft (25 Nm)
3.: 22 lb.ft (30 Nm)
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Installation

Procedures).

Brake Caliper - Vehicles With: SVT Performance Package
Removal
cold water.

Refer to: Brake Pads - Vehicles With: SVT Performance Package (206-04 Rear Disc Brake, Removal and
Installation).
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washers.
3. Disconnect parking brake cable from parking brake shoe actuation lever.
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4. Press inward on the tabs and detach the parking brake cable from the bracket.
5. 1. Remove and discard the bolts.

2. Remove the bracket.
3. Remove the brake caliper.
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Installation

Procedures).

Brake Disc - Vehicles With: SVT Performance Package
Removal
NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose may
occur.

2. Disconnect parking brake cable from parking brake shoe actuation lever
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3. Press inward on the tabs and detach the parking brake cable from the bracket.
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4. 1. Remove and discard the bolts.
2. Remove the bracket.
3. Position the brake caliper aside.

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Installation

Brake Disc Shield - Vehicles With: SVT Performance Package
Removal
1. Remove the parking brake shoes.

Refer to: Parking Brake Shoes - Vehicles With: SVT Performance Package (206-05 Parking Brake and

3. Remove the bolts and the brake disc shield.

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Installation

Brake Pads - Vehicles With: SVT Performance Package
Brake Caliper Piston Retractor
Removal

2. 1. Remove the brake pad pins.

2. Remove brake pad spring.
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3. Compress the brake caliper pistons using a brake pad spreader tool and remove the brake pads.
Use the General Equipment: Brake Caliper Piston Retractor
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Installation
with brake fluid.
Refer to: Specifications (206-00 Brake System - General Information) .

Rear Brake Flexible Hose - Vehicles With: SVT Performance Package
Removal
cold water.

washers.
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2. Remove the 2 brake hose bracket bolts and the brake hose.
Torque:
2.: 18 lb.ft (25 Nm)
3.: 22 lb.ft (30 Nm)
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Installation

Procedures).

206-05 Parking Brake and Actuation 2016 Mustang
Parking Brake
Symptom Chart(s)
Symptom Chart: Parking Brake and Actuation
The first indication that something may be wrong in the parking brake system is a change in the feeling through
the parking brake control. The parking brake not holding on an incline or dragging after being released are also
indicators of system concerns. Check the operation of the parking brake system with the vehicle on a hoist and
the parking brake control fully released.
Verify the customer concern.

Visually inspect for obvious signs of mechanical damage.
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If an obvious cause for an observed or reported concern is found, correct the cause.
If the cause is not visually evident, verify the symptom and go to the Symptom Chart below.

The red brake warning indicator is Parking brake not DIAGNOSE the red brake warning
always illuminated fully released indicator.
Low brake fluid level REFER to: Instrumentation, Message
Wiring, terminals or Center and Warning Chimes (413-01A) .
connectors
Brake master
cylinder inoperative
The parking brake does not apply/hold Refer to the Pinpoint Test GO to Pinpoint Test A
vehicle
The parking brake will not release Refer to the Pinpoint Test GO to Pinpoint Test B
The parking brake does not apply/hold Refer to the Pinpoint Test GO to Pinpoint Test C
vehicle (SVT Performance Package)
The parking brake will not release (SVT Refer to the Pinpoint Test GO to Pinpoint Test D
Performance Package)
Pinpoint Tests
The Parking Brake Does Not Apply Or Does Not Hold Vehicle
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 applies the brake shoes/pads.
Possible Sources
Parking brake cable(s)

Parking brake control
Rear brake caliper(s)
Parking brake cable equalizer
PINPOINT TEST A : THE PARKING BRAKE DOES NOT APPLY OR DOES NOT HOLD VEHICLE
A1 CHECK THE PARKING BRAKE CONTROL
Pull up the parking brake control handle.
Does the parking brake control move?
Yes GO to A2
No GO to A3
A2 INSPECT THE FOLLOWING PARKING BRAKE COMPONENTS
NOTE: Have an assistant pull and release the parking brake to help isolate disconnected cables or cables
that do not move.
Front parking brake cable
Rear parking brake cables and/or equalizer
Rear brake caliper actuators
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Is any damage found or are any components disconnected?
Yes CONNECT the component(s) or INSTALL new parking brake component(s) as necessary.
ADJUST the parking brake cables.
REFER to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation,
No VERIFY that the rear pads and brake discs are within thickness specifications.
REFER to: Specifications (206-00) .
If the rear pads and brake discs are OK, INSTALL new rear brake caliper(s). REFER to:
Brake Caliper (206-04 Rear Disc Brake, Removal and Installation).
A3 ISOLATE THE PARKING BRAKE CONTROL AND FRONT PARKING BRAKE CABLE
Disconnect the front parking brake cable from the rear parking brake cable equalizer.
Pull up the parking brake control handle.
Does the parking brake control handle move?
Yes GO to A4
No INSTALL a new parking brake control and front cable assembly as necessary.
REFER to: Parking Brake Control (206-05 Parking Brake and Actuation, Removal and
Installation).
A4 ISOLATE THE REAR PARKING BRAKE CABLES

Disconnect the rear parking brake cable from the rear brake caliper at the affected wheel end(s).
While holding the cable conduit, attempt to slide the cable inside the conduit.
Does the cable slide freely inside the conduit?
Yes The parking brake system is operating normally at this time. INSPECT the rear brake
components on the affected wheel end(s). INSTALL new rear brake components as
necessary and ADJUST the parking brake cables.
REFER to: Parking Brake Cable Adjustment (206-05 Parking Brake and Actuation,
No INSTALL new RH or LH rear parking brake cables as necessary.
REFER to: Parking Brake Cable LH (206-05 Parking Brake and Actuation, Removal and
Installation).
REFER to: Parking Brake Cable RH (206-05 Parking Brake and Actuation, Removal and
Installation).
Parking Brake Will Not Release
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.
Possible Sources
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Rear brake caliper(s)
Parking brake cable equalizer
PINPOINT TEST B : PARKING BRAKE WILL NOT RELEASE

B1 CHECK THE PARKING BRAKE CONTROL
Apply and release the parking brake control.
Does the parking brake control fully release?
Yes GO to B2
Installation).
B2 ISOLATE THE FRONT BRAKE CABLE

Do the rear wheel(s) spin freely?
Yes INSTALL a new parking brake control and front cable assembly as necessary.
Installation).
No GO to B3
B3 ISOLATE THE REAR PARKING BRAKE CABLES

Disconnect the rear parking brake cable from the rear brake caliper at the affected wheel end(s).
Do the wheel(s) spin freely?

Yes INSTALL new RH or LH rear parking brake cables as necessary.
REFER to: Parking Brake Cable LH (206-05 Parking Brake and Actuation, Removal and
Installation).
REFER to: Parking Brake Cable RH (206-05 Parking Brake and Actuation, Removal and
Installation).
No INPECT the rear brake calipers. INSTALL new rear brake calipers as necessary.
The Parking Brake Does Not Apply Or Does Not Hold Vehicle-SVT Performance Package
When the parking brake control is pressed, tension is applied to the front parking brake cable. This tension pulls
on the RH rear parking brake cable, which is attached to the RH rear parking brake shoe actuator and applies the
RH rear brake shoes. At the same time, the tension in the RH rear cable causes the RH rear conduit to attempt to
straighten out. This straightening effect causes the RH rear conduit to pull on the LH rear parking brake cable,
which is attached to the LH rear parking brake shoe actuator and applies the LH rear brake shoes.
Possible Sources
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Parking brake shoes, hardware, actuator levers and backing plates
PINPOINT TEST C : THE PARKING BRAKE DOES NOT APPLY OR DOES NOT HOLD VEHICLE-SVT
PERFORMANCE PACKAGE
C1 CHECK THE PARKING BRAKE CONTROL
Apply the parking brake.
Does the parking brake control move?
Yes GO to C2
No GO to C3
C2 CHECK FOR BROKEN CABLES
NOTE: Have an assistant pull and release the parking brake to help isolate disconnected cables or cables
that do not move.
Inspect the following items for damage and correct connections.
Front parking brake cable
LH rear parking brake cable
RH rear parking brake cable
Parking brake cable brackets and equalizer
Is any damage found or are any components disconnected?
Yes GO to C3
No CONNECT the component(s) or INSTALL new parking brake component(s) as necessary.
C3 CHECK THE PARKING BRAKE SHOES, HARDWARE, ACTUATOR LEVERS AND BACKING
PLATES
Remove the rear brake discs.
REFER to: Brake Disc (206-04 Rear Disc Brake, Removal and Installation).
Are the parking brake shoes, hardware, actuator levers and backing plates in good condition?
Yes GO to C4
No INSTALL new components as necessary.
REFER to: Parking Brake Shoes - Vehicles With: SVT Performance Package (206-05
Parking Brake and Actuation, Removal and Installation).
C4 CHECK THE PARKING BRAKE SHOE ADJUSTMENT

Check the parking brake shoe adjustment.
REFER to: Parking Brake Shoe Adjustment - Vehicles With: SVT Performance Package (206-05 Parking
Brake and Actuation, General Procedures).
Are the parking brake shoes adjusted to specification?
Yes INSTALL a new parking brake control.

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Installation).
No ADJUST the parking brake shoes.
REFER to: Parking Brake Shoe Adjustment - Vehicles With: SVT Performance Package
(206-05 Parking Brake and Actuation, General Procedures).
C5 ISOLATE THE PARKING BRAKE CONTROL AND FRONT CABLE

Apply the parking brake control.
Does the parking brake control pedal move?
Yes GO to C6
No INSTALL a new parking brake control.
Installation).
C6 ISOLATE THE REAR PARKING BRAKE CABLES

Disconnect the rear parking brake cable from the actuator lever at the affected wheel end(s).
While holding the cable conduit, attempt to slide the cable inside the conduit.
Does the cables slide freely inside the conduit?
Yes INSPECT the parking brake shoes, hardware and backing plate. INSTALL new
No INSTALL new rear parking brake cable(s).
REFER to: Parking Brake Cable LH - Vehicles With: SVT Performance Package (206-05
REFER to: Parking Brake Cable RH - Vehicles With: SVT Performance Package (206-05
Parking Brake Will Not Release-SVT Performance Package
When the parking brake is applied, pressing down on the control pedal again will release the parking brake control
and also release the tension on the parking brake cables. The cable conduits, cable springs and parking brake
shoe springs provide the force necessary to return the parking brake system to the released position.
Possible Sources

Parking brake shoes, hardware, actuator levers and backing plates
PINPOINT TEST D : PARKING BRAKE WILL NOT RELEASE-SVT PERFORMANCE PACKAGE

D1 CHECK THE PARKING BRAKE CONTROL
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Apply and release the parking brake control.
Does the parking brake control fully release?
Yes GO to D2
Installation).
D2 ISOLATE THE FRONT BRAKE CABLE

Do the rear wheel(s) spin freely?
Yes INSTALL a new parking brake control and front cable assembly as necessary.
Installation).
No GO to D3
D3 ISOLATE THE REAR PARKING BRAKE CABLES

Disconnect the rear parking brake cable from the actuator levers at the affected wheel end(s).
Do the wheel(s) spin freely?
Yes INSTALL new RH or LH rear parking brake cables as necessary.

REFER to: Parking Brake Cable LH - Vehicles With: SVT Performance Package (206-05
REFER to: Parking Brake Cable RH - Vehicles With: SVT Performance Package (206-05
No INSPECT the rear parking brake shoes, hardware and backing plates. INSTALL new
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Parking Brake Cable Adjustment
Feeler Gauge
Adjustment

2. Tighten the parking brake cable adjustment nut until one or both caliper levers are 2.0 mm off of their
stops.
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3. Fully apply and release the parking brake 5 times
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4. Tighten the parking brake cable adjustment nut until one or both caliper levers are 1.0 mm off of their
stops.

Parking Brake Cable Adjustment - Vehicles With: SVT Performance Package
Adjustment

2. Set the parking brake to the first click/position.
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3. NOTICE: While adjusting the parking brake cables, check for rotation of the rear wheels often to
prevent over tightening the cables. The cables must only be tightened until the rear wheels do not
spin freely. Make sure the rear wheel are not locked.
Raise the vehicle and tighten the parking brake cable adjustment nut until the rear wheels meet the
following criteria.
The rear wheel do not spin freely (have resistance).
The rear wheels are not locked.
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4. Lower the vehicle, and with the wheels off the ground in the full rebound position, release the parking brake
and confirm both rear wheels spin freely.

Parking Brake Shoe Adjustment - Vehicles With: SVT Performance Package
Caliper Gauge
Activation
Refer to: Brake Disc - Vehicles With: SVT Performance Package (206-04 Rear Disc Brake, Removal and
Installation).
2. Measure ID of the drum portion of the brake disc. Record the measurement.
Use the General Equipment: Caliper Gauge
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3. Measure the widest diameter of the parking brake shoes.
Use the General Equipment: Caliper Gauge
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4. Remove the backing plate plug.
5. Adjust the parking brake shoe clearance by rotating the adjuster until the parking brake shoes measure
0.59 mm (0.023 in) less than the recorded ID of the drum portion of the brake disc.
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6. Install the backing plate plug.
Refer to: Brake Disc - Vehicles With: SVT Performance Package (206-04 Rear Disc Brake, Removal and
Installation).

Parking Brake Control
Removal

Installation).
Installation).
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2. 1. Loosen the parking brake cable adjustment nut.
2. Rotate the cable outward, then pull the pin and cable upwards and disconnect from the equalizer.
3. Release the tabs and disconnect the front cable from the bracket.
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5. Remove the bolt and position the parking brake switch aside.
6. 1. Remove the 2 bolts.

2. Remove the nut and the parking brake control and front cable assembly.
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Installation
2. Adjust the parking brake cables.

Refer to: Parking Brake Cable Adjustment - Vehicles With: SVT Performance Package (206-05 Parking

Parking Brake Cable LH
Removal

Installation).
Installation).

2. Push inward on the 2 tabs and detach the LH cable from the bracket.
3. Rotate the cable, slide the pin upwards and detach the cable from the equalizer.
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3. 1. Remove the parking brake cable bracket nut.

2. Remove the parking brake cable bracket bolt.
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4.
Remove the 2 parking brake cable bracket bolts.
1. Torque: 18 lb.ft (25 Nm)
2. Torque: 20 lb.ft (27.5 Nm)

6. 1. Remove the parking brake cable bracket bolt.
2. Disconnect the parking brake cable from the brake caliper lever.
3. Push inwards on the 2 tabs, detach the parking brake cable from the brake caliper bracket and
remove the parking brake cable.
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Installation
2. Adjust the parking brake Cables.


Parking Brake Cable LH - Vehicles With: SVT Performance Package
Removal


2. Push inward on the tabs and detach the LH cable from the bracket.
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4. Remove the parking brake cable bracket bolts.
Torque:
1.: 18 lb.ft (25 Nm)
2.: 20 lb.ft (27.5 Nm)
5. Disconnect the parking brake cable from the actuation lever.

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6. 1. Detach the wheel speed sensor harness retainer and position the harness aside.
2. Push inward on the tabs and detach the cable from the bracket.
3. Remove the parking brake cable bracket bolt and remove the LH parking brake cable.
Installation

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Parking Brake Cable RH
Removal

Installation).
Installation).

2. Push inward on the 2 tabs and detach the RH cable from the bracket.
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5.
Remove the parking brake cable bracket bolts.
1. Torque: 20 lb.ft (27.5 Nm)
2. Torque: 18 lb.ft (25 Nm)
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7. 1. Remove the parking brake cable bracket bolt.

2. Disconnect the parking brake cable from the brake caliper lever.
3. Push inwards on the 2 tabs, detach the parking brake cable from the brake caliper bracket and
remove the parking brake cable.
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Installation
2. Adjust the parking brake Cables.


Parking Brake Cable RH - Vehicles With: SVT Performance Package
Removal


2. Push inward on the 2 tabs and detach the RH cable from the bracket.
3. Rotate the cable, slide the pin downwards and detach the cable from the equalizer.
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5. Remove the parking brake cable bracket bolts.

Torque:
1.: 20 lb.ft (27.5 Nm)
2.: 18 lb.ft (25 Nm)
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6. Disconnect the parking brake cable from the actuation lever.
7. 1. Detach the wheel speed sensor harness retainer and position the harness aside.
2. Push inward on the tabs and detach the cable from the bracket.
3. Remove the parking brake cable bracket bolt and remove the RH parking brake cable.
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Installation


Parking Brake Shoes - Vehicles With: SVT Performance Package
Materials
Name Specification
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
Removal

2. Remove the return springs and the adjuster.
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3. Remove the hold down springs, pins and the parking brake shoes.
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Installation
1. Using specified grease, lubricate the parking brake shoe contact points.
Material: Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
2. Adjust the parking brake shoes.

Refer to: Parking Brake Shoe Adjustment - Vehicles With: SVT Performance Package (206-05 Parking

206-06 Hydraulic Brake Actuation 2016 Mustang
Hydraulic Brake Actuation
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Brake Master Cylinder
Removal
cold water.
Vehicles with manual transmission
1. Remove the brake fluid reservoir cap.
2. Using a suitable suction device, syphon the brake fluid from the brake fluid reservoir. cardiagn.com
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3. Disconnect the clutch master cylinder tube.
4. Detach the clutch master cylinder tube bracket from the master cylinder studs.
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All vehicles
5. 1. Disconnect the brake fluid level sensor electrical connector.

2. Detach the wiring harness retainer from the brake fluid reservoir.
6. NOTICE: Make sure that all openings are sealed.
Disconnect the 2 brake tube fittings.

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7. Remove the 2 nuts and the brake master cylinder. Discard the nuts.
Installation
2. If installing a new brake master cylinder, bleed the master cylinder.

Refer to: Component Bleeding (206-00 Brake System - General Information, General Procedures).
If the brake master cylinder was removed to access other components, bleed the brake system.
Procedures).
3. If equipped with a manual transmission, bleed the clutch.
Refer to: Clutch System Bleeding (308-02 Clutch Controls, General Procedures).
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Brake Pedal and Bracket - 6-Speed Manual Transmission - 3160/6-Speed Manual Transmission - MT82
Removal
cold water.
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2. Using a suitable suction device, syphon the brake fluid from the brake fluid reservoir.
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3. Disconnect the clutch master cylinder supply tube from the brake fluid reservoir.
4. 1. Spread the clip and push the clip downward into the released position.
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5. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch.

Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
6. NOTICE: Do not service the brake pedal or brake booster without first removing the cruise control
deactivator switch. This switch must be removed with the clutch pedal in the at-rest position. The
switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove
the switch when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the cruise control deactivator switch.

Refer to: Cruise Control Deactivator Switch (419-03B Cruise Control - Vehicles With: Adaptive Cruise
Control, Removal and Installation).
7. Disconnect the accelerator pedal electrical connector.

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8. Disconnect the starter inhibitor switch electrical connector and detach the 6 wiring harness retainers.
Position the wiring harness aside.
9. 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, a new booster push rod clevis-locking pin should be used.
Remove and discard the booster push rod clevis-locking pin and position aside the booster push rod.
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10. NOTICE: Do not pry on the brake booster or damage to the brake booster may occur.
Have an assistant pull the brake booster and master cylinder assembly away from the dash panel. Remove
the 4 bolts, 4 nuts and remove the brake pedal/clutch pedal assembly.
Installation
1. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch.
The switch must be installed with the booster push rod attached to the brake pedal and with the
brake pedal in the at-rest position. Installing the switch with the brake pedal in any other position
will result in incorrect adjustment and may damage the switch.
2. Bleed the clutch.

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Brake Pedal and Bracket - 6-Speed Automatic Transmission - 6R80
Removal
cold water.
switch. The switch must be removed with the brake pedal in the at-rest position. The switch
Remove the stoplamp switch.

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2. Detach the 3 wiring harness retainers.
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4. Remove the 2 bolts, 4 nuts and remove the brake pedal and bracket.
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Installation

206-07 Power Brake Actuation 2016 Mustang
Power Brake System
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Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT
Removal
cold water.
NOTE: 5.0L 32V Ti-VCT engine shown, 5.2L 32V Ti-VCT similar.
All vehicles
1. Remove the cowl panel grill.

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2. Disconnect the battery cables.
3. Detach the vacuum check valve from the booster and position aside.
Vehicles equipped with manual transmission

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5. Using a suitable suction device, syphon the brake fluid from the brake fluid reservoir.

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7. Detach the clutch master cylinder tube bracket from the master cylinder studs.
All vehicles
8. 1. Detach the battery cable retainer.

2. Remove the nuts and the cross brace. Discard the nuts.
9. Remove the bolts and the cowl extension.
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10. Release the clamp, remove the pin type retainer and position the noise generator aside.
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11. 1. Disconnect the brake fluid level sensor electrical connector.
2. Detach the wiring harness retainer from the brake fluid reservoir.
12. Disconnect the 2 brake tubes at the HCU.

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13. Unclip the brake tubes.
14. Remove and discard the 2 master cylinder nuts. Remove the master cylinder and brake tubes.
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15. Disconnect the vacuum sensor electrical connector.
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
Remove the stop lamp switch.

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18. Remove and discard the 4 nuts.
19. Remove the brake booster.

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Installation

Procedures).
3. If equipped with a manual transmission, bleed the clutch.


Brake Vacuum Sensor
Removal
1. Disconnect the brake booster vacuum sensor electrical connector and remove the brake booster vacuum
sensor.
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Installation
NOTE: Please note the correct installation position. It is critical that the sensor be installed in the exact position
that it was removed.

206-09 Anti-Lock Brake System (ABS) and Stability Control 2016 Mustang
Anti-Lock Brake System (ABS) and Stability Control - Overview
Overview
The ABS and stability control systems are comprised of the following subsystems and features which assist the
driver in maintaining control of the vehicle:
Anti-lock braking
EBD
Electronic Stability Control (ESC)
Hill start assist
Launch control
Line lock
Selectable drive mode
Supplemental braking assist
Supports adaptive cruise control
Supports collision avoidance
Traction control
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Anti-lock braking helps maintain steering control by preventing the wheels from locking up during hard braking.
The EBD system helps maintain vehicle control by keeping a balanced braking condition between the front and
rear wheels.
The Electronic Stability Control (ESC) system helps prevent skids or lateral slides by modulating brake fluid to the
brake calipers and reducing engine torque.
The hill start assist system is designed to assist the driver during hill starts. Using the ABS, the hill start assist
system holds the vehicle on an incline for a short time, allowing the driver to release the brake pedal and press
the accelerator pedal without needing to use the parking brake.
The launch control feature works in conjunction with the ABS and the PCM to maximize traction from a standing
start acceleration in a straight line. Launch control enables a unique "drag start" traction control calibration
designed for high grip surfaces.
The line lock feature allows the rear wheels to spin freely while the front brakes are applied. This allows the rear
tires to be "conditioned" to allow maximum traction. This feature is intended for use at race tracks only and should
not be used on public roads.
The selectable drive mode system helps maintain vehicle traction by adapting the responses of the engine,
transmission, EPAS and stability control system to the demands of the current selected driving mode; normal,
snow-wet, sport and track.
The supplemental braking assist feature uses the hydraulic pump motor and HCU to provide additional braking
assist in the event of severe vacuum loss at the brake booster or during a severe braking event.
The ABS supports the adaptive cruise control system by applying the brakes as necessary to maintain the
distance gap set by the driver. For information on the adaptive cruise control system,
Refer to: Cruise Control - System Operation and Component Description (419-03B Cruise Control - Vehicles With:
Adaptive Cruise Control, Description and Operation).
The ABS supports the collision avoidance system by monitoring information and precharging the brake system
allowing the vehicle to stop in the shortest distance possible. For information on the collision avoidance system,
Refer to: Collision Warning and Collision Avoidance System - System Operation and Component Description
(419-03C Collision Warning and Collision Avoidance System, Description and Operation).
The traction control system helps prevent loss of traction by reducing drive wheel spin during acceleration.
Some noise from the system and pulsations in the brake pedal are normal conditions during most ABS and
stability control events. Also, longer than normal brake pedal travel may be experienced immediately following an
ABS or stability control activation.
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Anti-Lock Brake System (ABS) and Stability Control - System Operation and Component Description
System Operation
System Diagram
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Module Network Input Messages - ABS Module

Message Module
Accelerator PCM This message is sent to the GWM and then to the ABS module. The ABS
pedal position module uses accelerator pedal position information for correct operation of the
traction control, ESC and hill start assist features.
Message Module
Ambient air PCM This message is sent to the GWM and then to the ABS module. This message
temperature informs the ABS module of the current ambient air temperature. The ABS
module uses this information for calculations in determining the operational
status of the various stability control systems and features.
Adaptive cruise CCM This messages informs the ABS module the adaptive cruise control system no
control braking longer requires vehicle braking.
cancel
Adaptive cruise CCM This message is used to request vehicle deceleration by the ABS module for
control the adaptive cruise control system, including how much brake force is required
deceleration and if precharging of the brake system is necessary.
Battery low state BCM This message is sent to the GWM and then to the ABS module. This message
of charge informs the ABS module of a low state of charge in the vehicle 12-volt battery.
Cruise control PCM This message is sent to the GWM and then to the ABS module. The ABS
system status module uses cruise control system status for adaptive cruise control
deceleration and braking.
Brake pedal PCM This message is sent to the GWM and then to the ABS module. This message
applied informs the ABS module the driver has pressed the brake pedal. This message
is also used by the ABS module to check the brake pressure sensor located
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inside the HCU.
Clutch pedal PCM This message is sent to the GWM and then to the ABS module. This message
position is used by the ABS module for the hill start assist feature, launch control
feature and line lock feature.
Collision CCM This message is used to request vehicle deceleration by the ABS module for
mitigation by the collision avoidance system, including how much brake force is required and
braking how much precharging of the brake system is necessary.
deceleration
Door ajar status BCM This message is sent to the GWM and then to the ABS module. This message
informs the ABS module of the current door ajar status. There is a separate
message for each door. The ABS module resets the parameters used for ESC
when a door is opened and closed.
Driver seat belt RCM The ABS module resets the parameters used for the ESC function when the
buckle status driver seat belt is buckled or unbuckled.
Engine disable PCM This message is sent to the GWM and then to the ABS module. This message
status informs the ABS module the engine is currently disabled or enabled due to the
stop-start feature.
Engine RPM PCM This message is sent to the GWM and then to the ABS module. This message
informs the ABS module of the current engine RPM. This message is used by
the ABS module for the hill start assist feature and launch control feature.
Engine torque PCM This message is sent to the GWM and then to the ABS module. This message
output informs the ABS module of the current engine torque output. This information is
used for the hill start assist feature and launch control feature.
Gear lever PCM This message is sent to the GWM and then to the ABS module. This message
position informs the ABS module of the current transmission gear lever position. This
message is used for operation of the hill start assist feature and the ESC
feature. The hill start assist feature operates in forward and reverse gears but
the ESC feature does not operate when the transmission is in REVERSE.
Hill start assist IPC This message is sent to the GWM and then to the ABS module. This message
mode informs the ABS module of the current, driver selected mode for the hill start
assist feature; off, auto or manual.
Ignition key type BCM This message is sent to the GWM and then to the ABS module. This message
informs the ABS module of the current ignition key type; MyKey® admin key,
MyKey® restricted key, key not programmed - read failure, unknown key type
or invalid key type. The ABS module uses the ignition key type for activation
and deactivation of certain stability control features.
Message Module
Ignition status BCM This message is sent to the GWM and then to the ABS module. This message
informs the ABS module of the current ignition status; off, accessory, run, start,
unknown or invalid.
Launch control IPC This message is sent to the GWM and then to the ABS module. This message
request informs the ABS module the driver has requested launch control feature
activation.
Launch control PCM This message is sent to the GWM and then to the ABS module. This message
system status informs the ABS module of the launch control system status as selected by the
driver.
Line lock request IPC This message is sent to the GWM and then to the ABS module. This message
informs the ABS module the driver has requested line lock feature activation.
Park brake BCM This message is sent to the GWM and then to the ABS module. This message
status informs the ABS module of the current parking brake status; applied or
released. The ABS module uses this information for the hill start assist feature.
Power pack PCM This message is sent to the GWM and then to the ABS module. This message
status informs the ABS module of the current engine operation status; Off - torque not
available, On - torque not available, On - torque available or Start in Progress -
torque not available. This information is used for the activation and operation of
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the stability control features.
RCM serial RCM The ABS module stores the RCM serial number and verifies the serial number
number when the vehicle is started or the ignition is set to RUN or ACC. Over time, the
ABS module learns the offset of the sensors inside the RCM. When a new
serial number is found and the IVD Initialization procedure is carried out using a
diagnostic scan tool, the ABS module resets the offset number learned for
ESC.
Reverse gear PCM This message is sent to the GWM and then to the ABS module. This message
selected informs the ABS module the driver has requested REVERSE gear and the
current status of REVERSE gear; active, inactive or faulted. This message is
used for operation of the hill start assist feature and the ESC feature. The hill
start assist feature operates in forward and reverse gears but the ESC feature
does not operate when the transmission is in REVERSE.
Selectable drive FCIM This message is sent to the GWM and then to the ABS module. This message
mode informs the ABS module of the current, driver selected vehicle mode; Normal,
Sport, Snow-Wet or Track. The ABS module adjusts the thresholds for
anti-lock braking and stability control system intervention depending on the
mode selected.
Stability-traction FCIM This message is sent to the GWM and then to the ABS module. This message
control mode informs the ABS module of the current, driver selected mode for the traction
control and stability control features; on, off or sport.
Steering angle PSCM Several steering angle messages are sent to the ABS module from the PSCM.
sensor data These messages include steering angle sensor status, steering wheel angle
and steering wheel rotation count. The ABS module uses the steering angle
sensor data for ESC feature operation.
Transmission in PCM This message is sent to the GWM and then to the ABS module. This message
reverse informs the ABS module when the transmission is in REVERSE, this is used for
the hill start assist feature and the ESC feature. The hill start assist feature
operates in forward and reverse gears. The ESC feature does not operate
when the transmission is in REVERSE.
Vehicle BCM This message is sent to the GWM and then to the ABS module. This message
configuration provides the ABS module with the current optional and configured items such
data as tire size, axle ratio, manual or automatic transaxle, keyless entry and VIN.
Vehicle lateral RCM This message provides the ABS module with the current vehicle lateral
acceleration data acceleration data and notifies the ABS module if the data is valid or invalid. The
ABS module uses the lateral acceleration data for ESC feature operation.
Message Module
Vehicle RCM This message provides the ABS module with the current vehicle longitudinal
longitudinal acceleration data and notifies the ABS module if the data is valid or invalid. The
acceleration data ABS module uses the longitudinal acceleration data for ESC feature operation.
Vehicle yaw rate RCM This message provides the ABS module with the current vehicle yaw rate data
data and notifies the ABS module if the data is valid or invalid. The ABS module
uses the yaw rate data for ESC feature operation.
Anti-Lock Braking
The ABS module continuously monitors brake pedal input, longitudinal vehicle motion and the rotational speed of
each wheel. The ABS module receives the brake pedal input from the PCM and the longitudinal acceleration
sensor information from the RCM. The PCM sends the brake pedal input message to the GWM over the
HS-CAN1, the GWM relays the message to the ABS module over the HS-CAN2. The RCM sends the longitudinal
acceleration sensor message directly to the ABS module over the HS-CAN2. Wheel speed information is received
by the ABS module using 4 wheel speed sensors. When the ABS module detects an impending wheel lock during
a braking event, the ABS module modulates brake pressure to the appropriate brake caliper by opening and
closing the appropriate solenoid valves inside the HCU while the hydraulic pump motor is activated. Once the
affected wheel returns to the desired speed, the ABS module returns the solenoid valves in the HCU to their
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normal position and deactivates the hydraulic pump motor.
When the ABS module is initialized (ignition ON), a preliminary electrical check of the wheel speed and brake
booster vacuum sensors is carried out, and the hydraulic pump motor is activated for approximately one-half
second. During this time, a buzzing or humming noise may be heard and a vibration may be felt in the brake pedal,
this is a normal condition. During the module initialized self-test, the pump motor check is carried out at
approximately 10 km/h (6.2 mph). Any malfunction detected in the system causes the ABS module to set a DTC,
disable the ABS function and send a message to the IPC to illuminate the ABS warning indicator. The base
hydraulic power assist braking system functions normally.
Electronic Brake Force Distribution (EBD)
On initial application of the brake pedal, full pressure is applied to the rear brakes. The ABS module then uses
wheel speed sensor inputs to evaluate rear wheel slip. Once the rear wheel slip exceeds a predetermined
threshold, the ABS module commands the HCU to close the appropriate isolation valves 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. If the rear wheel slip continues and exceeds a second predetermined
threshold, the ABS module commands the HCU to open the dump valves to decrease the rear brake pressure and
allow the rear wheels to recover. A slight bump sensation may be felt in the brake pedal when EBD is active.
If the ABS is disabled due to a DTC being present in the ABS module, EBD continues to function unless the DTC
is for wheel speed sensors or the HCU. When EBD is disabled, the ABS warning indicator, the red brake warning
indicator and stability-traction control indicator (sliding car icon) illuminate.
AdvanceTrac
The AdvanceTrac feature is comprised of the traction control and ESC features.
Traction Control
The ABS module continuously monitors and compares the rotational speed of the drive wheels in relation to the
non-driven wheels. When the drive wheels begin to spin faster than the non-driven wheels, the ABS module
modulates brake pressure to the appropriate brake caliper(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 calculates
how much engine torque reduction is required to eliminate the wheel slip and sends this torque reduction message
along with a traction event message to the GWM over the HS-CAN2. The GWM sends the engine torque
reduction message to the PCM over the HS-CAN1 and the traction event message to the IPC over the HS-CAN3.
When the PCM receives the torque reduction message, it adjusts engine timing and decreases fuel injector pulses
to reduce the engine torque to the requested level. When the IPC receives the traction event message it flashes
the stability-traction control indicator (sliding car icon). Once the driven wheel speed returns to the desired speed,
the ABS module returns the solenoid valves in the HCU to their normal position, deactivates the hydraulic pump
motor and stops sending the traction event and torque reduction messages. The PCM returns engine timing and
fuel injectors to normal operation and the IPC extinguishes the stability-traction control indicator (sliding car icon).
Traction control can be disabled through the use of the stability-traction control switch in the center of the
instrument panel. This is independent of the ABS which cannot be disabled by the driver. When the driver disables
traction control, the FCIM communicates traction control status to the GWM over the MS-CAN. The GWM sends
the message to the ABS module over the HS-CAN2. The ABS module takes no further action in regards to
traction control until the driver activates the function or until the ignition is cycled from OFF to ON.
Traction control is disabled if there is a wheel speed sensor or solenoid valve DTC present in the ABS module.
Traction control is also disabled if there is a communication error between the ABS module and the GWM. When
traction control is disabled, the ABS module sends a message to the GWM over the HS-CAN2 which relays the
message to the IPC over the HS-CAN3 to illuminate the stability-traction control OFF indicator (sliding car OFF
icon).
Electronic Stability Control (ESC)
The ABS module continuously monitors the vehicle motion relative to the intended course. This is done by using
sensors to compare the steering wheel sensor messages and the yaw rate sensor messages with the actual
vehicle motion. The ABS module receives the steering wheel sensor messages from the PSCM and the yaw rate
sensor messages from the RCM, both messages are sent over the HS-CAN2. If the ABS module determines from
the inputs the vehicle is unable to travel in the intended direction, it modulates the brake pressure to the
appropriate brake caliper(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 calculates how much engine torque
reduction is required to reduce vehicle speed to help stabilize the vehicle and sends this torque reduction
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message, along with an ESC event message, to the GWM over the HS-CAN2. The GWM sends the torque
reduction message to the PCM over the HS-CAN1 and the ESC event message to the IPC over the HS-CAN3.
When the PCM receives the torque reduction message, it adjusts engine timing and decreases fuel injector pulses
to reduce the engine torque to the requested level. When the IPC receives this message, it flashes the stability-
traction control indicator (sliding car icon). Once the vehicle instability has been corrected, the ABS module
returns the solenoid valves in the HCU to their normal position, deactivates the hydraulic pump motor and stops
sending the traction event and torque reduction messages. The PCM returns engine timing and fuel injectors to
normal operation and the IPC extinguishes the stability-traction control indicator (sliding car icon).
ESC does not operate with the transmission in REVERSE. ESC is disabled if there is a wheel speed sensor, RCM
stability sensor or steering angle sensor DTC present in the ABS module. ESC is also disabled if there is a
communication error between the ABS module and the PSCM or the ABS module and the RCM. When ESC is
disabled, the ABS module sends a message to the GWM over the HS-CAN2 which relays the message to the IPC
over the HS-CAN3 to illuminate the stability-traction control OFF indicator (sliding car OFF icon).
Disabling AdvanceTrac
The traction control feature can be disabled through the use of the stability-traction control switch, on some
models the ESC feature can also be disabled. The ESC feature is disabled when REVERSE gear is selected or
when the stability-traction control switch is pressed in the following manner:
Button pressed momentarily: traction control is disabled, ESC is enabled.

Button pressed twice rapidly: Sport mode is enabled (if equipped), traction control and ESC are enabled
with modified intervention thresholds. Sport Mode is not available on vehicles equipped with Selectable
Driving Modes.
Button pressed and held for more than 5 seconds: AdvanceTrac off mode, traction control and ESC
are both disabled.
Button pressed again after deactivation: traction control and ESC are both enabled.
Regardless of the driver selected state of the AdvanceTrac feature, when the ignition is cycled from ON to OFF
and back to ON, both the traction control and the ESC are reset to enabled.
Hill Start Assist
When the vehicle is stopped on an incline the ABS module holds the brake pressure for approximately 2 seconds
while the driver transitions from the brake pedal to the accelerator pedal. This is accomplished by monitoring
several HS-CAN messages and several sensors to determine if the vehicle is stopped and not parked, and if the
vehicle is on an appropriate incline. The brake pedal message sent by the PCM and the wheel speed sensor
inputs allow the ABS module to determine the vehicle has come to a complete stop. The transmission selector
lever message sent by the PCM informs the ABS module the vehicle is not parked. The stability sensor messages
sent by the RCM enable the ABS module to determine if the vehicle is on an appropriate incline. Once the above
conditions have been met, the hill start assist feature automatically engages. As the driver releases the brake
pedal, the ABS module commands the HCU to close the isolation valves which maintain the current brake system
pressure, preventing the vehicle from rolling down the incline. Once the driver presses the accelerator pedal and
the torque produced by the engine reaches a specific level, the ABS module gradually releases the brake
pressure to make sure the vehicle is neither rolling back nor driving off until there is sufficient driving torque to
move the vehicle forward (or backward if reversing up the incline). For vehicles with an automatic transmission the
incline must be greater than 3.5 degrees (approximately a 6% grade), for vehicles with a manual transmission the
incline must be greater than 1.5 degrees (approximately a 3% grade). On vehicles with a manual transmission the
hill start assist feature can be disabled through the message center. On vehicles with an automatic transmission
the hill start assist feature cannot be disabled by the driver.
Supplemental Braking Assist
The ABS module uses the HCU and hydraulic pump motor to help bring the vehicle to a safe, controlled stop in the
event of severe vacuum loss in the brake booster. The ABS module continually monitors the vacuum in the brake
booster through the use of a vacuum sensor. When the vacuum sensor indicates vacuum is below a
predetermined level, a DTC is set in the ABS module. The ABS module sends a message to the GWM over the
HS-CAN2 to illuminate the red brake warning indicator, the GWM relays this message to the IPC over the
HS-CAN3. If a low vacuum condition occurs during a braking event or if the driver attempts to stop the vehicle with
a low vacuum condition in the brake booster, the ABS module activates the hydraulic pump motor in the HCU to
assist with vehicle braking.
On vehicles equipped with adaptive cruise control, the CCM monitors the area forward of the vehicle. When an
object enters this area and closes the distance gap set by the driver, the CCM sends either an adaptive cruise
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control deceleration request or a collision avoidance deceleration request to the ABS module over the HS-CAN2.
When the deceleration request message is received, the ABS module activates the hydraulic pump motor and
solenoid valves in the HCU to slow the vehicle down to maintain the distance gap set by the driver. Once the
distance gap set by the driver is achieved, the CCM stops sending the deceleration request message and the
ABS module deactivates the hydraulic pump motor and solenoid valves in the HCU. If the CCM determines the
amount of braking provided by the ABS module is insufficient, the CCM sends a forward collision avoidance
braking request message to the ABS module and warns the driver, both audibly and visually, through the use of
the HUD. After receiving the braking request message, the ABS module waits for brake pedal input and at that
time applies maximum braking assist using the hydraulic pump motor and the HCU.
Refer to: Cruise Control - System Operation and Component Description (419-03B Cruise Control - Vehicles With:
Adaptive Cruise Control, Description and Operation).
Refer to: Collision Warning and Collision Avoidance System - System Operation and Component Description
(419-03C Collision Warning and Collision Avoidance System, Description and Operation).
MyKey® Interaction
Through the MyKey® feature, traction control and ESC can be configured to be always on or allow the driver to
select traction control and ESC on or off. When MyKey® traction control feature is configured to be always on
and a MyKey® restricted key is in use, the ABS module ignores any requests made by the driver to disable
traction control or ESC. In addition, when MyKey® traction control feature is configured to be always on and a
MyKey® restricted key is in use, Sport mode and AdvanceTrac Off mode are not available. Refer to Disabling
AdvanceTrac for information on Sport mode and AdvanceTrac Off mode. Refer to the Owner's Literature for
additional information on the MyKey® feature and settings.
Stability-Traction Control Indicator (Sliding Car Icon)
Refer to: Instrument Panel Cluster (IPC) - System Operation and Component Description (413-01
Instrumentation, Message Center and Warning Chimes, Description and Operation).
Stability-Traction Control Disabled Indicator (Sliding Car OFF Icon)
Refer to: Instrument Panel Cluster (IPC) - System Operation and Component Description (413-01
Instrumentation, Message Center and Warning Chimes, Description and Operation).
One or both of the stability-traction control indicators may illuminate as a result of momentary sensor disturbances
due to environmental or driving conditions (including severe vehicle maneuvers or extreme off road usage). Once
Illuminated, the indicator remains illuminated until the environmental or driving condition is no longer present and
the ignition is cycled from ON to OFF and then back to ON again. If there are no other customer concerns,
symptoms, indicators or Diagnostic Trouble Codes (DTCs), the stability-traction control indicator may have been
illuminated due to these environmental or driving conditions.
Selectable Driving Modes
The MODE switch in the center of the instrument panel allows the driver to change between 4 driving modes.
These driving modes alter the throttle response, shift patterns, EPAS feel and stability control intervention
thresholds. Toggling the switch causes the FCIM to send messages to the PCM, PSCM, ABS module and IPC
message center. The IPC message center displays the current selected mode. The PCM, PSCM and ABS
module respond to the message by modifying their operation according to a preprogrammed set of instructions.
Normal: delivers a balanced combination of comfort, control and handling.

Snow-Wet: provides increased handling, braking and control during poor weather conditions.
Sport: provides increased steering, throttle and shift responses.
Track: provides increased steering, throttle and shift responses as well as modifying the threshold for
AdvanceTrac intervention.
One or more of the selectable drive modes is disabled if Diagnostic Trouble Codes (DTCs) are present in the
PCM, PSCM or ABS module. If the selectable drive modes are disabled, the IPC message center displays Drive
Mode Selection Not Available when the switch is toggled.
Launch Control
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The launch control feature works in conjunction with the stability control system and PCM to maximize traction
from a standing start acceleration in a straight line. Launch control enables a unique "drag start" traction control
calibration designed for high grip surfaces. The system allows the driver to set and hold a desired launch RPM
depending on tire temperature, surface condition or weather.
The driver activates and configures the launch control feature through the message center, see the Owner's
Literature for specific information. The launch control system can only be activated when the stability control
system is fully enabled. Once activated, the launch control feature remains ON until the driver deactivates it, the
system does not reset when the ignition is cycled.
Line Lock
The line lock feature works in conjunction with the stability control system to "lock" the front brakes and allow the
rear wheels to spin freely during throttle application to achieve maximum traction prior to use at a race track. The
line lock feature is intended for use at race tracks only and should not be used on public roadways.
The driver initializes the line lock feature through the message center, see the Owner's Literature for specific
information. Once initialized, the line lock feature is not activated and the vehicle brakes function normally. Line
lock remains initialized up to 40 km/h (25 mph), once vehicle speed exceeds 40 km/h (25 mph) the line lock
feature is automatically cancelled. Following initialization the line lock feature can be engaged, once engaged the
ABS module closes isolation valves in the HCU to maintain the brake pressure in the front brake calipers while
allowing the rear wheels to spin freely and a count-down timer begins. If the line lock feature is not used within
this time limit or a vehicle condition requires the line lock feature to deactivate, the line lock feature is deactivated.
Pressing the brake pedal while the line lock feature is activated automatically deactivates the line lock feature and
normal brake function resumes.
Anti-Lock Brake System (ABS) Module
The ABS module is attached directly to the HCU and is the electronic control unit for all of the ABS and stability
control systems. The ABS module monitors all sensor inputs and all CAN messages relating to ABS and stability
control, then directly controls the solenoid valves and the hydraulic pump motor in the HCU. The ABS module is
available separately for service.
When a new ABS module is installed, it must be programmed with the vehicle configuration information and
programmed with the latest level of module software.
Refer to: Module Configuration - System Operation and Component Description (418-01 Module Configuration,
When an ABS or stability control system fault has been corrected or a new component has been installed, the
ABS module must be calibrated. The calibration procedure (IVD Initialization) is carried out using a diagnostic
scan tool and is required for the stability control sensors to learn the zero-position of the vehicle. The calibration
procedure requires the vehicle to be on a level surface and not moving.
Brake Booster Vacuum Sensor
The brake booster vacuum sensor is a piezoelectric device used by the ABS module to monitor the vacuum in the
brake booster. The sensor is hardwired to the ABS module by 3 circuits. One circuit is for the 5 volt sensor
supply, one circuit is for sensor ground and one circuit is for sensor output. The sensor output ranges from 0.2 volt
to 4.9 volts, depending on the amount of vacuum in the booster.
Hydraulic Control Unit (HCU)
The HCU contains the solenoid valves, the hydraulic pump motor and the pressure sensor used by the ABS
module for the various stability control systems. The ABS module and the HCU are attached directly together. The
HCU is available separately for service.
Selectable Driving Modes Switch
The selectable driving modes switch is a momentary-contact, toggle style switch and is part of the FCIM. If a new
switch is required, then a new FCIM must be installed.
Stability Control Sensors
The stability control sensors for the vehicle dynamic system consist of the yaw rate sensor, lateral accelerometer
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and longitudinal accelerometer. The sensors are housed in the RCM which sends sensor information to the ABS
module over the HS-CAN2. If any of the sensors are defective, a new RCM must be installed.
The yaw rate sensor measures the yaw angle which is the difference between the direction the vehicle is
pointing when cornering and the direction the vehicle is actually moving.
The longitudinal accelerometer measures the acceleration and deceleration of the vehicle as it moves
forward and backward.
The lateral accelerometer measures the force created when a vehicle corners that tends to push a vehicle
sideways.
Lateral acceleration has 2 forms. The first is the centrifugal acceleration generated when the vehicle travels
around in a circle. The second is the acceleration due to gravity. On level ground there is no lateral acceleration
due to gravity. 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.
Stability-Traction Control OFF Switch
The stability-traction control OFF switch is either a momentary-contact, push-button style switch or a momentary-
contact, toggle style switch depending on optional vehicle features. Regardless of switch type, the stability-
traction control switch is part of the FCIM and if a new switch is required, then a new FCIM must be installed.
Steering Wheel Rotation Sensor
The steering wheel rotation sensor is part of the EPAS gear assembly. The steering wheel rotation speed, angle
and direction of travel is calculated by the PSCM and is sent to the ABS module over the HS-CAN2.
Wheel Speed Sensors
All 4 wheel speed sensors are active (magneto resistive) sensors operating on the Hall-effect principle to
generate a square wave signal proportional to the rotational speed of the wheel. Because these are active
sensors, receiving voltage from the ABS module and sending a varying voltage back to the ABS module, they are
able to detect much lower rotational speeds than passive (magnetic inductive) sensors. Each wheel speed sensor
is 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.
Wheel Speed Sensor Encoders
The front wheel speed senor encoders are non-magnetized, toothed rings pressed into the front wheel hub. The
rear wheel speed sensor encoders are magnetized, toothed rings pressed onto the rear wheel hub. As the wheel
hub rotates the wheel speed sensor is exposed to magnetic fields or alternating strength. The encoders are part
of the wheel hubs and are serviced with the hubs.
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Anti-Lock Brake System (ABS) and Stability Control
Diagnostic Trouble Code (DTC) Charts
DTC Charts
ABS Module DTC Chart

B10DF:46 Master Cylinder Isolation This DTC sets due to an internal failure of the ABS module or a
Valve: Calibration / calibration failure between the HCU and the ABS module.
Parameter Memory Using a diagnostic scan tool, CARRY OUT the Inlet Valve
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Failure Calibration and then the Master Cylinder Isolation Calibration.
CLEAR the DTC and REPEAT the self-test. If the DTC returns,
REPEAT the 2 calibration routines making sure to FOLLOW the
diagnostic scan tool directions.
INSTALL a new ABS module.
REFER to: Anti-Lock Brake System (ABS) Module (206-09
Anti-Lock Brake System (ABS) and Stability Control, Removal and
Installation).
C0001:01 TCS Control Channel "A" This DTC indicates part of the ABS module has failed internally.
Valve 1: General CLEAR the DTC. REPEAT the self-test.
Electrical Failure If the DTC returns, INSTALL a new ABS module.
Installation).
C0002:01 TCS Control Channel "A" This DTC indicates part of the ABS module has failed internally.
Installation).
C0003:01 TCS Control Channel "B" This DTC indicates part of the ABS module has failed internally.
Installation).
C0004:01 TCS Control Channel "B" This DTC indicates part of the ABS module has failed internally.
Installation).
C0010:01 Left Front Inlet Control: This DTC indicates part of the ABS module has failed internally.
General Electrical Failure CLEAR the DTC. REPEAT the self-test.
If the DTC returns, INSTALL a new ABS module.
Installation).
C0011:01 Left Front Outlet Control: This DTC indicates part of the ABS module has failed internally.
Installation).
C0014:01 Right Front Inlet Control: This DTC indicates part of the ABS module has failed internally.
Installation).
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C0015:01 Right Front Outlet This DTC indicates part of the ABS module has failed internally.
Control: General CLEAR the DTC. REPEAT the self-test.
Installation).
C0018:01 Left Rear Inlet Control: This DTC indicates part of the ABS module has failed internally.
Installation).
C0019:01 Left Rear Outlet Control: This DTC indicates part of the ABS module has failed internally.
Installation).
C001C:01 Right Rear Inlet Control: This DTC indicates part of the ABS module has failed internally.
Installation).
C001D:01 Right Rear Outlet This DTC indicates part of the ABS module has failed internally.
Control: General CLEAR the DTC. REPEAT the self-test.
Installation).
C0020:11 ABS Pump Motor GO to Pinpoint Test H

Control: Circuit Short To
Ground
Control: Circuit Short To
Battery
Control: Circuit Open
Control: Actuator Stuck
C0030:07 Left Front Tone Wheel: GO to Pinpoint Test B
Mechanical Failure
C0031:07 Left Front Wheel Speed GO to Pinpoint Test B
Sensor: Mechanical
Failure
C0031:11 Left Front Wheel Speed GO to Pinpoint Test K
Ground
C0031:15 Left Front Wheel Speed GO to Pinpoint Test K
Battery or Open
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Sensor: Signal Invalid
C0031:2F Left Front Wheel Speed GO to Pinpoint Test B
Sensor: Signal Erratic
C0031:4A Left Front Wheel Speed DIAGNOSE all other wheel speed sensor Diagnostic Trouble
Sensor: Incorrect Codes (DTCs) before diagnosing any "Incorrect Component
Component Installed Installed" wheel speed sensor Diagnostic Trouble Codes (DTCs).
INSTALL a new wheel speed sensor.
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Brake
System (ABS) and Stability Control, Removal and Installation).

Sensor: Signal Plausibility
Failure
C0033:07 Right Front Tone Wheel: GO to Pinpoint Test B
Mechanical Failure
C0034:07 Right Front Wheel Speed GO to Pinpoint Test B
Sensor: Mechanical
Failure
C0034:11 Right Front Wheel Speed GO to Pinpoint Test K
Ground
C0034:15 Right Front Wheel Speed GO to Pinpoint Test K
Battery or Open
C0034:2F Right Front Wheel Speed GO to Pinpoint Test B
C0034:4A Right Front Wheel Speed DIAGNOSE all other wheel speed sensor Diagnostic Trouble
Sensor: Incorrect Codes (DTCs) before diagnosing any "Incorrect Component
Component Installed Installed" wheel speed sensor Diagnostic Trouble Codes (DTCs).
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Brake
Failure
C0036:07 Left Rear Tone Wheel: GO to Pinpoint Test B
Mechanical Failure
C0037:07 Left Rear Wheel Speed GO to Pinpoint Test B
Sensor: Mechanical
Failure
C0037:11 Left Rear Wheel Speed GO to Pinpoint Test L
Ground
C0037:15 Left Rear Wheel Speed GO to Pinpoint Test L
Battery or Open
C0037:2F Left Rear Wheel Speed GO to Pinpoint Test B
C0037:4A Left Rear Wheel Speed DIAGNOSE DTC U2100:00 and all other wheel speed sensor
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Sensor: Incorrect Diagnostic Trouble Codes (DTCs) before diagnosing DTC
Component Installed C0037:4A.
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Brake

Failure
C0039:07 Right Rear Tone Wheel: GO to Pinpoint Test B
Mechanical Failure
C003A:07 Right Rear Wheel Speed GO to Pinpoint Test B
Sensor: Mechanical
Failure
C003A:11 Right Rear Wheel Speed GO to Pinpoint Test L
Ground
C003A:15 Right Rear Wheel Speed GO to Pinpoint Test L
Battery or Open
C003A:2F Right Rear Wheel Speed GO to Pinpoint Test B
C003A:4A Right Rear Wheel Speed DIAGNOSE DTC U2100:00 and all other wheel speed sensor
Sensor: Incorrect Diagnostic Trouble Codes (DTCs) before diagnosing DTC
Component Installed C003A:4A.
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Brake

Failure
C0040:64 Brake Pedal Switch "A": GO to Pinpoint Test C
C0044:28 Brake Pressure Sensor DIAGNOSE DTC C0040:64 before diagnosing this DTC.
"A": Signal Bias Level If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
Out of Range / Zero ignition from ON to OFF and back to ON. REPEAT the self-test. If
Adjustment Failure DTC C0044:28 returns, VERIFY all ABS module-to- HCU
fasteners are tightened to their correct torque specifications.
If all fasteners are tightened to their correct torque specifications,
Installation).
"A": Watchdog / Safety If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
Failure ignition from ON to OFF and back to ON. REPEAT the self-test. If
DTC C0044:47 returns, VERIFY all ABS module-to- HCU
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Installation).
"A": Internal Electronic If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
INSTALL a new ABS module and HCU assembly.
REFER to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake
"A": Not Programmed If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
ignition from ON to OFF and back to ON. REPEAT the self-test. If
Installation).
"A": Signal Plausibility If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
INSPECT the brake tubes and connections for damage and leaks.
REPAIR or INSTALL new brake tubes as necessary.
If brake tubes and connections are OK and there are no brake
fluid leaks, BLEED the brake system.
REFER to: Brake System Pressure Bleeding (206-00 Brake
CYCLE the ignition from ON to OFF and back to ON. CARRY
OUT the ABS module self-test. If this DTC returns, INSTALL a
new ABS module.
Installation).
C0044:8F Brake Pressure Sensor DIAGNOSE DTC C0040:64 before diagnosing this DTC.
"A": Erratic If DTC C0040:64 is not present, CLEAR the DTC. CYCLE the
ignition from ON to OFF and back to ON. REPEAT the self-test. If
DTC C0044:8F returns, VERIFY all ABS module-to- HCU
C0047:01 Brake Booster Pressure GO to Pinpoint Test M

Sensor: General Electric
Failure
Sensor: Signal Rate of
Change Below Threshold
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Sensor: Signal Rate of
Change Above Threshold
C0051:62 Steering Wheel Position GO to Pinpoint Test J
Sensor: Signal Compare
Failure
Failure
Sensor: Signal Incorrect
After Event
Sensor: Signal Above
Allowable Range
C0061:28 Lateral Acceleration GO to Pinpoint Test G
Sensor: Signal Bias Level
Out of Range / Zero
Adjustment Failure
C0061:2F Lateral Acceleration GO to Pinpoint Test G
C0061:64 Lateral Acceleration GO to Pinpoint Test G
Failure
C0062:28 Longitudinal Acceleration GO to Pinpoint Test G
Sensor: Signal Bias Level
Out of Range / Zero
Adjustment Failure
C0062:54 Longitudinal Acceleration This DTC sets if the stability sensors in the RCM have not been
Sensor: Missing calibrated or the calibration has been lost. CARRY OUT the IVD
Calibration Initialization routine, FOLLOW the diagnostic scan tool instructions.
If the module fails the initialization routine, VERIFY the RCM is
installed correctly and the fasteners are tightened to specifications.
REINSTALL the RCM or INSTALL a new RCM as necessary.
REFER to: Restraints Control Module (RCM) (501-20B
If the RCM is OK, CARRY OUT the RCM self-test. RETRIEVE
and RECORD any Diagnostic Trouble Codes (DTCs).
(501-20B Supplemental Restraint System, Diagnosis and Testing).
If the module passes the calibration routine, CLEAR the DTC.
CYCLE the ignition from ON to OFF and back to ON. CARRY
OUT the ABS module self-test. If the DTC returns, INSTALL a new
ABS module.
Installation).
C0062:64 Longitudinal Acceleration GO to Pinpoint Test G

Failure
C0062:76 Longitudinal Acceleration Due to the nature of the longitudinal acceleration sensor, the RCM
Sensor: Wrong Mounting must be installed in the correct orientation to the centerline of the
Position vehicle. This DTC sets if the RCM has been installed in the wrong
position.
VERIFY the RCM is installed correctly and the fasteners are
tightened to specifications. REINSTALL the RCM or INSTALL a
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new RCM as necessary.
If the RCM is OK, CARRY OUT the RCM self-test. RETRIEVE
and RECORD any Diagnostic Trouble Codes (DTCs).
C0063:28 Yaw Rate Sensor: Signal GO to Pinpoint Test G

Bias Level Out of Range
/ Zero Adjustment Failure
C0063:2F Yaw Rate Sensor: Signal GO to Pinpoint Test G
Erratic
C0063:64 Yaw Rate Sensor: Signal GO to Pinpoint Test G
C0064:28 Roll Rate Sensor: Signal GO to Pinpoint Test G
Bias Level Out of Range
/ Zero Adjustment Failure
C0064:64 Roll Rate Sensor: Signal GO to Pinpoint Test G
C006B:00 Stability System Active GO to Pinpoint Test O
Too Long: No Sub Type
Information
C0072:68 Brake Temperature Too This DTC is set due to HS-CAN concerns, CCM concerns or a
High: Event Information hard reset of the ABS module (battery disconnected or ignition ON
with ABS module electrical connector disconnected).
When this DTC is set, the ABS module disables adaptive cruise
control until the temperature is returned to normal. The DTCdoes
not illuminate any warning indicators but the message center
displays ADAPTIVE CRUISE CONTROL NOT AVAILABLE.
RETRIEVE and DIAGNOSE all CAN Diagnostic Trouble Codes
(DTCs) in the ABS module and the CCM. REFER to DTC Chart:
ABS Module in this section or
REFER to: Cruise Control (419-03B Cruise Control - Vehicles
With: Adaptive Cruise Control, Diagnosis and Testing).
If there are no CAN Diagnostic Trouble Codes (DTCs) present,
RETRIEVE and DIAGNOSE all CCM Diagnostic Trouble Codes
(DTCs) other than C0072:00.
If DTC C0072:00 is the only DTC present in the CCM or if DTC
C0072:68 is the only DTC present in the ABS module, ALLOW the
vehicle to cool down for 30 minutes. CLEAR all ABS module
Diagnostic Trouble Codes (DTCs) and REPEAT the self-test. If
ABS module DTC C0072:68 returns, INSTALL a new CCM.
REFER to: Cruise Control Module (CCM) (419-03B Cruise Control
- Vehicles With: Adaptive Cruise Control, Removal and
Installation).
C1015:08 Vacuum Supply: Bus GO to Pinpoint Test M

C1015:7A Vacuum Supply: Fluid GO to Pinpoint Test R
Leak or Seal Failure
C1015:7B Vacuum Supply: Low GO to Pinpoint Test R
Fluid Level
C1020:00 Brake System Fill Not This DTC is pre-set in a new ABS module and HCU assembly and
Complete: No Sub-Type can only be cleared when the Brake System Service Bleed is
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Information successfully carried out.
CARRY OUT the Brake System Service Bleed.
REFER to: Brake System Pressure Bleeding (206-00 Brake
C1109:64 Vehicle Dynamics Control This DTC sets in continuous memory and on-demand when the
Switch: Signal Plausibility information in the stability-traction control switch message from the
Failure FCIM is implausible (does not match other sensor inputs or
messages). This indicates a concern with the MS-CAN, HS-CAN2,
the GWM or the FCIM.
RETRIEVE and DIAGNOSE all GWM and FCIM Diagnostic
For GWM Diagnostic Trouble Codes (DTCs),
Communications Network, Diagnosis and Testing).
For FCIM Diagnostic Trouble Codes (DTCs),
REFER to: Information and Entertainment System (415-00A
REFER to: Information and Entertainment System (415-00A
C1137:64 Reverse Gear Switch: This DTC sets when the reverse gear message sent from the PCM
Signal Plausibility Failure indicates the transmission is in REVERSE when other stability
control inputs received by the ABS module indicate the vehicle is
moving forward.
VERIFY the reverse lamps operate correctly. If the lamps do not
operate correctly,
REFER to: Reversing Lamps (417-01 Exterior Lighting, Diagnosis
and Testing).
If the reverse lamps operate correctly, RETRIEVE and REPAIR all
non-network Diagnostic Trouble Codes (DTCs) in the PCM.
REFER to: Electronic Engine Controls (303-14A Electronic Engine
Controls - 2.3L EcoBoost (231kW/314PS), Diagnosis and Testing).
REFER to: Electronic Engine Controls (303-14B Electronic Engine
Controls - 3.7L Duratec (227kW/301PS), Diagnosis and Testing).
REFER to: Electronic Engine Controls (303-14C Electronic Engine
Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
C1A08:1C Pressure Sensor Supply: The brake system pressure sensor is supplied voltage by the ABS
Circuit Voltage Out of module. The ABS module monitors this output and sets this DTC
Range when the voltage is out of range.
DIAGNOSE DTC U3003:16 or U3003:17, before diagnosing
C1A08:1C.
If DTC U3003:16 or U3003:17 is not present, make sure all ABS
module-to- HCU fasteners are tightened to their correct torque
specifications.
Installation).
C1B14:11 Sensor Supply Voltage GO to Pinpoint Test M

"A": Circuit Short to
Ground
"A": Circuit Short to
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Battery
C1B15:1C Sensor Supply Voltage GO to Pinpoint Test M
"B": Circuit Voltage Out
of Range
P0942:46 Hydraulic Pressure Unit: The ABS module and HCU should not be swapped between
Calibration / Parameter different vehicles. This DTC sets when the identification data
Memory Failure stored in the ABS module does not match the identification data
from the HCU.
Using a diagnostic scan tool, CARRY OUT the Inlet Valve
Calibration routine and then the Master Cylinder Isolation
Calibration routine.
P0942:49 Hydraulic Pressure Unit: The ABS module and HCU should not be swapped between
Internal Electronic Failure different vehicles. This DTC sets when the identification data
stored in the ABS module does not match the identification data
from the HCU.
Using a diagnostic scan tool, CARRY OUT the Inlet Valve
P193B:86 Throttle / Pedal Signal: This DTC sets in continuous memory and on-demand when the
Signal Invalid information in the accelerator pedal position message from the
PCM is "faulted" instead of "OK". This indicates a concern with the
accelerator pedal sensor, wiring or PCM.
If ABS module Diagnostic Trouble Codes (DTCs) U0100:00 or
U0401:00 are also present, DIAGNOSE those Diagnostic Trouble
Codes (DTCs) before diagnosing DTC P193B:86.
If ABS module Diagnostic Trouble Codes (DTCs) U0100:00 or
U0401:00 are not present, RETRIEVE and RECORD all PCM
REFER to: Electronic Engine Controls (303-14A Electronic Engine
Controls - 2.3L EcoBoost (231kW/314PS), Diagnosis and Testing).
REFER to: Electronic Engine Controls (303-14B Electronic Engine
Controls - 3.7L Duratec (227kW/301PS), Diagnosis and Testing).
REFER to: Electronic Engine Controls (303-14C Electronic Engine
Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
U0001:88 High Speed CAN A HS-CAN fault was present at a point in time. The fault is not currently
Communication Bus: Bus present since the module is communicating with the diagnostic scan tool.
Off CLEAR the DTC. REPEAT the Network Test with the diagnostic scan
tool. VERIFY the integrity of the connectors and wiring. Refer to Wiring
Diagrams Cell 14 for schematic and connector information.
U0100:00 Lost Communication With GO to Pinpoint Test I
ECM / PCM "A": No Sub
Type Information
U0104:00 Lost Communication With GO to Pinpoint Test P
Cruise Control Module:
U0131:00 Lost Communication With GO to Pinpoint Test Q
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Power Steering Control
Module: No Sub Type
Information
U0140:00 Lost Communication With GO to Pinpoint Test D
Body Control Module: No
U0151:00 Lost Communication With GO to Pinpoint Test S
Restraints Control
Module: No Sub Type
Information
U0300:51 Internal Control Module CHECK vehicle service history for recent service actions related to the
Software Incompatibility: ABS module. This DTC sets due to incomplete or improper flash
Not Programmed programming procedures. If there have been recent service actions with
the ABS module, REPEAT the programming procedure as directed by the
U0401:00 Invalid Data Received GO to Pinpoint Test I
From ECM / PCM "A":
U0405:41 Invalid Data Received GO to Pinpoint Test P
From Cruise Control
Module: General
Checksum Failure
U0405:82 Invalid Data Received GO to Pinpoint Test P
From Cruise Control
Module: Alive / Sequence
Counter Incorrect / Not
Updated
U0420:41 Invalid Data Received GO to Pinpoint Test Q
From PSCM: General
Checksum Failure
From PSCM: Alive /
Sequence Counter
Incorrect / Not Updated
From PSCM: Signal
Invalid
U0422:00 Invalid Data Received GO to Pinpoint Test D
From Body Control
Module: No Sub Type
Information
U0452:41 Invalid Data Received The ABS module uses other module messages and sensor input to
From Restraints Control calculate the yaw rate, lateral acceleration and longitudinal
Module: General acceleration to verify the RCM messages. If the yaw rate, lateral
Checksum Failure acceleration and longitudinal acceleration data received from the
RCM do not match the calculated values more than 2 times, this
DTC is set.
If ABS module Diagnostic Trouble Codes (DTCs) C0061:xx,
C0062:xx, C0063:xx or C0064:xx are present, DIAGNOSE them
before diagnosing U0452:41.
Using a diagnostic scan tool, RETRIEVE and DIAGNOSE all RCM
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condition may be caused by an intermittent concern.
SET the ignition to OFF. WAIT one minutes, then DISCONNECT
and INSPECT all RCM electrical connectors and related in-line
U0452:86 Invalid Data Received Along with the yaw rate, lateral acceleration and longitudinal
From Restraints Control acceleration data the RCM also sends a rolling counter message
Module: Signal Invalid the ABS module uses to validate the RCM messages. If the rolling
counter indicates an invalid signal more than 4 times, this DTC is
set.
If ABS module Diagnostic Trouble Codes (DTCs) C0061:xx,
C0062:xx, C0063:xx or C0064:xx are present, DIAGNOSE them
before diagnosing U0452:86.
Using a diagnostic scan tool, RETRIEVE and DIAGNOSE all RCM
condition may be caused by an intermittent concern.
SET the ignition to OFF. WAIT one minutes, then DISCONNECT
and INSPECT all RCM electrical connectors and related in-line
U2007:46 Valve(s): Calibration / This DTC sets due to an internal failure of the ABS module or due
Parameter Memory to a calibration failure between the HCU and the ABS module.
Failure Using a diagnostic scan tool, CARRY OUT the Inlet Valve
Installation).
U2007:62 Valve(s): Signal Compare This DTC sets due to an internal failure of the ABS module or due
Failure to a calibration failure between the HCU and the ABS module.
Installation).
U2024:51 Control Module This DTC is only present when a new ABS module is installed, the
Cal-Config Data: Not ABS module is flashed or the ABS module is reconfigured.
Programmed Using a diagnostic scan tool, CONFIGURE the ABS module,
REFER to: Module Configuration - System Operation and
Component Description (418-01 Module Configuration, Description
and Operation).
Using a diagnostic scan tool, CARRY OUT the ABS module
self-test to clear the DTC.
U2100:00 Initial Configuration Not This DTC is pre-set in a new ABS module and clears automatically
Complete: No Sub Type when the ABS module is configured correctly.
Information CHECK the service history for recent service actions related to the
ABS module. This DTC sets due to incomplete or improper PMI
procedures.
If there have been recent service actions with the ABS module,
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REPEAT the PMI procedure as directed by the diagnostic scan
tool.
If there have been no recent service actions, INSTALL a new ABS
module to correct the failure to retain the configuration data.
Installation).
U2101:00 Control Module CHECK the service history for recent service actions related to the
Configuration ABS module. This DTC sets due to incomplete or improper PMI
Incompatible: No Sub procedures.
Type Information If there have been recent service actions with the ABS module,
tool.
Installation).
U2107:00 Collision Mitigation By This DTC sets when the collision deceleration message from the
Braking: No Sub Type CCM is sent too often or the duration of the message is too long.
Information This is most likely caused by a network communication concern or
an internal failure of the CCM.
RETRIEVE and REPAIR all Diagnostic Trouble Codes (DTCs) in
the CCM.
U2107:68 Collision Mitigation By This DTC sets when the vehicle deceleration detected is
Braking: Event implausibly high when compared to the vehicle deceleration
Information requested by the CCM. This is most likely caused by an abrupt
stop of the vehicle due to a collision, an extreme driving situation, a
mechanical or electrical failure of the cruise control system or an
internal failure of the ABS module.
RETRIEVE and REPAIR all other ABS module Diagnostic Trouble
Codes (DTCs) before diagnosing DTC U2107:68.
If there are no other ABS module Diagnostic Trouble Codes
(DTCs) present, RETRIEVE and REPAIR all Diagnostic Trouble
Codes (DTCs) in the CCM.
If there are no Diagnostic Trouble Codes (DTCs) in the CCM,
INSPECT the vehicle braking system for a dragging condition or
another condition that may cause rapid vehicle deceleration.
U2108:00 Adaptive Cruise Control: In order to detect errors in the CCM, the cruise control system is
No Sub Type Information momentarily shut off during a driver braking event. This DTC sets
when the ABS module detects cruise control system activation
during a driver braking event. This is most likely caused by a
network communication concern or an internal failure of the CCM.
RETRIEVE and REPAIR all Diagnostic Trouble Codes (DTCs) in
the CCM.
U2108:68 Adaptive Cruise Control: The ABS module monitors vehicle deceleration during adaptive
Event Information cruise control braking events to prevent an over-braking situation.
This DTC sets when vehicle deceleration is greater than 3.2
meters per second2. This is most likely caused by an abrupt stop
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of the vehicle due to a collision, an extreme driving situation, a
mechanical or electrical failure of the adaptive cruise control
system or an internal failure of the ABS module.
RETRIEVE and REPAIR all other ABS module Diagnostic Trouble
Codes (DTCs) before diagnosing DTC U2108:68.
If there are no other ABS module Diagnostic Trouble Codes
(DTCs) present, RETRIEVE and REPAIR all Diagnostic Trouble
Codes (DTCs) in the CCM.
If there are no Diagnostic Trouble Codes (DTCs) in the CCM,
INSPECT the vehicle braking system for a dragging condition or
another condition that may cause rapid vehicle deceleration.
U2200:00 Control Module CHECK the service history for recent service actions related to the
Configuration Memory ABS module. This DTC sets due to incomplete or improper PMI
Corrupt: No Sub Type procedures.
Information If there have been recent service actions with the ABS module,
tool.
Installation).
U3000:49 Control Module: Internal CLEAR the Diagnostic Trouble Codes (DTCs). CARRY OUT the
Electronic Failure ABS module self-test. RETRIEVE and RECORD all Diagnostic
If the DTC returns INSTALL a new ABS module.
Installation).
U3002:62 Vehicle Identification GO to Pinpoint Test N

Number: Signal Compare
Failure
U3003:08 Battery Voltage: Bus
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test A
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test F
U300A:29 Ignition Switch: Signal GO to Pinpoint Test A
Invalid
PCM DTC Chart

P0555 Brake Booster This DTC sets if the information in the brake booster vacuum sensor
Pressure Sensor message is outside of the programmed set of parameters. This is most
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Circuit likely due to vacuum sensor concerns, wiring harness concerns or vehicle
communication concerns.
Using a diagnostic scan tool, CARRY OUT the ABS module self-test.
DIAGNOSE any ABS module Diagnostic Trouble Codes (DTCs).
Circuit Range / likely due to vacuum sensor concerns, wiring harness concerns or vehicle
Performance communication concerns.
Pressure Sensor message contains a value lower than allowed by the programmed set of
Circuit Low parameters. This is most likely due to vacuum sensor concerns, wiring
harness concerns or vehicle communication concerns.
Pressure Sensor message contains a value higher than allowed by the programmed set of
Circuit High parameters. This is most likely due to vacuum sensor concerns, wiring
harness concerns or vehicle communication concerns.
Circuit Intermittent likely due to vacuum sensor concerns, wiring harness concerns or vehicle
communication concerns.
P1501 Vehicle Speed Sensor This DTC sets if the information in the wheel speed sensor message is
Out of Self Test Range outside of the programmed set of parameters. This is most likely due to
wheel speed sensor concerns, wiring harness concerns, wheel speed
sensor encoder concerns or vehicle communication concerns.
Symptom Chart
Symptom Chart: Anti-Lock Brake System (ABS) and Stability Control
Symptom Chart

respond to the Wiring, terminals or REFER to: Communications Network (418-00
diagnostic scan tool connectors Module Communications Network, Diagnosis and
ABS module concern Testing).
The brake warning Parking brake applied RETRIEVE all ABS module Diagnostic Trouble
indicator is always or Low brake fluid level Codes (DTCs) and GO to the DTC Chart: ABS
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never on Brake fluid level sensor Module.
Parking brake switch If there are no Diagnostic Trouble Codes (DTCs)
Brake booster vacuum present in the ABS module, DIAGNOSE the
sensor warning indicator.
IPC concern REFER to: Instrumentation, Message Center and
ABS concern Warning Chimes (413-01 Instrumentation,
Message Center and Warning Chimes, Diagnosis
and Testing).
The ABS warning IPC concern RETRIEVE all ABS module Diagnostic Trouble
indicator is always or ABS or stability control Codes (DTCs) and GO to the DTC Chart: ABS
never on concern Module.
If there are no Diagnostic Trouble Codes (DTCs)
present in the ABS module, DIAGNOSE the
warning indicator.
Warning Chimes (413-01 Instrumentation,
and Testing).
The stability-traction IPC concern RETRIEVE all ABS module Diagnostic Trouble
control indicator ABS or stability control Codes (DTCs) and GO to the DTC Chart: ABS
(sliding-car icon) is concern Module.
never or always on If there are no Diagnostic Trouble Codes (DTCs)
present in the ABS module, DIAGNOSE the
warning indicator.
Warning Chimes (413-01 Instrumentation,
and Testing).
ABS false activation, Front or rear suspension ELIMINATE the front and rear suspension as the cause of
ABS too sensitive, concern the problem.
ABS activates on REFER to: Suspension System (204-00 Suspension
normal stop System - General Information, Diagnosis and Testing).
RCM mounting CONFIRM the RCM is mounted correctly.
Supplemental Restraint System, Removal and
Installation).
Loose wheel speed sensor or INSPECT wheel speed sensor for looseness or excessive
excessive air gap air gap. TIGHTEN or INSTALL new as necessary.
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock
Brake System (ABS) and Stability Control, Removal and
Installation).
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock
Brake System (ABS) and Stability Control, Removal and
Installation).
Parking brake out of
adjustment (dragging) REFER to: Parking Brake (206-05 Parking Brake and
Actuation, Diagnosis and Testing).
The traction control Refer to the Pinpoint Test GO to Pinpoint Test E
system cannot be
disabled
The Line Lock Vehicle is on an incline The vehicle must be on a flat surface for Line Lock
feature cannot be Engine is not running feature use. MOVE vehicle to a flat surface and
selected from the Selectable driving ATTEMPT to select the Line Lock feature.
track application mode is set to START the engine and ATTEMPT to select the
menu (grayed out) Snow-Wet Line Lock feature.
Vehicle is traveling The Line Lock feature cannot be used with
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faster than 40-48 km/h Snow-Wet drive mode selected. SELECT Track
(25-30 mph) drive mode and ATTEMPT to select the Line Lock
Diagnostic Trouble feature.
Codes (DTCs) present The vehicle cannot be moving when selecting the
in the ABS module Line Lock feature. STOP the vehicle and
ATTEMPT to select the Line Lock feature.
Using a diagnostic scan tool, RETRIEVE all ABS
module Diagnostic Trouble Codes (DTCs). GO to
the DTC Chart: ABS Module
The Line Lock Vehicle is on an incline The vehicle must be on a flat surface for Line Lock
feature cannot be Engine is not running feature use. MOVE vehicle to a flat surface and
initialized Selectable driving ATTEMPT to initialize the Line Lock feature.
mode is set to START the engine and ATTEMPT to initialize the
Snow-Wet Line Lock feature.
Vehicle is traveling The Line Lock feature cannot be used with
faster than 40-48 km/h Snow-Wet drive mode selected. SELECT Track
(25-30 mph) drive mode and ATTEMPT to initialize the Line
Diagnostic Trouble Lock feature.
Codes (DTCs) present The vehicle cannot be moving when initializing the
in the ABS module Line Lock feature. STOP the vehicle and
ATTEMPT to initialize the Line Lock feature.
The Line Lock Spare tire is installed REPAIR and INSTALL the road wheel and
feature cannot be Driver or passenger ATTEMPT to engage the Line Lock feature.
engaged door is open CLOSE the open door and ATTEMPT to engage
Transmission is in the Line Lock feature.
PARK or REVERSE The transmission must be in a forward gear for the
Parking brake is Line Lock feature to engage. PLACE the
applied transmission in DRIVE or FIRST GEAR and
Steering wheel is not in ATTEMPT to engage the Line Lock feature.
the straight-ahead RELEASE the parking brake and ATTEMPT to
position engage the Line Lock feature
Vehicle is on an incline TURN the steering wheel to the straight-ahead
Engine is not running position and ATTEMPT to engage the Line Lock
Driver applied brake feature.
pressure is not high The vehicle must be on a flat surface for Line Lock
enough feature use. MOVE vehicle to a flat surface and
OK button not pressed ATTEMPT to engage the Line Lock feature.
while applying the START the engine and ATTEMPT to engage the
brake pedal to the Line Lock feature.
required force The brake pressure meter in the message center
Selectable driving must be completely filled before the Line Lock
mode is set to feature engages. REFER to the Owner's Literature
Snow-Wet for Line Lock feature operation. FOLLOW all
Vehicle speed instructions in the Owner's Literature and in the
exceeded 40-48 km/h message center.
(25-30 mph) after the The OK button must be pressed once the brake
feature was initialized pressure meter in the message center to engage
Diagnostic Trouble the Line Lock feature. REFER to the Owner's
Codes (DTCs) present Literature for Line Lock feature operation.
in the ABS module FOLLOW all instructions in the Owner's Literature
and in the message center.
The Line Lock feature cannot be used with
Snow-Wet drive mode selected. SELECT Track
drive mode and ATTEMPT to engage the Line
Lock feature.
The vehicle cannot be moving when selecting the
Line Lock feature. STOP the vehicle and
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ATTEMPT to engage the Line Lock feature.
Pinpoint Tests
U3003:16, U300A:29
The ABS module, hydraulic pump and solenoid valves require an operating voltage between 10 and 17 volts. The
parking brake system requires an operating voltage of 9 volts or higher. The ABS module receives this voltage
from the BJB. The ABS module uses a single ground circuit. The ABS module sets this DTC if there is excessive
resistance or an open in one or more of these circuits, a discharged battery or an inoperative charging system.

U3003:16 Battery Voltage: Circuit This DTC sets in continuous memory and on-demand if the voltage supplied
Voltage Below to the ABS module falls below 10 volts.
Threshold
U300A:29 Ignition Switch: Signal This DTC sets in continuous memory and on-demand if the ABS module
Invalid receives the power mode or ignition status message from the PCM and
BCM, but does not receive the hard-wired ignition switch input.
Possible Causes
Fuses
ABS module
Make sure BJB fuses 5 (50A), 28 (30A) and 62 (5A) are OK.
PINPOINT TEST A : U3003:16, U300A:29

probe adapter(s) may cause damage to the connector
A1 RECHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Using a diagnostic scan tool, clear the ABS module Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Is DTC U3003:16 or U300A:29 still present?
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Yes GO to A2
No The system is operating correctly at this time. The DTC may have set due to a previous
low battery voltage condition.
A2 CHECK FOR CHARGING SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) IN THE

POWERTRAIN CONTROL MODULE (PCM)

No GO to A3
A3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE

Yes If the battery passed the condition test but required a recharge, DIAGNOSE the charging
system.
If the battery passed the condition test and did not require a recharge, GO to A4
A4 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE VOLTAGE (VPWR_ABS) PID
Ignition ON.
Using a diagnostic scan tool, monitor the VPWR_ABS PID.
Is the PID display within 0.2 volt of the recorded battery voltage?
Yes GO to A7
No GO to A5
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A5 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE VOLTAGE SUPPLY
Ignition OFF.
Disconnect ABS module C135.
Ignition ON.
Measure:

C135-1 Ground
C135-30 Ground
C135-35 Ground
Is each voltage within 0.2 volt of the recorded battery voltage?
Yes GO to A6
No DISCONNECT and INSPECT C126 for corrosion, pushed-out pins, bent pins and spread
If C126 is OK, VERIFY BJB fuses 5 (50A), 28 (30A) and 62 (5A) are OK.
If OK, REPAIR the affected circuit for high resistance or an open.
A6 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect the battery negative cable.
REFER to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
Measure:

C135-14 Ground
Yes GO to A7
A7 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect ABS module C135 and related in-line connectors (if not previously disconnected).
Disconnect C126.
Using a good light source, inspect ABS module C135, C126 and related in-line connectors for the
following:
corrosion - install a new connector or terminal and clean module pins
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terminals?
Yes GO to A8
A8 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION

Connect ABS module C135 and related in-line connectors. Make sure they seat and latch correctly.
Connect C126. Make sure it seats and latches correctly.
Connect the battery negative cable.
Wheel Speed Sensor Erratic Signal Faults
The wheel speed sensor and encoder (tone wheel) generate a square wave signal proportional to wheel speed
and sends this information to the ABS module. The wheel bearing, encoder and wheel speed sensor must be
undamaged and free from contamination to produce a clean signal for use by the ABS module. Also, all 4 tires
and wheels must be of the same manufacturer recommended size for the wheel speed sensor to generate an
accurate wheel speed.

C0030:07, Tone Wheel: These Diagnostic Trouble Codes (DTCs) set in continuous memory and
C0033:07, Mechanical on-demand if there is damage to the wheel speed sensor encoder, damage
C0036:07, Failure to the wheel bearing, or contamination or deformation of the wheel bearing
C0039:07 seal.
C0031:07, Wheel Speed These Diagnostic Trouble Codes (DTCs) set in continuous memory and
C0034:07, Sensor: on-demand if the wheel speed sensor, encoder or wheel bearing is
C0037:07, Mechanical damaged, or if the wheel bearing is not installed correctly. These Diagnostic
C003A:07 Failure Trouble Codes (DTCs) also set if an incorrectly sized tire is installed on the
vehicle or if an excessive air gap exists between the wheel speed sensor
and the encoder due to an incorrect component being installed.
C0034:29, Sensor: Signal on-demand if the wheel speed sensor is damaged, if the encoder is missing
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C0037:29, Invalid or damaged, if there is an excessive gap between the sensor and encoder, if
C003A:29 the wrong sensor is installed (bi-directional versus uni-directional) or if the
tire size is incorrect for the vehicle.
C0031:2F, Wheel Speed These Diagnostic Trouble Codes (DTCs) set in continuous memory and
C0034:2F, Sensor: Signal on-demand if the wheel speed sensor is damaged, if the encoder is missing
C0037:2F, Erratic or damaged, if there is an excessive gap between the sensor and encoder
C003A:2F or high frequency interference.
C0034:64, Sensor: Signal on-demand if the wheel speed sensor is damaged, if the encoder is missing
C0037:64, Plausibility or damaged, if there is an excessive gap between the sensor and encoder, if
C003A:64 Failure the wrong sensor is installed (bi-directional versus uni-directional) or if the
tire size is incorrect for the vehicle.
Possible Causes

Tire size
Tire pressure
Wheel speed sensor
Wheel speed sensor encoder
Wheel bearing
ABS module
PINPOINT TEST B : WHEEL SPEED SENSOR ERRATIC SIGNAL FAULTS

B1 CHECK FOR ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Retrieve and record all ABS module Diagnostic Trouble Codes (DTCs).
Is DTC C003x:29 or C003x:64 present?

Yes GO to B2
No If DTC C0031:07, C0034:07, C0037:07 or C0039:0A is present, GO to B3
If DTC C0031:2F, C0034:2F, C0037:2F or C0039:2F is present, GO to B3
If DTC C0030:07, C0033:07, C0036:07 or C0039:07 is present, GO to B6
For all other ABS module Diagnostic Trouble Codes (DTCs), GO to the DTC Chart: ABS
Module.
B2 CHECK THE TIRE SIZE AND PRESSURE

Ignition OFF.
Verify all the tires and wheels are the same size and the tire size and inflation pressures are correct as
indicated on the VC label.
Are the tires and wheels OK?
Yes GO to B3
No INSTALL the correct size tire or wheel or ADJUST tire pressure as necessary.
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B3 CHECK THE WHEEL SPEED SENSOR MOUNTING
With the transmission in NEUTRAL, position the vehicle on a hoist.
Inspect the wheel speed sensor for correct installation and the fastener for looseness.
Is the wheel speed sensor installed correctly and the fastener tightened to specifications?
Yes GO to B5
No REINSTALL the wheel speed sensor and tighten the fastener to specifications.
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Brake System (ABS) and
Stability Control, Removal and Installation).
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Brake System (ABS) and
GO to B4
B4 CHECK THE WHEEL SPEED SENSOR PARAMETER IDENTIFICATIONS (PIDS)

Ignition ON.
Using a diagnostic scan tool, access the ABS module Parameter Identifications (PIDs).
Drive the vehicle at a speed greater than 20 km/h (12 mph) while monitoring the following Parameter
Identifications (PIDs):
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 Parameter Identifications (PIDs) within 5 km/h (3 mph) of each other and the
vehicle speed as indicated on the speedometer?
loose or incorrectly installed wheel speed sensor.
No GO to B5
B5 CHECK THE WHEEL SPEED SENSOR FOR DAMAGE
Ignition OFF.
Disconnect the suspect wheel speed sensor electrical connector.
Inspect the wheel speed sensor and harness for abrasions, broken connector tabs or water intrusion.
Is the wheel speed sensor and harness OK?
Yes GO to B6
No INSTALL a new wheel speed sensor.
B6 CHECK WHEEL SPEED SENSOR ENCODER FOR DAMAGE

Remove the suspect wheel speed sensor.
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Brake System (ABS) and Stability Control,
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REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Brake System (ABS) and Stability Control,
Inspect the wheel speed sensor encoder for abnormal wear, deformation or contamination.
Is the wheel speed sensor encoder OK?
Yes GO to B7
No INSTALL a new wheel hub as necessary.
REFER to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and
Installation).
REFER to: Wheel Bearing and Wheel Hub (204-02 Rear Suspension, Removal and
Installation).
B7 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT
NOTE: Make sure all test connections are made at the wheel speed sensor before the ignition is set to
ON.
NOTE: Use a meter with a min-max feature or recording capabilities to obtain accurate measurements.
The ABS module disables the voltage output immediately if the wheel speed sensor is not present.
Connect the meter to the suspect wheel speed sensor electrical connector, harness side.
Set the meter to measure DC voltage.
Set the meter range to greater than 15 volts.
Enable the min-max or recording feature on the meter.
Ignition ON.
For the LH front wheel speed sensor, measure:

C150-1 C150-2
For the RH front wheel speed sensor, measure:

C160-1 C160-2
For the LH rear wheel speed sensor, measure:

C440-1 C440-2
For the RH rear wheel speed sensor, measure:

C426-1 C426-2
Check the maximum recorded voltage on the meter.
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Yes INSTALL a new wheel speed sensor.

No GO to B8
B8 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Using a good light source, inspect ABS module C135 for the following:
Yes GO to B9
No
B9 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION

Connect ABS module C135. Make sure it seats and latches correctly.
Connect the suspect wheel speed sensor. Make sure it seats and latches correctly.
C0040:64
The ABS module receives BPP switch (stoplamp switch) input from the PCM through the GWM over the
HS-CAN2. The ABS module compares this information against the internal pressure sensor in the HCU. An
incorrectly installed BPP switch can cause a signal plausibility concern. An implausible signal can also be created
if the driver is resting one foot on the brake pedal while using the other foot to press the accelerator.
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C0040:64 Brake Pedal Switch "A": This DTC sets in continuous memory if the master cylinder pressure
Signal Plausibility Failure signal exceeds 15 bar and the BPP switch message from the PCM is
inactive for longer than 1 second.
Possible Causes
Wiring, terminals or connectors.

BPP switch
PCM
Make sure the brake pedal switch electrical connector is connected and free of corrosion and other
contaminants.
Make sure the brake pedal switch is installed correctly.
Make sure the brake pedal switch is operating correctly.
PINPOINT TEST C : C0040:64

C1 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Is DTC U0100:00, U0401:00 present?
Yes DIAGNOSE DTC U0100:00 or U0401:00 before diagnosing DTC C0040:64. GO to the
DTC Chart: ABS Module.
No GO to C2
C2 CHECK THE STOPLAMP SWITCH AND BRAKE PEDAL ASSEMBLY INSTALLATION
Inspect the stoplamp switch and brake pedal assembly, verify there is no brake pedal pressure
unintentionally applied due to incorrect stoplamp switch or brake pedal installation.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
REFER to: Brake Pedal and Bracket - 6-Speed Manual Transmission - 3160/6-Speed Manual
Transmission - MT82 (206-06 Hydraulic Brake Actuation, Removal and Installation).
REFER to: Brake Pedal and Bracket - 6-Speed Automatic Transmission - 6R80 (206-06 Hydraulic Brake
Are the stoplamp switch and brake pedal assembly installed correctly?
Yes GO to C3
No REINSTALL the stoplamp switch or brake pedal assembly.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
REFER to: Brake Pedal and Bracket - 6-Speed Manual Transmission - 3160/6-Speed
Manual Transmission - MT82 (206-06 Hydraulic Brake Actuation, Removal and
Installation).
REFER to: Brake Pedal and Bracket - 6-Speed Automatic Transmission - 6R80 (206-06
Hydraulic Brake Actuation, Removal and Installation).
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C3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) BPP (BRAKE PEDAL POSITION) (BOO1)
Ignition ON.
Using a diagnostic scan tool, monitor the PCM BOO1 PID while pressing and releasing the brake pedal.
Does the PID reflect the brake pedal movement?
Yes GO to C4
No DIAGNOSE the BPP switch.
C4 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE BRAKE ON / OFF (BOO_ABS) PID
Using a diagnostic scan tool, monitor the ABS module BOO_ABS PID while pressing and releasing the
brake pedal.
Does the PID reflect the brake pedal movement?
No GO to C5
C5 CHECK THE PCM (POWERTRAIN CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES
(DTCS)
Retrieve and record all PCM Diagnostic Trouble Codes (DTCs).
Are any PCM Diagnostic Trouble Codes (DTCs) present?
Yes GO to the DTC Chart: PCM.

No GO to C6
C6 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE TO HCU (HYDRAULIC
CONTROL UNIT) FASTENER TORQUE VALUES
Verify all ABS module-to- HCU fasteners are tightened to their correct torque specifications.
Are the ABS module-to- HCU fasteners tightened correctly
Yes GO to C8
No TIGHTEN all ABS module-to- HCU fasteners to their specified torque value. GO to C7
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C7 CHECK FOR RETURNING ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE
CODES (DTCS)
Ignition OFF.
Ignition ON.
Is DTC C0040:64 present?
Yes GO to C8
No The condition that caused the concern has been repaired. RETURN the vehicle to the
customer.
C8 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
terminals?
Yes GO to C9
C9 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION

U0140:00, U0422:00
With the ignition ON, the BCM sends messages to the ABS module through the GWM over the HS-CAN1. If the
ABS module does not receive these messages within a certain time frame, the module sets Diagnostic Trouble
Codes (DTCs). For information on the messages sent to the ABS module by the BCM, refer to the Network
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Message Chart.
REFER to: Anti-Lock Brake System (ABS) and Stability Control - System Operation and Component Description
(206-09 Anti-Lock Brake System (ABS) and Stability Control, Description and Operation).

U0140:00 Lost Communication With This DTC sets in continuous memory and on-demand when any of the
Body Control Module: No messages from the BCM are missing. This can be due to a GWM
Sub Type Information failure, BCM failure, a circuit failure or excessive load on the HS-CAN1
or HS-CAN2.
U0422:00 Invalid Data Received From This DTC sets in continuous memory and on-demand if the ABS module
Body Control Module: No receives "fault" or "unknown" in any one of the following BCM messages
Sub Type Information instead of valid message data; battery low state of charge, door ajar
status, ignition key type, ignition status, park brake status or vehicle
configuration data.
Possible Causes

GWM
BCM
PINPOINT TEST D : U0140:00, U0422:00

D1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Do both the BCM and the GWM pass the Network Test?
Yes GO to D2
No DIAGNOSE the no communication with the BCM or GWM.
and Testing).
D2 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE CONTINUOUS MEMORY

Ignition OFF.
Ignition ON.
Repeat the ABS module self-test.
Is DTC U0140:00 or U0422:00 retrieved again?
Yes GO to D3
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D3 REVIEW THE RECORDED ABS (ANTI-LOCK BRAKE SYSTEM) MODULE SELF-TEST
Check the recorded Diagnostic Trouble Codes (DTCs) from the ABS module self-test.
Was DTC U3003:16 or U3003:17 recorded in the ABS module?
Yes For DTC U3003:16, GO to Pinpoint Test A

For DTC U3003:17, GO to Pinpoint Test F
No GO to D4
D4 RETRIEVE ALL DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE GWM (GATEWAY MODULE
A)

No GO to D5
D5 RETRIEVE ALL DIAGNOSTIC TROUBLE CODES (DTCS) FROM THE BCM (BODY CONTROL
MODULE)
Yes DIAGNOSE the BCM Diagnostic Trouble Codes (DTCs).

No GO to D6
D6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0140:XX OR U0422:XX SET IN OTHER
MODULES
Is DTC U0140:xx or U0422:xx set in 1 or more modules in addition to the ABS module?

this concern, DISCONTINUE this test and FOLLOW the TSB instructions.
If no Technical Service Bulletins (TSBs) address this concern and DTC U0140:00 was set
by the ABS module, INSTALL a new ABS module.
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REFER to: Anti-Lock Brake System (ABS) Module (206-09 Anti-Lock Brake System (ABS)
and Stability Control, Removal and Installation).
The Traction Control System Cannot Be Disabled
NOTE: This test requires the use of at least 2 keys programmed to the vehicle, one admin key and one
restricted key.
The stability-traction control disabled indicator (sliding car OFF icon) in the IPC provides traction control system
status to the driver. When the driver deactivates the traction control, the IPC sends a message to the GWM over
the HS-CAN3 indicating the driver has requested the traction control to be disabled. The GWM relays this
message to the ABS module over the HS-CAN2. The ABS module continues to monitor for excessive wheel spin,
but no longer takes any action when a traction event is detected.
The ABS module then sends a message to the GWM over the HS-CAN2 to illuminate the stability-traction control
disabled indicator (sliding car OFF icon). The GWM relays this message to the IPC over the HS-CAN3. The IPC
responds by illuminating the stability-traction control disabled indicator (sliding car OFF icon). The traction control
system remains deactivated until the driver changes the traction control state in the message center or until the
ignition is cycled.
If equipped, MyKey® allows users to configure traction control to be either always on or selectable. If a MyKey®
restricted key is in use with the AdvanceTrac® always on feature configured to "on", the traction control system
cannot be disabled. An admin key must be used to enable and disable the traction control system.
Possible Causes
MyKey® restricted key in use

IPC concern
GWM concern
Message center concern
PINPOINT TEST E : THE TRACTION CONTROL SYSTEM CANNOT BE DISABLED
E1 VERIFY THE KEY IN USE IS NOT RESTRICTED
Place 1 key inside the vehicle and all other keys at least 1 meter (3 feet) away from the vehicle.
Turn the ignition to the ON mode.
Monitor the message center.
Does the message center display MYKEY ACTIVE DRIVE SAFELY?
Yes The current key is a restricted key and is functioning correctly.

REPEAT the test using different keys until the message center does not display MYKEY
ACTIVE DRIVE SAFELY. GO to E2
No GO to E2
E2 VERIFY THE MYKEY® TRACTION CONTROL SETTING IN THE MYKEY® MENU

Using the message center, verify the MyKey® traction control setting. Refer to the Owner's Literature for
information on setting the MyKey® functions.
Is the MyKey® traction control setting configured to "always on"?
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Yes GO to E3
No GO to E4
E3 VERIFY THE TRACTION CONTROL FUNCTION CAN BE DISABLED USING THE ADMIN KEY IN
THE DRIVER ASSIST MENU
Using the message center, verify the traction control function can be enabled and disabled using the
admin key. Refer to the Owner's Literature for information on enabling and disabling the traction control
function.
Can the traction control function can be enabled and disabled using the admin key?
Yes The system is operating correctly at this time. The concern was most likely caused by the
use of a restricted key.
INFORM the customer the traction control function can only be disabled using an admin
key when the MyKey® traction control setting is configured to "always on".
No GO to E4
E4 CHECK FOR ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Using a diagnostic scan tool, carry out the ABS self-test.
Retrieve and record all ABS Diagnostic Trouble Codes (DTCs).
Are there any ABS Diagnostic Trouble Codes (DTCs) present?
Yes GO to the DTC Chart: Anti-Lock Brake System (ABS) Module.

No GO to E5
E5 CHECK FOR GWM (GATEWAY MODULE A) DIAGNOSTIC TROUBLE CODES (DTCS)

Retrieve and record all GWM Diagnostic Trouble Codes (DTCs).
Yes GO to the DTC Chart: GWM.

No GO to E6
E6 CHECK FOR IPC (INSTRUMENT PANEL CLUSTER) DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, carry out the IPC self-test.
Retrieve and record all IPC Diagnostic Trouble Codes (DTCs).
Are there any IPC Diagnostic Trouble Codes (DTCs) present?
Yes GO to the DTC Chart: Instrument Panel Cluster (IPC)

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No The system is operating correctly at this time. The concern may have been caused due to
high network traffic or an intermittent fault condition.
U3003:17
The ABS module, hydraulic pump and solenoid valves require an operating voltage between 10 and 17 volts. The
ABS module receives this voltage from the BJB and has a single ground circuit. An overcharging condition in the
charging system results in the ABS module setting a DTC. This DTC may also set in the ABS module due to
battery charging or vehicle jump starting events.

U3003:17 Battery Voltage: Circuit Voltage This DTC sets in continuous memory and on-demand if the voltage
Above Threshold supplied to the ABS module is above 17 volts.
Possible Causes

ABS module

F1 CHECK FOR HIGH VOLTAGE DIAGNOSTIC TROUBLE CODES (DTCS) SET IN OTHER MODULES
Ignition ON.
Using a diagnostic scan tool, retrieve and record all Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
Yes DIAGNOSE the overcharging condition.

No GO to F2
F2 CHECK THE BATTERY VOLTAGE

Turn off all interior lights, exterior lights and accessories.
Start and run the engine at approximately 1,500 RPM for 3 minutes while monitoring the battery voltage.
Is the battery voltage between 13 and 15.2 volts ?
Yes GO to F3
No DIAGNOSE the overcharging condition.
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F3 RECHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U3003:17

Turn the engine off.
Ignition ON.
Clear the ABS module Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Repeat the ABS module self-test.
Yes GO to F4
No The system is operating normally at this time. The DTC may have been set previously
during battery charging or while jump starting the vehicle.
F4 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect and inspect ABS module C135 (if not previously disconnected).
terminals?
Yes GO to F5
F5 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION

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Stability Control Sensor Signal Faults
The ABS module receives vehicle yaw rate, lateral acceleration, longitudinal acceleration and roll rate from RCM
over the HS-CAN2. The yaw rate sensor, lateral accelerometer and longitudinal accelerometer are contained in
the RCM. A failure of the HS-CAN2, an incorrectly installed RCM, an internal failure of the RCM or the internal
sensors causes the ABS to set one or more Diagnostic Trouble Codes (DTCs).

C0061:28, Lateral Acceleration Sensor, Longitudinal These Diagnostic Trouble Codes (DTCs) set in
C0062:28, Acceleration Sensor, Yaw Rate Sensor, Roll continuous memory and on-demand if the
C0063:28, Rate Sensor: Signal Bias Level Out of sensor signal is greater than the programmed
C0064:28 Range / Zero Adjustment Failure maximum plausible sensor signal.
C0061:2F, Lateral Acceleration Sensor, Yaw Rate These Diagnostic Trouble Codes (DTCs) set in
C0063:2F Sensor: Signal Erratic continuous memory and on-demand if the
lateral acceleration sensor signal is out of
range when the vehicle is standing still.
C0061:64, Lateral Acceleration Sensor, Longitudinal These Diagnostic Trouble Codes (DTCs) set in
C0062:64, Acceleration Sensor, Yaw Rate Sensor, Roll continuous memory and on-demand if the
C0063:64, Rate Sensor: Signal Plausibility Failure sensor signal does not match the other stability
C0064:64 sensor signals.
Possible Causes
Underinflated tires
Incorrect or mismatched tires
Incorrect or incomplete ABS module IVD Initialization
Incorrectly installed RCM
RCM
PINPOINT TEST G : STABILITY CONTROL SENSOR SIGNAL FAULTS

G1 CHECK FOR RETURNING ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE
CODES (DTCS)
Ignition ON.
Ignition OFF.
Ignition ON.
Test drive the vehicle above 12 km/h (7 mph) and make at least 1 left turn and 1 right turn.
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Yes If any of the Diagnostic Trouble Codes (DTCs) listed in the DTC Fault Trigger Conditions
table are present, GO to G2
Module.
No The fault is not present and cannot be recreated at this time. CHECK OASIS for any
applicable Technical Service Bulletins (TSBs). If a TSB exists for this concern,
DISCONTINUE this test and FOLLOW the TSB instructions. If no Technical Service
Bulletins (TSBs) address this concern, INSPECT all in-line connectors and the wire
harness between the RCM and the ABS module for corrosion, loose terminals, spread
terminals, loose wire connections, frayed wire connections, pinched wire harnesses and
cut or pierced wire harnesses. REPAIR as necessary.
G2 CHECK THE WHEELS AND TIRES

Inspect the wheels and tires for any damage or excessive wear.
Verify all wheels and tires are the same size and match the size indicated on the VC label.
Verify the inflation pressure of all 4 tires is correct as indicated on the VC label.
Are the wheels and tires OK?
Yes GO to G3
No INSTALL the correct size wheel or tire as necessary. ADJUST tire pressure as necessary.

Ignition ON.
Yes GO to G4
No DIAGNOSE the RCM does not communicate with the diagnostic scan tool.
and Testing).
G4 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE CONTINUOUS MEMORY
Ignition OFF.
Ignition ON.
Yes If any of the Diagnostic Trouble Codes (DTCs) listed in the DTC Fault Trigger Conditions
Module.
No GO to G6
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G5 CHECK THE RCM (RESTRAINTS CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Are there any Diagnostic Trouble Codes (DTCs) present in the RCM?
Yes DIAGNOSE all RCM Diagnostic Trouble Codes (DTCs).

No GO to G6
G6 VERIFY STABILITY CONTROL SENSOR CALIBRATION
NOTE: The vehicle must be on level ground and at a complete standstill during IVD initialization. Any
vehicle movement results in false values for this test.
Using the diagnostic scan tool, carry out the IVD Initialization routine. Follow the diagnostic scan tool
directions.
Ignition OFF.
Ignition ON.
Is the Advance Trac® warning indicator illuminated?
Yes Using a diagnostic scan tool, CARRY OUT the ABS module self-test.
If any of the Diagnostic Trouble Codes (DTCs) listed in the DTC Fault Trigger Conditions
Module.
No The condition which caused the concern is no longer present. The concern was most likely
due to an incomplete calibration or a failed calibration of the stability control sensors.
G7 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE PID (PARAMETER IDENTIFICATION)
VALUES
NOTE: The vehicle must be on level ground and at a complete standstill during this step. Any vehicle
movement results in false values for this test.
Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, monitor the following ABS module Parameter Identifications (PIDs):
Yaw rate (YAW_RATE)
Lateral accelerometer (LAT_ACCL)
Longitudinal accelerometer (LONG_ACCL)
Roll rate (ROLL_RATE)
Is the YAW_RATE PID value between -0.05 and 0.05, the LAT_ACCL PID value between -0.4 and 0.4,
the LONG_ACCL PID value between -0.4 and 0.4, and the ROLL_RATE PID value between -0.05 and
0.05?
Yes GO to G9
No GO to G8
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G8 CHECK THE RCM (RESTRAINTS CONTROL MODULE) INSTALLATION AND MOUNTING
SURFACE
Ignition OFF.
Wait one minute then disconnect RCM C310A and C310B.
Inspect the RCM installation and make sure the fasteners are fully seated and tightened to specifications.
Installation).
Inspect the RCM mounting surface for damage, corrosion or dirt.
Is the RCM installed correctly and is the mounting surface clean and free from damage?
Yes GO to G9
No CLEAN or REPAIR the mounting surface or correctly REINSTALL the RCM as necessary.
G9 CHECK FOR CORRECT RCM (RESTRAINTS CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect ABS module C135 and related in-line electrical connectors.
Inspect the ABS module, RCM and related in-line electrical connectors for:
corrosion
loose or spread terminals
loose or frayed wire connections at terminals
pushed-out or bent pins
damage, pinched, cut or pierced wires
Repair any electrical connector concerns found,
Ignition OFF.
Wait one minute then connect RCM C310A and C310B. Make sure the connectors seat and latch
correctly.
Connect ABS module C135 and related in-line electrical connectors. Make sure the connectors seat and
latch correctly.
Is the Advance Trac® warning indicator illuminated?
Service Bulletins (TSBs) address this concern, DIAGNOSE the RCM concern.
ABS Pump Motor Faults
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The ABS module uses an internal solid state switch to operate the hydraulic pump motor. The ABS module tests
the hydraulic pump motor by activating it for 30 milliseconds. The ABS module monitors the voltage drop across
the hydraulic pump motor while the pump motor is being activated. After 30 milliseconds have passed, the ABS
module stops applying voltage to the pump motor and monitors the voltage the spinning hydraulic pump motor is
generating and the voltage drop across the hydraulic pump motor solid state switch. If the monitored voltages are
not within the specifications, the ABS module sets one or more Diagnostic Trouble Codes (DTCs).

C0020:11 ABS Pump Motor This DTC sets in continuous memory and on-demand if the voltage drop across
Control: Circuit Short the solid state switch is too high when the pump motor is activated. This can
To Ground be due to a shorted switch, a shorted motor or a locked motor.
C0020:12 ABS Pump Motor This DTC sets in continuous memory and on-demand if the pump motor supply
Control: Circuit Short voltage is greater than 0.93 volt for longer than 3 seconds when the pump
To Battery motor is deactivated.
C0020:13 ABS Pump Motor This DTC sets in continuous memory and on-demand if the pump motor supply
Control: Circuit Open voltage is less than 6 volts for longer than 2 seconds when the pump motor is
deactivated. This DTC also sets if the pump motor supply voltage is less than
7.3 volts for more than 2 seconds when the pump motor is activated.
C0020:71 ABS Pump Motor If insufficient voltage is generated by the pump motor immediately following a
Control: Actuator pump motor deactivation, a second pump motor test is carried out. If
Stuck insufficient voltage is again generated by the pump motor, this DTC sets.
Possible Causes
Fuse
HCU
ABS module

Make sure BJB fuse 5 (50A) and the fuse socket are OK.
PINPOINT TEST H : ABS (ANTI-LOCK BRAKE SYSTEM) PUMP MOTOR FAULTS

H1 VERIFY ALL WIRING CONNECTIONS
Ignition OFF.
Using a good light source, inspect each connector terminal for any corrosion.
Inspect the connector for any pushed-out terminals.
Using a suitable mating terminal, check each connector terminal for deformed or enlarged contacts by
comparing the mating terminal's fit between each of the following pins:
C135-1
C135-14
Is the connector free of terminal corrosion, pushed-out terminals and spread terminals?
Yes GO to H2
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No REPAIR the affected terminal.
H2 CHECK PUMP MOTOR OPERATION

Connect ABS module C135.
Ignition ON.
Using a diagnostic scan tool, activate the ABS pump motor (PMP_MTR) active command.
Listen for the ABS pump motor noise.
Does the ABS pump motor run for approximately 2 seconds?
Yes GO to H3
No GO to H4
H3 CHECK FOR FAULT REPEATABILITY

Ignition OFF.
Ignition ON.
Test drive the vehicle at speeds greater than 20 km/h (12 mph) and carry out at least 1 ABS stop.
Ignition OFF.
Ignition ON.
Are any ABS module Diagnostic Trouble Codes (DTCs) retrieved?
Yes For DTC C0020:11, C0020:12, C0020:13 and C0020:71, GO to H4

Module.
No The concern that caused the DTC is not present at this time.
DISCONNECT and INSPECT ABS module C135. CLEAR or REPAIR the connector as
necessary. ADDRESS the root cause of any connector or pin issues.
H4 CHECK THE PUMP MOTOR VOLTAGE SUPPLY TO THE ABS (ANTI-LOCK BRAKE SYSTEM)
MODULE
Ignition OFF.
Measure:

C135-1 Ground
Yes GO to H5
No VERIFY BJB fuse 5 (50A) is OK. If OK, REPAIR the circuit.
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H5 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Disconnect the battery negative cable.
Measure:

C135-14 Ground
Yes GO to H6
H6 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
Disconnect ABS module C135 (if not previously disconnected).
terminals?
Yes GO to H7
H7 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION
Connect the battery negative cable.
Service Bulletins (TSBs) address this concern, INSTALL a new ABS module and HCU
assembly.
REFER to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake System (ABS) and
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U0100:00, U0401:00
With the ignition ON, the PCM sends messages to the ABS module through the GWM over the HS-CAN1. If the
ABS module does not receive these messages within a certain time frame, the ABS module sets Diagnostic
Trouble Codes (DTCs). For information on the messages sent to the ABS module by the PCM, refer to the
Network Message Chart.

U0100:00 Lost Communication This DTC sets in continuous memory and on-demand when any of the
With ECM / PCM "A": messages from the PCM are missing. This can be due to a GWM failure,
No Sub Type PCM failure, a circuit failure or excessive load on the HS-CAN1 or HS-CAN2.
Information
U0401:00 Invalid Data Received This DTC sets in continuous memory and on-demand if the ABS module
From ECM / PCM "A": receives "fault" or "unknown" messages from the PCM instead of valid
No Sub Type accelerator pedal position, ambient air temperature, cruise control system
Information status, brake pedal applied, clutch pedal position, engine RPM, engine
torque output, gear lever position, launch control system status, power pack
status, reverse gear selected or transmission in reverse messages.
Possible Causes

GWM
PCM
PINPOINT TEST I : U0100:00, U0401:00
Ignition ON.
Do both the PCM and the GWM pass the Network Test?
Yes GO to I2
No DIAGNOSE the no communication with the PCM or GWM.
and Testing).
I2 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE CONTINUOUS MEMORY DIAGNOSTIC
Ignition OFF.
Ignition ON.
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Record the ABS module Diagnostic Trouble Codes (DTCs).
Is DTC U0100:00 or U0401:00 retrieved again?
Yes GO to I3
I3 REVIEW THE RECORDED ABS (ANTI-LOCK BRAKE SYSTEM) MODULE SELF-TEST

Check the recorded Diagnostic Trouble Codes (DTCs) from the ABS self-test.
Was DTC U3003:16 or U3003:17 recorded?

No GO to I4
I4 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) IN THE GWM (GATEWAY MODULE A)

No GO to I5
I5 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) IN THE PCM (POWERTRAIN CONTROL
MODULE)
Is DTC P0562 or P0563 present?
Yes DIAGNOSE the PCM Diagnostic Trouble Codes (DTCs).

No GO to I6
I6 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0100:XX OR U0401:XX SET IN OTHER
MODULES
Retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Is DTC U0100:xx OR U0401:xx set in 1 or more modules in addition to the ABS module?
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Steering Wheel Position Sensor Signal Faults
The PSCM monitors steering wheel rotation speed, angle and direction of rotation and sends the information to
the ABS module over the HS-CAN2. A failure of the HS-CAN2, PSCM or the internal sensors causes the ABS to
set one or more Diagnostic Trouble Codes (DTCs).

C0051:62 Steering Wheel This DTC sets in continuous memory and on-demand if the difference
Position Sensor: Signal between the steering wheel angle signal and the calculated reference signal
Compare Failure is too high.
C0051:64 Steering Wheel This DTC sets in continuous memory and on-demand if the difference
Position Sensor: Signal between the steering wheel angle signal and the calculated reference signal
Plausibility Failure is too high or if the steering wheel angle sensor does not match other
stability control sensor inputs (yaw rate, lateral acceleration, longitudinal
acceleration, roll rate).
C0051:67 Steering Wheel This DTC sets in continuous memory and on-demand if the center position of
Position Sensor: Signal the steering wheel cannot be determined after 30 seconds of driving at a
Incorrect After Event speed between 12 km/h (7 mph) and 50 km/h (31 mph).
C0051:85 Steering Wheel This DTC sets in continuous memory and on-demand if the absolute value of
Position Sensor: Signal the calculated steering wheel angle is greater than a predetermined
Above Allowable threshold.
Range
Possible Causes
Incorrectly mounted RCM

Incomplete or incorrect stability control sensor calibration
Wheels and tires
Front suspension components
Steering system components
PSCM
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PINPOINT TEST J : STEERING WHEEL POSITION SENSOR SIGNAL FAULTS
J1 CHECK THE WHEELS AND TIRES
Inspect the wheels and tires for any damage or excessive wear.
Verify all wheels and tires are the same size and match the size indicated on the VC label.
Verify the inflation pressure of all 4 tires is correct as indicated on the VC label.
Are the wheels and tires OK?
Yes GO to J2
No INSTALL the correct size wheel or tire as necessary.
ADJUST tire pressure as necessary.
J2 CHECK THE FRONT SUSPENSION AND STEERING COMPONENTS

Inspect the front suspension and steering components for any obvious signs of damage or missing
components.
Are the front suspension and steering components OK?
Yes GO to J3
No REPAIR or INSTALL new components as necessary.
J3 CHECK FOR PSCM (POWER STEERING CONTROL MODULE) DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition ON.
Using a diagnostic scan tool, carry out the PSCM self-test.
Are there any Diagnostic Trouble Codes (DTCs) present in the PSCM?
Yes DIAGNOSE all PSCM Diagnostic Trouble Codes (DTCs) before diagnosing any ABS
C0051:xx codes.
No GO to J4
J4 CHECK FOR ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Are any of the following Diagnostic Trouble Codes (DTCs) present in the ABS module; wheel speed
sensor, stability control sensor, lost communication with the PSCM or invalid data received from
the PSCM?
Yes DIAGNOSE those ABS module Diagnostic Trouble Codes (DTCs) before diagnosing any
C0051:xx codes, beginning with any lost communication or invalid data received from the
PSCM, followed by any stability control sensor (yaw rate, lateral acceleration and
longitudinal acceleration) Diagnostic Trouble Codes (DTCs) and finally any wheel speed
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sensor Diagnostic Trouble Codes (DTCs).
GO to the DTC Chart: ABS Module.
No GO to J5
J5 VERIFY STABILITY CONTROL SENSOR CALIBRATION

Using a diagnostic scan tool, carry out the IVD Initialization routine. Follow the diagnostic scan tool
directions.
Ignition OFF.
Ignition ON.
Are any C0051:xx Diagnostic Trouble Codes (DTCs) present?
Yes GO to J6
No The condition that caused the concern is no longer present. The concern was most likely
due to an incomplete calibration or a failed calibration of the stability control sensors.
J6 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE YAW RATE VALUE (YAW_RATE) PID
NOTE: The vehicle must be on level ground and at a complete standstill. Any vehicle movement results in
false values for this test.
Ignition ON.
Using a diagnostic scan tool, monitor the ABS module YAW_RATE PID.
Is the YAW_RATE PID value between -0.05 and 0.05?
Yes GO to J7
No GO to J9
J7 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE LATERAL ACCELERATION
(LAT_ACCL) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, monitor the ABS module LAT_ACCL PID.
Is the LAT_ACCL PID value between -0.4 and 0.4?
Yes GO to J8
No GO to J9
J8 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE LONGITUDINAL ACCELERATION

(LONG_ACCL) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, monitor the ABS module LONG_ACCL PID.
Is the LONG_ACCL PID value between -0.4 and 0.4?
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Yes GO to J10
No GO to J9
J9 CHECK THE RCM (RESTRAINTS CONTROL MODULE) INSTALLATION AND MOUNTING

SURFACE
Ignition OFF.
Inspect the RCM installation and make sure the fasteners are fully seated and tightened to specifications.
Installation).
Inspect the RCM mounting surface for damage, corrosion or dirt.
Is the RCM installed correctly and is the mounting surface clean and free from damage?
Yes GO to J10
No CLEAN or REPAIR the mounting surface or correctly REINSTALL the RCM as necessary.
J10 VERIFY ALL WIRING CONNECTIONS
NOTICE: The ignition must be set to OFF when disconnecting PSCM electrical connectors. Failure
to follow this direction may lead to Diagnostic Trouble Codes (DTCs) being set in the PSCM which
can not be cleared and result in the need to install a new EPAS gear.
Ignition OFF.
Disconnect PSCM C1463A and C1463B (if not previously disconnected).
terminals?
Yes GO to J11
J11 CHECK FOR CORRECT PSCM (POWER STEERING CONTROL MODULE) OPERATION
Connect PSCM C1463A and C1463B. Make sure they seat and latch correctly.
Connect RCM C310A and C310B (if previously disconnected). Make sure they seat and latch correctly.
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Service Bulletins (TSBs) address this concern, REFER to the EPAS symptom chart or
DTC chart. Click here to access Guided Routine (EPAS).

Wheel Speed Sensor Electrical Faults - Front
Active wheel speed sensors generate a square wave signal proportional to wheel speed which is sent to the ABS
module. Each wheel speed sensor is connected to the ABS module through 2 wires and a connector at each
wheel speed sensor. One wire is for sensor voltage supply from the ABS module and the other wire is for the
signal return to the ABS module. With the ignition ON, the ABS module carries out a self-test by sending a
reference voltage through the wheel speed sensors and their circuitry.

C0031:11 Left Front Wheel These Diagnostic Trouble Codes (DTCs) set in continuous memory and
Speed Sensor: on-demand if there is a short to ground in the sensor signal return circuit or if
Circuit Short to the sensor has an internal short to ground.
Ground
C0034:11 Right Front Wheel
Speed Sensor:
Circuit Short to
Ground
C0031:15 Left Front Wheel These Diagnostic Trouble Codes (DTCs) set in continuous memory and
Speed Sensor: on-demand if there is a short to battery voltage or an open in the sensor signal
Circuit Short to return circuit. A short to battery voltage may be due to the sensor signal return
Battery or Open circuit and the sensor voltage supply circuit shorted together. These Diagnostic
Trouble Codes (DTCs) also set if the sensor has an internal short to battery
C0034:15 Right Front Wheel
voltage or an open circuit.
Speed Sensor:
Circuit Short to
Battery or Open
Possible Causes

Wheel speed sensors
ABS module
Make sure the wheel speed sensor harness is routed correctly and is undamaged.
Make sure the wheel speed sensor electrical connector is free from any corrosion or other contaminants.
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PINPOINT TEST K : WHEEL SPEED SENSOR ELECTRICAL FAULTS - FRONT
K1 CHECK FOR FAULT REPEATABILITY
Ignition ON.
Using a diagnostic scan tool, clear all ABS module Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Test drive the vehicle above 20 km/h (12 mph) and carry out at least 1 ABS stop.
Bring the vehicle to a safe stop.
Is DTC C0031:11, C0031:15, C0034:11 or C0034:15 present?
Yes If the Rotunda Active Wheel Speed Sensor Tester is available, GO to K2

If the Rotunda Active Wheel Speed Sensor Tester is not available and DTC C0031:15 or
C0034:15 is present, GO to K5
C0034:11 is present, GO to K7
No The system is operating correctly at this time. INSPECT both front wheel speed sensor
electrical connectors and the ABS module electrical connector. REPAIR or CLEAN the
connector as necessary. ADDRESS the root cause of any connector or pin issues.
K2 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT USING THE ROTUNDA
ACTIVE WHEEL SPEED SENSOR TESTER
Ignition OFF.
Connect the Rotunda Active Wheel Speed Sensor Tester to the wheel speed sensor connectors.
Ignition ON.
Select the correct system polarity on the Rotunda Active Wheel Speed Sensor Tester and turn the power
switch to the ON position.
Is the tester output LED illuminated?

Yes GO to K3
No GO to K5
K3 CHECK THE WHEEL SPEED SENSOR FOR A SHORT TO VOLTAGE WITH THE ROTUNDA
Observe the current overload LED on the Rotunda Active Wheel Speed Sensor Tester.
Is the current overload LED illuminated?
Yes REPAIR the suspect wheel speed sensor circuit for a short to voltage.
No GO to K4
K4 CHECK THE WHEEL SPEED SENSOR OUTPUT WITH THE ROTUNDA ACTIVE WHEEL SPEED
SENSOR TESTER
Raise the suspect wheel until it can spin freely.
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While monitoring the Rotunda Active Wheel Speed Sensor Tester, slowly spin the suspect wheel.
Do the sensor output Light-emitting Diodes (LEDs) illuminate and flash?
Yes The system is operating correctly at this time. INSPECT all wheel speed sensor electrical
connectors and the ABS module electrical connectors. REPAIR or CLEAN the connector
as necessary. ADDRESS the root cause of any connector or pin issues.
K5 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT TO BATTERY VOLTAGE
Ignition OFF.
Ignition ON.

C135-9 Ground
C135-8 Ground

C135-5 Ground
C135-4 Ground

No GO to K6
K6 CHECK THE WHEEL SPEED CIRCUITS FOR AN OPEN

Ignition OFF.

C135-9 C150-1
C135-8 C150-2
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C135-5 C160-1
C135-4 C160-2
Yes GO to K7
K7 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS

Ignition OFF.
Disconnect the suspect wheel speed sensor electrical connector (if not previously disconnected).

C150-1 C150-2

C160-1 C160-2
Is the resistance greater 10,000 ohms?

Yes If DTC C0031:11 or C0034:11 is present, GO to K8
If DTC C0031:15 or C0034:15 is present, GO to K9
K8 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT TO GROUND


C135-9 Ground
C135-8 Ground

C135-5 Ground
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C135-4 Ground
Yes GO to K9
K9 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT
ON.
The ABS module immediately disables the voltage output if the wheel speed sensor is not present.
Ignition OFF.
Ignition ON.

C150-1 C150-2

C160-1 C160-2
Is the voltage greater 10 volts?

No GO to K10
K10 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
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terminals?
Yes GO to K11
K11 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION
Connect the suspect wheel speed sensor electrical connector. Make sure it seats and latches correctly.
Wheel Speed Sensor Electrical Faults - Rear
Active wheel speed sensors generate a square wave signal proportional to wheel speed which is sent to the ABS
module. Each wheel speed sensor is connected to the ABS module through 2 wires and a connector at each
wheel speed sensor. One wire is for sensor voltage supply from the ABS and the other wire is for the signal return
to the ABS. With the ignition ON, the ABS module carries out a self-test by sending a reference voltage through
the wheel speed sensors and their circuitry.

C0037:11 Left Rear Wheel These Diagnostic Trouble Codes (DTCs) set in continuous memory and
Speed Sensor: on-demand if there is a short to ground in the sensor signal return circuit or if
Circuit Short to the sensor has an internal short to ground.
Ground
C003A:11 Right Rear Wheel
Speed Sensor:
Circuit Short to
Ground
C0037:15 Left Rear Wheel These Diagnostic Trouble Codes (DTCs) set in continuous memory and
Speed Sensor: on-demand if there is a short to battery voltage or an open in the sensor signal
Circuit Short to return circuit. A short to battery voltage may be due to the sensor signal return
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Battery or Open circuit and the sensor voltage supply circuit shorted together. These Diagnostic
Trouble Codes (DTCs) also set if the sensor has an internal short to battery
C003A:15 Right Rear Wheel
voltage or an open circuit.
Speed Sensor:
Circuit Short to
Battery or Open
Possible Causes

Wheel speed sensors
ABS module
Make sure the wheel speed sensor harness is routed correctly and is undamaged.
Make sure the wheel speed sensor electrical connector is free from any corrosion or other contaminants.
PINPOINT TEST L : WHEEL SPEED SENSOR ELECTRICAL FAULTS - REAR

L1 CHECK FOR FAULT REPEATABILITY
Ignition ON.
Using a diagnostic scan tool, clear all ABS module Diagnostic Trouble Codes (DTCs).
Ignition OFF.
Ignition ON.
Test drive the vehicle above 20 km/h (12 mph) and carry out at least 1 ABS stop.
Bring the vehicle to a safe stop.
Is DTC C0037:11, C0037:15, C003A:11 or C003A:15 present?
Yes If the Rotunda Active Wheel Speed Sensor Tester is available, GO to L2

C003A:15 is present, GO to L5
C003A:11 is present, GO to L7
No The system is operating correctly at this time. INSPECT both rear wheel speed sensor
electrical connectors and the ABS module electrical connector. REPAIR or CLEAN the
connector as necessary. ADDRESS the root cause of any connector or pin issues.
L2 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT USING THE ROTUNDA
Ignition OFF.
Connect the Rotunda Active Wheel Speed Sensor Tester to the wheel speed sensor connectors.
Ignition ON.
Select the correct system polarity on the Rotunda Active Wheel Speed Sensor Tester and turn the power
switch to the ON position.
Is the tester output LED illuminated?
Yes GO to L3
No GO to L5
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L3 CHECK THE WHEEL SPEED SENSOR FOR A SHORT TO VOLTAGE WITH THE ROTUNDA
Observe the current overload LED on the Rotunda Active Wheel Speed Sensor Tester.
Is the current overload LED illuminated?
Yes REPAIR the suspect wheel speed sensor circuit for a short to voltage.
No GO to L4
L4 CHECK THE WHEEL SPEED SENSOR OUTPUT WITH THE ROTUNDA ACTIVE WHEEL SPEED
SENSOR TESTER
Raise the suspect wheel until it can spin freely.
While monitoring the Rotunda Active Wheel Speed Sensor Tester, slowly spin the suspect wheel.
Do the sensor output Light-emitting Diodes (LEDs) illuminate and flash?
Yes The system is operating correctly at this time. INSPECT all wheel speed sensor electrical
connectors and the ABS module electrical connectors. REPAIR or CLEAN the connector
as necessary. ADDRESS the root cause of any connector or pin issues.
L5 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT TO BATTERY VOLTAGE
Ignition OFF.
Ignition ON.
C135-6 Ground
C135-7 Ground

C135-10 Ground
C135-11 Ground

No GO to L6
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L6 CHECK THE WHEEL SPEED CIRCUITS FOR AN OPEN
Ignition OFF.

C135-6 C440-2
C135-7 C440-1

C135-10 C426-2
C135-11 C426-1
Yes GO to L7
L7 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS

Ignition OFF.
Disconnect ABS module C135 (if not previously disconnected)
Disconnect the suspect wheel speed sensor electrical connector (if not previously disconnected).
C440-1 C440-2

C426-1 C426-2
Is the resistance greater 10,000 ohms?
Yes If DTC C0037:11 or C003A:11 are present, GO to L8

If DTC C0037:15 or C003A:15 are present, GO to L9
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L8 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT TO GROUND

C135-6 Ground
C135-7 Ground

C135-10 Ground
C135-11 Ground
Yes GO to L9
L9 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT
ON.
The ABS module immediately disables the voltage output if the wheel speed sensor is not present.
Ignition OFF.
Ignition ON.

C440-1 C440-2

C426-1 C426-2
Is the voltage greater 10 volts?
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No GO to L10
L10 VERIFY ALL WIRING CONNECTIONS

Ignition OFF.
terminals?
Yes GO to L11
L11 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION
Connect the suspect wheel speed sensor electrical connector. Make sure it seats and latches correctly.
Brake Booster Vacuum Sensor Faults
The brake booster vacuum pressure sensor receives a sensor supply voltage of 5 volts from the ABS module.
The sensor is also grounded through the ABS module. The sensor uses the pressure differential between the
atmosphere and the brake booster vacuum chamber to produce a return voltage signal to the ABS module
between 0.2 volt and 4.9 volts. The ABS module uses other sensor inputs such as wheel speed, brake pedal and
stability sensors to determine if the vehicle is stopping and at what rate of deceleration. This information is
compared against the vacuum pressure sensor to determine the validity of the sensor signal and the working
condition of the sensor itself.
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C0047:01 Brake Booster This DTC sets when the signal returned by the sensor is above or below a
Pressure Sensor: predetermined limit. This is usually caused by a short to voltage, an open or an
General Electrical internal failure of the sensor.
Failure
C0047:26 Brake Booster This DTC sets when the rate of change in the signal transmitted by the vacuum
Pressure Sensor: sensor does not match a predetermined threshold depending on the brake
Signal Rate of system pressure, or if a characteristic oscillation in the vacuum signal is not
Change Below detected. A signal failure is reported when 3 valid braking cycles, within the
Threshold same ignition cycle, have met the above criteria. This is usually caused by a
failure in the sensor circuits, a vacuum leak in the brake booster, a mechanical
failure of the brake booster or an internal failure of the vacuum sensor.
C0047:27 Brake Booster This DTC sets when the rate of change in the signal transmitted by the vacuum
Pressure Sensor: sensor increases beyond a predetermined level when the brakes are not being
Signal Rate of applied. When this condition is detected, the ABS module starts a counter and
Change Above monitors the rate of change, if the rate of change increases beyond the limit 3
Threshold times during this time period, this DTC sets. This is usually caused by a failure
in the sensor circuits or an internal failure of the sensor.
C1015:08 Vacuum Supply: This DTC sets in continuous memory and on-demand if the ABS module does
Bus Signal / not receive any data from the vacuum sensor or the ABS module receives
Message Failure invalid data from the vacuum sensor.
C1B14:11 Sensor Supply The ABS module supplies 5 volts to the brake booster vacuum sensor. The
Voltage "A": Circuit ABS module monitors this output and sets this DTC when the module detects a
Short to Ground short to ground on the voltage supply circuit.
C1B14:12 Sensor Supply The ABS module supplies 5 volts to the brake booster vacuum sensor. The
Voltage "A": Circuit ABS module monitors this output and sets this DTC when the module detects a
Short to Battery short to battery voltage on the voltage supply circuit.
C1B15:1C Sensor Supply The ABS module supplies 5 volts to the brake booster vacuum sensor. The
Voltage "B": Circuit ABS module monitors this output and sets this DTC once the module
Voltage Out of determines the output voltage is either above or below the specified voltage for
Range a predetermined amount of time.
Possible Causes

Vacuum leak
Brake booster vacuum sensor
Brake booster
ABS module
Inspect the brake booster for vacuum leaks.

Inspect the brake booster for any obvious signs of damage.
Inspect the brake booster vacuum sensor harness and connector of any obvious signs of damage.
Make sure the brake booster vacuum sensor electrical connector is free from any corrosion or other
contaminants.
PINPOINT TEST M : BRAKE BOOSTER VACUUM SENSOR FAULTS

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M1 VERIFY ALL WIRING CONNECTIONS
Ignition OFF.
Disconnect brake booster vacuum sensor C1609.
Using a good light source, inspect each connector terminal for any corrosion.
Inspect both connectors for any pushed-out pins.
Using a suitable mating terminal, check each female terminal for deformed or enlarged contacts by
comparing the mating terminal's fit between each of the following pins:
C135-36
C135-44
C135-45
C1609-1
C1609-2
C1609-3
Yes GO to M2
No REPAIR the affected terminal.
M2 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Connect brake booster vacuum sensor C1609.
Ignition ON.
Is DTC C0047:26 present?
Yes GO to M3
No For DTC C0047:01, C0047:27, C1B14:11, C1015:08, C1B14:12 or C1B15:1C, GO to M4
For all other ABS module codes, GO to the DTC Chart: ABS Module.
M3 CHECK THE BRAKE BOOSTER AND VACUUM HOSES FOR LEAKS
Inspect the vacuum hoses, brake booster and brake booster seals for leaks or evidence of leaks.
Are any leaks or evidence of leaks found?
Yes REPAIR or INSTALL new components as necessary.

No GO to M4
M4 CHECK THE VACUUM SENSOR WIRING FOR A SHORT TO VOLTAGE

Ignition OFF.
Disconnect brake booster vacuum sensor C1609.
Ignition ON.
Measure:

C135-36 Ground
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C135-44 Ground
C135-45 Ground

No GO to M5
M5 CHECK THE VACUUM SENSOR WIRING FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C135-36 Ground
C135-44 Ground
C135-45 Ground
Yes GO to M6
M6 CHECK THE VACUUM SENSOR WIRING FOR AN OPEN

Measure:

C135-36 C1609-1
C135-44 C1609-3
C135-45 C1609-2
Yes GO to M7
M7 CHECK THE VACUUM SENSOR WIRING FOR A SHORT TOGETHER

Measure:
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C1609-1 C1609-2
C1609-1 C1609-3
C1609-2 C1609-3
Yes GO to M8
M8 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OUTPUT

Ignition ON.
Measure:

C1609-3 Ground
Is the approximately 4.7 volts?
Yes INSTALL a new brake booster vacuum sensor.

REFER to: Brake Vacuum Sensor (206-07 Power Brake Actuation, Removal and
Installation).
No GO to M9
M9 VERIFY ALL WIRING CONNECTIONS
Ignition OFF.
terminals?
Yes GO to M10
M10 CHECK FOR CORRECT ABS (ANTI-LOCK BRAKE SYSTEM) MODULE OPERATION
Connect brake booster vacuum sensor C1609. Make sure it seats and latches correctly.
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U3002:62
When the ignition is in RUN, the ABS module and the PCM share VIN information through the GWM over the
HS-CAN1 and the HS-CAN2.

U3002:62 Vehicle Identification Number: This DTC indicates the VIN message sent by the PCM over the
Signal Compare Failure HS-CAN1 does not match the VIN stored in the ABS module.
Possible Causes
Module configuration (ABS and PCM)

ABS module
PINPOINT TEST N : U3002:62

N1 VERIFY THE PCM (POWERTRAIN CONTROL MODULE) VIN (VEHICLE IDENTIFICATION
NUMBER)
Ignition ON.
Using a diagnostic scan tool, compare the VIN in the PCM to the VIN plate on the vehicle.
Does the VIN in the PCM match the VIN plate?
Yes GO to N2
No RECONFIGURE the PCM. FOLLOW the instructions on the diagnostic scan tool.
N2 VERIFY THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE PART NUMBER

Using a diagnostic scan tool, retrieve and record the ABS module part number.
Compare the part number retrieved to the part number in the parts catalog or equivalent.
Is the correct ABS module installed in the vehicle?
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Yes CONFIGURE the ABS module.
REFER to: Module Configuration - System Operation and Component Description (418-01
Module Configuration, Description and Operation).
No INSTALL a new ABS module.
C006B:00
The ABS module uses information from the wheel speed sensors, RCM and PSCM to determine when an ESC
intervention is necessary to help stabilize the vehicle. The ABS module uses the HCU to modulate the brake fluid
pressure to the brake calipers and continues to monitor the sensor and module input until the instability event has
been corrected. Once the sensors and modules indicate the instability event has been corrected, the ABS module
deactivates the HCU. Underinflated tires, wheels and tires not matching VC label specifications, suspension and
steering damage, or one or more wheel speed sensor failures contribute to the ABS module setting this DTC.

C006B:00 Stability System Active Too Long: This DTC indicates the ESC function has been active for longer
No Sub Type Information than the various sensors indicate is necessary.
Possible Causes
Tire pressure
Wheel and tire size
Chassis damage
Steering damage or alignment
Wheel speed sensor
Wheel speed sensor encoders
PSCM
RCM sensors
PINPOINT TEST O : C006B:00

O1 VERIFY ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Is DTC C006B:00 the only DTC present in the ABS module?
Yes GO to O2
No DIAGNOSE all other ABS module Diagnostic Trouble Codes (DTCs) before diagnosing
DTC C006B:00. GO to the DTC Chart: ABS Module.
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O2 VERIFY THE TIRE PRESSURE
Verify all tire inflation pressures are correct as indicated on the VC label.
Are the tires inflated to the correct pressure as indicated on the VC label?
Yes GO to O3
No ADJUST the tire pressure as necessary.
O3 VERIFY WHEEL AND TIRE SIZE

Verify all the tires and wheels are the same size and the size is correct as indicated on the VC label.
Are all 4 wheels and tires the correct size as indicated on the VC label?
Yes GO to O4
No INSTALL new wheels or tires as necessary.
O4 VERIFY SUSPENSION AND STEERING ALIGNMENT

Verify the suspension and steering alignment is correct.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and
Testing).
Are the suspension and steering alignment correct?
Yes GO to O5
No CORRECT the suspension or steering alignment.
REFER to: Suspension System (204-00 Suspension System - General Information,
O5 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE YAW RATE (YAW_RATE) PID
Using a diagnostic scan tool, monitor the YAW_RATE PID
Is the YAW_RATE PID value between -0.05 and 0.05?
Yes GO to O6
No GO to O9
O6 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE LATERAL ACCELEROMETER

(LAT_ACCL) PID (PARAMETER IDENTIFICATION)
Monitor the LAT_ACCL PID
Is the LAT_ACCL PID value between -0.4 and 0.4?
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Yes GO to O7
No GO to O9
O7 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE LONGITUDINAL ACCELEROMETER

SENSOR INPUT (LONG_ACCL) PID (PARAMETER IDENTIFICATION)
Monitor the LONG_ACCL PID
Is the LONG_ACCL PID value between -0.4 and 0.4?
Yes GO to O8
No GO to O9
O8 CHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE STEERING WHEEL ANGLE SENSOR
(STEER_ANGL) PID (PARAMETER IDENTIFICATION)
Monitor the STEER_ANGL PID while slowing rotating the steering wheel one complete revolution to the
left and then one complete revolution to the right.
Does the PID change in intervals of 4.5 degrees and show a 360-degree increase for each complete
revolution of the steering wheel?
Yes GO to O9
O9 CHECK THE RCM (RESTRAINTS CONTROL MODULE) INSTALLATION AND MOUNTING

SURFACE
Ignition OFF.
Inspect the RCM installation and verify all fasteners are tightened to specifications.
Inspect the RCM mounting surface for damage, corrosion, dirt and other irregularities.
Is the RCM installed correctly and the mounting surface clean and free from damage?
Yes GO to Pinpoint Test G

No CLEAR or REPAIR the RCM mounting surface as necessary. TIGHTEN the fasteners to
the correct toque specification.
U0104:00, U0405:41, U0405:82
With the ignition ON, the CCM sends messages to the ABS module over the HS-CAN2. If the ABS module does
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not receive these messages within a certain time frame, the ABS module sets a DTC. For information on the
messages sent to the ABS module by the CCM, refer to the Network Message Chart.

U0104:00 Lost Communication With Cruise This DTC sets in continuous memory and on-demand when any
Control Module: No Sub Type of the messages from the CCM are missing. This can be due
Information to a CCM failure, a circuit failure or excessive load on the
HS-CAN2.
U0405:41 Invalid Data Received From Cruise This DTC sets in continuous memory and on-demand if the
Control Module: General Checksum ABS module receives "fault" or "unknown" information in the
Failure collision mitigation by braking messages from the CCM instead
of valid checksum information.
U0405:82 Invalid Data Received From Cruise The CCM sends a rolling counter value to the ABS module.
Control Module: Alive / Sequence This DTC sets in continuous memory and on-demand if the
Counter Incorrect / Not Updated rolling counter value does not increase past 1.
Possible Causes

CCM
ABS module
PINPOINT TEST P : U0104:00, U0405:41, U0405:82

P1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the CCM pass the Network Test?

Yes GO to P2
No DIAGNOSE the no communication with the CCM concern.
and Testing).
P2 RECHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition OFF.
Ignition ON.
Yes GO to P3
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P3 REVIEW THE RECORDED ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE
CODES (DTCS)
Review the previously recorded ABS module Diagnostic Trouble Codes (DTCs).

No GO to P4
P4 CHECK THE CCM (CRUISE CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES (DTCS)
Using a diagnostic scan tool, carry out the CCM self-test.
Are any battery voltage Diagnostic Trouble Codes (DTCs) present?
Yes DIAGNOSE the CCM Diagnostic Trouble Codes (DTCs).

REFER to: Cruise Control (419-03B Cruise Control - Vehicles With: Adaptive Cruise
Control, Diagnosis and Testing).
No GO to P5
P5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0104:00 OR U0405:XX SET IN OTHER
MODULES
Retrieve and record all Continuous Memory Diagnostic Trouble Codes (CMDTCs).
Is DTC U0104:00 or U0405:xx set in 1 or more modules in addition to the ABS module?
Service Bulletins (TSBs) address this concern, INSTALL a new CCM.
REFER to: Cruise Control Module (CCM) (419-03B Cruise Control - Vehicles With:
Adaptive Cruise Control, Removal and Installation).
U0131:00, U0420:41, U0420:82, U0420:86
With the ignition ON, the PSCM sends messages to the ABS module over the HS-CAN2. If the ABS module does
not receive these messages within a certain time frame, the ABS module sets a DTC. For information on the
messages sent to the ABS module by the PSCM, refer to the Network Message Chart.
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U0131:00 Lost Communication With Power This DTC sets in continuous memory and on-demand when any of
Steering Control Module: No Sub the messages from the PSCM are missing. This can be due to a
Type Information PSCM failure, a circuit failure or excessive load on the HS-CAN2.
U0420:41 Invalid Data Received From This DTC sets in continuous memory and on-demand if the
Power Steering Control Module: checksum information in the steering angle sensor messages sent
General Checksum Failure from the PSCM does not match the checksum information
calculated by the ABS module.
U0420:82 Invalid Data Received From The PSCM sends a rolling counter value to the ABS module. This
Power Steering Control Module: DTC sets in continuous memory and on-demand if the rolling
Alive / Sequence Counter counter value does not increase past 1. Also, if the steering wheel
Incorrect / Not Updated angle sensor message number does not increase with each
message sent, this DTC sets.
U0420:86 Invalid Data Received From This DTC sets in continuous memory and on-demand if the ABS
Power Steering Control Module: module receives "fault" or "unknown" information in the steering
Signal Invalid wheel angle sensor messages from the PSCM instead of valid
steering wheel angle sensor information.
Possible Causes

PSCM
ABS module
PINPOINT TEST Q : U0131:00, U0420:41, U0420:82, U0420:86

Q1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Does the PSCM pass the Network Test?
Yes GO to Q2
No DIAGNOSE the no communication with the PSCM concern.
and Testing).
Q2 RECHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition OFF.
Ignition ON.
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Is DTC U0131:00 or U0420:xx retrieved again?
Yes GO to Q3
Q3 REVIEW THE RECORDED ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE
CODES (DTCS)

No GO to Q4
Q4 CHECK THE PSCM (POWER STEERING CONTROL MODULE) FOR DIAGNOSTIC TROUBLE
CODES (DTCS)
Using a diagnostic scan tool, carry out the PSCM self-test.
Are any battery voltage Diagnostic Trouble Codes (DTCs) present in the PSCM?
Yes DIAGNOSE the PSCM Diagnostic Trouble Codes (DTCs).

No GO to Q5
Q5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0131:00 OR U0420:XX SET IN OTHER
MODULES
Is DTC U0131:00 or U0420:xx set in 1 or more modules in addition to the ABS module?
Service Bulletins (TSBs) address this concern, REFER to the EPAS symptom chart or
DTC chart. Click here to access Guided Routine (EPAS).

C1015:7A, C1015:7B
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The ABS module uses the brake booster vacuum sensor to monitor the brake booster vacuum. On vehicles
equipped with a 2.3L EcoBoost engine, a gear driven vacuum pump supplies the necessary vacuum to the brake
booster. The vacuum pump is expected to produce at least 600 mBar (18 In-Hg). On vehicles equipped with all
other engines, the engine supplies the necessary vacuum to the brake booster. A leak in a vacuum hose, brake
booster, brake booster seal or vacuum pump (if equipped) prevents the brake booster from maintaining the
required amount of vacuum. Damage or an internal failure prevents the vacuum pump from operating at peak
capacity.

C1015:7A Vacuum Supply: Fluid Leak This DTC sets when the ABS module detects a decrease in brake
or Seal Failure booster vacuum without brake system activation.
C1015:7B Vacuum Supply: Low Fluid This DTC sets when the brake vacuum pump or engine is unable to
Level produce the vacuum necessary for brake system operation.
Possible Causes
Vacuum leak
Vacuum hose obstruction
Vacuum pump (if equipped)
Brake booster
PINPOINT TEST R : C1015:7A, C1015:7B

R1 CHECK FOR VACUUM LEAKS
Start the engine.
For vehicles equipped with a 2.3L EcoBoost engine, inspect the vacuum hose and each hose connection
from the vacuum pump to the brake booster for leaks.
For vehicles equipped with all other engines, inspect the vacuum hose and each hose connection from the
engine to the brake booster for leaks.
Are any vacuum leaks found?
Yes REPAIR the vacuum leak or INSTALL new components as necessary.

No If the vehicle is equipped with a 2.3L EcoBoost engine, GO to R2
If the vehicle is equipped with any other engine, INSTALL a new brake booster.
REFER to: Brake Booster - 3.7L Duratec (227kW/301PS) (206-07 Power Brake
REFER to: Brake Booster - 5.0L 32V Ti-VCT/5.2L 32V Ti-VCT (206-07 Power Brake
R2 CHECK THE VACUUM PUMP OUTPUT

Ignition OFF.
Disconnect the vacuum hose from the brake booster.
Connect a vacuum gauge to the vacuum hose.
Start the engine.
Monitor the vacuum gauge.
Does the vacuum gauge display greater than 600 mBar (18 In-Hg)?
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Yes INSTALL a new brake booster.
REFER to: Brake Booster - 2.3L EcoBoost (201kW/273PS) (206-07 Power Brake
No INSTALL a new vacuum pump.
REFER to: Brake Vacuum Pump - 2.3L EcoBoost (201kW/273PS) (206-07 Power Brake
U0151:00
With the ignition ON, the RCM sends messages to the ABS module over the HS-CAN2. If the ABS module does
not receive these messages within a certain time frame, the module sets Diagnostic Trouble Codes (DTCs). For
information on the messages sent to the ABS module by the RCM, refer to the Network Message Chart.

U0151:00 Lost Communication With This DTC sets in continuous memory and on-demand when any of
Restraints Control Module: No the messages from the RCM are missing. This can be due to a
Sub Type Information RCM failure, a circuit failure or excessive load on the HS-CAN2.
Possible Causes

RCM
PINPOINT TEST S : U0151:00
S1 CHECK THE COMMUNICATION NETWORK
Ignition ON.
Yes GO to S2
No DIAGNOSE the no communication with the RCM.
and Testing).
S2 RECHECK THE ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE CODES
(DTCS)
Ignition OFF.
Ignition ON.
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Yes GO to S3
S3 REVIEW THE RECORDED ABS (ANTI-LOCK BRAKE SYSTEM) MODULE DIAGNOSTIC TROUBLE
CODES (DTCS)

No GO to S4
S4 CHECK THE RCM (RESTRAINTS CONTROL MODULE) FOR DIAGNOSTIC TROUBLE CODES
(DTCS)
Are any Diagnostic Trouble Codes (DTCs) present in the RCM?
Yes DIAGNOSE the RCM Diagnostic Trouble Codes (DTCs).

No GO to S5
S5 CHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) U0151:XX SET IN OTHER MODULES
Is DTC U0151:xx set in 1 or more modules in addition to the ABS module?
Service Bulletins (TSBs) address this concern, DIAGNOSE the RCM concern.
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Anti-Lock Brake System (ABS) Module
Removal
1. NOTE: This step is necessary when installing a new HCU or ABS module.
NOTE: The PMI process must begin with the current ABS module installed. If the current ABS module
does not respond to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
Using a diagnostic scan tool, begin the PMI process for the ABS module following the on-screen
instructions.
2. Remove the HCU.

Refer to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake System (ABS) and Stability Control,
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3. NOTICE: Make sure the HCU and ABS module are clean and free of any brake fluid or foreign
material before separating the components. Do not allow any brake fluid or foreign material to
enter the mating side of the ABS module or component damage can occur.
4. Remove the 3 retainers and ABS. Discard the retainers.

Installation
instructions.
3. If a new HCU/ ABS module was installed, carryout the IVD initialization using the scan tool and following
the diagnostic scan tool on-screen instructions.
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Hydraulic Control Unit (HCU)
Removal
NOTE: The PMI process must begin with the current ABS module installed. If the current ABS module
does not respond to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
instructions.
2. Disconnect the ABS module electrical connector.
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3. NOTE: Make sure that all openings are sealed.
Disconnect the 6 brake tube fittings.

Torque:
1.: 155 lb.in (17.5 Nm)
2.: 20 lb.ft (27.5 Nm)
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4. Remove the bolt and separate the HCU from the bracket.
Installation
2. NOTE: The following steps are necessary if a new HCU or ABS module was installed.
Using a diagnostic scan tool, complete the PMI process for the ABS module following the on-screen
instructions.
Carry out the IVD initialization using the scan tool and following the diagnostic scan tool on-screen
instructions.
Procedures).
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Front Wheel Speed Sensor
Removal

2. Remove the retainer and position aside the fender splash shield.
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3. Disconnect the front wheel speed sensor electrical connector and detach the 2 harness retainers.
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4. Using compressed air, clean the area surrounding the front wheel speed sensor.
5. 1. Detach the 2 sensor harness retainers.

2. Remove the bolt and the front wheel speed sensor.
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Installation
2. Before installing a new sensor, inspect the sensor housing to make sure the sensor cavity is clean and free
of foreign material.

Rear Wheel Speed Sensor
Removal

2. Using compressed air, clean the area surrounding the rear wheel speed sensor.
3. 1. Disconnect the rear wheel speed sensor from electrical connector.

2. Detach the 2 sensor harness retainers.
3. Remove the bolt and the rear wheel speed sensor.
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Installation
2. Before installing a new sensor, inspect the sensor housing to make sure the sensor cavity is clean and free
of foreign material.

Stability Assist/Traction Control Switch
Removal
1. NOTE: The stability/traction control switch is part of the Front Controls Interface Module (FCIM).
Remove the FCIM.

Refer to: Front Controls Interface Module (FCIM) (415-00A Information and Entertainment System -
General Information - Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
Refer to: Front Controls Interface Module (FCIM) (415-00A Information and Entertainment System -
General Information - Vehicles With: AM/FM/CD/SYNC, Removal and Installation).
Installation
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308-01 Clutch 2016 Mustang
Clutch Disc and Pressure Plate - 5.0L 32V Ti-VCT
Clutch Alignment Tool
Removal
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Refer to: Transmission - 5.0L 32V Ti-VCT (308-03A Manual Transmission - 6-Speed Manual Transmission
- MT82, Removal).
2. NOTICE: If the parts are to be reused, index-mark the pressure plate to the flywheel. Failure to
install the pressure plate to the flywheel in the original position may result in a clutch system
vibration.
NOTICE: Loosen the bolts evenly to prevent clutch pressure plate damage.
Remove the pressure plate bolts by turning them 1 turn at a time in a star pattern until the clutch is fully
released. Remove the pressure plate and the clutch disc. Discard the pressure plate bolts.
Installation
1. Inspect the flywheel for damage, burn marks or wear and install a new flywheel if necessary.
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2. NOTICE: If installing a new pressure plate and/or flywheel, align the paint dot on the pressure plate
as close as possible to the paint dot on the flywheel or a clutch system vibration can occur.
NOTICE: If installing the original pressure plate, align it using the index-marks made during
removal or a clutch system vibration can occur.
Using a clutch aligner, position the clutch disc on the flywheel. If installing the original pressure plate, align
the pressure plate to the flywheel using the index-marks made during removal. If installing a new pressure
plate, align the pressure plate to the flywheel using the paint dots. Install new pressure plate bolts by
turning the bolts 1 turn at a time in a star pattern until the clutch is fully secured.
Use the General Equipment: Clutch Alignment Tool
Torque:
Stage 2: 60°
3. Install the transmission.
- MT82, Installation).
4. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction
procedure, following the on-screen instructions.
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308-01 Clutch 2016 Mustang
Pilot Bearing
308-001 (T58L-101-B)
Remover, Pilot Bearing
Removal
1. NOTE: The pilot bearing is not serviceable on vehicles equipped with a 5.2L engine. Install a new
flywheel.
Remove the clutch disc and pressure plate.
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Refer to: Clutch Disc and Pressure Plate - 2.3L EcoBoost (201kW/273PS) (308-01 Clutch, Removal and
Installation).
Refer to: Clutch Disc and Pressure Plate - 3.7L Duratec (227kW/301PS) (308-01 Clutch, Removal and
Installation).
Refer to: Flywheel (303-01D Engine - 5.2L 32V Ti-VCT, Removal and Installation).
2. Using the special tool, remove the pilot bearing.

Use Special Service Tool: 308-001 (T58L-101-B) Remover, Pilot Bearing.
Installation
1. Position the pilot bearing in the crankshaft. Using a driver, install the pilot bearing.
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2. Install the clutch disc and pressure plate.
Refer to: Clutch Disc and Pressure Plate - 2.3L EcoBoost (201kW/273PS) (308-01 Clutch, Removal and
Installation).
Refer to: Clutch Disc and Pressure Plate - 3.7L Duratec (227kW/301PS) (308-01 Clutch, Removal and
Installation).
Refer to: Flywheel (303-01D Engine - 5.2L 32V Ti-VCT, Removal and Installation).

308-02 Clutch Controls 2016 Mustang
Clutch Controls - Component Location
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Item Description
1 Clutch pedal
2 Clutch master cylinder
3 Clutch slave cylinder
4 Clutch hydraulic fluid tubes

Clutch System Bleeding
Brake/Clutch System Pressure Bleeder/Filler
Materials
Name Specification
Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid WSS-M6C65-A2
PM-20
Bleeding
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 the Poison
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Control Center at: 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.
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. Make sure all hydraulic tubes are correctly seated.
2. Make sure the clutch pedal is in the most upward position.
3. Check the fluid level of the brake/clutch reservoir. Fill the reservoir with the specified fluid to the MAX mark.
Material: Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid / PM-20 (WSS-M6C65-A2)
4. Using a suitable bleeder kit and a Vacuum Pump Kit, install the rubber stopper in the reservoir opening.
Make sure the rubber stopper has a tight fit. Alternate method: use a 50 mm (1.96 in) rubber stopper with
an 8 mm (0.31 in) pipe inserted through the rubber stopper.
Use the General Equipment: Brake/Clutch System Pressure Bleeder/Filler
5. Holding the rubber stopper in place, operate the vacuum pump to 15-20 inches of vacuum. Hold the vacuum
for one minute, then quickly relieve the vacuum. Remove the special tools.
6. Check the fluid level of the reservoir. Fill the reservoir with the specified fluid to the MAX mark. Install the
reservoir cap.
7. Press and release the clutch pedal 10 to 12 times or until clutch pedal effort is consistent and positive at
top of clutch pedal travel.
8. Repeat Steps 4 through 7 two additional times or until clutch pedal effort is consistent and positive at top of
clutch pedal travel.
9. Install the reservoir cap.
10. Check the clutch pedal reserve. Test the clutch system for normal operation.

Clutch Master Cylinder
Removal
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. Remove the brake pedal and bracket assembly.

Refer to: Brake Pedal and Bracket - 6-Speed Manual Transmission - 3160/6-Speed Manual Transmission -
MT82 (206-06 Hydraulic Brake Actuation, Removal and Installation).
2. Remove the clutch master cylinder bolts, then disconnect the clutch master cylinder from the clutch pedal
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and remove the master cylinder.
Installation
2. Bleed the clutch hydraulic system.


Clutch Pedal
Removal
1. The clutch pedal is serviced as part of the brake pedal assembly. Remove the brake pedal assembly.
Refer to: Brake Pedal and Bracket - 6-Speed Manual Transmission - 3160/6-Speed Manual Transmission -
MT82 (206-06 Hydraulic Brake Actuation, Removal and Installation).
Installation
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Clutch Slave Cylinder
Removal
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Refer to: Transmission - 2.3L EcoBoost (201kW/273PS) (308-03A Manual Transmission - 6-Speed Manual
Transmission - MT82, Removal).
Refer to: Transmission - 3.7L Duratec (227kW/301PS) (308-03A Manual Transmission - 6-Speed Manual
Transmission - MT82, Removal).
- MT82, Removal).
Refer to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission - 3160, Removal).
2. Remove the clutch slave cylinder bolts. Pull the clutch slave cylinder outward and release the tube from the
retaining clip.
3. Inspect the clutch slave cylinder for a damaged boot, leaking brake fluid or a worn or damaged release
bearing. Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new
clutch slave cylinder.
Installation
1. Install a new retaining clip.
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2. Position the clutch slave cylinder in the transmission, inserting the tube through the retaining clip. Install the
clutch slave cylinder bolts.
3. Install the transmission

Refer to: Transmission - 2.3L EcoBoost (201kW/273PS) (308-03A Manual Transmission - 6-Speed Manual
Transmission - MT82, Installation).
Refer to: Transmission - 3.7L Duratec (227kW/301PS) (308-03A Manual Transmission - 6-Speed Manual
Transmission - MT82, Installation).
- MT82, Installation).
Refer to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission - 3160,
Installation).
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308-03A Manual Transmission - 6-Speed Manual Transmission - 2016 Mustang
MT82
Specifications
Materials
Name Specification
High Temperature 4x4 Front Axle and Wheel Bearing Grease WSS-M1C267-A1
XG-11
XG-1-E1
TA-26
Motorcraft® MT82 Transmission Additive -
XL-18
Gasket Maker WSK-M2G348-A5
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TA-16
Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid WSS-M6C65-A2
PM-20
Motorcraft® Dual Clutch Transmission Fluid WSS-M2C200-D2
XT-11-QDC
Description Specifications
Gasket Maker TA-16 Material: Gasket Maker / TA-16 (WSK-M2G348-A5)
Motorcraft® DOT 4 LV High Performance Material: Motorcraft® DOT 4 LV High Performance Motor
Motor Vehicle Brake Fluid / PM-20 Vehicle Brake Fluid / PM-20 (WSS-M6C65-A2)
Motorcraft® Dual Clutch Transmission Fluid / Material: Motorcraft® Dual Clutch Transmission Fluid /
XT-11-QDC XT-11-QDC (WSS-M2C200-D2)
Motorcraft® Premium Long-Life Grease Material: Premium Long-Life Grease / XG-1-E1
XG-1-E1 (ESA-M1C75-B)
High Temperature 4x4 Front Axle and Wheel Material: High Temperature 4x4 Front Axle and Wheel Bearing
Bearing Grease / XG-11 Grease / XG-11 (WSS-M1C267-A1)
Motorcraft® Threadlock 262 TA-26 Material: Threadlock 262 / TA-26 (WSK-M2G351-A6)
Motorcraft® MT82 Transmission Additive Material: Motorcraft® MT82 Transmission Additive / XL-18
XL-18a
aXL-18 is only required after synchronizer replacement.
Capacities
Description Liters
Transmission Fluid 2.7 qt (2.6 L)
Item Specification
Transmission Weight 81.1 lb (36.8 kg)
Input Shaft Rotational Torque maximum 1.2 Nm (10.6 lb-in)
Transmission gear ratios
Gear 2.3L GTDI 3.7L 5.0L

1st 4.24:1 4.24:1 3.66:1
2nd 2.54:1 2.54:1 2.43:1
3rd 1.66:1 1.66:1 1.69:1
4th 1.24:1 1.24:1 1.31:1
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5th 1:1 1:1 1:1
6th 0.70:1 0.70:1 0.65:1
Reverse 3.84:1 3.84:1 3.32:1

MT82
Manual Transmission - Component Location
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Item Description
1 Transmission vent
2 Shift rail detents
3 Shift shaft stop pin
4 Reverse lamp switch
5 5th/6th gear shift fork pivot bolt
6 3rd/4th gear shift fork pivot bolt
7 Reverse shift fork pivot bolt
8 Reverse idler gear bracket bolt
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Item Description
2 5th/6th gear shift fork pivot bolt
3 3rd/4th gear shift fork pivot bolt
4 Reverse shift fork pivot bolt
7 OSS sensor
8 Drain plug
9 Fill plug

MT82
Manual Transmission - Overview
Overview
The MT82 is a fully synchronized 6-speed manual transmission with reverse gear. The name of the MT82 is
derived from the distance between the two shafts in the transmission:
M Manual.
T Transmission.
82 The distance between the main shaft and the counter shaft in millimeters.
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This transmission is a coaxial transmission with three shafts. The input shaft as well as the output shaft lie on a
single axis. All gear wheels have helical teeth and are constantly engaged. The transmission is designed for a
maximum torque of 480 Nm. In order to ensure secure mounting of the selector rods, they are passed through a
centre bearing mounting plate. The center bearing mounting plate is bolted to the housing. All gear selector forks
and shift forks are made of forged steel. The main selector shaft is mounted in the center bearing mounting plate.
The bearing of the transmission does not require preloading and therefore does not require shims. In order to
compensate for the heat expansion of the shafts, they run in one bearing which can slide in its seat and one
bearing which is pressed home in its seat. To improve gearshifting, 1st and 2nd gear have triple synchronizers and
3rd and 4th gear have double synchronizers. Only the 5th and 6th gears and the reverse gear have single
synchronizers. The transmission fluid is designed to last the entire service life of the transmission and does not
need to be changed during servicing.
Identification Tags
The transmission identification tag is located on the RH side of the transmission, near the driveshaft flange.
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Item Description
1 Replacement part number
2 Place of manufacture
3 Transmission build date
4 Build time

MT82
Manual Transmission - System Operation and Component Description
System Operation
System Operation
First Gear Powerflow
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In first gear, the shift shaft assembly pulls the 1st/2nd shift rail and fork back to slide the 1st/2nd synchronizer
sleeve onto 1st gear to lock it to the output shaft. Torque is transferred from the input shaft to the counter shaft
through 5th gear and from the counter shaft to the output shaft through 1st gear.
Second Gear Powerflow

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In second gear, the shift shaft assembly pushes the 1st/2nd shift rail and fork forward to slide the 1st/2nd
synchronizer sleeve onto 2nd gear to lock it to the output shaft. Torque is transferred from the input shaft to the
counter shaft through 5th gear and from the counter shaft to the output shaft through 2nd gear.
Third Gear Powerflow
In third gear, the shift shaft assembly pulls the 3rd/4th shift rail back which pivots the 3rd/4th shift fork to slide the
3rd/4th synchronizer sleeve forward onto 3rd gear to lock it to the counter shaft. Torque is transferred from the
input shaft to the counter shaft through 5th gear and from the counter shaft to the output shaft through 3rd gear.
Fourth Gear Powerflow

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In forth gear, the shift shaft assembly pushes the 3rd/4th shift rail forward which pivots the 3rd/4th shift fork to
slide the 3rd/4th synchronizer sleeve back onto 4th gear to lock it to the counter shaft. Torque is transferred from
the input shaft to the counter shaft through 5th gear and from the counter shaft to the output shaft through 4th
gear.
Fifth Gear Powerflow
In fifth gear, the shift shaft assembly pulls the 5th/6th shift rail back which pivots the 5th/6th shift fork to slide the
5th/6th synchronizer sleeve forward onto the input shaft to lock it to the output shaft. Torque is transferred from
the input shaft to the output shaft through the 5th/6th synchronizer sleeve and provides direct drive through the
transmission.
Sixth Gear Powerflow

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In sixth gear, the shift shaft assembly pushes the 5th/6th shift rail forward which pivots the 5th/6th shift fork to
slide the 5th/6th synchronizer sleeve back onto 6th gear to lock it to the output shaft. Torque is transferred from
the input shaft to the counter shaft through 5th gear and from the counter shaft to the output shaft through 6th
gear.
Reverse Powerflow
In reverse, the shift shaft assembly pulls the reverse shift rail back which pivots the reverse shift fork to slide the
reverse synchronizer sleeve forward onto reverse gear to lock it to the output shaft. Torque is transferred from the
input shaft to the counter shaft through 5th gear and from the counter shaft to the output shaft through the reverse
gear and reverse idler gear to rotate the output shaft in the opposite direction.
Internal Gearshift Mechanism
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Item Description
1 Shift shaft assembly
2 Reverse shift rail
3 Reverse shift fork
4 Shift fork pivot bolts
5 1st/2nd shift rail
6 1st/2nd shift fork
7 3rd/4th shift rail
8 3rd/4th shift fork
9 5th/6th shift rail
10 5th/6th shift fork
12 Shift shaft détente
Transmission Exploded View

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Item Description
1 Clutch slave cylinder bolt (2 required)
3 Input shaft seal
4 Countershaft bolt cover
5 Countershaft bolt
6 Input shaft snap ring
7 Front transmission case assembly
8 Shift fork pivot bolts (6 required)
9 OSS sensor bolt
10 OSS sensor
11 Shift rail detents (4 required)
12 Transmission case vent tube
14 Magnet
15 Input shaft
16 Output shaft roller bearing
17 5th gear synchronizer cone
18 5th gear synchronizer ring
19 Countershaft assembly
20 3rd/4th shift fork
21 3rd/4th shift rail
22 Output shaft assembly
23 5th/6th shift fork
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24 5th/6th shift rail
25 Center support bearing (output shaft)
26 Center support bearing (countershaft)
27 Center support
28 Spring
29 Dowels (2 required)
30 Spacers (2 required)
31 Interlock plate
32 Center support bolts (3 required)
33 Interlock plate bolts (2 required)
34 2nd gear needle bearing
35 2nd gear
36 2nd gear synchronizer ring assembly
37 Shift shaft assembly
38 1st/2nd gear synchronizer assembly
39 1st/2nd shift fork
40 Roll pin
41 1st/2nd shift rail
42 1st gear synchronizer ring assembly
43 1st/2nd gear synchronizer assembly snap ring
44 1st gear needle bearing
45 1st gear
46 Reverse gear needle bearing race
47 Reverse gear needle bearing
48 Reverse gear
49 Reverse gear synchronizer ring
50 Reverse gear synchronizer assembly
51 Reverse shift fork
52 Reverse shift rail
53 Rear transmission case assembly
55 Transmission case bolts
56 Output shaft seal
57 Output shaft flange
58 Output shaft flange bolt
Transmission Case
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Item Description
1 Clutch slave cylinder tube retaining clip
2 Bearing retaining bolts
3 Transmission case vent tube
4 Input shaft bearing
5 Countershaft bearing
6 Front transmission case
7 Dowel pin
8 Reverse idler gear bracket bolt
9 Reverse idler gear bracket
10 Reverse idler gear
11 Reverse idler gear needle bearing
12 Reverse idler gear shaft
13 Output shaft bearing
14 Shift shaft detent
15 Shift shaft seal
16 Rear transmission case
Counter Shaft
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Item Description
1 5th gear
2 6th gear
3 3rd gear
4 3rd gear needle bearing
5 3rd gear synchronizer ring assembly
6 3rd/4th gear synchronizer assembly snap ring
7 3rd/4th gear synchronizer assembly
8 4th gear synchronizer ring assembly
9 4th gear
10 4th gear needle bearing
11 Countershaft
Output Shaft
Item Description
1 5th/6th gear synchronizer assembly snap ring
2 5th/6th gear synchronizer assembly
3 6th gear synchronizer ring
4 6th gear synchronizer cone
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5 6th gear
6 6th gear needle bearing
7 Pocket bearing inner bearing race retainer
8 Pocket bearing inner bearing race
9 Output shaft
Synchronizer Assembly
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Item Description
1 Synchronizer hub
2 Synchronizer sleeve
3 Pressure pieces

MT82
Manual Transmission
NOTICE: If transmission noise is reported, first check the transmission fluid level. The vehicle should not
be driven if the transmission fluid level is low. A low transmission fluid level will damage the
transmission.
NOTE: If an observed or reported concern is found, correct the cause before proceeding.
Gear driven units produce a certain level of noise. Some noise is acceptable and audible at certain speeds or
under various driving conditions. Many conditions, such as road and weather can amplify normal vehicle noise.
The following overview is a guide to diagnose a transmission or clutch concern:
Verify and document the customer concern.

During the customer interview, if a leak was noticed or if a leak is the concern, check the
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transmission fluid level. The vehicle should not be driven if the transmission fluid level is low.
Check fluid level and condition.
Evaluate the clutch hydraulic system.
Evaluate the clutch.
Inspect gearshift mechanism.
Evaluate the transmission.
Check Fluid Level and Condition
An incorrect transmission fluid level may affect the transmission operation and can result in transmission damage.
REFER to: Transmission Fluid Level Check (308-03A Manual Transmission - 6-Speed Manual Transmission -
MT82, General Procedures).
Check Fluid Level and Condition
NOTICE: Excessive temperatures may break down the transmission lubricant. If there is reason to
believe the transmission has been subjected to temperatures exceeding 135°C (275°F) for an extended
period (greater than 20 minutes), change the lubricant immediately.
A low transmission fluid level can result in poor transmission shifting, engagement or damage. It also indicates a
leak in the transmission seals or gaskets.
1. Check the transmission fluid condition.

Allow the transmission fluid to drip onto a white cloth and examine the stain. Check the transmission
fluid for contamination or metal particles.
Evaluate Clutch Hydraulic System
1. Verify the clutch hydraulic fluid reservoir is filled to the correct level.
If the clutch hydraulic fluid level is low, add fluid as necessary. Check the clutch hydraulic system for
leaks.
Evaluate the Clutch
1. Apply and release the clutch pedal slowly to check pedal binding. Make sure the clutch pedal can be fully
applied and is not restricted by the floor mat.
2. With the engine idling and the park brake applied, move the gearshift lever into 4th gear. Increase engine
speed to 2,000 rpm and slowly release the clutch pedal.
If the engine stalls, the clutch is not slipping.
If the engine does not stall, the clutch is slipping.
Inspect Gearshift Mechanism
1. Inspect the gearshift mechanism for:

signs of damage.
missing or loose fasteners.
binding.
2. Repair as necessary.
Evaluate Transmission
NOTICE: The vehicle should not be driven if the transmission fluid level is low or damage may occur.
NOTE: Before attempting to repair any concerns, road test the vehicle to determine which system the concern is
in.
1. Road test the vehicle. Use the following methods to diagnose the concern.
Start the engine.
Evaluate the noise in NEUTRAL while vehicle is parked.
Check whether the noise is present with the clutch fully disengaged (clutch pedal applied).
Check to see if the pedal pulsates abnormally (clutch diaphragm finger runout).
Check whether the noise is present with the gearshift in the NEUTRAL position and the clutch
fully engaged (clutch pedal released). Apply the park brake and move the gearshift towards
the 1st gear position.
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With the clutch fully engaged (clutch pedal released) check whether the noise is present as
the engine speed is raised. If the noise reduces, note the engine speed at which this occurs.
Listen for any change in noise while applying and releasing the clutch pedal.
Listen for any change in noise while changing the engine rpm.
Drive the vehicle and shift through all the gears including REVERSE. Listen for any changes in noise.
Drive the vehicle in the gear in which the noise is most noticeable. Apply 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. Apply the clutch pedal and shift
the transmission into NEUTRAL. Release the clutch pedal and allow the vehicle to coast.
2. The following list of conditions are typical clutch concerns.

Clutch slippage
Clutch chatter or shudder
Clutch pedal feels spongy or has excessive travel. Clutch will not disengage
Clutch drag, also hard to shift
Clutch pedal pulsation
Clutch-related vibrations
Excessive noise
3. The following list of conditions are typical clutch hydraulic system concerns.
Clutch pedal feels spongy or has excessive travel. Clutch will not disengage
Clutch drag, also hard to shift
Clutch pedal pulsation
Clutch system leakage
4. Compare the road test results with the following symptom charts. The following list of conditions are typical
transmission concerns:
Symptom Chart: Manual Transmission
Symptom Possible Action

Sources
Transmission difficult to shift when cold Normal Excessive force to select gears
Condition when the transmission is cold
is a normal condition. Test
drive the vehicle to see if the
condition is still present when it
warms up.
Transmission difficult to shift Lubricant ADD or DRAIN and FILL with
specified lubricant.
REFER to: Transmission
Draining and Filling (308-03A
Manual Transmission -
6-Speed Manual Transmission
- MT82, General Procedures).
Internal shift CHECK the internal shift
mechanism mechanism for smooth
operation. REPAIR or INSTALL
a new mechanism as
necessary.
Sliding gears, CHECK for free movement of
synchronizers gears and synchronizers.
REPAIR or INSTALL new
Housings, shaft CHECK for binding condition
between the input shaft and the
engine crankshaft pilot bearing
or bushing. REPAIR or
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necessary.
REFER to: Pilot Bearing
(308-01 Clutch, Removal and
Installation).
Loose pressure CHECK for loose bolts at the
plate to pressure plate. INSTALL new
flywheel bolts components as necessary.
REFER to: Clutch Disc and
Pressure Plate - 2.3L
Installation).
Pressure Plate - 3.7L Duratec
(227kW/301PS) (308-01
Clutch, Removal and
Installation).
Pressure Plate - 5.0L 32V
Ti-VCT (308-01 Clutch,
Transmission will not shift — gearshift lever Gearshift lever INSTALL a new gearshift lever.
moves damaged REFER to: Gearshift Lever
(308-06A Manual Transmission
External Controls - 6-Speed
Manual Transmission - MT82,
Damaged or CHECK the internal shift
worn selector components. INSTALL new
arm. Loose component as necessary.
shift rail
bushings
Damaged or CHECK the internal shift
offset lever components. INSTALL new
plate component as necessary.
NOTE: While verifying the condition, Lubricant ADD or DRAIN and FILL with
specified lubricant.
determine whether the noise is gear REFER to: Transmission
rollover noise, release bearing rub or some Draining and Filling (308-03A
other transmission-related noise. Gear Manual Transmission -
rollover noise, inherent in manual 6-Speed Manual Transmission
transmissions, is caused by the constant - MT82, General Procedures).
mesh of gears turning at the engine idle
speed while the clutch is engaged and the
transmission is in NEUTRAL. Release
bearing rub is sometimes mistaken for
mainshaft bearing noise. Gear rollover
noise will disappear when the clutch is
disengaged or when the transmission is
engaged in gear. Release bearing rub will
disappear when the clutch is engaged. In
the event that a bearing is damaged, the
noise is more pronounced while engaged in
gear under load or coast than in NEUTRAL.
Noisy in forward gears
Components CHECK for screws and bolts of
grounding out body or other components
on the grounding out. CORRECT as
transmission necessary.
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Components CHECK the torque on the
housing bolts transmission-to-flywheel
housing bolts and the flywheel
housing-to-engine block bolts.
TIGHTEN the bolts to
specification.
Bearings or INSPECT the bearings.
gears INSPECT the gears and gear
teeth for wear or damage.
necessary.
Axle howl or The MT82 transmission may
whine be suspect of a gear whine
noise, which seems to be
emanating from the rear of the
vehicle at or in excess of 80
km/h (50 mph) at full operating
temperature. Drive the vehicle
at customer complaint speeds
in 5th gear (this is the direct
gear) to eliminate manual
transmission as noise source,
reach full operating
temperature and confirm if
noise is still present.
REFER to: Suspension System
(204-00 Suspension System -
General Information, Diagnosis
and Testing).
Gears clash when shifting from one forward Pilot bearing CHECK for a binding condition
gear to another between the input shaft and the
engine crankshaft pilot bearing.
necessary.
REFER to: Pilot Bearing
Installation).
Gear teeth REPAIR or INSTALL new
and/or components as necessary.
synchronizer
Damaged shift INSPECT for wear or damage.
forks or worn INSTALL new components as
shift fork necessary.
inserts
Transmission jumps out of gear Transmission- TIGHTEN the bolts to
to-engine specification.
mounting bolts
Crankshaft pilot INSTALL a new pilot bearing.
bearing REFER to: Pilot Bearing
Installation).
Internal INSPECT the synchronizer
Damage sleeves for free movement on
their hubs. INSPECT the
synchronizer blocking rings for
widened index slots, rounded
clutch teeth and smooth
internal surface. CHECK shift
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forks for worn or loose
mounting on shift rails.
INSPECT the synchronizer
sliding sleeve and the gear
clutch teeth for wear or
damage. REPAIR or INSTALL
a new component as
necessary.
Gear teeth If worn or damaged, INSTALL
new gears.
Transmission will not shift into one gear — Manual shift REPAIR or INSTALL new
all others OK linkage components as necessary.
Backup switch If REVERSE is the problem,
ball CHECK reverse lamp switch
for ball frozen in extended
position.
Internal INSPECT the shift rail and fork
components system, synchronizer system
and the gear clutch teeth for
restricted travel. REPAIR or
necessary.
Transmission is locked in one gear and Internal INSPECT the problem gears,
cannot be shifted out of that gear components shift rails, forks and the
synchronizer for wear or
damage. REPAIR as
necessary.
Fork on rail or CHECK the shift rail interlock
shift rail system. REPAIR as necessary.
Transmission leaks Lubricant CHECK the level and type.
Other IDENTIFY leaking fluid as
component engine, power steering or
leaking transmission fluid. REPAIR as
necessary.
False report REMOVE all traces of lube on
the exposed transmission
surfaces. CHECK the vent for
free breathing. OPERATE the
transmission and INSPECT for
new leakage. REPAIR as
necessary.
Internal INSPECT for leaks at the input
components shaft seal. INSPECT the case
for sand holes or cracks.
REPAIR or INSTALL a new
case as necessary.
Fill and drain CHECK fill and drain plugs and
plugs bore threads. REPAIR as
necessary. TIGHTEN plugs to
specified torque value.
Bearing failure Other part REMOVE, DISASSEMBLE and
failure CLEAN the transmission.
Raceways or Inspect for damaged parts and
rollers install new components as
Lubricant necessary. (Note: RESET the
Towing vehicle bearing preload if any new
further than 80 tapered bearings are installed.)
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km (50 mi) with
driveshaft
installed.
Vibration DETERMINE the cause of
break-up of vibration and CORRECT.
retainer and Otherwise, PROCEED as
brinelling of above.
races
Bearing(s)
Shafts or bore
Incorrect
preload
Input shaft oil INSTALL new components as
dam necessary and VERIFY the oil
dam installation is correct.
CHECK for correct installation
of the snap ring on the
mainshaft next to the oil dam.
Oil baffle in the INSTALL a new oil baffle,
input bearing making sure it is not damaged
shim pack during assembly.
Symptom Chart: NVH

NOTE: NVH symptoms should be Gear engagement Acceptable operating condition.
identified using the diagnostic tools Caused by the contact pattern of
that are available. Since it is possible these gears.
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, check for the next
likely system and continue diagnosis.
Transmission rattle noise — noise
occurs at 1st and 2nd gear on light
acceleration.
Transmission rattling/clattering noise — Incorrect fluid COMPARE with other like
occurs in NEUTRAL or in gear, at idle level or fluid vehicles. CHECK that the
quality transmission is filled to the correct
level and with the specified fluid.
REFER to: Transmission Fluid
Level Check (308-03A Manual
Transmission - 6-Speed Manual
Transmission - MT82, General
Procedures).
Transmission rattling/clattering noise — Worn or rough CHECK the reverse idler gear.
noise at idle in NEUTRAL reverse idler gear REPAIR as necessary.
Excessive CHECK the gear backlash.
backlash in gears ADJUST as necessary.
Worn countershaft REPAIR as necessary.
gears
Transmission whine — a mild whine at Rotating Acceptable noise.
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extreme speeds or high rpm gears/geartrain
Transmission whine — a high pitched Transmission Result of normal gear wear.
whine, also described as a squeal gears are worn REPAIR as necessary.
(high mileage
vehicle)
Mismatched gear INSPECT the gear sets for an
sets uneven wear pattern on the face
of the gear teeth. REPAIR as
necessary.
Damaged or worn INSPECT the transmission
transmission bearings. INSTALL new bearings
bearing as necessary.
Transmission growling/humming — Gear is cracked, INSPECT the transmission gears
noise occurs in the forward gears. The chipped or rough for damage or wear. INSTALL
noise is more prominent when the gear new gears as necessary.
is loaded. The problem gear can be
located as the noise occurs in a
specific gear position
Axle howl or The MT82 transmission may be
whine suspect of a gear whine noise,
which seems to be emanating
from the rear of the vehicle at or
in excess of 80 km/h (50 mph) at
full operating temperature. Drive
the vehicle at customer complaint
speeds in 5th gear (this is the
direct gear) to eliminate manual
reach full operating temperature
and confirm if noise is still
present.
and Testing).
If noise is not present, proceed
with gear noise analysis.
Transmission hissing — noise in Damaged or worn INSPECT the transmission
NEUTRAL or in forward gears. As bearings bearings. INSTALL new bearings
bearings wear or break up, the noise as necessary.
changes to a thumping noise
Transmission knocking/thudding — Bearings with INSPECT the transmission
noise at low speeds in forward gears damaged balls or bearings. INSTALL new bearings
rollers or with as necessary.
pitted and spalled
races
Transmission growling/humming — Incorrect driveline CHECK the driveline angle.
noise occurs in the forward gears. The angle REPAIR as necessary.
noise is more prominent when the gear REFER to: Driveshaft (205-01
is loaded. The problem gear can be Driveshaft, Diagnosis and
located as the noise occurs in a Testing).
specific gear position •Transmission
rumble/growl — noise at higher speeds
in forward gears, more pronounced in
a coast/deceleration condition
Driveshaft out of CHECK the driveshaft for
balance or damage, missing balance weights
damaged or undercoating. REFER to the
driveshaft runout and balance
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test.
Driveshaft, Diagnosis and
Testing).
Axle howl or The MT82 transmission may be
whine suspect of a gear whine noise,
which seems to be emanating
from the rear of the vehicle at or
in excess of 80 km/h (50 mph) at
full operating temperature. Drive
the vehicle at customer complaint
speeds in 5th gear (this is the
direct gear) to eliminate manual
reach full operating temperature
and confirm if noise is still
present.
and Testing).
If noise is not present, proceed
with gear noise analysis.
Transmission rumble/growl — noise at Damaged or worn CHECK transmission fluid for
all speeds in forward gears, more transmission excessive metal particles.
pronounced in a heavy acceleration bearing or gears REPAIR as necessary.
condition (high mileage
vehicles)

MT82
Transmission Fluid Level Check
Fluid Suction Gun
Materials
Name Specification
XT-11-QDC
1. NOTE: Make sure that the vehicle is level.
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2. Remove the fill plug.
3. Add or remove transmission fluid as necessary.

Refer to: Specifications (308-03A Manual Transmission - 6-Speed Manual Transmission - MT82,
Specifications).
Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
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4. Install the fill plug.
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MT82
Transmission Draining and Filling
Fluid Suction Gun
Materials
Name Specification
XT-11-QDC
1. NOTE: Make sure that the vehicle is level.
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2. Remove the drain plug and drain the transmission fluid.
3. Remove the fill plug.

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4. Fill the transmission.
Refer to: Specifications (308-03A Manual Transmission - 6-Speed Manual Transmission - MT82,
Specifications).
5. Install the fill plug.

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MT82
Input Shaft Seal - 5.0L 32V Ti-VCT
308-375
Remover, Input Shaft Seal
TKIT-1999-F/FLM/LT
TKIT-2005U-M
308-806
Installer, Front Seal
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
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Slide Hammer
Removal
1. Remove the clutch slave cylinder.

Refer to: Clutch Slave Cylinder (308-02 Clutch Controls, Removal and Installation).
2. Using the special tools, remove and discard the input shaft seal.
Use Special Service Tool: 308-375 Remover, Input Shaft Seal.
Installation
1. Using the special tools, install the input shaft seal.

Use Special Service Tool: 308-806 Installer, Front Seal.
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2. Install the clutch slave cylinder.
Refer to: Clutch Slave Cylinder (308-02 Clutch Controls, Removal and Installation).

MT82
Output Shaft Seal
205-153 (T80T-4000-W)
Handle
308-808
Installer, Rear Flange
TKIT-2010A-F
TKIT-2010A-LM
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TKIT-2010A-ROW
308-809
Installer, Syncro Gear Pack
TKIT-2010A-ROW
308-811
Installer, Rear Seal
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
308-938
Remover/Installer, Companion Flange Nut
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Transmission Jack
Two Leg Puller
Materials
Name Specification
TA-26
Removal

2. Support the transmission with a transmission jack and secure it with a safety strap.
3. Remove the bolts and remove transmission support insulator and crossmember.
4. Remove the output shaft flange bolt.
5. Remove the output shaft flange.

Use the General Equipment: Two Leg Puller cardiagn.com
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6. Remove and discard the output shaft seal.
Installation
1. Install a new seal on the special tools.

Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 308-811 Installer, Rear Seal.
2. Using the special tools, install a new seal.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 308-811 Installer, Rear Seal.
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3. Using the special tools, install the output shaft flange.
Use Special Service Tool: 308-808 Installer, Rear Flange. , 308-809 Installer, Syncro Gear Pack.
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4. Install the special tools. Clean the threads on the output shaft bolt and apply one dot of thread locking
adhesive to the lower end of the output shaft bolt threads. Using the special tools, install the output shaft
flange bolt.
Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.
Torque:
Stage 2: Loosen: 5 turn(s)
5. Install the transmission support insulator and crossmember and install the bolts.
Torque:
1: 76 lb.ft (103 Nm)
2: 46 lb.ft (63 Nm)
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MT82
Transmission Support Insulator
Transmission Jack
Retaining Strap
Removal

2. Remove the transmission support insulator nuts.
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3. Support the transmission with a transmission jack. Secure the transmission to the transmission jack.
Use the General Equipment: Retaining Strap
4. Remove the transmission support insulator bolts and the transmission support insulator.
Installation
1. Install the transmission support insulator and the bolts.
2. Install the transmission support insulator nuts.

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MT82
Vehicle Speed Sensor (VSS)
Removal

2. Remove the drain plug and drain the transmission fluid.

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3. Disconnect the VSS electrical connector.
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4. Remove the VSS bolt and the VSS.
Installation
1. Install the VSS and the VSS bolt.

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2. Connect the VSS electrical connector.

Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission - 6-Speed Automatic
Transmission - 6R80, General Procedures).

MT82
Removal 10/5/2015
Transmission - 5.0L 32V Ti-VCT
Transmission Jack
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2. Remove the upper RH catalytic converter nut.
3. NOTE: Support the transmission with a transmission jack for gearshift lever removal.
Remove the gearshift lever.

Refer to: Gearshift Lever (308-06A Manual Transmission External Controls - 6-Speed Manual Transmission
- MT82, Removal and Installation).
4. Remove the bolts and remove the transmission support insulator and crossmember from the back of the
transmission.
5. Remove the starter motor.
6. Remove the RH catalytic converter.

Refer to: Catalytic Converter RH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
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7. Remove the LH HO2S and the catalyst monitor.

Refer to: Heated Oxygen Sensor (HO2S) (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L
Refer to: Catalyst Monitor Sensor (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
8. Disconnect the electrical connectors and the wiring retainers and position the vehicle wiring harness aside.
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9. NOTE: If disassembly of the transmission is required, drain the transmission fluid.
Remove the drain plug and drain the transmission fluid.

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10. Remove the retainer and disconnect the hydraulic tube from the clutch master cylinder.
11. NOTE: Secure the transmission with a safety strap to the transmission jack.
Remove the bellhousing bolts, pull the transmission back to remove the input shaft from the clutch, lower
the transmission and remove it from the vehicle.
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MT82
Disassembly 04/30/2015
205-153 (T80T-4000-W)
Handle
307-003 (T57L-500-B)
Holding Fixture, Transmission
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308-130 (T87T-7025-DH)
Installer, Shift Rail Needle Bearing
TKIT-1987-FLMH
308-375
Remover, Input Shaft Seal
TKIT-1999-F/FLM/LT
TKIT-2005U-M
308-810
Remover, Syncro Gear Pack
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
308-812
Remover, Detent
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
308-938
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Slide Hammer Dent Puller

Slide Hammer
Three Leg Puller
Hydraulic Press
Center Punch
Two Leg Puller
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1.
2. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all
components with solvent and dry with compressed air.
3. Attach the transmission to the special tool.

4. 1. Remove the slave cylinder bolts.

2. Pull the clutch slave cylinder outward and release the tube from the retaining clip and if equipped,
remove the clutch slave cylinder spacer.
5. Inspect the clutch slave cylinder for the following:
Damaged boot
Leaking brake fluid
Worn or damaged release bearing
Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new
clutch slave cylinder.
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6. Using the special tools, remove and discard the input shaft seal.
Use Special Service Tool: 308-375 Remover, Input Shaft Seal.
7. Using a center punch, mark a location in the center of the countershaft bolt cover. Using a drill bit of the
appropriate size for the dent puller, drill a hole in the center of the countershaft bolt cover. Drill the hole to
pierce the countershaft bolt cover approximately 2 mm (0.078 in) in depth.
Use the General Equipment: Center Punch
8. Using the special tool, remove and discard the countershaft bolt cover.
Use the General Equipment: Slide Hammer Dent Puller
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9. Install the special tools, position the shift shaft into 4th gear.
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10. With the help of an assistant, hold the special tools and remove the countershaft bolt.
11. Using the special tools, hold the output shaft flange and remove the bolt.
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12. Using the three leg puller and the step plate, remove the output shaft flange.
13. Remove and discard the output shaft seal.

14. Remove the bolt and the OSS sensor.
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15. 1. Detach the electrical connector retainer.
2. Remove the reverse lamp switch.
16. Remove the LH and RH reverse gear shift fork pivot bolts.
17. Using the special tools, remove the shift rail detents.
Use Special Service Tool: 308-812 Remover, Detent.
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18. Remove the transmission case bolts.
19. Using the two leg puller and the step plate, remove the rear transmission case.
Use the General Equipment: Two Leg Puller
20. NOTE: To remove the reverse shift fork and the reverse shift rail assembly, the transmission must be in
neutral and the groves on the shift rail must be aligned with the interlock plate.
Remove the reverse shift fork and the reverse shift rail assembly.
Inspect the reverse shift fork and reverse shift rail assembly for wear or damage. Install new
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21. Using the special tools, remove the shift shaft stop pin.
22. Remove the shift shaft.
23.
Using the push/puller set, step plate and special tool, remove the 1st gear, the reverse gear and the
reverse gear synchronizer assembly.
Inspect the 1st and reverse gears for wear or damage. Install new gears as necessary.
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Inspect the reverse gear needle bearing and the reverse gear needle bearing race for wear or
damage. Install new components as necessary.
Inspect the reverse gear synchronizer assembly and the reverse gear synchronizer ring for wear or
damage. Install new components as necessary.
Use Special Service Tool: 308-810 Remover, Syncro Gear Pack.
24.
Remove the 1st gear needle bearing.
Inspect the 1st gear needle bearing for wear or damage. Install a new 1st gear needle bearing as
necessary.
25. NOTE: Note the position of each synchronizer ring component before removal.
Remove the 1st gear synchronizer ring assembly.

Inspect all synchronizer ring components for wear or damage. Install new components as
necessary.
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26. NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.
1. Remove the 3 pressure pieces.

27. NOTE: Index-mark the synchronizer sleeve to the synchronizer hub before removal.
Remove the 1st/2nd shift fork, the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.
Inspect the 1st/2nd shift fork and the 1st/2nd shift rail for wear or damage. Install new components
as necessary.
Inspect the 1st/2nd synchronizer sleeve for wear or damage. Install a new 1st/2nd synchronizer
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28. Remove the magnet.
29. Remove the bolts, spacers, spring and the interlock plate.
30. Remove the center support bolts.
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31. Remove the 1st/2nd synchronizer hub snap ring.
32. NOTICE: The center support must be pulled up evenly or damaged to the center support or
transmission case can occur.
Using the push/puller set, step plate and special tool, under the center support pull off the center support,
2nd gear and the 1st/2nd synchronizer hub.
Use Special Service Tool: 308-810 Remover, Syncro Gear Pack.
33. NOTE: Note the position of each synchronizer ring component before removal.
Remove the 1st/2nd synchronizer hub, the 2nd gear synchronizer ring assembly and the 2nd gear.
Inspect all the components for wear or damage. Install new components as necessary.
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34.
Remove the 2nd gear needle bearing.
Inspect the 2nd gear needle bearing for wear or damage. Install a new needle bearing as
necessary.
35.
Remove the center support.
Inspect the center support for wear or damage. Install a new center support as necessary.
36. NOTICE: When removing the bearings, do not over expand the bearing cages or damage to the
bearing cages can occur.
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Unlock the bearing cage tabs and slightly expand the bearing cages. Remove the center support bearings
by sliding them up the shaft assemblies.
37. Remove the 2 LH and the 2 RH shift fork pivot bolts.
38. Remove the 3rd/4th shift rail and the 3rd/4th shift fork.
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39. Remove the 5th/6th shift rail and the 5th/6th shift fork.
40. 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: Use an assistant when pressing out the countershaft and output shaft, do not allow the
shafts to bind during removal.
NOTICE: The countershaft bolt must be removed prior to pressing out the countershaft or damage
to the transmission case will occur.
With an assistant, support the transmission case on flat surface of a hydraulic press. Using the special
tools, press the countershaft out of the bearing and remove the countershaft and output shaft.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle. , 308-130 (T87T-7025-DH) Installer, Shift Rail
Needle Bearing.
41. NOTE: Removal of the input shaft is only required if damage is found to the input shaft, input shaft seal
or input shaft bearing. If damage is not found, no not remove the input shaft.
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Remove the input shaft snap ring.
42. 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: Use an assistant when pressing out the input shaft, do not allow the input shaft to drop
during removal.
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NOTE: Removal of the input shaft is only required if damage is found to the input shaft, input shaft seal
or input shaft bearing. If damage is not found, no not remove the input shaft.
With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the hydraulic
press, remove the input shaft.

MT82
Disassembly and Assembly of Subassemblies 04/30/2015
Countershaft
205-153 (T80T-4000-W)
Handle
308-130 (T87T-7025-DH)
Installer, Shift Rail Needle Bearing
TKIT-1987-FLMH
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Hydraulic Press
Bearing Separator
Materials
Name Specification
XT-11-QDC
DISASSEMBLY
NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.
NOTICE: Support the countershaft while using the hydraulic press to prevent damage to the shaft or
gears.
NOTICE: Removing the Fifth and Sixth gears may take up to 18,000 pounds of force. Do not heat the
gear.
1.
Using the special tools, bearing separator and a hydraulic press, remove the 5th gear.
Inspect the 5th gear for wear or damage. Install a new gear as necessary.
Use Special Service Tool: 308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing. , 205-153
(T80T-4000-W) Handle.
Use the General Equipment: Bearing Separator
2.
Using the special tool, bearing separator and a hydraulic press, remove the 6th gear.
Use Special Service Tool: 308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing.
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3.
Remove the 3rd gear.
Inspect the 3rd gear for wear or damage. Install a new gear as necessary.
4.
Remove the 3rd gear needle bearing.
Inspect the 3rd gear needle bearing for wear or damage. Install a new needle bearing as
necessary.
5. NOTE: Prior to removing the synchronizer rings, note the position of each synchronizer ring.
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Remove the 3rd gear synchronizer ring assembly.
Inspect all synchronizer ring components for wear or damage. Install new components as
necessary.
6. Remove the 3rd/4th gear synchronizer assembly snap ring.

7. Using the special tool, the bearing separator and a hydraulic press, remove the 4th gear and the 3rd/4th
gear synchronizer assembly.
Use Special Service Tool: 308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing.
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8. NOTE: Prior to removing the synchronizer rings, note the position of each synchronizer ring.
Remove the 4th gear from the 4th gear synchronizer ring assembly. Remove the 4th gear synchronizer ring
assembly from the 3rd/4th gear synchronizer assembly.
Inspect the 3rd/4th gear synchronizer assembly for wear or damage. Install a new 3rd/4th gear
synchronizer assembly as necessary.
Inspect the synchronizer ring components for wear or damage. Install new components as
necessary.
9. NOTICE: When removing the bearing, do not over expand the bearing cage or damage to the
bearing cage can occur.
Remove the 4th gear needle bearing.

Inspect the 4th gear needle bearing for wear or damage. Install a new needle bearing as necessary.
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10. Inspect the countershaft for scoring or worn or damaged splines. Install a new countershaft as necessary.
ASSEMBLY
NOTICE: Lubricate all components with the recommended transmission fluid before assembling.
1. NOTICE: When installing the bearing, do not over expand the bearing cage or damage to the
bearing cage can occur.
Install the 4th gear needle bearing.

2. NOTICE: The groove on the 3rd/4th gear synchronizer assembly must be facing away from 4th
gear or damage to the synchronizer assembly can occur.
NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slot and the 3 synchronizer
ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer
assembly and synchronizer ring assembly can occur.
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NOTE: The 4th gear synchronizer ring assembly outer ring has one identification notch.
With the groove on the 3rd/4th gear synchronizer assembly sleeve facing away from the 4th gear install the
4th gear synchronizer ring assembly and the 4th gear.
Align the 6 synchronizer ring tabs with the 6 gear slots and the 3 synchronizer ring tabs with the 3
synchronizer assembly slots.
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3. Using the bearing separator and a hydraulic press, install the 4th gear and the 3rd/4th gear synchronizer
assembly.
4. Install the 3rd/4th gear synchronizer assembly snap ring.

5. NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the
synchronizer assembly and synchronizer ring assembly can occur.
NOTE: The 3rd gear synchronizer ring assembly outer ring has 2 identification notches.
Position the 6th gear and the 3rd gear and the 3rd gear synchronizer ring assembly onto the bearing
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separator.
Align the 6 synchronizer ring tabs with the 6 gear slots.
6. NOTE: Lubricate the needle bearing with petroleum jelly to hold it in place during assembly.
Install the 3rd gear needle bearing.
7. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or
damage to the synchronizer assembly and synchronizer ring assembly can occur.
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NOTICE: Do not allow the 3rd gear needle bearing to slide down the countershaft while pressing
the components or damage to the needle bearing can occur.
While keeping the 3rd gear needle bearing from sliding down the countershaft, use the bearing separator
and a hydraulic press to install the 6th gear the 3rd gear and the 3rd gear synchronizer ring assembly.
Align the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.
8. Using the bearing separator and a hydraulic press, install the 5th gear.
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MT82
Output Shaft
Hydraulic Press
Bearing Separator
Materials
Name Specification
XT-11-QDC
DISASSEMBLY
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NOTICE: Hand-tighten the Bearing Separator to prevent gear damage.
NOTICE: Support the output shaft while using the press to prevent damage to the shaft or gears.
1. Remove the 5th/6th gear synchronizer assembly snap ring.
2.
Using the bearing separator and a hydraulic press, remove the 5th/6th gear synchronizer assembly.
Inspect the 5th/6th gear synchronizer assembly and the 6th gear synchronizer ring and cone for
wear or damage. Install new components as necessary.
3.
Remove the 6th gear.
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4.
Remove the 6th gear needle bearing.
Inspect the 6th gear needle bearing for wear or damage. Install a new needle bearing as necessary.
5. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.
ASSEMBLY
NOTICE: Lubricate all components with the recommended transmission fluid before reassembling.
1. Position the 5th/6th gear synchronizer assembly on the bearing separator and a hydraulic press.
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2. NOTICE: The 3 synchronizer ring tabs must engage into 3 synchronizer assembly slots or damage
to the synchronizer assembly and synchronizer ring can occur.
Install the 6th gear synchronizer ring and cone.

Align the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.
3. Install the 6th gear needle bearing.

4. Install the 6th gear.
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5. Using the bearing separator and a hydraulic press, install the 5th/6th gear synchronizer assembly and the
6th gear.
6. Install the 5th/6th gear synchronizer assembly snap ring.

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MT82
Synchronizers
Materials
Name Specification
High Temperature 4x4 Front Axle and Wheel Bearing Grease WSS-M1C267-A1
XG-11
DISASSEMBLY
1. NOTE: Make a note of/mark the installed positions of the components before removal.
1. Synchronizer sleeve.
2. Pressure pieces.
3. Synchronizer hub.
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2. NOTE: 3rd/4th gear only.
NOTE: Make a note of/mark the installed positions of the components before removal.
NOTE: Make sure that the endstops do not drop off of the synchronizer sleeve during disassembly so
that the correct installed position can be noted.
1. Remove the endstops from the synchronizer sleeve.

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ASSEMBLY
1. NOTE: 3rd/4th gear only.
1. Use grease to hold the endstops to the synchronizer sleeve.

Material: High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)
2. Install the synchronizer sleeve on the synchronizer hub.
2. NOTE: Make sure that the components are installed in their original positions.
2. Synchronizer sleeve.
3. Pressure pieces.
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MT82
Transmission Case
205-153 (T80T-4000-W)
Handle
307-541
Installer, Transfer Gear Bearing
TKIT-2005D1-F
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307-557
Installer, Ball Bearing
TKIT-2005U-FLM
TKIT-2005U-LM
TKIT-2006U-FLM/LM
TKIT-2006UF/FM
307-626
Installer, Differential Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
307-664
Case Bushing Installer
TKIT-2009OP-FLM
TKIT-2009OP-ROW
308-202 (T91T-7127-B)
Installer, Input Shaft Bearing
TKIT-1991-F/FM
TKIT-1991-FLM
308-812
Remover, Detent
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
Slide Hammer
Materials
Name Specification
TA-26
XT-11-QDC
DISASSEMBLY
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2.
Using the special tools, remove the input shaft bearing.
Inspect the input shaft bearing for wear or damage. Install a new bearing as necessary.
Use Special Service Tool: 308-202 (T91T-7127-B) Installer, Input Shaft Bearing. , 205-153 (T80T-
4000-W) Handle.
3.
Using the special tools, remove the countershaft bearing.
Inspect the countershaft bearing for wear or damage. Install a new bearing as necessary.
Use Special Service Tool: 308-202 (T91T-7127-B) Installer, Input Shaft Bearing. , 205-153 (T80T-
4000-W) Handle.
4. If replacing the transmission case, remove the clutch slave cylinder tube retaining clip.
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5. If replacing the transmission case, remove the transmission case vent tube.
6. Using a brass drift, tap the dowel pins flush with the transmission case.
7.
Remove the bolt and the reverse idler gear assembly.
Inspect the reverse idler gear for wear or damage. Install a new gear as necessary.
Inspect the reverse idler gear needle bearing and shaft for wear or damage. Install new
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9.
Using the special tools, remove the output shaft bearing.
Inspect the output shaft bearing for wear or damage. Install a new bearing as necessary.
Use Special Service Tool: 307-664 Case Bushing Installer. , 205-153 (T80T-4000-W) Handle.
10. If replacing the transmission case, use the special tools to remove the shift shaft detent.
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11. If leakage is present, remove the shift shaft seal.
12. Clean and inspect the front and rear transmission cases.
Inspect the shift shaft and shift rail bearing for wear or damage. Install new components as
necessary.
Inspect the rear countershaft for wear or damage. Install a new rear transmission case as
necessary.
ASSEMBLY
NOTICE: Lubricate all components with the recommended transmission fluid before reassembling.
1. If removed, install the shift shaft seal.

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2. If removed, use a soft-faced hammer to install the shift shaft detent.
3. NOTICE: Do not heat the transmission case higher the 120°C (248°F) maximum or damage to the
Using a heat gun, heat the transmission case to maximum of 120°C (248°F).
4. NOTICE: Install the output shaft bearing with the grooved side of the outer output shaft bearing
race facing the inside of the transmission case or damage to the transmission case can occur.
Using the special tools, install the output shaft bearing.

Use Special Service Tool: 307-541 Installer, Transfer Gear Bearing. , 205-153 (T80T-4000-W) Handle.
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5. Apply threadlock and install the bearing retaining bolts.
6. Install the reverse idler gear shaft.

7. Install the reverse idler gear and the reverse idler gear needle bearing.
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8. Install the reverse idler gear bracket.
9. Apply threadlock and install the reverse idler gear bracket bolt.
10. NOTICE: Do not heat the transmission case higher the 120°C (248°F) maximum or damage to the
Using a heat gun, heat the transmission case to maximum of 120°C (248°F).
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11. Using the special tools, install the countershaft bearing.
Use Special Service Tool: 307-557 Installer, Ball Bearing. , 205-153 (T80T-4000-W) Handle.
12. NOTICE: Install the input shaft bearing with the grooved side of the outer input shaft bearing race
facing the inside of the transmission case or damage to the transmission case can occur.
Using the special tools, install the input shaft bearing.

Use Special Service Tool: 307-626 Installer, Differential Seal. , 205-153 (T80T-4000-W) Handle.
13. Apply threadlock and install the bearing retaining bolts.

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14. NOTE: Before installing the vent tube, lightly coat the vent tube "O" ring with recommended transmission
fluid.
If removed, install the transmission case vent tube with the notch pointing to the front of the transmission
case.
15. If removed, install the clutch slave cylinder tube retaining clip.
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MT82
Assembly 07/31/2015
205-153 (T80T-4000-W)
Handle
308-806
Installer, Front Seal
TKIT-2010A-F
TKIT-2010A-LM
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TKIT-2010A-ROW
308-808
Installer, Rear Flange
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
308-809
Installer, Syncro Gear Pack
TKIT-2010A-ROW
308-811
Installer, Rear Seal
TKIT-2010A-F
TKIT-2010A-LM
TKIT-2010A-ROW
308-938
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Materials
Name Specification
TA-26
Motorcraft® MT82 Transmission Additive -
XL-18
Gasket Maker WSK-M2G348-A5
TA-16
NOTICE: Lubricate all components with the recommended transmission fluid before assembling.
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means
to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
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2. NOTICE: Do not heat the input shaft bearing higher than 120°C (248°F) maximum or damage to the
input shaft bearing can occur.
Using a heat gun, heat the input shaft bearing inner race to a maximum of 120°C (248°F).
3. Install the input shaft.

4. Install the input shaft snap ring.
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5. NOTICE: Make sure the small diameter side of the output shaft roller bearing cage is facing the
input shaft or damage to the output shaft bearing can occur.
With the small diameter side of the output shaft roller bearing cage facing the input shaft, install the output
shaft roller bearing.
6. NOTE: Apply petroleum jelly to hold the 5th gear synchronizer ring and the 5th gear synchronizer cone in
place during assembly.
Install the 5th gear synchronizer ring and the 5th gear synchronizer cone.
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7. Assemble the output shaft and countershaft assemblies.
8. NOTICE: Do not heat the countershaft bearing higher than 120°C (248°F) maximum or damage to
the countershaft bearing can occur.
Using a heat gun, heat the countershaft bearing inner race to a maximum of 120°C (248°F).
9. Install the output shaft and countershaft assembly.
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10. NOTICE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork
can occur.
Install the 5th/6th shift fork, the 5th/6th shift rail. Apply threadlock and sealer and loosely install the shift
fork pivot bolts.
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can occur.
Install the 3rd/4th shift fork, the 3rd/4th shift rail. Apply threadlock and sealer and loosely install the shift
fork pivot bolts.
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12. Tighten the 2 LH and the 2 RH shift fork pivot bolts.
13. Push down the 3rd/4th shift rail and the 5th/6th shift rail to lock the transmission into 2 gears.
14. NOTICE: When installing the bearings, do not over expand the bearing cages or damage to the
bearing cages can occur.
Slightly expand the center support bearing cages and slide the center support bearings down the shaft
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assemblies. Lock the bearing cage tabs.
15. Loosely install the center support and finger tighten the bolts.
16. NOTICE: Install the countershaft bolt with the transmission in the vertical position with the input
shaft facing down.
Apply threadlock and install the countershaft bolt.

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17. Remove the center support and the bolts.
18. Pull up on the 3rd/4th shift rail and 5th/6th shift rail to unlock the transmission from 2 gears.
19. NOTICE: The center support must be tightened evenly or damage to the center support or
Install the center support, apply threadlock and evenly tighten the center support bolts.
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20. Install the spring and spacers.

21. NOTE: Make sure the interlock plate moves freely.
Install the interlock plate, apply threadlock and install the interlock plate bolts.
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22. Install the 2nd gear needle bearing.
23. Install the 2nd gear.
synchronizer ring assembly can occur.
NOTE: The 2nd gear synchronizer ring assembly outer ring has 2 identification notches.
Install the 2nd gear synchronizer ring assembly.
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25. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer hub slots or damage to
the synchronizer hub and the synchronizer ring assembly can occur.
NOTICE: The long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear or damage to
the synchronizer hub can occur.
With the long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear, use the special tool and
install the 1st/2nd synchronizer hub.
Use Special Service Tool: 308-809 Installer, Syncro Gear Pack.
26. Install the 1st/2nd synchronizer hub snap ring.
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27. NOTE: Align the index marks made during removal on the synchronizer sleeve and the synchronizer
hub.
With the groove on the 1st/2nd synchronizer sleeve facing 2nd gear, install the 1st/2nd shift fork the 1st/2nd
shift rail and the 1st/2nd synchronizer sleeve.
28. NOTE: Slide the synchronizer sleeve up to install the pressure pieces.
Install the 3 pressure pieces.

damage to the synchronizer assembly and the synchronizer ring assembly can occur.
NOTE: The 1st gear synchronizer ring assembly outer ring has one identification notch.
Install the 1st gear synchronizer ring assembly.
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30. Install the 1st gear needle bearing.

synchronizer assembly and synchronizer ring assembly can occur.
Install the 1st gear.
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32. Using the special tool, install the reverse gear needle bearing race.
33. Install the reverse gear needle bearing.

34. Install the reverse gear.
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35. NOTICE: The shift shaft must be installed in the neutral position prior to installing the shift shaft
stop pin or damage to the shift shaft pin can occur.
Install the shift shaft in the neutral position, using a soft-faced hammer install the shift shaft stop pin.
36. Install the reverse gear synchronizer ring.

damage to the synchronizer assembly and the synchronizer ring can occur.
Using the special tool, install the reverse gear synchronizer assembly.
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38. NOTE: To install the reverse shift fork and the reverse shift rail assembly, the transmission must be in
neutral and the grooves on the shift rails must be aligned with the interlock plate.
Install the reverse shift fork and the reverse shift rail assembly.
39. Install the magnet.

40. Shift the transmission into 4th gear.
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41. NOTE: Art shown with internal components removed for clarity.
NOTE: Do not wait longer than 10 minutes to install the rear transmission case assembly due to rapid
cure of the sealant.
Clean the sealing surfaces of the front transmission case and the sealing surfaces of the rear transmission
case. Thinly coat the sealing surface of the front transmission case assembly and the sealing surface of
the rear transmission case assembly with gasket maker.
Material: Gasket Maker / TA-16 (WSK-M2G348-A5)
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42. NOTICE: The rear transmission case assembly must be installed evenly with the transmission
shifted into 4th gear, do not allow the shift rails to bind during installation or damage to the
transmission case assembly can occur.
Using the special tools, install the rear transmission case assembly.
Use Special Service Tool: 308-809 Installer, Syncro Gear Pack. , 308-808 Installer, Rear Flange.
can occur.
Apply threadlock and sealer and install the shift fork pivot bolts.
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44. Loosely install the bolts.
45. Using a brass drift, tap the dowel pins flush with the transmission case.
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47. Using a soft-faced hammer install the 4 shift rail detents.
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48. 1. Install the reverse lamp switch.
2. Attach the electrical connector retainer.
49. Install the OSS sensor and the bolt.

50. Install a new output shaft seal on the special tools.
Use Special Service Tool: 308-811 Installer, Rear Seal. , 205-153 (T80T-4000-W) Handle.
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51. Using the special tools, install the output shaft seal.
52. Using the special tools, install the output shaft flange.
Use Special Service Tool: 308-809 Installer, Syncro Gear Pack. , 308-808 Installer, Rear Flange.
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53. Clean the threads on the output shaft bolt and apply one dot of threadlock to the lower end of the output
shaft bolt threads. Using the special tools, install the output shaft flange bolt and tighten in 3 stages.
Torque:
Stage 2: Loosen: 5 turn(s)
54. Install the countershaft bolt cover in the clutch housing. Using the special tools, drive the countershaft bolt
cover into the clutch housing.
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55. Using the special tool, install the new input shaft seal.
Use Special Service Tool: 308-806 Installer, Front Seal.
56. 1. Position the clutch slave cylinder and if equipped, the clutch slave cylinder spacer and connect the
tube in the retaining clip.
2. Install the 2 bolts.
57. Add 1 bottle (.91 fl oz (27 ml)) of XL-18 to the transmission if a new synchronizer was installed.
Material: Motorcraft® MT82 Transmission Additive / XL-18
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MT82
Installation 10/1/2015
Materials
Name Specification
XG-1-E1
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1. Clean the input shaft and apply a small amount of grease to the splined surface and the pilot bearing
surface.
Material: Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)
2. Install the bellhousing bolts.

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3. Connect the clutch master cylinder tube and install the retainer.
4. Connect the electrical connectors and the wiring retainers.

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5. Install the LH HO2S and the catalyst monitor.
Refer to: Heated Oxygen Sensor (HO2S) (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L
Refer to: Catalyst Monitor Sensor (303-14C Electronic Engine Controls - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
6. Install the RHRH catalytic converter.

Refer to: Catalytic Converter RH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
7. Install the starter motor.

8. Install the transmission support insulator and crossmember and the bolts.
9. Install the gearshift lever.
Refer to: Gearshift Lever (308-06A Manual Transmission External Controls - 6-Speed Manual Transmission
- MT82, Removal and Installation).
10. Install the upper RH catalytic converter nut.

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Refer to: Transmission Draining and Filling (308-03A Manual Transmission - 6-Speed Manual Transmission
- MT82, General Procedures).
12. Connect the battery.

13. Fill and bleed the clutch hydraulic system.


308-06A Manual Transmission External Controls - 6-Speed Manual 2016 Mustang
Transmission - MT82
External Controls - Component Location
External Controls
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1 — Gearshift lever knob
2 — Gearshift lever boot
3 — Gearshift lever

Transmission - MT82
External Controls - Overview
Overview
The manual transmission external controls consists of the following:
Gearshift lever assembly

A service kit which includes (roll pin, spring, plastic blocker, shoulder bolt and anti-rattle washer)
A rear isolator
A front hub bushing
A tunnel seal, foam gasket and boot
Gearshift lever knob
Gearshift lever boot
System Operation
The manual transmission is controlled by a floor-mounted gearshift lever located in the floor console. When the
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operator moves the floor mounted gearshift lever, that movement is transmitted through a lever that is attached to
the transmission.

Transmission - MT82
Gearshift Lever
Transmission Jack
Removal
1. With the vehicle in N, position it on a hoist.

2. Rotate the gearshift knob counterclockwise and remove the gearshift knob.
3. Using an interior trim remover, release the gearshift lever boot from the floor console starting at the front
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sides and moving rearward.
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4. Release the retainers and remove the gearshift lever boot.

6. Support the crossmember with a transmission jack, remove the crossmember bolts and lower the
transmission.
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7. Remove the gearshift lever nuts.
8.
Remove the gearshift lever assembly.
1. Remove the gearshift lever-to-transmission bolt.
2. Remove the gearshift lever bolt.
3. Remove the gearshift lever assembly from the transmission by pulling towards the rear of the
vehicle.
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9.
Inspect the following components for damage. If damage is found, replace the components as necessary.
1. Rubber Boot
2. Service kit (roll pin, spring, plastic blocker, shoulder bolt and anti-rattle washer)
3. Rear isolator
4. Tunnel seal and foam gasket
5. Front hub bushing
Installation
1.
Install the gearshift lever assembly.
1. Install the gearshift lever bolt.
2. Install the gearshift lever-to-transmission bolt.
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2. Install the gearshift lever nuts.
3. Support the crossmember with a transmission jack, raise the transmission and install the crossmember
bolts.
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5. Install the gearshift lever boot and attach the retainers.
6. Install the gearshift lever boot to the floor console.

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7. Install the gearshift knob.

Transmission - MT82
Gearshift Lever Boot
Removal
1. Rotate the gearshift knob counterclockwise and remove the gearshift knob.
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2. Using an interior trim remover, release the gearshift lever boot from the floor console starting at the front
sides and moving rearward.
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3. Release the retainers and remove the gearshift lever boot.
Installation
1. Install the gearshift lever boot and attach the retainers.

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2. Install the gearshift lever boot to the floor console.
3. Install the gearshift knob.

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Transmission - MT82
Disassembly and Assembly 02/12/2015
Gearshift Lever
Punch
DISASSEMBLY
1. Remove the boot.
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2. Remove the tunnel seal.
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3. Remove the isolator.
4. Remove the steel sleeve.

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5. Remove the polymer bushing.
6. NOTE: The anti-rattle washer is installed above the roll pin.
1. Remove the anti-rattle washer.

2. Using a punch, remove the roll pin.
3. Remove and discard the bolt.
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ASSEMBLY
1. 1. Install a new bolt.

2. Install the roll pin.
3. Install the anti-rattle washer.
2. Install the polymer bushing.

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3. Install the steel sleeve.
4. Install the isolator.

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5. Install the tunnel seal.
6. Install the boot.

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309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 2016 Mustang
(308kW/418PS)
Exhaust System
Overview
NOTICE: Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is
continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely
blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel
can destroy the catalyst and render the catalytic converter useless. The addition of lead to the catalytic
converter can also solidify the catalyst, causing excessive back pressure in the exhaust system and
possibly causing engine damage.
NOTICE: Extremely high temperatures of 1,100°C (2,012°F) or above due to misfiring or an over-rich
fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter. Do
not continue to operate the vehicle if the engine is misfiring, there is a power loss or other unusual
operating conditions, such as engine overheating and backfiring.
NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause
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deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket
during vehicle operation.
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases
through the catalytic converters and a muffler assembly. The catalytic converters also play a major role in
reducing air pollutants.
The exhaust system consists of:
a LH one-piece catalytic converter manifold that is mounted to the LH cylinder head.
a RH one-piece catalytic converter manifold that is mounted to the RH exhaust manifold.
a muffler inlet pipe that is mounted to the LH catalytic convrter to the muffler and tailpipe assembly.
a underbody resonator which is part of the muffler and tailpipe assembly.
a muffler and tailpipe assembly with isolators.
The catalytic converter plays a major role in the emission control system by operating as a gas reactor. Its
function is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce
air pollutants.
The catalyst material inside the catalytic converter consists of a ceramic substrate.
The catalytic converter is designed to provide a long life. No maintenance is necessary.
Sound insulators and shields, attached to the underbody and exhaust system to protect the vehicle from exhaust
system heat and should be inspected at regular intervals to make sure they are not dented or out of position. If a
sound insulator and shield is damaged or shows evidence of deterioration, install a new insulator and shield. The
sound insulators and shields for the muffler, muffler pipe, resonator and catalytic converter pipe are installed
separately.
Some exhaust fasteners must be discarded and new ones installed as indicated in the procedures. Discard any
damaged or heavily corroded fasteners and install new ones as necessary. Some exhaust fasteners are of a
prevailing torque design. Use only new fasteners with the same part number as the original. Tighten the fasteners
to the specified torque during reassembly to make sure of correct retention of exhaust components.

(308kW/418PS)
Exhaust System
Symptom Chart(s)
Symptom Chart: Symptom Chart - Exhaust System
Verify the customer concern. Inspect the components of the exhaust system for obvious signs of damage or other
mechanical concerns using the following chart.
Visual Inspection Chart - Mechanical
Mechanical
Exhaust pipe pinched or crushed
Damaged muffler and tailpipe
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Broken or damaged exhaust hanger brackets
Damaged catalytic converters
Loose or damaged heat shields
Verify the exhaust system is installed correctly, with clamps correctly located and tightened to specifications. If the
fault is not visually evident, determine the symptom. GO to Symptom Chart below.
Symptom Chart

Vehicle has low or no Exhaust pipe REFER to the Powertrain Control/Emissions Diagnosis
power — vehicle pinched or crushed (PC/ED) manual.
performance complaint Damaged catalytic
converters
Loose obstruction in
exhaust
Restricted exhaust CHECK drain holes for foreign material. PARK the vehicle
(possible frozen inside to thaw. TEST the vehicle for normal operation. If
condensate in muffler) the concern is still present, REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
Burning smell — usually Foreign material INSPECT the exhaust system for foreign material or
occurs at idle, with caught in exhaust missing heat shields. REPAIR or INSTALL new
possible traces of system components as necessary.
smoke Missing heat shields
Odor — described as a Catalytic converters At times, a slight sulfur smell is normal for catalytic
sulfur or rotten egg Excessive sulfur converters. The cause is the sulfur content in the gasoline
smell content in fuel being used. ADVISE the customer no repair is required.
Rich fuel conditions REFER to the Powertrain Control/Emissions Diagnosis
Misfire conditions (PC/ED) manual.
Visible rust on surface Catalytic Surface rust is a characteristic of materials used on

of exhaust pipes converters/exhaust system exhaust systems. Exposure to heat or road salt may result
in surface rust. INSPECT for perforations. If there are no
perforations, the condition is normal.
Symptom Chart: Symptom Chart - NVH
Symptom Chart

Rattle, squeaks or buzz Loose or damaged heat INSPECT the exhaust system for loose or missing heat
type noise — from the shield shields or foreign material trapped between the heat
bottom of the vehicle shields and the exhaust system components. If any heat
shields are loose, INSTALL worm gear clamp
7L5Z-5A231-AA and tighten to 7 Nm. If the heat shields
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are missing or a rattle, noise or buzz condition persists,
INSTALL a new heat shield or component as necessary.
Loose or damaged VERIFY the exhaust isolators are correctly installed.
exhaust isolators INSPECT the exhaust isolators for wear or damage.
INSTALL new isolators as necessary.
Damaged exhaust INSPECT the exhaust system components for damage or
isolator hanger bracket broken hangers. INSTALL new components as necessary.
CHECK for loose or damaged exhaust hanger brackets or
fasteners. TIGHTEN the bolts to specification or INSTALL
new components as necessary.
Loose or damaged MOVE the exhaust system to simulate the bouncing action
catalytic converters or of the vehicle, checking for exhaust-to-body contact while
muffler 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.
Exhaust grounded to INSPECT for signs of exhaust components-to-body
chassis contact. REPAIR or INSTALL new components as
necessary.
Drone or clunk type noise Loose or damaged INSPECT the exhaust isolators for wear or damage.
— from the bottom of the exhaust isolators INSTALL new isolators as necessary.
vehicle
Exhaust grounded to INSPECT for signs of exhaust components-to-body
chassis contact. REPAIR or INSTALL new components as
necessary.
Whistles, boom, hum or Exhaust system leak INSPECT the entire exhaust system for leaks. CHECK for
ticking type noise — noise punctures, loose or damaged clamps/fasteners, gaskets,
tends to change as the sensors or broken welds. EXAMINE the chassis for
engine warms. The noises grayish-white or black exhaust soot, which indicates
are often accompanied by exhaust leakage at that point. To magnify a small leak,
exhaust fumes have an assistant hold a shop towel over the tail pipe outlet
while listening for a leak. REPAIR or INSTALL new
Catalytic converters 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 converters.
DETERMINE if there are loose or broken baffles in the
muffler, or a loose or broken element in the catalytic
necessary.
Exhaust CONFIRM the drain holes are the noise source. INSTALL
muffler/resonator drain new components as necessary.
hole enlarged due to
corrosion
Hissing or rushing noise Exhaust system CHECK the exhaust system for leaks. Using a rubber
— high frequency sound Exhaust flow through mallet, TAP on the exhaust components to duplicate the
and the vehicle pipes noise concern. Lightly TAP on the muffler and the catalytic
performance is unaffected converter. DETERMINE if there are loose or broken baffles
in the muffler, or a loose or broken element in the catalytic
necessary.
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Pinging noise — occurs Catalytic Cool down pinging is a result of the exhaust system
when exhaust system is converters/exhaust expanding and contracting during heating and cooling. This
hot, engine turned off system is a normal condition.
Vibration — occurs at idle Loose or damaged INSPECT the exhaust isolators for wear or damage.
and at low speeds. Also exhaust isolator INSTALL new isolators as necessary.
accompanied by a clunk
Loose or damaged INSPECT the exhaust isolator hanger brackets for wear or
or buzz type noise
exhaust isolator hanger damage. INSTALL or REPAIR as necessary.
brackets
Exhaust system REPAIR or INSTALL new components as necessary.
grounded to chassis
Engine drumming noise — Damaged or misaligned INSPECT the exhaust system for loose or damaged
normally accompanied by exhaust system fasteners or isolators. REPAIR or INSTALL new
vibration components as necessary.
Sputter type noise — Damaged or worn INSPECT the exhaust system for leaks or damage.
noise worse when cold, exhaust system REPAIR as necessary.
lessens or disappears
when the vehicle is at
operating temperature
Thumping noise — from Misaligned exhaust CHECK the exhaust system to chassis clearance. CHECK
the bottom of the vehicle, system the exhaust system isolators for damage. REPAIR as
worse during acceleration necessary.
Engine vibration — is felt Strain on exhaust REPAIR or INSTALL new components as necessary.
with increases and system isolators
decreases in engine rpm
Drumming noise — Exhaust system REPAIR or INSTALL new components as necessary.
occurs inside the vehicle vibration excites the
during idle or high idle, hot body resonances
or cold. Very inducing interior noise
low-frequency drumming
is very rpm dependent

(308kW/418PS)
Catalytic Converter LH
Base Part Number: 5E214
303-050 (T70P-6000)
303-F072
Support Bar, Engine
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Removal
NOTE: If the catalytic converter is not being replaced, the HO2S and the catalyst monitor sensor do not need to
be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.
NOTE: Clean all exhaust connections before reassembly.

2. Disconnect the battery negative and positive cable.

3. NOTICE: Make sure to minimize damage to the sealer foam and avoid pulling apart dash seal
brackets from retainer pins. Excessive damage may allow engine noise, fumes, air or water to
enter the passenger compartment.
Loosen the dash seal.

1. Remove the nuts.
3. Hand start the nuts.
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4. Steering wheel in straight ahead position.
5. Remove the LH motor mount nut.

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6. Remove the RH motor mount nut.
Remove and discard the nuts, remove the strut tower cross brace.
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damage.

13.
Detach the steering column lower shaft from the coupling.
components that could lead to loss of steering control during vehicle operation and could
result in serious personal injury or death.
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).
NOTE: Vehicles equipped with LHD.
Remove and discard the bolt.

2. NOTE: Vehicles equipped with RHD.

3. Pull apart the steering column lower shaft from the coupling.
4. After reassembly, inspect the steering column lower shaft.
14. Remove the muffler inlet pipe.

Refer to: Muffler Inlet Pipe (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS),
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15. Remove the bolts and stud bolts and remove the LH motor mount bracket.
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2. Disconnect the catalyst monitor sensor electrical connector.
17. Remove and discard the nuts, remove the LH catalytic converter.
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Installation
2. 1. Position the catalytic converter onto the engine and finger-tight the nuts.
2. Tighten the nuts in the sequence shown.
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3. Check the exhaust system for leaks.

(308kW/418PS)
Catalytic Converter RH
Removal
NOTE: If the catalytic converter is not being replaced, the HO2S and the catalyst monitor sensor do not need to
be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.

2. Loosen the clamps, release the tabs and slide the clamps back on the muffler. Separate the muffler and
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tailpipe from the RH catalytic converter and LH muffler inlet pipe.

2. Remove and discard the nuts and remove the catalytic convertor.
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4. Remove and discard the gasket.
Installation

(308kW/418PS)
Muffler and Tailpipe
Materials
Name Specification
Threadlock and Sealer -
TA-25-B
Removal
NOTE: Do not excessively bend, twist or allow the exhaust to hang from the flexible joint or damage to the
exhaust system may occur.
NOTE: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.
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2. 1. Convertible top vehicles only, remove the retainers and the brace.
2. During assembly, clean the retainers and apply the thread lock.
Material: Threadlock and Sealer / TA-25-B
3. Loosen the clamps and separate the muffler and tailpipe from the RH catalytic converter and LH muffler
inlet pipe.
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4. 1. Remove the LH and RH rear exhaust hanger isolator bracket bolts from the rear subframe.
2. Unhook the rear exhaust hanger isolators and remove the muffler and tailpipe.
Installation

(308kW/418PS)
Muffler Inlet Pipe
Removal

2. Loosen the clamps and separate the muffler and tailpipe from the RH catalytic converter and LH muffler
inlet pipe.
3. Loosen the ball clamp, release the bracket tab and remove the muffler inlet pipe.
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Installation

310-01D Fuel Tank and Lines - 5.2L 32V Ti-VCT 2016 Mustang
Specifications
Item Specification
Fuel Tank Capacity
Fuel Tank Capacity - 2.3L GTDi 15.5 gal (58.67 L)
Fuel Tank Capacity - 3.7L Duratec, 5.0L Ti-VCT, 5.2L Ti-VCT 16.0 gal (60.55 L)
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Fuel Tank and Lines - Overview
The fuel system consists of the :
saddle-type fuel tank.

quick connect fuel and vapor tube couplings.
fuel tank filler pipe assembly, which cannot be modified in any way, that also contains a restrictor plate to
permit only unleaded fuel to be pumped into the tank.
has an Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is
serviced only by the installation of a new fuel tank filler pipe assembly.
two Fuel Pump Control Modules (FPCM).
fuel rail.
fuel injectors.
an in-line serviceable fuel filter
Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).
Electronic Returnless Fuel System (ERFS).
Fuel Level Sensor
Fuel Pump (FP) module containing:
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Two electric Fuel Pumps which provide pressurized fuel to the fuel rail.
The Fuel Level Sender
A check valve which maintains system pressure after the pump is shut off.
A pressure relief for overpressure protection in the event of restricted fluid flow.
The vehicle:
has a serviceable fuel level sender mounted on the fuel pump module.
has a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped into
the fuel tank.
has an Easy Fuel (capless) fuel tank filler pipe assembly, which cannot be modified in any way.
has a supplemental refueling adapter located in the luggage compartment.
has fuel tubes (liquid and vapor) combined in a bundle along with the brake tubes mounted on the
underside of the floorpan and covered with a protective cover shield.
has quick connect and spring lock fuel tube couplings.
has two Fuel Pump Control Modules (FPCM) that shut off fuel in the event of a collision.
Fuel Pump Shut-off Feature
NOTE: Refer to the Description and Operation, Intelligent Access with Push Button Start in Section 419-01A to
review the procedures for achieving the various ignition states (ignition OFF, ignition in ACCESSORY, ignition
ON and ignition START) on vehicles with this feature.
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump and Sender Shut-off
Feature that is initiated by the event notification signal.
The event notification signal is a signal provided by the RCM to the FPDM. Signal communication between the
RCM and the FPDM allows the PCM to shut-off the Fuel Pump.
Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first turning the
ignition to the OFF position and then turn the ignition to the ON position. In some instances the vehicle may not
start the first time and may take one additional ignition cycle.

Fuel Tank and Lines
Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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Fuel Level Sender
Removal
1. Remove the Fuel Pump and Sender Unit.

Refer to: Fuel Pump and Sender Unit (310-01D Fuel Tank and Lines - 5.2L 32V Ti-VCT, Removal and
Installation).
2.
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Installation

Fuel Level Sensor
292-00004
Fuel Tanker 100 GPM
310-123
Locking Ring, Fuel Tank
TKIT-2004J-F
TKIT-2005U-LM
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Removal

Refer to: Fuel System Pressure Release (310-00D Fuel System - General Information - 5.2L 32V Ti-VCT,

3. NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter and a 6 ft. length of 5/8 in. semi-rigid fuel drain tube into the Easy
Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.
4. NOTE: This step is to remove approximately 3/16 tank of the fuel (3 gallons) from a completely full fuel
tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel
Pump and Sender Unit mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove as much fuel as possible from the tank.
Use Special Service Tool: 292-00004 Fuel Tanker 100 GPM.

6. Remove the access cover and position aside.
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7. Disconnect electrical connector and fuel tube quick release coupling.
Refer to: Quick Release Coupling (310-00D Fuel System - General Information - 5.2L 32V Ti-VCT, General
Procedures).
8. NOTICE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the Fuel
Pump and Sender Unit when removing the lock ring.
Using the special tool remove the Fuel Pump and Sender Unit lock ring.
Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.
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9. NOTICE: The Fuel Pump and Sender Unit must be handled carefully to avoid damage to the float
arm.
Position the Fuel Pump and Sender Unit aside. Using the Fuel Storage Tanker, completely drain the
remaining fuel from the LH saddle of the fuel tank.
10. NOTE: Inspect the surfaces of the Fuel Pump and Sender Unit flange and fuel tank O-ring seal contact
surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank.
Install a new Fuel Pump and Sender Unit or fuel tank if the O-ring seal contact area is bent, scratched or
corroded.
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12. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of
any dirt or foreign material.

13. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level
sensor when removing the lock ring.
Using the special tool remove the Fuel Level Sensor lock ring.
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14. Disconnect the internal fuel tube-to-Fuel Level Sensor quick connect coupling.
Procedures).
Installation
1. NOTE: Make sure to install a new Fuel Level Sensor O-ring seal.
NOTE: Make sure the alignment tabs on the Fuel Level Sensor and the fuel tank meet prior to tightening
the Fuel Level Sensor lock ring.
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Fuel Lines
Removal
1. Remove the fuel tank.

Refer to: Fuel Tank (310-01D Fuel Tank and Lines - 5.2L 32V Ti-VCT, Removal and Installation).
2. Remove LH Catalytic Converter.

Refer to: Catalytic Converter LH (309-00D Exhaust System - 5.2L 32V Ti-VCT, Removal and Installation).
3. Remove the heat shield.

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4. Release the fuel line from the retainers.
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5. Disconnect the fuel line-to-fuel rail jumper tube spring lock coupling.
Refer to: Spring Lock Couplings (310-00D Fuel System - General Information - 5.2L 32V Ti-VCT, General
Procedures).
6. Remove the nuts, bolts, push-pins and splash shield.

7. Remove the nuts and the fuel tank deflector.
8. NOTE: Some residual fuel may remain in the fuel lines and filter. Upon disconnecting or removal,
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carefully drain into a appropriate container.
Disconnect the fuel line quick release couplings at the fuel filter.
Refer to: Quick Release Coupling (310-00D Fuel System - General Information - 5.2L 32V Ti-VCT,
Release the retainers and remove the fuel line.
Installation
1. NOTE: Make sure the fuel lines are completely seated and that the quick release couplings are locked
correctly in place. Pull on the fuel lines to make sure they are fully seated. Pressurize the system and
check for leaks.
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Fuel Pump and Sender Unit
292-00004
Fuel Tanker 100 GPM
310-123
TKIT-2004J-F
TKIT-2005U-LM
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Removal



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Procedures).
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8. Using the lock ring wrench remove the Fuel Pump and Sender Unit lock ring.
9. Disconnect the internal fuel tube-to-Fuel Pump and Sender Unit quick connect coupling and remove the Fuel
Pump and Sender Unit.
Procedures).
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Installation
1. NOTE: Make sure to install a new Fuel Pump and Sender Unit O-ring seal.
NOTE: Make sure the alignment tabs on the Fuel Pump and Sender Unit and the fuel tank meet prior to
tightening the Fuel Pump and Sender Unit lock ring.

Fuel Tank
310-123
TKIT-2004J-F
TKIT-2005U-LM
Materials
Name Specification
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TA-25-B
Removal
NOTE: Removal steps in this procedure may contain installation steps.


3. Drain the fuel tank.

Refer to: Fuel Tank Draining (310-00D Fuel System - General Information - 5.2L 32V Ti-VCT, General
Procedures).

5. Index mark the driveshaft and pinion flange for reference during installation.
Remove the driveshaft to pinion flange bolts.
Support the driveshaft.

flange.
Separate the driveshaft from the pinion flange.
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Remove the driveshaft center support bearing bolts and lower the driveshaft away from the rear axle
flange.
8. Release the clamp and disconnect the fuel tank filler pipe from the fuel tank.
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9. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
Procedures).
10. Remove the nut and position the LH emergency brake cable bracket aside.
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11. Remove the nut and position the RH emergency brake cable bracket aside.
12. Using an appropriate impact tool and a TP50 "Torx Plus" Socket Driver, remove the fuel tank strap bolts.
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13. NOTICE: Once the fuel tank is removed from the vehicle, reinstall the driveshaft center support
bearing bolts by hand and support the rear of the driveshaft with a jackstand or mechanics wire.
1. Lower the front of the fuel tank.

Installation
1. 1. Position the fuel tank above the rear differential.

2. Raise the fuel tank into position.
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2. Clean the bolts and weld nuts lightly with a wire brush.
Apply the thread locking sealant to the bolt threads.
NOTE: To insure that the bolts are threaded in straight, start the bolts by hand and turn several
threads before tightening.
Position the fuel tank straps and install the bolts.

3. Reposition the LH emergency brake cable bracket and install the nut.
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4. Reposition the RH emergency brake cable bracket and install the nut.
5. Connect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
Procedures).
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6. Connect the hose to the fuel tank and tighten the clamp .
may occur.
Align the index marks on the driveshaft to the rear axle pinion flange.
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8. Clean the bolts.
Install the bolts.
9. Clean the bolts.

Apply thread locking sealant to the bolt threads.
Install the bolts.
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corroded.
Install a new O-ring seal.
Using the special tool install the Fuel Pump and Sender Unit lock ring.
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13. Connect electrical connector and fuel tube quick release coupling.
Procedures).
14. Install the access cover.

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corroded.
Install a new Fuel Level Sensor O-ring seal.
16. NOTICE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the fuel
level sensor when removing the lock ring.
Using the special tool install the fuel level sensor lock ring.
Connect the electrical connector.
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Fuel Tank Filler Pipe
292-00004
Fuel Tanker 100 GPM
Removal

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4. NOTE: This step is to remove approximately one-eighth tank of the fuel from a completely full fuel tank
and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the fuel tank
filler pipe inlet.
Attach the Fuel Storage Tanker to the fuel drain tube and remove approximately one-eighth (approximately
2 gallons) of fuel from the tank.
5. Remove the rear wheel on the LH side.
6. Remove the retainers and position aside LH rear wheel splash shield aside.
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7. NOTE: Some fuel may remain in the fuel tank filler pipe after draining. Carefully disconnect the fuel tank
filler pipe hose from the fuel tank and drain any residual fuel into a suitable container.
Release the clamp and disconnect the Fuel Tank Filler Pipe from the fuel tank.
8. 1. Disconnect the vapor tube Quick Release Coupling.

2. Remove retainers and the Fuel Tank Filler Pipe.
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Installation

Fuel Filter
Removal


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4. NOTE: Some residual fuel may remain in the fuel lines and filter. Upon disconnecting or removal,
carefully drain into a appropriate container.
Disconnect the fuel line quick release couplings.

Loosen the bolt and remove the fuel filter from the fuel filter bracket.
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Installation
1. NOTE: Make sure the fuel lines are completely seated and that the quick release couplings are locked
correctly in place. Pull on the fuel lines to make sure they are fully seated. Pressurize the system and
check for leaks.

310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L 2016 Mustang
Specifications
Item Specification
Fuel Pressure
Engine running - 2.3L GTDi (Low pressure side) 50.8–75.4 psi (350–520 kPa)
Engine running - 3.7L Duratec, 5.0L Ti-VCT 53.1–63.1 psi (366–435 kPa)
Fuel Tank Capacity
Fuel Tank Capacity - 3.7L Duratec, 5.0L Ti-VCT 16.0 gal (60.55 L)
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Fuel System - Overview
Overview
The fuel system consists of the :

quick connect fuel and vapor tube couplings.
fuel tank filler pipe assembly, which cannot be modified in any way, that also contains a restrictor plate to
permit only unleaded fuel to be pumped into the tank.
has an Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is
serviced only by the installation of a new fuel tank filler pipe assembly.
has a Fuel Pump Control Module located under the rear seat cushion LH side of the vehicle.
fuel rail.
fuel injectors.
Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).
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Mechanical Returnless Fuel System (MRFS).
Fuel Level Sensor
Fuel Pump (FP) module containing:
The electric FP module which provides pressurized fuel to the high pressure Fuel Pump (FP) .
The Fuel Level Sender.
A lifetime fuel filter providing filtration to protect the fuel injectors from foreign material.
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump and Sender Unit Shut-off
The event notification signal is a signal provided by the RCM to the Fuel Pump Control Module. Signal
communication between the RCM and the Fuel Pump Control Module allows the PCM to shut-off the Fuel Pump.

Fuel System
Symptom Chart(s)
Symptom Chart: Fuel System
for information regarding Ford-specific diagnostic practices.
NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns, refer to Refer to
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Symptom Chart
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Slow to fill Fuel tank filler pipe Refer to GO to Pinpoint Test A
Fuel tank filler pipe vent tube, if
equipped
EVAPsystem
Fuel tank inlet check valve (part
of the fuel tank)
Fuel level vent valve (part of the
fuel tank)
All other fuel system Fuel system components Refer to Powertrain Control/Emissions
concerns Diagnosis (PC/ED) manual.
Diagnostic Routine(s)
Slow to Fill
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 ORVR system.
PINPOINT TEST A : SLOW TO FILL

A1 CHECK COMPONENTS FOR SIGNS OF DAMAGE
Visually inspect the following components for signs of damage:
Fuel tank filler pipe
Fuel tank filler pipe vent tube, if equipped
EVAP system
Fuel tank inlet check valve (part of the fuel tank)
Fuel level vent valve (part of the fuel tank)
Was the cause of the concern found?
Yes REPAIR or INSTALL new components to correct the concern.

No GO to A2
A2 CHECK THE SYSTEM FOR ANY EVAP (EVAPORATIVE EMISSION) DTC'S

Connect the scan tool.
Check the system for any EVAP DTC's.
Are any DTC's present?
Yes Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.

No GO to A3
A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK

NOTE: During normal fuel fill the Fuel Tank Pressure (FTP) Sensor value starts at 2.6 volts and will
increase .3 to .7 of a volt from its starting point.
Monitor the Fuel Tank Pressure (FTP) reference value while filling the fuel tank. Refer to the Reference
Values in the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Refer to Powertrain
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Is FTP within specification?
Yes GO to A5
No GO to A4
A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM
DISCONNECTED
Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP canister.
NOTE: During normal fuel fill the Fuel Tank Pressure (FTP) Sensor value starts at 2.6 volts and will
increase .3 to .7 of a volt from its starting point.
Monitor the FTP reference value while filling the fuel tank. Refer to Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Is FTP within specification?
Yes INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or
restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system
components.
No GO to A5
A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION
Remove the fuel tank filler pipe assembly.
REFER to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).
Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for a blockage or restriction.
Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted?
Yes If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be
repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube.
No GO to A6
A6 CHECK THE FUEL TANK INLET CHECK VALVE

Inspect the fuel tank inlet check valve for restriction or sticking.
Is the fuel tank inlet check valve restricted or sticking?
Yes If possible, REPAIR the restriction. If the restriction cannot be repaired, INSTALL a new
fuel tank.
REFER to: Fuel Tank (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).
No INSTALL a new fuel tank.
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Fuel System Pressure Check
310-D009 (D95L-7211-A)
Fuel Pressure Test Kit
Check
NOTE: This Fuel System Pressure Check is for the low pressure side of the system.

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3. Disconnect the fuel jumper tube-to-fuel rail quick release coupling.

4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.
Use Special Service Tool: 310-D009 (D95L-7211-A) Fuel Pressure Test Kit.
5. NOTE: The FPDM electrical connector was previously disconnected to release the fuel system pressure
and must be reconnected to test the fuel system pressure.
Reconnect the FPDM electrical connector.

7. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to completing the
fuel system pressure test.
Test the fuel system pressure to make sure it is within the specified range. For additional information, refer
to Specifications in this section.
8. After completion of the fuel system pressure test, disconnect the battery ground cable, open the drain
valve on the Fuel Pressure Test Kit and release any residual fluid into an appropriate container.
9. Remove the Fuel Pressure Test Kit by reversing the installation steps.
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Fuel Tank Draining
292-00004
Fuel Tanker 100 GPM
310-123
TKIT-2004J-F
TKIT-2005U-LM
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Draining



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arm.
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corroded.

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Using the special tool remove the fuel level sensor lock ring.
14. NOTICE: The fuel level sensor must be handled carefully to avoid damage to the float arm.
Position the fuel level sensor aside. Using the Fuel Storage Tanker, completely drain the RH saddle of the
fuel tank.
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15. NOTE: Inspect the surfaces of the Fuel Level Sensor flange and fuel tank O-ring seal contact surfaces.
Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new
Fuel Level Sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
Remove and discard the Fuel Level Sensor O-ring seal.

Quick Release Coupling
Disconnect
NOTICE: When reusing liquid or vapor tube connections, 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 may 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 may occur. Always install blanking plugs to any open orifices or tubes.
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: Type 1
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1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure.

3.
4.
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Connect
1. Inspect and clean both quick coupling ends.
2. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the tabs are locked in place.
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Disconnect
cause fuel leaks.
NOTE: Type 2

3.
1.
4.
Connect
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2.

Disconnect
cause fuel leaks.
NOTE: Type 3

3.
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Connect
1.
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2.

Disconnect
cause fuel leaks.
NOTE: Type 4

3.
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4.
Connect
1.
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Disconnect
NOTICE: When reusing liquid 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 may occur.
cause fuel leaks.
NOTE: Type 5

3.
1.
4.
Connect
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Disconnect
NOTICE: When reusing liquid 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 may occur.
cause fuel leaks.
NOTE: Type 8

3. 1. Release the secondary locking tab.

2. Depress the primary locking tab.
3. Separate the quick release coupling from the tube.
Connect
1. 1. Push the quick release coupling onto the tube.
2. NOTE: Pull on the quick release coupling and the fitting to make sure it is securely fastened.
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Lock the secondary locking tab.


Spring Lock Couplings
310-S039 (T90T-9550-S)
Disconnect Tool, Spring Lock Coupling
TKIT-1990-LMH
Disconnect
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. Apply clean engine oil to the end of the tube before inserting
the tube into the connector.
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damage can occur. Always install plugs to any open orifices or tubes.
1. If servicing a liquid fuel tube spring lock coupling, release the fuel system pressure.

3. If equipped, remove the fuel tube safety clip.
4. Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock coupling to
release.
Use Special Service Tool: 310-S039 (T90T-9550-S) Disconnect Tool, Spring Lock Coupling.
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5. Separate the spring lock coupling from the tube.
Connect
1. Align and push the spring lock coupling onto the tube until fully seated.
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2. If equipped, install the fuel tube safety clip.
3. Pull on the coupling to make sure it is fully engaged.


Fuel System Pressure Release
Pressure release
NOTE: The FPDM is located on the LH side, beneath the rear seat cushion.

2. NOTE: On vehicles equipped with Gasoline Turbocharged Direct Injection (GTDI), running the engine
with the FPDM disconnected will remove most of the pressure from both the low and high pressure sides
of the system.
Disconnect the FPDM electrical connector.
3. Start the engine and allow it to idle until the engine stalls.
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4. Turn the ignition switch to the off position.
5. When the fuel system service is complete, reconnect the FPDM electrical connector.
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7. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the
engine.
8. When service on the fuel system is complete, start the engine and check for leaks.

310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT 2016 Mustang
Specifications
Item Specification
Fuel Tank Capacity
Fuel Tank Capacity - 3.7L Duratec, 5.0L Ti-VCT 16.0 gal (60.55 L)
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Fuel Tank and Lines - Overview
Fuel System
The fuel tank and lines consist of the:

Fuel, vapor and brake tubes in an integrated bundle assembly.
Quick connect fuel and vapor tube couplings.
Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is serviced
only by the installation of a new fuel tank filler pipe assembly.
A supplemental refueling adapter located in the spare tire compartment.
A Fuel Pump Control Module (FPCM) .
FPDM
A Mechanical Returnless Fuel System (MRFS).
Fuel Level Sensor
A Fuel Pump (FP) and Sender Unit containing:
The electric Fuel Pump (FP) and Sender Unit which provides pressurized fuel to the high pressure
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Fuel Pump (FP) .
The Fuel Level Sender
A lifetime fuel filter providing filtration to protect the fuel injectors from foreign material.
The vehicle:
has a serviceable fuel level sender mounted on the fuel pump module.
has a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped into
the fuel tank.
has an Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way.
has a lifetime in tank fuel filter serviced as part of the fuel pump.
has fuel tubes (liquid and vapor) combined in a bundle along with the brake tubes mounted on the
underside of the floorpan and covered with a protective cover shield.
has quick connect and spring lock fuel tube couplings.
has a FPDM that shuts off fuel in the event of a collision.
NOTE: Refer to the Description and Operation, Intelligent Access with Push Button Start in Section 419-01A to
review the procedures for achieving the various ignition states (ignition OFF, ignition in ACCESSORY, ignition
ON and ignition START) on vehicles with this feature.
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump and Sender Shut-off
The event notification signal is a signal provided by the RCM to the FPDM. Signal communication between the
RCM and the FPDM allows the PCM to shut-off the Fuel Pump.

Fuel Tank and Lines
Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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Fuel Level Sender
Removal
1. Remove the Fuel Pump and Sender Unit.

Refer to: Fuel Pump and Sender Unit (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).

Release the locking tab.
Remove the Fuel Level Sender.
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Installation

Fuel Level Sensor
292-00004
Fuel Tanker 100 GPM
310-123
TKIT-2004J-F
TKIT-2005U-LM
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Removal



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arm.
corroded.
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13. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level
sensor when removing the lock ring.
Using the special tool remove the Fuel Level Sensor lock ring.
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14. Disconnect the internal fuel tube-to-Fuel Level Sensor quick connect coupling.
Installation
1. NOTE: Make sure to install a new Fuel Level Sensor O-ring seal.
NOTE: Make sure the alignment tabs on the Fuel Level Sensor and the fuel tank meet prior to tightening
the Fuel Level Sensor lock ring.
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Fuel Lines
Removal

2. Remove LH Catalytic Converter.

Refer to: Catalytic Converter LH (309-00C Exhaust System - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8
3. Remove the nuts and the heat shield.

4. Release the fuel line from the retainers.

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5. Disconnect the fuel line-to-fuel rail jumper tube spring lock coupling.
Refer to: Spring Lock Couplings (310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L

7. Remove the nuts and the fuel tank deflector.
8. Release the retainers and remove the fuel line.

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Installation
1. NOTE: Make sure the fuel tubes are completely seated and that the quick connect couplings are locked
correctly in place. Pull on the tube to make sure it is fully seated. Upon completion, pressurize the
system and check for leaks.
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Fuel Pump and Sender Unit
292-00004
Fuel Tanker 100 GPM
310-123
TKIT-2004J-F
TKIT-2005U-LM
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Removal



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8. Using the lock ring wrench remove the Fuel Pump and Sender Unit lock ring.
9. Disconnect the internal fuel tube-to-Fuel Pump and Sender Unit quick connect coupling and remove the Fuel
Pump and Sender Unit.
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Installation
1. NOTE: Make sure to install a new Fuel Pump and Sender Unit O-ring seal.
NOTE: Make sure the alignment tabs on the Fuel Pump and Sender Unit and the fuel tank meet prior to
tightening the Fuel Pump and Sender Unit lock ring.

Fuel Tank
310-123
TKIT-2004J-F
TKIT-2005U-LM
Materials
Name Specification
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TA-25-B
Removal


3. Drain the fuel tank.

Refer to: Fuel Tank Draining (310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L Ti-VCT
V8 (308kW/418PS), General Procedures).

5. Index mark the driveshaft and pinion flange for reference during installation.
Remove the driveshaft to pinion flange bolts.
Support the driveshaft.

flange.
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Separate the driveshaft from the pinion flange.
Remove the driveshaft center support bearing bolts and lower the driveshaft away from the rear axle
flange.
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8. Release the clamp and disconnect the fuel tank filler pipe from the fuel tank.
9. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
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10. Remove the nut and position the LH emergency brake cable bracket aside.
11. Remove the nut and position the RH emergency brake cable bracket aside.
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12. Using an appropriate impact tool and a TP50 "Torx Plus" Socket Driver, remove the fuel tank strap bolts.
13. NOTICE: Once the fuel tank is removed from the vehicle, reinstall the driveshaft center support
bearing bolts by hand and support the rear of the driveshaft with a jackstand or mechanics wire.
1. Lower the front of the fuel tank.

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Installation
1. 1. Position the fuel tank above the rear differential.

2. Raise the fuel tank into position.
2. Clean the bolts and weld nuts lightly with a wire brush.
NOTE: To insure that the bolts are threaded in straight, start the bolts by hand and turn several
threads before tightening.
Position the fuel tank straps and install the bolts.
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3. Reposition the LH emergency brake cable bracket and install the nut.
4. Reposition the RH emergency brake cable bracket and install the nut.
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5. Connect the fuel vapor tube assembly-to-fuel tank quick connect coupling.
6. Connect the hose to the fuel tank and tighten the clamp .
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may occur.
Align the index marks on the driveshaft to the rear axle pinion flange.
8. Clean the bolts.

Install the bolts.
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9. Clean the bolts.
Apply thread locking sealant to the bolt threads.
Install the bolts.

corroded.
Install a new O-ring seal.
Using the special tool install the Fuel Pump and Sender Unit lock ring.
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13. Connect electrical connector and fuel tube quick release coupling.
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corroded.
Install a new Fuel Level Sensor O-ring seal.
Using the special tool install the fuel level sensor lock ring.
Connect the electrical connector.
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Fuel Tank Filler Pipe
292-00004
Fuel Tanker 100 GPM
Removal

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4. NOTE: This step is to remove approximately one-eighth tank of the fuel from a completely full fuel tank
and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the fuel tank
filler pipe inlet.
Attach the Fuel Storage Tanker to the fuel drain tube and remove approximately one-eighth (approximately
2 gallons) of fuel from the tank.
5. Remove the rear wheel on the LH side.
6. Remove the retainers and position aside LH rear wheel splash shield aside.
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7. NOTE: Some fuel may remain in the fuel tank filler pipe after draining. Carefully disconnect the fuel tank
filler pipe hose from the fuel tank and drain any residual fuel into a suitable container.
Release the clamp and disconnect the Fuel Tank Filler Pipe from the fuel tank.
8. 1. Disconnect the vapor tube Quick Release Coupling.

2. Remove retainers and the Fuel Tank Filler Pipe.
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Installation

310-02 Acceleration Control 2016 Mustang
Acceleration Control - Overview
Overview
The acceleration controls consist of the accelerator pedal and sensor assembly.
The throttle is controlled by an APP sensor on the accelerator pedal assembly. The APP sensor sends a signal to
the PCM in response to throttle pedal movements initiated by the driver. The PCM sends a signal to the electronic
throttle control which increases and decreases throttle position.
The engine management system electronically operates the throttle of the engine in response to throttle 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.
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Acceleration Control
Symptom Chart(s)
REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. See Section 3, Symptom Charts.
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Accelerator Pedal
Removal
NOTE: To prevent setting Diagnostic Trouble Codes (DTCs), make sure the ignition switch is in the OFF position
prior to disconnecting the accelerator pedal electrical connector.
injury.
2. Disconnect the accelerator pedal sensor electrical connector. Remove the 3 nuts and the accelerator pedal
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and sensor assembly.
Installation

211-02 Power Steering 2016 Mustang
Power Steering - Overview
Overview
The EPAS system provides steering assist to the driver by replacing the conventional hydraulic valve system with
a steering gear equipped with an integrated electrical motor and PSCM. The motor operation and level of steering
assist provided is controlled by the PSCM.
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Power Steering - System Operation and Component Description
System Operation
System Diagram
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PSCM Network Input Messages

Message Module
ABS active ABS Used to confirm the operational state of the ABS.
Message Module
Ignition status BCM This message is first sent to the GWM and then to the PSCM. Used to confirm
the ignition status of the vehicle.
Power pack PCM This message is first sent to the GWM and then to the PSCM. Used to confirm
status the status of the operating mode; off - torque not available, on - torque not
available, start in progress - torque not available or on - torque available.
Power system BCM This message is first sent to the GWM and then to the PSCM. Used to confirm
status the status of the vehicle battery and charging system.
Stability control ABS Used to confirm the operational state of the stability control system.
brake active
Steering wheel ABS Used to verify the validity of the steering angle sensor.
angle
Suspension VDM This message informs the PSCM of the current driver selected suspension
driver mode mode; normal, comfort or sport. The PSCM adjusts the steering feel to match
request the suspension setting.
Traction control ABS Used to confirm the operational state of the traction control system.
brake active
Vehicle BCM This message is first sent to the GWM and then to the PSCM. Used to
configuration compare the PSCM configuration against the vehicles specific configuration
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information (central car configuration).
Vehicle lateral ABS Used by the PSCM for steering assist calculations.
acceleration
Vehicle lateral RCM Used by the PSCM for steering assist calculations.
acceleration
Vehicle ABS Used by the PSCM for steering assist calculations.
longitudinal
acceleration
Vehicle speed PCM This message is first sent to the GWM and then to the PSCM. Used to
determine the level of assist supplied to the steering gear.
Vehicle yaw rate ABS Used by the PSCM for steering assist calculations.
Wheel speed ABS Used to determine the level of assist supplied to the steering gear and to
data validate the steering wheel component angle by comparing the rotational
speeds of each wheel. The difference in the speed of each wheel is used to
derive a steering angle for comparison against the absolute steering angle
message from the SASM.
EPAS System
The PSCM controls the functions of the EPAS system and communicates with other modules over the HS-CAN2.
To activate, the EPAS system requires battery voltage and ignition voltage at the PSCM, the PSCM must
communicate with other modules over the HS-CAN2 and the PSCM must receive the power pack status message
from the PCM.
The main input for calculating the level of EPAS assist is the steering torque sensor signal (internal to the PSCM).
Vehicle speed is also taken into consideration in order to achieve the vehicle speed dependent steering assist
characteristic.
The EPAS gear uses an electric, reversible motor to apply the steering assist by moving the rack inside the
steering gear. The motor is connected to the rack of the steering gear by a toothed belt and pulley-bearing
assembly.
The PSCM continually monitors and adjusts steering efforts based on the steering torque sensor signal, motor
position and HS-CAN2 inputs to enhance the feel of the steering system. 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. Compensation is made to reduce the effect of pull or
drift experienced when driving on roads with a high degree of camber. Compensation is also made for the impact
of wheel imbalance on steering feel, up to a predetermined threshold.
The steering torque sensor senses the torque at the steering wheel. It is integrated into the PSCM and works by
measuring the relative rotation between an input and output shaft which are connected by a torsion bar. The
steering torque sensor sends out 2 PWM signals which allows a channel to channel cross-check and an accurate
correction of the neutral point.
The PSCM is self-monitoring and is capable of setting and storing Diagnostic Trouble Codes (DTCs). Depending
on the DTC set, the PSCM may enter a failure mode. In addition, the PSCM may send a request to the IPC to
display a message in the message center, alerting the driver of a potential EPAS concern. The warning message
is sent over the HS-CAN2 to the GWM which relays the message to the IPC over the HS-CAN3.
Failure Modes
When a DTC is present in the PSCM, the EPAS enters 1 of 2 modes of operation.
The EPAS enters a reduced steering assist mode to protect the internal components of the EPAS when a
non-critical safety concern is detected by the PSCM, concerns such as a loss of the vehicle speed message, low
battery voltage, high battery voltage or an over-temperature condition are considered non-critical safety concerns.
This reduced steering assist mode gives the steering operation a heavier than normal feel.
The EPAS enters a manual steering mode (no electrical steering assistance is provided) when a concern
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considered to be a critical safety concern is detected. In manual steering mode, the vehicle has mechanical
steering only which gives the steering operation a heavy feel.
Selectable Steering
The selectable steering button on the FCIM allows the driver to select 1 of 3 steering modes. These steering
modes alter the feel and response of the EPAS system. After a selection is made, a soft feedback bump may be
felt in the steering wheel. Pressing the switch causes the FCIM to send a message to the IPC and the PSCM.
The IPC displays the current mode in the message center and the PSCM modifies EPAS operation according to
the selected steering mode.
Normal: Default system setting. The system defaults to standard mode if the battery is disconnected.
Sport: Slightly higher effort required for steering with more road feel through the steering wheel.
Comfort: Slightly less effort required for steering with less road feel through the steering wheel.
If the vehicle is equipped with the selectable drive mode feature, the steering feel changes when a new drive
mode is selected. This automatic selection can be overridden by using the selectable steering button. For
additional information on the selectable drive mode feature,
Refer to: Anti-Lock Brake System (ABS) and Stability Control - System Operation and Component Description
EPAS Steering Gear
The EPAS gear is an assembly consisting of a PSCM, a motor, and a steering torque sensor, all of which are
serviced as an assembly. The inner and outer tie rods and the steering gear bellows boots are available
separately for service.
The steering torque sensor is mounted near the input shaft of the EPAS gear and is used by the PSCM to
determine how much force is being used to turn the steering wheel.
The EPAS gear has one inner tie rod located at each end of the gear assembly and is available separately
for service.
The EPAS gear has one outer tie rod located at each end of the gear assembly and is available separately
for service.
The EPAS gear has one bellows boot located at each side of the EPAS gear assembly. Each boot is held
in place with 2 boot clamps. The boots and clamps are available for service.
PSCM
The PSCM is the ECU for the EPAS system. The module monitors all sensor inputs and HS-CAN2 messages
relating to the EPAS system and directly controls the output of the EPAS motor.
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Power Steering
Interactive Diagnostics
Click here to access Guided Routine (EPAS).
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Steering Gear
204-816
Rack Holding Tool
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Boot Clamp Pliers

Oil Drain Equipment
Materials
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Name Specification
XG-1-E1
XO-5W30-QSP (U.S.)
Removal
All vehicles
1. If installing a new steering gear, connect the scan tool and upload the module configuration information
from the PSCM.

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4. On both sides. Remove the tie rod end.

Refer to: Tie Rod End (211-02 Power Steering, Removal and Installation).
Remove the bolts and the underbody shield.
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Remove the bolts and the support brackets.

1. Remove the 2 rearward underbody shield bolts.

2. Remove the 2 remaining underbody shield bolts and remove the underbody shield.
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9. 1. NOTE: If equipped.
Remove the underbody shield bolt.
2. NOTE: It is not necessary to separate the underbody shield from the V-brace.
Remove the 6 V-brace bolts and remove the V-brace and underbody shield.
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NOTICE: DO NOT hammer, pry or force steering column and column shafts during installation or
removal. Failure to follow this instruction may cause damage to steering components that could
lead to loss of steering control during vehicle operation and could result in serious personal injury
or death.
NOTICE: DO NOT attempt to remove or install the steering column lower coupler at the steering
gear without first loosening the steering column dash seal and fasteners. Failure to follow this
instruction may cause damage to steering components that could lead to loss of steering control
during vehicle operation and could result in serious personal injury or death.
Detach the steering column lower shaft from the lower coupler.
2. Pull apart the steering column shaft from the coupler.
3. Secure the lower shaft to the frame rail to avoid damaging it during steering gear removal.
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11. Disconnect the 2 EPAS gear electrical connectors and unclip the 4 wiring fasteners and position the wiring
harness aside.
12. NOTICE: When servicing inner tie rods, install a new bellows boot and clamps. The boots and
clamps are designed to provide 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 failure of the steering gear components. Zip ties must not be
used as they do not provide an airtight seal.
NOTICE: The inner ball joint grease is not compatible with water contamination. Do not allow water
to become trapped in the grease or degradation and failure of the joint may occur.
1. On both sides. Remove and discard the inner bellows boot clamp.
2. On both sides. Remove and discard the outer bellows boot clamp.
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13. NOTE: Move the bellows boot enough to gain access to the inner tie rod nut.
On both sides.
Position aside the bellows boot.
14. On both sides.

Position aside the steering stop.
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15. NOTE: The rack must be positioned completely to the LH side to gain clearance for tools.
Position the steering rack completely to the LH side.
16. NOTICE: Hold the steering gear rack while loosening the inner tie rod. Failure to hold the rack
securely could result in steering gear damage.
NOTICE: The steering gear rack holding tool must be reversed to remove the RH tie rod or damage
to the rack and/or special tool may occur.
NOTE: The holding tool can only be used on the LH side of the steering gear.
NOTE: LH side shown RH side similar.

On both sides.
Using the special tool to hold the rack and an appropriate size crows foot wrench or open end wrench,
remove and discard the inner tie rod.
Use Special Service Tool: 204-816 Rack Holding Tool.
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17. On both sides.
Remove and discard the steering stop.
2.3L EcoBoost (231kW/314PS)

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19. NOTE: If equipped with 2.3L EcoBoost and automatic transmission.
Remove the transmission fluid cooler tubes bracket-to-engine mount nut.
Remove the transmission fluid cooler tubes bracket-to-transmission nut and position the tubes aside.
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3.7L Duratec (227kW/301PS)
21. Open the starter motor solenoid battery cable cover.
22. 1. Remove the starter motor solenoid battery cable nut and then disconnect the starter motor solenoid
battery cable.
2. Remove the starter motor solenoid wire nut and then disconnect starter motor solenoid wire.
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Remove the bolt and ground wire from the RH side of the engine.
24. Remove the nut from the front of the RH engine mount bracket stud bolt and position the brackets for the
transmission cooling tubes and wire harness aside.
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25. Remove the nut from the front of the RH engine mount bracket stud bolt and position the bracket for the
wire harness aside.
5.0L 32V Ti-VCT/5.2L 32V Ti-VCT
26. Detach the wire harness retainers from the oil pan.
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5.2L 32V Ti-VCT
27. Detach the O2 sensor wire harness retainer from the oil pan and position the harness aside.
All vehicles
28. Remove and discard the LH steering gear bolt.

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29. Remove and discard the RH steering gear bolt.
30. On convertible vehicles. If equipped.

Remove the steering gear bracket bolt and the steering gear bracket.
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31. NOTE: The steering gear rack must be positioned so that the end of the rack is flush with the RH side of
the steering gear case to gain clearance for removal.
Position the steering gear rack so the end of the rack is flush with the RH side of the steering gear case.
32. NOTE: It will be necessary to slide the steering gear to the LH side of the vehicle, then rotate and remove
by lowering the RH side of the steering gear in order to remove it from the vehicle.
Remove the steering gear.

1. Slide the steering gear to the LH side of the vehicle.
2. Lower the RH side of the steering gear and remove it from the vehicle.
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1. 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
NOTICE: DO NOT attempt to remove or install the steering column lower coupler at the
steering gear without first loosening the steering column dash seal and fasteners. Failure to
follow this instruction may cause damage to steering components that could lead to loss of
steering control during vehicle operation and could result in serious personal injury or
death.
Remove and discard the steering coupler bolt.

2. Remove the steering coupler.
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Installation
All vehicles
1. Install the steering coupler

2. Install the new steering coupler bolt.
NOTE: The steering gear is shipped without the inner tie rods attached. The inner tie rods, bellows boots,
bellows boot clamps and tie rod end jamb nuts are supplied in a kit and are to be installed after the steering
gear is installed into the vehicle.
2. NOTE: It will be necessary to raise the LH side of the steering gear and slide it to the LH side of the
vehicle, then rotate and raise the RH side of the steering gear in order to install it into the vehicle.
Install the steering gear.

1. Lift the LH side of the steering gear and slide it to the LH side of the vehicle.
2. Raise the RH side of the steering gear and slide it to the RH side of the vehicle.
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On convertible vehicles. If equipped.

Install the steering gear bracket and the steering gear bracket bolt.

Install the new RH steering gear bolt.
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Install the new LH steering gear bolt.
6. On convertible vehicles. If equipped.

Tighten the steering gear bracket bolt.
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7. Tighten the new RH steering gear bolt.
8. Tighten the new LH steering gear bolt.

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5.2L 32V Ti-VCT
9. Position the O2 sensor wire harness and attach the harness retainer to the oil pan.
5.0L Ti-VCT V8 (308kW/418PS)
10. Attach the wire harness retainers to the oil pan.

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11. Position the bracket for the wire harness and install the nut on the front of the RH engine mount bracket
stud bolt.
12. Position the brackets for the transmission cooling tubes and wire harness and install the nut on the front of
the RH engine mount bracket stud bolt.
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3.7L Duratec (227kW/301PS)
Position the ground wire and install the bolt to the RH side of the engine.
14. 1. Connect starter motor solenoid wire and install the starter motor solenoid wire nut.
2. Connect the starter motor solenoid battery cable and install the starter motor solenoid battery cable
nut.
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15. Close the starter motor solenoid battery cable cover.
Position the tubes and install the transmission fluid cooler tubes bracket-to-transmission nut.
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Install the transmission fluid cooler tubes bracket-to-engine mount nut.

18. Install the new engine oil filter.

(WSS-M2C946-A)
Torque:
Stage 2: 180°
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All vehicles
19. On both sides.

Position the new steering stop.
20. Position the steering rack completely to the LH side.

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21. NOTICE: Hold the steering gear rack while tightening the inner tie rod. Failure to hold the rack
NOTICE: The steering gear rack holding tool must be reversed to install the RH tie rod or damage
NOTE: LH side shown RH side similar.
On both sides.
install the inner tie rod and steering stop.
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22. NOTICE: Install the steering stop using hand force only. Striking the steering stop may cause
damage to the stop.
NOTE: An audible click will be heard when the steering stop seats onto the inner tie rod. Make sure that
the steering stop is fully seated and cannot be separated by hand.
On both sides.
Install the steering stop onto the inner tie rod using hand force only.
23. On both sides.

Apply the specified grease to the steering gear-to-bellows boot mating surface and bellows boot groove on
the inner tie-rod.
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1. NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear
housing bead and the groove in the inner tie rod.
On both sides. Install the new steering gear bellows boot.

2. On both sides. Install the new inner bellows boot clamp.
3. On both sides. Install the new outer bellows boot clamp.
25. On both sides.

Thread the tie-rod end jam nut onto the inner tie rod.
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26. Position the EPAS gear wiring harness, clip the 4 wiring fasteners and connect the 2 electrical connectors.
27. NOTICE: Make sure steering gear is centered before connecting the steering column shaft.
Damage to the steering gear and/or clockspring may result.
Turn the steering gear input shaft completely to the right then completely to the left and return to the center
position.
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28. NOTICE: DO NOT hammer, pry or force steering column and column shafts during installation or
removal. Failure to follow this instruction may cause damage to steering components that could
lead to loss of steering control during vehicle operation and could result in serious personal injury
or death.
NOTICE: DO NOT attempt to remove or install the steering column lower coupler at the steering
gear without first loosening the steering column dash seal and fasteners. Failure to follow this
instruction may cause damage to steering components that could lead to loss of steering control
during vehicle operation and could result in serious personal injury or death.
Position the V-brace and underbody shield and install the 6 V-brace bolts.
2. Install the underbody shield bolt.
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1. Position the underbody shield and install the 2 rearward underbody shield bolts.
2. Install the 2 remaining underbody shield bolts.
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Install the 2 support brackets and the bolts.

Torque:
Bracket to subframe bolts.: 22 lb.ft (30 Nm)
Bracket to cooler bolts.: 93 lb.in (10.5 Nm)
Position the underbody shield and install the bolts.

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35. On both sides.

Install the tie rod end.

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37. Turn the steering wheel lock-to-lock to assure the steering stops are fully seated.

Refer to: Specifications (303-01A Engine - 2.3L EcoBoost (231kW/314PS), Specifications).
(WSS-M2C946-A)
All vehicles
39. When installing a new steering gear, it must be configured (using vehicle as-built data or module
configuration information retrieved earlier in this procedure). Connect a scan tool and follow the scan tool
instructions.

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Tie Rod
204-816
Rack Holding Tool
TKIT-2014D-FL_ROW
TKIT-2014D-ROW2
Boot Clamp Pliers
Materials
Name Specification
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XG-1-E1
Removal
NOTICE: When servicing inner tie rods, install a new bellows boot and clamps. The boots and clamps are
designed to provide 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 failure of the steering gear components. Zip ties must not be used as they do not provide an
airtight seal.
NOTICE: The inner ball joint grease is not compatible with water contamination. Do not allow water to
become trapped in the grease or degradation and failure of the joint may occur.
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 rack when loosening and tightening the inner tie rod.
1. Remove the tie rod end.


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1. Remove the 2 rearward underbody shield bolts.

2. Remove the 2 remaining underbody shield bolts and remove the underbody shield.
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Remove the underbody shield bolt.
2. NOTE: It is not necessary to separate the underbody shield from the V-brace.
Remove the 6 V-brace bolts and remove the V-brace and underbody shield.
6. 1. Remove and discard the inner bellows boot clamp.

2. Remove and discard the outer bellows boot clamp.
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7. NOTE: Move the bellows boot enough to gain access to the inner tie rod nut.
Position aside the bellows boot.
8. Position aside the steering stop.

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9. Position the steering rack completely to the left.
NOTICE: The steering gear rack holding tool must be reversed to remove the RH tie rod or damage
remove and discard the inner tie rod.
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11. Remove and discard the steering stop.
Installation
1. Position the new steering stop.

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NOTICE: The steering gear rack holding tool must be reversed to install the RH tie rod or damage
install the inner tie rod and steering stop.
3. NOTICE: Install the steering stop using hand force only. Striking the steering stop may cause
damage to the stop.
NOTE: An audible click will be heard when the steering stop seats onto the inner tie rod. Make sure that
the steering stop is fully seated and cannot be separated by hand.
Install the steering stop onto the inner tie rod using hand force only.
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4. Apply the specified grease to the steering gear-to-bellows boot mating surface and bellows boot groove on
the inner tie-rod.
1. NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear
housing bead and the groove in the inner tie rod.
Install the new steering gear bellows boot.

2. Install the new inner bellows boot clamp.
3. Install the new outer bellows boot clamp.
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6. Thread the tie-rod end jam nut onto the inner tie rod.
Position the V-brace and underbody shield and install the 6 V-brace bolts.
2. Install the underbody shield bolt.
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1. Position the underbody shield and install the 2 rearward underbody shield bolts.
2. Install the 2 remaining underbody shield bolts.

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11. Install the tie rod end.

12. Turn the steering wheel lock-to-lock to assure the steering stops are fully seated.

Tie Rod End
Tie Rod End Remover
Removal
1. NOTICE: Disconnect the battery ground cable anytime the steering linkage is being serviced or
damage to the steering gear may occur resulting in steering gear replacement.

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3. 1. Loosen the tie rod end jam nut.

2. Remove and discard the outer tie rod end nut.
Torque:
3. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel spindle or
damage to the wheel spindle may result.
NOTICE: Use care when installing the tie rod separator or damage to the outer tie-rod end
boot may occur.
Separate the outer tie rod end from the wheel spindle.
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4. NOTE: Count and record the number of turns required to remove the outer tie-rod end for reference
during installation.
Remove the tie-rod end.
Installation
2. Check and if necessary, adjust front toe.


211-04 Steering Column 2016 Mustang
Steering Column - Overview
Authoring Template
Steering Column Overview
The steering column is the mechanical linkage between the steering wheel and the steering gear. The steering
wheel is mounted to a shaft, which passes through the center of the steering column. The shaft is centered by
bearings within the steering column. The upper and lower steering column shafts then connect the steering column
to the steering gear. The lower steering column shaft is a collapsible shaft and needs to be measured any time
the shaft has been disconnected from the upper shaft or the coupling.
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Item Description
1 Steering column
2 Steering column upper shaft
3 Steering column lower shaft
4 Steering column coupling

Steering Column Collapsed Check
Inspection
Left hand drive
1. With the steering system fully assembled, measure the lengths of the lower shaft. If either length is out of
range, discard the lower shaft and install a new one. Do not attempt to repair the shaft.
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Right hand drive
2. With the steering system fully assembled, measure the lengths of the lower shaft. If either length is out of
range, discard the lower shaft and install a new one. Do not attempt to repair the shaft.
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Steering Wheel Cover Repair
Materials
Name Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
Activation
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.

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2. Position the loose leather out of the way.
3. Apply the specified adhesive evenly over the wheel spoke.

Material: Instant Gel Adhesive / TA-19 (WSK-M2G402-A4)
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.
6. Apply pressure (for at least 30 seconds) until the leather is bonded to the wheel spoke.
7. If removed, install the steering wheel.


Steering Column
Removal
All vehicles
removal. Failure to follow this instruction may cause damage to steering components that could lead to
loss of steering control during vehicle operation and could result in serious personal injury or death.
NOTICE: Do not allow the steering column to rotate while the steering column shaft system is
disconnected or damage to the steering column electrical components may result.
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Remove the SCCM.

Refer to: Steering Column Control Module (SCCM) (211-05 Steering Wheel and Column Electrical

3. Position the steering column in the full up/rearward position.
4. NOTE: Vehicles equipped with electronic steering column lock shown, vehicles without similar.
Remove the retainers and disconnect the steering column electrical connectors.
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5. NOTICE: 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
Remove and discard the bolt and pull apart the upper steering column shaft from the steering column.
6. NOTE: The front and rear fasteners are not the same. DO NOT install in place of one another.
Remove the steering column.

2. Remove and discard the bolts. Remove the steering column.
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With security pack
Remove the steering column lock module.

Refer to: Steering Column Lock Module (211-05 Steering Wheel and Column Electrical Components,
Installation
With the steering system fully assembled, remove the anti-rotation pin and the spindle bolt.
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Steering Column Lower Shaft
Removal
NOTICE: DO NOT attempt to remove or install the steering column lower u-joint at the steering gear
without first loosening the steering column dash seal and fasteners. Failure to follow this instruction may
cause damage to steering components that could lead to loss of steering control during vehicle
operation and could result in serious personal injury or death.
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2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Keep the steering wheel in the straight-ahead position.

1. Remove the nuts.
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Remove the steering column lower shaft.

2. NOTE: Vehicles equipped with LHD.


5. Pull apart the steering column lower shaft from the steering column upper shaft.
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Installation


Steering Column Upper Shaft
Steering Wheel Holder
Removal
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Keep the steering wheel in straight ahead-position.

Use the General Equipment: Steering Wheel Holder
3. Position the steering column in the full up/rearward position.

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1. Remove the nuts.
Remove and discard the bolt and loosen the upper shaft from the lower shaft by partially pulling them apart
from each other.
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Remove the steering column upper shaft.

1. Remove the nuts.
3. Pull apart the upper shaft from the steering column.
4. Pull apart and remove the upper shaft from the lower shaft.
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Installation
1.
Install the steering column upper shaft.
1. NOTICE: 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
Connect the upper shaft to the steering column.

2. Install the bolt.
3. Seat the dash seal.
2. Connect the upper shaft to the lower shaft and install the bolt.
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3. Tighten the dash seal nuts.


Steering Wheel
Removal
NOTICE: To prevent damage to the clockspring, make sure the front wheels are in the straight-ahead
position.
1. Remove the driver airbag module.

Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).
2. 1. Disconnect the steering wheel switches electrical connector.

2. Remove the steering wheel bolt and the steering wheel.
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3. Tape the clockspring rotor to the outer housing to keep it from rotating.
Installation
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Steering Column Coupling
Steering Wheel Holder
Removal
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Keep the steering wheel in the straight-ahead position.

Use the General Equipment: Steering Wheel Holder
3. NOTICE: Make sure to minimize damage to the sealer foam and avoid pulling apart dash seal
brackets from retainer pins. Excessive damage may allow engine noise, fumes, air or water to
enter the passenger compartment.

1. Remove the nuts.
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4.
Detach the steering column lower shaft from the coupling.
1. NOTICE: 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
NOTE: Vehicles equipped with LHD.


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5. Remove and discard the bolt. Pull apart the coupling from the steering gear.
Installation

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211-05 Steering Wheel and Column Electrical Components 2016 Mustang
Steering Wheel and Column Electrical Components - Overview
Steering Column Switches Overview
The steering column switches are located on and around the steering column. They enable the driver to control
various vehicle functions while remaining focused on driving. The steering column switches consist of:
Left multifunction switch - mounted on the left side of the SCCM and is used to control the turn signals,
low/high beam selection and the flash-to-pass feature.
Refer to: Exterior Lighting - System Operation and Component Description (417-01 Exterior Lighting,
Right multifunction switch - mounted on the right side of the SCCM and is used to control the windshield
wipers and washer.
Refer to: Wipers and Washers - System Operation and Component Description (501-16 Wipers and
Washers, Description and Operation).
Steering wheel switches - mounted on the front of the steering wheel and can be serviced separately from
the steering wheel. These are used to access settings and controls displayed in the message center or for
control of the cruise control system, the audio system and the SYNC® system.
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For the message center (left upper switch),
Refer to: Message Center - System Operation and Component Description (413-01 Instrumentation,
Message Center and Warning Chimes, Description and Operation).
For the cruise control system (left lower switch),
Refer to: Cruise Control - System Operation and Component Description (419-03A Cruise Control,
Refer to: Cruise Control - System Operation and Component Description (419-03B Cruise Control -
Vehicles With: Adaptive Cruise Control, Description and Operation).
For the audio system (right upper switch), Refer to the appropriate section in Group 415 for the
procedure.
For the SYNC® system (right lower switch), Refer to the appropriate section in Group 415 for the
procedure.
Paddle shifter switches - mounted on rear of the steering wheel and are used to control the the
transmission up and down shifts.
Refer to: External Controls - System Operation and Component Description (307-05 Automatic
Transmission External Controls, Description and Operation).
The steering column and steering wheel switches interface with other modules and components on the vehicle
through the SCCM, which communicates on the High Speed Controller Area Network 2 (HS2-CAN).
Push Button Start Ignition System Overview
The push button start ignition system is used to place the ignition in the ON or OFF mode and to start or shut off
the vehicle powertrain. The push button ignition switch is integrated into the FCIM.
Steering Column Lock System Overview
The steering column lock deters vehicle theft by locking the steering column and preventing the steering wheel
from being used to turn the front wheels.

Steering Wheel and Column Electrical Components - System Operation and Component Description
System Operation
System Diagram - Push Button Ignition Switch
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Network Message Chart - Push Button Ignition Switch
GWM Module Network Input Messages

Message Module
Ignition status BCM This message informs the GWM of the current ignition status; off, run,
start, unknown or invalid.
PCM Module Network Input Messages

Message Module
Ignition status BCM This message informs the PCM of the current ignition status; off, run,
start, unknown or invalid.
Push Button Ignition Switch
The push button ignition switch is used to control the ignition mode.
There are 2 circuits the BCM monitors from the ignition switch to change the ignition mode. One circuit is
monitored for voltage and the other for a ground signal. When the START/STOP button is pressed, one circuit
routes battery voltage to the BCM while a voltage signal from the BCM on the second circuit is routed to ground,
indicating a request to change the ignition state. Changing the ignition state from the OFF mode works in
conjunction with the PATS. The BCM must recognize a valid programmed key before it changes the ignition mode
out of OFF.
Refer to the following table for information about achieving the various ignition states.
Ignition Entry Desired Action To Take

Condition Ignition Mode
Off ON (engine off) Press the START/STOP button without applying the brake pedal.
Off or on START Apply and the brake pedal (automatic transmission) or fully apply the clutch
(manual transmission) and then press the START/STOP button.
On (engine off) OFF Press the START/STOP button.
On (engine OFF Press and hold the START/STOP button.
running)
Ignition Mode LED Indicator
The ignition mode LED indicates the ignition mode of the vehicle. The BCM controls the voltage to the ignition
mode LED indicator. Refer to the following table.
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Ignition Mode Ignition Mode LED Indicator
Off Off
On (engine off) Flashing
On (engine running) On
OFF
The BCM controls the relays providing voltage to the vehicle electrical systems. When the ignition is in the ON
mode, a single press and release of the START/STOP button changes the ignition to the OFF mode. No
programmed key is required to change the ignition to the OFF mode when the vehicle is running.
If the vehicle is in motion, a momentary press of the START/STOP button does not shut the vehicle off. If the
vehicle is moving at a speed greater than 15 km/h (9 mph), the START/STOP button must be pressed and held
for longer than one second (or pressed 3 times within 2 seconds) to turn the ignition off.
When the BCM changes the ignition state to OFF, it communicates the ignition mode to the other modules by
sending an ignition status message over the CAN.
ON
The BCM must recognize a programmed key before it changes the ignition mode out of OFF. When the
START/STOP button is pressed when the ignition is off, the BCM checks the vehicle for a valid programmed key
as part of the PATS function. If no valid programmed key is detected, the ignition remains off.
When the ignition is in the ON mode, the BCM activates the run/start relay to provide voltage to the vehicle
electrical systems and communicates the ignition mode to the other modules by sending an ignition status
message over the CAN.
When the vehicle enters ON mode, multiple indicators in the IPC prove out and the IPC displays the gear selection
and the vehicle mileage.
START
If the brake pedal is applied when the START/STOP button is pressed with the ignition in the off mode, the vehicle
temporarily goes into the START mode so long as a valid programmed key is detected within the vehicle.
In addition to activating the run/start relay, the BCM communicates the ignition mode to the other modules by
sending an ignition status message over the CAN.
Once the ignition has entered START mode, the ignition mode indicator in the ignition switch illuminates.
The engine can be started from any ignition mode.
System Diagram - Steering Column Lock
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Network Message Chart - Steering Column Lock

Message Module
Engine rpm data PCM Provides the BCM with the engine speed to indicate if it is running or
not.
Wheel rotation ABS module Provides the BCM with the vehicle speed to indicate if it is moving or
count stationary.
Steering Column Lock
The steering column lock is used to deter vehicle theft by electronically locking the steering column. This prevents
the steering wheel from being rotated to turn the front wheels.
The steering column unlocks when:
the passive entry feature is used to open the driver door.

the driver door is opened after unlocking the vehicle with a RKE transmitter.
the START/STOP button is pressed and a valid programmed passive key is detected.
the remote start feature is activated.
The steering column locks after:
the ignition is turned off and 45 seconds have elapsed since the delayed accessory feature has turned off.
45 seconds have elapsed since the remote feature turns off the vehicle.
The BCM controls the voltage provided to the steering column lock module using a relay (located in the BJB) and
communicates with it over a LIN. The BCM monitors input from various systems to determine when to send a
command to lock or unlock the steering column. The steering column lock module locks and unlocks the steering
column as directed by commands received from the BCM.
If the BCM detects a fault from the steering column lock module or the LIN, the BCM prevents the vehicle from
starting.
The BCM does not provide power to the steering column lock module when the vehicle is moving or the engine is
running.
Steering Column Lock Messages
The message center displays a message when the BCM detects a fault from the steering column lock module.
The Steering Malfunction message displays when a fault with the electronic steering column lock system is
present and must be diagnosed.
The Turn the wheel while starting message displays when the steering column lock module is unable to unlock the
steering column because of a high amount of torque against the lock (such as when the wheels are against a curb
when the vehicle is shut off). The torque against the steering column lock must be relieved for the steering column
to unlock.
Turn the vehicle off, rotate and hold the steering wheel in one direction while turning the vehicle on. If the message
displays again, turn the vehicle off, rotate and hold the steering wheel in the other direction while turning the
vehicle on.
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Push Button Ignition Switch
The push button ignition switch is a momentary dual contact switch that provides direct input to the BCM and
PCM. Both sets of contacts are normally open. When the START/STOP button is pressed, one set of contacts
provides a ground signal to the BCM and the other set of contacts supplies voltage to the BCM and the PCM.
The ignition mode LED indicator is located near the top of the START/STOP button and is controlled by the BCM.
The ignition switch is part of the FCIM and cannot be serviced separately.
Steering Column Lock Module
The steering column lock module locks and unlocks the steering column based on commands received from the
BCM. The steering column lock module monitors the position of the steering column lock and, if a fault is
detected, reports the failure to the BCM.
When the steering column lock module is replaced, the BCM must configured/trained to the new steering column
lock module for the steering column lock module to operate correctly.
The BCM sets a DTC if a fault is detected with the steering column lock module. Additionally, if the BCM is not
configured to the steering column lock module, the steering column module keeps the column locked, a
programming and/or configuration DTC sets and the vehicle does not start. To configure the BCM to the steering
column lock module,
Refer to: Anti-Theft Security Access (419-01B Passive Anti-Theft System (PATS), General Procedures).
BCM
The BCM controls the run/start relays and sets the vehicle ignition mode based on inputs and communicates the
ignition mode to other modules over the CAN. If a fault is detected in the ignition switch system, Diagnostic
Trouble Codes (DTCs) are set in the BCM.
The BCM requires at least 2 keys to be programmed, and the PMI and parameter reset procedures carried out
when replaced. Additionally, if equipped with a steering column lock module, the BCM to Electronic Steering
Column Lock (ESCL) configuration must be carried out.

Steering Wheel and Column Electrical Components
DTC Charts
BCM DTC Chart

B1026:04 Steering Column Lock: System DIAGNOSE all other Diagnostic Trouble Codes (DTCs) present. If no other Diagnostic
Internal Failure Trouble Codes (DTCs) are present, INSTALL a new steering column lock module.
B1026:05 Steering Column Lock: System CARRY OUT the BCM to Electronic Steering Column Lock (ESCL) configuration/training
Programming Failure procedure.
REFER to: Anti-Theft Security Access (419-01B Passive Anti-Theft System (PATS), General
Procedures).
B1026:09 Steering Column Lock: Component INSTALL a new steering column lock module.
Failure
B1026:49 Steering Column Lock: Internal INSTALL a new steering column lock module.
Electronic Failure
B1026:51 Steering Column Lock: Not CARRY OUT the BCM to Electronic Steering Column Lock (ESCL) configuration/training
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Programmed procedure.
Procedures).
B1026:56 Steering Column Lock: Invalid / CARRY OUT the BCM to Electronic Steering Column Lock (ESCL) configuration/training
Incompatible Configuration procedure.
Procedures).
B1026:77 Steering Column Lock: Commanded INSTALL a new steering column lock module.
Position Not Reachable
B1026:87 Steering Column Lock: Missing GO to Pinpoint Test D
Message
B1026:92 Steering Column Lock: Performance GO to Pinpoint Test D
or Incorrect Operation
B1026:93 Steering Column Lock: No Operation DIAGNOSE all other Diagnostic Trouble Codes (DTCs) present. If no other Diagnostic
Trouble Codes (DTCs) are present, INSTALL a new steering column lock module.
B1026:96 Steering Column Lock: Component INSTALL a new steering column lock module.
Internal Failure
B108A:01 Start Button: General Electrical GO to Pinpoint Test A
Failure
B108A:24 Start Button: Signal Stuck High GO to Pinpoint Test A
B1142:29 Ignition Status 1: Signal Invalid GO to Pinpoint Test A
B1184:11 Steering Column Lock Output: Circuit GO to Pinpoint Test D
Short To Ground
B1184:15 Steering Column Lock Output: Circuit GO to Pinpoint Test D
B1240:11 Start Button Mode Indicator: Circuit GO to Pinpoint Test B
Short to Ground
B1240:15 Start Button Mode Indicator: Circuit If the ignition mode indicator is inoperative, GO to Pinpoint Test B If the ignition mode
Short to Battery or Open indicator is always on, GO to Pinpoint Test C
B130F:12 Run Accessory Control: Circuit Short
to Battery REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B130F:14 Run Accessory Control: Circuit Short
to Ground or Open REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
Trouble Codes (DTCs) REFER to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Diagnosis
and Testing).
SCCM DTC Chart

B1007:09 High-Beam Headlamp
Switch: Component Failure REFER to: Headlamps (417-01 Exterior Lighting, Diagnosis and Testing).
B1008:09 Wiper Mode Switch:
Component Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1051:09 Front Washer Switch:
B10AD:02 Rain Sensor: General Signal
Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B10AD:08 Rain Sensor: Bus
Signal/Message Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B10AD:49 Rain Sensor: Internal
Electronic Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B10AD:55 Rain Sensor: Not Configured
REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:02 Wiper motor module:
General Signal Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:08 Wiper motor module: Bus
Signal/Message Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:11 Wiper motor module: Circuit
Short To Ground REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:49 Wiper motor module:
Internal Electronic Failure REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:55 Wiper motor module: Not
Configured REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
B1131:9A Wiper motor module:
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Component or System REFER to: Wipers and Washers (501-16 Wipers and Washers, Diagnosis and Testing).
Operating Conditions
B11D9:16 Vehicle Battery: Circuit GO to Pinpoint Test E
B11D9:17 Vehicle Battery: Circuit GO to Pinpoint Test F
B12F7:09 Single Wipe Switch:
B137F:09 Steering Wheel Left Switch For a cruise control system concern,
Pack: Component Failure REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and Testing).
REFER to: Cruise Control (419-03B Cruise Control - Vehicles With: Adaptive Cruise Control, Diagnosis and
Testing).
For a message center concern,
REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center
and Warning Chimes, Diagnosis and Testing).
Pack: Circuit Short to REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and Testing).
Ground REFER to: Cruise Control (419-03B Cruise Control - Vehicles With: Adaptive Cruise Control, Diagnosis and
Testing).
Pack: Circuit Voltage Above REFER to: Cruise Control (419-03A Cruise Control, Diagnosis and Testing).
Threshold REFER to: Cruise Control (419-03B Cruise Control - Vehicles With: Adaptive Cruise Control, Diagnosis and
Testing).
B1380:09 Steering Wheel Right Switch Refer to the appropriate section in Group 415 for the procedure.
Pack: Component Failure
Pack: Circuit Short to
Ground
Pack: Circuit Voltage Above
Threshold
B1D36:09 Turn Indicator Switch:
Component Failure REFER to: Turn Signal and Hazard Lamps (417-01 Exterior Lighting, Diagnosis and Testing).
U2100:00 Initial Configuration Not CHECK vehicle service history for recent service actions related to this module. This DTC sets due to incomplete or
Complete: No Sub Type improper PMI procedures. If there have been recent service actions with this module, REPEAT/CARRY OUT the
Information PMI procedure as directed by the diagnostic scan tool. If there have been no recent service actions, INSTALL a new
SCCM to correct the failure to retain configuration data.
REFER to: Steering Column Control Module (SCCM) (211-05 Steering Wheel and Column Electrical Components,
U2101:00 Control Module Configuration This DTC sets if the steering wheel switches do not match the switch function configuration data in the SCCM.
Incompatible: No Sub Type CHECK the parts catalog and CONFIRM that the correct SCCM and steering wheel control switches are installed in
Information the vehicle. INSTALL the correct components, as necessary.
BCMB DTC Chart

P2533:14 Ignition Switch Run/Start Position Circuit: Circuit GO to Pinpoint Test G
Short to Ground or Open
Codes (DTCs) REFER to: Body Control Module B (BCMB) (419-10 Multifunction
Electronic Modules, Diagnosis and Testing).
Symptom Chart
Symptom Chart: Steering Column Switches
Symptom Chart
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Condition Possible Causes Actions
No power in ON Refer to the GO to Pinpoint Test A
Pinpoint Test
Key not detected displays in the Refer to the

message center Pinpoint Test REFER to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System
(PATS), Diagnosis and Testing).
The ignition mode indicator is Refer to the GO to Pinpoint Test B

inoperative Pinpoint Test
The ignition mode indicator is always Refer to the GO to Pinpoint Test C

on Pinpoint Test
The steering column is always or Refer to the GO to Pinpoint Test D

never locked Pinpoint Test
Pinpoint Tests
No Power in ON
REFER to: Steering Wheel and Column Electrical Components - System Operation and Component Description (211-05 Steering Wheel and Column Electrical
Components, Description and Operation).
When in ON mode, the BCM activates the integral run/start relay which distributes fused voltage to various components.
The integral run/start relay in the BCM receives voltage from the BCM fuse 34 (30A).

B108A:01 Start Button: General Electrical Sets continuous when the BCM detects a fault from one of the ignition switch input circuits.
Failure
B108A:24 Start Button: Signal Stuck High Sets continuous when the BCM detects a short to voltage from one of the ignition switch input circuits.
B1142:29 Ignition Status 1: Signal Invalid Sets during the on-demand self-test when the BCM detects a fault from one of the ignition switch input
circuits.
Possible Causes
Battery voltage concern

Fuse
PATS concern
FCIM (includes the ignition switch)
BCM
Inspect the battery and battery cables.

PINPOINT TEST A : NO POWER IN ON

connector.
NOTE: Make sure there are no charging system concerns or low voltage Diagnostic Trouble Codes (DTCs) before diagnosing the ignition switch or
ignition mode concern.
A1 CHECK VEHICLE BATTERY
Is the battery OK?
Yes GO to A2
No CORRECT the battery condition and VERIFY correct charging operation. Refer to the appropriate section in Group 414 for the
procedure.
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A2 CHECK FOR IGNITION ON MODE
NOTE: If DTC B108A:01, B108A:24 or B1142:29 is present, go to step A4.

Press and release the START/STOP button while monitoring the ignition mode indicator at the top of the button.
Does the ignition mode indicator flash on and off continuously?
Yes GO to A16
No GO to A3
A3 CHECK FOR A PATS (PASSIVE ANTI-THEFT SYSTEM) CONCERN

Press the START/STOP button while monitoring the message center.
Does No key detected display in the message center?
Yes
REFER to: Passive Anti-Theft System (PATS) (419-01B Passive Anti-Theft System (PATS), Diagnosis and Testing).
No GO to A4
A4 CHECK THE IGNITION SWITCH 1 (START_STOP_1) PID (PARAMETER IDENTIFICATION)

Using a diagnostic scan tool, view the BCM Parameter Identification (PIDs).
Monitor the BCM PID START_STOP_1 while pressing and releasing the START/STOP button.
Does the PID change state when the START/STOP button is pressed and released?
Yes GO to A11
No GO to A5
A5 CHECK THE START/STOP 1 INPUT CIRCUIT FOR A SHORT TO VOLTAGE

Disconnect PCM C175B, C1551B or C1381B.
Measure:

C2402A-12 Ground

No GO to A6
A6 CHECK THE START/STOP 1 INPUT CIRCUIT FOR A SHORT TO GROUND

Measure:

C2402A-12 Ground
Yes GO to A7
A7 BYPASS THE FCIM (FRONT CONTROLS INTERFACE MODULE) WHILE MONITORING THE IGNITION SWITCH 1 (START_STOP_1) PID
Connect BCM C2280B.
Monitor the BCM PID START_STOP_1.
Connect:
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C2402A-12 C2402A-26
Does the PID indicate the START/STOP button is pressed with the jumper wire connected?
Yes GO to A18
No GO to A8
A8 CHECK FOR VOLTAGE TO THE IGNITION SWITCH

Measure:

C2402A-26 Ground
Yes GO to A10
No VERIFY BCM fuse 12 (7.5A) is OK. If OK, GO to A9
A9 CHECK THE IGNITION SWITCH VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

Disconnect BCM C2280A.
Measure:

C2402A-26 C2280A-10
Yes GO to A19
A10 CHECK THE BCM (BODY CONTROL MODULE) START/STOP 1 INPUT CIRCUIT FOR AN OPEN
Measure:

C2402A-12 C2280B-51
Yes GO to A19
A11 CHECK THE IGNITION SWITCH 2 (START_STOP_2) PID (PARAMETER IDENTIFICATION)

Monitor the BCM PID START_STOP_2 while pressing the START/STOP button.
Does the PID change state when the START/STOP button is pressed and released?
Yes GO to A19
No GO to A12
A12 CHECK THE BCM (BODY CONTROL MODULE) START/STOP 2 INPUT CIRCUIT FOR A SHORT TO GROUND
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Measure:

C2402A-13 Ground
Yes GO to A13
A13 BYPASS THE FCIM (FRONT CONTROLS INTERFACE MODULE) WHILE MONITORING THE IGNITION SWITCH 2 (START_STOP_2) PID
Connect BCM C2280B.
Monitor the BCM PID START_STOP_2.
Connect:

C2402A-13 Ground
Does the PID indicate the START/STOP button is pressed with the jumper wire connected?
Yes GO to A14
No GO to A15
A14 CHECK THE IGNITION SWITCH GROUND CIRCUIT FOR AN OPEN

Measure:

C2402A-26 C2402A-1

Yes GO to A18
A15 CHECK THE BCM (BODY CONTROL MODULE) START/STOP 2 INPUT CIRCUIT FOR AN OPEN
Measure:

C2402A-13 C2280B-5
Yes GO to A19
A16 CARRY OUT A NETWORK TEST

Using a diagnostic scan tool, carry out the network test.
Do the IPC and the BCM pass the network test?
Yes VERIFY the BCM fuse 34 (30A) is OK. If OK, GO to A17
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No
A17 CHECK FOR AN INTERMITTENT COMMUNICATION CONCERN

Using a diagnostic scan tool, retrieve the Continuous Mode Diagnostic Trouble Codes (CMDTCs) from all modules.
Are multiple communication Diagnostic Trouble Codes (DTCs) set in multiple modules?
Yes DIAGNOSE an intermittent network concern.

No GO to A19
A18 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Disconnect and inspect all FCIM connectors.
Repair:
Reconnect the FCIM connectors. Make sure they seat and latch correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new FCIM. Refer to
the appropriate section in Group 415 for the procedure.

Repair:
The Ignition Mode Indicator Is Inoperative

B1240:11 Start Button Mode Indicator: Circuit Short to Ground Sets when the BCM detects a short to ground from the ignition mode status indicator
circuit.
B1240:15 Start Button Mode Indicator: Circuit Short to Battery or Sets when the BCM detects an open from the ignition mode status indicator circuit.
Open
Possible Causes
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BCM
PINPOINT TEST B : THE IGNITION MODE INDICATOR IS INOPERATIVE

connector.
B1 CHECK FOR VOLTAGE TO THE IGNITION MODE INDICATOR
Start the engine.
Measure:

C2402A-5 Ground
Yes GO to B4
No GO to B2
B2 CHECK THE IGNITION MODE INDICATOR CIRCUIT FOR A SHORT TO GROUND

Connect FCIM C2402A.
Ignition OFF.
Measure:

C2402A-5 Ground
Yes GO to B3
B3 CHECK THE IGNITION MODE INDICATOR CIRCUIT FOR AN OPEN

Measure:

C2402A-5 C2280B-39
Yes GO to B5
B4 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:
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B5 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
Reconnect the BCM connectors and all other previously disconnected connectors. Make sure they seat and latch correctly.
The Ignition Mode Indicator Is Always On

B1240:15 Start Button Mode Indicator: Circuit Short to Battery or Sets when the BCM detects a short to voltage from the ignition mode status indicator
Open circuit.
Possible Causes

BCM
PINPOINT TEST C : THE IGNITION MODE INDICATOR IS ALWAYS ON
connector.
C1 ISOLATE THE BCM (BODY CONTROL MODULE)
Ignition ON.
Observe the ignition mode indicator.
Does the ignition mode indicator continue to illuminate?
Yes GO to C2
No GO to C4
C2 CHECK THE IGNITION MODE INDICATOR CIRCUIT FOR A SHORT TO VOLTAGE

Measure:

C2402A-5 Ground
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No GO to C3
C3 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
C4 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:
The Steering Column Is Always Or Never Locked


B1026:87 Steering Column Lock: Missing Message Sets when the BCM detects no messages from the steering column lock module.
B1026:92 Steering Column Lock: Performance or Sets when the BCM detects messages from the steering column lock module when the BCM has not
Incorrect Operation activated the steering column lock module relay.
B1184:11 Steering Column Lock Output: Circuit Short Sets when the BCM detects a short to ground from the steering column lock module relay control
To Ground circuit.
B1184:15 Steering Column Lock Output: Circuit Short Sets when the BCM detects a short to voltage or an open from the steering column lock module
To Battery or Open relay control circuit.
Possible Causes
Fuse
Steering column lock module relay
Steering column lock module
BCM
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PINPOINT TEST D : THE STEERING COLUMN IS ALWAYS OR NEVER LOCKED
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.
D1 CHECK FOR BCM (BODY CONTROL MODULE) DTC (DIAGNOSTIC TROUBLE CODE) B1184:11 OR B1184:14
Ignition ON.
Is DTC B1184:11 or B1184:14 present?
Yes GO to D2
No GO to D7
D2 CHECK THE STEERING COLUMN LOCK MODULE RELAY (DTC (DIAGNOSTIC TROUBLE CODE) B1184:11 OR B1184:14
Ignition OFF.
Disconnect Steering Column Lock Module Relay.
Ignition ON.
Is DTC B1184:11 or B1184:14 still present?
Yes REMOVE the known good relay. GO to D3

No REMOVE the known good relay. INSTALL a new steering column lock module relay.
D3 CHECK THE STEERING COLUMN LOCK MODULE RELAY COIL GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Connect:

Action
Action
Steering column lock module relay, cavity 3 Steering column lock module relay, cavity 2
Does the test lamp illuminate?
Yes GO to D4
D4 CHECK THE STEERING COLUMN LOCK MODULE RELAY COIL CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
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Ignition OFF.
Ignition ON.
Measure:

Ground
Steering column lock module relay, cavity 1

No GO to D5
D5 CHECK THE STEERING COLUMN LOCK MODULE RELAY COIL CONTROL CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Measure:

Ground
Yes GO to D6
D6 CHECK THE STEERING COLUMN LOCK MODULE RELAY COIL CONTROL CIRCUIT FOR AN OPEN
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Measure:

C2280F-9
Yes GO to D15
D7 CHECK THE STEERING COLUMN LOCK MODULE RELAY

Ignition OFF.
Check the operation of the electric steering column lock system.
Does the steering column lock and unlock correctly?
Yes REMOVE the known good relay. INSTALL a new steering column lock module relay.
No REMOVE the known good relay. GO to D8
D8 CHECK THE STEERING COLUMN LOCK MODULE RELAY VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:
Ground
Yes GO to D9
No VERIFY the BJB fuse 19 (20A) is OK. If OK, REPAIR the circuit.
D9 CHECK THE STEERING COLUMN LOCK MODULE VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE
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Disconnect BCM C2280G.
Disconnect Steering Column Lock Module C2434.
Ignition ON.
Measure:

Ground

No GO to D10
D10 CHECK THE STEERING COLUMN LOCK MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C2280G-8
Measure:

C2434-2
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Yes GO to D11
D11 CHECK THE STEERING COLUMN LOCK MODULE GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C2434-3 Ground
Yes GO to D12
D12 CHECK THE STEERING COLUMN LOCK MODULE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO VOLTAGE
Connect BCM C2280G.
Ignition ON.
Measure:

C2434-4 Ground

No GO to D13
D13 CHECK THE STEERING COLUMN LOCK MODULE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
Connect BCM C2280B.
Ignition OFF.
Measure:

C2434-4 Ground
Yes GO to D14
D14 CHECK THE STEERING COLUMN LOCK MODULE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN
Measure:
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C2434-4 C2280B-25
Yes INSTALL a new steering column lock module.


Repair:
Routine (BCM).
B11D9:16
The SCCM continuously monitors its voltage supply circuit. If voltage decreases below a predefined limit, the SCCM ceases functions. DTC B11D9:16 can set if
the vehicle battery has been discharged. The vehicle battery may become discharged due to excessive load on the charging system from aftermarket
accessories or if the vehicle has been left unattended with the accessories on.

B11D9:16 Vehicle Battery: Circuit Below This DTC sets in continuous memory if the SCCM detects battery voltage below 8 volts from the battery
Threshold voltage supply circuit.
Possible Causes

High circuit resistance
SCCM
PINPOINT TEST E : B11D9:16

connector.
NOTE: Failure to disconnect the battery when instructed may result in false resistance readings.
E1 RECHECK THE SCCM (STEERING COLUMN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
Ignition ON.
Using the diagnostic scan tool, clear the SCCM Diagnostic Trouble Codes (DTCs).
Using the diagnostic scan tool, carry out the SCCM self-test.
Is DTC B11D9:16 still present?
Yes GO to E2
No The system is operating normally at this time. The DTC may have been set due to a previous low battery voltage condition.
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E2 CHECK FOR CHARGING SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) IN THE PCM (POWERTRAIN CONTROL MODULE)
Using the diagnostic scan tool, carry out the PCM KOEO self-test.
Using the diagnostic scan tool, retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from the PCM.
Are any charging system Diagnostic Trouble Codes (DTCs) present in the PCM?
Yes Refer to the appropriate section in Group 414 for the procedure.
No GO to E3
E3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE

Ignition OFF.
Carry out the battery condition test.
Is the battery OK and fully charged?
Yes GO to E4
No Refer to the appropriate section in Group 414 for the procedure.
E4 CHECK THE SCCM (STEERING COLUMN CONTROL MODULE) VOLTAGE SUPPLY USING THE SYSTEM BATTERY VOLTAGE
(VBAT_SCCM) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Measure and record:

Using a diagnostic scan tool, monitor the SCCM PID VBAT_SCCM.
Is the voltage within 0.2 volt of the recorded battery voltage?
Yes GO to E7
No GO to E5
E5 CHECK THE SCCM (STEERING COLUMN CONTROL MODULE) VOLTAGE SUPPLY FOR HIGH RESISTANCE
Ignition OFF.
Ignition ON.
Measure:
C226A-7 Ground
Is the voltage within 0.2 volt of the recorded battery voltage?
Yes GO to E6
No REPAIR the SCCM voltage supply circuit for high resistance.
E6 CHECK THE SCCM (STEERING COLUMN CONTROL MODULE) GROUND CIRCUIT FOR HIGH RESISTANCE
Ignition OFF.
Disconnect the negative battery cable.
Measure:

C226A-5 Ground
Yes CONNECT the negative battery cable. GO to E7
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No REPAIR the SCCM ground circuit for high resistance.
E7 CHECK FOR CORRECT SCCM (STEERING COLUMN CONTROL MODULE) OPERATION

Disconnect and inspect all of the SCCM connectors.
Repair:
Reconnect the SCCM connectors and make sure they seat and latch correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new SCCM.
REFER to: Steering Column Control Module (SCCM) (211-05 Steering Wheel and Column Electrical Components, Removal and
Installation).
B11D9:17
The SCCM continuously monitors the voltage supply circuit. If voltage increases above a predefined limit, the SCCM ceases functions. DTC B11D9:17 can set if
the vehicle has been recently jump started or the vehicle battery has been recently charged.

B11D9:17 Vehicle Battery: Circuit Above This DTC sets in continuous memory if the SCCM detects battery voltage above 19 volts from the battery
Threshold voltage supply circuit.
Possible Causes
Charging system
SCCM
PINPOINT TEST F : B11D9:17

F1 CHECK FOR CHARGING SYSTEM DIAGNOSTIC TROUBLE CODES (DTCS) SET IN OTHER MODULES
Ignition ON.
Using the diagnostic scan tool, retrieve the Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules.
Are any high battery voltage and/or charging system Diagnostic Trouble Codes (DTCs) present in other modules?
Yes Refer to the appropriate section in Group 414 for the procedure.
No GO to F2
F2 CHECK THE BATTERY VOLTAGE

Turn off all interior/exterior lights and accessories.
Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery voltage.
Does the battery voltage rise to 16.5 volts or higher?
Yes DIAGNOSE the overcharging condition. Refer to the appropriate section in Group 414 for the procedure.
No GO to F3
F3 RECHECK FOR DTC (DIAGNOSTIC TROUBLE CODE) B11D9:17

Ignition OFF.
Ignition ON.
Using a diagnostic scan tool, clear the SCCM Diagnostic Trouble Codes (DTCs) and repeat the self-test.
Is DTC B11D9:17 present?
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Yes INSTALL a new SCCM.
REFER to: Steering Column Control Module (SCCM) (211-05 Steering Wheel and Column Electrical Components, Removal and
Installation).
No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump
starting the vehicle.
P2533:14
The BCMB check for voltage from the RUN/START circuit when the self-test is commanded. If no voltage is detected, DTC P2533:14 sets.
BCMB DTC Fault Trigger Conditions

P2533:14 Ignition Switch Run/Start Position Circuit: Circuit Short To Sets during the on-demand self-test when the BCMB detects no voltage from the
Ground or Open RUN/START input circuit.
Possible Causes
Fuse
BCM
BCMB
PINPOINT TEST G : P2533:14

G1 CHECK FOR VOLTAGE TO THE BCMB (BODY CONTROL MODULE B)
Ignition OFF.
Disconnect BCMB C4368A.
Ignition ON.
Measure:

C4368A-7 Ground
Is the voltage graeter than 11 volts?

Yes GO to G3
No GO to G2
G2 CHECK THE BCMB (BODY CONTROL MODULE B) RUN/START INPUT CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C4368A-7 C2280C-8
Yes GO to G4
G3 CHECK FOR CORRECT BCMB (BODY CONTROL MODULE B) BCM (BODY CONTROL MODULE) OPERATION
Disconnect and inspect all BCMB connectors.
Repair:
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Reconnect the BCMB connectors. Make sure they seat and latch correctly.
and FOLLOW TSB instructions. If no Technical Service Bulletins (TSBs) address this concern, INSTALL a new BCMB.
G4 CHECK FOR CORRECT BCM (BODY CONTROL MODULE) OPERATION

Repair:

Steering Column Control Module (SCCM)
Removal
NOTE: The PMI process must begin with the current SCCM installed. If the current SCCM does not
respond to the diagnostic scan tool, the tool may prompt for As-Built Data as part of the repair.
Using a diagnostic scan tool, begin the PMI process for the SCCM following the on-screen instructions.
2. Remove the steering wheel.

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3. Remove the steering column shrouds.
Refer to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and Installation).
4. Detach the retainer and disconnect the clockspring electrical connector.
5. 1. Disconnect the SCCM electrical connector.

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6. 1. Pull the SCCM retaining clip.
2. Remove the SCCM from steering column.
Installation
Using a diagnostic scan tool, complete the PMI process for the SCCM following the on-screen instructions.

Steering Column Lock Module
Center Punch
Removal
NOTE: Prior to the removal of the steering column lock module , it is necessary to upload the BCM
configuration information to the scan tool. This information must be downloaded back into the same BCM
after installation of a new steering column lock module in order to establish the correct configuration of
the BCM into the new steering column lock module.
Using a diagnostic scan tool, begin the PMI process for the BCM following the on-screen instructions.
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4. 1. Release the retainers and detach the steering column lock module electrical connectors.
2. Using a center punch, partially push out the retainers on both sides.
Use the General Equipment: Center Punch
5. Remove the retainers from the both sides and the steering column lock module.
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Installation
Using a diagnostic scan tool, complete the PMI process for the BCM following the on-screen instructions.
Carry out the BCM to steering column lock module training procedure.
Carry out the BCM self-test. Clear the Diagnostic Trouble Codes (DTCs) and then retrieve the Diagnostic
Trouble Codes (DTCs) from the BCM to confirm all Diagnostic Trouble Codes (DTCs) have been cleared.

Steering Column Multifunction Switch LH
Removal

NOTICE: Make sure the component terminals are not bent or damaged.
2. NOTE: The steering wheel is removed for clarity.
Remove the retainers and the LH steering column multifunction switch.

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Installation

Steering Column Multifunction Switch RH
Removal

NOTICE: Make sure the component terminals are not bent or damaged.
2. NOTE: The steering wheel is removed for clarity.
Remove the retainers and the RH steering column multifunction switch.

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Installation

Steering Wheel Multifunction Switch
Removal
1. Remove the driver airbag.

Refer to: Driver Airbag (501-20B Supplemental Restraint System, Removal and Installation).
2. Remove the retainers, disconnect the electrical connectors and remove the switch and bezel assemblies.
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3. NOTE: This step is only necessary when installing new upper steering wheel switches.
On both sides.
Remove the retainers and the upper steering wheel switch.
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Lower steering wheel switch
4. 1. Remove the retainers.

3. Remove the lower steering wheel switches.
Installation

412-00 Climate Control System - General Information 2016 Mustang
Specifications
Specifications
Motorcraft® PAG Refrigerant Compressor Oil YN-12-D WSH-M1C231-B
Motorcraft® R-134a Refrigerant YN-19 (US); CYN-16-R (Canada) WSH-M17B19-A
Motorcraft® A/C System Flushing Solvent YN-23 —
Motorcraft® A/C Cooling Coil Coating YN-29 —
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Capacities
Motorcraft® PAG Refrigerant Compressor Oil YN-12-D vehicles with 2.3L EcoBoost and 3.7L Duratec 3.4 fl
oz ( 100 ml )
vehicles with 5.0L 32V Ti-VCT 4 fl oz ( 120 ml )
Motorcraft® R-134a Refrigerant YN-19 (US); vehicles with 2.3L EcoBoost and 3.7L Duratec 21oz (
CYN-16-R (Canada) 0.6 kg)
vehicles with 5.0L 32V Ti-VCT 24 oz ( 0.7 kg)
A/C Compressor Clutch Air Gap
mm
A/C compressor clutch air gap vehicles with 2.3L EcoBoost 0.21 - 0.55
vehicles with 3.7L Duratec and 5.0L 32V Ti-VCT 0.3 - 0.6

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Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) - Overview
Overview
The Dual Automatic Temperature Control (DATC) system maintains the selected vehicle interior temperature by
heating and/or cooling the air depending on the HVAC control panel selection.
The driver may override the automatic mode of operation.

The temperature control setting is the desired cabin air temperature.
The blower motor control override buttons vary the blower motor speed.
The driver side and passenger side temperature settings can be individually controlled.
During A/C operation, the system reduces the relative humidity of the air inside the vehicle.
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Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) - Overview
Overview
The Dual Automatic Temperature Control (DATC) system maintains the selected vehicle interior temperature by
heating and/or cooling the air depending on the HVAC control panel selection.
The driver may override the automatic mode of operation.

The temperature control setting is the desired cabin air temperature.
The blower motor control override buttons vary the blower motor speed.
The driver side and passenger side temperature settings can be individually controlled.
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Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) - Component
Location
NOTE: 5.0L shown all other engines similar.
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Item Description
1 Driver Side Register
2 Sunload Sensor
3 Center Registers
4 Passenger Side Register
5 FCIM
6 In-Vehicle Temperature And Humidity Sensor
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Item Description
1 Center Register Air Discharge Temperature Sensor
2 Blower Motor Speed Control
3 Air Inlet Door Actuator
4 Blower Motor
5 Passenger Side Temperature Door Actuator
6 Driver Side Temperature Door Actuator
7 Footwell Air Discharge Sensor
8 Air Distribution Door Actuator
9 Evaporator Temperature Sensor
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Item Description
1 Climate Control Housing
2 Thermostatic Expansion Valve
3 Evaporator Outlet Line
4 Condenser Outlet Line
5 A/C Compressor Inlet Line
6 A/C Compressor
7 A/C Compressor Outlet Line
8 A/C Pressure Transducer
9 Condenser
10 Receiver Drier

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Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) - System Operation
and Component Description
System Operation
System Diagram
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Module Network Input Messages APIM

Climate control button status FCIM This message contains the climate control button status.
Module Network Input Messages FCIM

Message Module
Ambient air PCM This message contains raw value from the ambient air temperature
temperature sensor.
Climate control APIM This message contains both the climate control system voice commands
requests as well as all climate control system touch screen inputs.
A/C clutch status PCM This message contains the status of the A/C compressor clutch.
Module Network Input Messages PCM
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Message Module
HVAC A/C FCIM This message requests the A/C compressor to be engaged.
request
Evaporator FCIM This message contains the evaporator temperature. The PCM uses the
temperature evaporator temperature to determine the A/C compressor output.
The Refrigerant Cycle
For information regarding base refrigerant operation within the HVAC system, refer to the current Ford Web
Based Technical Training courses. The diagram below shows the refrigerant system state in each component on
this vehicle.
The following statements apply to this refrigerant system:
The PCM controls the A/C clutch relay.

The evaporator temperature sensor monitors the temperature of the air that has passed through the
evaporator core and sends a signal to the PCM. If the temperature of the evaporator core discharge air is
low enough to cause the condensed water vapor to freeze, the A/C clutch is disengaged by the PCM.
The line pressure is monitored so that A/C compressor operation is interrupted if the system pressure
becomes too high or too low.
The A/C compressor relief valve opens and vents refrigerant to relieve unusually high system pressure.
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Item Description
1 High pressure liquid
2 Low pressure liquid
3 High pressure vapor
4 Low pressure vapor
Control System Logic
The climate control system controls are in one or more locations depending on vehicle option content:
FCIM (Dual Automatic Temperature Control (DATC) system)

FDIM (part of APIM)
When the FDIM touchscreen or voice commands are used and A/C is selected, the APIM sends a function
request message over the HS-CAN3 to the GWM. The GWM sends the message to the FCIM over the Medium
Speed Controller Area Network (MS-CAN). The GWM sends the requests to the PCM over the High Speed
Controller Area Network (HS-CAN)1. The PCM controls the A/C clutch relay.
When the customer directly inputs an A/C request into the FCIM, the module sends the request to the GWM over
the Medium Speed Controller Area Network (MS-CAN). The GWM sends the request to the PCM over the High
Speed Controller Area Network (HS-CAN)1. The PCM controls the A/C clutch relay.
The FCIM requires Programmable Module Installation (PMI) when it is replaced.
A/C Request
When an A/C request is received by the PCM, the PCM engages the A/C clutch relay when all of the following
conditions are met:
The PCM does not detect excessively high or low refrigerant pressure from the A/C pressure transducer.
The PCM does not detect an ambient air temperature below approximately 32.0°F (°C).
The PCM does not detect temperatures from the Mass Airflow/Intake Air Temperature sensor that does
not correlate with other temperature sensor readings at ignition ON. (Most Mass Airflow (MAF) sensors
have an integrated Intake Air Temperature (IAT) sensor).
The PCM does not receive a message from the FCIM detecting an evaporator temperature below
approximately 33.8°F (1°C).
The PCM monitors multiple temperature sensors correlation (AAT, CHT, ECT IAT, MAF...). The PCM runs this
logic after an engine off and a calibrated soak period, typically 6 to 8 hours. This soak period allows the Ambient
Air Temperature (AAT) sensor and the other temperature sensors to stabilize and not differ by greater than a
calibrated value, typically 18ºC (32.4ºF). If a sensor input is found to be reporting a temperature imbalance the
PCM does not allow the A/C clutch to engage. For more information on PCM sensors, Refer to Powertrain
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The PCM monitors the discharge pressure measured by the A/C pressure transducer. The PCM interrupts A/C
compressor operation in the event the A/C pressure transducer indicates high system discharge pressures. It is
also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient
temperature, the PCM does not allow the A/C clutch to engage.
The FCIM may adjust the air inlet door depending on the humidity measured by the in-vehicle temperature and
humidity sensor.
The sunload sensor supplies information to the FCIM indicating the intensity of the sun on the vehicle. The FCIM
adjusts the system based on the intensity.
Heating and Ventilation
The heating and ventilation system:
controls the temperature of the air inside the vehicle.

reduces the relative humidity of the air inside the vehicle (during A/C compressor operation).
delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
The heating and ventilation system uses a reheat method to provide conditioned air to the passenger
compartment. Temperature blending is controlled by the temperature doors, which regulate the amount of air that
flows through and around the heater core, where it is then mixed and distributed. All airflow from the blower
motor passes through the A/C evaporator core.
Vehicles equipped with Auto Start-Stop have a cabin heater coolant pump.
Air Handling
There are 4 door actuators that control the air flow into the passenger compartment:
Air distribution
Air inlet
Driver side temperature
Passenger side temperature
All of the door actuators contain a reversible electric motor and a potentiometer. The potentiometer circuit
consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected
to the other. A signal circuit is connected to a contact wiper, which is driven along the variable resistor by the
actuator shaft. The signal to the FCIM from the contact wiper indicates the position of the actuator door. The
FCIM powers the actuator motors to move the doors to the desired positions. The desired door positions are
calculated by the FCIM based on the set temperature, in-vehicle temperature, ambient air temperature and
sunload.
When an airflow mode, desired driver or passenger temperature, fresh air, or recirculation mode is selected, the
FCIM moves the actuator motor in the desired direction.
The FCIM sends a PWM signal to the blower motor speed control to regulate the blower speed as necessary.
The blower motor speed control provides variable ground feed for the blower motor based on the input from the
FCIM. A delay function provides a gradual increase or decrease in blower motor speed under all conditions.
AUTO
When AUTO is selected:
the HVAC system operates in a manner to achieve and maintain the temperature set by the operator.
the driver and passenger side temperature doors are automatically controlled by the FCIM based on the
temperature setting.
the A/C compressor is automatically controlled by the PCM from information sent by the FCIM, based on
the temperature setting. The A/C compressor does not operate if the outside temperature is below
approximately 32.0°F (°C).
the blower motor speed is automatically controlled through the blower motor speed control that receives a
PWM signal from the FCIM based on the temperature setting, but can be manually overridden.
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the FCIM controls the air inlet door to recirculate, partially recirculate or open to the fresh air position
depending on the in-car temperature and humidity sensor inputs.
OFF
When OFF is selected:
the air inlet door closes, preventing outside air and allowing only recirculated air.
the blower motor is off.
MAX A/C
When MAX A/C is selected:
the air inlet door closes, preventing outside air and allowing only recirculated air.
the recirculated air indicator is illuminated (recirculated air forced on).
the footwell vent doors and defrost vent/register doors operate in combination to direct airflow to the
instrument panel registers.
the temperature doors move to the full cool position. Air temperature can be manually overridden.
the A/C button is illuminated.
the A/C compressor operates if the outside temperature is above approximately 32.0°F (°C) .
the blower motor is commanded to the highest speed. The blower motor speed is adjustable.
PANEL
When PANEL mode is selected:
the recirculated air request button is enabled. If the recirculated air request button is selected (indicator
on), the air inlet door closes, preventing outside air from entering the passenger compartment. If the
recirculated air request button is not selected (indicator off), the air inlet door opens, allowing only outside
air into the passenger compartment.
the footwell vent doors and defrost vent/register doors operate in combination to direct airflow to the
instrument panel registers.
blended air temperature is available. Only when A/C compressor operation has been selected by pressing
the A/C button (indicator on) can the airflow temperature be cooled below the outside air temperature.
the blower motor is on and the speed is adjustable.
PANEL/FLOOR
When PANEL/FLOOR mode is selected:

the air distribution doors operate in combination to direct airflow to the floor duct and the instrument panel
registers. A small amount of airflow from the side window demisters and defrost duct is present.
FLOOR
When FLOOR mode is selected:
the air distribution doors operate in combination to direct airflow to the floor duct. A small amount of
airflow from the defroster duct and side window demisters is present.
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FLOOR/DEFROST
When FLOOR/DEFROST mode is selected:
the air distribution doors operate in combination to direct airflow to the floor duct, the defroster duct and
the side window demisters.
MAX DEFROST
When MAX DEFROST mode is selected:
The recirculated air request button is disabled. The air inlet door opens, allowing only outside air into the
The air distribution doors operate in combination to direct airflow to the defroster duct and side window
demisters. A small amount of airflow from the floor duct is present.
The A/C is turned on in defrost mode. The A/C compressor operates as long as the outside temperature
is above approximately 32.0°F (°C).
The temperature is set to the highest setting and is not adjustable.
The fan is set to the highest speed and is not adjustable.
MAX DEFROST can be exited by pressing the AUTO button.
MyTemp
The MyTemp feature can be used to store and recall a preset driver's temperature. This feature is provided so
this temperature can be quickly adjusted to a frequently used setting with a single button press. For additional
information about MyTemp, refer to the Owner's Literature.
Remote Start - Message Center Set To Auto
Remote start is an optional feature available on this vehicle. In addition to being able to start the vehicle
remotely, the remote start feature also utilizes other vehicle systems to increase the level of comfort to the
vehicle occupants upon entering the vehicle. Additional information on the remote start feature and the other
vehicle systems, refer to Owner's Literature.
Set the climate control to operate in Auto mode through the information display setting: Remote Start > Climate
Control > Heater–A/C > Auto, refer to the Owner's Literature for more information.
When the factory remote start feature is used, the Dual Automatic Temperature Control (DATC) system
automatically sets certain parameters in an attempt to achieve a comfortable cabin temperature. These
parameters are set based on outside air temperature. During remote start, the outside air temperature is
continually evaluated and HVAC system behavior can change if the outside air changes between cold, moderate
and warm temperatures.
For cold ambient air temperatures as determined by the FCIM AUTO mode to request heat:
the airflow mode is set to AUTO if Front Defrost is set to Off in the message center. (if the FCIM requests
FOOTWELL in AUTO mode, FOOTWELL/DEFROST will be used in remote start mode).
the airflow mode is set to DEFROST if Front Defrost is set to Auto in the message center.
the temperature is set to 22 C (71.6 F).
the blower speed is set to AUTO.
the air inlet mode is set to AUTO.
A/C is set to AUTO.
For moderate and warm ambient air temperatures as determined by the FCIM AUTO mode to request heat or
cooling:
the airflow mode is set to AUTO.

the temperature is set to 22 C (71.6 F).
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the blower speed is set to AUTO.
the air inlet mode is set to AUTO.
A/C is set to AUTO.
Remote Start - Message Center Set To Last User Settings
Set the climate control to operate using the last climate control settings through the information display setting:
Remote Start > Climate Control > Heater–A/C > Last Settings, refer to the Owner's Literature for more
information.
When the factory remote start feature is used and the IPC message center is set to last user settings, the Dual
Automatic Temperature Control (DATC) system automatically sets certain parameters in an attempt to achieve a
comfortable cabin temperature. These parameters are set based on outside air temperature. During remote
start, the outside air temperature is continually evaluated and HVAC system behavior can change if the outside
air changes between cold, moderate and warm temperatures.
For cold ambient air temperatures as determined by the FCIM AUTO mode to request heat:
the airflow mode is set to the last user setting if Front Defrost is set to Off in the message center.
the airflow mode is set to DEFROST if Front Defrost is set to Auto in the message center.
the temperature is set to the last user setting.
the blower speed is set to the last user setting.
the air inlet mode is set to the last user setting.
A/C is set to the last user setting.
For moderate and warm ambient air temperatures as determined by the FCIM AUTO mode to request heat or
cooling:
the airflow mode is set to the last user setting.

the temperature is set to the last user setting.
the blower speed is set to the last user setting.
the air inlet mode is set to the last user setting.
A/C is set to the last user setting.
FCIM - Dual Automatic Temperature Control (DATC)
The Dual Automatic Temperature Control (DATC) system uses the FCIM as the HVAC control module. The FCIM
also controls the outputs for rear window defrost and climate controlled seats. For vehicles equipped with
touchscreen audio, the Dual Automatic Temperature Control (DATC) system uses voice commands or the
touchscreen to control the system. For details on the FCIM communication, refer to Control System Logic in this
section.
The FCIM utilizes a Field-Effect Transistor (FET) protective circuit strategy for its actuator outputs. Output load
(current level) is monitored for excessive current (typically short circuits) and is shut down (turns off the voltage
or ground provided by the module) when a fault event is detected. A short circuit DTC is stored at the fault event
and a cumulative counter is started.
When the demand for the output is no longer present, the module resets the Field-Effect Transistor (FET) circuit
protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut
down by a previous short (Field-Effect Transistor (FET) protection) and the circuit is still shorted, the Field-Effect
Transistor (FET) protection shuts off the circuit again and the cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure
is carried out. The Field-Effect Transistor (FET) protected circuit has 3 predefined levels of short circuit tolerance
based on the harmful effect of each circuit fault on the Field-Effect Transistor (FET) and the ability of the Field-
Effect Transistor (FET) to withstand it. A module lifetime level of fault events is established based upon the
durability of the Field-Effect Transistor (FET). If the total tolerance level is determined to be 600 fault events, the
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3 predefined levels would be 200, 400 and 600 fault events.
When each tolerance level is reached, the short circuit DTC that was stored on the first failure cannot be cleared
by a command to clear the Diagnostic Trouble Codes (DTCs). The module does not allow the DTC to be cleared
or the circuit to be restored to normal operation until a successful self-test proves that the fault has been
repaired. After the self-test has successfully completed (no on-demand Diagnostic Trouble Codes (DTCs)
present), DTC U1000:00 and the associated DTC (the DTC related to the shorted circuit) automatically clears
and the circuit function returns.
When each level is reached, the DTC associated with the short circuit sets along with DTC U1000:00. These
Diagnostic Trouble Codes (DTCs) can be cleared using the diagnostic scan tool. The module never resets the
fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur.
If the number of short circuit fault events reach the third level, then Diagnostic Trouble Codes (DTCs) U1000:00
and U3000:49 set along with the associated short circuit DTC. DTC U3000:49 cannot be cleared and a new
module must be installed after the repair.
Ambient Air Temperature (AAT) Sensor
The Ambient Air Temperature (AAT) sensor contains a thermistor. The sensor varies its resistance with the
temperature. As the temperature rises, the resistance falls. As the temperature falls, the resistance rises. The
Ambient Air Temperature (AAT) sensor is hardwired to the PCM through separate input and return circuits. If the
outside air temperature is below approximately 0°C (32°F), the PCM does not allow the A/C compressor clutch
to engage.
The PCM sends raw ambient air temperature data to the HVAC module. The HVAC module filters the raw data,
sends it to the APIM and the touchscreen displays the outside temperature.
After replacing an Ambient Air Temperature (AAT) sensor, the sensor data must be reset by either driving the
vehicle at speeds consistently about 20 MPH for at least 5 minutes to update the filtered data or perform the
multiple button press reset procedure to update to the current raw value.
The multiple button reset for the Ambient Air Temperature (AAT) sensor is as follows:
On the HVAC panel controls, press the A/C and Recirc buttons simultaneously, then, release both.
Within 2 seconds press the A/C button again.
Blower Motor
The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing and
the plenum chamber where it is mixed and distributed.
Blower Motor Speed Control
The blower motor speed control uses a PWM signal from the FCIM to determine the desired blower speed and
varies the ground feed for the blower motor to control the speed.
Compressor Clutch Assembly
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 clutch pulley. The magnetic force locks the clutch disc and hub assembly and the A/C
clutch 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 clutch pulley.
An A/C clutch diode is integrated into the coil for A/C clutch field coil circuit spike suppression.
Evaporator Core
The evaporator core is an aluminum plate/fin type and is located in the climate control housing. A mixture of
liquid refrigerant and oil enters the evaporator through the evaporator inlet tube and continues out of the
evaporator through the evaporator outlet tube as a vapor. During A/C compressor operation, airflow from the
blower motor is cooled and dehumidified as it flows through the evaporator fins.
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Heater Core
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.
Climate Control Housing
The climate control housing directs airflow from the blower motor through the evaporator core and heater core.
All airflow from the blower motor passes through the evaporator core. The airflow is directed through or around
the heater core by the temperature doors. Airflow is then distributed to the selected outlet by the airflow mode
doors.
Air Distribution Door Actuator
The air distribution door actuator contains a reversible electric motor and a potentiometer. The potentiometer
allows the FCIM to monitor the position of the airflow mode door.
Air Inlet Door Actuator
The air inlet door actuator contains a reversible electric motor and a potentiometer. The potentiometer allows the
FCIM to monitor the position of the air inlet door. The FCIM may adjust the air inlet door depending on the
humidity measured by the in-vehicle temperature and humidity sensor. If the vehicle cabin becomes too humid,
and recirculated air is not selected, the FCIM adjusts the air inlet door to allow more fresh air. When the humidity
level drops, it may adjust back to partial recirculated air. Additionally, when recirculated air is not selected, the
FCIM may also adjust the system based on the in-vehicle and outside ambient temperatures to reduce loading
on the compressor when required.
Driver Side Temperature Door Actuator
The driver side temperature door actuator contains a reversible electric motor and potentiometer. The
potentiometer allows the FCIM to monitor the position of the temperature blend door.
Passenger Side Temperature Door Actuator
The passenger side temperature door actuator contains a reversible electric motor and potentiometer. The
Air Conditioning (A/C) Pressure Transducer
The PCM monitors the discharge pressure measured by the A/C pressure transducer. As the refrigerant
pressure changes, the resistance of the A/C pressure transducer changes. It is not necessary to recover the
refrigerant before removing the A/C pressure transducer.
In-Vehicle Temperature And Humidity Sensor
The in-vehicle temperature and humidity sensor contains a thermistor and a sensing element which separately
measures the in-vehicle air temperature and the humidity, then sends those readings to the FCIM. The in-vehicle
temperature and humidity sensor has an electric fan within the sensor that draws in-vehicle air across the two
sensing elements. The FCIM may adjust the air inlet door based on the in-vehicle temperature and humidity
sensor information to maintain the desired humidity of the passenger cabin air.
Autolamp/Sunload Sensor
The autolamp/sunload sensor supplies information to the FCIM indicating the intensity of the sun on the vehicle.
The FCIM compensates high sun load with higher blower and reduced discharge temperatures.
Evaporator Temperature Sensor
The evaporator temperature sensor contains a thermistor. The sensor varies its resistance with the temperature.
As the temperature rises, the resistance falls. As the temperature falls, the resistance rises. The evaporator
temperature sensor is an input to the FCIM and the information is relayed to the PCM over the CAN. If the
evaporator temperature is below approximately 1°C (33.8°F), the PCM does not allow the A/C compressor to
operate.
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Air Discharge Temperature Sensors
There are 2 air discharge temperature sensors in the Dual Automatic Temperature Control (DATC) system:
Center register air discharge temperature sensor

Footwell air discharge temperature sensor
The air discharge temperature sensors contain a thermistor and are inputs to the FCIM. The sensors vary their
resistance with the temperature. As the temperature rises, the resistance falls. As the temperature falls, the
resistance rises. The FCIM uses the sensor information to maintain the desired temperature of the passenger
cabin air.
Externally Controlled Variable Displacement A/C Compressor (2.3L)
NOTE: Proper Air Conditioning (A/C) system diagnosis on a vehicle's compressor is dependent on correct
refrigerant system charge and tested in ambient temperatures above 21.1°C (70°F).
The externally controlled variable displacement compressor has:
a non-serviceable shaft seal.

a serviceable pressure relief valve installed in the rear of the compressor to protect the refrigerant system
against excessively high refrigerant pressures.
a serviceable A/C clutch and field coil.
Uses Motorcraft® PAG Refrigerant Compressor Oil YN-12-D. This oil contains special additives required
for the A/C compressor. The oil may have some slightly dark-colored streaks while maintaining normal oil
viscosity. This is normal for this A/C compressor because of break-in wear that can discolor the oil.
Variable displacement compressors have a swash plate that rotates to reciprocate pistons, which compresses
refrigerant. Variable displacement compressors change the swash plate angle to change the refrigerant
displacement. The externally controlled variable displacement compressor changes the swash plate angle in
accordance with an electrical signal from the PCM. Externally controlled variable displacement compressor
manages displacement by controlling refrigerant differential pressure before and after a throttle at the discharge
side; achieving precise cooling capability control in accordance with cabin environment and driving conditions.
The PCM sends a PWM signal to the solenoid in the compressor to control the compressor displacement based
upon the:
Evaporator temperature
Ambient air temperature
Engine RPM
Vehicle speed
A/C high side pressure
Intake air temperature
Fixed Displacement A/C Compressor (3.7L, 5.0L and 5.2L)
The fixed displacement compressor has:

Fixed displacement A/C compressors are always at 100% displacement. The pistons are placed around an
angled plate (swash plate) and are pushed back and forth as the plate rotates. Cooling performance is controlled
by switching the compressor clutch on or off depending upon the evaporator temperature.
Condenser
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The A/C condenser is an aluminum fin-and-tube design heat exchanger. 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.
The receiver drier is mounted on the left side of the condenser.
Receiver Drier
The receiver drier stores high-pressure liquid. The desiccant bag mounted inside the receiver drier removes any
retained moisture from the refrigerant.
Thermostatic Expansion Valve (TXV)
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 refrigerant flow 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.
Service Gauge Port Valves

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Item Description Torque
1 Low-pressure service gauge port valve cap 0.8 Nm (7 lb-in)
2 Low-pressure service gauge port valve —
3 Low-pressure Schrader-type valve 2.26 Nm (20 lb-in)
4 High-pressure Schrader-type valve 3.4 Nm (30 lb-in)
5 High-pressure service gauge port valve —
6 High-pressure service gauge port valve cap 0.8 Nm (7 lb-in)
The service gauge port fitting is an integral part of the refrigerant line or component.
Prior to leak testing, blow air over the service gauge port valves to ensure an accurate test.
Special couplings are required for both the high-side and low-side service gauge ports.
A very small amount of leakage around the Schrader-type valve with the service gauge port valve cap
removed is considered normal. Install a new Schrader-type valve core if the seal leaks excessively.
The A/C service gauge port valve caps are used as primary seals in the refrigerant system to prevent
leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the
A/C service gauge port valve caps to the correct torque after they are removed.
Follow the procedure and the notes for electronic leak testing. Refer to:
Refer to: Electronic Leak Detection (412-00 Climate Control System - General Information, General
Procedures).
Refrigerant System Dye

A fluorescent refrigerant system dye wafer is added to the receiver drier desiccant bag at the factory to assist in
refrigerant system leak diagnosis. This fluorescent dye wafer dissolves after about 30 minutes of continuous A/C
operation. 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.
Refer to: Fluorescent Dye Leak Detection (412-00 Climate Control System - General Information, General
Procedures).
Replacement desiccant bags, either separately or part of the receiver drier assembly, are equipped with a new
fluorescent dye wafer. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks.
If the system has been out of refrigerant through the winter the dye at the leak point may have oxidized and may
not fluoresce. If this happens, recharge and operate the A/C system to circulate the oil and allow any residual
dye to show up at the leak point. It is important to understand that dye adheres to the oil not the refrigerant; the
refrigerant carries the oil out of the leak point.
NOTE: Check for leaks using a Rotunda-approved UV lamp and dye enhancing glasses.
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Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) - Component
Location
NOTE: 5.0L shown all other engines similar.
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Item Description
1 Driver Side Register
2 Center Registers
3 Passenger Side Register
4 FCIM
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Item Description
1 Blower Motor Speed Control
2 Air Inlet Door Actuator
3 Blower Motor
4 Driver Side Temperature Door Actuator
5 Air Distribution Door Actuator
6 Evaporator Temperature Sensor
Item Description
1 Climate Control Housing
2 Thermostatic Expansion Valve
3 Evaporator Outlet Line
4 Condenser Outlet Line
5 A/C Compressor Inlet Line
6 A/C Compressor
7 A/C Compressor Outlet Line
8 A/C Pressure Transducer
9 Condenser
10 Receiver Drier
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Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) - Overview
Overview
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 outlet air temperature.
The blower motor switch varies the blower motor speed.
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Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) - System
Operation and Component Description
System Operation
System Diagram
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Module Network Input Messages PCM

Message Module
HVAC A/C FCIM This message requests the A/C compressor to be engaged.
request
Message Module
Evaporator FCIM This message contains the evaporator temperature. The PCM uses the
temperature evaporator temperature to determine the A/C compressor output.
Module Network Input Messages FCIM

Module
A/C clutch status PCM This message contains the status of the A/C compressor clutch.
Ambient air PCM This message contains raw value from the ambient air
temperature temperature sensor.
The Refrigerant Cycle
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For information regarding base refrigerant operation within the HVAC system, refer to the current Ford Web
Based Technical Training courses. The diagram below shows the refrigerant system state in each component on
this vehicle.
The following statements apply to this refrigerant system:
The PCM controls the A/C clutch relay.

The evaporator temperature sensor monitors the temperature of the air that has passed through the
evaporator core and sends a signal to the PCM. If the temperature of the evaporator core discharge air is
low enough to cause the condensed water vapor to freeze, the A/C clutch is disengaged by the PCM.
The line pressure is monitored so that A/C compressor operation is interrupted if the system pressure
becomes too high or too low.
The A/C compressor relief valve opens and vents refrigerant to relieve unusually high system pressure.
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Item Description
1 High pressure liquid
2 Low pressure liquid
3 High pressure vapor
4 Low pressure vapor
When the customer directly inputs an A/C request into the FCIM, the module sends the request to the GWM over
the MS-CAN. The GWM sends the request to the PCM over the HS-CAN. The PCM controls the A/C clutch
relay. The GWM also sends the climate control button status to the IPC.
A/C Request
When an A/C request is received by the PCM, the PCM engages the A/C clutch relay when all of the following
conditions are met:
The PCM does not detect excessively high or low refrigerant pressure from the A/C pressure transducer.
The PCM does not detect an ambient air temperature below approximately 32.0°F (°C).
The PCM does not detect temperatures from the Mass Airflow/Intake Air Temperature sensor that does
not correlate with other temperature sensor readings at ignition ON. (Most Mass Airflow (MAF) sensors
have an integrated Intake Air Temperature (IAT) sensor).
The PCM does not receive a message from the FCIM detecting an evaporator temperature below
approximately 33.8°F (1°C).
The PCM monitors multiple temperature sensors correlation (AAT, CHT, ECT IAT, MAF...). The PCM runs this
logic after an engine off and a calibrated soak period, typically 6 to 8 hours. This soak period allows the Ambient
Air Temperature (AAT) sensor and the other temperature sensors to stabilize and not differ by greater than a
calibrated value, typically 18ºC (32.4ºF). If a sensor input is found to be reporting a temperature imbalance the
PCM does not allow the A/C clutch to engage. For more information on PCM sensors, Refer to Powertrain
The PCM monitors the discharge pressure measured by the A/C pressure transducer. The PCM interrupts A/C
compressor operation in the event the A/C pressure transducer indicates high system discharge pressures. It is
also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient
temperature, the PCM does not allow the A/C clutch to engage.
The FCIM may adjust the air inlet door depending on the humidity measured by the in-vehicle temperature and
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humidity sensor.
The sunload sensor supplies information to the FCIM indicating the intensity of the sun on the vehicle. The FCIM
adjusts the system based on the intensity.
Heating and Ventilation
The heating and ventilation system:
controls the temperature of the air inside the vehicle.

reduces the relative humidity of the air inside the vehicle (during A/C compressor operation).
delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
The heating and ventilation system uses a reheat method to provide conditioned air to the passenger
compartment. Temperature blending is controlled by the temperature door, which regulates the amount of air that
flows through and around the heater core, where it is then mixed and distributed. All airflow from the blower
motor passes through the A/C evaporator core.
Air Handling
There are 3 door actuators that control the air flow into the passenger compartment:
Air distribution
Air inlet
Driver side temperature
All of the door actuators contain a reversible electric motor and a potentiometer. The potentiometer circuit
consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected
to the other. A signal circuit is connected to a contact wiper, which is driven along the variable resistor by the
actuator shaft. The signal to the FCIM from the contact wiper indicates the position of the actuator door. The
FCIM powers the actuator motors to move the doors to the desired positions. The desired door positions are
calculated by the FCIM based on the set temperature and ambient air temperature.
When an airflow mode, desired temperature, fresh air, or recirculation mode is selected, the FCIM moves the
actuator motor in the desired direction.
The FCIM sends a PWM signal to the blower motor speed control to regulate the blower speed as necessary.
The blower motor speed control provides variable ground feed for the blower motor based on the input from the
FCIM. A delay function provides a gradual increase or decrease in blower motor speed under all conditions.
OFF
When OFF is selected:
the recirculated air request button is disabled.

the air inlet door actuator closes off outside air and admits only recirculated air.
the A/C request button is disabled.
the blower motor is off.
MAX A/C
When MAX A/C is selected:
the air inlet door actuator closes off outside air and admits only recirculated air.
the recirculated air request button is disabled and the indicator is illuminated.
the air distribution doors operate in combination to direct airflow to the instrument panel registers.
the temperature door moves to the full cool position. The air temperature is adjustable.
the A/C request button is illuminated and disabled.
the A/C compressor operates if the outside temperature is above approximately 32.0°F (°C).
the blower motor is commanded to the highest speed. The blower motor speed is adjustable.
PANEL
When PANEL mode is selected:
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the air distribution doors operate in combination to direct airflow to the instrument panel registers.
PANEL/FLOOR
When PANEL/FLOOR mode is selected:
the air distribution doors operate in combination to direct airflow to the floor duct and the instrument panel
registers. A small amount of airflow from the side window demisters and defrost duct is present.
FLOOR
When FLOOR mode is selected:
the air distribution doors operate in combination to direct airflow to the floor duct. A small amount of
airflow from the defroster duct and side window demisters is present.
FLOOR/DEFROST
When FLOOR/DEFROST mode is selected:

the air distribution doors operate in combination to direct airflow to the floor duct, the defroster duct and
the side window demisters.
DEFROST
When DEFROST mode is selected:
the recirculated air request button is disabled. The air inlet door opens, allowing only outside air into the
the air distribution doors operate in combination to direct airflow to the defroster duct and side window
the A/C is turned on in defrost mode. The A/C compressor operates as long as the outside temperature is
above approximately 32.0°F (°C).
blended air temperature is available.
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MAX DEFROST
When MAX DEFROST mode is selected:
the recirculated air request button is disabled. The air inlet door opens, allowing only outside air into the
the air distribution doors operate in combination to direct airflow to the defroster duct and side window
the A/C is turned on in defrost mode. The A/C compressor operates as long as the outside temperature is
above approximately 32.0°F (°C).
the temperature is set to the highest setting and is not adjustable.
the fan is set to the highest speed and is not adjustable.
Remote Start
When the factory remote start feature is used, the EMTC system runs at the setting it was set to when the
vehicle was last turned off. You cannot adjust the climate control system during remote start operation. Turn the
ignition on to return the system to its previous settings.
Set the climate control to operate using the last climate control settings through the information display setting:
Remote Start > Climate Control > Heater–A/C > Last Settings, refer to the Owner's Literature for more
information.
FCIM - Electronic Manual Temperature Control (EMTC)
The EMTC system uses the FCIM as the HVAC control module. The FCIM also controls the outputs for rear
window defrost and climate controlled seats. For details on the FCIM communication, refer to Control System
Logic in this section.
The FCIM utilizes a Field-Effect Transistor (FET) protective circuit strategy for its actuator outputs. Output load
(current level) is monitored for excessive current (typically short circuits) and is shut down (turns off the voltage
or ground provided by the module) when a fault event is detected. A short circuit DTC is stored at the fault event
and a cumulative counter is started.
When the demand for the output is no longer present, the module resets the Field-Effect Transistor (FET) circuit
protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut
down by a previous short (Field-Effect Transistor (FET) protection) and the circuit is still shorted, the Field-Effect
Transistor (FET) protection shuts off the circuit again and the cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure
is carried out. The Field-Effect Transistor (FET) protected circuit has 3 predefined levels of short circuit tolerance
based on the harmful effect of each circuit fault on the Field-Effect Transistor (FET) and the ability of the Field-
Effect Transistor (FET) to withstand it. A module lifetime level of fault events is established based upon the
durability of the Field-Effect Transistor (FET). If the total tolerance level is determined to be 600 fault events, the
3 predefined levels would be 200, 400 and 600 fault events.
When each tolerance level is reached, the short circuit DTC that was stored on the first failure cannot be cleared
by a command to clear the Diagnostic Trouble Codes (DTCs). The module does not allow the DTC to be cleared
or the circuit to be restored to normal operation until a successful self-test proves that the fault has been
repaired. After the self-test has successfully completed (no on-demand Diagnostic Trouble Codes (DTCs)
present), DTC U1000:00 and the associated DTC (the DTC related to the shorted circuit) automatically clears
and the circuit function returns.
When each level is reached, the DTC associated with the short circuit sets along with DTC U1000:00. These
Diagnostic Trouble Codes (DTCs) can be cleared using the diagnostic scan tool. The module never resets the
fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur.
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If the number of short circuit fault events reach the third level, then Diagnostic Trouble Codes (DTCs) U1000:00
and U3000:49 set along with the associated short circuit DTC. DTC U3000:49 cannot be cleared and a new
module must be installed after the repair.
Ambient Air Temperature (AAT) Sensor
The Ambient Air Temperature (AAT) sensor contains a thermistor. The sensor varies its resistance with the
temperature. As the temperature rises, the resistance falls. As the temperature falls, the resistance rises. The
Ambient Air Temperature (AAT) sensor is hardwired to the PCM through separate input and return circuits. If the
outside air temperature is below approximately 0°C (32°F), the PCM does not allow the A/C compressor clutch
to engage.
The PCM sends raw ambient air temperature data to the HVAC module. The HVAC module filters the raw data,
sends it to the APIM and the touchscreen displays the outside temperature.
After replacing an Ambient Air Temperature (AAT) sensor, the sensor data must be reset by either driving the
vehicle at speeds consistently about 20 MPH for at least 5 minutes to update the filtered data or perform the
multiple button press reset procedure to update to the current raw value.
The multiple button reset for the Ambient Air Temperature (AAT) sensor is as follows:
On the HVAC panel controls, press the A/C and Recirc buttons simultaneously, then, release both.
Within 2 seconds press the A/C button again.
Blower Motor
The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing and
the plenum chamber where it is mixed and distributed.
Blower Motor Speed Control
The blower motor speed control uses a PWM signal from the FCIM to determine the desired blower speed and
varies the ground feed for the blower motor to control the speed.
Compressor Clutch Assembly
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 clutch pulley. The magnetic force locks the clutch disc and hub assembly and the A/C
clutch 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 clutch pulley.
An A/C clutch diode is integrated into the coil for A/C clutch field coil circuit spike suppression.
Evaporator Core
The evaporator core is an aluminum plate/fin type and is located in the climate control housing. A mixture of
liquid refrigerant and oil enters the evaporator through the evaporator inlet tube and continues out of the
evaporator through the evaporator outlet tube as a vapor. During A/C compressor operation, airflow from the
blower motor is cooled and dehumidified as it flows through the evaporator fins.
Heater Core
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.
Climate Control Housing
The climate control housing directs airflow from the blower motor through the evaporator core and heater core.
All airflow from the blower motor passes through the evaporator core. The airflow is directed through or around
the heater core by the temperature door. Airflow is then distributed to the selected outlet by the airflow mode
doors.
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Air Distribution Door Actuator
The air distribution door actuator contains a reversible electric motor and a potentiometer. The potentiometer
allows the FCIM to monitor the position of the airflow mode door.
Air Inlet Door Actuator
The air inlet door actuator contains a reversible electric motor and a potentiometer. The potentiometer allows the
FCIM to monitor the position of the air inlet door. The FCIM drives the actuator motor in the direction necessary
to move the door to the position set by the recirculation button and when the MAX A/C, Defrost or MAX Defrost
buttons are selected.
Driver Side Temperature Door Actuator
The EMTC system has one temperature door actuator located on the driver side of the climate control housing.
The driver side temperature door actuator contains a reversible electric motor and potentiometer. The
Evaporator Temperature Sensor
The evaporator temperature sensor contains a thermistor. The sensor varies its resistance with the temperature.
As the temperature rises, the resistance falls. As the temperature falls, the resistance rises. The evaporator
temperature sensor is an input to the FCIM and the information is relayed to the PCM over the CAN. If the
evaporator temperature is below approximately 1°C (33.8°F), the PCM does not allow the A/C compressor to
operate.
Air Conditioning (A/C) Pressure Transducer
The PCM monitors the discharge pressure measured by the A/C pressure transducer. As the refrigerant
pressure changes, the resistance of the A/C pressure transducer changes. It is not necessary to recover the
refrigerant before removing the A/C pressure transducer.
In-Vehicle Temperature And Humidity Sensor
The in-vehicle temperature and humidity sensor contains a thermistor and a sensing element which separately
measures the in-vehicle air temperature and the humidity, then sends those readings to the FCIM. The in-vehicle
temperature and humidity sensor has an electric fan within the sensor that draws in-vehicle air across the two
sensing elements. The FCIM may adjust the air inlet door based on the in-vehicle temperature and humidity
sensor information to maintain the desired humidity of the passenger cabin air.
Externally Controlled Variable Displacement A/C Compressor (2.3L)

The externally controlled variable displacement compressor has:

Variable displacement compressors have a swash plate that rotates to reciprocate pistons, which compresses
refrigerant. Variable displacement compressors change the swash plate angle to change the refrigerant
displacement. The externally controlled variable displacement compressor changes the swash plate angle in
accordance with an electrical signal from the PCM. Externally controlled variable displacement compressor
manages displacement by controlling refrigerant differential pressure before and after a throttle at the discharge
side; achieving precise cooling capability control in accordance with cabin environment and driving conditions.
The PCM sends a PWM signal to the solenoid in the compressor to control the compressor displacement based
upon the:
Evaporator temperature
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Ambient air temperature
Engine RPM
Vehicle speed
A/C high side pressure
Intake air temperature
Fixed Displacement A/C Compressor (3.7L, 5.0L and 5.2L)
The fixed displacement compressor has:

Fixed displacement A/C compressors are always at 100% displacement. The pistons are placed around an
angled plate (swash plate) and are pushed back and forth as the plate rotates. Cooling performance is controlled
by switching the compressor clutch on or off depending upon the evaporator temperature.
Condenser
The A/C condenser is an aluminum fin-and-tube design heat exchanger. 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.
The receiver drier is mounted on the left side of the condenser.
Receiver Drier
The receiver drier stores high-pressure liquid. The desiccant bag mounted inside the receiver drier removes any
retained moisture from the refrigerant.
Thermostatic Expansion Valve (TXV)
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 refrigerant flow 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.
Service Gauge Port Valves
1
Item Description
Low-pressure service gauge port valve cap
Torque
0.8 Nm (7 lb-in)
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2 Low-pressure service gauge port valve —
3 Low-pressure Schrader-type valve 2.26 Nm (20 lb-in)
4 High-pressure Schrader-type valve 3.4 Nm (30 lb-in)
5 High-pressure service gauge port valve —
6 High-pressure service gauge port valve cap 0.8 Nm (7 lb-in)
The service gauge port fitting is an integral part of the refrigerant line or component.
Prior to leak testing, blow air over the service gauge port valves to ensure an accurate test.
Special couplings are required for both the high-side and low-side service gauge ports.
A very small amount of leakage around the Schrader-type valve with the service gauge port valve cap
removed is considered normal. Install a new Schrader-type valve core if the seal leaks excessively.
The A/C service gauge port valve caps are used as primary seals in the refrigerant system to prevent
leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the
A/C service gauge port valve caps to the correct torque after they are removed.
Follow the procedure and the notes for electronic leak testing. Refer to:
Refer to: Electronic Leak Detection (412-00 Climate Control System - General Information, General
Procedures).
Refrigerant System Dye
A fluorescent refrigerant system dye wafer is added to the receiver drier desiccant bag at the factory to assist in
refrigerant system leak diagnosis. This fluorescent dye wafer dissolves after about 30 minutes of continuous A/C
operation. 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.
Refer to: Fluorescent Dye Leak Detection (412-00 Climate Control System - General Information, General
Procedures).
Replacement desiccant bags, either separately or part of the receiver drier assembly, are equipped with a new
fluorescent dye wafer. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks.
If the system has been out of refrigerant through the winter the dye at the leak point may have oxidized and may
not fluoresce. If this happens, recharge and operate the A/C system to circulate the oil and allow any residual
dye to show up at the leak point. It is important to understand that dye adheres to the oil not the refrigerant; the
refrigerant carries the oil out of the leak point.
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NOTE: Check for leaks using a Rotunda-approved UV lamp and dye enhancing glasses.

Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC)
DTC Chart: Front Controls Interface Module (FCIM) - Dual Automatic Temperature Control (DATC)
Network Diagnostic Trouble Codes (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 Diagnostic Trouble Codes (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.
FCIM - Dual Automatic Temperature Control (DATC) DTC CHART
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B105A:12 Cabin Temperature GO to Pinpoint Test N
Sensor Fan: Circuit
Short To Battery
B105A:14 Cabin Temperature GO to Pinpoint Test N
Sensor Fan: Circuit
Short To Ground or
Open
B1081:07 Left Temperature INSPECT for a binding or damaged linkage or door. REPAIR
Damper Motor: as necessary. If no condition is found, INSTALL a new driver
Mechanical Failure side temperature door actuator.
REFER to: Driver Side Temperature Door Actuator (412-00
Climate Control System - General Information, Removal and
Installation).
.
B1081:11 Left Temperature GO to Pinpoint Test I
Damper Motor: Circuit
Short To Ground
Short To Battery
Open
B1082:07 Right Temperature INSPECT for a binding or damaged linkage or door. REPAIR
Damper Motor: as necessary. If no condition is found, INSTALL a new
Mechanical Failure passenger side temperature door actuator.
REFER to: Passenger Side Temperature Door Actuator
(412-00 Climate Control System - General Information,
B1082:11 Right Temperature GO to Pinpoint Test J
Short To Ground
Short To Battery
Open
B1083:07 Recirculation Damper INSPECT for a binding or damaged linkage or door. REPAIR
Motor: Mechanical as necessary. If no condition is found, INSTALL a new air inlet
Failure mode door actuator.
REFER to: Air Inlet Door Actuator (412-00 Climate Control
System - General Information, Removal and Installation).
B1083:11 Recirculation Damper GO to Pinpoint Test D
Motor: Circuit Short To
Ground
Battery
Motor: Circuit Open
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B1086:07 Air Distribution Damper INSPECT for a binding or damaged linkage or door. REPAIR
Motor: Mechanical as necessary. If no condition is found, INSTALL a new air
Failure distribution door actuator.
REFER to: Air Distribution Door Actuator (412-00 Climate
Control System - General Information, Removal and
Installation).
B1086:11 Air Distribution Damper GO to Pinpoint Test E
Ground
Battery
Motor: Circuit Open
B10AF:11 Blower Fan Relay: GO to Pinpoint Test K
B10AF:15 Blower Fan Relay: For an inoperative blower motor, GO to Pinpoint Test K
Circuit Short To Battery For all other blower motor symptoms, GO to Pinpoint
or Open Test L
B10B5:11 Left Panel Air GO to Pinpoint Test M

Discharge
Temperature: Circuit
Short To Ground
B10B5:15 Left Panel Air GO to Pinpoint Test M
Discharge
Short To Battery or
Open
B10B6:11 Left Floor Air Discharge GO to Pinpoint Test M
Short To Ground
B10B6:15 Left Floor Air Discharge GO to Pinpoint Test M
Short To Battery or
Open
B10B8:63 Push Buttons: Circuit / This DTC sets when the buttons have been held down too
Component Protection long. ATTEMPT to clean buttons. CLEAR the Diagnostic
Time-Out Trouble Codes (DTCs) and REPEAT the self-test. If the DTC
returns, INSTALL a new FCIM. Refer to the appropriate section
B10B9:12 Blower Control: Circuit GO to Pinpoint Test K
Short To Battery
B10B9:14 Blower Control: Circuit For an inoperative blower motor, GO to Pinpoint Test K
Short To Ground or For all other blower motor symptoms, GO to Pinpoint
Open Test L
B11E5:12 Left HVAC Damper GO to Pinpoint Test I

Position Sensor: Circuit
Short To Battery
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Short To Ground or
Open
B11E6:12 Right HVAC Damper GO to Pinpoint Test J
Short To Battery
B11E6:14 Right HVAC Damper GO to Pinpoint Test J
Short To Ground or
Open
B11E7:12 Air Distribution Damper GO to Pinpoint Test E
Short To Battery
Short To Ground or
Open
B11F0:12 Air Intake Damper GO to Pinpoint Test D
Short To Battery
Short To Ground or
Open
B1A61:11 Cabin Temperature GO to Pinpoint Test N
Sensor: Circuit Short To
Ground
B1A61:15 Cabin Temperature GO to Pinpoint Test N
Battery or Open
B1A63:11 Right Solar Sensor: GO to Pinpoint Test O
B1A63:15 Right Solar Sensor: GO to Pinpoint Test O
or Open
B1A64:11 Left Solar Sensor: GO to Pinpoint Test O
B1A64:15 Left Solar Sensor: GO to Pinpoint Test O
or Open
B1A69:12 Humidity Sensor: GO to Pinpoint Test N
B1A69:14 Humidity Sensor: GO to Pinpoint Test N
or Open
B1B71:11 Evaporator GO to Pinpoint Test P
Temperature Sensor:
B1B71:15 Evaporator GO to Pinpoint Test P
Temperature Sensor:
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or Open
C1B14:11 Sensor Supply Voltage GO to Pinpoint Test Q
A: Circuit Short To
Ground
C1B14:12 Sensor Supply Voltage GO to Pinpoint Test Q
A: Circuit Short To
Battery
All Other FCIM — Refer to the appropriate section in Group 415 for the
Diagnostic Trouble procedure.
Codes (DTCs) not
listed in this chart

P0532 A/C Refrigerant GO to Pinpoint Test A
Pressure Sensor “A”
Circuit Low
Circuit High
P0645 A/C Clutch Relay GO to Pinpoint Test B
Control Circuit
P06A0 Variable A/C GO to Pinpoint Test R
Compressor Control
Circuit
P1464 A/C Demand Out Of If the HVAC selector was not powered off, POWER the HVAC off,
Self Test Range CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
self-test. If the DTC returns, GO to Pinpoint Test H
P193E A/C Clutch Request GO to Pinpoint Test S
Signal
All Other PCM — For 2.3L PCM DTC Chart,
Diagnostic Trouble REFER to: Electronic Engine Controls (303-14A Electronic
Codes (DTCs) Engine Controls - 2.3L EcoBoost (231kW/314PS),
For 3.7L PCM DTC Chart,
REFER to: Electronic Engine Controls (303-14B Electronic
Engine Controls - 3.7L Duratec (227kW/301PS), Diagnosis
and Testing).
REFER to: Electronic Engine Controls (303-14C Electronic
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REFER to: Electronic Engine Controls (303-14D Electronic
Engine Controls - 5.2L 32V Ti-VCT, Diagnosis and
Testing).
Symptom Chart(s)
Symptom Chart: Climate Control - Dual Automatic Temperature Control (DATC)
Symptom Chart

A module does not Fuse(s)
communicate with the Wiring, terminals or REFER to: Communications Network (418-00
diagnostic scan tool connectors Module Communications Network, Diagnosis and
Testing).
Externally Controlled Variable Refer to Pinpoint Test GO to Pinpoint Test R
Displacement Compressor
(EVDC) poor
performance/does not operate
correctly
Unable To Duplicate The Refer to Pinpoint Test GO to Pinpoint Test C
Customer Concern And No
Diagnostic Trouble Codes
(DTCs) Present
HVAC functions are Communication Refer to the appropriate section in Group 415 for
inoperative/do not operate network the procedure.
correctly from touchscreen FCIM
only APIM
Reduced outlet airflow Plugged cabin air filter INSPECT the cabin air filter.
REFER to: Cabin Air Filter (412-00 Climate Control
System - General Information, Removal and
Installation).
If OK, DIAGNOSE for low refrigerant charge, A/C
always commanded on or blower motor not
operating correctly.
Improper refrigerant level CARRY OUT the refrigerant system tests.
REFER to: Refrigerant System Tests - 2.3L
EcoBoost (201kW/273PS) (412-00 Climate Control
System - General Information, General
Procedures).
Duratec (227kW/301PS) (412-00 Climate Control
Procedures).
REFER to: Refrigerant System Tests - 5.0L 32V
Ti-VCT (412-00 Climate Control System - General
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If refrigerant charge is OK, GO to Pinpoint Test H
Blower motor GO to Pinpoint Test L
The air inlet door is Refer to Pinpoint Test GO to Pinpoint Test D
inoperative
Incorrect or erratic direction of Refer to Pinpoint Test GO to Pinpoint Test E
airflow from outlets
Insufficient, erratic or no heat Refer to Pinpoint Test GO to Pinpoint Test F
The A/C is inoperative Refer to Pinpoint Test GO to Pinpoint Test G
The A/C is always on — A/C Refer to Pinpoint Test GO to Pinpoint Test H
mode always commanded ON
Temperature control is Refer to Pinpoint Test GO to Pinpoint Test I
correctly — driver side
Temperature control is Refer to Pinpoint Test GO to Pinpoint Test J
correctly — passenger side
The blower motor is Refer to Pinpoint Test GO to Pinpoint Test K
inoperative
The blower motor does not Refer to Pinpoint Test GO to Pinpoint Test L
operate correctly
Insufficient A/C cooling Improper refrigerant level CARRY OUT the refrigerant system tests.
EcoBoost (201kW/273PS) (412-00 Climate Control
Procedures).
Duratec (227kW/301PS) (412-00 Climate Control
Procedures).
If OK, DIAGNOSE for a temperature door actuator
not operating correctly.
Temperature door actuator For inadequate temperature out of the driver
side, GO to Pinpoint Test I
For inadequate temperature out of the
passenger side, GO to Pinpoint Test J
A/C pressure relief valve A/C pressure relief valve CHECK the high side system pressure.
discharging REFER to: Specifications (412-00 Climate Control
System - General Information, Specifications).
If the pressure is below the A/C pressure relief
valve open pressure, INSTALL a new A/C pressure
relief valve. Refer to the appropriate section in
Group 412 for the procedure.
High system pressure CHECK the high side system pressure.
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REFER to: Specifications (412-00 Climate Control
If the system pressure is above the A/C pressure
relief valve open pressure, REPAIR the A/C system
for a restriction.
Climate control does not IPC information VERIFY Remote Start - Message Center
operate only when remote display settings Set To Auto, or Remote Start - Message
start is used Non-Ford approved Center Set To Last User Settings.
remote start system REFER to: Climate Control System -
installed Vehicles With: Dual Automatic Temperature
Control (DATC) - System Operation and
Component Description (412-00 Climate
Control System - General Information,
VERIFY module communications network
operation. DIAGNOSE Diagnostic Trouble
Codes (DTCs) if present.
Symptom Chart: Noise, Vibration, and Harshness (NVH)
Symptom Chart

Noisy A/C compressor A/C compressor INSPECT the A/C compressor pulley bearing for roughness. If
pulley bearing worn bearing roughness is found, INSTALL a new A/C compressor
clutch and A/C clutch field coil.
REFER to: Air Conditioning (A/C) Clutch and Air Conditioning
(A/C) Clutch Field Coil (412-00 Climate Control System -
General Information, General Procedures).
Excessive hissing from Incorrect A/C CHECK the A/C refrigerant level.
the plenum when the A/C refrigerant level REFER to: Refrigerant System Tests - 2.3L EcoBoost
is on (201kW/273PS) (412-00 Climate Control System - General
REFER to: Refrigerant System Tests - 3.7L Duratec
(227kW/301PS) (412-00 Climate Control System - General
REFER to: Refrigerant System Tests - 5.0L 32V Ti-VCT
Pinpoint Test(s)
P0532, P0533
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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.

P0532 A/C Refrigerant Pressure This DTC sets if the feedback voltage is less than 0.26 volt for at least 2
Sensor "A" Circuit Low seconds and the ambient air temperature is greater than 0°C (32°F).
P0533 A/C Refrigerant Pressure This DTC sets if the feedback voltage is greater than 4.95 volts for at
Sensor "A" Circuit High least 2 seconds and the ambient air temperature is greater than 0°C
(32°F).
Possible Sources

PCM
Inspect for loose or corroded PCM and A/C pressure transducer connections.
PINPOINT TEST A : P0532, P0533

A1 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) PRESSURE SENSOR (ACP_PRESS)
PID (PARAMETER IDENTIFICATION) WITH THE MANIFOLD GAUGE SET READINGS
Allow the A/C system to stabilize to the outside ambient temperature.
Ignition ON.
With the manifold gauge set connected, compare the pressure readings of the manifold gauge set and
the PCM ACP_PRESS PID.
Are the pressure values of the manifold gauge set and the ACP_PRESS PCM PID within ± 103 kPa
(15 psi)?
Yes IGNORE the Diagnostic Trouble Codes (DTCs). REFER to the Symptom Chart in this
section.
No GO to A2
A2 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF.
Disconnect PCM, 2.3L C1551B, 3.7L C1381B or 5.0L and 5.2L C175B.
Disconnect A/C pressure transducer C1260.
Disconnect Turbocharger boost pressure sensor C1588 (if equipped).
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Disconnect Generator current sensor C1645.
Ignition ON.
Measure:

C1260-1 Ground
C1260-2 Ground
C1260-3 Ground

No GO to A3
GROUND
Ignition OFF.
Measure:

C1260-1 Ground
C1260-2 Ground
C1260-3 Ground

Yes GO to A4
A4 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR CIRCUITS FOR AN OPEN
Measure:

2.3L

C1260-1 C1551B-56
C1260-2 C1551B-31
C1260-3 C1551B-52
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3.7L

C1260-1 C1381B-18
C1260-2 C1381B-52
C1260-3 C1381B-11

5.0L or 5.2L

C1260-1 C175B-18
C1260-2 C175B-52
C1260-3 C175B-11
Yes GO to A5
A5 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR CIRCUITS FOR A SHORT
TOGETHER
Measure:

C1260-1 C1260-2
C1260-1 C1260-3
C1260-2 C1260-3
Yes INSTALL a new A/C pressure transducer.

REFER to: Air Conditioning (A/C) Pressure Transducer (412-00 Climate Control System -
General Information, Removal and Installation).
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Ignition OFF.
Repair:
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
P0645
Voltage is provided to the A/C clutch relay. 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.

P0645 A/C Clutch This DTC sets when the PCM grounds the relay circuit and more voltage than
Relay Control expected is detected on the relay circuit. This DTC also sets when the relay circuit is
Circuit 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.
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Possible Sources

A/C clutch relay
PCM
Inspect BJB fuses 23 (10A) and 42 (15A).
PINPOINT TEST B : P0645

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.
B1 CHECK THE VOLTAGE TO THE A/C (AIR CONDITIONING) CLUTCH RELAY VOLTAGE SUPPLY
CIRCUITS
Ignition OFF.
Disconnect A/C clutch relay.
Ignition ON.
Measure:

A/C clutch relay socket 1 Ground
Yes GO to B2
No VERIFY BJB fuses 23 (10A) and 42 (15A) are OK. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of the circuit short. If OK, REPAIR the
circuit.
B2 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY
Carry out the component test on the A/C clutch relay.
Did the relay pass the component test?
Yes GO to B3
No INSTALL a new A/C clutch relay.
B3 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY CONTROL CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
Measure:
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No GO to B4
GROUND
Ignition OFF.
Measure:

Yes GO to B5
B5 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY CONTROL CIRCUIT FOR AN OPEN
Measure:

2.3L
A/C clutch relay socket 2 C1551B-2

3.7L
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5.0L or 5.2L
Yes GO to B6

Ignition OFF.
Repair:
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
Unable To Duplicate The Customer Concern And No Diagnostic Trouble Codes (DTCs) Present
This diagnostic procedure tests the functions of the HVAC system and identifies the correct HVAC symptom
pinpoint test.
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System Operation
REFER to: Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC) - System
Operation and Component Description (412-00 Climate Control System - General Information, Description and
Operation).
PINPOINT TEST C : UNABLE TO DUPLICATE THE CUSTOMER CONCERN AND NO

DIAGNOSTIC TROUBLE CODES (DTCS) PRESENT
(DTCS)
Ignition ON.
Are any climate control related Diagnostic Trouble Codes (DTCs) present?

No GO to C2
C2 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) FOR DIAGNOSTIC TROUBLE
CODES (DTCS)
Ignition ON.
Using a diagnostic scan tool, perform FCIM self-test.
Yes REFER to the FCIM DTC chart in this section.

No GO to C3
C3 CHECK THE BLOWER MOTOR OPERATION

Ignition ON.
Select panel mode.
Observe blower motor operation and select each blower motor speed.
Does the blower motor operate in all ranges?
Yes GO to C4
No If the blower motor does not operate in any setting, GO to Pinpoint Test K
If the blower motor does not correctly change speeds or shut off, GO to Pinpoint Test L
C4 CHECK AIRFLOW OPERATION

Select the highest blower motor setting.
While observing the airflow, select each of the airflow positions (panel, panel/floor, floor, floor/defrost,
defrost).
Is the airflow directed to the correct outlets?
Yes GO to C5
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No GO to Pinpoint Test E
C5 VERIFY TEMPERATURE CONTROL OPERATION

Start the vehicle and allow it to reach normal operating temperature.
With the A/C off, select panel mode.
Change the driver and passenger temperature settings from the coldest to the warmest and back to the
coldest.
Does the temperature change between very warm to cool?
Yes GO to C6
No If the temperature does not get very warm, GO to Pinpoint Test F
If the driver side temperature does not change at all, GO to Pinpoint Test I
If the passenger side temperature does not change at all, GO to Pinpoint Test J
C6 VERIFY THE AIR CONDITIONING COMPRESSOR DOES NOT ENGAGE WITH A/C (AIR
CONDITIONING) OFF
With the engine running and the A/C off, select panel mode.
Select the coldest temperature setting.
Is the outlet temperature close to ambient air temperature?
Yes GO to C7
No If the driver side temperature is warmer than ambient air temperature, GO to Pinpoint Test
I
If the passenger side temperature is warmer than ambient air temperature, GO to
Pinpoint Test J
If the outlet temperature is significantly colder than ambient air temperature and the A/C
compressor clutch is engaged, GO to Pinpoint Test H
C7 VERIFY THE A/C (AIR CONDITIONING) COMPRESSOR IS OPERATIONAL IN THE A/C (AIR
CONDITIONING) MODE
Make sure the ambient air temperature is above 0°C (32°F).
With the engine running, select panel mode.
Press the A/C button (indicator on).
Is the A/C compressor operational when the panel and A/C button (indicator on) is pressed?
Yes GO to C8
C8 CHECK THE RECIRCULATED AIR OPERATION

With the engine running, press the recirculated air button (indicator off).
Select panel mode.
Observe airflow noise.
Press the recirculated air button (indicator on).
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Does the airflow noise increase when the recirculated air mode is selected (indicator on)?
Yes GO to C9
C9 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) LEFT DISCHARGE FLOOR
TEMPERATURE (LDFTEMP) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the FCIM Parameter Identifications (PIDs).
Monitor the LDFTEMP PID.
Is the temperature coming out of the driver footwell vent similar to the PID?
Yes GO to C10
No GO to Pinpoint Test M
C10 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) LEFT DISCHARGE PANEL
TEMPERATURE (LDPT) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, view the FCIM Parameter Identifications (PIDs).
Monitor the LDPT PID.
Is the temperature coming out of the driver side register similar to the PID?
Yes GO to C11
No GO to Pinpoint Test M
C11 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) INTERIOR TEMPERATURE
SENSOR (INT_TEMP) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool view the FCIM Parameter Identifications (PIDs).
Monitor the INT_TEMP PID.
Is the air temperature at the cabin temperature sensor similar to the PID?
Yes GO to C12
C12 CHECK THE TOUCHSCREEN CONTROLS OPERATION

Using the touchscreen controls, select each climate control function.
Using the touchscreen controls, select each audio control function.
Do all touchscreen controls operate?
Yes The system is operating correctly.

No Refer to the appropriate section in Group 415 for the procedure.
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The Air Inlet Door Is Inoperative
To rotate the air inlet door actuator, the FCIM supplies voltage and ground to the air inlet door actuator through
the door actuator motor circuits. To reverse the air inlet door actuator rotation, the FCIM reverses the voltage and
ground circuits. The air inlet door actuator feedback resistors are supplied a ground from the FCIM by the air
inlet door actuator return circuits and a 5-volt reference voltage on the air inlet door actuator reference circuits.
The FCIM uses the actuator feedback resistor wiper arm position and the voltage on the air distribution door
actuator feedback circuits to determine the air inlet door actuator position.
During an actuator calibration cycle, the FCIM drives the air inlet door until the door reaches both internal stops
in the FCIM case. If the air inlet door is temporarily obstructed or binding during a calibration cycle, the FCIM
may interpret this as the actual end of travel for the door. When this condition occurs and the FCIM commands
the actuator to its end of travel, the air intake may not be from the expected source.

B1083:11 Recirculation Damper Motor: This DTC sets when the module senses lower than expected voltage
Circuit Short To Ground on an actuator motor circuit when voltage is applied to drive the
motor, indicating a short to ground. The motor can move only in one
direction.
B1083:12 Recirculation Damper Motor: This DTC sets when the module senses higher than expected voltage
Circuit Short To Battery on the actuator motor circuit when ground is applied to drive the
motor, indicating a short to voltage. The motor can move only in one
direction.
B1083:13 Recirculation Damper Motor: This DTC sets when the module senses no voltage on the actuator
Circuit Open motor circuit when ground is applied to drive the motor, indicating an
open circuit. The motor cannot move.
B11F0:12 Air Intake Damper Position This DTC sets when the module senses greater than 5 volts on the
Sensor: Circuit Short to actuator feedback circuit, indicating a short to voltage.
Battery
B11F0:14 Air Intake Damper Position This DTC sets when the module senses less than 1 volt on the
Sensor: Circuit Short to actuator feedback circuit, indicating an open circuit or a short to
Ground or Open ground.
Possible Sources

Air inlet door actuator
Air inlet door binding or stuck
FCIM
PINPOINT TEST D : THE AIR INLET DOOR IS INOPERATIVE

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D1 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Disconnect Air distribution door actuator C232.
Disconnect In-vehicle temperature and humidity sensor C233.
Disconnect Driver side temperature door actuator C2091.
Disconnect Passenger side temperature door actuator C2092.
Disconnect Air inlet door actuator C282.
Ignition ON.
Measure:

C282-1 Ground
C282-2 Ground
C282-3 Ground
C282-5 Ground
C282-6 Ground
Is there any voltage present?

No GO to D2
D2 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:
C282-1 Ground
C282-2 Ground
C282-3 Ground
C282-5 Ground
C282-6 Ground
Yes GO to D3
D3 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR AN OPEN
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Measure:

C282-1 C2402A-2
C282-2 C2402A-16
C282-3 C2402A-3
C282-5 C2402A-24
C282-6 C2402A-25
Yes GO to D4
D4 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TOGETHER
Measure:

C282-1 C282-2
C282-1 C282-3
C282-1 C282-5
C282-1 C282-6
C282-2 C282-3
C282-2 C282-5
C282-2 C282-6
C282-3 C282-5
C282-3 C282-6
C282-5 C282-6
Yes INSTALL a new air inlet door actuator.

REFER to: Air Inlet Door Actuator (412-00 Climate Control System - General Information,
D5 CHECK FOR CORRECT FRONT CONTROLS INTERFACE MODULE OPERATION

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Repair:
Reconnect all FCIM connectors. Make sure they seat and latch correctly.
Service Bulletins (TSBs) address this concern, INSTALL a new FCIM. Refer to the
Incorrect Or Erratic Direction Of Airflow From Outlets
To rotate the air distribution door actuator, the FCIM supplies voltage and ground to the air distribution door
actuator through the door actuator motor circuits. To reverse the air distribution door actuator rotation, the FCIM
reverses the voltage and ground circuits. The air distribution door actuator feedback resistors are supplied a
ground from the FCIM by the air distribution door actuator return circuits and a 5-volt reference voltage on the air
distribution door actuator reference circuits. The FCIM uses the actuator feedback resistor wiper arm position
and the voltage on the air distribution door actuator feedback circuits to determine the air distribution door
actuator position.
During an actuator calibration cycle, the FCIM drives the air distribution door until the door reaches both internal
stops in the FCIM case. If the air distribution door is temporarily obstructed or binding during a calibration cycle,
the FCIM may interpret this as the actual end of travel for the door. When this condition occurs and the FCIM
commands the actuator to its end of travel, the airflow may not be from the expected outlets.

B1086:11 Air Distribution Damper This DTC sets when the module senses lower than expected voltage
Motor: Circuit Short to on an actuator motor circuit when voltage is applied to drive the
Ground motor, indicating a short to ground. The motor can move only in one
direction.
B1086:12 Air Distribution Damper This DTC sets when the module senses higher than expected
Motor: Circuit Short to Battery voltage on the actuator motor circuit when ground is applied to drive
the motor, indicating a short to voltage. The motor can move only in
one direction.
B1086:13 Air Distribution Damper This DTC sets when the module senses no voltage on the actuator
Motor: Circuit Open motor circuit when ground is applied to drive the motor, indicating an
B11E7:12 Air Distribution Damper This DTC sets when the module senses greater than 5 volts on the
Position Sensor: Circuit Short actuator feedback circuit, indicating a short to voltage.
to Battery
B11E7:14 Air Distribution Damper This DTC sets when the module senses less than 1 volt on the
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Position Sensor: Circuit Short actuator feedback circuit, indicating an open circuit or a short to
to Ground or Open ground.
Possible Sources

Air distribution door actuator
Air distribution door binding or stuck
FCIM
PINPOINT TEST E : INCORRECT OR ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS

E1 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C232-1 Ground
C232-2 Ground
C232-3 Ground
C232-5 Ground
C232-6 Ground

No GO to E2
E2 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

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C232-1 Ground
C232-2 Ground
C232-3 Ground
C232-5 Ground
C232-6 Ground
Yes GO to E3
E3 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR AN OPEN

Measure:

C232-1 C2402A-2
C232-2 C2402A-22
C232-3 C2402A-3
C232-5 C2402A-20
C232-6 C2402A-21
Yes GO to E4
E4 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TOGETHER
Measure:

C232-1 C232-2
C232-1 C232-3
C232-1 C232-5
C232-1 C232-6
C232-2 C232-3
C232-2 C232-5
C232-2 C232-6
C232-3 C232-5
C232-3 C232-6
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C232-5 C232-6
Yes INSTALL a new air distribution door actuator,

REFER to: Air Distribution Door Actuator (412-00 Climate Control System - General
Information, Removal and Installation).
TEST the system for normal operation. If the concern is still present, GO to E5
E5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
Insufficient, Erratic Or No Heat
When the engine is at operating temperature hot coolant flows from the coolant pump through the heater core
and back to the coolant pump. Correct coolant temperatures are critical for good heater performance.
Possible Sources

Temperature door actuator(s)
Air trapped in the coolant system
Heater core
Inspect for low engine coolant level.
PINPOINT TEST F : INSUFFICIENT, ERRATIC OR NO HEAT

F1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
Ignition OFF.
Check the engine coolant level.
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Is the engine coolant at the correct level as indicated on the engine coolant recovery reservoir?
Yes GO to F3
No GO to F2
F2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS

Pressure test the cooling system for leaks. Refer to the appropriate section in Group 303 for the
procedure..
Does the engine cooling system leak?
Yes REPAIR the engine coolant leak. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation.
No FILL and BLEED the cooling system. Refer to the appropriate section in Group 303 for
the procedure.
After filling and bleeding the cooling system, GO to F3
F3 CHECK FOR COOLANT FLOW TO THE HEATER CORE

Run the motor until it reaches normal operating temperature. Select the floor position on the control
assembly. Set the temperature control to full warm and the blower to the lowest setting.
Increase engine speed to 3,500 RPM and hold for 30 seconds.
Allow the engine to idle for 30 seconds.
Using a suitable temperature measuring device, check the heater core inlet hose to see if it is hot.
Is the heater core inlet hose hot?
Yes GO to F4
No BLEED the cooling system per the cooling system draining and vacuum filling general
procedure. Refer to the appropriate section in Group 303 for the procedure.
After bleeding the cooling system, GO to F4
F4 CHECK FOR A PLUGGED OR RESTRICTED HEATER CORE
Using a suitable temperature measuring device, measure the heater core outlet hose temperature.
Is the heater core outlet hose temperature similar to the inlet hose temperature (within
approximately 6-17°C [10-30°F])?
Yes DIAGNOSE for a temperature door actuator not operating correctly.

For inadequate temperature out of the driver side, GO to Pinpoint Test I
For inadequate temperature out of the passenger side, GO to Pinpoint Test J
No INSTALL a new heater core.
REFER to: Heater Core (412-00 Climate Control System - General Information, Removal
and Installation).
The A/C Is Inoperative
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Operation).
Possible Sources

Communication network
Ambient Air Temperature (AAT) sensor
Evaporator temperature sensor
Intake Air Temperature (IAT) or other temperature sensors
Active grille shutters
FCIM
PCM
PINPOINT TEST G : THE A/C (AIR CONDITIONING) IS INOPERATIVE

G1 CHECK THE A/C (AIR CONDITIONING) SYSTEM PRESSURE
Ignition OFF.
With the R-134a manifold gauge set connected, check the A/C system pressure.
Is the A/C system pressure above 290 kPa (42 psi)?
Yes GO to G2
No CHECK the A/C system for leaks.
REFER to: Electronic Leak Detection (412-00 Climate Control System - General
REFER to: Fluorescent Dye Leak Detection (412-00 Climate Control System - General
After the leak is repaired, RECHARGE the A/C system.

REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).

Ignition ON.
Do the FCIM and the PCM pass the network test?
Yes GO to G3
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No DIAGNOSE the FCIM or PCM does not communicate with the diagnostic scan tool.
G3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) PRESSURE
SENSOR (ACP_PRESS) PID (PARAMETER IDENTIFICATION)
Ignition ON.
With a manifold gauge set connected, compare the pressure readings of the manifold gauge set and the
PCM ACP_PRESS PID.
(15 psi)?
Yes GO to G4
No DIAGNOSE the A/C pressure transducer. GO to Pinpoint Test A
G4 ELECTRIC COOLING FAN FUNCTIONAL CHECK

Ignition ON.
Does the electric cooling fan operate during the KOEO self-test?
Yes GO to G5
No DIAGNOSE the electric cooling fan operation. REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual, Section 3 Symptom Charts.
G5 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) INTAKE AIR TEMPERATURE (IAT)
PID (PARAMETER IDENTIFICATION) AND THE OTHER TEMPERATURE SENSOR READINGS TO
THE PCM (POWERTRAIN CONTROL MODULE) AMBIENT AIR TEMPERATURE (AAT) PID
NOTE: Compare multiple engine sensor readings to the ambient temperature to determine sensors are
reading correctly. A faulty sensor can cause the PCM to disable the A/C with or without a DTC.
Allow the vehicle exterior and interior to stabilize to ambient temperature. This can take a soak period of
at least 6 hours.
Monitor the CHT, ECT, IAT, MAPT, and AAT Parameter Identifications (PIDs) (as applicable).
Are the temperature values similar (typically within 18ºC (32.4ºF)?
Yes GO to G6
No DIAGNOSE the suspect temperature sensor. REFER to Powertrain Control/Emissions
G6 COMPARE THE EVAPORATOR TEMPERATURE SENSOR TO THE PCM (POWERTRAIN

CONTROL MODULE) AMBIENT AIR TEMPERATURE (AAT) PID (PARAMETER IDENTIFICATION)
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Ignition OFF.
Disconnect Evaporator temperature sensor C296.
Measure:

C296-1 (component side) C296-2 (component side)
Compare the resistance values to the table below:
Ambient Temperature °F (°C) Resistance ohms

-39.9°F (-40°C) 98,625 - 103,275 ohms
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Ignition ON.
Monitor the AAT PID.
Is the resistance within the specified values for the temperatures?
Yes GO to G7
No INSTALL a new evaporator temperature sensor.
REFER to: Evaporator Temperature Sensor (412-00 Climate Control System - General
G7 VERIFY THE GRILLE SHUTTER OPERATION USING THE PCM (POWERTRAIN CONTROL
MODULE) GRILL SHUTTER A POSITION - COMMANDED (GRILL_A_CMD) PID (PARAMETER
IDENTIFICATION)
complete.
Using a diagnostic scan tool, view PCM PID.
Using a diagnostic scan tool, select the PCM PID GRILL_A_CMD and command the grille shutter from
100% (open) to 0% (closed) while observing the grille shutter operation from the front of the vehicle.
Does the grille shutter fully open and close when commanded by the scan tool?
Yes GO to G8
No DIAGNOSE the active grille shutter is inoperative or does not operate correctly.
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G8 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) A/C (AIR CONDITIONING)
SWITCH (CC_SW_AC) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) ON
Using a diagnostic scan tool, view FCIM Parameter Identifications (PIDs).
Monitor the CC_SW_AC PID.
Yes GO to G9
No GO to G17
G9 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) REQUEST
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) ON
Start the engine.
Using a diagnostic scan tool, monitor the PCM AC_REQ PID.
On the HVAC controls, select PANEL and then press the A/C button (indicator on).
Does the PID display Yes when the button is pressed?
Yes GO to G11
No GO to G10
G10 RESET THE AMBIENT AIR TEMPERATURE (AAT) SENSOR

On the HVAC controls, press the A/C (air conditioning) and Recirc buttons simultaneously, then release
both. Within 2 seconds press A/C button again.
Start the engine.
On the HVAC controls, set the temperature to full cold, select PANEL and select the A/C button
(indicator on).
Does the A/C compressor turn on?
Yes RETEST the A/C system for normal operation.

REFER to: Refrigerant System Tests - 2.3L EcoBoost (201kW/273PS) (412-00 Climate
Control System - General Information, General Procedures).
REFER to: Refrigerant System Tests - 3.7L Duratec (227kW/301PS) (412-00 Climate
REFER to: Refrigerant System Tests - 5.0L 32V Ti-VCT (412-00 Climate Control System
- General Information, General Procedures).
No GO to G11
G11 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING)
COMPRESSOR COMMANDED STATE (ACC_CMD) PID (PARAMETER IDENTIFICATION) WITH THE
A/C (AIR CONDITIONING) COMMANDED ON
Using a diagnostic scan tool, activate the PCM ACC_CMD PID.
Yes GO to G18
No GO to G12
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G12 CHECK THE VOLTAGE TO THE A/C (AIR CONDITIONING) CLUTCH RELAY
Ignition OFF.
Disconnect the A/C clutch relay.
Ignition ON.
Measure:

Yes GO to G13
No VERIFY BJB fuses 23 (10A) and 42 (15A) are OK.
circuit short.
G13 BYPASS THE A/C (AIR CONDITIONING) CLUTCH RELAY

Ignition OFF.

A/C clutch relay socket 3 A/C clutch relay socket 5

Ignition ON.
Does the A/C compressor clutch engage?
Yes REMOVE the fused jumper wire. INSTALL a new A/C clutch relay.
No LEAVE the fused jumper wire installed. GO to G14
G14 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL VOLTAGE
SUPPLY CIRCUIT FOR AN OPEN
Disconnect A/C compressor clutch field coil C100.
Measure:

C100-1 Ground
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Yes REMOVE the fused jumper wire. GO to G15

No REMOVE the fused jumper wire.
REPAIR the circuit.
G15 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C100-2 Ground
Yes GO to G16
G16 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH AIR GAP
Measure the A/C compressor clutch air gap at 3 equally spaced locations between the clutch hub and
the A/C compressor clutch pulley.
REFER to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control System - General
Is the A/C compressor clutch air gap greater than 0.6 mm (0.0236 in)?
Yes ADJUST the A/C compressor clutch air gap.
REFER to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control
No INSTALL a new A/C compressor clutch and A/C clutch field coil.
REFER to: Air Conditioning (A/C) Clutch and Air Conditioning (A/C) Clutch Field Coil
(412-00 Climate Control System - General Information, General Procedures).
G17 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Repair:
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G18 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Repair:
corrosion (replace connector or terminals – clean module pins)
damaged or bent pins – replace terminals/pins
pushed-out pins – replace pins as necessary
Operate the system and verify the concern is still present.
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
The A/C Is Always On - A/C Mode Always Commanded On

Operation).
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P1464 A/C Demand Out Of Self Test This DTC sets when the PCM senses an A/C request during a PCM
Range self-test.
Possible Sources
A/C clutch relay

PCM
FCIM
PINPOINT TEST H : THE A/C (AIR CONDITIONING) IS ALWAYS ON - A/C (AIR

CONDITIONING) MODE ALWAYS COMMANDED ON
H1 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY
Yes GO to H2
H2 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL VOLTAGE SUPPLY
CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C100-1 Ground

No GO to H3
H3 COMPARE THE EVAPORATOR TEMPERATURE SENSOR TO THE PCM (POWERTRAIN

Ignition OFF.
Allow the vehicle exterior and interior to stabilize to ambient temperature.
Disconnect Evaporator Temperature Sensor C296.
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Measure:


-39.9°F (-40°C) 98,625 - 103,275 ohms
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Ignition ON.
Yes GO to H4
H4 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) A/C (AIR CONDITIONING)
SWITCH STATUS (CC_SW_AC) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Select panel mode, press and release the A/C button (indicator off) on the FCIM controls.
Does the PID display Active when pressed and Inactive when released?
Yes GO to H5
No GO to H8
H5 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR (ACP_PRESS) PARAMETER

IDENTIFICATION (PID)
Using a diagnostic scan tool, view the PCM Parameter Identification (PIDs).
PCM Parameter Identification (PID) ACP_PRESS.
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(15 psi)?
Yes GO to H6
No INSTALL a new A/C pressure transducer.
H6 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) REQUEST
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) OFF
Monitor the AC_REQ PID.
While in panel mode, release the A/C button (indicator off) on the FCIM controls.
Does the PID display No?
Yes GO to H9
No GO to H7
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH FCIM (FRONT CONTROLS
INTERFACE MODULE) DISCONNECTED
Ignition ON.
Yes GO to H9
No GO to H8
H8 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Ignition OFF.
Repair:
cardiagn.com
H9 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
The Temperature Control Is Inoperative Or Does Not Operate Correctly - Driver Side
Temperature Door Actuator - Driver side,

Operation).
During an actuator calibration cycle, the FCIM drives the temperature door until the door reaches both internal
stops in the HVAC case. If the temperature door is temporarily obstructed or binding during a calibration cycle,
the module may interpret this as the actual end of travel for the door. When this condition occurs and the module
commands the actuator to its end of travel, the airflow may not be the expected temperature.
cardiagn.com
B1081:11 Left Temperature Damper This DTC sets when the module senses lower than expected voltage
Motor: Circuit Short To on an actuator motor circuit when voltage is applied to drive the
direction.
B1081:12 Left Temperature Damper This DTC sets when the module senses higher than expected voltage
Motor: Circuit Short To on the actuator motor circuit when ground is applied to drive the
Battery motor, indicating a short to voltage. The motor can move only in one
direction.
B1081:13 Left Temperature Damper This DTC sets when the module senses no voltage on the actuator
Motor: Open Circuit motor circuit when ground is applied to drive the motor, indicating an
B11E5:12 Left HVAC Damper Position This DTC sets when the module senses greater than 5 volts on the
Battery
B11E5:14 Left HVAC Damper Position This DTC sets when the module senses less than 1 volt on the
Possible Sources

Driver side temperature door actuator
FCIM
PINPOINT TEST I : THE TEMPERATURE CONTROL IS INOPERATIVE OR DOES NOT

OPERATE CORRECTLY - DRIVER SIDE
I1 CHECK THE DRIVER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT TO
VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C2091-1 Ground
C2091-2 Ground
C2091-3 Ground
C2091-5 Ground
C2091-6 Ground
cardiagn.com

No GO to I2
I2 CHECK THE DRIVER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT TO
GROUND
Ignition OFF.
Measure:

C2091-1 Ground
C2091-2 Ground
C2091-3 Ground
C2091-5 Ground
C2091-6 Ground
Yes GO to I3
I3 CHECK THE DRIVER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR AN OPEN
Measure:

C2091-1 C2402A-2
C2091-2 C2402A-10
C2091-3 C2402A-3
C2091-5 C2402A-8
C2091-6 C2402A-9
Yes GO to I4
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I4 CHECK THE DRIVER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT
TOGETHER
Measure:

C2091-1 C2091-2
C2091-1 C2091-3
C2091-1 C2091-5
C2091-1 C2091-6
C2091-2 C2091-3
C2091-2 C2091-5
C2091-2 C2091-6
C2091-3 C2091-5
C2091-3 C2091-6
C2091-5 C2091-6
Yes INSTALL a new driver side temperature door actuator.

REFER to: Driver Side Temperature Door Actuator (412-00 Climate Control System -
TEST the system for normal operation. If the concern is still present, GO to I5
I5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
The Temperature Control Is Inoperative Or Does Not Operate Correctly - Passenger Side
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Temperature Door Actuator - Passenger side,

Operation).

B1082:11 Right Temperature Damper This DTC sets when the module senses lower than expected voltage
direction.
B1082:12 Right Temperature Damper This DTC sets when the module senses higher than expected voltage
direction.
B1082:13 Right Temperature Damper This DTC sets when the module senses no voltage on the actuator
B11E6:12 Right HVAC Damper This DTC sets when the module senses greater than 5 volts on the
Position Sensor: Circuit actuator feedback circuit, indicating a short to voltage.
Short to Battery
B11E6:14 Right HVAC Damper This DTC sets when the module senses less than 1 volt on the
Position Sensor: Circuit actuator feedback circuit, indicating an open circuit or a short to
Short to Ground or Open ground.
Possible Sources

Passenger side temperature door actuator
FCIM
PINPOINT TEST J : THE TEMPERATURE CONTROL IS INOPERATIVE OR DOES NOT

OPERATE CORRECTLY - PASSENGER SIDE
J1 CHECK THE PASSENGER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT
TO VOLTAGE
Ignition OFF.
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Ignition ON.
Measure:

C2092-1 Ground
C2092-2 Ground
C2092-3 Ground
C2092-5 Ground
C2092-6 Ground

No GO to J2
TO GROUND
Ignition OFF.
Measure:

C2092-1 Ground
C2092-2 Ground
C2092-3 Ground
C2092-5 Ground
C2092-6 Ground
Yes GO to J3
J3 CHECK THE PASSENGER SIDE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR AN OPEN
Measure:
cardiagn.com
C2092-1 C2402A-2
C2092-3 C2402A-3

C2092-2 C2402B-18
C2092-5 C2402B-13
C2092-6 C2402B-14
Yes GO to J4
TOGETHER
Measure:

C2092-1 C2092-2
C2092-1 C2092-3
C2092-1 C2092-5
C2092-1 C2092-6
C2092-2 C2092-3
C2092-2 C2092-5
C2092-2 C2092-6
C2092-3 C2092-5
C2092-3 C2092-6
C2092-5 C2092-6
Yes INSTALL a new passenger side temperature door actuator.

REFER to: Passenger Side Temperature Door Actuator (412-00 Climate Control System -
TEST the system for normal operation. If the concern is still present, GO to J5
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J5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Repair:
The Blower Motor Is Inoperative
Voltage is supplied to the blower motor relay switched contact from the BJB. Ground to the relay coil is a
dedicated circuit. When the blower motor relay coil receives power from the FCIM, the relay coil is energized and
voltage is delivered to the blower motor speed control. Power and ground for the blower motor is provided by the
blower motor speed control. The FCIM sends a PWM signal to the blower motor speed control to control the
blower speed.

B10AF:11 Blower Fan Relay: This DTC sets when the module senses low voltage on the relay coil voltage
Circuit Short To circuit when the module is energizing the circuit. The blower motor relay is
Ground permanently inactive.
B10AF:15 Blower Fan Relay: This DTC sets when the module senses greater than expected voltage on
Circuit Short To the blower motor relay coil voltage circuit, indicating an open circuit or a
Battery or Open short to voltage. The blower motor relay is inactive when circuit is open; the
blower motor relay is on all the time when shorted to battery.
B10B9:12 Blower Control: This DTC sets when the module senses high voltage on the blower motor
Circuit Short To control PWM circuit, indicating a short directly to voltage. The blower motor
Battery is inoperative.
B10B9:14 Blower Control: This DTC sets when the module senses no voltage on the blower motor
Circuit Short To control PWM circuit, indicating a short directly to ground or an open circuit.
Ground or Open The blower motor runs at full speed if the circuit is shorted to ground. The
blower motor is inoperative if the circuit is open.
cardiagn.com
Possible Sources

Fuse
Blower motor relay
Blower motor
Blower motor speed control
FCIM
PINPOINT TEST K : THE BLOWER MOTOR IS INOPERATIVE

K1 CHECK THE BLOWER MOTOR RELAY
Ignition OFF.
Disconnect Blower motor relay.
Carry out the component test on the blower motor relay.
Yes GO to K2
No INSTALL a new blower motor relay.
K2 CHECK THE BLOWER MOTOR RELAY SWITCH CONTACT SUPPLY VOLTAGE

Measure:

Blower motor relay socket 3 Ground
Yes GO to K3
K3 CHECK THE BLOWER MOTOR RELAY COIL GROUND CIRCUIT FOR AN OPEN
Measure:

cardiagn.com
Yes GO to K4
K4 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:

Yes GO to K5
K5 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR AN OPEN
Measure:

Blower motor relay socket 2 C2402A-11

Yes GO to K6
K6 CHECK THE BLOWER MOTOR SPEED CONTROL VOLTAGE CIRCUIT

Disconnect Blower motor speed control C297.
Connect Blower motor relay.
Ignition ON.
Select PANEL on the HVAC controls.
Measure:

cardiagn.com
C297-5 Ground
Yes GO to K7
K7 CHECK THE BLOWER MOTOR SPEED CONTROL GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C297-1 Ground
Yes GO to K8
K8 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition ON.
Measure:
C297-2 Ground

No GO to K9
K9 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR
AN OPEN
Ignition OFF.
Measure:
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C297-2 C2402A-23
Yes GO to K10
K10 CHECK THE OUTPUTS TO THE BLOWER MOTOR

Disconnect Blower motor C2066.
Connect Blower motor speed control C297.
Ignition ON.
Measure:

C2066-1 C2066-2
Yes INSTALL a new blower motor.

REFER to: Blower Motor (412-00 Climate Control System - General Information,
No GO to K11
K11 CHECK THE CIRCUITS TO THE BLOWER MOTOR FOR AN OPEN
Ignition OFF.
Measure:

C297-6 C2066-1
C297-5 C2066-2
Yes GO to K12
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K12 CHECK THE BLOWER MOTOR CIRCUITS FOR A SHORT TOGETHER
Measure:

C2066-1 C2066-2
Yes INSTALL a new blower motor speed control.

REFER to: Blower Motor Speed Control (412-00 Climate Control System - General
TEST the system for normal operation. If the concern is still present, GO to K13
K13 CHECK FOR CORRECT FRONT CONTROLS INTERFACE MODULE (FCIM) OPERATION
Repair:
The Blower Motor Does Not Operate Correctly
blower speed.
cardiagn.com

Circuit Short To the blower relay coil voltage circuit, indicating an open circuit or a short to
Battery or Open voltage. Blower relay is inactive when circuit is open; blower relay is on all
the time when shorted to battery.
Possible Sources

Blower motor relay
FCIM
PINPOINT TEST L : THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY

L1 VERIFY THE BLOWER MOTOR OPERATION
Ignition ON.
Select PANEL on the HVAC controls. Adjust the blower motor setting to the minimum and maximum
settings.
Does the blower motor operate at any setting?
Yes GO to L2
No GO to Pinpoint Test K
L2 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C2402A-23 Ground
cardiagn.com
No GO to L3
L3 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A
SHORT TO GROUND
Ignition OFF.
Measure:

C2402A-23 Ground
Yes GO to L4
L4 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C2402A-11 Ground

No GO to L5
L5 CHECK THE BLOWER MOTOR OPERATION WITH THE BLOWER MOTOR RELAY
DISCONNECTED
Ignition OFF.
Ignition ON.
Does the fan still operate all the time?
Yes REPAIR the blower motor speed control voltage circuit CH402 (YE/GN) for a short to
voltage.
cardiagn.com
No GO to L6
L6 CHECK FOR CORRECT BLOWER MOTOR SPEED CONTROL OPERATION

Ignition OFF.
Disconnect and inspect all the blower motor speed control connectors.
Repair:
Reconnect the blower motor speed control connectors. Make sure they seat and latch correctly.

TEST the system for normal operation. If the concern is still present, GO to L7

Ignition OFF.
Repair:

Air Discharge Temperature Sensor Circuit Faults
The 2 air discharge temperature sensors contain a thermistor. The sensor varies its resistance with the
temperature. As the temperature rises, the resistance falls. As the temperature falls, the resistance rises.
cardiagn.com
Operation).

B10B5:11 Left Panel Air Discharge Temperature: This DTC sets when the FCIM senses erratic voltages
Circuit Short To Ground from the left panel air discharge temperature sensor.
B10B5:15 Left Panel Air Discharge Temperature: This DTC sets when the FCIM senses erratic voltages
Circuit Short To Battery or Open from the left panel air discharge temperature sensor.
B10B6:11 Left Floor Air Discharge Temperature: This DTC sets when the FCIM senses erratic voltages
Circuit Short To Ground from the left floor air discharge temperature sensor.
B10B6:15 Left Floor Air Discharge Temperature: This DTC sets when the FCIM senses erratic voltages
Circuit Short To Battery or Open from the left floor air discharge temperature sensor.
Possible Sources

Air discharge temperature sensor(s)
FCIM
PINPOINT TEST M : AIR DISCHARGE TEMPERATURE SENSOR CIRCUIT FAULTS

M1 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR OUTPUT VOLTAGE CIRCUIT
Ignition OFF.
Disconnect the suspect air discharge temperature sensor:
Driver side register air discharge temperature sensor C2438
Driver side footwell air discharge temperature sensor C2436
Ignition ON.
Turn the HVAC system on.
Measure:

Driver side footwell air discharge temperature sensor

C2436-1 C2436-2

Driver side register air discharge temperature sensor

C2438-1 C2438-2
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Is the voltage between 4.7 and 5.1 volts?
Yes INSTALL a new air discharge temperature sensor. Refer to the appropriate section in
Group 412 for the procedure. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the
self-test. If Diagnostic Trouble Code (DTC) returns, GO to M9
No GO to M2
M2 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO
VOLTAGE
Disconnect FCIM C2402B.
Measure:


C2436-1 Ground


C2438-2 Ground

No GO to M3
M3 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL RETURN CIRCUIT FOR A
SHORT TO VOLTAGE
Measure:


C2436-2 Ground
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C2438-1 Ground

No GO to M4
M4 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO
GROUND
Ignition OFF.
Measure:


C2436-1 Ground

C2438-2 Ground
Yes GO to M5
M5 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL RETURN CIRCUIT FOR A
SHORT TO GROUND
Measure:

cardiagn.com
C2436-2 Ground


C2438-1 Ground
Yes GO to M6
M6 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL CIRCUIT FOR AN OPEN
Measure:


C2436-1 C2402B-4


C2438-2 C2402B-5
Yes GO to M7
M7 CHECK THE AIR DISCHARGE TEMPERATURE SENSOR SIGNAL RETURN CIRCUIT FOR AN
OPEN
Measure:

cardiagn.com
C2436-2 C2402A-2


C2438-1 C2402A-2
Yes GO to M8
M8 CHECK AIR DISCHARGE TEMPERATURE SENSOR SIGNAL CIRCUIT AND THE SIGNAL
RETURN FOR A SHORT TO TOGETHER
Measure:


C2436-1 C2436-2

C2438-1 C2438-2
Yes INSTALL a new air discharge temperature sensor.Refer to the appropriate section in
Group 412 for the procedure. CLEAR the Diagnostic Trouble Codes (DTCs). REPEAT the
self-test. If Diagnostic Trouble Code (DTC) returns, GO to M9
cardiagn.com
M9 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Repair:
B105A:12, B105A:14, B1A61:11, B1A61:15, B1A69:12, B1A69:14
In-Vehicle Temperature and Humidity Sensor,

Operation).

B105A:12 Cabin Temperature This DTC sets when the module senses higher than expected voltage
Sensor Fan: Circuit Short on the in-vehicle temperature and humidity sensor fan motor circuit. The
To Battery in-vehicle temperature and humidity sensor fan motor is inactive.
B105A:14 Cabin Temperature This DTC sets when the module senses no voltage on the in-vehicle
Sensor Fan: Circuit Short temperature and humidity sensor fan motor circuit, indicating an open or
To Ground or Open a short directly to ground. The in-vehicle temperature and humidity
sensor fan motor is active.
B1A61:11 Cabin Temperature This DTC sets when the module senses lower than expected voltage on
Sensor: Circuit Short to the in-vehicle temperature and humidity sensor feedback circuit,
Ground indicating a short to ground.
B1A61:15 Cabin Temperature This DTC sets when the module senses greater than expected voltage
Sensor: Circuit Short to on the in-vehicle temperature and humidity sensor feedback circuit,
Battery or Open indicating a short to voltage or an open circuit or sensor.
B1A69:12 Humidity Sensor: Circuit This DTC sets when the module senses greater than expected voltage
Short To Battery on the in-vehicle temperature and humidity sensor humidity input circuit,
indicating a short to voltage.
B1A69:14 Humidity Sensor: Circuit This DTC sets when the module senses no voltage on the in-vehicle
Short To Ground or Open temperature and humidity sensor humidity input circuit, indicating a
short to ground or an open circuit or sensor.
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Possible Sources
Fuse
In-vehicle temperature and humidity sensor
FCIM
Make sure the in-vehicle temperature and humidity sensor harness is not chaffed.
PINPOINT TEST N : B105A:12, B105A:14, B1A61:11, B1A61:15, B1A69:12, B1A69:14

N1 CHECK THE IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
Ignition OFF.
Disconnect BCM fuse 21 (5A).
Ignition ON.
Measure:

C233-1 Ground
C233-2 Ground
C233-3 Ground
C233-4 Ground
C233-5 Ground
C233-6 Ground

No GO to N2
TO GROUND
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Ignition OFF.
Measure:

C233-1 Ground
C233-2 Ground
C233-3 Ground
C233-4 Ground
C233-5 Ground
C233-6 Ground
Yes GO to N3
N3 CHECK THE IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR CIRCUITS FOR AN OPEN
Measure:

C233-3 C2402A-3
C233-5 C2402A-2
C233-1 C2402B-27
C233-2 C2402B-29
C233-4 C2402B-19
Positive Measurement / Negative Lead

Lead Action
C233-6 BCM fuse 21 cavity, (component side)
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Yes GO to N4
TOGETHER
Measure:

C233-1 C233-2
C233-1 C233-3
C233-1 C233-4
C233-1 C233-5
C233-1 C233-6
C233-2 C233-3
C233-2 C233-4
C233-2 C233-5
C233-2 C233-6
C233-3 C233-4
C233-3 C233-5
C233-3 C233-6
C233-4 C233-5
C233-4 C233-6
C233-5 C233-6
Yes GO to N5
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N5 CHECK FOR CORRECT IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR OPERATION
Inspect the disconnected connectors.
Repair:
Reconnect all disconnected connectors. Make sure they seat and latch correctly.
Yes INSTALL a new in-vehicle temperature sensor.

REFER to: In-Vehicle Temperature and Humidity Sensor (412-00 Climate Control System
- General Information, Removal and Installation).
TEST the system for normal operation. If the concern is still present, GO to N6
N6 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:
B1A63:11, B1A63:15, B1A64:11, B1A64:15
Sunload Sensor,
Operation).
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B1A63:11 Right Solar Sensor: Circuit This DTC sets when the control module senses lower than expected
Short To Ground voltage on the RH sensor feedback circuit, indicating a short to ground.
B1A63:15 Right Solar Sensor: Circuit This DTC sets when the control module senses higher than expected
Short To Battery or Open voltage on the RH sensor feedback circuit, indicating a short to voltage
or an open circuit or sensor.
B1A64:11 Left Solar Sensor: Circuit This DTC sets when the control module senses lower than expected
Short To Ground voltage on the LH sensor feedback circuit, indicating a short to ground.
B1A64:15 Left Solar Sensor: Circuit This DTC sets when the control module senses higher than expected
Short To Battery or Open voltage on the LH sensor feedback circuit, indicating a short to voltage
or an open circuit or sensor.
Possible Sources

Sunload sensor
FCIM
Inspect loose or corroded FCIM and sunload sensor connections.
PINPOINT TEST O : B1A63:11, B1A63:15, B1A64:11, B1A64:15

O1 CHECK THE SUNLOAD SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Disconnect Sunload sensor C286.
Ignition ON.
Measure:
C286-1 Ground
C286-2 Ground
C286-3 Ground
C286-4 Ground

No GO to O2
O2 CHECK THE SUNLOAD SENSOR CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
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Measure:

C286-1 Ground
C286-2 Ground
C286-3 Ground
C286-4 Ground
Yes GO to O3
O3 CHECK THE SUNLOAD SENSOR SIGNAL CIRCUITS FOR AN OPEN

Measure:

C286-1 C2402B-22
C286-3 C2402B-21

C286-2 C2280B-24
C286-4 C2280B-22
Yes GO to O4
O4 CHECK THE SUNLOAD SENSOR SIGNAL CIRCUITS FOR A SHORT TO EACH OTHER
Measure:

C286-1 C286-2
C286-1 C286-3
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C286-1 C286-4
C286-2 C286-3
C286-2 C286-4
C286-3 C286-4
Yes INSTALL a new sunload sensor.

REFER to: Sunload Sensor (412-00 Climate Control System - General Information,
TEST the system for normal operation. If the concern is still present, GO to O5
O5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:
B1B71:11, B1B71:15
Evaporator Temperature Sensor,

Operation).
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B1B71:11 Evaporator Temperature The module senses excessive voltage drop on the sensor reference
Sensor: Circuit Short To voltage circuit, indicating a short directly to ground. The module
Ground defaults to calculated evaporator temperature and the compressor is
shut off.
B1B71:15 Evaporator Temperature The module senses no voltage drop on the sensor reference voltage
Sensor: Circuit Short To circuit, indicating a short directly to voltage or an open circuit. The
Battery or Open module defaults to calculated evaporator temperature and the
compressor is shut off.
Possible Sources

FCIM
PINPOINT TEST P : B1B71:11, B1B71:15

P1 CHECK THE EVAPORATOR TEMPERATURE SENSOR RESISTANCE
Ignition OFF.
Measure:

Compare the evaporator temperature sensor measured resistance with the table below.
-39.9°F (-40°C) 98,625 - 103,275 ohms
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Yes GO to P2
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P2 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Ignition ON.
Measure:

C2402A-19 Ground

No GO to P3
P3 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR A SHORT TO

GROUND
Ignition OFF.
Measure:

C2402A-19 Ground

Yes GO to P4
P4 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR AN OPEN

Measure:

C2402A-19 C296-1
Yes GO to P5
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P5 CHECK THE EVAPORATOR TEMPERATURE SENSOR SIGNAL AND SIGNAL RETURN
CIRCUITS FOR A SHORT TOGETHER
Measure:

C296-1 C296-2
Yes GO to P6
P6 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
C1B14:11, C1B14:12
A 5-volt reference voltage and ground is supplied to the climate control sensors and actuators from the FCIM.

C1B14:11 Sensor Supply Voltage A: This DTC sets when the module senses less than 5 volts on the
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Circuit Short to Ground sensor reference voltage circuit, indicating a short to ground.
C1B14:12 Sensor Supply Voltage A: This DTC sets when the module senses greater than 5 volts on the
Circuit Short to Battery sensor reference voltage circuit, indicating a short to voltage.
Possible Sources

FCIM
PINPOINT TEST Q : C1B14:11, C1B14:12

Q1 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) DTCS
Ignition ON.
Is DTC C1B14:11 present?
Yes GO to Q2
No GO to Q5
Q2 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C2402A-3 Ground
Yes GO to Q3
Q3 CHECK THE REFERENCE VOLTAGE CIRCUIT AND THE SIGNAL RETURN CIRCUIT FOR A
SHORT TOGETHER
Measure:

C2402A-3 C2402A-2
Is the resistance greater than 200 ohms?
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Yes GO to Q6
No GO to Q4
Q4 CHECK THE A/C (AIR CONDITIONING) COMPONENTS

Measure:

C2402A-3 C2402A-2
While measuring the resistance, disconnect the following components one at a time, in order. Stop
disconnecting components if the measured resistance rises above 200 ohms.
In-vehicle temperature and humidity sensor C233
Driver side temperature door actuator C2091
Air distribution door actuator C232
Passenger temperature door actuator C2092
Air inlet door actuator C289
Did the resistance rise above 200 ohms?
Yes INSTALL a new sensor or actuator (the last one to be disconnected). Refer to the
appropriate section in Group 412 for the procedure. When installing an actuator,
CONNECT the actuator electrical connector before the FCIM. This allows the actuator to
be calibrated when the FCIM is connected.
Q5 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE

Measure:
C2402A-3 Ground

No GO to Q6
Q6 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:
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P06A0
The externally controlled variable displacement compressor is electronically controlled by the PCM. The PCM
pulse width modulates the ground to the externally controlled variable displacement compressor to change the
displacement of the A/C compressor.
Operation).

P06A0 Variable A/C Compressor The PCM senses greater than expected voltage on the sensor feedback
Control Circuit circuit, indicating a short to voltage or an open circuit or sensor.
Possible Sources

A/C compressor
PCM
Inspect for loose or corroded PCM and A/C compressor connections.
PINPOINT TEST R : P06A0

R1 EXTERNALLY CONTROLLED VARIABLE DISPLACEMENT COMPRESSOR (EVDC)
PERFORMANCE CHECK
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NOTE: The performance check test is used to determine if the Externally Controlled Variable
Displacement Compressor (EVDC) is able to change the displacement by measuring the amperage to the
solenoid and monitoring the manifold pressure gauges soon after the air conditioning clutch is engaged.
Ignition OFF.
Disconnect BJB fuse 42 (15A).
Measure:

BJB fuse 42 socket, component side BJB fuse 42 socket, component side
With a manifold gauge set connected, monitor the low side and high side pressures.
Start the engine. Run the engine until it reaches normal operating temperature.
Select the floor position on the HVAC controls. Set the temperature control to full warm and the blower to
the highest setting. Set the A/C to off. Close all windows and doors. Run for 5 minutes to heat up the
climate control housing.
Monitor the multi meter and the manifold gauges. Select the PANEL position on the HVAC controls. Set
the temperature control to full cold and the blower to the highest setting. Set the recirculated air mode to
on. Set the A/C to on.
Record the highest amperage measurement and the A/C pressures.
Did the amperage initially increase approximately 0.8A, and did the low side pressure decrease and
the high side pressure increase and after a few minutes did the amperage and high side pressure
decrease and low side pressure increase?
Yes The Externally Controlled Variable Displacement Compressor (EVDC) is able to change
the displacement. CHECK refrigerant charge amount.
No GO to R2
R2 CHECK FOR VOLTAGE TO THE A/C (AIR CONDITIONING) COMPRESSOR CONTROL
SOLENOID
Ignition OFF.
Connect BJB fuse 42 (15A).
Disconnect A/C Compressor Control Solenoid C1110.
Ignition ON.
Measure:

C1110-2 Ground
Yes GO to R3
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R3 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR DISPLACEMENT CONTROL SOLENOID
PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect PCM 2.3L C1551B.
Measure:

C1110-1 Ground
Yes GO to R4

PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C1110-1 Ground

No GO to R5

PWM (PULSE WIDTH MODULATION) CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

2.3L

C1110-1 C1551B-41
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Yes INSTALL a new A/C compressor.
For 2.3L
REFER to: Air Conditioning (A/C) Compressor - 2.3L EcoBoost (201kW/273PS) (412-00
Climate Control System - General Information, Removal and Installation).
CLEAR the DTC and REPEAT the self-test. If the DTC returns, GO to R6
R6 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
For 2.3L,
P193E
The PCM controls the A/C compressor clutch field coil based on messages received from the BCM over the
HS-CAN. When the FCIM determines it is necessary to activate the A/C compressor due to driver request or
automatic climate control settings, the FCIM sends a message to the BCM over the MS-CAN, the BCM then
sends a message to the PCM to activate the A/C compressor.
An internal failure of the PCM, BCM or FCIM, or a failure in the MS-CAN or HS-CAN, causes the PCM to set a
DTC.

P193E A/C Clutch Request This DTC sets when the PCM does not receive the A/C enable request from
Signal the BCM.
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Possible Sources
Network concerns
BCM
PCM
FCIM
PINPOINT TEST S : P193E

S1 VERIFY THE CUSTOMER CONCERN
Ignition ON.
Yes GO to S2
S2 CHECK THE COMMUNICATION NETWORK

Do the BCM, PCM and the FCIM pass the Network Test?
Yes GO to S3
No DIAGNOSE the BCM, PCM or FCIM does not communicate with the diagnostic scan tool.
S3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) REQUEST
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION)
Start the engine.
On the HVAC controls, select PANEL mode, then press the A/C button (indicator ON).
Does the AC_REQ PID display YES when the A/C button indicator is illuminated?
Yes GO to S7
No GO to S4
S4 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) A/C (AIR CONDITIONING)
SWITCH (CC_SW_AC) PID (PARAMETER IDENTIFICATION)
Using a diagnostic scan tool, monitor the FCIM CC_SW_AC PID while pressing and releasing the A/C
button.
Does the PID display Active when the A/C button indicator is illuminated?
Yes GO to S6
No GO to S5
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S5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Ignition OFF.
Repair:
S6 VERIFY CORRECT BCM (BODY CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all BCM electrical connectors.
Repair:
damaged or bent pins – install new terminals or pins
Reconnect all BCM electrical connectors. Make sure they seat and latch correctly.


S7 VERIFY CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Disconnect and inspect all PCM electrical connectors.
Repair:
damaged or bent pins – install new terminals or pins
Reconnect all PCM electrical connectors. Make sure they seat and latch correctly.
cardiagn.com
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,

cardiagn.com
Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC)
DTC Chart: Front Controls Interface Module (FCIM) - Electronic Manual Temperature Control (EMTC)
Network Diagnostic Trouble Codes (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 Diagnostic Trouble Codes (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.
FCIM - Electronic Manual Temperature Control (EMTC) DTC CHART
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B105A:12 Cabin Temperature GO to Pinpoint Test P
Sensor Fan: Circuit
Short To Battery
B105A:14 Cabin Temperature GO to Pinpoint Test P
Sensor Fan: Circuit
Short To Ground or
Open
B1081:07 Left Temperature INSPECT for a binding or damaged linkage or door. REPAIR
Damper Motor: as necessary. If no condition is found, INSTALL a new driver
Mechanical Failure side temperature door actuator.
REFER to: Driver Side Temperature Door Actuator (412-00
Climate Control System - General Information, Removal and
Installation).
.
Short To Ground
Short To Battery
Open
B1083:07 Recirculation Damper INSPECT for a binding or damaged linkage or door. REPAIR
Motor: Mechanical as necessary. If no condition is found, INSTALL a new air inlet
Failure mode door actuator.
REFER to: Air Inlet Door Actuator (412-00 Climate Control
System - General Information, Removal and Installation).
Ground
Battery
Motor: Circuit Open
B1086:07 Air Distribution Damper INSPECT for a binding or damaged linkage or door. REPAIR
Motor: Mechanical as necessary. If no condition is found, INSTALL a new air
Failure distribution door actuator.
REFER to: Air Distribution Door Actuator (412-00 Climate
Control System - General Information, Removal and
Installation).
Ground
Battery
Motor: Circuit Open
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B10AF:11 Blower Fan Relay: GO to Pinpoint Test J
B10AF:15 Blower Fan Relay: For an inoperative blower motor, GO to Pinpoint Test J
Circuit Short To Battery For all other blower motor symptoms, GO to Pinpoint
or Open Test K
B10B8:63 Push Buttons: Circuit / This DTC sets when the buttons have been held down too
Component Protection long. ATTEMPT to clean buttons. CLEAR the Diagnostic
Time-Out Trouble Codes (DTCs) and REPEAT the self-test. If the DTC
returns, INSTALL a new FCIM. Refer to the appropriate section
B10B9:12 Blower Control: Circuit GO to Pinpoint Test J
Short To Battery
B10B9:14 Blower Control: Circuit For an inoperative blower motor, GO to Pinpoint Test J
Short To Ground or For all other blower motor symptoms, GO to Pinpoint
Open Test K

Short To Battery
Short To Ground or
Open
Short To Battery
Short To Ground or
Open
Short To Battery
Short To Ground or
Open
B1A61:11 Cabin Temperature GO to Pinpoint Test P
Ground
B1A61:15 Cabin Temperature GO to Pinpoint Test P
Battery or Open
B1A69:12 Humidity Sensor: GO to Pinpoint Test P
B1A69:14 Humidity Sensor: GO to Pinpoint Test P
or Open
B1B71:11 Evaporator GO to Pinpoint Test L
Temperature Sensor:
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B1B71:15 Evaporator GO to Pinpoint Test L
Temperature Sensor:
or Open
A: Circuit Short To
Ground
A: Circuit Short To
Battery
All Other FCIM — Refer to the appropriate section in Group 415 for the
Diagnostic Trouble procedure.
Codes (DTCs) not
listed in this chart
information about these practices,

Circuit Low
Circuit High
P0645 A/C Clutch Relay GO to Pinpoint Test B
Control Circuit
P06A0 Variable A/C GO to Pinpoint Test N
Compressor Control
Circuit
P1464 A/C Demand Out Of If the HVAC selector was not powered off, POWER the HVAC off,
Self Test Range CLEAR the Diagnostic Trouble Codes (DTCs) and REPEAT the
self-test. If the DTC returns, GO to Pinpoint Test H
P193E A/C Clutch Request GO to Pinpoint Test O
Signal
All Other PCM — For 2.3L PCM DTC Chart,
Diagnostic Trouble REFER to: Electronic Engine Controls (303-14A Electronic
Codes (DTCs) Engine Controls - 2.3L EcoBoost (231kW/314PS),
REFER to: Electronic Engine Controls (303-14B Electronic
Engine Controls - 3.7L Duratec (227kW/301PS), Diagnosis
and Testing).
cardiagn.com
REFER to: Electronic Engine Controls (303-14C Electronic
REFER to: Electronic Engine Controls (303-14D Electronic
Engine Controls - 5.2L 32V Ti-VCT, Diagnosis and
Testing).
Symptom Chart(s)
Symptom Chart: Climate Control - Electronic Manual Temperature Control (EMTC)
Symptom Chart

A module does not Fuse(s)
communicate with the Wiring, REFER to: Communications Network (418-00 Module
diagnostic scan tool terminals or Communications Network, Diagnosis and Testing).
connectors
Externally Controlled Variable Refer to Pinpoint Test GO to Pinpoint Test N

Displacement Compressor
(EVDC) poor
performance/does not operate
correctly
Unable To Duplicate The Refer to Pinpoint Test GO to Pinpoint Test C
Customer Concern And No
Diagnostic Trouble Codes
(DTCs) Present
Reduced outlet airflow Plugged cabin air filter INSPECT the cabin air filter.
REFER to: Cabin Air Filter (412-00 Climate Control
System - General Information, Removal and
Installation).
If OK, DIAGNOSE for low refrigerant charge, A/C
always commanded on or blower motor not operating
correctly.
Improper refrigerant CARRY OUT the refrigerant system tests.
level REFER to: Refrigerant System Tests - 2.3L EcoBoost
(201kW/273PS) (412-00 Climate Control System -
If refrigerant charge is OK, GO to Pinpoint Test H
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Blower motor GO to Pinpoint Test K
The air inlet door is inoperative Refer to Pinpoint Test GO to Pinpoint Test D
Incorrect or erratic direction of Refer to Pinpoint Test GO to Pinpoint Test E
airflow from outlets
Insufficient, erratic or no heat Refer to Pinpoint Test GO to Pinpoint Test F
The A/C is inoperative Refer to Pinpoint Test GO to Pinpoint Test G
The A/C is always on — A/C Refer to Pinpoint Test GO to Pinpoint Test H
mode always commanded ON
Temperature control is Refer to Pinpoint Test GO to Pinpoint Test I
correctly
The blower motor is Refer to Pinpoint Test GO to Pinpoint Test J
inoperative
The blower motor does not Refer to Pinpoint Test GO to Pinpoint Test K
operate correctly
Insufficient A/C cooling Improper refrigerant CARRY OUT the refrigerant system tests.
level REFER to: Refrigerant System Tests - 2.3L EcoBoost
If OK, DIAGNOSE for a temperature door actuator not
operating correctly.
Temperature door GO to Pinpoint Test I
actuator
A/C pressure relief valve A/C pressure relief CHECK the high side system pressure.
discharging valve REFER to: Specifications (412-00 Climate Control
If the pressure is below the A/C pressure relief valve
open pressure, INSTALL a new A/C pressure relief
valve. Refer to the appropriate section in Group 412
for the procedure.
High system pressure CHECK the high side system pressure.
REFER to: Specifications (412-00 Climate Control
If the system pressure is above the A/C pressure
relief valve open pressure, REPAIR the A/C system
for a restriction.
Climate control does not IPC information VERIFY Remote Start - Message Center Set
operate only when remote start display settings To Auto, or Remote Start - Message Center
is used Non-Ford Set To Last User Settings.
approved REFER to: Climate Control System - Vehicles
remote start With: Electronic Manual Temperature Control
system installed (EMTC) - System Operation and Component
Description (412-00 Climate Control System -
cardiagn.com
General Information, Description and
Operation).
VERIFY module communications network
operation. DIAGNOSE Diagnostic Trouble
Codes (DTCs) if present.
Symptom Chart: Noise, Vibration, and Harshness (NVH)
Symptom Chart

Noisy A/C compressor A/C compressor INSPECT the A/C compressor pulley bearing for roughness. If
pulley bearing worn bearing roughness is found, INSTALL a new A/C compressor
clutch and A/C clutch field coil.
REFER to: Air Conditioning (A/C) Clutch and Air Conditioning
(A/C) Clutch Field Coil (412-00 Climate Control System -
Excessive hissing from Incorrect A/C CHECK the A/C refrigerant level.
the plenum when the A/C refrigerant level REFER to: Refrigerant System Tests - 2.3L EcoBoost
is on (201kW/273PS) (412-00 Climate Control System - General
(227kW/301PS) (412-00 Climate Control System - General
Pinpoint Test(s)
P0532, P0533
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.
cardiagn.com
P0532 A/C Refrigerant Pressure This DTC sets if the feedback voltage is less than 0.26 volt for at least 2
Sensor "A" Circuit Low seconds and the ambient air temperature is greater than 0°C (32°F).
P0533 A/C Refrigerant Pressure This DTC sets if the feedback voltage is greater than 4.95 volts for at
Sensor "A" Circuit High least 2 seconds and the ambient air temperature is greater than 0°C
(32°F).
Possible Sources

PCM
Inspect for loose or corroded PCM and A/C pressure transducer connections.
PINPOINT TEST A : P0532, P0533

A1 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) PRESSURE SENSOR (ACP_PRESS)
PID (PARAMETER IDENTIFICATION) WITH THE MANIFOLD GAUGE SET READINGS
Allow the A/C system to stabilize to the outside ambient temperature.
Ignition ON.
With the manifold gauge set connected, compare the pressure readings of the manifold gauge set and
the PCM ACP_PRESS PID.
(15 psi)?
Yes IGNORE the Diagnostic Trouble Codes (DTCs). REFER to the Symptom Chart in this
section.
No GO to A2
VOLTAGE
Ignition OFF.
Disconnect A/C pressure transducer C1260.
Disconnect Turbocharger boost pressure sensor C1588 (if equipped).
Disconnect Generator current sensor C1645.
Ignition ON.
Measure:

C1260-1 Ground
C1260-2 Ground
C1260-3 Ground
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No GO to A3
GROUND
Ignition OFF.
Measure:

C1260-1 Ground
C1260-2 Ground
C1260-3 Ground
Yes GO to A4
A4 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR CIRCUITS FOR AN OPEN
Measure:

2.3L

C1260-1 C1551B-56
C1260-2 C1551B-31
C1260-3 C1551B-52

3.7L

C1260-1 C1381B-18
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C1260-2 C1381B-52
C1260-3 C1381B-11

5.0L or 5.2L

C1260-1 C175B-18
C1260-2 C175B-52
C1260-3 C175B-11
Yes GO to A5
A5 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR CIRCUITS FOR A SHORT
TOGETHER
Measure:

C1260-1 C1260-2
C1260-1 C1260-3
C1260-2 C1260-3
Yes INSTALL a new A/C pressure transducer.


Ignition OFF.
Repair:
cardiagn.com
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
P0645
Voltage is provided to the A/C clutch relay. 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.

P0645 A/C Clutch This DTC sets when the PCM grounds the relay circuit and more voltage than
Relay Control expected is detected on the relay circuit. This DTC also sets when the relay circuit is
Circuit 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.
Possible Sources

A/C clutch relay
PCM
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PINPOINT TEST B : P0645
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.
B1 CHECK THE VOLTAGE TO THE A/C (AIR CONDITIONING) CLUTCH RELAY VOLTAGE SUPPLY
CIRCUITS
Ignition OFF.
Ignition ON.
Measure:

Yes GO to B2
No VERIFY BJB fuses 23 (10A) and 42 (15A) are OK. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of the circuit short. If OK, REPAIR the
circuit.
B2 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY


Yes GO to B3
VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

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No GO to B4
GROUND
Ignition OFF.
Measure:

Yes GO to B5
B5 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY CONTROL CIRCUIT FOR AN OPEN
Measure:

2.3L

3.7L

5.0L or 5.2L
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Yes GO to B6

Ignition OFF.
Repair:
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
Unable To Duplicate The Customer Concern And No Diagnostic Trouble Codes (DTCs) Present
This diagnostic procedure tests the functions of the HVAC system and identifies the correct HVAC symptom
pinpoint test.
System Operation
REFER to: Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) - System
Operation).
PINPOINT TEST C : UNABLE TO DUPLICATE THE CUSTOMER CONCERN AND NO
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DIAGNOSTIC TROUBLE CODES (DTCS) PRESENT
(DTCS)
Ignition ON.
Using a scan tool, perform PCM self-test.
Are any climate control related Diagnostic Trouble Codes (DTCs) present?

No GO to C2
C2 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) FOR DIAGNOSTIC TROUBLE
CODES (DTCS)
Ignition ON.
Yes REFER to the FCIM DTC chart in this section.

No GO to C3
C3 CHECK THE BLOWER MOTOR OPERATION

Ignition ON.
Select panel mode.
Observe blower motor operation and select each blower motor speed.
Does the blower motor operate in all ranges?
Yes GO to C4
No If the blower motor does not operate in any setting, GO to Pinpoint Test J
If the blower motor does not correctly change speeds or shut off, GO to Pinpoint Test K
C4 CHECK AIRFLOW OPERATION

While observing the airflow, select each of the airflow positions (panel, panel/floor, floor, floor/defrost,
defrost).
Is the airflow directed to the correct outlets?
Yes GO to C5
No GO to Pinpoint Test E
C5 VERIFY TEMPERATURE CONTROL OPERATION

Start the vehicle and allow it to reach normal operating temperature.
With the A/C off, select panel mode.
Change the driver and passenger temperature settings from the coldest to the warmest and back to the
coldest.
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Does the temperature change between very warm to cool?
Yes GO to C6
No If the temperature does not get very warm, GO to Pinpoint Test F
If the temperature does not change at all, GO to Pinpoint Test I
C6 VERIFY THE AIR CONDITIONING COMPRESSOR DOES NOT ENGAGE WITH A/C (AIR
CONDITIONING) OFF
With the engine running and the A/C off, select panel mode.
Select the coldest temperature setting.
Is the outlet temperature close to ambient air temperature?
Yes GO to C7
No If the temperature is warmer than ambient air temperature, GO to Pinpoint Test I
If the outlet temperature is significantly colder than ambient air temperature and the A/C
compressor clutch is engaged, GO to Pinpoint Test H
C7 VERIFY THE A/C (AIR CONDITIONING) COMPRESSOR IS OPERATIONAL IN THE A/C (AIR
CONDITIONING) MODE
Make sure the ambient air temperature is above 0°C (32°F).
With the engine running, select panel mode.
Press the A/C button (indicator on).
Is the A/C compressor operational when the panel and A/C button (indicator on) is pressed?
Yes GO to C8
C8 CHECK THE RECIRCULATED AIR OPERATION
With the engine running, press the recirculated air button (indicator off).
Select panel mode.
Observe airflow noise.
Press the recirculated air button (indicator on).
Does the airflow noise increase when the recirculated air mode is selected (indicator on)?
Yes The system is operating correctly.

The Air Inlet Door Is Inoperative
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To rotate the air inlet door actuator, the FCIM supplies voltage and ground to the air inlet door actuator through
the door actuator motor circuits. To reverse the air inlet door actuator rotation, the FCIM reverses the voltage and
ground circuits. The air inlet door actuator feedback resistors are supplied a ground from the FCIM by the air
inlet door actuator return circuits and a 5-volt reference voltage on the air inlet door actuator reference circuits.
The FCIM uses the actuator feedback resistor wiper arm position and the voltage on the air distribution door
actuator feedback circuits to determine the air inlet door actuator position.
During an actuator calibration cycle, the FCIM drives the air inlet door until the door reaches both internal stops
in the FCIM case. If the air inlet door is temporarily obstructed or binding during a calibration cycle, the FCIM
may interpret this as the actual end of travel for the door. When this condition occurs and the FCIM commands
the actuator to its end of travel, the air intake may not be from the expected source.

B1083:11 Recirculation Damper Motor: This DTC sets when the module senses lower than expected voltage
Circuit Short To Ground on an actuator motor circuit when voltage is applied to drive the
motor, indicating a short to ground. The motor can move only in one
direction.
B1083:12 Recirculation Damper Motor: This DTC sets when the module senses higher than expected voltage
Circuit Short To Battery on the actuator motor circuit when ground is applied to drive the
motor, indicating a short to voltage. The motor can move only in one
direction.
B1083:13 Recirculation Damper Motor: This DTC sets when the module senses no voltage on the actuator
Circuit Open motor circuit when ground is applied to drive the motor, indicating an
B11F0:12 Air Intake Damper Position This DTC sets when the module senses greater than 5 volts on the
Battery
B11F0:14 Air Intake Damper Position This DTC sets when the module senses less than 1 volt on the
Possible Sources

Air inlet door actuator
Air inlet door binding or stuck
FCIM
PINPOINT TEST D : THE AIR INLET DOOR IS INOPERATIVE

D1 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:
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C282-1 Ground
C282-2 Ground
C282-3 Ground
C282-5 Ground
C282-6 Ground

No GO to D2
D2 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C282-1 Ground
C282-2 Ground
C282-3 Ground
C282-5 Ground
C282-6 Ground
Yes GO to D3
D3 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR AN OPEN

Measure:

C282-1 C2402A-2
C282-2 C2402A-16
C282-3 C2402A-3
C282-5 C2402A-24
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C282-6 C2402A-25
Yes GO to D4
D4 CHECK THE AIR INLET DOOR ACTUATOR CIRCUITS FOR A SHORT TOGETHER
Measure:

C282-1 C282-2
C282-1 C282-3
C282-1 C282-5
C282-1 C282-6
C282-2 C282-3
C282-2 C282-5
C282-2 C282-6
C282-3 C282-5
C282-3 C282-6
C282-5 C282-6

Yes INSTALL a new air inlet door actuator.
REFER to: Air Inlet Door Actuator (412-00 Climate Control System - General Information,
D5 CHECK FOR CORRECT FRONT CONTROLS INTERFACE MODULE OPERATION

Repair:
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Incorrect Or Erratic Direction Of Airflow From Outlets
To rotate the air distribution door actuator, the FCIM supplies voltage and ground to the air distribution door
actuator through the door actuator motor circuits. To reverse the air distribution door actuator rotation, the FCIM
reverses the voltage and ground circuits. The air distribution door actuator feedback resistors are supplied a
ground from the FCIM by the air distribution door actuator return circuits and a 5-volt reference voltage on the air
distribution door actuator reference circuits. The FCIM uses the actuator feedback resistor wiper arm position
and the voltage on the air distribution door actuator feedback circuits to determine the air distribution door
actuator position.
During an actuator calibration cycle, the FCIM drives the air distribution door until the door reaches both internal
stops in the FCIM case. If the air distribution door is temporarily obstructed or binding during a calibration cycle,
the FCIM may interpret this as the actual end of travel for the door. When this condition occurs and the FCIM
commands the actuator to its end of travel, the airflow may not be from the expected outlets.

B1086:11 Air Distribution Damper This DTC sets when the module senses lower than expected voltage
Motor: Circuit Short to on an actuator motor circuit when voltage is applied to drive the
direction.
B1086:12 Air Distribution Damper This DTC sets when the module senses higher than expected
Motor: Circuit Short to Battery voltage on the actuator motor circuit when ground is applied to drive
the motor, indicating a short to voltage. The motor can move only in
one direction.
B1086:13 Air Distribution Damper This DTC sets when the module senses no voltage on the actuator
Motor: Circuit Open motor circuit when ground is applied to drive the motor, indicating an
B11E7:12 Air Distribution Damper This DTC sets when the module senses greater than 5 volts on the
Position Sensor: Circuit Short actuator feedback circuit, indicating a short to voltage.
to Battery
B11E7:14 Air Distribution Damper This DTC sets when the module senses less than 1 volt on the
Position Sensor: Circuit Short actuator feedback circuit, indicating an open circuit or a short to
to Ground or Open ground.
Possible Sources

Air distribution door actuator
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Air distribution door binding or stuck
FCIM
PINPOINT TEST E : INCORRECT OR ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS

E1 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C232-1 Ground
C232-2 Ground
C232-3 Ground
C232-5 Ground
C232-6 Ground

No GO to E2
E2 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure:

C232-1 Ground
C232-2 Ground
C232-3 Ground
C232-5 Ground
C232-6 Ground
Yes GO to E3
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E3 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR AN OPEN

Ignition OFF.
Measure:

C232-1 C2402A-2
C232-2 C2402A-22
C232-3 C2402A-3
C232-5 C2402A-20
C232-6 C2402A-21
Yes GO to E4
E4 CHECK THE AIR DISTRIBUTION DOOR ACTUATOR CIRCUITS FOR A SHORT TOGETHER
Measure:

C232-1 C232-2
C232-1 C232-3
C232-1 C232-5
C232-1 C232-6
C232-2 C232-3
C232-2 C232-5
C232-2 C232-6
C232-3 C232-5
C232-3 C232-6
C232-5 C232-6
Yes INSTALL a new air distribution door actuator,

REFER to: Air Distribution Door Actuator (412-00 Climate Control System - General
TEST the system for normal operation. If the concern is still present, GO to E5
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E5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
Insufficient, Erratic Or No Heat
When the engine is at operating temperature hot coolant flows from the coolant pump through the heater core
and back to the coolant pump. Correct coolant temperatures are critical for good heater performance.
Possible Sources

Temperature door actuator(s)
Air trapped in the coolant system
Heater core
Inspect for low engine coolant level.
PINPOINT TEST F : INSUFFICIENT, ERRATIC OR NO HEAT

F1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
Ignition OFF.
Check the engine coolant level.
Is the engine coolant at the correct level as indicated on the engine coolant recovery reservoir?
Yes GO to F3
No GO to F2
F2 CHECK THE ENGINE COOLING SYSTEM FOR LEAKS

Pressure test the cooling system for leaks. Refer to the appropriate section in Group 303 for the
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procedure..
Does the engine cooling system leak?
Yes REPAIR the engine coolant leak. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation.
No FILL and BLEED the cooling system. Refer to the appropriate section in Group 303 for
the procedure.
After filling and bleeding the cooling system, GO to F3
F3 CHECK FOR COOLANT FLOW TO THE HEATER CORE

Run the motor until it reaches normal operating temperature. Select the floor position on the control
assembly. Set the temperature control to full warm and the blower to the lowest setting.
Increase engine speed to 3,500 RPM and hold for 30 seconds.
Allow the engine to idle for 30 seconds.
Using a suitable temperature measuring device, check the heater core inlet hose to see if it is hot.
Is the heater core inlet hose hot?
Yes GO to F4
No BLEED the cooling system per the cooling system draining and vacuum filling general
procedure. Refer to the appropriate section in Group 303 for the procedure.
After bleeding the cooling system, GO to F4
F4 CHECK FOR A PLUGGED OR RESTRICTED HEATER CORE

Using a suitable temperature measuring device, measure the heater core outlet hose temperature.
Is the heater core outlet hose temperature similar to the inlet hose temperature (within
approximately 6-17°C [10-30°F])?
Yes DIAGNOSE for a blend door actuator not operating correctly.

For inadequate temperature, GO to Pinpoint Test I
No INSTALL a new heater core.
REFER to: Heater Core (412-00 Climate Control System - General Information, Removal
and Installation).
The A/C Is Inoperative

Operation).
Possible Sources

Communication network
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Ambient Air Temperature (AAT) sensor
Intake Air Temperature (IAT) or other temperature sensors
Active grille shutters
FCIM
PCM
PINPOINT TEST G : THE A/C (AIR CONDITIONING) IS INOPERATIVE

G1 CHECK THE A/C (AIR CONDITIONING) SYSTEM PRESSURE
Ignition OFF.
With the R-134a manifold gauge set connected, check the A/C system pressure.
Is the A/C system pressure above 290 kPa (42 psi)?
Yes GO to G2
No CHECK the A/C system for leaks.
REFER to: Electronic Leak Detection (412-00 Climate Control System - General
REFER to: Fluorescent Dye Leak Detection (412-00 Climate Control System - General
After leak is repaired, RECHARGE the A/C system.

Ignition ON.
Do the FCIM and the PCM pass the network test?
Yes GO to G3
No DIAGNOSE the FCIM or PCM does not communicate with the diagnostic scan tool.
G3 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) PRESSURE
SENSOR (ACP_PRESS) PID (PARAMETER IDENTIFICATION)
Ignition ON.
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PCM ACP_PRESS PID.
(15 psi)?
Yes GO to G4
No DIAGNOSE the A/C pressure transducer. GO to Pinpoint Test A
G4 ELECTRIC COOLING FAN FUNCTIONAL CHECK

Ignition ON.
Does the electric cooling fan operate sometime during the KOEO self-test?
Yes GO to G5
No DIAGNOSE the electric cooling fan operation. REFER to Powertrain Control/Emissions
G5 COMPARE THE PCM (POWERTRAIN CONTROL MODULE) INTAKE AIR TEMPERATURE (IAT)
PID (PARAMETER IDENTIFICATION) AND THE OTHER TEMPERATURE SENSOR READINGS TO
THE PCM (POWERTRAIN CONTROL MODULE) AMBIENT AIR TEMPERATURE (AAT) PID
NOTE: Compare multiple engine sensor readings to the ambient temperature to determine sensors are
reading correctly. A faulty sensor can cause the PCM to disable the A/C with or without a DTC.
Allow the vehicle exterior and interior to stabilize to ambient temperature. This can take a soak period of
at least 6 hours.
Monitor the CHT, ECT, IAT, MAPT, and AAT Parameter Identifications (PIDs) (as applicable).
Are the temperature values similar (typically within 18ºC (32.4ºF)?

Yes GO to G6
No DIAGNOSE the suspect temperature sensor. REFER to Powertrain Control/Emissions
G6 COMPARE THE EVAPORATOR TEMPERATURE SENSOR TO THE PCM (POWERTRAIN

Ignition OFF.
Measure:

cardiagn.com
-39.9°F (-40°C) 98,625 - 103,275 ohms
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Ignition ON.
Yes GO to G7
G7 VERIFY THE GRILLE SHUTTER OPERATION USING THE PCM (POWERTRAIN CONTROL
MODULE) GRILL SHUTTER A POSITION - COMMANDED (GRILL_A_CMD) PID (PARAMETER
IDENTIFICATION)
complete.
Using a diagnostic scan tool, view PCM PID.
Using a diagnostic scan tool, select the PCM PID GRILL_A_CMD and command the grille shutter from
100% (open) to 0% (closed) while observing the grille shutter operation from the front of the vehicle.
Does the grille shutter fully open and close when commanded by the scan tool?
Yes GO to G8
No DIAGNOSE the active grille shutter is inoperative or does not operate correctly.
G8 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) A/C (AIR CONDITIONING)
SWITCH (CC_SW_AC) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) ON
Yes GO to G9
No GO to G17
G9 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING) REQUEST
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) ON
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Start the engine.
On the HVAC controls, select PANEL and then press the A/C button (indicator on).
Does the PID display Yes when the button is pressed?
Yes GO to G11
No GO to G10
G10 RESET THE AMBIENT AIR TEMPERATURE (AAT) SENSOR

On the HVAC controls, press the A/C (air conditioning) and Recirc buttons simultaneously, then release
both. Within 2 seconds press A/C button again.
Start the engine.
On the HVAC controls, set the temperature to full cold, select PANEL and select the A/C button
(indicator on).
Yes RETEST the A/C system for normal operation.

REFER to: Refrigerant System Tests - 2.3L EcoBoost (201kW/273PS) (412-00 Climate
REFER to: Refrigerant System Tests - 3.7L Duratec (227kW/301PS) (412-00 Climate
No GO to G11
G11 CHECK THE PCM (POWERTRAIN CONTROL MODULE) A/C (AIR CONDITIONING)
COMPRESSOR COMMANDED STATE (ACC_CMD) PID (PARAMETER IDENTIFICATION) WITH THE
A/C (AIR CONDITIONING) COMMANDED ON
Using a diagnostic scan tool, activate the PCM ACC_CMD PID.
Yes GO to G18
No GO to G12
G12 CHECK THE VOLTAGE TO THE A/C (AIR CONDITIONING) CLUTCH RELAY
Ignition OFF.
Ignition ON.
Measure:

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Yes GO to G13
No VERIFY BJB fuses 23 (10A) and 42 (15A) are OK.
circuit short.
G13 BYPASS THE A/C (AIR CONDITIONING) CLUTCH RELAY

Ignition OFF.

A/C clutch relay socket 3 A/C clutch relay socket 5
Ignition ON.
Does the A/C compressor clutch engage?
Yes REMOVE the fused jumper wire. INSTALL a new A/C clutch relay.
No LEAVE the fused jumper wire installed. GO to G14
G14 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL VOLTAGE
SUPPLY CIRCUIT FOR AN OPEN
Measure:
C100-1 Ground
Yes REMOVE the fused jumper wire. GO to G15

No REMOVE the fused jumper wire.
REPAIR the circuit.
G15 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL GROUND
CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:
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C100-2 Ground
Yes GO to G16
G16 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH AIR GAP
Measure the A/C compressor clutch air gap at 3 equally spaced locations between the clutch hub and
the A/C compressor clutch pulley.
REFER to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control System - General
Is the A/C compressor clutch air gap greater than 0.6 mm (0.0236 in)?
Yes ADJUST the A/C compressor clutch air gap.

REFER to: Air Conditioning (A/C) Clutch Air Gap Adjustment (412-00 Climate Control
No INSTALL a new A/C compressor clutch and A/C clutch field coil.
REFER to: Air Conditioning (A/C) Clutch and Air Conditioning (A/C) Clutch Field Coil
(412-00 Climate Control System - General Information, General Procedures).
G17 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Repair:
G18 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Repair:
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For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
The A/C Is Always On - A/C Mode Always Commanded On

Operation).

P1464 A/C Demand Out Of Self Test This DTC sets when the PCM senses an A/C request during a PCM
Range self-test.
Possible Sources
A/C clutch relay

PCM
FCIM
PINPOINT TEST H : THE A/C (AIR CONDITIONING) IS ALWAYS ON - A/C (AIR

CONDITIONING) MODE ALWAYS COMMANDED ON
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H1 CHECK THE A/C (AIR CONDITIONING) CLUTCH RELAY
Yes GO to H2
H2 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR CLUTCH FIELD COIL VOLTAGE SUPPLY
CIRCUIT FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C100-1 Ground

No GO to H3
H3 COMPARE THE EVAPORATOR TEMPERATURE SENSOR TO THE PCM (POWERTRAIN
Ignition OFF.
Allow the vehicle exterior and interior to stabilize to ambient temperature.
Disconnect Evaporator Temperature Sensor C296.
Measure:


-39.9°F (-40°C) 98,625 - 103,275 ohms
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
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68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Ignition ON.
Yes GO to H4
H4 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) A/C (AIR CONDITIONING)
SWITCH STATUS (CC_SW_AC) PID (PARAMETER IDENTIFICATION)
Ignition ON.
Select panel mode, press and release the A/C button (indicator off) on the FCIM controls.
Does the PID display Active when pressed and Inactive when released?
Yes GO to H5
No GO to H8
H5 CHECK THE A/C (AIR CONDITIONING) PRESSURE SENSOR (ACP_PRESS) PARAMETER
IDENTIFICATION (PID)
Using a diagnostic scan tool, view the PCM Parameter Identification (PIDs).
PCM Parameter Identification (PID) ACP_PRESS.
(15 psi)?
Yes GO to H6
No INSTALL a new A/C pressure transducer.
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH THE A/C (AIR CONDITIONING) OFF
While in panel mode, release the A/C button (indicator off) on the FCIM controls.
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Yes GO to H9
No GO to H7
SIGNAL (AC_REQ) PID (PARAMETER IDENTIFICATION) WITH FCIM (FRONT CONTROLS
INTERFACE MODULE) DISCONNECTED
Ignition ON.
Yes GO to H9
No GO to H8
H8 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:

H9 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

Ignition OFF.
Repair:
cardiagn.com
For 2.3L,
For 3.7L,
For 5.0L,
For 5.2L,
The Temperature Control Is Inoperative Or Does Not Operate Correctly
Temperature Door Actuator - Driver side,

Operation).

B1081:11 Left Temperature Damper This DTC sets when the module senses lower than expected voltage
direction.
B1081:12 Left Temperature Damper This DTC sets when the module senses higher than expected voltage
direction.
B1081:13 Left Temperature Damper This DTC sets when the module senses no voltage on the actuator
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B11E5:12 Left HVAC Damper Position This DTC sets when the module senses greater than 5 volts on the
Battery
B11E5:14 Left HVAC Damper Position This DTC sets when the module senses less than 1 volt on the
Possible Sources

Driver side temperature door actuator
FCIM
PINPOINT TEST I : THE TEMPERATURE CONTROL IS INOPERATIVE OR DOES NOT

OPERATE CORRECTLY
I1 CHECK THE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
Measure:

C2091-1 Ground
C2091-2 Ground
C2091-3 Ground
C2091-5 Ground
C2091-6 Ground

No GO to I2
I2 CHECK THE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT TO GROUND

Ignition OFF.
Measure:
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C2091-1 Ground
C2091-2 Ground
C2091-3 Ground
C2091-5 Ground
C2091-6 Ground
Yes GO to I3
I3 CHECK THE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR AN OPEN

Measure:

C2091-1 C2402A-2
C2091-2 C2402A-10
C2091-3 C2402A-3
C2091-5 C2402A-8
C2091-6 C2402A-9

Yes GO to I4
I4 CHECK THE TEMPERATURE DOOR ACTUATOR CIRCUITS FOR A SHORT TOGETHER

Measure:

C2091-1 C2091-2
C2091-1 C2091-3
C2091-1 C2091-5
C2091-1 C2091-6
C2091-2 C2091-3
C2091-2 C2091-5
C2091-2 C2091-6
C2091-3 C2091-5
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C2091-3 C2091-6
C2091-5 C2091-6
Yes INSTALL a new driver side temperature door actuator.

REFER to: Driver Side Temperature Door Actuator (412-00 Climate Control System -
TEST the system for normal operation. If the concern is still present, GO to I5
I5 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Repair:
The Blower Motor Is Inoperative
blower speed.

B10AF:11 Blower Fan Relay: This DTC sets when the module senses low voltage on the relay coil voltage
Circuit Short To circuit when the module is energizing the circuit. The blower motor relay is
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Ground permanently inactive.
Battery or Open voltage. The blower motor relay is inactive when circuit is open; the blower
motor relay is on all the time when shorted to battery.
B10B9:12 Blower Control: This DTC sets when the module senses high voltage on the blower motor
Circuit Short To control PWM circuit, indicating a short directly to voltage. The blower motor
Battery is inoperative.
Possible Sources

Fuse
Blower motor relay
Blower motor
FCIM
PINPOINT TEST J : THE BLOWER MOTOR IS INOPERATIVE

J1 CHECK THE BLOWER MOTOR RELAY
Ignition OFF.
Carry out the component test on the blower motor relay.
Yes GO to J2
No INSTALL a new blower motor relay.
J2 CHECK THE BLOWER MOTOR RELAY SWITCH CONTACT SUPPLY VOLTAGE

Measure:

Yes GO to J3
cardiagn.com
J3 CHECK THE BLOWER MOTOR RELAY COIL GROUND CIRCUIT FOR AN OPEN
Measure:

Yes GO to J4
J4 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR A SHORT TO GROUND
Measure:


Yes GO to J5
J5 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR AN OPEN
Measure:

Blower motor relay socket 2 C2402A-11
Yes GO to J6
cardiagn.com
J6 CHECK THE BLOWER MOTOR SPEED CONTROL VOLTAGE CIRCUIT
Connect Blower motor relay.
Ignition ON.
Measure:

C297-5 Ground
Yes GO to J7
J7 CHECK THE BLOWER MOTOR SPEED CONTROL GROUND CIRCUIT FOR AN OPEN
Ignition OFF.
Measure:

C297-1 Ground

Yes GO to J8
J8 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A
SHORT TO VOLTAGE
Ignition ON.
Measure:

C297-2 Ground
cardiagn.com
No GO to J9
J9 CHECK THE BLOWER MOTOR CONTROL PWM (PULSE WIDTH MODULATION) CIRCUIT FOR
AN OPEN
Ignition OFF.
Measure:

C297-2 C2402A-23
Yes GO to J10
J10 CHECK THE OUTPUTS TO THE BLOWER MOTOR

Disconnect Blower motor C2066.
Ignition ON.
Measure:

C2066-1 C2066-2
Yes INSTALL a new blower motor.

REFER to: Blower Motor (412-00 Climate Control System - General Information,
No GO to J11
J11 CHECK THE CIRCUITS TO THE BLOWER MOTOR FOR AN OPEN

Ignition OFF.
Measure:
cardiagn.com
C297-6 C2066-1
C297-5 C2066-2
Yes GO to J12
J12 CHECK THE BLOWER MOTOR CIRCUITS FOR A SHORT TOGETHER

Measure:

C2066-1 C2066-2

TEST the system for normal operation. If the concern is still present, GO to J13
J13 CHECK FOR CORRECT FRONT CONTROLS INTERFACE MODULE (FCIM) OPERATION
Repair:
The Blower Motor Does Not Operate Correctly
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blower speed.

Battery or Open voltage. Blower relay is inactive when circuit is open; blower relay is on all
the time when shorted to battery.
Possible Sources

Blower motor relay
FCIM
PINPOINT TEST K : THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY
K1 VERIFY THE BLOWER MOTOR OPERATION
Ignition ON.
Select PANEL on the HVAC controls. Adjust the blower motor setting to the minimum and maximum
settings.
Does the blower motor operate at any setting?
Yes GO to K2
SHORT TO VOLTAGE
Ignition OFF.
Ignition ON.
cardiagn.com
Measure:

C2402A-23 Ground

No GO to K3
SHORT TO GROUND
Ignition OFF.
Measure:

C2402A-23 Ground
Yes GO to K4
K4 CHECK THE BLOWER MOTOR RELAY COIL CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C2402A-11 Ground

No GO to K5
cardiagn.com
K5 CHECK THE BLOWER MOTOR OPERATION WITH THE BLOWER MOTOR RELAY
DISCONNECTED
Ignition OFF.
Ignition ON.
Does the fan still operate all the time?
Yes REPAIR the blower motor speed control voltage circuit CH402 (YE/GN) for a short to
voltage.
No GO to K6
K6 CHECK FOR CORRECT BLOWER MOTOR SPEED CONTROL OPERATION

Ignition OFF.
Disconnect and inspect all the blower motor speed control connectors.
Repair:
Reconnect the blower motor speed control connectors. Make sure they seat and latch correctly.

TEST the system for normal operation. If the concern is still present, GO to K7
K7 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION
Ignition OFF.
Repair:
cardiagn.com
B1B71:11, B1B71:15
Evaporator Temperature Sensor,

Operation).

B1B71:11 Evaporator Temperature The module senses excessive voltage drop on the sensor reference
Sensor: Circuit Short To voltage circuit, indicating a short directly to ground. The module
Ground defaults to calculated evaporator temperature and the compressor is
shut off.
B1B71:15 Evaporator Temperature The module senses no voltage drop on the sensor reference voltage
Sensor: Circuit Short To circuit, indicating a short directly to voltage or an open circuit. The
Battery or Open module defaults to calculated evaporator temperature and the
compressor is shut off.
Possible Sources

FCIM
PINPOINT TEST L : B1B71:11, B1B71:15
L1 CHECK THE EVAPORATOR TEMPERATURE SENSOR RESISTANCE
Ignition OFF.
Measure:

Compare the evaporator temperature sensor measured resistance with the table below.

-39.9°F (-40°C) 98,625 - 103,275 ohms
cardiagn.com
-4.0°F (-20°C) 28,640 - 29,600 ohms
32.0°F (°C) 9695 - 9895 ohms
68.0°F (20°C) 3675 - 3810 ohms
77.0°F (25°C) 2950 - 3050 ohms
86.0°F (30°C) 2370 - 2565 ohms
103.9°F (40°C) 1565 - 1635 ohms
Yes GO to L2
L2 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR A SHORT TO

VOLTAGE
Ignition ON.
Measure:

C2402A-19 Ground

No GO to L3
L3 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR A SHORT TO

GROUND
Ignition OFF.
Measure:

C2402A-19 Ground
Yes GO to L4
cardiagn.com
L4 CHECK THE EVAPORATOR TEMPERATURE SENSOR INPUT CIRCUIT FOR AN OPEN

Measure:

C2402A-19 C296-1
Yes GO to L5
L5 CHECK THE EVAPORATOR TEMPERATURE SENSOR SIGNAL AND SIGNAL RETURN

CIRCUITS FOR A SHORT TOGETHER
Measure:

C296-1 C296-2
Yes GO to L6
Repair:
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C1B14:11, C1B14:12
A 5-volt reference voltage and ground is supplied to the climate control sensors and actuators from the FCIM.

C1B14:11 Sensor Supply Voltage A: This DTC sets when the module senses less than 5 volts on the
Circuit Short to Ground sensor reference voltage circuit, indicating a short to ground.
C1B14:12 Sensor Supply Voltage A: This DTC sets when the module senses greater than 5 volts on the
Circuit Short to Battery sensor reference voltage circuit, indicating a short to voltage.
Possible Sources

FCIM
PINPOINT TEST M : C1B14:11, C1B14:12

M1 CHECK THE FCIM (FRONT CONTROLS INTERFACE MODULE) DTCS
Ignition ON.
Is DTC C1B14:11 present?
Yes GO to M2
No GO to M5
M2 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Measure:

C2402A-3 Ground
cardiagn.com
Yes GO to M3
M3 CHECK THE REFERENCE VOLTAGE CIRCUIT AND THE SIGNAL RETURN CIRCUIT FOR A
SHORT TOGETHER
Measure:

C2402A-3 C2402A-2
Is the resistance greater than 200 ohms?
Yes GO to M6
No GO to M4
M4 CHECK THE A/C (AIR CONDITIONING) COMPONENTS

Measure:

C2402A-3 C2402A-2
While measuring the resistance, disconnect the following components one at a time, in order. Stop
disconnecting components if the measured resistance rises above 200 ohms.
In-vehicle temperature and humidity sensor C233
Air distribution door actuator C232
Driver side temperature door actuator C2091
Air inlet door actuator C282
Did the resistance rise above 200 ohms?
Yes INSTALL a new sensor or actuator (the last one to be disconnected). Refer to the
appropriate section in Group 412 for the procedure. When installing an actuator,
CONNECT the actuator electrical connector before the FCIM. This allows the actuator to
be calibrated when the FCIM is connected.
M5 CHECK THE REFERENCE VOLTAGE CIRCUIT FOR A SHORT TO VOLTAGE

Measure:

C2402A-3 Ground
cardiagn.com

No GO to M6
M6 CHECK FOR CORRECT FCIM (FRONT CONTROLS INTERFACE MODULE) OPERATION

Ignition OFF.
Repair:
P06A0
The externally controlled variable displacement compressor is electronically controlled by the PCM. The PCM
pulse width modulates the ground to the externally controlled variable displacement compressor to change the
displacement of the A/C compressor.
Operation).

P06A0 Variable A/C Compressor The PCM senses greater than expected voltage on the sensor feedback
Control Circuit circuit, indicating a short to voltage or an open circuit or sensor.
Possible Sources
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A/C compressor
PCM
Inspect for loose or corroded PCM and A/C compressor connections.
PINPOINT TEST N : P06A0

N1 EXTERNALLY CONTROLLED VARIABLE DISPLACEMENT COMPRESSOR (EVDC)
PERFORMANCE CHECK
NOTE: The performance check test is used to determine if the Externally Controlled Variable
Displacement Compressor (EVDC) is able to change the displacement by measuring the amperage to the
solenoid and monitoring the manifold pressure gauges soon after the air conditioning clutch is engaged.
Ignition OFF.
Disconnect BJB fuse 42 (15A).
Measure:

BJB fuse 42 socket, component side BJB fuse 42 socket, component side
With a manifold gauge set connected, monitor the low side and high side pressures.
Start the engine. Run the engine until it reaches normal operating temperature.
Select the floor position on the HVAC controls. Set the temperature control to full warm and the blower to
the highest setting. Set the A/C to off. Close all windows and doors. Run for 5 minutes to heat up the
climate control housing.
Monitor the multi meter and the manifold gauges. Select the PANEL position on the HVAC controls. Set
the temperature control to full cold and the blower to the highest setting. Set the recirculated air mode to
on. Set the A/C to on.
Record the highest amperage measurement and the A/C pressures.
Did the amperage initially increase approximately 0.8A, and did the low side pressure decrease and
the high side pressure increase and after a few minutes did the amperage and high side pressure
decrease and low side pressure increase?
Yes The Externally Controlled Variable Displacement Compressor (EVDC) is able to change
the displacement. CHECK refrigerant charge amount.
No GO to N2
N2 CHECK FOR VOLTAGE TO THE A/C (AIR CONDITIONING) COMPRESSOR CONTROL

SOLENOID
Ignition OFF.
Connect BJB fuse 42 (15A).
Disconnect A/C Compressor Control Solenoid C1110.
Ignition ON.
Measure:
cardiagn.com
C1110-2 Ground
Yes GO to N3
N3 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR DISPLACEMENT CONTROL SOLENOID

PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A SHORT TO GROUND
Ignition OFF.
Disconnect PCM 2.3L C1551B.
Measure:

C1110-1 Ground
Yes GO to N4
N4 CHECK THE A/C (AIR CONDITIONING) COMPRESSOR DISPLACEMENT CONTROL SOLENOID
PWM (PULSE WIDTH MODULATION) CIRCUIT FOR A SHORT TO VOLTAGE
Ignition ON.
Measure:

C1110-1

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100-00 General Information 2016 Mustang

Description and Operation Procedure revision date: 01/12/2016

About This Manual

Warnings, Notices and Notes

NOTICES (in some publications, CAUTIONS)

Notices provide information to avoid damage to the vehicle or a component.

Notes provide information critical for a complete and effective repair.

Specified Chemicals or Materials

Vehicle LH and RH definition

Powertrain LH and RH definition

The following rules apply, unless specified differently in the procedure:

Reuse standard fasteners.

Examples of self-locking nuts and bolts

SEALS AND GASKETS

Replace seals and gaskets, unless specified differently in the procedure.

EXTERIOR TRIM PARTS

Other color coding

Alternating Blue and White

ILLUSTRATION TASK SEQUENCE

Simple procedure example showing color-coding and task sequence.

Example of hidden fastener information

Location symbols show the location of a component or system on the vehicle.

ISO warning symbols may be used to indicate potential hazards.

These symbols direct the use of personal protection equipment

ELEMENTS OF DIAGNOSIS AND TESTING

Diagnosis and Testing may include:

MODULE NAMES MATCH THE DIAGNOSTIC SCAN TOOL

MODULE DESCRIPTIVE NAMES

Example: “Driver Active Motion Seat Module [SCMG]”.

Copyright © 2016 Ford Motor Company

Description and Operation Procedure revision date: 12/22/2014

Item Part Number Description

Steering Wheel Symbols

Body type symbols are used to identify different body configurations.

Item Part Number Description

Gearshift lever and selector lever position symbols

Item Part Number Description

Item Part Number Description

Cutting tool symbols

Item Part Number Description

Apply Chemical or load symbols

Item Part Number Description

Item Part Number Description

These symbols indicate the type of welding to be used.

Drilling and grinding symbols

These symbols indicate the type of drilling or grinding to be used.

Item Part Number Description

Mandatory Protective equipment - Health and safety symbols

Prohibition - Health and safety symbols and component damage

Warning symbols - Health and safety and component damage

Control Diagram symbols - Description and Operation procedures

Copyright © 2016 Ford Motor Company

Description and Operation Procedure revision date: 12/19/2014

Battery and Battery Charging Health and Safety Precautions

Description and Operation Procedure revision date: 01/8/2015

Body Repair Health and Safety and General Precautions

Copyright © 2016 Ford Motor Company

Description and Operation Procedure revision date: 01/8/2015

Brake and Clutch Systems Health and Safety Precautions

Description and Operation Procedure revision date: 01/8/2015

Climate Control System Health and Safety Precautions

Copyright © 2016 Ford Motor Company

Description and Operation Procedure revision date: 08/5/2013

Effective Diagnostic Techniques